H2O HC 1000, Installation, Operation And Maintenance Manual

Page 1: ...not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instruction If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier WARNING If the information in this manual is not followed exactly a...

Page 2: ... professional service technician qualified in hot water boiler and heater installation and maintenance Improper installation and or operation could create carbon monoxide gas in flue gases which could cause serious injury property damage or death Improper installation and or operation will void the warranty Warning For proper operation of a spa or hot tub the following safety rules should be obser...

Page 3: ... qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water Warning Do not bypass any of the instruments in the safety loop Doing so may cause serious damage to the unit and its surroundings D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 4: ...HC SERIES GENERAL SPECIFICATIONS iv H2O BOILER HC SERIES IOM Manual PAGE INTENTIONALLY LEFT BLANK D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 5: ...moval of Existing Boiler 10 2 3 Clearance from Combustible Material 11 2 4 Location 12 2 5 Relief Valve piping 13 2 6 Water Connection 13 2 6 1 Potable water heater connection 14 2 6 2 Piping Arrangement 14 2 7 Condensate Line 17 2 8 Gas Line Connections 17 2 9 Electrical connection 18 2 10 Vent Connection 18 2 10 1 Suggested Single wall Vent system 19 2 10 2 Vent Sizing 22 2 11 General Instructio...

Page 6: ... Manual SECTION 4 MAINTENANCE 33 4 1 Maintenance Schedule 34 4 2 General Procedure 34 4 3 Service Notes 36 4 2 Troubleshooting 37 Technical Data 39 Control System Schematic 39 Reports 41 D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 7: ...0 115 1 60 115 1 60 Heating Surface Ft 2 67 105 172 200 229 Shipping Weight 1 approx lbs 550 750 950 1 350 1 500 Water Content USG 12 17 26 30 34 Minimum Water Flow Rate USGPM 12 19 24 24 32 Inlet Gas Pressure 2 Inches WC 7 14 Flue Duct Material Stainless Steel air tight corrosion resistant Max Working Pressure PSIG 160 Max Working Temp F 210 Min Inlet Water Temp F Any temperature above freezing p...

Page 8: ... 66 1 676 40 5 1029 HC 1500 35 890 45 1 150 35 6 905 75 6 1 920 40 5 1029 HC 2000 35 890 45 1 143 37 75 959 81 75 2 076 40 5 1029 HC 2500 35 890 45 1 143 44 1 118 86 2 184 40 5 1029 Model Ø Gas Inlet G in Ø Water Inlet H in Ø Water Outlet I in Ø Flue Vent J in Ø Water Drain K in Ø Cond Drain L in HC 600 1 2 2 7 HC 1000 1 2 2 9 HC 1500 2 2 2 10 HC 2000 2 3 3 10 HC 2500 2 3 3 12 Note Depth of the un...

Page 9: ...SECTION 1 INTRODUCTION 1 H2O BOILER HC SERIES IOM Manual SECTION 1 INTRODUCTION D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 10: ...changer The exact mechanism of heat exchange is an engineering phenomenon involving combination of counter flow condensation heat recovery fouling factors and two phase conditions The working of heat exchanger is a simple process The gas burner ignites the gas and air mixture inside the combustion chamber the central space of the four coils The hot gas particles cool and condense as they pass thro...

Page 11: ...ired outlet hot water temperature Using a digital high precision temperature controller the owner will identify the required hot water temperature A temperature sensor installed on the boiler water heater outlet manifold continuously measures the outlet water temperature A servomotor controlling the gas butterfly valve and the air damper allows for throttling of the air gas mixture flowing into th...

Page 12: ... pressure relief valve should be installed Gas Pressure Switch One manual reset low gas pressure switch is installed on the gas train in between the gas pressure regulator and the first safety shut off valve If the line pressure drops below 7 wc the switch will open and the unit will immediately shut down One high gas pressure switch is also installed If the gas manifold pressure increases above t...

Page 13: ...gnition system is being used which eliminates the need for pilot gas train Figure 4 Pilot gas train 1 4 2 Main Gas Line Referring to Figure 6 gas from the main supply line flows at a maximum pressure of 14 wc through the manual gas valve into the main gas line From the pressure regulator it will then flow through the two safety shut off valves into the second manual shut off valve Finally gas flow...

Page 14: ...all applicable local codes In the United States of America the installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 latest edition All electrical wiring must be carried out in accordance with the National Electrical Code ANSI NFPA No 70 latest edition and any additional state or local cod...

Page 15: ...supply soft water to the boiler or water heater then a sodium based ion exchanger may be used Note that soft water is defined as one having less than 0 12 British or 0 17 US hardness level Consult a local water treatment consultant to determine if water treatment is required WARNING Exceeding the maximum allowable gas manifold pressure could result in over firing of the unit and may cause permanen...

Page 16: ...SECTION 2 INSTALLATION 8 H2O BOILER HC SERIES IOM Manual SECTION 2 INSTALLATION D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 17: ...erature sensor installed on the outlet manifold Condensates drain kit Flame sensor inside burner Flue gas connection Pressure Pressure temperature gauge All Safety features as described in Section 1 3 Please contact H2O BOILER if items listed above are missing Please be familiar with major parts of the boiler before operating Always exercise caution when transporting Instructions provided are only...

Page 18: ... operate a summer exhaust fan Close fireplace dampers Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe After it has been determined that each a...

Page 19: ...P FRONT FLUE BACK L SIDE R SIDE FLOOR ALL 40 40 1 24 24 24 Non Combustible Note Refer to appliance rating plate for specified clearances for combustible material Note Indicated clearances are minimum values leave enough space for burner removal and cleaning of the heat exchanger D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 20: ...o the blower is kept clear of any obstruction so that combustion air can flow freely through to the air intake blower A resilient pad to separate the boiler water heater from floor when the appliance is installed directly on carpeting the appliance shall be installed on a metal or wood panel extending beyond the full width and depth of the appliance by at least 3 in 76 2 mm in any direction or if ...

Page 21: ...e The relief valve is installed in vertical position and should remain in that position at all times 2 6 Water Connection All pre installation work has been completed at the factory Two water manifolds inlet and outlet headers are provided with the unit Cold water inlet and hot water outlet connections are clearly marked on the respective manifolds of the boiler water heater The cold water supply ...

Page 22: ...into the potable water used for space heating A water heater that will be used to supply potable water shall not be connected to any heating system or component s previously used with a non potable water heating appliance Water heaters for combination water space heating cannot be used in space heating application only 2 6 2 Piping Arrangement Typical flow arrangements for primary and secondary wa...

Page 23: ...le Boiler w Storage Tank Figure 7 Primary Secondary Piping for Condensing Boilers Single with storage tank Multiple Boilers Figure 8 Primary Secondary Piping for Condensing Boilers Multiple D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 24: ...S IOM Manual Variable Flow Arrangements Primary Only Single Boiler Figure 9 Primary Only Variable Flow Single Multiple Boilers Figure 10 Primary Only Variable Flow Multiple D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 25: ... of that system at test pressures in excess of psi 3 5 kPa The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than psi 3 5 kPa The appliance and its gas connection must be leak tested before placing the appliance in operation Install gas line f...

Page 26: ...rrent ANSI Z223 1 NFPA 54 National Fuel Gas Code or CSA B149 1 Natural Gas and Propane Installation Codes as applicable Provisions for adequate combustion and ventilation air in accordance with one of the following The National Fuel Gas Code ANSI Z223 1 NFPA 54 Current Edition CSA B149 1 Natural Gas and Propane Installation Code Current Edition or Applicable provisions of the local building code N...

Page 27: ...L 29 4C corrosion resistance for use with Class II III and IV gas boilers ANSI Z21 13 UL 1738 and ULC 636 Type BH special gas vent NovaFlex Z FLEX Z Vent Stainless Steel AL 29 4C corrosion resistance for use with Class II III and IV gas boilers ANSI Z21 13 UL 1738 and ULC 636 Type BH special gas vent DuraVent FasNSeal Stainless Steel AL 29 4C corrosion resistance for use with Class II III and IV g...

Page 28: ...SECTION 2 INSTALLATION 20 H2O BOILER HC SERIES IOM Manual Figure 11 Vent Terminal Termination D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 29: ... to building or the combustion air inlet to any other appliance 6 in 15 cm for appliances 10 000 Btuh 3 kW 12 in 30 cm for appliances 10 000 Btuh 3 kW and 100 000 Btuh 30 kW 36 in 91 cm for appliances 100 000 Btuh 30 kW 4 ft 1 2 m below or to side of opening 1 ft 300 mm above opening K Clearance to a mechanical air supply inlet 6 ft 1 83 m 3 ft 91 cm above if within 10 ft 3 m horizontally L cleara...

Page 30: ...lt in damage to the area adjacent to the appliance or to lower floors of the structure When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the appliance The pan must not restrict combustion air flow The duct should be corrosion resistant air tight and short as possible A condensate drain is highly recommended for long duct or sing...

Page 31: ...on must be leak tested before placing the boiler in operation The boiler water heater when installed must be electrically grounded and bonded in accordance with the local codes or in the absence of such codes in accordance with the National Electrical Code ANSI NFPA 70 The boiler water heater should be located in an area where leakage of the tank or connections will not result in damage to the are...

Page 32: ...SECTION 2 INSTALLATION 24 H2O BOILER HC SERIES IOM Manual PAGE INTENTIONALLY LEFT BLANK D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 33: ...SECTION 3 OPERATION 25 H2O BOILER HC SERIES IOM Manual SECTION 3 OPERATION D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 34: ...ating temperature switch Low water cut off switch Low gas pressure switch Air Pressure Switches Flow Switch B Remote Enable Disable Every boiler water heater is fully tested at the factory prior to shipment When the unit is tested at the factory a jumper is placed between terminals identified as Remote Enable Disable see Figure 13 If BMS is used this jumper should be replaced by wires from the BMS...

Page 35: ...s not established and detected by the flame sensor the gas valves will immediately shut down and the boiler water heater goes into the lock out mode The unit will not re start until the burner controller is manually reset 3 1 4 Main Flame Once pilot flame is established burner controller will send 120V to the two main safety shut off valves From these valves gas flows into the gas butterfly valve ...

Page 36: ...ater will shut down and goes into the standby mode The unit will automatically re start when the water temperature drops below the operating set point minus the differential temperature NOTE If as a result of mal functioning of the temperature controller the discharge water temperature increases above that of the high limit temperature switch the unit will automatically shut down and will not re s...

Page 37: ...n must be carried out in accordance to all applicable local codes and factory guidelines When required a proper drain should be installed on the vent Condensate Line Connection Inspect the condensate line and ensure it is installed in accordance with the factory guidelines Power Connection Inspect all wiring connections to the unit and ensure they comply with all applicable local codes Ensure that...

Page 38: ...n gas line are opened the unit will be in regular operating mode The Dungs air pressure switch installed on the side of the burner blower has been factory set at 0 3 wc The boiler should be purged of any combustible gases before starting Test Points o Measure gas line pressure upstream of the gas pressure regulator to ensure it is within the specified range of 7 14 wc o Measure the gas manifold pr...

Page 39: ...safety factors and application specifics may affect boiler requirements Table 7 HC Series boiler capacity selection safety factor of 25 already included HC Model Temperature Difference F 20 30 40 50 60 70 80 90 100 110 120 130 600 Flow GPM 43 29 21 17 14 12 11 10 9 Press Drop PSI 1 0 5 0 3 0 2 0 2 0 1 0 1 0 1 0 1 1000 Flow GPM 71 47 36 29 24 20 18 16 14 Press Drop PSI 1 0 5 0 3 0 2 0 2 0 1 0 1 0 1...

Page 40: ...SECTION 3 OPERATION 32 H2O BOILER HC SERIES IOM Manual PAGE INTENTIONALLY LEFT BLANK D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 41: ...SECTION 4 MAINTENANCE 33 H2O BOILER HC SERIES IOM Manual SECTION 4 MAINTENANCE D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 42: ...Perform annual maintenance procedure Perform commissioning start up for year round usage 4 2 General Procedure The following maintenance procedure is required to be performed annually and prior to every cold unit start Address existing problems o Address any existing problems reported by the owner building operator and resolve before proceeding with the maintenance service Inspect mechanical room ...

Page 43: ...he fasteners securing the cover o Remove the burner pilot UV flame sensor and the flame observation port o Check for calcification on the surfaces of the pilot and flame sensor o Clean the glass on the flame observation port o Replace the components if determined unserviceable o Check for any piping orifice blockages o Inspect the central plate and the burner for any sign of damage or corrosion In...

Page 44: ...ust ducts are always free of any debris and restrictions This will allow the electric motor to operate under normal loads as well as allowing for a clean combustion process Do not store anything against the boiler and ensure that the boiler is kept in a clean environment Do not store any combustible material flammable liquid or vapor in the vicinity of the boiler Should overheating occur or the ga...

Page 45: ...nections to ensure they are all securely connected see the schematic wiring diagram for terminals Check the two safety shut off valves Replace if defective Check the electrical connections to ensure they are all securely connected see burner catalogue for terminals Measure gas pressure and air pressure in the pilot burner at the available test port Ensure it is within the specified 2 5 wc If press...

Page 46: ...f the appropriate size Unclean combustion Insufficient air in the mechanical room Unit out of adjustment Check all the louvers and air openings in the mechanical room to ensure they are free of any obstructions and there is sufficient inflow of fresh air into the room Using a gas analyzer re adjust the air and gas settings Air bubble sound in the unit Poor water circulation in one or both coils Fo...

Page 47: ...Technical Data 39 H2O BOILER HC SERIES IOM Manual Technical Data Control System Schematic Figure 13 Control system schematic D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 48: ...Technical Data 40 H2O BOILER HC SERIES IOM Manual PAGE INTENTIONALLY LEFT BLANK D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 49: ...Technical Data 41 H2O BOILER HC SERIES IOM Manual Reports D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...

Page 50: ...D VAC Sales Inc Massapequa NY Email Dmann dvachvac com Tel 516 256 3131 https dvachvac com commercial boilers D VAC Sales Inc Email dmann dvachvac com Tel 516 256 3131 www dvachvac com ...