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Quantum GAS-FIRED BOILERS B. Connecting The Gas Piping, C. Checking The Gas Piping

Models: GAS-FIRED BOILERS

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B. CONNECTING THE GAS PIPING

B. CONNECTING THE GAS PIPING

Refer to Fig.12 for the general layout at the boiler. It shows the basic fittings you will need. The gas line enters the boiler from the right side jacket panel. The boiler may receive the gas supply pipe through the left side, or rear jacket panel by relocating the gas valve connector and pipe assembly. The boiler is equipped with a ‘/z” NPT connection on the gas valve for supply piping. 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 Z223.1- latest revision. In Canada, follow the CSA- B 149.1 and .2 Installation Codes for Gas Burning 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.Tighten all joints securely.

8.Propane gas connections should only be made by a licensed propane installer.

9.Two stage regulation should be used by the propane installer.

10.Propane gas piping should be checked out by the propane installer.

C. 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 joint. Bubbles forming indicate leak. CORRECT EVEN THE SMALLEST LEAK AT ONCE.

WARNING

NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS.

TABLE 3 GAS PIPE SIZES

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Quantum GAS-FIRED BOILERS B. Connecting The Gas Piping, C. Checking The Gas Piping, Gas Pipe Sizes

Contents

INSTALLATION INSTRUCTIONS DUNKIRK BOILERSBOILERS Page TABLE OF CONTENTS INTRODUCTION RULES FOR SAFE INSTALLATION AND OPERATIONBEFORE INSTALLING THE BOILER ELECTRICAL WIRINGCHECK-OUTPROCEDURES AND ADJUSTMENTS MAINTENANCE AND CLEANINGSERVICE HINTS REPAIR PARTSINTRODUCTION 7$%/6$/9/5$7,1*61$785$/$13523$1*$66 BOILER RATINGS AND CAPACITIESBOILERS FOR USE AT HIGH ALTITUDE 7$%/$02/1$785$/*$6+,*+$/7,785$7,1*6 7$%/%02/3523$1*$6+,*+$/7,785$7,1*67$%/&02/1$785$/*$6+,*+$/7,785$7,1*6 7$%/02/3523$1*$6+,*+$/7,785$7,1*67$%/02/1$785$/*$6+,*+$/7,785$7,1*6 7$%/02/3523$1*$6+,*+$/7,785$7,1*6BEFORE INSTALLING THE BOILER RULES FOR SAFE INSTALLATION AND OPERATIONA. CODES B. BOILER SIZING C. CONSIDERATIONS FOR BOILER LOCATIOND. LOCATING THE BOILER E.COMBUSTION AIR AND VENT PIPE REQUIREMENTS2,/5&/$5$1&6 81,7F. CONDENSATE DRAIN REQUIREMENTS G.FOUNDATION REQUIREMENTSPLACING THE BOILER NEAR BOILER PIPING A. SUPPLY AND RETURN LINESFIGURE 2 SINGLE ZONE BOILER PIPING Page Page B.PRESSURE RELIEF VALVE FIGURE 5 SINGLE ZONE BOILER PIPINGC.EXPANSION TANK AND MAKE-UPWATER FIGURE 6 DIAPHRAGM TYPE EXPANSION TANK PIPING Page FIGURE 8 CONDENSATE - DRAIN PIPING D. CONDENSATE DRAIN PIPINGF. CHILLED WATER PIPING COMBUSTION AIR AND VENT PIPEA. CONNECTIONS AND TERMINATION 4.Combustion air and vent piping lengths 0,1,0800$ ,080 917,1FIGURE 9 ROOF VENT/INTAKE TERMINATIONS FIGURE 10 SIDEWALL VENT/INTAKE TERMINATIONS FIGURE 11 COMBUSTION AIR AND VENT PIPING GAS SUPPLY PIPING B.INSTALLATIONA. CHECK GAS SUPPLY B. CONNECTING THE GAS PIPING C. CHECKING THE GAS PIPINGNEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS TABLE 3 GAS PIPE SIZESA. ELECTRIC POWER SUPPLY ELECTRICAL WIRINGFIGURE 12 GAS PIPING B. INSTALL YOUR THERMOSTAT C. Connect Circulator Pump WiringFIGURE 13 FIELD WIRING CONNECTIONS D.FIGURE 14 SCHEMATIC WIRING DIAGRAM FIGURE 15 LADDER WIRING DIAGRAM CONTROLS AND ACCESSORIES E. DRAFT INDUCER TEMPERATURE SAFETY SWITCHA. INTEGRATED BOILER CONTROL IBC B. GAS CONTROL VALVEF. CASTING TEMPERATURE SAFETY SWITCH G. DIFFERENTIAL PRESSURE AIR PROVING SWITCHH.DRAFT INDUCER I. CIRCULATOR PUMPL. FLAME ROLLOUT SAFETY SHUTOFF START - UPK. A.S.M.E. RATED PRESSURE RELIEF VALVE M. OPTIONAL EXTERNAL CONDENSATE PUMP3.Repeat step 2 for all remaining zones FOR YOUR SAFETY READ BEFORE OPERATING D. PLACING BOILER IN OPERATIONOPERATING INSTRUCTIONS TO TURN OFF GAS TO APPLIANCEPage E. TEST IGNITION SYSTEM SAFETY SHUTOFF DEVICE B. INSPECT VENTING AND AIR INTAKE SYSTEMC. INSPECT CONDENSATE DRAIN D. INSPECT SYSTEM PIPINGF. TEST HIGH LIMIT CONTROL AND ADJUST G. TEST OTHER SAFETY CONTROLSI. MEASURE THE NATURAL GAS INPUT RATE 3600xheating value from stepFIGURE 18 GAS VALVE FIGURE 17 MANIFOLD PRESSURE MEASUREMENT DETAILTop view of gas control J. SET THERMOSTAT TO DESIRED ROOM TEMPERATURE K REVIEW ALL INSTRUCTIONSINSTALLATION AND CHECK-OUTCERTIFICATE Date InstalledϒInstallation instructions have been followed ϒCheckout procedure and adjustments performedA. BEGINNING OF EACH HEATING SEASON MAINTENANCE AND CLEANINGB.DAILY DURING HEATING SEASON C. MONTHLY DURING HEATING SEASON 2.Cleaning Flue passages between boiler sectionsD.PERIODICALLY DURING HEATING SEASON l.Connect gas line to gas valve d.Reinstall and connect the condensate trap, using the hose clamps to secure the various condensate lines to their fittings SERVICE HINTS DETAILED SEQUENCE OF OPERATION DETAILED SEQUENCE OF OPERATION END OF NORMAL SEQUENCE OF OPERATION DETAILED SEQUENCE OF OPERATIONTROUBLE SHOOTING INITIAL SERVICE CHECKS6 67067$786 67$7861,&$76 TROUBLE SHOOTINGTROUBLESHOOTING CHART TROUBLE SHOOTINGELECTRICAL SHOCK HAZARD MAY CAUSE SERIOUS INJURY OR DEATHTROUBLE SHOOTING TROUBLESHOOTING CHARTTROUBLE SHOOTING TROUBLESHOOTING CHARTTROUBLE SHOOTING TROUBLESHOOTING CHARTTROUBLE SHOOTING TROUBLESHOOTING CHARTTROUBLE SHOOTING TROUBLESHOOTING CHARTDIFFERENTIAL AIR PRESSURE SWITCH CHECK REPAIR PARTS JACKET AND BASE ASSEMBLYREPAIR PARTS $&.7$1%$6$660%70180%5 6&5,37,21CONDENSATE DRAIN TRAP ASSEMBLY 2116$75$,175$3$660%70180%5 6&5,37,21REPAIR PARTS BOILER BLOCK AND PIPING ASSEMBLYREPAIR PARTS 2,/5%/2&.$13,3,1*$660%70180%5 6&5,37,21D.MIXER AND AIR PRESSURE SWITCH ASSEMBLY REPAIR PARTSREPAIR PARTS 0, 5$1$,53566856 ,7&+$660%70180%5 6&5,37,21REPAIR PARTS FLUE ADAPTER AND EXHAUST ASSEMBLY8$$375$1 +$8675$660% 70180%5