H2O HC Series, Installation, Operation And Maintenance Manual

Page 1: ...ot 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 suppl...

Page 2: ...by a 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 c...

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 safe...

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: ...oval 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 Arrangeme...

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 In...

Page 7: ...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...

Page 8: ...6 661 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 Gas Inl...

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: ...hanger 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 e...

Page 11: ...red 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 hea...

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...

Page 13: ...nition 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 o...

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...

Page 15: ...upply 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 lo...

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: ...rature 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...

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...

Page 19: ...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 v...

Page 20: ...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 i...

Page 21: ...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...

Page 22: ...nto 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 wat...

Page 23: ...e 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...

Page 24: ...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...

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...

Page 26: ...rent 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...

Page 27: ...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 f...

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...

Page 30: ...t 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...

Page 31: ...n 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 suc...

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: ...ting 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 shi...

Page 35: ...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 controll...

Page 36: ...ter 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 re...

Page 37: ...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 l...

Page 38: ...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 a...

Page 39: ...afety 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...

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: ...erform 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 ever...

Page 43: ...e 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...

Page 44: ...st 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 agains...

Page 45: ...ections 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 th...

Page 46: ...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 obs...

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...