Manuals / Quantum / Household Appliance / Boiler

Quantum GAS-FIRED BOILERS installation instructions

Models: GAS-FIRED BOILERS

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d.Reinstall and connect the condensate trap, using the hose clamps to secure the various condensate lines to their fittings.

e.Follow the instructions under “NEAR BOILER PIPING” for”filling condensate trap with water”

4.Inspection of the flue connector requires the following steps (Refer to the repair parts diagram.)

a.Loosen the clamp on the draft inducer end of the 2" flexible coupling that connects the vent tee to the draft inducer. Disconnect (unplug) wiring harness from draft inducer motor and draft inducer temperature safety switch. Remove four (4) bolts that attach draft in ducer to flue connector.

b.Remove draft inducer and gasket from top of flue connector.

c.Inspect interior of flue connector. Any buildup of sediment or aluminum oxide on the inside surface must be cleaned. 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.

d.Connect wiring harness leads to the draft inducer motor and the draft inducer tempera ture safety switch.

e.Connect the 2" flexible coupling to the draft inducer outlet.

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Quantum GAS-FIRED BOILERS installation instructions

Contents

DUNKIRK BOILERS INSTALLATION INSTRUCTIONSBOILERS 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 BOILER RATINGS AND CAPACITIES 7$%/6$/9/5$7,1*61$785$/$13523$1*$66BOILERS FOR USE AT HIGH ALTITUDE 7$%/$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*6RULES FOR SAFE INSTALLATION AND OPERATION BEFORE INSTALLING THE BOILERA. CODES B. BOILER SIZING C. CONSIDERATIONS FOR BOILER LOCATIOND. LOCATING THE BOILER E.COMBUSTION AIR AND VENT PIPE REQUIREMENTS2,/5&/$5$1&6 81,7F. CONDENSATE DRAIN REQUIREMENTS G.FOUNDATION REQUIREMENTSPLACING THE BOILER NEAR BOILER PIPING A. SUPPLY AND RETURN LINESFIGURE 2 SINGLE ZONE BOILER PIPING Page Page FIGURE 5 SINGLE ZONE BOILER PIPING B.PRESSURE RELIEF VALVEC.EXPANSION TANK AND MAKE-UPWATER FIGURE 6 DIAPHRAGM TYPE EXPANSION TANK PIPING Page FIGURE 8 CONDENSATE - DRAIN PIPING D. CONDENSATE DRAIN PIPINGCOMBUSTION AIR AND VENT PIPE F. CHILLED WATER PIPINGA. CONNECTIONS AND TERMINATION 4.Combustion air and vent piping lengths 0,1,0800$ ,080 917,1FIGURE 9 ROOF VENT/INTAKE TERMINATIONS FIGURE 10 SIDEWALL VENT/INTAKE TERMINATIONS FIGURE 11 COMBUSTION AIR AND VENT PIPING B.INSTALLATION GAS SUPPLY PIPINGA. 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 SIZESELECTRICAL WIRING A. ELECTRIC POWER SUPPLYFIGURE 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 17 MANIFOLD PRESSURE MEASUREMENT DETAIL FIGURE 18 GAS VALVETop 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 performedMAINTENANCE AND CLEANING A. BEGINNING OF EACH HEATING SEASONB.DAILY DURING HEATING SEASON 2.Cleaning Flue passages between boiler sections C. MONTHLY DURING HEATING SEASOND.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