Caution : Do not tamper with the unit or its controls.Call a qualified service technician.
GAS FIRED HOT WATER BOILERAND WATER HEATER
Save these instructions for future reference.
Printed in Canada 2006/02/13 X40037 Rev. G
Model Series :
HGRC
DNS-0607 Rev A Division ICPUTC Canada Corporation
Sherbrooke, Quebec J1L 1V8 3400, Industrial Boulevard
Manufactured by :
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PART 1 INSTALLATION
FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE, COMBUSTIBLE, CORROSIVE AND VAPOUR CAUSING LIQUIDS IN THE VICINITY OF THIS APPLIANCE. DANGER, WARNING AND CAUTION The words DANGER, WARNING and CAUTION are used to identify the levels of seriousness of certain hazards. It is important that you understand their meaning. You will find those words in the manual as follows:
DANGER
Immediate hazards which WILL result in death or serious injury.
WARNING
Hazards or unsafe practices which CAN result in death or injury.
CAUTION
Hazards or unsafe pratices which CAN result in personal injury, product or property damage. 1) HGRC LINE The “HGRC” series boilers and water heaters are natural gas or propane gas fired units and are available with inputs ranging from 68,000 Btu/h to 340,000 Btu/h. The model designations are as shown in Figure 1. 2) DESCRIPTION OF MAIN COMPONENTS 2.1) Heat exchanger The heat exchanger consists of 6 finned copper tubes mounted between 2 steel manifolds. A double pass system is used. Standard components used in conjunction with the exchanger include a temperature / pressure gauge, a safety valve, a temperature limiting device and a drain valve.
FIGURE 1
HGRC Series HGRC 000 XX - XX X X X Option N Standard aquastat V Motorised vent damper Y Motorised vent damper and 2 aquastats Altitude N Normal (0 to 2000 feet) H High (2000 to 4500 feet) Gas N Natural P Propane Type C Constant pilot of ignition E Intermittent pilot EM Intermittent pilot + Modulation Unit type AC Boiler designation HW Hot water supply heater Capacity (Input) in thousands of Btu/h Series: Boilers or water heaters gas HGRC
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2.2) Gas train The gas train consists of a removable burner tray assembly. Basically, the gas train incorporates a combination gas control (valve and pressure regulator), and a complete ignition system, including a pilot. 2.3) Draft hood All models use an integral type draft-hood that must not be altered in any way. 2.4) Type of ignition The HGRC series is available with 3 types of ignition: a. A pilot that is burning continuously; b. An intermittent pilot that lights on demand only; c. Hot surface ignition that utilises a glow rod to light
the gas upon demand. 2.5) Modulation The HGRC series is equipped with an optional, thermostatically modulating gas valve, that uses a thermal sensor located in the water outlet to control the gas input to the burners. A modulation of up to 50% of input is possible. 2.6) Motorized vent damper The HGRC series is equipped with an optional, motorized vent damper on the vent pipe to minimize heat loss during off-cycle periods in order to increase the seasonal efficiency of the unit. When requested, this package is completely installed and wired at the factory.
We recommend that you have a qualified technician install your appliance.
3) DELIVERY Carefully check your unit upon delivery for any evidence of damage that may have occurred during shipping and handling. Make sure that the information on the boiler rating plate matches that on the shipping papers. Any claims for damages or lost parts must be made against the carrier without delay. 4) INSTALLATION Your unit must be installed according to regulations set out by competent authorities. Consult the latest editions of the CAN/CGA B149.1 or B149.2 Installation Codes for current guidelines. 4.1) Location The unit must be installed in a clean and dry area, as closely as possible to the chimney or power vent.
CAUTION Any excessive accumulation of dust around the boiler must not be tolerated, especially construction related dust such as dry plaster dust and insulation fibres. These dust particles tend to be sucked in by the burners and to clog them, possibly leading to severe soot formation. Observance of this condition is essential for the appliance warranty to remain valid.
WARNING
This unit must be installed on a non-combustible floor. It must NOT be installed directly on a carpeted or wooden floor.
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FIGURE 2 Installation of accessories supplied with the unit
4.2) Minimum clearances The following clearances from combustible materials must be respected: Top: 0.2 m 9" Sides: 0.6 m 24" Flue-pipe: 0.2 m 9" Front: 1.2 m 48" Rear: 0.2 m 9" Floor: Non combustible Consider the above when planning for additional clearances for maintenance. 4.3) Motorized damper clearances
(when used) A minimum clearance of 152.4 mm (6") between the motorized damper and combustible materials shall be maintained at all times. Furthermore, there must be adequate provision for service access to the damper.
5) COMBUSTION AIR SUPPLY The unit location must provide sufficient fresh air for proper combustion. Consult the appropriate sections of the CAN/CGA B149 code for more details. When the unit is located in an enclosed area, such as a boiler room, where outside air cannot be supplied, 2 fresh air openings must be provided. One must be located 0.1 m to 0.5 m (6" to 18") from the floor, the other as close as possible to the ceiling. Consult the CAN/CGA B149 Code. 6) GAS SUPPLY AND PIPING Gas piping must be installed in accordance with CAN/CGA B149 and local regulations. Table 1 gives the minimum pipe diameters for each model. Please note that the low pressure gas piping must never be smaller in diameter than the gas valve inlet. A manual cut-off valve must be installed as closely as possible to the appliance.
DNS 0295 Rev. B
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TABLE 1
Recommended gas piping dimensions
Distance from the unit gas regulator, in equivalent feet, for a pressure loss of less than 0.5" W.C. Model
0-25 25-50 50-100 100-200 200-300 300-500
HGRC068 ½" ½" ¾" 1" 1" 1"
HGRC105 ¾" ¾" 1" 1" 1 ¼" 1 ¼"
HGRC136 ¾" 1" 1" 1 ¼" 1 ¼" 1 ¼"
HGRC170 1" 1" 1 ¼" 1 ¼" 1 ¼" 1 ½"
HGRC204 1" 1" 1 ¼" 1 ¼" 1 ¼" 1 ½"
HGRC238 1" 1 ¼" 1 ¼" 1 ¼" 1 ½" 1 ½"
HGRC272 1" 1 ¼" 1 ¼" 1 ½" 1 ½" 2"
HGRC306 1" 1 ¼" 1 ¼" 1 ½" 1 ½" 2"
HGRC340 1 ¼" 1 ¼" 1 ¼" 1 ½" 2" 2"
CAUTION The unit must be completely isolated from corrosive chemical vapours and excessively moist air. FAILURE TO COMPLY WITH THIS CONDITION CAN RENDER YOUR WARRANTY NULL AND VOID. When a mechanical air supply device is used, the installer must make certain that no air movement is created around the unit. Furthermore, this mechanical device (fan, damper, etc.) must be electrically connected to the unit to lockout the latter in case of device failure. 7) ELECTRICAL WIRING All wiring must be in accordance with local authorities and the “Canadian Electrical Code - CSA C22.1/ Part I”. The unit must be connected to a 15 amp protected circuit with a single phase voltage of 120 VAC at 60 Hz. The installer must wire the unit according to the appropriate electrical diagram. If a motorized damper is used, the wire harness provided with the unit must be used without modification for this connection. Consult the following figures for the appropriate electrical diagrams:
Figure 4.1: Constantly burning pilot Figure 4.2: Constantly burning pilot with motorized
damper Figure 4.3: Intermittent pilot (electronic),
White-Rodgers Figure 4.4: Intermittent pilot (electronic), Honeywell Figure 4.5: Intermittent pilot (electronic), Honeywell
and motorized damper Figure 4.6: Intermittent pilot (hot surface) Figure 4.7: Intermittent pilot (hot surface) with
motorized damper Figure 4.8: Constantly burning pilot with side wall
venting Figure 4.9: Constantly burning pilot with side wall
venting and motorized damper Figure 4.10: Intermittent pilot (electronic)
White-Rodgers with side wall venting Figure 4.11: Intermittent pilot (electronic) Honeywell
with side wall venting Figure 4.12: Intermittent pilot (electronic) Honeywell
with motorized damper and side wall venting
Figure 4.13: Intermittent pilot (hot surface) with side wall venting
Figure 4.14: Intermittent pilot (hot surface) with motorized damper and side wall venting
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CAUTION Please note that HGRC boilers and water heaters require water circulation whenever the burners are on. The factory mounted pump relay is installed for this purpose. Failure to circulate water through the exchanger when the burners are operating voids the warranty. The unit is equipped with a 120/24 VAC step down tranformer for all internal needs. All 24 VAC connections are built-in at the factory. A supplementary 120/24 Vac step down transformer shall be planned for if external equipment needs 24 VAC voltage (zone valves, etc.). On all units the external terminals “W” and “R” are for the connection of a room thermostat or an operating control (aquastat, indoor-outdoor control, etc.). Simply putting a jumper on “W” and “R” and having the appliance run on its high Limit Control is inefficient and not recommended.
CAUTION If any of the original wires, as supplied with the appliance must be replaced, they must be replaced with 16 gauge TEW (105°C) wire or equivalent. 8) WATER PIPING 8.1) Overview A pressure regulator must be installed on the water feed line to the unit and adjusted to a pressure lower than the unit’s safety valve setting. The system must be equipped with a circulating pump, expansion tank, air vents and maintenance valves as indicated in Figure 5. Also, we strongly recommend the installation of a flow-switch. The installation of a by-pass between the return and supply pipes is good plumbing practice and ensures good return temperature in the heat exchanger.
8.2) Variable volume water system Heating systems incorporating zone valves, zone circulators or three way mixing valves operate with reduced water circulation through the unit. The installation must be planned by considering that a minimum water flow must circulate through the unit. A water flow lower than the minimum threshold could result in a significant water temperature elevation, provoking a knocking noise, vibrations and short cycling operation. All these conditions are unstable and damaging to the appliance. Always size your circulating pump so that the minimum flow of water never falls below the minimum flow recommended in Tables 5 and 6. If short cycling operation persist, the use of a modulating gas valve should be considered.
CAUTION For proper operation and to prevent condensation on the external surfaces of the heat exchanger, the return temperature of your HGRC unit must always exceed 38°C (100°F). A transition period below that temperature is acceptable, but a permanent return temperature below 38°C (100°F) voids your warranty. 9) DRAFT HOOD The draft hood delivered with your HGRC unit must be installed without any modifications and fastened to the collar of the appliance by way of metal screws. 10) VENTING 10.1) Chimney
CAUTION An inadequate chimney can result in the improper operation of the unit.
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The chimney must have sufficient draft to ensure the normal and safe operation of the appliance. Consult the CAN/CGA B149 Installation Code. Also, the installation must conform to all regulations of the authorities having jurisdiction. 10.2) Through the wall venting All HGRC units are approved for installation with through the wall venting packages. Please consult Table 2 for correct package selection and refer to the wiring diagrams related to side wall venting. Note : Please refer to the Instruction Manual supplied
with your side wall venting package. 10.3) Motorized vent damper (when used) The HGRC unit can be equipped with a motorized damper device that closes the vent pipe when the main burners are off. This damper is factory installed and wired and must not be modified or relocated.
CAUTION The draft hood and the motorized damper must be installed without any modification. The venting system shall be arranged such a way that the automatic vent damper device can serve only the appliance for which it was supplied HGRC. The orientation of the damper in the venting system shall be such that the arrow on the body of the damper is in the direction of the flow of the combustion gases. Also, the damper actuator is equipped with a coupling which is arrow shaped. When the damper is open, this arrow points in the direction of the gas flow and when the damper is closed, it is perpendicular to the gas flow. These indicators (arrows) shall be in a visible location following installation.
CAUTION
The damper must be in the “Open” position when the appliance main burners are operating. It may be necessary to manually operate the damper if the main burners have to be operated during a damper actuator breakdown.
CAUTION It is dangerous and not permitted to modify the unit wiring to allow "damperless" burner operation if the motorized damper is still in place. To manually open the damper, please follow these steps: 1. Remove the vent damper junction box cover; 2. Place the selection switch in the "SERVICE"
position; 3. Using a screwdriver, turn the manual adjustment
screw counter-clockwise until the arrow points in the direction of the gas flow;
4. To close the damper, continue rotating the screw in the counter-clockwise direction.
CAUTION To ensure normal damper operation, put the switch back in the "NORMAL" position.
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TABLE 2 Side wall venting selection chart
Model Package # Power vent Reducer 1
(power vent) Reducer 2
(draft hood) Flue-pipe Vent hood
HGRC68 SG-1 HSJ 5"-4" N/A 5" VH-1-4
HGRC105 SG-2 HSJ 6"-4" N/A 6" VH-1-4
HGRC136 SG-3 HS1 6"-4" N/A 6" VH-1-4 HGRC170 HGRC204 SG-4 HS1 6"-4" 7"-6" 6" VH-1-4
HGRC238 HGRC272 HGRC306
SG-5 HS2 N/A 8"-6" 6" VH-1-6
HGRC340 SG-7 HS2 N/A 9"-6" 6" VH-1-6
Notes : Reducer 2 is directly at the outlet of the draft hood and reducer 1 is at the inlet of the power vent. The maximum equivalent length for all models is 100 feet. (900 elbow = 10 equivalent feet, 450 elbow = 5 equivalent feet)
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PART 2 OPERATION
1) FUEL Use only natural gas or propane gas. Never use any other type of gas. 2) STARTING UP YOUR SYSTEM 2.1) Filling your system with water All existing piping must be drained and cleaned with fresh water circulation before filling the new HGRC unit. 1. Close all manual air vents and open the cold water
feed valve to fill the system slowly; 2. Purge the air from the system by letting the
circulating pump run. Check for proper operation of the automatic air vents and manually actuate the manual air vents;
3. Check the system pressure and adjust the pressure regulator as required;
4. Check the system for leaks after the unit has reached normal operation temperature.
2.2) Lighting the pilot
CAUTION On all types of ignition, wait a minimum of 5 minutes before attempting to relight the pilot. If the unit is equipped with a motorized vent damper, this delay must be with the damper open. 2.2.1) Constantly burning pilot 1. Set the button on the gas valve to “PILOT”; 2. Press down the button fully and light the pilot with a
match; 3. Hold down the button for 30 seconds to help purge
the air from the pilot gas line; 4. Release the button; 5. The pilot should stay lit. If not, check the
thermocouple and its connection to the gas valve; 6. The pilot flame should envelop the thermocouple. If
it does not, adjust the flame by turning the screw marked “PILOT ADJUSTMENT” on the gas valve.
2.2.2) Intermittent electronic and hot surface ignition pilots
These systems activate the pilot upon demand. You do not have to manually light the pilot.
CAUTION On a 36C type White-Rodgers valve, do not put the knob of the gas valve to the pilot position. This position is not applicable for intermittent pilot systems. The operation will be erratic. 2.3) Lighting the main burners
CAUTION On all types of ignition, wait a minimum of 5 minutes before attempting to relight the pilot. Simulate a demand by jumping terminals “W” and “R” located on the exterior of the unit control panel. On all types of ignitions, the ignition should be smooth without flame roll-out or orifice burning. 2.3.1) Constant pilot After the pilot is standing, turn the gas knob to the “ON” position. 2.3.2) Intermittent electronic pilot 1. Turn the gas knob to the “ON” position. The pilot
should begin to spark and when all air is expelled from the pilot line, the pilot should appear;
2. The sparks should stop and after a short delay (longer on White-Rodgers systems) the main gas valve should open the gas to the main burners.
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2.3.3) Intermittent hot surface ignition pilot 1. Turn the gas knob to the “ON” position. The glow
rod on the pilot should begin to heat and when hot enough, allow the gas to flow to the pilot. Once all air is expelled from the pilot line, the pilot should light;
2. The glow rod should turn off and the main gas valve open the gas to the main burners.
2.4) Verifications and adjustments Once the main burners are in operation the following points MUST be checked. 2.4.1) Manifold pressure Install a pressure gauge downstream from the gas valve on the pressure tap provided on the vertical section of the gas train pipe. The pressure observed after 5 minutes of operation should correspond to the value specified in Table 3. If your gas train is equipped with a modulating gas valve make sure that this valve is not modulating when the reading is being taken. If you need to adjust the pressure, do so by turning the main setting screw on the gas valve.
TABLE 3 Pressures Manifold
Models Pressure ("W.C.) Natural Gas
Pression ("W.C.) Propane Gas
HGRC 068 @ 340 3.5 10.0
2.4.2) Pilot control safety checks Constantly burning pilot 1. Cut the gas supply by moving the gas valve knob to
“OFF”; 2. The valve must close in the following 90 seconds.
You should hear a little CLICK. Intermittent pilots (electronic and hot surface) 1. Cut the gas supply by moving the gas valve knob to
“OFF”; 2. The control circuit should close the valve within 1
second.
2.4.3) Temperature control limit check Adjust the temperature control limit below the present water temperature. The gas supply to the burners should stop immediately. Set the control for a higher temperature and the burners should come on again. 2.4.4) Modulating valve (if used) With the boiler running, turn the thermostatic valve knob through its various positions. The gas flow to the burners should decrease when the selected setting point is reached. Consult Table 4 to select the correct valve setting for your needs.
TABLE 4 Temperature modulation
Selector position Modulation temperature o F (oC)
1 49°C (120°F)
2 57°C (135°F)
3 66°C (150°F)
4 74°C (165°F)
5 82°C (180°F)
6 91°C (195°F)
7 99°C (210°F)
8 107°C (225°F)
9 116°C (240°F) 2.4.5) Gas leaks Check the whole system for gas leaks after the installation is completed. Use a solution of soap and water on the pipe joints.
DANGER
If there is an major leak is detected or the smell of gas is strong : 1. Open the windows, 2. Do not activate any electrical switches, 3. Extinguish all flames, 4. Immediately call your gas supplier from
another building.
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PART 3 MAINTENANCE
1) MAINTENANCE Your boiler should be inspected once a year by a qualified technician. The following points require particular attention. 1.1) Heat exchanger The heat exchanger should be checked for soot deposits. If necessary, follow the procedures below to clean the heat exchanger. Consult Figure 3. 1. Remove the burner tray to avoid the soot falling on
the burners; 2. Remove the connecting flue-pipe and the draft
hood; 3. Remove the “V” shaped baffles; 4. Clean the heat exchanger with a suitable brush; 5. Vacuum the debris at the bottom of the unit; 6. Reinstall everything. 1.2) Drawer assembly (burner tray) Your HGRC boiler is equipped with a burner tray to allow you to remove the burners and manifold without dismantling the appliance. To remove the burner tray, disconnect the union on the gas piping and disconnect the wiring harness. Pull out the tray.
1.3) Combustion chamber While the burner tray and the draft hood are off, use a light to properly check the condition of the combustion chamber and repair if necessary. 1.4) Flue-pipe and connecting pipe Inspect and clean if necessary. 1.5) Miscellaneous 1. If a fresh air intake mechanical device is used,
check if it is functioning properly; 2. Inspect the circulating pump and lubricate if
necessary; 3. Test the high temperature Limit Control and the
operating controls; 4. Test the safety valve.
CAUTION The installer must follow local regulations with respect to the installation of carbon monoxide (CO) detectors. The installer must also follow the guidelines set out in the instructions above, concerning the maintenance schedule of the appliance.
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PART 4
INFORMATION
Model: Serial number:
Boiler installation date:
Service telephones - Day:
Night:
Dealer name and address:
RESULTS OF START-UP TEST
Gas inlet pressure:
" W.C."
Gas outlet pressure:
" W.C."
Heat exchanger water inlet temperature:
°F or °C
Heat exchanger water outlet temperature:
°F or °C
Water pressure of distribution system:
Psi
Hi-Limit temperature adjustment:
°F or °C
Test performed by:
TABLE 5Natural gas
TABLE 6Propane gas
Input Minimum Output USGPM Pressure Recovery Input at 20°F loss rate
(Btu/h) (Btu/h) (Btu/h) delta T (ft. of water) (USGPH)HGRC068 58,000 N/A 46,400 4.7 0.5 48.7HGRC105 87,000 43,500 69,600 7.1 0.5 73.1HGRC136 116,000 58,000 92,800 9.4 0.5 97.5HGRC170 145,000 72,500 116,000 11.8 0.5 121.8HGRC204 174,000 87,000 139,200 14.1 0.5 146.2HGRC238 203,000 101,500 162,400 16.5 0.6 170.6HGRC272 232,000 116,000 185,600 18.9 0.7 194.9HGRC306 261,000 130,500 208,800 21.2 0.8 219.3HGRC340 290,000 145,000 232,000 23.6 0.9 243.7
Model
Notes: - In high altitude (2,000 to 4,500 feet), apply a 10% reduction on input, min. input, output and USGPH. - The recovery rates (USGPH) are applicable only on water heaters.
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Input Minimum Output USGPM Pressure RecoveryInput at 20°F loss rate
(Btu/h) (Btu/h) (Btu/h) delta T (ft. of water) (USGPH)HGRC068 68,000 N/A 54,400 5.5 0.5 57.1HGRC105 102,000 51,000 81,600 8.3 0.5 85.7HGRC136 136,000 68,000 108,800 11.1 0.5 114.2HGRC170 170,000 85,000 136,000 13.8 0.5 142.9HGRC204 204,000 102,000 163,200 16.6 0.5 171.5HGRC238 238,000 119,000 190,400 19.3 0.6 200.0HGRC272 272,000 136,000 217,600 22.1 0.7 228.6HGRC306 306,000 153,000 244,800 24.9 0.8 257.1HGRC340 340,000 170,000 272,000 27.7 0.9 285.7
Model
Notes: -In high altitude (2,000 to 4,500 feet), apply a 10% reduction on input, min. input, output and USGPH. -The recovery rates (USGPH) are applicable only on water heaters.
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Technical dataHGRC gas fired hot water boiler and water heater
68,000 to 340,000 BTU/h
Model ModelHGRC HGRC
T-°C T-°F USGPM L/S ft. W.C. Kpa T-°C T-°F USGPM L/S ft. W.C. Kpa
11 20 5.4 1 1 3 11 20 19 3.59 1.2 3.616.6 30 3.6 0.7 1 3 16.6 30 12.7 2.4 1.2 3.622 40 2.7 0.5 1 3 22 40 9.5 1.8 1 3
11 20 8.2 1.5 1 3 11 20 21.7 4.1 1.3 3.916.6 30 5.4 1 1 3 16.6 30 14.5 2.74 1.2 3.622 40 4.1 0.8 1 3 22 40 10.9 2.06 1 311 20 10.9 2.1 1 3 11 20 24.5 4.63 1.5 4.5
16.6 30 7.2 1.4 1 3 16.6 30 16.3 3.08 1.2 3.622 40 5.4 1 1 3 22 40 12.2 2.31 1 311 20 13.6 2.6 1 3 11 20 27.2 5.14 1.8 5.4
16.6 30 9.1 1.7 1 3 16.6 30 18.1 3.42 1.2 3.622 40 6.8 1.3 1 3 22 40 13.6 2.57 1 311 20 16.3 3.1 1.2 3.6
16.6 30 10.9 2.1 1 322 40 8.2 1.5 1 3
272
Water PressureTemperatureoutput loss Rise output lossWater Pressure Temperature
204
Rise
136 306
170 340
68 238
105
Temperature Rise / Output / Pressure (natural gas)
ModelHGRC-WC T40°F T60°F T80°F T100°F T120°F T140°F T22°C T33°C T45°C T56°C T67°C T78°C
68 143 95 71 57 48 41 541 360 269 216 182 155105 214 143 107 86 71 61 810 541 405 326 269 231136 285 190 143 114 95 82 1079 719 541 431 360 310170 357 238 178 143 119 102 1351 901 674 541 450 386204 428 285 214 171 143 122 1620 1079 810 647 541 462238 713 333 250 200 167 143 2699 1260 946 757 632 541272 571 381 285 228 190 163 2161 1442 1079 863 719 617306 642 428 321 257 214 184 240 1620 1215 973 810 696340 713 476 357 285 238 204 2699 1802 1351 1079 901 772
Recovery Rate (USGPH) Recovery Rate (litres/hour)
Recovery Rate (natural gas)
Technical dataHGRC gas fired hot water boiler and water heater
68,000 to 340,000 BTU/h
Number of units
Instant. 5,3 10,6 15,9 21,2 26,5 31,0 Instant. 20 40 60 80 100 1203 351 35,7 30,6 28,0 24,8 21,9 19,5 1327 135 116 106 94 83 745 406 58,1 51,8 45,7 40,4 36,2 31,7 1536 220 196 173 153 137 120
10 471 119 104 91,1 80,0 70,5 64,5 1782 450 395 345 303 267 24415 516 176 155 136 120 106 92,5 1954 665 585 515 455 400 35020 557 236 207 182 161 141 124 2109 895 785 690 610 535 47025 598 285 250 219 190 168 148 2265 1080 945 830 720 635 56030 642 335 291 356 223 195 172 2432 1270 1100 970 845 740 65040 720 420 367 320 280 244 214 2727 1590 1390 1210 1060 925 81050 810 489 425 372 351 285 251 3068 1850 1610 1410 1330 1080 95060 901 555 489 417 362 316 272 3409 2100 1810 1580 1370 1190 103080 1051 629 547 476 412 357 3977 2380 2070 1800 1560 1350100 1150 660 576 502 433 4355 2500 2180 1900 1640150 1393 705 602 518 5273 2670 2280 1960200 1597 914 793 687 6046 3460 3000 2600250 1801 1149 996 6819 4350 3770300 2005 1347 1202 7591 5100 4550
Storage capacity per unit (USG) Storage capacity per unit (litres)
Minimum water heater capacity Minimum water heater capacityUSGPH (litres/hour)
Apartment Buildings*
*Source: ASHRAE Handbook, Québec Plumbing Code
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Technical dataHGRC gas fired hot water boiler and water heater
68,000 to 340,000 BTU/h
Motels and HotelsNumber of units
Instant. 4 8 12 16 Instant. 15 30 45 603 to 20 43 4.3 2.8 1.9 1,5 163 16,3 10,6 7,2 5,7
21 to 100 24 3.4 2.2 1.4 1,3 91 12,9 8,03 5,3 4,9101 and up 17 2.5 1.8 1.2 1,0 64 9,5 6,8 4,5 3,8
Minimum water heater capacity per unit (litres/hour)
Storage capacity per unit (litres)
Minimum water heater capacity per unit(USGPM)
Storage capacity per unit (USG)
Dormitories and Fraternities
Instant. 4 8 12 16 Instant. 15 30 45 6040 2.9 1.75 1.2 1 151 11 6.6 4.5 3.8
Minimum water heater capacity per unit(USGPM)
Storage capacity per occupant (USG)
Minimum water heater capacity per unit (litres/hour)
Storage capacity per occupant (litres)
Instant. 4 8 12 16 Instant. 15 30 45 6040 2.9 1.75 1.2 1 151 11 6.6 4.5 3.8
Minimum water heater capacity per occupant (litres/hour)
Storage capacity per unit (litres)
Minimum water heater capacity per occupant(USGPM)
Storage capacity per unit (USG)
Reception Halls
Nombre de douche
20 25 30 35 40 75 95 115 132 1505 à 10 41 37 32 28 22 155 140 121 106 83
11 à 15 33 28 22 19 16 125 106 83 72 6116 à 20 28 23 18 15 13 106 87 68 57 4921à 30 26 20 15 12 10 98 76 57 45 3831 à 40 25 20 15 12 10 95 76 57 45 38
Minimum water heater capacity per shower(USGPM)
Storage capacity per shower (USG)
Minimum water heater capacity per shower (litres/hour)
Storage capacity per shower (litres)
Sports Arenas
20 25 30 35 40 75 95 115 132 15040 40 35 30 25 170 151 132 114 95
Minimum water heater capacity per washing machine(USGPM)
Storage capacity per washing machine (USG)
Minimum water heater capacity per washing machine (litres/hour)
Storage capacity per washing machine (litres)
Laundromats
FIGURE 3
DNS-0608 Rev. B
Model Overall Draft Vent pipe Gas valveHGRC dimensions hood diameter diameter
"LA" "LB" "LC" "LD"HGRC068 494 mm (19 7/16") 238 mm (9 3/8") 127 mm (5") 12,7 mm (1/2")HGRC105 558 mm (21 15/16") 558 mm (11 7/8") 152 mm (6") 12,7 mm (1/2")HGRC136 621 mm (24 7/16") 365 mm (14 3/8") 152 mm (6") 12,7 mm (1/2")HGRC170 685 mm (26 15/16") 429 mm (16 7/8") 178 mm (7") 12,7 mm (1/2")HGRC204 748 mm (29 7/16") 492 mm (19 3/8") 178 mm (7") 12,7 mm (1/2")HGRC238 812 mm (31 15/16") 556 mm (21 7/8") 203 mm (8") 19 mm (3/4")HGRC272 875 mm (34 7/16") 620 mm (24 3/8") 203 mm (8") 19 mm (3/4")HGRC306 938 mm (36 15/16") 683 mm (26 7/8") 203 mm (8") 19 mm (3/4")HGRC340 1002 mm (39 7/16") 746 mm (29 3/8") 229 mm (9") 19 mm (3/4")
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FIGURE 4.1Wiring diagram, constantly burning pilot
FIGURE 4.2Wiring diagram, constant pilot with motorized damper
DNS-0281 Rev.A
DNS-0282 Rev.A
FIGURE 4.3Wiring diagram, intermittent electronic pilot - WR
DNS-0284 Rev. A
20
FIGURE 4.4Wiring diagram, intermittent electronic pilot - HON
DNS-0283 Rev.A
21
FIGURE 4.5Wiring diagram, intermittent electronic pilot (HON) with motorized damper
FIGURE 4.6Wiring diagram, intermittent hot surface ignition pilot - HON
DNS-0285 Rev.A
DNS-0286 Rev B
22
FIGURE 4.7Wiring diagram, intermittent hot surface ignition pilot with motorized damper
FIGURE 4.8Wiring diagram, constant pilot with side wall venting
DNS-0287 Rev B
DNS-0288 Rev.A
23
FIGURE 4.9Wiring diagram, constant pilot - side wall vent - motorized damper
FIGURE 4.10Wiring diagram, intermittent electronic pilot WR & side wall venting
DNS-0289 Rev.A
DNS-0290 Rev.A
24
FIGURE 4.11Wiring diagram, intermittent electronic pilot HON & side wall venting
FIGURE 4.12Wiring diagram, intermittent electronic pilot HON - side wall vent - motorized damper
DNS-0291 Rev.A
DNS-0292 Rev.A
25
FIGURE 4.13Wiring diagram, intermittent hot surface pilot with side wall venting
FIGURE 4.14Wiring diagram, intermittent hot surface pilot - side wall venting - motorized damper
X00165 Rev. C
DNS-0294 Rev.B
26
FIGURE 5
DNS-0296 Rev. B
Typical plumbing arrangement for space heating
27
COMPONENTSAND
REPLACEMENT PARTS
PARTS LISTModel : HGRC (HGRC068 to HGRC340)
28
DNS-0392 Rev.C
PARTS LISTModel : HGRC (HGRC068 to HGRC340)
29
ITEM DESCRIPTION NUMBER COMMENTS1A Heat exchanger B01234-0X HGRC heating 1B Heat exchanger B01235-0X HGRC hot water 2A Intermediary heat exchanger header (Steel) K01001 Without inlet/outlet connector2B Intermediary heat exchanger header (Stainless steel) K01002 Without inlet/outlet connector3A Heat exchanger header (Steel) K01003 HGRC heating 3B Heat exchanger header (Stainless steel) K01004 HGRC hot water 4 Finned tube kit K01005-0X With supporting plates5 Heat exchanger header mounting kit K01006 Includes nuts, bolts and silicone joint (12)6 Heat exchanger deflector B00263-0X
7A Burner drawer kit K01014-0X Without modulating valve - Constant7B Burner drawer kit K01015-0X Without modulating valve - Hot surface ignition7C Burner drawer kit K01016-0X With modulating valve - Hot surface ignition7D Burner drawer kit K01019-0X Without modulating valve - Electronic (Used with No. 42)7E Burner drawer kit K01020-0X With modulating valve - Electronic (Used with No. 42)8 Draft hood assembly K01017-0X9 Complete combustion chamber K01007-0X Includes all panels and insulation staples
10 Outside heat exchanger insulation B01318-0111 Inside heat exchanger insulation B01318-0312 Front / rear inside heat exchanger insulation B01318-1X13 Front / rear outside heat exchanger insulation B01318-2X14 Top outside heat exchanger insulation B01318-0215 Top inside heat exchanger insulation B01318-0416 Top heat exchanger insulation B01318-3X17 Rear outside panel B01352-0X18 Right heat exchanger panel B0131619 Exterior front panel B01351-0X20 Header cover panel, side B01370-0121 Header cover panel, side B01370-0222 Header cover panel, bottom B0136923 Header cover panel, top B01331 With inlet/outlet openings24 Header cover panel, top B01330 Without inlet/outlet openings25 Heat exchanger support kit K01008-0X Includes all tracks and supports26 Floor B01317-0X27 Heat exchanger adaptor B01323-0X28 Heat exchanger support, interior B01320-0229 Special screw kit A0025930 Side panel electrical box B01356-02 Fuse side31 Side panel electrical box B01356-01 Power side32 Electrical box B0135433 Cover, electrical box K01010 With logo label
34A Fuse, 1A L01G001 Constant pilot only34B Fuse, 3A time-delay L01G008 Electronic pilot only35 Fuse holder L02G00136 8 position terminal strip K01011 Includes 2 terminal strips and 2 retaining staples37 Ground connector kit K0101238 6 position terminal strip L05F00239 Relay 24VAC SPDT L01H009 Circulator relay
40A Transformer 120V / 24V 20 VA L01F002 Constant pilot only40B Transformer 120V / 24V 40 VA L01F003 Electronic pilot only41 Simple aquastat R02F00142 Ignition control R03I005 HGRC-238 to HGRC-340 (not used anymore)43 Rear burner support B01337-0X44 Right drawer side B01339-1X45 Left drawer side B01339-0X46 Burner deflector B01346-0X47 Front deflector B01455-0X48 Drawer cover B01340-0X49 Drawer collector B01373-0X Without valves and accessories
PARTS LISTModel : HGRC (HGRC068 to HGRC340)
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MODEL XHGRC068 1HGRC105 2HGRC136 3HGRC170 4HGRC204 5HGRC238 6HGRC272 7HGRC306 8HGRC340 9
TABLE OF VARIABLES
When the part number changes based on the size of the furnace, complete the code in the “NUMBER” column by replacing the X with the corresponding number in the table to the right.
ITEM DESCRIPTION NUMBER COMMENTS50A Ignition cable R03Z004 Electronic pilot HGRC-238 to HGRC-34050B Thermocouple 30" R02K004 Constant pilot50C Wire harness B01460 Electronic pilot HGRC-068 to HGRC-20451A Constant pilot R03G00451B Electronic pilot R03H004 Elect.pilot HGRC-068 to HGRC-34051C Electronic pilot R03H002 HGRC-238 to HGRC-340 when #42 is used52A Gas valve 1/2” X 1/2” R01F020 Constant pilot, HGRC-068 to HGRC-20452B Gas valve 3/4” X 3/4” R01F021 Constant pilot, HGRC-238 to HGRC-34052C Gas valve 1/2” X 1/2” R01J004 Elect. pilot HGRC-068 to HGRC-20452D Gas valve 3/4” X 3/4” R01H009 HGRC-238 to HGRC-340 when #42 is used52E Vanne à gaz 3/4” X 3/4” R01J007 Elect. pilot HGRC-238 to HGRC-34053A Gas supply pilot tube K01013-01 Includes 2 parts HGRC-068 to HGRC-13653B Gas supply pilot tube K01013-02 Includes 2 parts HGRC-170 to HGRC-23853C Gas supply pilot tube K01013-03 Includes 2 parts HGRC-272 to HGRC-34054A Modulate gas valve 1/2” X 1/2” R01K001 HGRC-068 to HGRC-20454B Modulate gas valve 3/4” X 3/4” R01K004 HGRC-238 to HGRC-34055 Hgrc burner B01393 Each
56A Low altitude natural gas orifice HGRC (Dim 0.111) B01238-01 HGRC low altitude only (each)56B High altitude natural gas orifice HGRC (Dim 0.104) B01238-03 HGRC high altitude only (each)56C Low altitude propane gas orifice HGRC (Dim 0.064) B01238-02 HGRC low altitude only (each)56D High altitude propane gas orifice HGRC (Dim 0.055) B01238-04 HGRC high altitude only (each)57A Thermo-pressure gauge 0/60 psi R02L001 HGRC only57B Thermo-pressure gauge 0/250 psi R02L003 Hot water HGRC only58A Reducer hexagonal 1” X 1/4” steel G08F003 Heating HGRC only58B Reducer hexagonal 1” X 1/4” stainless steel G08G001 Hot water HGRC only59A T reducer 1 1/4 x 1 1/4 X 1 steel G05H004 Heating HGRC only59B T reducter 1 1/4 x 1 1/4 X 1 brass G05I001 Hot water HGRC only60 Drain valve G11Z001-1
61A Steel nipple 3/4" X 2" G01J002 Heating HGRC only61B Steel nipple 3/4" X 2" G02J006 Hot water HGRC only62A Steel nipple 1 1/4" X 5" G01L007 Heating HGRC only62B Stainless steel nipple 1 1/4" X 5" G02L003 Hot water HGRC only63A Safety valve #30 G11F012 Heating HGRC only63B Safety valve temp/pressure 150# G11F020 Hot water HGRC only64 Complete propane conversion kit K01018 Includes conversion kit with orifices65 Propane conversion kit R01Z00366 Normal altitude propane HGRC orifices B01238-0267 Orifice insert .012 R04G00368 Draft hood spill out switch R02N00769 Burner roll out switch R02N00770 Therm-o-disk protector B0139671 Therm-o-disk holder B01338
