H2O HC Series Installation, Operation And Maintenance Manual

Gas-fired stainless steel boilers and water heaters

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EMAIL: Dmann@dvachvac.com TEL: (516) 256-3131

Gas-Fired Stainless Steel Boilers and Water Heaters

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

D-VAC Sales Inc.

MASSAPEQUA, NY

HC Series

WARNING: If the information in this

manual is not followed exactly, a fire

or explosion may result causing

property damage, personal injury or

loss of life.

Do not store or use gasoline or other

flammable vapors and liquids in the

vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

 Do not try to light any appliance.

 Do 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

performed by a qualified installer, service

agency or the gas supplier.

Email: dmann@dvachvac.com

service

must

Tel: (516) 256-3131

www.dvachvac.com

Table of Contents

Summary of Contents for H2O HC Series

Page 1 D-VAC Sales Inc. MASSAPEQUA, NY EMAIL: Dmann@dvachvac.com TEL: (516) 256-3131 HC Series Gas-Fired Stainless Steel Boilers and Water Heaters INSTALLATION, OPERATION AND MAINTENANCE MANUAL WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
Page 2 H2O BOILER HC SERIES IOM Manual Note: The installation must conform with one or more of the following, as applicable: 1) Local codes or, in the absence of local codes, The National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Code.
Page 3 H2O BOILER SERIES IOM Manual Warning: Do not use this boiler if any part has been under water. Immediately call a 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.
Page 4 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: Table Of Contents
H2O BOILER HC SERIES IOM Manual Table of Contents HC SERIES GENERAL SPECIFICATIONS ........................ vii HC SERIES GENERAL LAYOUT & DIMENSIONS ....................viii SECTION 1: INTRODUCTION ............................1 Boiler/Water Heater Heat Exchanger ......................2 Control System..............................3 Safety Features ..............................3 Gas Lines ................................
Page 6 H2O BOILER HC SERIES IOM Manual SECTION 4: MAINTENANCE ............................. 33 Maintenance Schedule ..........................34 General Procedure ............................34 Service Notes ..............................36 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: Hc Series General Specifications
H2O BOILER HC SERIES IOM Manual HC SERIES GENERAL SPECIFICATIONS Table 1: HC Series General Specifications HC 600 HC 1000 HC 1500 HC 2000 HC 2500 Input BTU/hr 600,000 1,000,000 1,500,000 2,000,000 2,500,000 Output BTU/hr 570,000 950,000 1,425,000 1,900,000 2,375,000 Boiler Eff.
Page 8: Hc Series General Layout & Dimensions
H2O BOILER HC SERIES IOM Manual viii HC SERIES GENERAL LAYOUT & DIMENSIONS Figure 1: General layout of the HC series boilers Table 2: HC series dimensions Model “A” in. “B” in. “C” in. “D” in. “E” in. (mm) (mm)
Page 9: Section 1: Introduction
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: Boiler/Water Heater Heat Exchanger
H2O BOILER SERIES IOM Manual 1.1 Boiler/Water Heater Heat Exchanger The H2O HC series is a gas-fired water tube boiler and water heater with nominal input rating ranging from 600,000 to 2,500,000 Btu/hr. Each unit consists of several stainless steel coiled tubes (SA-249 Type 316L), 1” diameter and 0.049” wall thickness. The coils are held parallel vertically by means of stainless steel ready rods and adjustment nut assemblies.
Page 11: Control System
1.3 Safety Features Each H2O BOILER HC series boiler and water heater is equipped with a number of safety features.  Low Water Cut Off Switch: One “McDonnell & Miller” low water cut off switch is installed on the outlet manifold.
Page 12  Additional flow switch is to be installed on the inlet piping of the boiler (by user).  Flow switch’s paddle length is sized according to the manufacturer’s instruction for the intended pipe size.  Contact H2O BOILER for installation instruction of the Flow switch. D-VAC Sales Inc. Email: dmann@dvachvac.com Tel: (516) 256-3131...
Page 13: Gas Lines
H2O BOILER HC SERIES IOM Manual 1.4 Gas Lines 1.4.1 Pilot Gas Line Referring to Figure 5, gas from the main supply line flows at the maximum pressure of 14” wc, through the manual valve into the pilot line. From the pressure regulator it will then flow through the safety shut off valves into the burner.
Page 14: Gas Manifold And Control Assembly Tests
Figure 5: Main burner gas train 1.4.3 Gas Manifold and Control Assembly Tests Safe operation and all performance criteria of all H2O BOILER products, incorporating the installed gas manifold and control assembly, are proven before delivery when the products are factory tested in accordance with the ANSI Z21.13- CSA 4.9- 2017 standards for Gas-fired hot...
Page 15: Freeze Protection And Storage
H2O BOILER representative.  IF adjustments to the factory settings of air and gas flows are made, ensure that the manifold gas pressure does not exceed the pressure specified on the boiler label.
Page 16: Section 2: Installation
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: Water Heater/ Boiler Package
 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.
Page 18: Removal Of Existing Boiler
H2O BOILER HC SERIES IOM Manual 2.2 Removal of Existing Boiler At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
Page 19: Clearance From Combustible Material
H2O BOILER HC SERIES IOM Manual 2.3 Clearance from Combustible Material Table 3: Clearances from combustible material MODELS FRONT FLUE BACK L, SIDE R, SIDE FLOOR Non- 40” 40” 1” 24” 24” 24” Combustible Note: Refer to appliance rating plate for specified clearances for combustible material.
Page 20: Location
H2O BOILER HC SERIES IOM Manual 2.4 Location Notes:  Never install directly on carpet.  For other than a direct vent appliance, the appliance must be located as close as practicable to a chimney or gas vent.  The appliance should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the appliance or to lower floors of the structure.
Page 21: Relief Valve Piping
H2O BOILER HC SERIES IOM Manual 2.5 Relief Valve piping A pressure relief valve is supplied as standard equipment. The relief valve is extra protection against damage that could be caused by excessive water pressure. Either, mal-functioning of controls, or creation of steam pockets due to water stagnation in some parts of the coils, may cause such excessive pressure.
Page 22: Potable Water Heater Connection
H2O BOILER HC SERIES IOM Manual 2.6.1 Potable water heater connection In the case where water heater is being used for water (potable) heating and space heating:  The piping and components connected to the water heater for the space heating application shall be suitable for use with potable water.
Page 23 H2O BOILER HC SERIES IOM Manual Single 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...
Page 24 H2O BOILER HC SERIES 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: Condensate Line
H2O BOILER HC SERIES IOM Manual 2.7 Condensate Line Connect 3/4” ABS tubing from the condensate drain “U” trap, directly to the floor drain. Notice that the line MUST be pitched downward towards the floor drain to avoid traps. DO NOT install any valve of any type, or any other instrument between the condensate drain “U”...
Page 26: Electrical Connection
H2O BOILER HC SERIES IOM Manual instruments (main gas valve, boiler/water heater gas regulator, and low gas pressure switch) could be easily isolated and removed, whenever necessary. The valve should be clearly marked, located outside the unit’s housing, readily visible and accessible for turning on and off. If the unit is to be installed in, under, or directly attached to a pool, or spa, structure, the said manual valve should be located outside the structure.
Page 27: Suggested Single Wall Vent System
H2O BOILER HC SERIES IOM Manual 2.10.1 Suggested Single wall Vent system It is recommended to install prefabricated factory-made vent parts each designed to be assembled with the other without requiring field fabrication. Table 4 Suggested Venting System Manufacturer Vent Part Model...
Page 28 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 H2O BOILER HC SERIES IOM Manual Table 5: Vent Termination Guide Line Canadian installation (note 1) US installation (note 2) Clearance above grade, 12 in (30 cm) 12 in (30 cm) (Note 7) veranda, porch, deck, or balcony Clearance to window or door 6 in (15 cm) for appliances ≤...
Page 30: Vent Sizing
H2O BOILER HC SERIES IOM Manual The vent for this appliance shall not terminate:  Over public walkways; or  Near soffit vents or crawl space vents or other areas where condensate or vapor could create a nuisance or hazard or cause popery damage; or ...
Page 31: General Instructions
H2O BOILER HC SERIES IOM Manual NOTES:  The exhaust venting system must meet the requirements of type BH, category II or IV boilers (i.e. corrosion resistant, water and air-tight).  The exhaust duct outlet to the atmosphere MUST be wind protected by an approved wind cap.
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Page 33: Section 3: Operation
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: Sequence Of Operation
H2O BOILER HC SERIES IOM Manual All units are factory assembled with Low Water Cut Off, ASME pressure relief valves (HV stamp), pressure gauges, high temperature limit cut off, gas pressure switch, air pressure switch, drain valves and vent valves. Flame sensors provided are either flame rod or UV sensor.
Page 35: Pilot Flame
H2O BOILER HC SERIES IOM Manual  When the air pressure switch is closed and safety loop is satisfied, pre-purge will start.  Blower continues to run at its maximum frequency for a period identified as the purge time. 3.1.3 Pilot Flame ...
Page 36: Continuous Operation
H2O Boiler representative.  IF adjustments to the factory settings of air and gas flows are made, ensure that the manifold gas pressure does not exceed the pressure specified on the boiler label.
Page 37: Pre-Commissioning
H2O BOILER HC SERIES IOM Manual 3.2 PRE-COMMISSIONING Water connections (Return and Supply Lines)  Purge air from the piping system, and from the boiler/water heater. To purge the unit, run water through the open coils for at least 5 minutes. The coils are now completely purged.
Page 38: Commissioning
H2O BOILER HC SERIES IOM Manual 3.3 Commissioning  Purge heat exchanger coils in accordance with the procedure outlined in paragraph I of section 3.2.  Measure and meter the flow rate through the unit to be at least at the minimum of flow rates indicated in Table 1.
Page 39: Boiler Capacity And Recovery Rate
 The pressure drop (PSI) is also shown in Table 7 based on the selected flow rate. Note: This chart provides approximate values for estimation purposes; conditional safety factors and application specifics may affect boiler requirements. Table 7: HC Series boiler capacity selection (safety factor of 25% already included) Temperature Difference (°F) Model Flow (GPM) Press.
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Page 41: Section 4: Maintenance
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: Maintenance Schedule
H2O BOILER HC SERIES IOM Manual The H2O BOILER HC Series units require the following maintenance duties performed to ensure long and problem free service life. Failure to perform the maintenance duties described in this manual and unit component literature may result in severe damage to the unit and/or the mechanical system.
Page 43 H2O BOILER HC SERIES IOM Manual  Clean up condensate drain o Inspect the condensate drain system including the drain line, vent line, fittings and condensate trap. o Ensure there are no restrictions.  Inspect all piping o Inspect all gas and water piping and check for leaks.
Page 44: Service Notes
H2O BOILER HC SERIES IOM Manual 4.3 Service Notes  H2O BOILER boilers and water heaters have been designed and developed based on a unique patented technology. When operated properly, the products will provide the owner with years of trouble free performance. To benefit for many years, from the unique...
Page 45: Troubleshooting
H2O BOILER HC SERIES IOM Manual 4.2 Troubleshooting Fault Cause Corrective Action    Blower does not start Power not supplied to the unit. Ensure power switch is on.  Check both fuses on the power and the supply sides.
Page 46 H2O BOILER HC SERIES IOM Manual   Unit out of adjustment Check the gas manifold pressure to ensure it complies with the value given in the factory test report. If required, re-adjust the boiler/water (see factory test report for the adjustment values).
Page 47: Technical Data
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...
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Page 49: Reports
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...

This manual is also suitable for:

Hc 600 Hc 1500 Hc 1000 Hc 2000 Hc 2500