Dunkirk QL Installation & Operation Manual

 GAS-FIRED, DIRECT VENT, WET RECUPERATED,
CONDENSING, HOT WATER
INSTALLATION INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler
Improper installation, adjustment, alteration, service, or maintenance can cause injury or
property damage. Refer to this manual. For assistance or additional information consult a qualified
installer, service agency, or the gas supplier.
DUNKIRK, NEW YO 14048 - 716 366-5500
“ Member: The Hydronics Institute
Revision-C 03/21/01
TABLE OF CONTENTS
BOILER RATINGS AND CAPACITIES citi tire etter ce cence eae
RULES FOR SAFE INSTALLATION AND OPERATION ....ooiiiiiiian
BEFORE INSTALLING THE BOILER PP
codes
boiler sizing
considerations for boiler location
locating the boiler
combustion air and vent pipe requirements
condensate drain requirements
foundation requirements
removing existing boiler from common venting system
PLACING THE BOILER................ RSS SRE OO CPP PRO PRET R EP REP E PP PPT RE EPP RE RTE enano
NEAR BOILER PIPING............er.eeoccccrmroooroocceoocaeae reee eran nencanenaacanerroceoaee rene
supply and retum lmes
pressure relief valve
expansion tank and make-up water
condensate drain piping
filling evaporative recooler Sump with water
chilled water piping -
COMBUSTION AIR AND VENT PIPE............ Lasers censé ec aesrr annee O EEE EREE
A. connections and terminations
B. installation
GAS SUPPLY PIPING...............eeeeececreeccareenaecenererneoeeonene can crceeeereceneee J
A. check gas supply
B. connecting the gas piping
C. checking the gas piping
ELECTRICAL WIRING...........Ñ....e...000rmcer eee ree. TTT een UT
À. electric power supply
B. install your thermostat
C. connect circulator pump wiring
D. schematic wiring diagram
E. ladder wiring diagram
CONTROLS AND ACCESSORIES............eeeeeenecoos Deoranecaneonoonoeneororcrenoorareravece ore.
. integrated boiler contro!
tri-timer module
2-stage gas valve
. hot surface igniter
high limit aquastat control
vent temperature safety switch
. casting temperature safety switch
. fan/outlet pressure switch
inlet pressure switch
gas pressure switch
Tarima
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START-UP
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MAINTENANCE AND CLEANING
A. beginning of each season
B. daily
C. monthly
D. periodically
E. end of each heating season
F. annual examination and cleaning
SERVICE HINTS.........…..…..…aeereserse er en en ne eca ce see een are san eee nan mean e men me rene re eee Ce TURC EST CESR SCT TRES
A. flow chart / detailed sequence of operation
B. trouble shooting
C. fan/outlet & inlet pressure switch check
ET s irae aaa te eee an emma aenns a seca ri rea shanna t et tens h estes net te sas
A. QL - jacket and base assemblies
B. QL - pressure switch and drain manifold assembly
C. QL - block and piping assembly
D. OL - mixer assembly
E. QL - recovery heat exchanger assembly
F. QL - evaporative recooler assembly
G. QL - sump feeder assembly
CHAPPOSVOZETF
CHECH-OUT PROCEDURES AND ADJUSTMENTS
PASTRHOTHOOES
condensate pump
condensate flow switch
draft inducer
circulator pump
drain valve
relief valve
flame rollout safety shutoff
(optional) external condensate pump
strainer
check valve
sump feeder
water treatment and freeze protection
filling boiler with water and purging air with diaphragm type expansion tanks
filling boiler with water and purging air with conventional closed type expansion tanks
placing boiler in operation
I. for your safety read before operating
II. operating Instructions
III. to turn off gas to appliance
verify proper sequence of operation
inspect venting and air mtake system
“inspect condensate drain
inspect system piping
test ignition system safety shutoff
test high limit control
test other safety controls
set thermostat heat anticipator
measure the gas input rate
set thermostat to desired room. temperature
review all instructions
installation and cheCh-out certificate
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JUNCTION BOY YOR
120 Y. PONER E 24 Y.
THERMOSTAT LEADS
cas sor |
OPENING (1/77
NPT)
STANDARD SUPPLY —]
Je RETURN OPENINCS
1 1/4" NPT CONNECTIONS
PROVIDED INSIDE BOILER
CABINET.
COMBUSTION AIR
INTIXZ FILING
(27 FYT)
. CONDENSATX DRAIN — ——|
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SUPFLY & RETURN OPENINGS
1 1/4 NET CONNECTIONS
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BOITE YATZR PRESSURE CAUCE
ALTIRNATE OPENING FOR
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ALTERNATE OPENING FOR
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YENT TIT
(2 PTC)
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CONDENSATE DRAIN
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LU HE SUPPLY - de RETURN OPENINGS _
1 1/47 HPT CONNECTIONS.
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TABLE 1 SEA LEVEL RATINGS — NATURAL AND PROPANE GASES
++ Heating Net I=B=R Shipping Flue
Model Input *(MBH) Capacity Rating Weight Dia.
*(MBH) *(MBH) (165.) |
QL-100 100 95 83 275 2” PVC
*1 MBH = 1,000 Btuh
Btuh = British Thermal Units Per Hour
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. MLE. (American Society of Mechanical Engineers) Boiler
and Pressure Vessel Code Section IV Standards for heating boilers.
++ AFUE (Annual Fuel Utilization Efficiency) and Heating Capacity is based on the D.O.E.
(Department of Energy) test procedure.
J
The QL Boilers are certified in accordance with ANSI (American National Standards Institute)
721.13 standards as gas fired direct vent condensing hot water boilers.
New York City MEA Number 132-97-E.
The Heating Capacity indicates the amount of heat available after subtracting the losses up the stack.
Most of this heat 1s available to heat water. A small portion 1s heat from the jacket and surfaces of the
boiler, and it 1s assumed that this heat stays in the structure. The Net I=B=R Rating represents the
portion of the remaining heat that can be applied to heat the radiation or terminal units (ie. finned tube
baseboard, cast iron radiators, radiant floor, etc.). The difference between the Heating Capacity and the
Net I=B=R Rating, called the piping and pickup allowance, establishes a reserve for heating the volume
of water in the system and offsetting heat losses from the piping. The Net [=B=R Ratings shown are
based on a piping and pickup factor of 1.15 in accordance with the I=B=R Standard as published by the
Hydronics Institute. The Net I=B=R Rating of the boiler selected should be greater than or equal to the
calculated peak heating load (heat loss) for the building or area(s) served by the boiler and associated hot
water heating systems. The manufacturer should be consulted before selecting a boiler for installations
having unusual piping and pickup requirements.
BOILERS FOR USE AT HIGH ALTITUDE
The QL boilers are factory equipped for operation at altitudes ranging from 0-2,000 feet above sea level.
For use of these boilers at altitudes above 2,000 feet above sea level, the gas input ratings (MBH) must
be reduced. | |
U.S.A. ONLY : For altitudes above 2,000 feet above sea level, input ratings should be reduced as shown
in Table 1A for natural gas fired boilers or in Table 1B for propane gas fired boilers. In most cases the
furnished sea level orifices will also be used for higher elevations. Reduced input ratings are achieved by
the natural deration of the gas at higher elevations and fine tuned by adjusting the manifold pressure.
CANADA ONLY: For altitudes in the range of 2,000 — 4,500 feet above sea level, boilers may be field
equipped for use at high altitude by using a certified high altitude field conversion kit. The change in
main burner orifice size results in a 10% reduction of the boiler gas mput rating (MBH). The conversion
shall be carried out by a manufacturer’s authorized representative, in accordance with the requirements of
the manufacturer, provincial or territorial authorities having jurisdiction, and in accordance with the
requirements of the CSA-B149.1 and CSA-B149.2 Installation Codes. The certified field conversion kit
includes a conversion data plate, indicating that the boiler has been converted for high altitude use. The
correct conversion information must be entered on the conversion data plate.
TABLE lA QL-100 NATURAL GAS HIGH ALTITUDE RATINGS
ELEVATION (FEET) 0-2000 | 3,000 | 4,000 | 5,000 | 6,000 | 7,000 | 7,500 | 8,500 | 9,500 | 10,500
NOMINAL INPUT 100.0 | 95.9 | 95.1 | 945 | 93.7 | 93.0 | 926 | 889 | 852 | 81.6
(MBH)
HEATING CAPACITY 95.0 | 91.1 | 90.3 | 89.8 | 89.0 | 88.4 | 88.0 | 845 | 80.9 | 77.5
(MBH)
NET I=B=R RATING 83 79 79 78 77 77 | 77 73 70 67 |
(MBH) |
GAS ORIFICE DRILL 44 44 44 44 44 44 44 44 44 44
SIZE
FAN/OUTLET :
PRESSURE SWITCH -0.45 | -0.45 | -0.45 | -0.45 | -0.45 | -0.45 | -0.45 | -0.45 | -0.45 | 0.45
SETPOINT (INCHES |
WATER COLUMN)
INLET PRESSURE | |
SWITCH SETPOINT -1.10 | -1.10 | -1.10 | -1.10 | -1.10 | -1.10 | -1.10 | -1.10 | -1.10 | -1.10
(INCHES WATER
COLUMN)
TABLE 1B QL-100 PROPANE GAS HIGH ALTITUDE RATINGS
ELEVATION (FEET) 0-2000 | 3,000 | 4,000 | 5,000- | 6,000 | 7,000 | 7,500 | 8,500 | 9,500 [| 10,500
NOMINAL INPUT 100.0 | 96.1 95.4 94.8 04.1 93.4 93.1 89.4 85.7 | 82.0
(MBH) —_
HEATING CAPACITY 95.0 91.3 90.6 90.1 89.4 88.7 83.4 84.9 81.4 77.9
(MBH) 7
NET I=B=R RATING 83 79 79 78 78 77 77 74 71 68 -
(MBH) | |
GAS ORIFICE DRILL 50 50 50 50 50 50 50 50 50 50
SIZE |
FAN/OUTLET | | |
PRESSURE SWITCH 0.45 | 0.45 | -0.45 | 045 | -0.45 | -0.45 | -0.45 | 0.45 | -0.45 | -0.45
SETPOINT (INCHES | a
WATER COLUMN)
INLET PRESSURE
SWITCH SETPOINT -1.10 | -1.10 | -1.10 | -0.85 | -0.85 | -0.85 | -0.85 | -0.85 | -0.85 | -0.85
(INCHES WATER (upto | (over
COLUMN) 4500’) | 4500”)
%
The Quantum Leap® (QL) is a gas fired direct vent hot water boiler featuring a wet recuperated
combustion system that increases efficiency by recovering latent heat from the exhaust and using water
(condensate) as the medium to transfer the heat back into the incoming combustion air. The Quantum
Leap’s high Annual Fuel Utilization Efficiency means annual energy and cost savings even when
compared to similar sized condensing boilers which lack the additional high efficiency features that the
Quantum Leap® provides. A revolutionary cast aluminum heat exchanger means better heat transfer and
thermal storage than similarly sized cast iron boilers. Sealed combustion, premix gas burner, and low
flame temperature means drastically reduced CO and NOx emissions, which contribute to a cleaner and
healthier environment.
The heating system water absorbs large amounts of heat from the cast aluminum heat exchanger,
cooling the flue gases and causing condensation. This is the normal limit of condensing boilers - but the
Quantum Leap® goes much further! More energy savings are realized as the Quantum Leap® boiler
collects, stores and circulates “warm” condensate through a long heat transfer coil in the heat recovery
unit removing even more of the valuable energy from the flue gas and creating “hot” condensate. The
“hot” condensate from the heat recovery unit is sprayed into the evaporative re-cooling tower,
transferring valuable heat to the incoming combustion air. The “hot” condensate, having given up its heat
to the combustion air, goes back to the storage sump as “warm” condensate and is again pumped by the
condensate pump through the heat recovery unit and then the evaporative re-cooling tower continuously
recovering heat. Excess condensate is safely piped to a floor drain. |
The Quantum LeapO,unlike normal residential atmospheric and induced draft units, takes its
combustion air directly from the outdoors (sealed combustion) and does not compete with building
occupants for fresh air. Sealed combustion (also known as “direct vent”) is the safest and best way to
obtain plenty of clean combustion air. The induced draft fan draws in the outside combustion air, then
takes the cooler flue gases from the boiler and heat recovery unit and provides a positive removal of the
flue gases from the building through inexpensive and readily a available PVC pipe.
RULES FOR SAFE INSTALLAT
|. 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 requirements before
installation. The installation must conform with these requirements in their entirety. In the absence of
these codes, use NFPA Installation Codes and good industry practice.
3. Before servicing the boiler - allow the boiler to cool. Always shut off any electricity and gas supply
connected to the boiler prior to servicing.
4. Inspect gas line for leaks.
5. Be certain gas input rate is correct. Over firing may result in early failure of the boiler sections. This
may cause dangerous operation. Under firing may result in too much air for the pre-mix burner
causing poor or loss of combustion.
6. Never vent the products of combustion from this boiler to an enclosed space. Always vent to the
outdoors. Never vent to another room or to inside a building.
Be sure there 1s adequate outdoor air supply to boiler for complete combustion.
Follow a regular service and maintenance schedule for efficient and safe operation.
Keep boiler area clean of debris and free of combustible and flammable materials.
0. Proper through the wall or through the roof combustion venting shall be in accordance with the
materials and methods described in this manual.
11. This boiler and related hot water heating systems are not do it yourself items. They must be installed
and serviced by qualified professionals.
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6
This boiler has been equipped for residential installations. If used for commercial applications, any
additional code requirements must be adhered to for installation. This may require additional controls
including but not limited to a low water cut off, a manual reset high temperature limit, and wiring and/or
piping modifications. The manufacturer is not responsible for any field mstallation changes made to a
boiler installation which are not described or acknowledged in this manual.
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Complete all of the following prior to installing the boiler.
A. CODES
This boiler product is a gas fired direct vent condensing boiler and must be installed 1n accordance
with all applicable federal, state and local building codes including, but not limited to the following :
United States - Installation shall conform with National Fuel Gas Code (NFPA-54/ANSI Z223.1-
latest edition)
Canada - Installation shall be in accordance with CSA-B149.1 and 2 Installation
codes.
New York City — MEA Number 132-97-E.
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 the National Fuel Gas Code, ANSI Z223.1 - latest revision.
Installers - Follow local regulations with respect to installation of CO (Carbon Monoxide)
| detectors. Follow maintenance recommendations in this manual. a
Techniciens - Veuillez vous conformer á la réglementation en vigeur concernant 1” installation
des détecteurs d’oxyde de carbone. Suivre les consignes d’entretien figurant dans
le manuel d’instruction ci-joint.
B. BOILER SIZING
e Check to be sure you have selected the QL boiler with the proper capacity before starting the
installation. The I=B=R Rating of the boiler selected should be greater than or equal to the
calculated peak heating load (heat loss) for the building or area(s) served by the boiler and
associated hot water heating systems. See boiler rating and capacity table in this manual.
e Heat loss calculations should be based on approved methods.
C. CONSIDERATIONS FOR BOILER LOCATION
Before selecting a location for the boiler, the following should be considered. Each boiler
considered for installation must be: |
° Supplied with the correct type of gas (natural gas or propane).
° Connected to a suitable combustion air intake piping system to supply the correct amounts of fresh
(outdoor) air for combustion. (Maximum length 1007) |
° Connected to a suitable venting system to remove the hazardous products of gas combustion
(Maximum length 1007). |
* Connected to a suitable hot water heating system.
>» Supplied with a suitable electrical supply for all boiler motors and controls.
* Connected to a properly located thermostat or operating control. (not included with boiler)
= Placed on level surface (must NOT be installed on carpeting)
° Condensate drain line must be pitched down to floor drain or external condensate pump with
reservoir at 1/4” per foot (wood frame or blocks may be used to raise boiler).
D. LOCATING THE BOILER
TABLE 2 BOILER CLEARANCE
UNIT COMBUSTIBLE ACCESSIBILITY / CLEANING SERVICING
CONSTRUCTION
TOP 1” 24” 24”
LEFT SIDE 1” 24” 24”
RIGHT SIDE 8” - -
BASE 0 - -
FRONT 1” 24” 247
INTAKE/VENT 0 _ _
PIPING
NEAR BOILER
HOT WATER 1” - -
PIPING
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. The boiler must be located where ambient temperatures (minimum possible room temperatures
where boiler is installed assuming boiler is not in operation and therefore contributes no heat to
the space) are always at or above 32 F to prevent freezing of liquid condensate.
3. 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 of removable walls or partitions.
4. The boiler is approved for installation in closets and on combustible floors. This boiler shall NOT
be installed on carpeting.
5. The clearances shown in table - 2 indicate required clearances per AGA listing. A minimum 1”
clearance must be maintained between combustible construction and each of the left, right, top and
back surfaces of the boiler. A minimum 8” clearance 1s required on the right side, to allow room
for the inlet air pipe. An 18” clearance must be maintained at a side where passage is required tc
access another side for cleaning or servicing, inspection or replacement of any parts that normally
may require such attention. Allow at least 24” at the front, top and left side for servicing. No
clearances are required to venting or combustion air intake piping.
6. Equipment shall be installed in a location which facilitates the operation of venting and
combustion air intake piping systems as described in this manual.
7. Advise owner of boiler to keep venting and combustion air intake passages free of obstructions.
Both the venting and combustion air intake piping systems connected to the outdoors must permit
flow through the piping systems without restrictions for the boiler to operate.
8. The boiler shall be installed such that the automatic gas ignition system components are protected
from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement,
control replacement, etc.)
E. COMBUSTION AIR AND VENT PIPE REQUIREMENTS
This boiler requires a dedicated direct vent system. In a direct vent system, all air for combustion is taken
directly from outside atmosphere, and all flue products are discharged to outside atmosphere.
Combustion air and vent pipe connections must terminate together in the same atmospheric pressure zone,
either through the roof or sidewall (roof termination preferred). See Fig. .9 & 10 for required clearances.
CAUTION
KEEP BOILER AREA CLEAN OF DEBRIS AND FREE OF FLAMMABLE AND
COMBUSTIBLE MATERIALS, VAPORS AND LIQUIDS
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” Armatlex or
equivalent. In extreme cold climate areas, use 3/4” Armaflex or equivalent.
Combustion air must be clean outdoor air. Combustion air must not be taken from inside structure
because that air frequently is contaminated by halogens, which include fluorides, chlorides, phosphates,
bromides and iodides. These elements are found in aerosols, detergents, bleaches, cleaning solvents,
salts, air fresheners, paints, adhesives and other household products.
Locate combustion air inlet as far away as possible from swimming pool and swimming pool pump
house.
All combustion air and vent pipes must be airtight and watertight. Combustion air and vent piping must
also terminate exactly as shown in fig.9 or 10.
Vent connections serving appliances vented by natural draft shall not be connected into any portion of
mechanical draft systems operating under positive pressure.
solvent cements are combustible. Keep away from heat, sparks, and open flame. Use only in well
ventilated areas. Avoid breathing in vapor or allowing contact with skin or eyes.
FAILURE TO FOLLOW THE AFOREMENTIONED WARNINGS COULD RESULT IN FIRE,
PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.
F. CONDENSATE DRAIN REQUIREMENTS
Condensate drain line to be pitched down to floor drain at a minimum of 1/4” per foot. An external
condensate pump (not furnished) may be used if floor drain is not available. The condensate pump must
be designed for flue gas condensate application
NOTE: Condensate trap is built into evaporative recooler sump, external trap is not required and should
not be used.
NOTE: Wood frame or blocks may be used to raise boiler to maintain drain piich or to be above
condensate pump reservoir.
Boiler must : be placed on level surface. Boiler is NOT to be installed On carpeting.
NOTE: 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.
NOTE: Wood frame or blocks may be used to raise boiler to maintain drain pitch or to be above
external condensate pump reservoir.
10
H. REMOVAL OF EXISTING BOILER FROM COMMON VENT SYSTEM
When an existing boiler is removed from a common venting system, the common venting system is
likely to be too large for proper venting of the appliances remaining connected to it. At the time of
removal of an existing boiler, the following steps shall be followed with each appliance remaming
connected to the common venting system placed in operation, while the other appliances remaming
connected to the common venting system are not in operation.
1.
2.
Seal any unused openings in the common venting system.
Visually inspect the venting system for proper size and horizontal pitch and determine there 1s no
blockage or restrictions, leakage, corrosion and other deficiencies which could cause an unsafe
condition. |
Insofar as is practical, close all building doors and windows and all doors between the space in
which the appliances remaining connected to the common venting system-are located and other
spaces of the building. Turn on clothes dryer and any appliance not connected to the common
venting system. Turn on any exhaust fans, such as range hoods and bathroom exhaust, so they
will operate at maximum speed. Do not operate a summer exhaust fan. Close fire dampers.
Place in operation the appliance being inspected. Follow the lighting instructions. Adjust
thermostat so appliances 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 the smoke from a cigarette, cigar or pipe.
After it has been determined that each appliance remaining connected to the common venting
system properly vents when tested as outlined above, return doors, windows, exhaust fans and
any other gas- burning appliance to their previous condition of use.
Any improper operation of the common venting system should be corrected so the installation
conforms with the National Fuel Code, NFPA-54/ANSI -7223.1-latest revision, or section 5 of
CSA-B149 for Canadian standards. When resizing any portion of the common venting system,
the common venting system should be resized to approach the minimum size as determined using
the appropriate tables in part 11 in the National Fuel Gas Code, NEPA-54/AN SI- 7223.1-latest
revision, or section 5 of CSA-B149 for Canadian standards.
The boiler should be placed to provide the most direct connections to the combustion air, vent and
system piping as possible.
Place crated boiler as close to selected location as possible and uncrate boiler. The uncrated boiler may be
moved into position with an appliance dolly or 2-wheel hand truck. The. dolly or hand truck should be
inserted under the left hand side of the boiler. It is possible to slide the boiler for a short distance on a
smooth floor or surface.
NOTE: Refer to manual section “LOCATING THE BOILER” for required « clearances for servicing
and mamtenance.
11
CAUTION
Copper supply and return piping must NOT be installed directly into aluminum boiler section castings
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 packaged boiler is furnished with iron piping in the front boiler section for the
supply and return connections. | |
Зы ГЕ LA
When the installation of the boiler is for a new heating system, first install all of the radiation units
(panels, radiators, baseboard, or tubing) and the supply and return mains. After all heating system piping
and components have been installed, make final connection of the system piping to the boiler.
A hot water boiler installed above radiation level must be equipped with a low water cut off device. A
periodic inspection is necessary, as is flushing of float type devices, per low water cut off manufacturers
specific instructions.
A. SUPPLY AND RETURN LINES
The packaged boiler unit is set up to receive 1 1/4”NPT supply and return piping from right side access.
“The boiler unit can also be piped from the left side by reversing supply elbow and return tee, and from
the rear of the unit by removing plugs in the rear boiler section. | |
NOTE: Rear piping access requires the relocation of the circulator pump.
e : ке
>
SUPPLY TO
SYSTEM
RETURN FROM
SYSTEM
PURGE (DRAIN)
VALVE
ZONE SERVICE
VALVE
SUPPLY TO
ZONES
ZONE SERVICE
VALVE
RETURN FROM
ZONES
PURGE (DRAIN)
VALVES
ZONE SERVICE
CIRCULATOR ZONE SERVICE VALVE
= PUMP VALVE
ZONE SERVICE
VALVE
SUPPLY TO
ZONES
ZONE SERVICE
VALVE
FLOW
CHECK
RETURN FROM
ZONES
PURGE (DRAIN)
VALVES
ZONE SERVICE
ZONE SERVICE VALVE
VALVE |
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. DO NOT disconnect (unplug) the circulator
pump wiring at the integrated boiler control, or the “Call For Heat” status light will not function
B. PRESSURE RELIEF VALVE |
The boiler 1s furnished with a factory installed relief valve in the top of the boiler. Provide 3/4” 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
pipes between such safety valves and the atmosphere. Installation of the safety relief valve shall conform
to ANSI/ASME Boiler and Pressure Vessel Code, Section IV. The manufacturer is not responsible for
any water damage.
BETO
PIPING
Q A
- =
S =
о © NS 0
/
C. EXPANSION TANK AND MAKE-UP WATER
Determine required system fill pressure, system design temperature, and system water content. Boiler
contains 2.6 gallons (U.S.). Size expansion tank accordingly. Consult expansion tank manufacturer for
proper sizing information. Connect properly sized expansion tank (not furnished) as shown in fig.6 for
diaphragm type expansion tank and fig.7 for conventional closed type expansion tanks. For diaphragm
type expansion tanks, adjust the tank air pressure to match the system fill pressure. Install air vent
(furnished) as shown for diaphragm type expansion tank system only. Install make-up water connections
as shown and per local codes. If a pressure reducing valve is used, adjust to match the system fill
pressure. In connecting the cold make-up water supply to the boiler, make sure that clean water supply 15
available. When the water supply is from a well or pump, a sand strainer should be installed at the pump.
14
AUTOMATIC AIR
VENT*
3/4"x1/8" BUSHING*
|_— 3/4" TEE*
MANUAL FILL
VALVE >
и
Q TH О | 3/4” NIPPLE (FURNISHED
COMBINATION QUICK FILL DD =,
VALVE, STRAINER, CHECK A | AND INSTALLED ON
PACKAGED BOILER)
VALVE AND PRESSURE
REDUCING VALVE
COLD WATER — = 0
FILL
IZ A * —— FURNISHED IN
PARTS BAG.
——— 3/4” STREET ELL*
DIAPHRAGM TYP
EXPANSION TANK
CLOSED TYPE
~~" EXPANSION TANK
__— EXPANSION TANK SERVICE
VALVE (GATE VALVE OR
FULL PORT BALL VALVE)
PRESSURE REDUCING |
VALVE AND N
CHECK VALVE
S
COLD WATER —
FILL
- MANUAL FILL
| VALVE
+,
D. CONDENSATE DRAIN PIPING
Condensate trap is built into evaporative recooler sump, external trap is not required and should NOT be
used. | -
Provide 1/2” PVC Condensate drain and fittings. Condensate drain to be pitched down to floor drain at a
minimum of 1/4” per foot. |
Install furnished 1/2” threaded PVC close nipple and 1/2” PVC tee to overflow fitting on evaporative
recooler as shown in fig. 8. |
The 1/2-in. diameter schedule 40 PYC or CPYC condensate drain piping and pipe fittings must conform
to ANSI standards and ASTM D1785 or D2846. Schedule 40 PVC or CPVC cement and primer must
conform to ASTM D2564 or F493. In Canada, use CSA or ULC certified schedule 40 PVC or CPVC
drain pipe and cement.
A condensate pump with a reservoir (not furnished) may be used to remove condensate to a drain line
(sanitary line) above boiler if a floor drain is not available or 15 inaccessible.
DRAIN PIPE TO
BE PITCHED DOWN
TO FLOOR DRAIN
AT A MINIMUM
1/4" PER FOOT
TO
DRAIN
THREADED CLOSE CONDENSATE
NIPPLE(PVC) FURNISHED DRAIN
PVC TEE |
1/2" SLIPx1/2" SLIPx1/2" NPT
FURNISHED
E. FILLING EVAPORATIVE RECOOLER SUMP WITH WATER
ON THE INITIAL START UP THE EVAPORATIVE RECCOLER SUMP MUST BE
MANUALLY FILLED WITH WATER
The following are the steps required to initially fill the evaporative recooler sump for start up. These steps
should only be required at the initial startup or 1f maintenance requires draining of the sump:
1. Remove 2-in. Fernco coupling from the air intake fitting on the boiler.
2. Temporarily place a 2-in. 90 degree PVC elbow snugly on the air intake fitting.
3. Pour about five (5) quarts of cold tap water into the elbow on the air intake fitting.
4. Excess water should go through the overflow in the evaporative recooler and out through the
condensate drain line. Verify proper operation of the drain line (or external condensate pump 1f
used). |
5. Remove PVC elbow and reinstall 2-in. Fernco coupling.
6. This process can be done without removing the 2-in. Fernco coupling by inserting a flexible hose
“or tube into the sump through the coupling while the coupling is in place, and filling the sump
through the hose.
7. Tt may be necessary to manually prime the condensate pump. This is accomplished by
disconnecting the pump’s condensate discharge line from the inlet side of the check valve and
manually providing suction on the line to draw water out of the sump and into the pump.
F. CHILLED WATER PIPING
The boiler, when used in connection with a refrigeration system, must be installed so the chiller
medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium
from entering the boiler.
The boiler piping system of a hot water boiler connected to heating coils is located in air handling
units where they may be exposed to refrigerated air circulation must be equipped with flow control
valves or other automatic means to prevent gravity circulation of the boiler water during cooling
cycle.
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— 7
A. CONNECTIONS AND TERMINATION
For boilers for connection to gas vents or chimneys, vent installations shall be in accordance with
part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1-latest revision and
applicable provisions of the local building codes.
Provisions for combustion and ventilation air must be in accordance with section 5.3, Air For
Combustion and Ventilation, of the National Fuel Gas Code, ANSI Z223.1-latest revision, Or
applicable provisions of the local building code.
These boilers require a dedicated direct vent system. All air for combustion is taken directly from
outdoors through combustion air intake pipe. All flue products are discharged to the outdoors
through vent pipe. |
1. See Fig.9 & 10 for combustion air and vent pipe roof and sidewall termination.
(Roof termination is preferred) Combustion air and vent pipes must terminate together in same
atmospheric pressure zone as shown. Construction through which vent and air intake pipes
may be installed is a maximum 24 inches, minimum 1/4 inch thickness.
17
Combustion air and vent pipe fittings must conform to American National Standards Institute
(ANSI) standards and American Society for Testing and Materials (ASTM) standards D1785
(schedule-40 pvc), D2665 (PVC-DWV), D2241 (SDR-21 and SDR-26 PVC), D2661
(ABS-DWV), or F628 (schedule-40 ABS). Pipe cement and primer must conform to ASTM
standards D2564 (PVC) or D2235 (ABS). In Canada construct all combustion air and vent
pipes for this unit of CSA or ULC certified schedule-40 PVC, PVC-DWV or ABS-DWV pipe
and pipe cement. SDR pipe is NOT approved in Canada.
Combustion air and vent piping connections on boiler are sized for 2-in. pipe. Any pipe size
change (to 3-in.) must be made outside of the boiler casing in vertical run of pipe to allow for
proper drainage of vent condensate. When using 3-in. vent and combustion air intake pipe, the
first two (2) feet of vent pipe and the first four(4) feet of combustion air intake pipe at the
boiler must be 2” pipe.
NOTE: The transition from 2-in. pipe to 3-in. pipe must be made in a vertical run.
Combustion air and vent piping length:
2-in. pipe to have a minimum length of 2 feet with four (4) 90 degree elbows.
2-in. pipe to have a maximum length of 20 feet plus four (4) 90 degree elbows.
3-1n. pipe to have a minimum length of 20 feet with four (4) 90 degree elbows including
initial length of 2” pipe. :
3-in. pipe to have a maximum length of 100 feet plus four (4) 90 degree elbows including
initial length of 2” pipe.
For additional elbows, reduce the maximum vent length as shown:
2-in. 90 degree elbow - 1 1/2 feet per additional elbow.
3-in. 90 degree elbow - 3 feet per additional elbow.
Example: To add 2 additional 90 degree elbows to a 3-in. pipe.
- Each elbow is 3 additional feet per 90 degree elbow for a total of 6 feet.
(1 elbow @ 3 feet + 1 elbow @ 3 feet = 6 additional feet of pipe)
The total additional pipe is then subtracted from the maximum allowable pipe
length to give the new maximum length of 94 feet with 6, 90 degree elbows.
(original 100 feet max. - 6 feet for 2 additional elbows = new 94 feet maximum
length)
. Combustion air and vent piping to be pitched back to boiler at minimum 1/4” per foot from
intake and vent terminals so that all moisture in combustion air and vent piping drains to
boiler. Pipes must be pitched continuously with no sags or low spots where moisture can
accumulate and block the flow or air of flue gas. Combustion air and vent pipes must be
airtight and watertight.
Consideration 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 should be positioned so that it will not be effected by wind eddy, air born
leaves, snow, or allow recirculation of flue gasses.
° Termination should be positioned where it will not be damaged or subject to foreign
objects, such as stones, balls, etc..
* Termination should be positioned where vent vapors are not objectionable.
13
° Put vent on a wall away from the prevailing winter wind. Locate or guard the vent to
prevent accidental contact with people or pets.
e Terminate the vent above normal snowline. Avoid locations where snow may drift and
block the vent. Ice or snow may cause the boiler to shut down if the vent becomes
obstructed.
* Under certain conditions, flue gas will condense moisture and may be corrosive. In
such cases, steps should be taken to prevent building materials at the vent from being
damaged by exhaust of flue gas.
7. The venting system shall terminate at least 3 feet above any forced air inlet (except the boilers
combustion air inlet) within 10 feet. The venting system shall terminate at least 12 inches from any
air opening into any building. The bottom of the vent shall be located at least 12 inches above grade.
Termination of the vent shall be not less than 7 feet above an adjacent public walkway. The vent
terminal shall not be installed closer than 3 feet from the inside corner of an L shaped structure.
Termination of the vent should be kept at least 3 feet away from vegetation. The venting system shall
terminate at least 4 feet horizontally from, and in no case above or below, unless a 4 foot horizontal
distance is maintained, from electric meters, gas meters, regulators, and relief equipment.
- | 15” MAXIMUM
—< 3" MAXIMUM-=] |=— >
SEPARATION DD
= 7 —
ee TOUL D
— IT COMBUSTION
8” MINIMUM IR
VERTICAL SEPARATION
BETWEEN COMBUSTION
ATR INTAKE AND VENT
MAINTAIN 12" MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL
12" SEPARATION »
BETWEEN BOTTOM OF
— COMBUSTION AIR INTAKE
7 VENT — | __— AND BOTTOM OF VENT
—
— — a
TE m — MAINTAIN 12” MINIMUM CLEARANCE
„ещо ~*~ ABOVE HIGHEST ANTICIPATED
[Bd | к | Y SNOW LEVEL OR GRADE
oT y — _ |
MAXIMUM
__—| SEPARATION
ph
157
18° | MAXIMUM
|, MAXIMUM
|LESS THAN 12° CLEARANCE
O
<
Es
0
\
+
=
=
12" SEPARATION 77
| BETWEEN BOTTOM OF
— COMBUSTION AIR INTARÉ
__— AND BOTTOM OF VENT
A TE — Г TT — a
3” ок
— | MAXIMUM | MAINTAIN 12" MINIMUM CLEARANCE
__— | SEPARATION | | ~*~ ABOVE HIGHEST ANTICIPATED
zu SNOW LEVEL OR GRADE
7 -
„А
pe TT 18 —”
- |_— MAXIMUM
| 12° OR MORE CLEARANCE |
2 COMBUSTION AIR
INTAKE PIPING N
SEE FIG.9 & 10
FOR VENT/INTAKE
TERMINATIONS
a VENT PIPING
| EXHAUST TEE
(FURNISHED)
2" DIAMETER VENT AND
COMBUSTION AIR INTAKE
PIPING — 20' MAXIMUM LENGTH
WITH 4 — 90 ELBOYWS
2' MINIMUM LENGTH
>
3” COMBUSTION AIR
INTAKE PIPING
3" VENT PIPING
SEE FIG.9 & 10
FOR VENT/INTAKE
TRANSITION NE NT TERMINATIONS
26 TO 38 IN TRANSITION FITTING
VERTICAL RUN NAN 26 TO 39 IN
& VERTICAL RUN
2' LENGTH OF 2° PIPE
С
L
EXHAUST TEE
(FURNISHED)
| 4’ LENGTH OF 2” PIPE
3” DIAMETER VENT AND
COMBUSTION AIR INTAKE
PIPING — 100’ MAXIMUM LENGTH
| WITH 4 — 90° ELBOWS
20° MINIMUM LENGTH
B. INSTALLATION
1.
NU Bo
10
12.
13.
Attach combustion air intake piping to supplied Fernco 2” coupling in evaporative recooler
Attach vent piping to furnished 2” PVC exhaust tee on draft Inducer outlet.
NOTE: All pipe joints are to be water tight.
Working from the boiler to the outside, cut pipe to required length(s).
Deburr inside and outside of pipe.
Chamfer outside edge of pipe for better distribution of primer and cement.
Clean and dry all surfaces to be joined.
Check dry fit of pipe and mark insertion depth on pipe.
NOTE: It is recommended that all pipes be cut, prepared, and pre assembled before permanently
cementing any joint.
After pipes have been cut and pre assembled, apply cement primer to pipe fitting socket and end
of pipe to insertion mark. Quickly apply approved cement to end of pipe and fitting socket (over
primer). Apply cement in light, uniform coat on the inside of socket to prevent buildup of excess
cement. Apply second coat.
While cement is still wet, insert pipe into socket with a 1/4 turn twist. Be sure pipe is fully
inserted into fitting socket.
. Wipe excess cement from joint. A continuous bead of cement will be visible around perimeter of a
properly made joint.
. Handle pipe joint carefully until cement sets.
11.
Support combustion air and vent piping a minimum of every 5 feet using pre formed metal
hanging straps.
Slope combustion air and vent pipes toward boiler a minimum of 1/4” per linear foot with no sags
between hangers.
Use appropriate methods to seal openings where vent and combustion air pipes pass through roof
or side wall.
22
EEE
ET T Era En A
E = . =
LL. о E
NA AR S ON a ES
A. CHECK GAS SUPPLY
The gas pipe to your boiler must be the correct size for the length of run and for the total BTU per
hour input of all gas utilization equipment connected to it. See table - 3 for the proper size. Be sure
your gas line complies with local codes and gas company requirements.
The boiler and its individual shutoff valve must be disconnected from the gas supply piping system
during any pressure testing of that system at test pressures in excess of % psig (3.5kPa).
The boiler must be isolated from the gas supply piping system by closimg its individual manual shutoff
valve during any pressure testing of the gas supply piping system at test pressures equal to or less
than % psig (3.5kPa).
The MAXIMUM GAS SUPPLY PRESSURE is 14.0-inches w.c.
The MINIMUM GAS SUPPLY PRESSURE 1s 5.0-inches w.c.
. 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 rotating the gas valve and pipe assembly. The boiler is
equipped with a 1/2-in. NPT connection on the gas valve for supply pipmg. The following rules
apply:
1. Use only those piping materials and joining methods listed as acceptable by the authority having
jurisdiction, or in the absence of such requirements, by the National Fuel Gas Code, ANSI-
7223.1- latest revision. In Canada, follow the CSA B149.1 and .2 installation Codes for Gas
Buming Appliances and Equipment.
2. Use pipe joint compound suitable for liquefied petroleum gas on male threads only.
3. Use ground joint unions.
4. Install a sediment trap upstream of gas controls.
5. Use two pipe wrenches when making the connection to the gas valve to keep it from turning.
6. Install a manual shutoff valve in the vertical pipe about 5 feet above floor.
7
8
9.
1
Tighten all jomnts securely.
Propane gas connections should only be made by a licensed propane installer.
Two stage regulation should be used by the propane mstaller.
0. Propane gas piping should be checked out by the propane installer.
. CHECKING THE GAS PIPING
After all connection have been made, check immediately for leaks. Open the manual shutoff valve.
Test for leaks by applying soap suds (or a liquid detergent) to each jomt. Bubbles forming indicate
leak. CORRECT EVEN THE SMALLEST LEAK AT ONCE.
WARNING
NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS.
23
TABLE 3 NATURAL GAS
| Pipe Capacity - BTU Per Hour Input
Length of Includes Fittings
Pipe - Ft. —
| 1/2” 3/4” 1” 11/4”
20 92,000 150,000 350,000 625,000
40 63,000 130,000 245,000 445,000
60 50,000 105,000 195,000 365,000
PROPANE GAS |
Pipe Capacity - BTU Per Hour Input
Length of | Includes Fittings
Pipe - Ft. Copper Tubing* Iron Pipe
5/8” 3/47 1/2” 3/47
20 131,000 216,000 189,000 393,000
40 90,000 145 000 129,000 267,000
60 72,000 121,000 103,000 217,000
* Outside diameter
The length of pipe or tubing should be measured from the gas meter or propane second stage regulator
GAS SUPPLY
PIPING
MANUAL
SHUT-OFF
VALVE
SEDIMENT
TRAP
GROUND JOINT
UNION
TURN OFF ELECTRICAL POWER AT FUSE BOX BEFORE MAKING ANY LINE
VOLTAGE CONNECTIONS. FOLLOW LOCAL ELECTRICAL CODES.
SRT AAA TA ETE EEE
ETA a OR TROL ася
All electrical work must conform to local code
as well ational Electrical Code, ANSI/NFPA-70,
latest revision. In Canada, electrical wiring shall comply with the Canadian Electrical Codes,
CSA-C22.1 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 power turned off at the fuse box.
Run a separate 120 volt circuit from a separate over current protection device in the electrical service
entrance panel. This should be a 15 ampere circuit. A service swiich has been pre-wired and located
on the exterior boiler jacket. See fig.13 for diagram showing location of service switch junction box
and power supply connection points. Connect black (hot) lead from the power supply to the unused
terminal on the service switch. Connect the white (neutral) lead from the power supply to the white
lead in the service switch junction box. Connect the green (ground) lead from the power supply to the
ground in the service switch junction box.
The boiler, when installed, must be electrically grounded in accordance with the requirements of the
authority having jurisdiction or, in the absence of such requirements, with the National Electrical
Code, ANSI/NFPA-70, latest revision. In Canada, electrical wiring shall comply with the Canadian
Electrical Codes, CSA-C22.1 and .2.
Run a 14 gauge or heavier copper wire from the boiler to a grounded connection in the service panel
or a properly driven and electrically grounded ground rod.
B. INSTALL YOUR THERMOSTAT
The thermostat location has an important effect on the operation of your boiler system. BE SURE TO
FOLLOW THE INSTRUCTIONS INCLUDED WITH YOUR THERMOSTAT.
Locate the thermostat about five feet above the floor on an inside wall. It may be mounted directly on
the wall or on a vertical mounted outlet box. It should be sensing average room temperature.
Avoid the Following:
DEAD SPOTS: COLD SPOTS: HOT SPOTS:
Behind doors Concealed pipes or ducts Concealed pipes Lamps
Corners and alcoves Stairwells - drafts Fireplace — Direct sunlight
Unheated rooms on TV sets Kitchens
other side of wall Radios
Set heat anticipator at 0.6 amps. Connect 24 volt thermostat leads to the two(2) red wires located in
service switch junction box, located on outer jacket of boiler. See fig.13 for service switch junction
ET % PE
CAUTION |
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING
ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER
OPERATION AFTER SERVICING. |
C. Connect Circulator Pump Wiring
See Fig.13 for service switch junction box and circulator pump field wiring connections. Connect
the circulator pump to the service switch junction box. If the two 120 volt circulator wire
terminals inside the junction box are not used, please leave the two wire nuts to prevent the short
circuit.
ÓN
4 WIRE COLOR CODE
BK = BLACK
24 VOLT a = ha
THERMOSTAT © Cep
.— SERVICE SWITCH
>
— HOT TO UNUSED
SWITCH TERMINAL
120 VOLTS
- NEUTRAL 60 BZ 1 9
120 VOLT
CIRCULATOR PUMP
SERVICE SWITCH
JUNCTION BOX
| |
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|
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If any of the original wire as supplied with this appliance must be replaced, it must be replaced with
‚ туре 150 °С Thermoplastic wire or its equivalent.
120 VOLT POWER SUPPLY
Li |
T
ON / OFF / —
À P7-1 5 P7-2 ит
Ti P4-1 m p4-3 P7-3 4
—! . — e
() CIRCULATOR MOTOR P11-2
eel, >
P11-1 A
RA 54 P11-4
Pii-3 qi
| IK Pst Y P5-3
P10-1 — a |
DRAFT INDUCER Р10-2
P8-9 Re PE
CONDENSATE PUMP
6K PB-7 °С
CONDENSATE FLOW SWITCH
SKI P6-1 HOT SURFACE IGNITER ps-2 5K2
> 120 VAC ‹
I P1-3
TRANSFORMER
Po 24 VAC ‹
P2-1 P2-2
CASTING TEMPERATURE E TS Va
SAFETY SWITCH | | |
(MANUAL RESET) {1-8 © en = Pg—4
A D——— ——
P9-3 P8-5 а
P11-7 @ e ‹
| ps-1 | PB-2 P8-6 gg
{i} > <e Kip, >> : < ——
KI К PES P8-3 RE Оо
GAS PRESSURE SWITCH
Ÿ P3-1
| MICROPROCESSOR
ELECTRONIC
AIR FAN / OUTLET LOGIC & TIMERS x
PROVING PRESSURE SWITCH A 6K RELAY = 30 SECOND DELAY ON MAKE (N.C.)
SWITCHES INLET PRESSURE SWITCH| INDICATOR LIGHTS A A] 7K RELAY = 45 SECOND DELAY ON MAKE (N.C.)
2 P33 3 POWER ж | BK RELAY = 30 SECOND DELAY ON MAKE (N.C.
men |
$ p3-6 (С) IGNITER Ли |
HIGH uur О) VALVE | /N CIRCULATOR PUMP/CALL FOR HEAT STATUS LIGHT
Loe FLAME
7 CONTROL О /2\ BLOWER STATUS LIGHT
YENT TEMPERATURE 1013-10 CONTROL
SAFETY SWITCH /3\ CONDENSATE PUMP STATUS LIGHT
p3-7 p3-4
® ®— ‹— /4\ BURNER STATUS LIGHT
THERMOSTAT
/5\ POWER SUPPLY. PROVIDE DISCONNECT MEANS AND
OVERLOAD PROTECTION AS REQUIRED
OTE:
- NOTE: 25" LABELS ARE FOR REFERENCE BETWEEN
SCHEMATIC AND LADDER DIAGRAM.
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This section provides a brief description of the key controls and accessories found m the Quantum Leap
Wet Recuperated 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 accessories described.
A.
INTEGRATED BOILER CONTROL (IBC)
The Integrated Boiler Control (IBC) is a microprocessor based controller for a high efficiency gas
boiler that monitors all safety controls and which controls the operation of the combustion air blower,
circulator pump, burner, and a combination hot surface igniter/flame sensor. This controller 1s not
intended for use with a vent damper. This controller is mounted on the control panel inside ofthe
boiler and contains four (5) diagnostic indicator lights.
TRI-TIMER TIME-DELAY RELAY MODULE
The Tri-Timer Module is connected to the IBC. The module controls the timed sequences of
operation for the gas pressure switch, gas valve regulator, and condensate flow switch.
2-STAGE GAS CONTROL VALVE
The electrically controlled 24 Volt 2-Stage Combination Gas Control Valve is designed to meet the
requirements for use with hot surface ignition systems found in the Quantum Leap. The valveis
piped to both the gas/air mixer and gas pressure switch. The valve facilitates both the high and.
normal fire (hence 2 stages) gas pressures as timed by the Tri-Timer.
HOT SURFACE IGNITER
The 120 volt Hot Surface Igniter heats up to 1800°F to initiate combustion of the gas inthe Quantum
Leap burner. The igniter is mounted next to the burner through the gas/air mixer. The igniter also
serves as a means for proving the main burner flame by flame rectification. In the event of a lack of
flame signal on three (3) consecutive trials for ignition, the IBC will lockout. The “VALVE &
FLAME?” diagnostic indicator lamps (lamp “D” & “E” on the IBC, See Fig. 16) will blink indicating
the failure mode as a lack of flame signal. The IBC is manually reset from lockout by either removing
and reestablishing the thermostat’s call for heat, or by turning the service switch off, then back on.
IGH LIMIT AQUASTAT CONTROL
The High Limit Aquastat Control determines the maximum boiler water temperature and also
provides a means for protecting the boiler and heating system from unsafe operating conditions which
could damage the boiler. The aquastat is mounted in the 44” NPT control well and %” x 2” bushing
on the top of the front boiler section at the hot water outlet connection to the circulation pump. The
aquastat is tied in with the IBC and is factory set at 180°F water temperature. The high limit setpoint
is field adjustable and may be set anywhere between 100°F and 200°F. The field setpoint adjustment
for each installation depends on heating system requirements.
29
F. VENT TEMPERATURE SAFETY SWITCH
The Vent Temperature Safety Switch 1s a disc thrmostat (145°F setpoint) located on the induced draft
fan outlet port. The switch protects the PVC vent pipe from a potential high temperature condition for
the discharging flue gases. This condition would typically be a result of running without the condensate
pump. The condensate pump facilitates the saturation of the incoming combustion air. The absence of
condensate pump operation translates to higher flue gas vent temperatures. This condition often points
to a condensate pump shutdown in response to a dry condensate sump condition. The vent temperature
safety switch automatically resets when the vent temperature decreases. (15°F switch differential)
G. CASTING TEMPERATURE SAFETY SWITCH
In the event of lack of of loss of water in the boiler, the Casting Temperature Safety Switch installed on
the top of the aluminum boiler section shuts off the boiler by shutting off power to the Integrated Boiler
Control (IBC) and causes the Power Indicator Light to go out. This fault requires manual reset of the
casting temperature safety switch to restart the boiler. Verify that the boiler is properly filled with
water before resetting this switch.
EH. FAN/QUTLET PRESSURE SWITCH
The disphragm type fan/outlet pressure switch 1s connected by vinyl tubing to the draft inducer suction
port. The fan/outlet pressure switch monitors flow by sensing the fan suction pressure measured In
inches of water (“ w.c.). The facotry setting on this switch 1s —0-45w.c. The contacts are normally
open. (negative sign means vacuum or negative pressure sensed). The fan/outlet pressure switch shuts
off the main burner if fan suction is inadequate due to a blocked vent pipe or weak or blocked draft
inducer. After five (5) minutes of lack of adequate fan suction, the IBC will lockout. The “PURGE”
indicator light will blink, indicating a failure to prove adequate combustion air flow or flue gas flow.
The IBC is manually reset from lockout as described in the Sequence of Operation section of this
chaper. -
I. INLET PRESSURE SWITCH
The diaphragm type inlet pressure switch 15 connected by vinyl tubing to a hose tee in a vinyl tubing me
which connects to both the evaporative recooler suction port and the mixer suction port. The inlet
pressure switch monitors and senses pressure measured in inches of water (“w.c.) for proving
combustion air flow at the mixer inlet and at the evaporative recooler inlet. The reason for this
“averaged” pressure indication is to permit the inlet pressure switch to monitor the potential blockage
of combustion air inlet piping and potential high condensate level in sump due to blocked condensate
drain. The factory setting on this switch is —1.10”w.c. (negative sign means vacuum or negative
pressure sensed). The contacts are normally closed. The inlet pressure switch closes or opens as
described in the Sequence of Operation section of this chapter. |
J. GAS PRESSURE SWITCH
The (differential) gas pressure switch is used to provide feedback to the IBC to track the successful
transition from the initial high gas firing rate (4.5”w.c. gas pressure — duration 30 seconds from gas
valve energizing) to the normal gas firing rate (3.0"w.c. gas pressure). The normal firing rate 1s used
for the duration of the call for heat after the initial high fire period. If this timed transition to the lower
gas pressure is not sensed by the gas pressure switch, the gas valve closes and flame
extinguishes. The IBC then goes through another ignition sequence. Continuous cycling of the boiler
on and off every two (2) minutes is an'indication that the gas valve may be stuck on high fire.
30
K. CONDENSATE PUMP
The condensate pump takes the cooler condensed flue gas solution which collects m the condensate
sump of the evaporative recooler and pumps it through the recovery heat exchanger coil in counterflow
with the hot flue gases being drawn from the boiler to the induced draft fan. The cooler condensate
absorbs valuable heat from the flue gases prior to their discharge through the vent piping to the
outdoors. Additional condensate is produced from the contact of the hot gases with the cool surface of
the recovery coil. After having picked up heat, the condensate 1s then pumped to the evaporative
recooler and sprayed over the tower fill material in conterflow with the incoming combustion air. The
combustion air absorbs heat and moisture from the hot condensate, increasing energy efficiency and
allowing lower flame temperature which helps reduce NOx levels contributing to a cleaner and healthier
enviroment. During normal boiler operation the overall condensate volume 1s simultaneously reduced
by its absorption by the incoming combustion air and increased by condensation of flue gas occuring in
the cast aluminum boiler sections and recovery heat exchanger. When the condensate level in the sump
rises to the overflow level, the net condensate produced drains through connecting piping (not provided
with boiler) to a floor drain . For this purpose, the boiler must be installed so that proper pitch of
piping to the floor drain can be accomplished. Use wood frame or blocks to raise the boiler as required
for proper installation.
I. CONDENSATE FLOW SWITCH
The condensate flow switch is located in the condensate pump discharge piping downstream of the
check valve, and is mounted on the side of the evaporative recooler. Te switch protects the condensate
pump from dry operation (running with the condensate sump empty) by shutting off the condensate
pump and allowing boiler to run without the pump. On each call for heat, the condensate pump starts
and the flow switch verifies that condensate flow is adequate to allow the condensate pump to continue
to run. The factory setting on the flow switch is 0.25 gpm. The flow switch has normally closed -
contacts.
M. DRAFT INDUCER
“The draft inducer (blower) provides a means for pulling combustion air into and through the
evaporative recooler, mixer, burner, the flue ways of the cast aluminum boiler sections and the recovery
heat exchanger before being discharged through the vent piping to the outdoors. See applicable
sections for proper sizing and installation of combustion air and vent piping in this manual.
N. CIRCULATOR PUMP
Every forced hot water system requires at least one circulating pump. The circulating pump imparts the
necessary energy to move the water through the closed loop supply and retura piping systems, terminal
heating equipment (1.e. finned tube radiators; etc. ) and back through the boiler for reheating. To
provide the required hot water flow rates, the circulator pump must be properly sized to overcome
frictional losses (usually measured in feet of water, also referred to as “pump head loss”) of the supply
and return piping systems and boiler. The circulatop pump is furnished in a carton within the boiler
cabinet for a single zone or zone valve controlled heating system and should be correctly located on the
downstream (i.e., pumping away) side of the expansion tank. For a pump controlled system (where
there is a circulator for each zone) the circulator provided with the boiler can work for one zone. For
more details on piping and circulators, see Near Boiler Piping section of this manual.
31
0. DRAIN VALVE
The manual drain valve provides a means of draining the water in the heating system, including the
boiler and hot water supply and return piping systems installed above the drain valve. This drain
valve is installed in the %” tapping at the bottom of the front boiler section. Any piping installed
below the elevation of this drain valve will require additional drain valves to be installed at low points
in the piping systems in order to drain the entire system.
P. A.S.M.E. RATED PRESSURE RELIEF VALVE
Each boiler must have a properly sized and installed American Society of Mechanical Engineers rated
pressure relieft valve. Water expands as it is heated by the burner/boiler sections. If there 1s no place
for the water to expand its volume, (i.e. a prperly sized and properly functioning expansion tank)
pressure on the inside of the boiler and heating system will increase. The relief valve will
automatically open at 30 psig pressure to relieve the strain on the boiler and heating system from the
increasing pressure. The pressure relief valve discharge must be piped with piping same size as the
valve discharge opening to an open drain, tub or sink, or other suitable dramage point not subject to
freezing, in accordance with A.5.MLE. specifications. Failure to provide the pressure relief valve with
piping as herein described may cause water damage and/or serious bodily mjury. The boiler |
manufacturer is not responsible for any water damage.
Q. FLAME ROLLOUT SAFETY SHUTOFF
As required, this boiler is equipped with a manual reset flame rollout safety shutoff means, which
shuts off main burner gas in the event that the flow of combustion products through the flueways 1s
reduced. In the event of blocked flueways, enough air will not be available to support combustion,
and the Intergrated Boiler Control (IBC) will lockout due to loss of flame signal (after 3 trials for
ignition). The “VALVE & FLAME” diagnostic indicator lamps (lamp “D” & “E” on the IBC, see
Fig. 16) will blink indicating the failure mode as a lack of flame signal. The IBC 1s manually reset
from lockout by either removing and reestablishing the thermostat’s call for heat, or by turning the
service switch off, then back on. If the boiler cannot be restored to normal operating condition by
resetting the control, contact a qualified service agency to check heat exchanger flueways for
blockage. |
R. (OPTIONAL) EXTERNAL CONDENSATE PUMP
For installations where there is no floor drain or other appropriate drainage receptacle available to
receive net condensate pump with integral sump is required. This unit can be installed to pump the
condensate to a remote tie in point to a sanitary sewer system. For this application, the boiler must be
installed so that proper pitch of piping to the external condensate reservoir (sump) can be
accomplished. Use wood frame or blocks to raise boiler as required for proper installation.
32
STRAINER
The polypropylene strainer is located on the suction side of the condensate pump. The strainer is
equipped with a 20 mesh 304 stainless steel screen, which prevents dirt and debns from entering the
condensate pump. The strainer screen can be cleaned if necessary.
CHECK VALVE
The PVC plastic ball type check valve is located in the condensate pump discharge piping. The
check valve keeps the circulating condensate inside the recovery coil from draming back to the
sump after each run cycle. This helps prevent inadvertent loss of prime in the condensate pump,
and also avoids the condensate pump having to purge air from inside the recovery coil at the start
of each run cycle.
SUMP FEEDER
The Quantum Leap propane fired boilers are equipped with an automic water feeder for the
condensate sump. The sump feeder is required due to the lower water vapor content of flue products
produced from buming propane gas, as opposed to natural gas combustion products that have
significantly higher water vapor content. This is due to the fact that the hydrogen content 1s lower in
propane gas than in natural gas. Therefore the combustion of propane gas produces less condensate
than the combustion of the equivelent Btu’s of natural gas.
The Sump Feeder consists of (3) major componets. (1) Liquid Level Control Assembly, which 1s
located at the base of thé condensate sump. (2) Solenoid Valve Assembly which 1s mounted to the
base pan support rail. (3) Sump Feeder Wiring Harness, which 1s linked to the Solenoid Valve and
Liquid Level Control in a J-Box located at the base of the QL boiler. This component assembly is
powered by the 24 volt transformer. |
With a low water level condition in the sump this will close the contacts mn the liquid level control.
This powers the solenoid valve, which opens and fills the sump. Once the desired level is reached,
the liquid level control contacts open, removing power from the solenoid valve.
33
A. WATER TREATMENT AND FREEZE PROTECTION
1. When filling the boiler and heating system, water treatment 1s generally not required or desired. For
localities where the water is unusually hard (above 7 grains hardness) or for low pH water conditions (below
7.0), consult a local water treatment specialist.
a. This boiler is designed for use in a closed hydronic heating system ONLY!
b. Excessive feeding of fresh make-up water to the boiler may lead to premature failure of the boiler
sections.
2. Use clean fresh tap water for initial fill and make-up of boiler.
a. À sand filter must be used if fill and make-up water from a well 15 to be used.
b. Consideration should be given to cleaning the heating system, particularly in retrofit situations,
where a new boiler is being installed in an older piping system.
c. In older systems, 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.
a. Choice and use of antifreeze must be in accordance with local plumbing codes.
b. Do not use automotive antifreeze as the type of corrosion inhibitors used will coat the boiler's heat
transfer surfaces and greatly reduce capacity and efficiency.
c. Consult antifreeze manufacturer's literature for compatibility of antifreeze with aluminum boiler.
Some brands have corrosion inhibitors that break down more rapidly or become ineffective at higher
operating temperatures when used with aluminum. Follow the antifreeze manufacturers instructions
on determining thé proper ratio of antifreeze to water for the expected low temperature conditions,
and for maintaining the quality of the antifreeze solution from year to year.
d. Use of antifreeze in any boiler will reduce capacity by as much as 10 to 20%, due to differing heat
transfer and pumping characteristics. This must be taken into consideration when sizing the heating
system, pump(s), and expansion tank. Consult antifreeze manufacturer's literature for specific
information on reduced capacity.
‘e. Water content of the boiler is 2.6 gallons. (10 liters)
f For recommended manufactured antifreeze (NFP-50) please contact Interstate Chemical
Co. New York Customer Service at 1-800-422-2436. _
B. FILLING BOILER WITH WATER AND PURGING AIR FOR SYSTEMS WITH DIAPHRAGM TYPE
EXPANSION TANKS
Refer to appropriate "Near Boiler Piping” diagrams.
1. Close all zone service valves on the supply and return piping. Open the feed valve and fill boiler
with water. Make sure air vent is open. Hold relief valve open until water runs air free for five
seconds to rapidly bleed air from boiler, then let the relief valve snap shut.
2. Open the zone service valve on the supply pipe for the first zone. Open the purge valve on the first
zone. Feed water will fill the zone, pushing air out the purge valve. Close the purge valve when the
“water runs air free. Close the zone service valve.
3. Repeat step 2 for all remaining zones.
4. Open all service valves. Any air remaining trapped in the return lines between the service valves and
the boiler will be pushed towards the air vent when the boiler is placed in operation.
5. Inspect piping system. Repair any leaks immediately.
C. FILLING BOILER WITH WATER AND PURGING AIR FOR SYSTEMS WITH CONVENTIONAL
CLOSED TYPE EXPANSION TANKS |
Refer to appropriate "Near Boiler Piping” diagrams.
1. Close all zone service valves on the supply and retum piping and close the expansion tank service
valve. Drain expansion tank. Open the feed valve and fill boiler with water. Hold relief valve open
until water runs air free for five seconds to rapidly bleed air from boiler, then let the relief valve snap
shut. 2A
ND
US
6.
Open the zone service valve on the supply pipe for the first zone. Open the purge valve on the first
zone. Feed water will fill the zone, pushing air out the purge valve. Close the purge valve when the
water runs air free. Close the zone service valve.
Repeat step 2 for all remaining zones.
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. |
Open all service valves. Any air remaining trapped in the return lines between the service valves and
the boiler will be pushed towards the expansion tank when the boiler is placed in operation.
Inspect piping system. Repair any leaks immediately.
NOTE: DO NOT use stop leak compounds. Leaks in threaded connections in the aluminum boiler sections must be
repaired immediately. Aluminum threads will not seal themselves.
D. PLACING BOILER IN OPERATION
4 FOR YOUR SAFETY READ BEFORE OPERATING E
WARNING: If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal injury or loss
of life.
A. This appliance does not have a pilot. It is equipped
with an ignition device which oulomatically lights
the burner. Do not try to light the burner by hand.
If you connol reach your gos supplier, coll the fire
depariment.
C. Use only your hand ta turn the gos control knob.
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next ta the floor because
some gas is heavier than air and will settle an the floor
WHAT TO DO IF YOU SMELL GAS
Da not try to light any appliance.
Do not touch any electrical switch: do not use ony
phone in the building.
Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's:
instructions.
1. STOP! Reod the sofety information above on this
label.
2. Set the thermostot to lowest setting.
3. Turn off ali electric power to appliance.
4. This appliance is equipped with en ignition device
which automaticaliy lights the burner. DO not try
to light the burner by hand.
GAS CONTROL
KNOB SHOWN
IN OFF POSITION =
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the applionce if service
is to be performed.
3. Open the door and remove the top jocket panel.
Z TO TURN OFF GAS TO APPLIANCE
Never use tools. If the knob will not turn by hand,
don't try to repair it, call a qualified service technician.
force or attempted repair may result in a fire or
explosion.
D. Do not use this appliance if any port has been under
water. Immediately call a qualified service technician
to inspect the appliance ond lo replace any part of the
control system and any gas control which hos been
under water,
5. Open the doer, ond remave the top jacket panel.
6. Rotate the gas control knab either ciackwise / Y
or counterclockwise / \ to "OFF".
7. Wait five (5) minutes to clear out ony gos. Then smell
for gas, including near the floor. If you smell gas,
STOP! . Fallow “B” in the safety information above on
this label. If you don’t smell gas, go to the next step.
B. Rotate the gas control knob either clockwise 77 x
or counterclockwise 7/7” to “on”.
9. Ciose the door, ond replace the top jacket panel
10. Turn on all electric power to the appliance.
"11. Set thermostat to desired setting.
12. the appliance will not operate, follow the instructions
"To Turn Off Gas To Appliance” and cali your service
technicion or gos supplier.
4. Turn gas control knob either clockwise m
or counterclockwise 7 X to "OFF. Do not force.
5. Close the door, and replace the top jacket panel.
Quantum Leap Boller
Safe lighting and other performance criteria were met with the gas manifold and control assembly
provided on the boiler when the boiler underwent tests specified in ANSI Z21.13-latest revision.
FIGURE 1 16
INDICATOR LA: LAMPS
DRAFT INDUCER
CONDENSATE PUMP
GAS VALVE / BURNER
STATUS LAMPS
CALL FOR HEAT / CIRCULATOR PUMP
y
DIAGNOSTIC
INDICATOR LAMPS
|
5
=
+ 00000
OO
POWER
PURGE
IGNITOR
VALVE
FLAME
\. VERIFY PROPER SEQUENCE OF OPERATION. The sequence can be followed via the
diagnostic indicator lamps on the integrated boiler control, and with the status lamps on the upper front
panel of the boiler 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.
| STATUS DIAGNOSTIC
SEQUENCE OF OPERATION LAMPS INDICATOR
| | | LAMPS
Power ON, boiler standing by. Lamp A is illuminated indicating 24 1.0 A. € ©
volt power is being supplied to the integrated boiler control. 2.0 B. o
| 3.0 C.O
40 D. O
НВ. О
Thermostat calls for heat, energizing system circulator and 1. А. ©
illuminating lamp 1. 2. B.O
3.0 C.O
4. D.O
В.О
Integrated boiler control goes through self check of internal circuitry AS
(1-2 seconds) and energizes draft inducer and condensate pump, Bo
illuminating lamps 2 and 3. CO
a. | DO
E. O
36
Draft mducer comes up to speed and establishes combustion airflow, | 1. @
causing the normally open fan/outlet pressure. switch contacts to close | 2. €
and to verify that the normally closed inlet pressure switch contacts 3.8
are closed. Lamp B 1s 1lluminated indicating that combustion airflow | 4.
15 proved and the 15 second pre purge cycle is under way.
Condensate 1s pumped through the recovery heat exchanger and,
evaporatie recooler condensate loop by the condensate pump. 2. € ©
Normally closed condensate flow switch contacts open when 3. @ O
condensate flow 1s established. | 4. O
0 O
After pre purge, Lamp B goes out and Lamp C illuminates, indicating e
the hot surface 1gniter 13 powered for the 20 second igniter warm-up O
period. The bright yellow orange glow of the hot surface igniter can @
be observed through the observation port in the front boiler section O
just above the 1gmter. O
After igniter warm-up, the two stage gas valve is energized, and opens | 1. & e
on the high firing rate regulator (4.57 w.c.) for a 6 second trial for 28 O
ignition. Lamps 4 and D illuminates. The blue orange glow of the - 3.8
burner can be seen through the observation port. 4. e
Two seconds later, Lamp C goes out as power 1s turned off to the hot | 1.
rym tm ee Tr
A Cet Вяз Ноа
FARR) EE EU Ris
surface igniter. During the last two seconds of the 6 second trial for |2.@.
Jlgnition, main burner flame is proven by flame rectification through 3.8
the hot surface igniter, providing a flame signal to the integrated boiler | 4. 8 -
control. The gas valve remains energized, and the boiler runs.
Thirty seconds after the gas. valve is energized, the gas valve switches | 1. ®
to the normal firing rate regulator (3.0”w.c.). The boiler runs tor the | 2. O
duration of the call for heat. 3.8 O
| 3
Thermostat ends call for heat, de-energizing gas valve and system 1. O ®
circulator. Burner stops firing. Lamps 1, 4, and D go out. Draft 2.
inducer remains powered and condensate pump remain powered. 3.
|| Lamp B illuminates, mdicating draft inducer 1s running for 30 second | 4.
postpurge. Condensate pump runs during postpurge period.
After 30 seconds, draft inducer and condensate pump are de-
energized. Lamp 2, 3, and B goes out. Boiler stands by for next call
for heat.
попы нровьшоова необ оовь носов Ноовы осн»
ОВО
tri
O
NOTE: First couple of cold starts may be rough due to gas line not + being completely purged of a air,
— causing low firing rate and high excess air levels.
B. Operate the boiler. INSPECT VENTING AND AIR INTAKE SYSTEM. Verify that all vent/air
intake connections are gastight and watertight. Repair any leaks immediately.
C. INSPECT CONDENSATE DRAIN. Verify that all connections are watertight, and that condensate
flows freely. Repair any leaks immediately.
D. INSPECT SYSTEM PIPING. Verify that all connections are watertight. Repair any leaks immediately.
37
E. Test ignition system safety SHUTOFF device as follows:
1. turn off manual gas valve
2. set thermostat to call for heat
3. boiler begins normal sequence of operation
4. after approximately 45 seconds (pre purge and igniter warm-up period), lamps 4 and D illuminate,
indicating gas valve 1s powered
5. after 6 seconds, gas valve closes, lamps 4 and D go out as integrated boiler control senses that
flame is not present |
6. torestart system, follow operating instructions under “Start-up-Place in Operation”
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 control to the design temperature requirements
of the system. Maximum high limit setting is 200°F. Minimum high limit setting 1s 100°F.
TEST OTHER SAFETY CONTROLS. Ifthe boiler is equipped with a low water cut off, a manual
high limit, or additional safety controls, test for operation as outlined by the control manufacturer.
Burner should be operating and should go off when controls are tested. When safety controls are
restored, burner should reignite.
SET THERMOSTAT HEAT ANTICIPATOR (IF USED) AND VERIFY THERMOSTAT
OPERATION. For a single thermostat connected to the red thermostat lead wires in the furnished
field wiring junction box, the heat anticipator should be set at 0.6 amps. For other wiring
configurations, refer to the instructions provided by the thermostat manufacturer regarding
adjustment of heat anticipator. Cycle boiler with thermostat. Raise the thermostat to the highest
setting and verify boiler goes through normal start up cycle. Lower thermostat to lowest setting and
verify boiler goes off. a
MEASURE THE NATURAL GAS INPUT RATE. Correct mput rate is essential for proper and
efficient operation of the burner and boiler.
1. Determine elevation at installation site.
2 Refer to the Boiler Ratings and Capacities section of this manual to determine the correct mput
rate for the local elevation.
3. Obtain the yearly average heating value of the local gas supply from the gas utility. At sea level
elevation, it should be approximately 1000 Btu's per standard cubic foot.
Operate boiler for 5 minutes.
Turn off all other gas appliances, extinguishing standing pilots where applicable.
At gas meter, measure time in seconds required to use one cubic foot of gas.
Calculate input rate according to the following formula:
Btuh imput rate = 3600 x heating value from step 3
Time for step 6
8. Measured input rate should be within +/-2% of the input rating from step 2. If within 2%, go to
step 9. If not, adjustment is required, proceed as follows:
a. Turn boiler off.
b. Set up U-tube manometer or differential pressure gauge for measuring manifold pressure, see
FIG.17.
c. Manometer or gauge must be able to read at least 0.0 to 5.0 inches water column of
differential pressure, and resolve to at least 0.1 inches water column.
d. Turn boiler on.
e
38
~ VINYL САР(2)
cf ROTOR CLAMP
©” ~~ SUCTION
DIFFERENTIAL
, PRESSURE
GAUGE
GAS
PRESSURE
SWITCH
U-TUBE
MANOMETER
GAS
VALVE
TO MIXER
\/
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 MANOMETER OR
A DIFFERENTIAL PRESSURE GAUGE. THE DIAGRAM SHOWS THE CONNECTION OF
BOTH MEASURING DEVICES BUT ONLY ONE DEVICE IS REQUIRED TO MEASURE THE
MANIFOLD PRESSURE. |
(1)— REMOVE 1/8” PLUG. INSTALL APPROPRIATE BARBED FITTING AND CONNECT THE
PRESSURE SIDE LINE FROM THE U-TUBE MANOMETER OR THE DIFFERENTIAL
PRESSURE GAUGE.
(2)— REMOVE THE VINYL CAP, CONNECT THE SUCTION SIDE LINE FROM THE U-TUBE
MANOMETER OR THE DIFFERENTIAL PRESSURE GAUGE.
"REFER TO "CHECK OUT PROCEDURE AND ADJUSTMENTS" IN THIS MANUAL WHEN
READING MANIFOLD PRESSURE. |
WHEN MEASUREMENT IS COMPLETE, DISCONNECT U-TUBE MANOMETER OR
DIFFERENTIAL PRESSURE GAUGE. BE SURE TO REINSTALL 1/8" PLUG, USING
APPROPRIATE PIPE THREAD SEALANT APPROVED FOR USE WITH NATURAL AND
LIQUIFIED PETROLEUM GASSES AND ALSO TO REPLACE VINYL CAP ON SUCTION LINE.
CRC
e. Verify that high fire manifold pressure is 4.5 inches w.c., just after burner
ignites. If within +/-0.2 (4.3 to 4.7) inches w.c., proceed to step f. If not,
adjustment is required. This adjustment must be made during the first thirty
seconds of burner firing, before the gas valve switches to normal firing rate.
Prepare for adjustment as follows: (see fig. 18 for gas valve detail)
I. Remove high fire regulator cover screw from outlet side of gas valve.
II. Insert 3/32” Allen wrench (hex key wrench) into adjustment screw.
Ш. Remove and reapply call for heat to recycle burner so ignition sequence
starts again. |
IV. Just after the burner ignites, turn adjustment screw clockwise to INCrease
pressure, or counter clockwise to decrease pressure. Hi fire pressure
should be set at 4.5 inches w.c.
V. Remove Allen wrench and replace cover screw.
NOTE:
NORMAL FIRE REGULATOR COVER SCREW MUST BE INSTALLED AT ALL TIMES UNLESS
ADJUSTING MANIFOLD PRESSURE. NORMAL FIRING RATE AND MANIFOLD PRESSURE MUST
ONLY BE MEASURED WITH COVER SCREW FIRMLY INSTALLED.
MAIN mn
я = O
INLET
1/2” №.Р.Т. REDUNDANT (PILOT)
| SOLENOID
Pa
| —— INLET PRESSURE TAP
O
3/16 INT.HEX-1/8 N.P.T. MANUAL KNOB
PLUG
NORMAL FIRE REGULATOR REGULATOR VENT MECO
COVER SCREW - WITH HOSE BARB FOR
3/32" HEX KEY WRENCH MIXER REFERENCE PRESSURE
ADJUSTMENT SCREW A
h HIGH FIRE
SS BE \ 1 REGULATOR COVER
N SCREW 3/32" HEX
& KEY WRENCH
OUTLET PRESSURE TAP Se ADJUSTMENT SCREW
1/8 N.P.T. CONNECTED TO LO -
CAS PRESSURE SWITCH O OUTLET
| = 1/2” №.Р.Т.
wf
Normal fire manifold pressure and input rate must always be measured with
normal fire regulator cover screw installed. Cover screw must be removed for
adjustment. Manifold pressure reading will change (increase) when cover screw
Is removed. |
I. Remove normal fire regulator cover screw on top of gas valve, and insert
3/32” Allen wrench into adjustment screw.
II. Turn adjustment screw clockwise to increase input rate, or counter
clockwise to decrease input rate.
III. Replace cover screw, or cover hole temporarily with your finger to check
new manifold pressure setting. Do not set manifold pressure lower than
2.5 inches w.C. or higher than 3.5 inches w.c. when adjusting input rate.
IV.Measure new input rate (cover screw must be installed). Repeat steps
I.-IV. until the input rate is within +/-2% of the nameplate input rating.
40
V. If the actual input rate can not be set to within 2% of the correct input
rating by adjusting manifold pressure, a change in main burner orifice
size is required. Consult the boiler manufacturer for information on
correct orifice sizing. The specific gravity (G) and the higher heating
value (HHV) of the local natural gas must be obtained from the local gas
utility in order to determine the proper orifice size.
g. After adjusting input rate, turn boiler off, remove manometer or pressure gauge,
reinstall 1/8” plug in gas pressure switch line, and reinstall vinyl cap on reference
pressure line. Turn boiler on.
9. Restore all gas appliances that may have been shut off (while measuring boiler input rate)
to normal operating conditions.
J. SET THERMOSTAT TO DESIRED ROOM TEMPERATURE. Observe several operating
cycles to verify proper operation. |
K. REVIEW ALL INSTRUCTIONS shipped with this boiler with owner or maintenance person.
Instructions must be affixed on or adjacent to the boiler.
L. COMPLETE AND SIGN THE INSTALLATION AND CHECK-OUT CERTIFICATE ON
THE FOLLOWING PAGE.
41
INSTALLATION AND CHECK-OUT CERTIFICATE
Boiler Model Serial # Date Installed
M] Installation instructions have been followed Measured BTU/HR input
[] Checkout procedure and adjustments performed
D Maintenance and Service issues reviewed with owner/ maintenance person
О Installation instructions booklet affixed on or adjacent to boiler
Installer (Company)
Address
Phone
Installer’s Name
Signature
42
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 (i.e. the primary heat
exchanger) will cause the formation of aluminum oxide. This oxide formation is normal, 1s generally
uniform throughout the boiler sections, and represents a negligible mass of aluminum that 1s
consumed by oxidation during the life of the boiler. If left unchecked, this buildup may eventually
cause blockage of the flue gas passages in the boiler sections, reducing efficiency, and ultimately
shutting down the boiler due to lack of combustion air flow. Aluminum oxide formation Is negligible
in the recovery heat exchanger because the condensate is diluted, and because the flue side of the
recovery coil never dries out, even during extended periods between run cycles. Regular service and
maintenance by a qualified service agency must be performed to assure safe trouble free
operation and maximum efficiency.
A. Beginning of each heating season
1. Annual service call by a qualified service agency, which includes:
a. Examine flue passages between boiler sections, burner, recovery heat exchanger,
evaporative recooler sump, and condensate lines, and clean if necessary following the
annual examination and cleaning instructions in paragraph “F” onthe next page.
b. Visually inspect venting and air intake system for proper function, deterioration or leakage.
If the vent or air intake show any signs of deterioration or leakage, repair or replace them
immediately. Insure proper reassembly and resealing of the vent and air intake system.
c. Check for and remove any obstruction to the flow of combustion air or venting of flue
gases.
d. Follow instructions for “Placing boiler in Operation”.
e. Follow instructions for “Check Out Procedure and Adjustments”.
f. Visually inspect condensate drain line for proper operation and deterioration. Check for
plugged condensate drain line. |
g. Check the silicone rubber seals between boiler sections. Insure that there are no leaks.
Use RTV silicone rubber adhesive sealant (available in caulking gun tubes) rated for at
least 400° F to replace or repair seals in locations where original seals have deteriorated.
h. Check all gasketed joints for leakage, and tighten bolts or replace gaskets if necessary.
i. Open jacket door and remove jacket top panel and check for piping leaks around circulator,
relief valve, and other fittings. Repair, 1f found. DO NOT use stop leak compounds.
2. Check that boiler area is free from combustible materials, gasoline, and other flammable
vapors and liquids. |
3. Circulator pump, condensate pump, and blower motor furnished with boiler are permanently
lubricated from the factory and require no further lubrication. Additional or non-factory
supplied pumps and/or motors should be lubricated according to the pump and/or motor
manufacturer’s Instruction.
B. Daily during heating season
1. Check for and remove any obstruction to the flow of combustion air or venting of tlue gases.
2. Check that boiler area is free from combustible materials, gasoline, and other flammable
vapors and liquids. | a.
An
C. Monthly during heating season
1.
2.
3.
5.
Open jacket door and remove jacket top panel and check for piping leaks around circulator,
relief valve, and other fittings. If found, contact a qualified service agency to repair. DO
NOT use stop leak compounds. |
Test relief valve. Refer to valve manufacturers instructions packaged with relief valve.
Visually inspect venting and air intake system for proper function, deterioration, or leakage.
If the vent or air intake show any signs of deterioration or leakage, contact a qualified service
agency to repair or replace them immediately and to insure proper reassembly and resealing of
the vent and air intake system. |
Visually inspect the clear vinyl condensate lines and the PVC condensate drain pipe for proper
operation, leakage, and deterioration. If the condensate lines or drain pipe show any signs of
blockage, leakage, or deterioration contact a qualified service agency to clean, repair, or
replace them immediately.
Check air vent(s) for leakage.
D. Periodically during heating season
1.
Where low water cut offs are used, a periodic inspection of the low water cut off 1s necessary,
including flushing of float type devices. Refer to low water cut off manufacturer’s specific
instructions. |
E. End of each heating season - annual shut down procedure
1.
2.
Follow instructions “To Turn Off Gas To Appliance”.
If heating system is to remain out of service during freezing weather, and does not contain
antifreeze, drain system completely. If boiler will be exposed to freezing temperatures, drain
condensate sump and condensate lines. Otherwise, do not drain system or boiler.
F. Annual examination and cleaning of boiler components.
‘The following service procedures must be performed only by a qualified service agency.
Boiler owner should not attempt these procedures.
1. Before Servicing, turn off electrical power to boiler at service switch. Close manual gas
valve to turn off gas supply to boiler.
2. Flue passages between boiler sections are examined by removing six (6) sheet metal
screws and the inspection plate on the left side jacket panel, and then removing the twenty
socket head cap (20) screws and the exposed cleanout cover plate on the boiler sections,
being careful to not damage the gasket. Refer to repair parts diagram, QL-block and
piping assembly. The procedure for examining and cleaning the burner is also described
below.
a. Any buildup of sediment or aluminum oxide (white powdery or flaky substance) in the
flue passages must be cleaned as follows:
b. Open jacket door and remove jacket top panel. Disconnect condensate drain lines from
barbed fittings on the bottom of the boiler and the bottom of the mixer. Keep the open
ends of the drain lines above the water level in the condensate sump to prevent the
sump from draining. Remove inlet pressure switch hose from barbed elbow fitting on
mixer. Remove blue 2” diameter combustion air hose from mixer.
c. Confirm that manual gas valve is closed and disconnect gas line to gas valve at union.
disconnect wires to gas valve, gas pressure switch and igniter.
d. Loosen but do not remove five (5) nuts attaching mixer assembly to boiler. Remove
two (2) igniter screws and very carefully remove the igniter. Use care when removing
the igniter, it is very brittle!!
e. Remove five (5) nuts and remove mixer assembly. Remove burner.
f. Aluminum oxide deposits are water soluble and may be rinsed away with spraying or
running water. Before rinsing, connect a 1/2” [.D. hose to the barbed fitting on the
bottom of the boiler and run the hose to a bucket or drain.
44
g. Use a flexible handle nylon brush to loosen sediment and aluminum oxide on all
heating surfaces of boiler, being careful to not damage the refractory fiber insulation in
the combustion chamber area. Moisture will not harm the refractory fiber, but poking
with a cleaning brush may. Refer to the repair parts diagrams.
h. After brushing and rinsing, remove any remaining loosened sediment using a shop vac
with a snorkel attachment. Again, be careful to not damage the refractory fiber
insulation in the combustion chamber area.
i. Inspect burner for any foreign matter in the flame ports or inside the burner. Any
foreign matter should be removed by blowing with compressed air or vacuuming.
j. Inspect interior of mixer for any signs of sediment or aluminum oxide and clean if
necessary.
k. Reinstall burner and position mixer assembly over studs. Install five (5) nuts but do
not tighten. Reinstall igniter and igniter gasket and fasten with two (2) screws. Use
care when installing the igniter. It is very brittle!! Tighten five (5) nuts holding
mixer assembly.
|. Connect:
° gas line to gas valve
°е condensate drain lines to mixer and boiler
° inlet pressure switch hose to mixer
* blue combustion air hose to mixer
* gas pressure switch wires -
° igniter wires
° gas valve wires |
m. Install cleanout cover plate and gasket. -Fasten with screws.
n. Install inspection plate and fasten with screws.
Visually inspect evaporative recooler sump. Visually inspect condensate lines leading
from the mixer, the boiler sections, the recovery heat exchanger, the sump, and the
exhaust tee to the drain manifold. Refer to repair parts diagrams. Any foreign material or
debris that is visible in the sump or the condensate lines needs to be cleaned out as follows:
a. Remove condensate line from the barbed fitting on the bottom of the mixer, and insert
the open end into a bucket or pan that is positioned on the floor in front of the boiler
below the sump, or route the open end to a floor drain. This will cause the condensate
sump and the condensate lines to drain out. As an option, disconnect the condensate
pump discharge line from the inlet side of the check valve, and arrange the condensate
pump discharge line to run into a bucket. Turn the power to the boiler on at the service
switch, and initiate a call for heat. The condensate pump will run, empiying the sump
contents into the bucket. (The pump will only run for thirty seconds since the flow
switch will not sense flow with the discharge line disconnected. Turn service switch off
then back оп to repeat pump cycle.) Turn the service switch off after the sump 15
drained. 5
b. Once the sump and condensate lines are emptied of water, the remaining lines can be
disconnected from the fittings on the recovery heat exchanger, the boiler, the-exhaust
tee, and the sump.
c. Remove the drain manifold and condensate line assembly. Run cold water through the
condensate lines to thoroughly flush out any sediment or debris in the lines and/or
manifold.
d. Remove the screen from the strainer and clean out any debris. Reassemble the strainer.
45
C.
h.
Remove the 1 14" PVC cleanout plug from the top surface of the sump. Inspect the
interior of the sump and the sump inlet and outlet fittings. Any blockage of the sump
inlet and outlet fittings must be cleared. Reinstall the cleanout plug in the top of the
sump.
Reinstall and connect the drain manifold assembly, using the hose clamps to secure the
various condensate lines to their fittings.
If the condensate pump discharge line is not already disconnected from the check valve
inlet (from step “a” above), disconnect it now. Follow the instructions under “Near
Boiler Piping” for “filling evaporative recooler with water”. (Having the condensate
pump discharge line disconnected allows the condensate pump to prime.)
Reconnect the condensate pump discharge line to the inlet side of the check valve.
4. Inspection of the recovery heat exchanger requires the following steps (Refer to the
repair parts diagram.)
a.
= 0
Loosen the clamp on the draft inducer end of the 2" ilexible coupling that connects the
vent pipe to the draft inducer. Disconnect (unplug) wiring harness from draft inducer
motor and vent temperature safety switch. Disconnect 3/8" O.D. pressure switch
tubing from draft inducer suction pressure port. Remove four (4) bolts that attach draft
inducer to recovery heat exchanger housing.
Remove draft inducer, gasket, and air orifice plate from top of recovery heat exchanger
housing.
Disconnect 14” O.D. and 3%" O.D. condensate lines from barbed fittings at top of
recovery coil inside recovery heat exchanger housing, and pull disconnected condensate
lines out through the wall of the housing.
Lift the recovery coil up and out of the recovery heat exchanger housing.
Examine the recovery coil for any signs of corrosion or oxidation. If damage is
extensive or there are any signs of leaks replace coil. Coil may be cleaned with any
commercially available condenser coil cleaner designed for aluminum condenser coils.
Be sure to rinse thoroughly to remove all traces of coil cleaning solution before
reassembling recovery heat exchanger. |
Reinstall recovery coil into recovery heat exchanger housing.
. Insert and attach 4" and %" condensate lines and clamp.
Reinstall air orifice plate, insuring that orifice plate is properly located in mounting
flange on top surface of recovery heat exchanger housing. Position the draft inducer
gasket and the draft inducer and fasten with four (4) screws. Be sure to connect ground
wire from draft inducer motor to one of the four mounting screws.
Connect wiring harness leads to the draft inducer motor and the vent temperature safety
switch. Connect 3/8" pressure switch tubing to draft inducer suction pressure port.
Connect the 2" flexible coupling to the draft inducer outlet.
46
POWER ON fr
STAND BY
y >
THERMOSTAT
CALLS FOR
HEAT
POSITIVE
у CHECKS PROOF OF
CIRCULATOR М.О. FAN/ AIRFLOW. IBC WAITS DRAFT INDUCER ENERGIZES
- FOR 45 SECONDS THROUGH 1K1 CONTACTS
QUILET PRESSURE
SWITCH
CONTACTS
ENERGIZES THRU
2K1 CONTACTS
y
IBC SELFCHECK OF
INTERNAL CIRCUITRY
1-2 SECONDS
SIMULTANEOUSLY WITH
CONDENSATE PUMP.
FOR FAN/OUTLET
PRESSURE SWITCH
CONTACTS
TO OPEN.
IBC
WAITS FOR
IBC
CHECKS
Y CHECKS UP TO 5 MINUTES
CONDENSATE PUMP ENERGIZES CLOSED, INLET PRESSURE CLOSED FOR FAN/OUTLET
THRU 1K1 AND 6K1 CONTACTS
SIMULTANEQUSLY WITH
DRAFT INDUCER. BOILER COMPLETES RUN
CYCLE WITH CONDENSATE
ИМ |PUMP OFF. NEXT RUN CYCLE
CONDENSATE PUMP WILL
BE NORMALLY ENERGIZED.
SWITCH CONTACTS
— REMAIN
CLOSED.
CONTACTS TO CLOSE
INDICATING FAN
X
6K 30 SECOND TIMER IS | У $
ENERGIZED IN CONDENSATE IS CONTROL LOCKOUT. PURGE
PUMP CIRCUIT | | CONDENSATE LIGHT BLINKS. RESET REQUIRED
6K TIMER OPENS N.C. : LEVEL IN. SUMP CIRCULATOR REMAINS ENERGIZED
6K1 CONTACTS AND TOO HIGH AS LONG AS THERMOSTAT
DE—ENERGIZES CONDENSATE (BLOCKED |
PUMP. PREVENTS COND.
COND. DRAIN)
PUMP FROM RUNNING
OR BLOCKED
DRY OR WITH INLET AIR PIPE
LOCKED ROTOR.
CONTACTS OPENN
WITHIN 30 SECONDS X NO y
Pa
В”
AFTER THE CONDENSATE
PUMP 1S ENERGIZED,
INDICATING COND.
OR INLET DRAIN PIPE
TO CLEAR, CLOSING
INLET PRESSURE
CONDENSATE PUMP
REMAINS POWERED AS
LONG AS FLOW SWITCH
SENSES FLOW OR UNTIL
END OF RUN CYCLE.
| AIRFLOW PROVED.
* SEE FIG. 16, PAGE 34 FOR LOCATION OF INDICATOR LAMPS. * DRAFT INDUCER
в RUNS FOR 15 | PY
— MICROPROCESSOR LIGHTS ON PURGE.
— BLINKING MICROPROCESSOR LIGHT
— LIGHT TURNS OFF — CIRCULATOR PUMP/CALL FOR HEAT STATUS LIGHT
— INTEGRATED BOILER CONTROL /A — DRAFT INDUCER STATUS LIGHT
— POWER © — ICNITER AN — CONDENSATE PUMP STATUS LIGHT
— PURGE — VALVE /FLAME
— BURNER STATUS LIGHT
Eis
‚ >
RÉESS PE EETISE, dis Grae LET
LEE RÉ Зои Е Ha o: Ad plat A ë
A I BA Ni Er EH
CONTROL WILL ATTEMPT
2 ADDITIONAL
> IGNITION SEQUENCES. >
PROBLEM ESTABLISHING 4
STARTING WITH PRE—PURGE L ¢
IF MAIN BURNER DOES
NOT PROVE FLAME IN 3
TRIALS — CONTROL LOCKOUT -
FLAME SIGNAL.
MAIN
BURNER PROVE
FLAME WITHIN
INITIAL TRIAL
FOR IGNITION
YES
30 SECONDS AFTER GAS VALVE IS ENERGIZED
N.C. BK1 TIMER CONTACTS OPEN, SWITCHING
PERIOD?
GAS VALVE TO NORMAL FIRING RATE
REGULATOR “AT -3.0” W.C.
DURING THE LAST 2 SECONDS OF THE
6 SECOND IGNITION TRIAL, MAIN BURNER
FLAME IS PROVED BY FLAME RECTIFICATION
THROUGH THE HOT SURFACE IGNITER, PROVIDING
A FLAME SIGNAL TO IBC. GAS VALVE REMAINS
ENERGIZED. BOH_ER RUNS.
4
2 SECONDS INTO 6 SECOND
IGNITION TRIAL, POWER (©)
TURNED OFF TO THE HOT
SURFACE IGNITER.
A
GAS PRESSURE SWITCH SENSES HIGH FIRING
RATE GAS PRESSURE, CLOSES CONTACTS,
POWERING 7K 45 SECOND DELAY ON MAKE TIMER.
GAS VALVE OPENS ON HIGH FIRING RATE
REGULATOR AT 4.5” W.C. FOR 6 SECOND TRIAL
FOR IGNITION. BLUE ORANGE GLOW OF THE
BURNER CAN BE SEEN THRU OBSERVATION PORT.
8K 30 SECOND DELAY ON
MAKE TIMER IS ENERGIZED.
GAS
PRESSURE
SWITCH SENSED
THAT GAS VALVE
HAS SHIFTED TO
NORMAL FIRING
GAS PRESSURE SWITCH
CONTACTS OPEN, REMOVING
POWER FROM 7K 45 SECOND
TIMER BEFORE END OF 45
SECOND DELAY. CAUSES 7K1
CONTACTS TO REMAIN CLOSED
AND GAS VALVE CONTINUES
TO BE ENERGIZED AND
BOILER RUNS.
Y
HIGH FIRE RATE REGULATOR
ON GAS VALVE ENERGIZED
THRU 8K1 CONTACTS.
GAS VALVE ENERGIZED THRU 3K1,
4K1 AND 7K1 CONTACTS.
BURNER STATUS LIGHT ON —
FRONT PANEL ILLUMINATES |
WHENEVER GAS VALVE
IS ENERGIZED.
GAS PRESSURE SWTCH
SENSES VALVE IS STILL
FIRING AT HIGH FIRE AFTER
8K1 TIMER CONTACTS SHOULD
HAVE OPENED. 7K TIMER
REMAINS POWERED
(45 SECONDS FROM
BURNER ENERGIZATION)
PURGE LIGHT GOES OUT. HOT SURFACE IGNITER
POWERED THRU 5K1 AND 5K2 CONTACTS FOR
20 SECOND IGNITER WARMUP. BRIGHT YELLOW
ORANGE GLOW OF THE HOT SURFACE IGNITER
CAN BE OBSERVED THROUGH THE
OBSERVATION PORT IN FRONT OF BOILER
SECTION JUST ABOVE IGNITER. O
AFTER 45 SECONDS OF 7K
TIMER ENERGIZING, 7K1
CONTACTS OPEN, REMOVING
POWER FROM GAS VALVE.
FLAME SIGNAL LOST, MAIN
BURNER EXTINGUISHES.
IBC WILL RECYCLE STARTING
WITH PRE—PURGE.
SAFETY SEQUENCES DURING OPERATION
VENT TEMPERATURE SAFETY SWITCH
IF VENT TEMPERATURE REACHES VENT
TEMPERATURE SAFETY SWITCH SETPOINT,
SAFETY SWITCH CONTACTS OPEN IMMEDIATELY
CLOSING GAS VALVE. (LIGHT GOES OUT) 00
Y
DRAFT INDUCER RUNS THRU 30 SECOND POST
PURGE AND SWITCHES OFF.
v
CIRCULATOR RUNS WITH THERMOSTAT ON
CALL FOR HEAT.
CASTING TEMPERATURE SAFETY SWITCH
IF BURNER OPERATES WHEN BOILER HAS NO
WATER, ALUMINUM BOILER SECTIONS
HEAT UP RAPIDLY.
y
CASTING TEMPERATURE SAFETY SWITCH
CONTACTS WILL OPEN BREAKING. 24 VOLT POWER
TO IBC. POWER INDICATOR LIGHT GOES OUT.
REQUIRES MANUAL RESET TO RE-CLOSE
CONTACTS. (LIGHT GOES OUT)
y
WHEN VENT TEMPERATURE SAFETY SWITCH
CONTACTS REMAKE BEFORE END OF CALL
FOR HEAT, CONTROL GOES INTO NORMAL
LIGAT.OFF SEQUENCE.
LOSS OF FLAME SIGNAL
IF AN ESTABLISHED FLAME SIGNAL IS LOST
WHILE CONTROL EXPECTS THAT THE BURNER (5)
IS OPERATING, CONTROL WILL IMMEDIATELY
DE—ENERGIZE GAS VALVE. (LIGHT GOES OUT)(?)
y
DRAFT INDUCER RUNS THRU 30 SECOND POST
PURGE
v
CONTROL WILL ATTEMPT TO RE-LIGHT BOILER
3 TIMES. IF FLAME IS NOT PROVEN, CONTROL
LOCKOUT — PROBLEM ESTABLISHING A es
© FLAME SIGNAL.
HIGH SUMP LEVEL
IF CONDENSATE DRAIN 1S BLOCKED AND THE
WATER LEVEL IN SUMP GETS TOO HIGH AND
POTENTIALLY BLOCKS OFF AIR INLET, CONTROL
WILL DE—ENERGIZE GAS VALVE.
(LIGHT GOES OUT) (25)
DRAFT INDUCER WILL REMAIN POWERED FOR
30 SECOND POST PURGE.
;
IF CALL FOR HEAT REMAINS, DRAFT INDUCER
REMAINS POWERED WHILE IBC WAITS 5 MINUTES
FOR SUMP WATER LEVEL TO DROP, ALLOWING AIR
FLOW TO RE-ESTABLISH.
y
IF THE SUMP LEVEL DOES NOT DROP WITHIN
THIS TIME, THE CONTROL WILL LOCKOUT.
PURGE INDICATOR LIGHT WILL BLINK.
fod
PROBLEM WITH COMBUSTION AIRFLOW.
LOSS OF COMBUSTION AIRFLOW
IF COMBUSTION AIRFLOW IS LOST WHILE BURNER
IS FIRING (FAN/OUTLET OR INLET PRESSURE
SWITCH CONTACTS OPEN) GAS VALVE WILL
BE DE—ENERGIZED. (LIGHT GOES OUT)
DRAFT INDUCER RUNS THRU 30 SECOND POST
HI LIMIT CONTROL
IF BOILER WATER TEMPERATURE REACHES
HI LIMIT (AQUASTAT). SETPOINT, HI LIMIT
N.C. CONTACTS OPEN IMMEDIATELY,
CLOSING GAS VALVE. (LIGHT GOES OUT) 00
PURGE
y
IF CALL FOR HEAT REMAINS, IBC WAITS
5 MINUTES FOR AIRFLOW TO BE RE-ESTABLISHED.| |
7
IF AIR FLOW DOES NOT RE-ESTABLISH
CONTROL LOCKOUT — PROBLEM WITH
COMBUSTION AIRFLOW.
y —
DRAFT INDUCER CONTINUES TO RUN FOR 30
SECOND POST PURGE AND SWITCH OFF.
y
CIRCULATOR RUNS AS LONG AS THERMOSTAT
CALLS FOR HEAT.
y
WHEN HI LIMIT CONTACTS REMAKE BEFORE END
OF CALL FOR HEAT — CONTROL GOES INTO
A NORMAL LIGHT OFF SEQUENCE.
SAFETY SEQUENCES DURING OPERATION (CONT.)
CONDENSATE PUMP
МА
IF CONDENSATE FLOW SWITCH CONTACTS CLOSE
(FLOW LOST) 6K 30 SECOND DELAY ON
MAKE TIMER wiLL BE ENERGIZED.
A -
IF 6K TIMER IS ENERGIZED FOR 30 SECONDS
6K1 CONTACTS OPEN, BREAKING POWER TO
CONDENSATE PUMP AND CONDENSATE PUMP
FRONT PANEL STATUS. PROTECTS FROM
DRY PUMP OPERATION. A
— у
BOILER WILL COMPLETE RUN CYCLE WITH
CONDENSATE PUMP OFF.
y
NEXT RUN CYCLE WiLL RUN NORMAL OR WILL
SHUTOFF AGAIN IF FLOW SWITCH DOES NOT
DETECT LOOP FLOW AFTER 30 SECONDS.
CIRCULATOR PUMP
CIRCULATOR WILL BE ENERGIZED AS LONG AS THERMOSTAT CALLS FOR
HEAT DURING LOCKOUT.
y
RECOVERY FROM ANY LOCKOUT REQUIRES RESET WHICH IS ACCOMPUSHED
BY REMOVING AND REAPPLYING THE THERMOSTAT CALL FOR HEAT
OR POWER TO CONTROL.
END OF NORMAL SEQUENCE OF OPERATION
THERMOSTAT ENDS CALL FOR HEAT.
GAS VALVE AND CIRCULATOR PUMP
A ARE DE—ENERGIZED. 90
DRAFT INDUCER RUNS FOR 30 SECOND POST
PURGE. CONDENSATE PUMP RUNS DURING __
POST PURGE.
DRAFT INDUCER AND CONDENSATE PUMP ARE
DE—ENERGIZED AFTER 30 SECOND POST PURGE.
A
A |
BOILER STANDS BY FOR NEXT CALL FOR HEAT.
WARNING [1 7
FIRE, EXPLOSION OR SHOCK HAZARD MAY CAUSE
PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
DO NOT ATTEMPT TO MODIFY THE PHYSICAL OR
ELECTRICAL CHARACTERISTICS OF THIS
BOILER IN ANY WAY.
IMPORTANT
>
CIN 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.
IF ANY COMPONENT DOES NOT FUNCTION PROPERLY, MAKE SURE IT IS CORRECILY
INSTALLED AND WIRED BEFORE REPLACING IT.
STATIC ELECTRICITY DISCHARGE CAN DAMAGE THE INTEGRATED BOILER CONTROL (IBC).
TOUCH METAL SURFACE TO DISCHARGE STATIC ELECTRICITY BEFORE TOUCHING IBC.
THE IBC CANNOT BE REPAIRED. IF IT MALFUNCTIONS IT MUST BE REPLACED.
ONLY TRAINED, EXPERIENCED SERVICE TECHNICIANS SHOULD SERVICE THE IBC SYSTEMS. FOLLOWING
TROUBLESHOOTING, CHECK OUT THE SYSTEM FOLLOWING THE SEQUENCE OF OPERATHON SECTION
OF THIS CHAPTER FOR A NORMAL LIGHT OFF SEQUENCE.
ALL CONTROLS ARE FACTORY TESTED AT LEAST ONCE IN THE ASSEMBLY PROCESS AND A DEFECTIVE
CONTROL IS GENERALLY THE LEAST LIKELY CAUSE. IF YOU SUSPECT YOU HAVE A DEFECTIVE CONTROL,
DOUBLE CHECK YOUR PATH THROUGH THE TROUBLESHOOTING CHART BEFORE YOU RELPLACE IT.
IT IS ALSO IMPORTANT TO REMEMBER THAT THE LIKELIHOOD OF COMING ACROSS TWO IDENTICAL
DEFECTIVE CONTROLS IN A ROW IS ALMOST NiL. IF IT SEEMS TO BE HAPPENING, CHANCES ARE
THAT EITHER THERE IS NOTHING WRONG WITH THE CONTROL OR IT IS BEING DAMAGED BY
SOME OTHER PROBLEM (A SHORT BURNING OUT A TRANSFORMER, FOR EXAMPLE).
INITIAL SERVICE. CHECKS
1. BEFORE TROUBLESHOOTING:
A. MAKE SURE THAT CIRCUIT BREAKER IS ON OR FUSE IS OK AT ELECTRICAL PANEL.
B. MAKE SURE THAT SERVICE SWITCH 15 ON.
C. MAKE SURE THAT GAS IS ON AT THE GAS METER, AT ALL APPROPRIATE MANUAL
SHUTOFF VALVES AND AT THE GAS CONTROL VALVE.
D. MAKE SURE THAT THE THERMOSTAT IS CALLING FOR HEAT.
E. CHECK THAT WIRE CONNECTORS AT THE INTEGRATED BOILER CONTROL AND AT THE
ORIGINATING CONTROL ARE SECURELY PLUGGED IN OR CONNECTED. |
F. CHECK THAT HOSES ARE SECURELY CONNECTED AND ARE NOT PLUGGED OR DAMAGED.
2. TROUBLESHOOTING TOOLS:
A. VOLTMETER TO CHECK 120 VAC AND 24 VAC.
B. CONTINUITY TESTER. |
C. INCLINED MANOMETER OR PRESSURE GAUGE WITH 01.5” RANGE (0.01 SCALE) FOR
MEASURING SUCTION PRESSURES AT PRESSURE SWITCHES.
D. U—TUBE MANOMETER OR DIFFERENTIAL PRESSURE GAUGE WITH 0-14" RANGE (0.1"
SCALE) FOR MEASURING INLET AND MANIFOLD GAS PRESSURES.
Mas
3. WHAT 15 SYSTEM: STATUS?
A. CONSULT THE CHART ON THE FOLLOWING PACE.
B. FIGURE 16 ON PAGE 34 SHOWS THE LOCATION ON THE BOILER OF THE DIAGNOSTIC
INDICATOR LAMPS AND BOILER STATUS LAMPS.
SYSTEM STATUS
THE INDICATOR AND STATUS LIGHTS TRACK THE
OPERATING SEQUENCE. IF THE SYSTEM LOCKS OUT, THE LIGHTS
INDICATE THE POINT IN THE SEQUENCE OF OPERATION WHERE LOCKOUT
OCCURS. IF THIS TABLE DOES NOT READILY PROVIDE THE REASON FOR
BOILER MALFUNCTION OR NON-OPERATION, REFER TO THE FOLLOWING
PAGES FOR MORE DETAILED TROUBLESHOOTING PROCEDURES.
LIGHT SYMBOL | STATUS INDICATES
ON IBC IS ENERGIZED THROUGH 24 VOLT TRANSFORMER.
POWER
OFF IBC IS NOT ENERGIZED.
on IBC 15 ENERGIZING THE DRAFT INDUCER AND AIR
FLOW IS PROVEN.
OFF DURING PURGE CYCLE — DRAFT INDUCER IS NOT
- POWERED OR AIR FLOW IS NOT PROVEN.
PURGE OFF
OFF DURING IGNITER AND RUN CYCLE - NORMAL
OPERATION, PURGE CYCLE COMPLETE.
IBC IS LOCKED OUT. PROBLEM COULD INDICATE
“BLINKING | CONDENSATE LEVEL TOO HIGH IN SUMP, FALSE POSITIVE
PROOF OF AIR FLOW OR BLOCKED VENT OR INTAKE AIR
PIPE OR BLOCKED EVAPORATIVE RECOOLER.
© ON IBC IS ENERGIZING IGNITER.
IGNITER
(с) OFF | IGNITER IS NOT ENERGIZED
O on IBC 15 ENERGIZING 2—STAGE GAS CONTROL VALVE
TO OPEN.
©) OFF 2-STAGE GAS CONTROL VALVE IS CLOSED.
VALVE/ | |
FLAME IBC IS LOCKED OUT. PROBLEM IS FLAME HAS NOT BEEN
PROVEN IN THREE (3) IGNITION ATTEMPTS. MAY BE DUE
BLINKING | TO BROKEN IGNITER OR LACK OF OR LOW FLAME SIGNAL,
OR NO GAS, OR BLOCKED FLUEWAY OR RECOVERY
HEAT EXCHANGER.
es A ON IBC IS ENERGIZING CIRCULATOR PUMP CIRCUIT.
CALL FOR | |
HEAT /\ OFF CIRCULATOR PUMP IS NOT ENERGIZED.
/A ON IBC IS ENERGIZING DRAFT INDUCER CIRCUIT.
DRAFT x
INDUCER
/2\ OFF DRAFT INDUCER 1S NOT ENERGIZED.
A ON IBC IS ENERGIZING -CONDENSATE PUMP CIRCUIT.
CONDENSATE
PUMP
AN OFF CONDENSATE PUMP IS NOT ENERGIZED.
A ON IBC IS ENERGIZING 2—STAGE GAS CONTROL VALVE
CIRCUIT. (GAS VALVE OPEN).
BURNER
A OFF 2-STAGE GAS CONTROL VALVE IS NOT ENERGIZED
(GAS VALVE CLOSED)
TROUBLESHOOTING CHART 1
GREEN POWER INDICATOR LIGHT 1S
ILLUMINATED ON THE IBC (A)
NO
—P—
CHART 2
ELECTRICAL SHOCK HAZARD.
MAY CAUSE SERIOUS INJURY OR DEATH.-
1 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.
YES
Y
WHAT TO DO IF YOU SMELL GAS
e DO NOT TRY TO LIGHT ANY APPLIANCE
e DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY
PHONE IN YOUR BUILDING.
o IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBORS
PHONE. FOLLOW THE GAS SUPPLIER'S INSTRUCTIONS.
e IF YOU CAN NOT REACH YOUR GAS SUPPLIER, CALL THE
FIRE DEPARTMENT.
CHECK SYSTEM STATUS. IF LOCKED
OUT NOTE FAILURE MODE. WHICH
INDICATOR LIGHT 1S BLINKING?
RESET SYSTEM BY TURNING SERVICE
SWITCH OFF THEN ON. IF NOT
LOCKED OUT, SET THERMOSTAT TO
CALL FOR HEAT.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO
SHUT OFF, DO NOT TURN OFF OR DISCONNECT THE ELECTRICAL
SUPPLY TO THE PUMP. INSTEAD, SHUT OFF THE GAS AT A
LOCATION EXTERNAL TO THE APPLIANCE.
DO NOT USE THE BOILER IF ANY PART OF THE GAS CONTROL
SYSTEM HAS BEEN UNDER WATER. A QUALIFIED SERVICE
TECHNICIAN SHOULD INSPECT THE BOILER AND REPLACE ANY
PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH
HAS BEEN UNDER WATER.
USE ONLY YOUR HAND TO TURN THE GAS CONTROL KNOB.
NEVER USE TOOLS. IF THE KNOB WILL NOT TURN BY HAND,
DON'T TRY TO REPAIR IT. FORCE OR ATTEMPTED REPAIR MAY
RESULT IN A FIRE OR EXPLOSION. :
FALSE POSITIVE PROOF OF AIRFLOW. CHECK
FAN /OUTLET PRESSURE SWITCH CONTACTS, { 4
Y
NO
CIRCULATOR STARTS? /N
YES
>
CHART 2
CLOSED
IF CONTACTS ARE CLOSED WITH NO
AIRFLOW, REPLACE PRESSURE SWITCH.
IBC CHECKS NORMALLY OPEN FAN/OUTLET
PRESSURE SWITCH CONTACTS
OPEN
CHART 3.
TROUBLESHOOTING CHART 2
NO
FE
CHART 1
CHECK THAT CIRCUIT BREAKER IS ON OR
FUSES ARE OK AT THE ELECTRICAL PANEL
y
CHECK THAT SERVICE SWITCH IS ON
y ÓN
CHECK CASTING TEMPERATURE SAFETY
SWITCH. PUSH RESET BUTTON ON SWITCH.
CONTACTS OPEN (BUTTON UP) OR CLOSED
(BUTTON DOWN)?
OPEN
+ CLOSED
CHECK WIRING TO IBC. 120 VAC BETWEEN
TERMINALS 1 AND 3 AT WIRING HARNESS
PLUG CN7?
NO
X
CHECK WATER LEVEL IN BOILER.
FOR AIR TRAPPED IN TOP OF BOILER.
CONTACTS WILL NOT STAY CLOSED UNTIL
CHECK
BOILER COOLS OFF,
+ YES
NO
CHART 1
120 VAC BETWEEN TERMINALS 1 AND 3.
AT CONNECTOR CN3 ON IBC?
NO
REPLACE /REPAIR WIRING FROM SERVICE
SWITCH TO IBC
y YES
120 VAC AT TRANSFORMER PRIMARY
TERMINALS?
NO
REPLACE IBC
4 YES
24 VAC AT TRANSFORMER SECONDARY
TERMINALS?
NO
REPAIR WIRING TO TRANSFORMER
Y YES
24 VAC AT WIRING HARNESS PLUG CN2?
NO
REPLACE TRANSFORMER
J YES
REPLACE IBC
CHECK FOR 120 VAC BETWEEN TERMINALS
1 AND 3 AT CONNECTOR CN5 ON IBC?
NO
PUSH RESET BUTTON ON CASTING TEMP.
CHECK CONTINUITY OF CASTING TEMP.
SAFETY SWITCH CONTACTS. CONTACTS
SAFETY SWITCH.:
OPEN OR- CLOSED?
CLOSED y OPEN
REPLACE CAST. TEMP.
SAFETY SWITCH.
7
REPLACE/REPAIR WIRING FROM
TRANSFORMER TO IBC
y YES
CHECK FOR 120 VAC AT CIRCULATOR
NO
REPLACE IBC
y YES
REPAIR/REPLACE CIRCULATOR
REPLACE/REPAIR WIRING FROM
IBC TO CIRCULATOR
fur =.
TROUBLESHOOTING CHART 3 7 HART
OPEN CHART &
E >
FF 1
X
REPLACE IBC
NO| CHECK FOR 120 VAC BETWEEN | no| CONDENSATE PUMP STARTS
TERMINALS 1 AND 3 AT (SIMULTANEOUSLY WITH
CONNECTOR CN4 ON IBC DRAFT INDUCER) A
YES | YES
=
REPAIR/REPLACE WIRING
FROM IBC TO TIMER
NO! CHECK FOR 120 VAC BETWEEN
TERMINAL CN8—9 AND GROUND
YES
CHECK FOR 120 VAC BETWEEN | 3
NO! TERMINAL CN8-8 ANO GROUND AFTER 30 SECONDS, CONDENSATE
. REPLACE TIMER (MUST BE CHECKED WITHIN 30 PUMP CONTINUES .TO RUN AS
SECONDS AFTER CALL FOR HEAT LONG AS THERMOSTAT CALLS
STARTS) FOR HEAT AND DURING
Jes POST PURGE
CHECK FOR 120 VAC AT TES NO
NO! CONDENSATE PUMP LEADS ON
REPAIR / REPLACE WIRING FROM |8 WIRING HARNESS (MUST BE | NORMAL OPERATION
TIMER TO CONDENSATE PUMP. CHECKED WITHIN 30 SECONDS
— AFTER CALL FOR HEAT STARTS)
RE
CHECK CONDENSATE PUMP FOR
BLOCKAGE OR LOCKED ROTOR
FILL SUMP AND PRIME CONDITION. CLEAN OR REPLACE
PUMP PER NEAR BOILER CONDENSATE PUMP.
PIPING INSTRUCTIONS. Y
"FILLING EVAP КЕ- NO
COOLER WITH WATER” кф
CHECK WATER LEVEL IN SUMP. IS CONDENSATE PUMP PRIMED?
y YES
CLEAN CONDENSATE
PUMP SUCTION LINES NO
AND STRAINER BETWEEN
SUMP AND CONDENSATE
PUMP. IF NOT PLUGGED OR
REMOVE 3/4"0D COND. PUMP OUTLET HOSE FROM INLET SIDE OF CHECK VALVE AND
DIRECT INTO SMALL BUCKET. TEMPORARILY DISCONNECT AND RECONNECT ONE
ELECTRICAL LEAD FROM .THE FLOW SWITCH TO RESTART THE COND. PUMP. 15
THE PUMP FLOW 0.5 OR MORE GPM? NOTE—PUMP SHOULD STOP IN 3Q SECONDS.
DIRTY, REPLACE
CONDENSATE PUMP. ~ —
CHECK VALVE RESTRICTED |<4—
OR DEFECTIVE. CLEAN
OR REPLACE CHECK VALVE.
y YES
RECONNECT 3/47 OD CONDENSATE PUMP OUTLET HOSE TO INLET SIDE OF CHECK
VALVE. DISCONNECT 3/4” OD CONDENSATE PUMP OUTLET HOSE FROM BOTTOM OF
FLOW SWITCH AND DIRECT INTO A SMALL BUCKET. TEMPORARILY DISCONNECT
AND RECONNECT ONE ELECTRICAL LEAD FROM THE FLOW SWITCH TO RESTART
THE CONDENSATE PUMP. IS THE PUMP FLOW 0.5 OR MORE GPM? NOTE
PUMP SHOULD STOP IN 30 SECONDS.
Y YES
FLOW SWITCH RESTRICTED | NO
OR DEFECTIVE. CLEAN [€
OR REPLACE FLOW
SWITCH
RECONNECT 3/4"0D COND. PUMP OUTLET HOSE TO BOTTOM OF FLOW SWITCH.
DISCONNECT 3/4700 COND. PUMP OUTLET HOSE AT 90° BARBED ELBOW FITTING
AT ENTRANCE OF CONDENSATE TO RECOVERY HEAT EXCHANGER, AND DIRECT
INTO SMALL BUCKET AGAIN, TEMPORARILY DISCONNECT AND RECONNECT ONE
ELECTRICAL LEAD FROM THE FLOW SWITCH TO RESTART THE COND. PUMP. IS
THE PUMP FLOW 0.5 OR MORE GPM? (ASSURE THAT SUMP WATER LEVEL 1S
ADEQUATE TO CHECK FLOW. PUMP SHOULD CONTINUE TO RUN AFTER 30 SECONDS.)
RECOVERY COIL BLOCKED
CLEAR BLOCKAGE IN
COIL OR REPLACE
COIL
+ YES
RECONNECT 3/4700 COND. PUMP OUTLET HOSE TO BARBED ELBOW FITTING ON
RECOVERY HEAT EXCHANGER. DISCONNECT 1/2°0D CONDENSATE HOSE FROM THE
90° SWIVEL FITTING ON TOP OF THE EVAPORATIVE RECOOLER AND DIRECT INTO
SMALL BUCKET. (DEPRESS COLLET ON SWIVEL FITTING AND PULL HOSE OUT.)
AGAIN, TEMPORARILY DISCONNECT AND RECONNECT ONE ELECTRICAL LEAD FROM
THE FLOW SWITCH TO RESTART THE CONDENSATE PUMP. 15 THE PUMP FLOW 0.5
OR MORE GPM? (ASSURE THAT THE SUMP WATER LEVEL IS - ADEQUATE TO CHECK
FLOW. PUMP SHOULD CONTINUE TO RUN AFTER 30 SECONDS.)
NO
| REPLACE FLOW SWITCH |4—
Y YES
RECONNECT 1/2°0D COND. HOSE TO SWIVEL FITTING ON. TOP OF EVAPORATIVE
RECOOLER. ASSURE THAT HOSE SUPPORT IS FULLY INSERTED INTO HOSE ENO.
INSERT HOSE FULLY INTO SWIVEL FITTING. ARE FLOW SWITCH CONTACTS CLOSED
ON NO FLOW AND OPEN ON FLOW.
4 YES
| NORMAL OPERATION |
CHART 3
OPEN
3
DRAFT INDUCER STARTS
(SIMULTANEOUSLY WITH
CONDENSATE PUMP)
A
TROUBLESHOOTING CHART 4
YES
CHECK FOR 120-VAC
BETWEEN TERMINALS 1
AND 3 AT CONNECTOR
CN4 ON IBC
YES
CHECK FOR 120 VAC AT
NO
Tu
NO
REPLACE IBC |
REPAIR /REPLACE
WIRING FROM IBC
ye
CHART 5
DRAFT INDUCER LEADS >
ON WIRING HARNESS TO DRAFT INDUCER
YES
Y
REPAIR /REPLACE
DRAFT INDUCER
CONTACTS
OPEN CLEAN QUT VENT PIPE,
| CHECK FOR SAGS OR
IBC WAITS |
MINUTES FOR = T0 5 IS VENT PIPE CLEAR | NO LOW SPOTS WHERE
y NORMALLY
OPEN FAN /OUTLET TE (NO BLOCKAGE) CONDENSATE MAY
PURGE LIGHT ON? NO PRESSURE SWITCH YES PUDDLE AND BLOCK
© CONTACTS TO CLOSE, y THE VENT
INDICATING DRAFT CHECK FAN/OUTLET
YES ~. INDUCER SUCTION 15 PRESSURE SWITCH PER
PRESENT INSTRUCTIONS ON NO | CLEAN OUT SAMPLING
CONTACTS FOLLOWING PAGES. ARE LINES OR REPLACE
CLOSED SAMPLING LINES CLEAR DEFECTIVE SWITCH
AND CONNECTED
PROPERLY?
YES
CHECK DRAFT INDUCER | мо
MOTOR RPM. IS 17 DRAFT INDUCER
3400—3600? |
YES
CHECK FOR BROKEN OR
LOOSE IMPELLER ON
DRAFT INDUCER AND
CONTACTS REPLACE DRAFT
y OPEN INDUCER IF FOUND TO
ROKEN OR LOOSE
IBC CHECKS THAT BE B
NORMALLY CLOSED INLET|
PRESSURE SWITCH IS INTAKE AIR PIPE ¡NO CLEAN OUT INTAKE
CONTACTS REMAIN {P| CLEAR (NO BLOCKAGE) » AIR PIPE
CLOSED, INDICATING
INTAKE AIR PIPE IS YES
CLEAR. + CONDENSATE DRAIN PIPE
CLOSED IS CONDENSATE LEVEL OR DRAIN TEE 15
Y NO BLOCKED, CAUSING
IN SUMP BELOW THE bl CONDENSATE LEVEL TO
CHECK PRESSURE BOTTOM OF THE INTAKE
SWITCH WIRING. IF AIR PIPE? BLOCK INTAKE AIR PIPE.
WIRING OK, REPLACE CLEAR BLOCKAGE IN
IBC YES DRAIN PIPE OR TEE.
7
CHECK INLET PRESSURE |
SWITCH PER NO, [ REPLACE DEFECTIVE
INSTRUCTIONS ON P| PRESSURE SWITCH
FOLLOWING PAGES.
+ DOES SWITCH CHECK OK?
15 SECOND PRE PURGE COMPLETE
PURGE LIGHT OFF. SIMULTANEOUSLY NO REPLACE IBC ]
IGNITER LIGHT ON AS IGNITER © >
CIRCUIT IS ENERGIZED
CHART 4
YES
IGNITER /SENSOR WARMS
UP AND GLOWS YELLOW/
ORANGE DURING 20
SECOND WARM UP.
YES
y
AFTER 20 SECOND
IGNITER WARM UP, GAS
VALVE IS ENERGIZED
©
2 SECONDS LATER POWER
IS REMOVED FROM
IGNITER /SENSOR ©)
DOES MAIN BURNER
LIGHT?
NO
YES
YES |
Х CHART 6
к
TROUBLESHOOTING CHART 9
CHECK FOR 120 VAC
BETWEEN TERMINALS 1
AND 2 AT CONNECTOR
CN1 ON IBC (DURING
IGNITER WARM UP)
yE
CHECK FOR 120 VAC AT
IGNITER /SENSOR LEADS
ON WIRING HARNESS
(DURING IGNITER
WARM UP)
NO
YES |
CHECK FOR 24 VAC
ACROSS TERMINALS PM
AND C ON THE GAS
CONTROL, WHILE VALVE/
FLAME INDICATOR LIGHT
IS LIT
YES
Y
CHECK IF IGNITER/
SENSOR POSITION IS OK?
TIP SHOULD BE SLANTED
TOWARDS BURNER
NO
JE
CHECK GAS SUPPLY
PRESSURE AT INLET
PRESSURE TAPPING ON
GAS CONTROL. IS GAS
PRESSURE GREATER
THAN 5.0" W.C.?
NO
YES
CHECK FOR 24 VAC
ACROSS THE TERMINALS
HI AND C ON THE GAS
CONTROL, WHILE THE
VALVE/FLAME LED IS UT.
NO
YES
CHART 6
REPLACE IBC
YES
REPAIR /REPLACE WIRING
FROM IBC TO IGNITER/
SENSOR
BREPLACE IGNITER /SENSOR]
CHECK FOR 24 VAC
ACROSS TERMINALS
CN6—2 AND CN6—5 ON
IBC, WHILE THE VALVE/
FLAME LED IS UT
NO
—
Des
CHECK FOR 24 VAC
ACROSS TERMINALS
THE TIMER, WHILE THE
VALVE /FLAME LED 15 LIT.
CN8—4 AND CN8-3 ОМ №
REPLACE IBC
NO
REPAIR/REPLACE WIRING
JE
CHECK FOR 24 VAC
ACROSS TERMINALS
CN8-4 AND CN8—2 ON
THE TIMER, WHILE THE
BETWEEN IBC AND TIMER
VALVE/FLAME LED IS LIT.
YES
REPAIR/REPLACE WIRING
BETWEEN TIMER AND
GAS CONTROL
RESTORE IGNITER/SENSOR
TO CORRECT POSITION.
DO NOT RELOCATE
ARE ALL MANUAL SHUT—
OFFS IN THE GAS
SUPPLY LINE AND ON
THE GAS CONTROL IN
THE OPEN OR ON
pr REPLACE TIMER |
No
OPEN OR TURN ON ALL
MANUAL SHUTOFFS
POSITION?
ye
CONTACT THE GAS
UTILITY TO TURN THE
GAS ON
CHECK FOR 24 VAC
ACROSS TERMINALS
CN8—4 AND CN8-6 ON
THE TIMER WHILE THE
NO
—
REPAIR /REPLACE WIRING
BETWEEN CN8—2 AND
CNB—6
VALVE/FLAME LED IS LIT.
YES
CHART 6
mi” i
TROUBLESHOOTING CHART 6
__ CHART 5 CHART 5 CHART 5
YES YES y YES
ACROSS TERMINALS {wo
CN8—4 AND CN8—5 ON —e REPLACE TIMER
THE TIMER WHILE THE
VALVE /FLAME LED IS UT
YES
y
REPAIR/REPLACE WIRING BETWEEN TIMER AND CAS
CONTROL |
| |
ADJUST HI FIRE MANIFOLD PRESSURE TO 4.5” W.C. PER
CHECK MANIFOLD PRESSURE PER FIGURE! NO "CHECK OUT PROCEDURE AND ADJUSTMENTS’
17, 15 MANIFOLD PRESSURE 4.57 WC m1 pARAGRAPH 16.e. IF 4.5" CAN NOT BE OBTAINED,
2 REPLACE GAS CONTROL
YES
y
POSSIBLY MIXTURE TOO LEAN!
CHECK GAS LINES DOWNSTREAM OF GAS
VALVE AND GAS ORIFICE FOR BLOCKAGE.| NO CLEAN/REPLACE GAS LINES AND/OR GAS ORIFICE.
ARE GAS LINES AND ORIFICE CLEAR? BE SURE TO USE CORRECT ORIFICE SIZE.
IS GAS ORIFICE CORRECT SIZE? SEE
REPAIR PARTS DIAGRAM.
YES
y
POSSIBLY MIXTURE TOO RICH!
CHECK FLUE PASSAGES IN BOILER PER | NO, | CLEAN BOILER FLUE PASSAGES PER MAINTENANCE AND
"MAINTENANCE AND CLEANING”. ARE CLEANING INSTRUCTIONS
FLUE PASSAGES IN BOILER CLEAN?
YES
y
CHECK FLUE PASSAGES IN RECOVERY :
HEAT EXCHANGER PER "MAINTENANCE [NO CLEAN RECOVERY COIL FLUE PASSAGES PER
AND CLEANING”. ARE FLUE PASSAGES 7 MAINTENANCE AND CLEANING INSTRUCTIONS
IN .RECOVERY HEAT EXCHANGER CLEAN?
YES
- y
WHILE RECOVERY HEAT EXCHANGER IS
OPEN, CHECK AIR ORIFICE FOR CORRECT|NO
SIZE. SEE REPAIR PARTS DIAGRAM, 15 [> REPLACE WITH CORRECT AIR ORIFICE. |
AIR ORIFICE CORRECT SIZE?
YES
X
X
CHECK MIXER AND BURNER FOR
BLOCKAGE PER MAINTENANCE AND ¡NO [ CLEAN MIXER AND BURNER PER MAINTENANCE AND
—
CLEANING INSTRUCTIONS. ARE AIR >
PASSAGES IN MIXER AND BURNER CLEANING INSTRUCTIONS
CLEAN?
Y NO #1 _
RUNS SMOOTHLY FOR ABOUT 6
SECONDS THEN SHUTS OFF.
DOES MAIN BURNER | NO #2 : INDICATES POOR FLAME SIGNAL| NO RESTORE IGNITER/SENSOR
RUN UNTIL CALL FOR | CHECK IGNITER /SENSOR DO NOT RELOCATE.
HEAT ENDS OR HI NO #3 POSITION. TIP SHOULD BE
LIMIT AQUASTAT - BE SLANTED TOWARDS BURNER.
CONTACTS OPEN?
* NO #4 YES
YES || CHECK FLAME SIGNAL >0.6uA?} 9 OXIDE COATING ON
x IF THE ANSWER IS NO, CHOOSE CONSULT BOILER MFGR. FOR IGNITER PREVENTING
THE APPROPRIATE PATH (#1, SPECIFIC INSTRUCTIONS. IFLAME SIGNAL, REPLACE
#2, #3 OR #4) BASED ON REQUIRES SPECIAL TOOLS. IGNITER /SENSOR.
SYMPTOMS SHOWN.
YES
Ty Y Y
3 REPLACE IBC |
CHART 7
TROUBLESHOOTING CHART 7
CHART 6
YES NO #4 NO #3 NO #2
Ÿ - CLEAN OR REPLACE GAS ORIFICE.
RUNS FOR 25-30 SECONDS, THEN CE
Ÿ OFF SOON AFTER GAS CONTROL A
SWITCHES TO NORMAL FIRING RATE.
fer mia aan AD] H—T——— == | мн | вые | —‹
CHECK HI FIRE AND NORMAL MIXTURE TOO LEAN. NOT
MANIFOLD PRESSURE PER FIGURE [yo | ENOUGH GAS. CHECK Gas
17 AND "CHECK OUT PROCEDURES a] ORFICE SIZE. IS GAS ORIFICE
— —|— — — —|-- — — | AND ADJUSTMENTS" PARAGRAPH SIZE CORRECT? CHECK REPAIR
. 16. ADJUST NORMAL MANIFOLD PARTS LIST FOR CORRECT SIZE.
PRESSURE TO OBTAIN NORMAL IS GAS ORIFICE CLEAR OF
FIRING RATE, CAN GAS VALVE BE BLOCKAGE?
ADJUSTED TO NORMAL INPUT YES
RATE? Y
YES REPLACE GAS CONTROL.
NO
y
MIXTURE TOO LEAN-TOO MUCH AIR,
CHECK AIR ORIFICE SIZE. SEE |NO, REPLACE WITH RIGHT
REPAIR PARTS LISTING FOR CORRECT SIZE AIR ORIFICE.
SIZE. 15 AIR ORIFICE CORRECT?
YES
Ÿ
[ NO
CHECK FLAME SIGNAL > O.6uA? — | REPLACE IGNITER /SENSOR |
CONSULT BOILER MFGR. FOR |
SPECIFIC INSTRUCTIONS. REQUIRES | YES
SPECIAL TOOLS. —
REPLACE I8C | |
| | REPLACE CAS CONTROL |
7 A
RUNS FOR 40-50 SECONDS THEN NO
OFF CHECK HI FIRE AND NORMAL GAS CONTROL NOT SWITCHING TO "NORMAL
IRE MANIFOLD PRESSURES и FIRING RATE WITHIN ALLOTTED TIME.
or CURE 17 AND "CHECK QU ror NO + DISCONNECT ONE ELECTRICAL LEAD FROM
EDURES AND ADJUSTMEN GAS PRESSURE SWITCH. CHECK FOR 24 VAC
PARAGRAPH 1.6. DOES GAS ACROSS HI AND C ON GAS CONTROL. IS 24
CONTROL SWITCH TO NORMAL
» VA iL P | ?
MANIFOLD PRESSURE OF 3.0+ 0.5 C STILL PRESENT AFTER 40 SECONDS
W.C. IN LESS THAN 40 SECONDS? e
YES | | . |
| REPLACE TIMER |
Y
ARE NORMALLY OPEN GAS
NO |
PRESSURE SWITCH CONTACTS |
CLOSED DURING HI FIRE, AND OPEN — >| REPLACE GAS PRESSURE SWITCH
DURING NORMAL FIRE?
. YES
y
SEE TROUBLESHOOTING PATH #2
IMMEDIATELY ABOVE
,
BOILER SHUTS OFF BEFORE END OF BOILER OFF ON HIGH LIMIT. 1S |— REPLACE
NO, | ACTUAL BOILER WATER TEMP. AQUASTAT
CALL FOR HEAT.
AQUASTAT CONTACTE aM GREATER THAN HI LIMIT SET POINT | YES
- MINUS 8F CONTROL DIFFERENTAL? |— | OK
YES
7 CHECK TROUBLE-
No VENT TEMP. SAFETY SWITCH TRIPPED] Ng
ARE VENT TEMP. SAFETY SWITCH IS CONDENSATE PUMP PUMPING »| SHOOTING CHART
7 FA
CONTACTS CLOSED: WATER? CHECK STATUS LIGHT. 5 CONDENSATE
PUMP STARTS...
Ue YES
7
SEE TROUBLESHOOTING PATH | NO
42 ABOVE CHECK FLUE SAS (VENT) TEMP. 5 REPLACE VENT
| TEMP. SAFETY
> VES YES SWITCH
Ÿ CHART 8 |
a
CHART 8
TROUBLESHOOTING CHART 8
CHART 7 CHART 7
Les Ш YES
| CHECK BOILER
CHECK ALL HEAT TRANSFER INPUT RATE PER
SURFACES PER "MAINTENANCE & |NO | "CHECK OUT
CLEANING" INSTRUCTIONS. ARE PROCEDURE AND
HEAT TRANSFER SURFACES FOULED? ADJUSTMENTS”
YES PARAGRAPH |
Y
CLEAN ALL BOILER HEAT TRANSFER
SURFACES PER "MAINTENANCE &
CLEANING” INSTRUCTIONS
Y
SET THERMOSTAT BELOW ROOM
TEMPERATURE TO END CALL FOR
HEAT
YES
Y
NO NO
DOES CIRCULATOR PUMP STOP? /N |—B[ ARE THERMOSTAT CONTACTS OPEN?|—B| — REPLACE THERMOSTAT
- TS YES
№
| REPLACE IBC |
| Y NO REMOVE WIRING HARNESS So
DOES GAS CONTROL CLOSE? p{ CONNECTOR CNY FROM CAS —s
‚ (©) > CONTROL, DOES GAS CONTROL REPLACE GAS CONTROL
YES | | CLOSE? ;
+ YES
DO DRAFT INDUCER AND
CONDENSATE PUMP STOP AFTER 30|NO y
SECOND POST PURGE? —» REPLACE IBC |
E
SYSTEM OK
REPEAT PROCEDURES UNTIL
SYSTEM STARTS NORMALLY
FAN
OUTLET
PRESSURE SWITCH
INLET
PRESSURE SWITCH
THE FOLLOWING STEPS AND DIAGRAM INDICATE THE LOCATION OF THE CONNECTION
POINTS REQUIRED TO CHECK THE FAN/OUTLET OR INLET PRESSURE.
THE FAN/OUTLET OR INLET PRESSURE SWITCH IS A SAFETY DEVICE WHICH
WILL PREVENT THE BOILER FROM FIRING IF THERE IS AN AIR INTAKE OR VENT
BLOCKAGE.
TURN OFF SERVICE SWITCH, OR LOWER THERMOSTAT SETTING.
REMOVE SUCTION LINES FROM PRESSURE SWITCH(ES) AND INSTALL TEE AND HOSE
HOOK-UPS. |
INSTALL TEES AND SUCTION LINES AS SHOWN TO INCLINED MANOMETER OR
PRESSURE GAUGE WITH THE ABILITY TO READ .017 TO 1.5" W.C.
TURN ON SERVICE SWITCH AND SET THERMOSTAT TO CALL FOR HEAT.
-
FAN/QUTLET PRESSURE SWITCH
INLET PRESSURE SWITCH
BOILER SUCTION | PRESSURE BOILER SUCTION PRESSURE.
STATUS W.C SWITCH STATUS wc SWITCH
ve CONTACTS be CONTACTS
NOT \ NORMALLY NOT о NORMALLY
RUNNING 0 OPEN RUNNING CLOSED
SETPOINT — 45” |
SETPOINT |—1.10"/QL—100
RUNNING —.55" TO
WITH NO Des” CLOSED
BLOCKAGE RUNNING LESS THAN
RUNNING | LESS THAN BLOCKAGE
WITH OR EQUAL TO| OPEN
WITH SETPOINT OPEN
BLOCKAGE
IF MANOMETER READINGS DO NOT CORRESPOND TO THE CHART ABOVE,
CHECK FOR POSSIBLE CAUSES:
—~ BLOCKAGE OR MOISTURE IN SUCTION LINES TO SWITCH.
— BLOCKAGE IN AIR INTAKE OR VENT PIPES.
— UNDERSIZED AIR INTAKE OR VENT PIPES.
~ LOOSE BLOWER WHEEL ON MOTOR SHAFT.
— BLOWER MOTOR NOT AT PROPER RPM. .
— INCORRECT PRESSURE SWITCH OR PRESSURE SWITCH SETPOINT.
WHEN PRESSURE READING IS PROPER AND THE PRESSURE SWITCH IS OPERATING
PROPERLY, REMOVE TEES AND REINSTALL SUCTION LINES TO THE PRESSURE SWITCH
er
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OL - JACKET AND BASE ASSEMBLIES
KEY # | ITEM NUMBER DESCRIPTION QUANTITY
1 740001072 QL-2 FRONT DISPLAY PANEL - BLUE 1
2 43100020 QL-2 DOOR PANEL - BLUE 1
3 43100019 QL-2 RIGHT PANEL - BLUE 1
4 740001042 QL-2 LEFT PANEL - BLUE 1
5 74001022 QL-2 BACK PANEL - BLUE 1
6 740001012 QL-2 TOP PANEL - BLUE 1
7 43100018 QL-2 BASE WITH GLIDES 1
8 14662801 AT140B1016 TRANSFORMER 24 VAC 1
9 14662803 $9301A1027 INTEGRATED BOILER CONTROL 1
10 14631079 EP-1290 TIME DELAY RELAY MODULE 1
11 14631153 IDI 1091M5-24V GREEN LED PANEL MOUNT STATUS
LAMPS
12 14631152 IDI 1091M5-125VAV GREEN LED PANEL MOUNT STATUS 3
LAMPS
13 14631121 16246 PRESSURE GAUGE - MARSH 1
14 14631122 RRT2.5UAC2-30-240FC TEMPERATURE GAUGE 1
15 14631095 P1-30-101-11 DOOR PULL 1
16 14631099 HINGE SET Z-05315 (UPPER) 2
17 14631098 HINGE SET Z-05800 (LOWER) 2
18 14631083 RACO 865 SWITCH COVER 1
19 14631081 P & S 660 SWITCH 1
20 14631082 RACO 660 27x 4” BOX 1
21 14631120 HEYCO OCB-1500 BUSHING 1
22 14631091 CO-2366 GLIDE 4
23 740004005 QL-2 DOOR LATCH BRACKET 1
24 14631096 02-20-611-10 MAG CATCH 2
25 - 14695013 5/16” HEX. NUT - 2
26 14695302 5/16”-18x3/4” HEX. HEAD CAP SCREW 2
27 - 14631174 419-1AA1 2 1/2” PLUG 2
28 14631171 415-1AA1 1 1/27 PLUG 1
29 14631176 BPF 3 1/2” PLUG 1
30 14631172 416-1AA1 1 3/4” PLUG 1
31 14631173 417-1AA1 2” PLUG 1
32 14631175 421-1AA1 3” PLUG 4
Т 14631085 WIRING HARNESS 1
I 14631097 1/8”x1/8” STAINLESS STEEL RIVET (FOR HINGES) 8
Ï 43100027 JACKET COMPLETE -
{ - NOT SHOWN
an
DRAIN MANIFOLD
SUB ASSEMBLY
LOCATED IN BASE
SUB ASSEMBLY
CONNECT TO MIXER
SUCTION PORT
CONNECT TO
DRAFT INDUCER
SUCTION- PORT
On TE
(10> |
CONNECT TO EVAPORATIVE
RE-COOLER SUCTION PORT
64
QL - PRESSURE SWITCH AND DRAIN MANIFOLD ASSEMBLIES
KEY # ITEM NUMBER DESCRIPTION QUANTITY
1 14631035 59019 1/2”IDx1/8” THK VINYL TUBING RE QUIRED
2 14631141 57134 3/4” SNAP GRIP CLAMP 7
3 14631110 62128 1/2” IDx1/2”IDx1/2NPT TUBE TEE 2
4 14631101 62017 1/2” NPTx1/2”ID TUBE STRAIGHT 1
5 14631131 1/2?NPT PVC SCH 40 TEE 1
6 14631033 59006 1/4” 1Dx3/8”0D VINYL TUBING AS
REQUIRED
7 14631143 3/8” HOSE CLAMP HC-6ST 6
8 14631139 3/8” NPTx1/2ID TUBE ADPT 62012 1
9 14631115 3/8” PVC 90 EL S-80 SP 808-003 1
10 14631114 3/8”xCLOSE PVC NIP S-80 SP 881-005 1
11 14631104 1/4”ID TUBE TEE 1
12 14631075 FS6110A-1985 FAN / OUTLET PRESSURE SWITCH 1
13 14631076 FS6111A-1986 INLET PRESSURE SWITCH 1
13A 43331108 HIGH ALTITUDE INLET PRESS. SW. (QL-100 PROPANE 1
OVER 4500’ ELEVATION ONLY )
14 14631140 1/2”ID TUBE x1/4”I1D TUBE HOSE ADAPT 62055 1
65
e
E
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E
66
QL - BLOCK AND PIPING ASSEMBLY
KEY # § ITEM NUMBER DESCRIPTION QUANTITY
1 14631156 HOFFMAN VENT #77 1
2 14693001 3/4” x 1/8” BUSHING 1
3 14693076 3/4” BLACK TEE ]
4 14693040 3/4” x 90 STREET ELBOW |
5 14607005 3/4” x 4 NIPPLE — 2
6 14622011 3/4” ASME RELIEF VALVE 1
7 14607201 3/4”x 2 NIPPLE | |
8 14695810 1/4720 HEX NUT W/SERRATED WASHER HEAD a |
9 14695802 8-32X3/16” SOC HD CAP SCREW _ | 2 |
10 14631002 36T26-6539 CASTING TEMP. SAFETY SWITCH 1 |
11 14695801 1/47-20x1 1/2 SOC HD CAP SCREW | 5
12 14695805 1/47-20x1 1/4 STUD 9
13 41700210 QL-2 TESTED BLOCK (INCLUDES 8,11,14 AND 20) 1
14 14693126 1 1/4” SQ HEAD PLUG 12
15 14695040 1/4”x1 1/4”? CARRIAGE BOLT 4
16 14631101 62017 1/2” NPTx1/2”1D TUBE STRAIGHT
17 14607805 1 1/4” x 2” NIPPLE STD BLACK 3
18 14693049 1 1/4” x3/4”x1 1/4” TEE 2
19 14622000 3/4” DRAIN VALVE 1
20 14693056 1” SQ SOCKET PLUG 4
21 14619002 EMPIRE SIGHT GLASS 1
22 14631194 1/4”NPTx1/4”0D MALE COMPRESS ALIGN FITTING 1
23 14693003 3/4”x1/4” BUSHING 1
24 14631196 PP-43-0500 1/4” 0D POL YPROPYLENE TUB ING (157 LONG) 1.25 FEET |
25 14631193 1/4"NPTx1/40D FEM COMPRESS ALIGN FITTING 1
26 14631121 16246 PRESSURE GAUGE 1
27 14693004 3/4” x 1/2” BUSHING 2
28 14662804 123869A CONTROL WELL 1/2” NPT 1
29 14662802 L4080D1192 HI LIMIT AQUASTAT 1
30 14631021 CLEANOUT COVER PLATE GASKET 1
31 740004004 CLEANOUT COVER PLATE | ]
32 14631055 1-1/4” x 13-1/27 Nipple 1
33 14693042 1-1/4” Elbow 1
34 14631122 RRT2.SUAC2-30-240FC TEMPERATURE GAUGE 1
35 “14695803 14” -20 X 5/16” SOC HD CAP SCREW 20
36 14631198 — 63PT-4-40 TUBING INSERT 2
to 14626043 DUNKIRK BALL VALVE SET 1
i 14626049 “FLANGE SET WITH BOLTS AND NUTS 1
+ 14626045 GRUNDFOS CIRCULATING PUMP 1
1 14626047 TACO CIRCULATING PUMP 1
te
{ - NOT SHOWN
67
QL - MIXER ASSEMBLY
KEY £ | ITEM NUMBER DESCRIPTION QUANTITY
1 14631023 BURNER GASKET 1
2 14631052 BURNER 1
3 14631025 MIXER GASKET 1
4 14695810 1/4?-20 HEX NUT W/SERRATED WASHER HEAD 5
5 41700004 QL MIXER CASTING MACHINED 1
6 14631105 62030 1/8” NPTx1/4”ID TUBE ELBOW 1
7 14631101 62017 1/2” NPTx1/2”ID TUBE STRAIGHT 1
8 14631039 2” STAINLESS STEEL CLAMP 1
9 14631017 2” FLEXADUX R-3 1.92ft.
10 14695809 10-32?x3/8” MACHINE SCREW 2
11 43100003 QL-2 HOT SURFACE IGNITER 1
12 14631024 HOT SURFACE IGNITER GASKET 1
13 14631106 62002 1/8” NPTx1/4”ID TUBE STRAIGHT 2
14 14631143 3/8” HOSE CLAMP HC-6ST | 7
15 14631060 MIXER BUSHING 1
16 14607803 1/2”NPTx4 1/2” BLACK NIPPLE 1
> ‚ AS
17 14631033 59006 1/4”IDx3/8”0D VINYL TUBING REQUIRED
18 14631151 VINYL CAP 1
19 14631104 62064 1/4”ID TUBE TEE 1
20 14693804 1/8”NPT ALLEN HD STEEL PLUG 1
21 14693803 1/8”NPT BLACK TEE 1
22 14607804 1/8”NPTx2 1/2” BLACK PIPE NIPPLE 1
23 14693801 1/2?NPT BLACK STREET ELBOW 1
24 14631071 GAS VALVE 36E96-236 (NATURAL AND PROPANE GASES) 1
25 14631074 GFS-4560-1963 GAS PRESSURE SWITCH 1
26 14607801 1/8”x4 1/2” 304 ST. ST. NIPPLE 1
27 14631066 GAS ORIFICE - NATURAL GAS #44 100,000 BTU/HR 1
27 14631063 GAS ORIFICE - PROPANE GAS #50 100,000 BTU/HR 1
+ 43331102 QL-100 NATURAL TO PROPANE CONV KIT (0-4,500”) 1
+ 43331103 QL-100 NATURAL TO PROPANE CONV KIT (4,500-10,500”) 1
+ 43331106 QL-100 PROPANE TO NATURAL CONV KIT (0-4,500”) 1
+ 43331107 1
QL-100 PROPANE TO NATURAL CONV KIT (4,500-10,500”)
* = NOT SHOWN
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QL - RECOVERY HEAT EXCHANGER ASSEMBLY
71
KEY # | ITEM NUMBER DESCRIPTION QUANTITY
1 43100004 QL-2 EXHAUST TEE ASSEMBLY (INCLUDES 1A-1G) 1
1A 14631101 62017 14” NPT x 14” ID TUBE STRAIGHT ]
1B 14631013 PVC 11” MALE SLIP x 4” FEMALE NPT 1
1C 14631014 PVC SCH 40 2” x 1 14” REDUCER 1
1D 14631016 2” РУС SCH 40 SANITARY TEE 1
IF 14631161 2” PVC PIPE SCH 40 x 2” ]
1F 14631015 2” FERNCO COUPLING 1
1G 14695815 Y” ALUMINUM FLAT WASHER 1
2 14631028 VENT SWITCH GASKET ]
3 14631003 36T x 11-10734 VENT TEMP SAFETY SWITCH 1
4 14695808 #4-20 x 4” EWH PLASTIFORM SCREW 2
5 14631077 116516-11 INDUCED DRAFT BLOWER 1
SA 43100029 QL-2 REPLACEMENT BLOWER ASSY (INCLUDES 2,3,4,5,6) ]
6 14631026 BLOWER GASKET 1
7 740004023 AIR ORIFICE PLATE 134” — 100,000 BTU/HR 1
8 14631042 COIL INSERT 1
9 14631040 RECOVERY COIL 1
10 14631005 1/8” NPT ¥* HOSE ID BRASS BARB FITTING 1
11 14631027 RECOVERY COIL GASKET 1
‹ 12 146958101 и” — 20 НЕХ МОТ W/SERRATED WASHER BLOCK 4
13 41700005 RECOVERY COIL HOUSING MACHINED 1
14 14631101 62017 % NPT x 14” 1D TUBE STRAIGHT 1
15 14631143 3/8” HOSE CLAMP HC-6ST 1
16 14631200 3/8” ID x %” OD NORPRENE TUBING (COIL OUTLET) AS REQUIRED
17 14631201 и” ТО x 77” OD NORPRENE TUBING (COIL OUTLET) AS REQUIRED
18 14631151 PC250-12 VINYL CAP 1
19 14631143 3/8” HOSE CLAMP HC-6ST | 1
A(*) 14631199 CTT6079PP POLYPROPYLENE CLAMP CABLE TIE 4
B(*) 14631133 3/8” ID x 3/8” ID TUBE ELBOW | 1
(+) 43100001 RECOVERY COIL ASSEMBLY (INCLUDES 8,9,16,17,A & В) 1
(*) = NOT SHOWN a |
CONNECT TO
RECOVERY COIL
OUTLET
CONNECT TO RECOVERY
COIL INLET
—
CUT AWAY TO
SHOW POLYPRO
FLEXRINGS
* CONNECT TO
DRAIN MANIFOLD
we er
EPA
QL - EVAPORATIVE RECOOLER ASSEMBLY
KEY # ITEM NUMBER DESCRIPTION QUANTITY
1 14631133 3/8”IDx3/8”ID TUBE ELBOW 1
2 14631041 EVAP RECOOLER 8: CAP - 2 PCS 1
3 14695811 6-32x3/4” MACHINE SCREW 6
4 14631022 EVAPORATIVE RECOOLER GASKET 1
5 14631043 GRID CAP 3/8” TH. 1069 2
6 14695812 6-32 ESNA NUT NM 18-8 SS ‚6
7 14631031 5/8” POLYPRO FLEXRINGS 0.4 CU. FT.
8 14631011 1 1/2” NPT PVC SCH 40 HEX HD PLUG 1
9 14631012 1/2” NPT PVC SCH 40 STREET ELBOW 1
10 14631020 1/2” SLIPx1/2?SLIPx1/2”NPT PVC TEE 1
11 14631019 1/2”NPT PVC SCH 80 CLOSE NIPPLE 1
, , AS
12 14631034 59012 3/8”1Dx1/16” THK VINYL TUBING REQUIRED
13 14631015 FERNCO COUPLING 1
, | AS
14 14631017 2” FLEXADUX R-3 REQUIRED
15 14631039 2” STAINLESS STEEL CLAMP 1
16 14631132 62052 1/2”ID x 1/2”?ID TUBE ELBOW 1
17 14631141 57134 3/4” SNAP GRIP CLAMP 11
18 14631035 59019 1/2”1Dx 1/8” THK VINYL TUBING RE QUIRED
19 14631103 62043 1/2” NPTx1/2”ID TUBE ELBOW | 1
20 43100017 QL-2 REPLACEMENT FLOW SWITCH W/BUSHINGS 1
21 14631101 62017 1/2”NPTx1/2”ID TUBE STRAIGHT 3
23 43100002 CONDENSATE PUMP MARCH AC-1A-MD-1/2” W/ 1
. TERMINALS
24 740004002 CONDENSATE PUMP BRACKET 1
25 14695807 #6x1/2” SHEET METAL SCREWS 2
26 14631142 57131 9/16” SNAP GRIP CLAMP | 3
27 14631139 62012 3/8” NPTx1/2”I1D TUBE STRAIGHT 2
28 14631197 P777-20 3/8” PLASTIC STRAINER 1
29 14631195 U45BC-V 1/2” PVC BALL CHECK VALVE ]
30 14631116 62011 3/9” NPTx3/8”ID TUBE STRAIGHT 1
73
DRAIN MANIFOLD
SUB ASS Y
SOLENOID VALVE
SUB ASS' Y
LIQUID LEYEL CONTROL
SUB ASS Y
DOE TA
Las
E
UB
3
=. "2.5
\ TEE \
ó
*
Ll
re
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LJ
A
y -
QL SUMP FEEDER ASSEMBLY
SOLENOID
VALVE.
LIQUID LEVEL
CONTROL
WRENUTS (TYP)
ARK—LES TERMINAL
ADAPTERS
exismee C__"
24 VOLT TRANSFORMER
GOILER
WIRING
QL SUMP FEEDER WIRING DIAGRAM
74
QL - SUMP FEEDER ASSEMBLY
KEY # | ITEM NUMBER DESCRIPTION QUANTITY
1 14631046 LIQUID LEVEL CONTROL SENSOR ]
2 43100050 1 1/2" NPT PVC TAPPED PLUG 1
3 14631106 1/8" NPT X 1/4" ID HOSE BARB ADAPTER - PLASTIC 2
4 14631033 2 1/4" X 1/4" ID CLEAR VINYL TUBING 1
5 14631143 3/8" HC-6ST ROTOR CLAMP 3
6 14691002 NYLON TIE 6
7 14631086 20" #2 BRAIDED SHIELD 2
8 14631045 SOLENOID VALVE 15212DGM 1
9. 42531004 SOLENOID VALVE BRACKET 1
10 14695074 #10 X 1/2" SL SCREWS 3
11 14631047 1/8" NPT X 1/4" OD COMPRESSION ADAPTER - BRASS 1
12 14631050 1/2" X 1/2" X 1/4" HOSE BARB TEE - PLASTIC 1
13 14631033 8" X 1/4" ID CLEAR VINYL HOSE 1
14 14631141 3/4" SNAP GRID CLAMPS 2
15 14634040 ARK-LES 3000 S-10 -1 TERMINAL ADAPTERS 2 |
16 43300827 SUMP FEEDER WIRING HARNESS 1
17 14631086 42" #2 BRAIDED SHIELD 1
18 14631199 TIE CABLE TYTON 1
19 14631082 2" X 4" J-BOX 1
20 14695060 #10 X 1/2" TEK SCREWS 1
21 14634047 72 B WIRE NUTS 1
22 14631049 2" X 4" J-BOX COVER PLATE 1
75