Quantum GAS-FIRED BOILERS manual

DUNKIRK BOILERS DUNKIRK, NEW YORK 14048 - 716 366-5500 Member: The Hydronics Institute GAS-FIRED, DIRECT VENT, CONDENSING, HOT WATER BOILERS INSTALLATION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler WARNING Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Ref[...]

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1 TABLE OF CONTENTS INTRODUCTION ............................................................................. 3 BOILER RATINGS AND CAPACITIES .................................................................................. 4 RULES FOR SAFE INSTALLATION AND OPERATION ....................................................... 7 BEFORE INSTALLING THE [...]

2 H. draft inducer............................................................................................................... ....... 33 I. circulator pump........................................................................................................... ....... 33 J. drain valve..........................................................[...]

This appliance is a gas-fired direct vent hot water boiler with cast aluminum boiler sections. A revolutionary cast aluminum heat exchanger means better heat transfer and thermal storage than similarly sized cast iron boilers, which results in higher efficiency. The heating system water absorbs large amounts of heat from the cast aluminum heat exch[...]

BOILER RATINGS AND CAPACITIES 4 These low pressure gas-fired hot water boilers are design certified by CSA International for use with natural and propane gases. The boilers are constructed and hydrostatically tested for a maximum working pressure of 50 psig (pounds per square inch gage) in accordance with A.S.M.E. (American Society of Mechanical En[...]

5 U.S.A. ONLY: For altitudes above 2,000 feet above sea level, input ratings should be reduced as shown in tables IA, C, & E for natural gas boilers or in tables 1B, D & F for propane fired boilers. Reduced input ratings are achieved by the natural deration of the gas at higher elevations and fine tuned by adjusting the manifold pressure. C[...]

6 (/(9 $ 7 , 2 1)((7          120, 1$ /, 1387 0% +         +($ 7 &$ 3 &, 7 <0%+ ?[...]

7 l . Read the entire installation manual before beginning the installation. Failure to follow these rules for safe installation and operation and these instructions could cause a malfunction of the boiler and result in death, serious bodily injury, and/or property damage. 2. Check all applicable state and local building codes and utility company r[...]

Where required by the authority having jurisdiction, the installation must conform to the American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, No.CSD-1. The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to t[...]

9 1. Select a location which is level, central to the piping systems served and as close to the vent and air intake terminals as possible. 2. Accessibility clearances, if more stringent (i.e. larger clearances) than required fire protection clearances, must be used for the boiler installation. Accessibility clearances may be achieved with the use o[...]

10 CAUTION KEEP BOILER AREA CLEAN OF DEBRIS AND FREE OF FLAMABLE AND COMBUSTIBLE MATERIALS, VAPORS AND LIQUIDS WARNING When vent pipe is exposed to temperatures below freezing, such as when it passes through an unheated space or when a chimney is used as a raceway, vent pipe must be insulated with 1/2 Armaflex or equivalent. In extreme cold clim[...]

11 NOTE: 1. If boiler is not level condensate drain lines will not function properly. Adjustable feet are located on the boiler to make up for minor surface irregularities or tilt. 2. Wood frame or blocks may be used to raise boiler to maintain drain pitch or to be above external condensate pump reservoir. H. REMOVAL OF EXISTING BOILER FROM COMMON [...]

12 CAUTION Copper supply and return piping. must NOT be installed directly into aluminum boiler section casings due to galvanic corrosion between dissimilar metals. Iron or steel bushings or pipe nipples should be used between copper system piping and boiler to make final connection to boiler. Also, the use of dielectric unions is acceptable. The p[...]

FIGURE 2 SINGLE ZONE BOILER PIPING 13[...]

FIGURE 3 MULTI ZONE BOILER PIPING WITH ZONE VALVES 14[...]

NOTE: When zoning with circulators, the furnished circulator pump should be used as one of the zone pumps. Each stripped end of the electrical wires for the circulator pump inside the junction box should be taped or wire nutted to prevent short circuits. Unplug the circulator pump wiring at the integrated boiler control. FIGURE 4 MULTI ZONE BOILER [...]

B. PRESSURE RELIEF VALVE The boiler is furnished with a factory installed relief valve in the top of the boiler. Provide ¾ piping from the supplied relief valve to a local floor drain, but leave an air gap between piping and drain. No shutoff of any description shall be placed between safety relief valve and the boiler, or on the discharge pipe[...]

FIGURE 6 DIAPHRAGM TYPE EXPANSION TANK PIPING 17[...]

FIGURE 7 CONVENTIONAL (closed type) EXPANSION TANK PIPING 18[...]

D. CONDENSATE DRAIN PIPING The condensate trap is built into the boiler, an external trap is not required and should NOT be used. Provide ½ PVC condensate drain and fittings. Condensate drain to be pitched down to floor drain at a minimum of ¼ per foot. Install furnished ½ PVC tee to overflow fitting as shown in Fig. 8 . The ½ diame[...]

20 E. FILLING CONDENSATE TRAP WITH WATER ON THE INITIAL START UP THE CONDEN SATE TRAP MUST BE MANUALLY FILLED WITH WATER The following are the steps required to initially fill the condensate trap for start up, these steps are only required at the initial start up or if maintenance requires draining of the condensate trap: 1. Disconnect the vent con[...]

In Canada construct all combustion air and vent pipes for this unit of CSA or ULC certified schedule-40 CPVC, schedule-40 PVC, PVC-DWV or ABS-DWV pipe and pipe cement. SDR pipe is NOT approved in Canada. 3. Combustion air and vent piping connections on boiler are sized for 2" pipe. Any pipe size change (to 3") must be made outside of the [...]

22 6. C o nsideration for the following should be used when determining an appropriate location for termination of combustion air and vent piping.  Comply with all clearances required as stated in paragraph 7.  Termination should be positioned where vent vapors will not damage plants/shrubs or air conditioning equipment.  Termination shoul[...]

23 FIGURE 10 SIDEWALL VENT/INTAKE TERMINATIONS[...]

FIGURE 11 COMBUSTION AIR AND VENT PIPING 24[...]

25 B. INSTALLATION 1. Attach combustion air intake piping to supplied Fernco 2" coupling on mixer. Attach vent piping to furnished 2" CPVC vent tee on draft inducer outlet. NOTE: All pipe joints are to be water tight. 2. Working from the boiler to the outside, cut pipe to required length(s). 3. Deburr inside and outside of pipe. 4. Chamfe[...]

B. CONNECTING THE GAS PIPING Refer to Fig.12 for the general layout at the boiler. It shows the basic fittings you will need. The gas line enters the boiler from the right side jacket panel. The boiler may receive the gas supply pipe through the left side, or rear jacket panel by relocating the gas valve connector and pipe assembly. The boiler is e[...]

All electrical work must conform to local codes as well as the National Electrical Code, ANSI/ NFPA70, latest revision. In Canada, electrical wiring shall comply with the Canadian Electrical Codes, CSAC22.1 and .2 A. ELECTRIC POWER SUPPLY Prior to making any line voltage connections, service switch at boiler should be in the off position and the po[...]

28 t o either of the unused brass screws on the service switch. Connect the white (neutral) lead from the power supply to the white screw on the service switch. Connect the green (ground) lead from the power supply to the ground (green) screw on the service switch. The receptacle on the service switch is always powered regardless of whether the swi[...]

C. FIGURE 13 FIELD WIRING CONNECTIONS 29[...]

30 If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°C Thermoplastic wire or its equivalent D. FIGURE 14 SCHEMATIC WIRING DIAGRAM[...]

31 E. FIGURE 15 LADDER WIRING DIAGRAM[...]

This section provides a brief description of the key controls and accessories found in this boiler. See the Troubleshooting section of the Service Hints chapter of this installation manual for detailed sequences of operation and troubleshooting procedures. See the Repair Parts chapter of this manual for locations of all control components and acces[...]

33 higher aquastat setting or over firing. The temperature safety switch automatically resets when the vent temperature decreases. (15 °F switch differential). F. CASTING TEMPERATURE SAFETY SWITCH In the event of lack of or loss of water in the boiler, the Casting Temperature Safety Switch (300 °F setpoint) installed on the top of the aluminum bo[...]

34 K. A.S.M.E. RATED PRESSURE RELIEF VALVE Each boiler must have a properly sized and installed American Society of Mechanical Engi- neers rated pressure relief valve. Water expands as it is heated by the burner/boiler sections. If there is no place for the water to expand its volume, (i.e. a properly sized and properly functioning expansion tank) [...]

c. In older system, obviously discolored, murky, or dirty water, or a pH reading below 7, are indications that the system should be cleaned. d. A pH reading between 7 and 8 is preferred. 3. Antifreeze if needed, must be of a type specifically designed for use in closed hydronic heating systems and with aluminum. a. Choice and use of antifreeze must[...]

4. Open the expansion tank service valve and the tank vent. Fill the tank to the proper level and close the tank vent. Remove the handle from the expansion tank service valve so the homeowner doesnt accidentally close it. 5. Open all service valves. Any air remaining trapped in the return lines between the service valves and the boiler will be p[...]

37 A. VERIFY PROPER SEQUENCE OF OPERATION The sequence can be followed via the diagnostic indicator lamps on the Honeywell S9301A integrated boiler control in Fig. 16. This is the normal sequence of operation. A more detailed sequence of operation containing potential faults can be found in the service hints section. 6(48(1&(2 )2 3(5$7,2 [...]

NOTE: First couple of cold starts may be rough due to gas line not being completely purged of air, causing low firing rate and high excess air levels.. B. INSPECT VENTING AND AIR INTAKE SYSTEM Operate the boiler and verify that all vent/air intake connections are gastight and watertight. Repair any leaks immediately. C. INSPECT CONDENSATE DRAIN Ver[...]

39 F. TEST HIGH LIMIT CONTROL AND ADJUST While burner is operating, move indicator on high limit control below actual boiler water temperature. Burner should go off while circulator continues to operate. Raise limit setting above boiler water temperature and burner should reignite after pre purge and igniter warm- up period. Set the high limit cont[...]

40 THE FOLLOWING STEPS AND DIAGRAM INDICATE THE LOCATION OF THE CONNECTION POINTS REQUIRED TO MEASURE THE MANIFOLD PRESSURE. THE MANIFOLD PRESSURE MAY BE MEASURED USING A U-TUBE MANOMTERE OR A DIFFERENTILA PRESSURE GAUGE. THE DIAGRAM SHOWS THE CONNECTION OF BOTH MEASURING DEVICES BUT ONLY ONE DEVICE IS REQUIRED TO MEASURE THE MANIFOLD PRESSURE. © [...]

41 I. Remove regulator cover screw on top of gas valve, and insert an appropriate screw- driver into adjustment screw. II. Turn adjustment screw clockwise to increase input rate, or counter clockwise to de- crease input rate. III. Replace cover screw, or cover hole temporarily with your finger to check new mani- fold pressure setting. Do not set ma[...]

42 INSTALLATION AND CHECK-OUT CERTIFICATE Boiler Model Serial # Date Installed___________ Measured BTU/HR input____________ ¡ Installation instructions have been followed ¡ Checkout procedure and adjustments performed ¡ Maintenance and Service issues reviewed with owner/ maintenance person ¡ Installation booklet affixed on or adjacent to boiler[...]

43 Maintenance as outlined below can be performed by the owner unless otherwise noted. The acidic nature of flue gasses condensing on the aluminum boiler sections will cause the formation of aluminum oxide. This oxide formation is normal, is generally uniform throughout the boiler sections, and represents a negligible mass of aluminum that is consu[...]

C. MONTHLY DURING HEATING SEASON 1. Remove jacket front and top panels and check for piping leaks around relief valve and other fittings. If found, contact a qualified service agency to repair. DO NOT use stop leak compounds. 2. Test relief valve. Refer to valve manufacturers instructions packaged with relief valve. 3. Visually inspect venting and [...]

45 c. Remove air baffle from 1%z x2" flexible coupling and clean air baffle if necessary. Refer to repair parts diagram, mixer and pressure switch assembly. d. Confirm that manual gas valve is closed and disconnect gas line to gas valve at union. Disconnect wires to gas valve. and igniter. e. Loosen but do not remove five (5) nuts attaching[...]

46 d. Reinstall and connect the condensate trap, using the hose clamps to secure the various condensate lines to their fittings. e. Follow the instructions under NEAR BOILER PIPING forfilling condensate trap with water 4. Inspection of the flue connector requires the following steps (Refer to the repair parts diagram.) a. Loosen the cla[...]

47 SERVICE HINTS DET AILED SEQUENCE OF OPERA TION[...]

48 DETAILED SEQUENCE OF OPERATION[...]

49 END OF NORMAL SEQUENCE OF OPERATION DETAILED SEQUENCE OF OPERATION[...]

50 TROUBLE SHOOTING IMPORTANT 1. IN A RESET FROM LOCKOUT CONDITION, ALL ELECTRICAL METER READINGS AT THE GAS CONTROL VALVE (24 VAC) MUST BE TAKEN WITHIN THE TRIAL FOR IGNITION PERIOD. 2. IF ANY COMPONENT DOES NOT FUNCTION PROPERLY, MAKE SURE IT IS CORRECTLY INSTALLED AND WIRED BEFORE REPLACING IT. 3. STATIC ELECTRICITY DISCHARGE CAN DAMAGE THE INTE[...]

51 TROUBLE SHOOTING /,*+7 67$7 86 ,1',&$ 7(6 21 ,%& , 6(1(5*, =(' 7+528*+  92/ 77 5$16)250(5 2)) , %& , 6 127 (1(5*,= (' %/, 1., 1* , %& 5(&(, 9(6 02 5( 7+$1  9$& 21 ,%& , 6(1(5*, =, 1* 7+( '5$)7 , 1'8&(5 $1&apos[...]

52 TROUBLE SHOOTING !!WARNING!! ELECTRICAL SHOCK HAZARD MAY CAUSE SERIOUS INJURY OR DEATH. THE FOLLOWING PROCEDURES MAY EXPOSE YOU TO DANGEROUS LINE VOLTAGE. USE CAUTION TO AVOID TOUCHING LIVE ELECTRICAL CONTACTS. SERVICE MUST BE PERFORMED BY A TRAINED, EXPERIENCED SERVICE TECHNICIAN. WHAT TO DO IF YOU SMELL GAS:  DO NOT TRY TO LIGHT ANY APPLIAN[...]

53 TROUBLE SHOOTING TROUBLESHOOTING CHART 2[...]

54 TROUBLE SHOOTING TROUBLESHOOTING CHART 3[...]

55 TROUBLE SHOOTING TROUBLESHOOTING CHART 4[...]

56 TROUBLE SHOOTING TROUBLESHOOTING CHART 5[...]

57 TROUBLE SHOOTING TROUBLESHOOTING CHART 6[...]

DIFFERENTIAL AIR PRESSURE SWITCH CHECK The following steps and diagram indicate the locations of the connection points required to check the differential air pressure. The differential air pressure switch is a safety device which will prevent the boiler from firing if there is an air intake, boiler heat exchanger or vent blockage. Turn off service [...]

REPAIR PARTS 59 A. JACKET AND BASE ASSEMBLY[...]

REPAIR PARTS 60 .(<  ,7 ( 0  180 %(5 '(6&5, 37, 21 48 $ 17,7<    )5 2 1 7   3$1 (/     5 , * + 7  3$1 (/     /()7  3$1 (/     %$&. 3$1 (/   ?[...]

REPAIR PARTS 61 B. CONDENSATE DRAIN TRAP ASSEMBLY .(<  , 7(0  18 0 %(5 '(6&5,37, 2 1 48 $ 17, 7<      ò ´ , '[  ´  7 + . 9 , 1 </ 7 8 %, 1 * $6 5 (4 8 , 5 ('      ô ´  61 $3 * 5, [...]

REPAIR PARTS 62 C. BOILER BLOCK AND PIPING ASSEMBLY[...]

REPAIR PARTS 63 .(<   ,7(0  180 %(5 '(6&5,37,21 4 8$17,7<   +2 ))0$1  9 (1 7       ô   [     %8 6+ , 1 *    ô   %/$& .  7 ((    ô   [   [...]

REPAIR PARTS 64 D. MIXER AND AIR PRESSURE SWITCH ASSEMBLY[...]

REPAIR PARTS 65 .(<  ,7(0  180 %(5 '( 6&5, 37,21 48$17,7<    % 851(5 *$ 6. ( 7  $  % 851( 5%6,   %  %851(5%6,  &   %851(5 %6,  [...]

REPAIR PARTS 14683301 66 Rev. 3, August 2003 E. FLUE ADAPTER AND EXHAUST ASSEMBLY .(<  ,7 ( 0  180 %(5 '(6 &5, 37, 21 48$ 17 , 7<   (;+ $8 67  7 (( $66(0 %/<    $ %&  '  (  )  $    ´ 1[...]