Absolute ABS-1500 Installation And Operating Manual Download

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Gas-Fired Condensing Hot Water Boiler

Installation and Operating Manual

Innovative Industrial Inc.

ABS 1500-2000-2500-3000-4000/V.01/4/2016

ABS - 1500

ABS - 2000

ABS - 2500

ABS - 3000

ABS - 4000

CAUTION

Please read this manual and retain a copy for future
reference. Improper Installation, adjustment, alterations,
service or maintainer can cause serious injury, property
damage or death. Refer to this manual for assistances

or additional information or consult a qualified installer,

service agent.

Innovative Industrial Inc.

122 Burton Street

Hamilton, Ontario, Canada L8l 3R5

Cast Aluminum Sectional Heat Exchanger

-  10 to 1 Turndown
-  Honeywell Sola Boiler Control System
-  Compact Light Weight Packaged Boiler
-  Five Models from 1,500 to 4,000 MBH
-  Low NO

Standard

- Fully Packaged CSA/ASME Boilers

Document # 2050-20

Summary of Contents for ABS-1500

Page 1: ...tions service or maintainer can cause serious injury property damage or death Refer to this manual for assistances or additional information or consult a qualified installer service agent Innovative Industrial Inc 122 Burton Street Hamilton Ontario Canada L8l 3R5 Cast Aluminum Sectional Heat Exchanger 10 to 1 Turndown Honeywell Sola Boiler Control System Compact Light Weight Packaged Boiler Five M...

Page 2: ...all safety and warnings symbols The installation and service manual is part of the documentation along with the boiler The installer is to explain the function of the boiler and heating system before the boiler goes into full service For service or parts contact your local sales representative Notice In the interests of technical progress the information in this installation and service manual is ...

Page 3: ...ief valve requirements 17 4 Installation 18 4 1 General installation Instructions 18 4 2 Delivery and installation 18 4 2 1 Site preparation 19 4 2 2 Hoisting the boiler 19 4 2 3 Multiply boiler arrangements 20 4 3 Flue gas discharge and air supply 22 4 3 1 General 22 4 4 Boiler Venting Types 22 4 4 1 Venting options 23 4 4 2 Vent Termination Inlet Outlets 23 4 4 3 Combustion Air Supply Requiremen...

Page 4: ...consumption 53 5 4 Limit Controls 53 5 4 1 Temperature control 53 5 4 2 Low water level protection LWCO flow and content 53 5 4 3 High limit protection 53 5 4 4 Air pressure switch 53 5 4 5 High gas pressure switch HGP 54 5 4 6 Low gas pressure switch LGP 54 6 Gas connection 55 6 1 Gas connection 55 6 1 2 Manual gas valve upstream of boiler The manual valves supplied by others 55 6 1 3 Gas line pi...

Page 5: ...IMPORTANT SAFETY WARNING 69 10 Commission report 72 10 1 Installation and Location details 72 11 Maintenance 73 11 1 General Maintenance 73 11 1 1 Inspection of air box and dirt trap 73 11 1 2 Cleaning the Whirlwind 73 11 1 3 Cleaning the fan 74 11 1 4 Cleaning the heat exchanger 74 11 1 5 Cleaning the burner assembly 75 11 1 6 Cleaning the siphon 75 11 1 7 Cleaning replacing the ignition ionizati...

Page 6: ......

Page 7: ...lled equipment as well as any safety precautions and requirements and shut down procedures The heating contractor also needs to inform the operator owner of the need for professional annual servicing of the boiler prior to the heating season Contaminated air Chemicals can contaminate the air and cause by products during the combustion process These by products are poisonous to the occupants and ve...

Page 8: ...ways disconnect main service to boiler before servicing WARNING Only properly qualified personnel that hold all necessary licenses shall work on the installation and service of this boiler Unlicensed and untrained service technicians are strictly prohibited from installing or servicing this boiler WARNING Do not touch the boiler hot surfaces can be a burn hazard WARNING Pressure hazard Annually te...

Page 9: ...not reach your gas supplier call the fire department C Use only your hand to turn lever operated manual gas shut off valves If the lever handle will not turn by hand call a qualified service technician or the gas supplier D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control syste...

Page 10: ... heat exchanger we provide an industry leading warranty The fully water cooled combustion chamber host a knitted metal fiber premix burner A turndown ratio of 10 1 allows for ultimate combustion control and reduces short cycling of the boiler With precise combustion control the ABSOLUTE ABS SERIES is able to achieve CO2 levels that maximize condensation of the natural gas Low NOx and CO emissions ...

Page 11: ... off mode awaiting the negative conditions to return to normal before re starting The Sola controller has 4 20 MA RS 485 Mod Bus interface The Honeywell and the Sola controls cannot override the standard flame safety controls External controls or commands can modulate the boiler as required by the BMS All Absolute boilers are fully test fired after assembly to ensure the boiler and controls comply...

Page 12: ...firming the reason for the failure The products of combustion in the form of hot flue gases are forced through the heat exchanger transferring their heat to the system water the flue gas temperature is reduced to approximately 9 14 F 5 8 C above the temperature of the system return water then discharged via the condensate collector to the flue gas outlet connection to atmosphere Because of the low...

Page 13: ...2 F Honeywell Touch Screen 7 H Anchor Bolt 3 4 J Wiring Junction 1 2 Ref Description Size Ref Description Size 1 NTC Temperature Sensor Supply Water 1 2 8 Aquastat Manual Reset 3 4 2 Pressure Relief Valve 11 2 9 NTC Temperature Sensor Return Water 1 2 3 Air Vent 1 4 10 Spare 1 2 4 Spare 1 2 11 Spare 1 5 Flow Switch Optional 1 12 Spare 1 2 6 Low Water Cut Off Manual Reset 3 4 13 Boiler Drain 1 2 7 ...

Page 14: ...Absolute Boilers ABS 1500 2000 2500 3000 4000 14 3 1 Boiler Version 26 24 6 5 7 8 9 11 12 14 15 23 17 18 25 16 10 2 3 4 1 20 21 19 28 22 27 13 29 ...

Page 15: ...Gauge 9 Aqua state Manual Reset 10 Boiler Return 11 NTC Temperature Sensor Return Water 12 Spare 1 2 13 Gas Connection manual gas valve by Other 14 Boiler Drain 15 Condensate Pan 16 Anchor Bolt 17 Positioning wheels 18 Fork Left Packet 19 Combustion Air Inlet 20 Inspection glass 21 Ignition Ionization electrode 22 Boiler Control Panel 23 Condensate Pan Drain 24 Combustion Air Fan 25 Base Frame 26 ...

Page 16: ...ange In w c 3 5 to 14 w c Flue Gas Vent Diameter Inch 10 ID Combustion Air Vent Diameter Inch 10 ID Maximum Flue Gas Temperature F C 230 110 Condensate Drain Connection Inch 1 1 4 NPT Combustion AirTemperature F C 4 to 104 20 to 40 Gas Vent Category ANSI Z21 13 CSA 4 9 Gas Vent Category II or IV Water Heating Return Inch 4 inch 150 ANSI Flange Heating supply Inch 4 inch 150 ANSI Flange Maximum Wat...

Page 17: ...iagnostic capabilities Firing capabilities fully modulating 4 20MA Capable of BMS control 4 20MA Local remote switch enable disable optional Available for conventional chimney direct vent and sealed combustion venting systems Fully factory pressure and fire tested Distinctive powder coated enamel steel Removable casing without the use of tools Rigid steel boiler frame with castors for easy of mane...

Page 18: ...06 05 10 606 07 10 606 10 10 605 12 10 605 14 10 604 16 10 605 18 Absolute 2500 10 607 05 10 606 07 10 606 10 10 606 12 10 605 14 10 605 16 10 605 18 Absolute 3000 10 607 05 10 607 07 10 606 10 10 606 12 10 606 14 10 606 16 10 605 18 Absolute 4000 10 608 05 10 608 07 10 607 10 10 607 12 10 606 14 10 606 16 10 606 18 Model 100 PSI 110 PSI 120 PSI 130 PSI 140 PSI 150 PSI 160 PSI Absolute 1500 10 604...

Page 19: ...the carrier and BEFORE the bill of ladling is signed The carrier MUST be notified immediately if any damage is detected The overall dimensions of the crate are 36 inches 92cm wide 70 inches 178 cm high with the length of 50 1 8 127 cm At the base of the packaging is a 30 76 cm wide pallet enabling it to be transported with a pallet truck forklift truck or 4 wheel transport boards Excluding the cra...

Page 20: ...ch unit in advance Adequate space must be allowed for pre connections and future service and maintenance requirements All piping must include ample provisions for thermal expansion If lead lag confirmations is to be utilized it is important to identify the lead boiler and place this boiler in the area that allows the control to be easy access for both operator and service personnel WARNING Always ...

Page 21: ...Absolute Boilers ABS 1500 2000 2500 3000 4000 21 4 2 3 Multiply boiler arrangements Front 36 6 Minimum between boilers Front 36 Side 18 Side 18 Front 36 Back 24 Back 24 Side 18 Front 36 Side 18 ...

Page 22: ...oiler in the protective packaging whenever possible Remove fixing strips packaging lid and all other packaging leaving the boiler on the pallet Place the packaging lid on the end of the pallet creating a ramp secure with screws Roll the boiler on its wheels off the pallet and down the ramp to the boiler room floor CAUTION The wheels are designed for transport purposes only and must not be used whe...

Page 23: ...sdiction The vent shall then extend vertically 5 ft 1 5M minimum through the roof ceiling Category II Negative breaching pressure ranging from 0 to 0 29 inches water column 0 to 22mbar Category IV Positive breeching pressure ranging from 0 to 0 20 inches water column 0 to 50 mbar Follow the vent manufactures recommended and supplied instructions regarding vent connection cleaning sealing and suppo...

Page 24: ...iler and property Not obstructing the flow of combustion and ventilation air Vent and air intake connection to the Boiler Ensure both vent and air intake is properly supported to the building The boiler is not designed to take any weight vertically Horizontal sections of venting must be properly supported in a manner to prevent any sagging or low spots For Category II AND IV ensure the slope is to...

Page 25: ...s and stainless steel material Air supply structure The air supply pipe must also be airtight Horizontal sections in the air supply must slope away from the boiler towards the supply opening and incorporate a drain connection if the route rises from a lower point It is necessary to provide an easily removable air vent for maintenance reasons WARNING Motorized louvers shall be interlocked with the ...

Page 26: ...ove mentioned codes WARNING Do not place intake or exhaust terminations above a walkway or sidewalk as the condensation can cause icing of walking surface Maintains a minimum of 4 feet horizontal from any gas or electric meter WARNING The boiler vent shall not be connected to any other portion of a mechanical draft system without consulting a vent manufacturer DANGER Do not use a barometric damper...

Page 27: ...the building structure so that the flue gases do not cause damage to the building The vent terminal locations follow local and national codes requirements Model Combustion Flue gas Vent ø Vent Length Min Vent length Max 90 Elbow 45 Elbow Air required CFM Length Length Inch mm Ft m Ft m Ft m Ft m ABS 1500 360 10 254 5 1 5 100 1 5 10 3 5 1 5 ABS 2000 467 10 254 5 1 5 100 1 5 10 3 5 1 5 ABS 2500 584 ...

Page 28: ...appliance Any improper interconnection of venting systems may result in leakage of flue gases into the occupied space Any unused opening of the vent system must be properly sealed Visually inspect the venting system for proper size and horizontal pitch determine there is no blockage restriction Leakage corrosion and other deficiencies could cause an unsafe condition Close all building doors window...

Page 29: ...cies could cause an unsafe condition Close all building doors windows and all doors between the appliances which remain connected to the common venting system are located and other space of the building Turn on clothes dryers exhaust fan at maximum speed and any appliance not connected to the common vent system close fireplace dampers Do not operate a summer exhaust fan Place in operation each of ...

Page 30: ...tion WARNING In all installations avoid vent termination locations where excessive debris or snow could accumulate leading to blocking of the vent terminals or where prevailing winds and rain could enter the vent terminal creating additional resistance to the venting system Vent terminals should avoid being installed where the building exterior could be tarnished from the flue gases a shield or an...

Page 31: ...r L shape in the building structure Less than 4 ft 1 2m above a meter regulator assembly horizontally from a vertical centerline of the regulator vent outlet to a maximum vertical distance of 15ft 4 6m Less than 1ft 03m above grade or normal snow level in the area is expected Less than 3ft 0 9m from windows doorways and combustion air supplies nearby buildings or other appliances Under a veranda p...

Page 32: ... and local code requirements The boiler shall not be used as pipe anchor The lower connection blue is for the return the upper connection red is the supply 1 6 5 7 8 9 2 3 4 15 11 12 14 13 16 10 The supply connection manifold has the following ports connections for 1 Pressure Relief valve 2 NPT 2 Air Separator 3 Spare 4 Flow Switch 5 Supply Connection 6 NTC 7 Low Water Cut Off 8 Pressure Gauge 9 A...

Page 33: ...ller than and no larger than 2 inch NPT The pressure shall not exceed 10 above the MAWP and must be of an automatic reset type The valve opening must be routed away so that no injury to persons or damage to property will result Consult local codes When replacing this safety relief valve the relief capacity must be than the minimum relief capacity as listed on the rating plate Please see page 19 fo...

Page 34: ...will reduce the efficiency of the boiler and should be prevented However provided the above is complied with any scale produced will not be too detrimental to the boiler efficiency and will not reduce the anticipated life expectancy of the boiler WARNING The boiler water shall be maintained between 7 and 8 ph at all times Failures to do so will nullify any and all warranties implied Suitable chemi...

Page 35: ...ler failure that may not be covered under the warranty Proper flow rates may be achieved through a combination of primary and secondary flow loops Multiple zones and pumps may result in different flow rates at different times Consideration must be given to all possible conditions and their consequences The flow rate published for all boiler models are applicable 100 firing rate ...

Page 36: ...tem it must be installed so the chilled medium is piped in parallel with the boiler with appropriate valve to present the chilled medium from entering the boiler The boiler piping system of a hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigeration air circulation must be equipped with flow controls valves or other automatic means to prev...

Page 37: ...in 12 All external connections can be made on the terminal strips one low voltage 24V AC and one main power voltage 120V AC Each boiler must be fused protected for a single phase power source 120 1 60 15A the circuit must be earth grounded and provided with a service switch that is within hand reach WARNING Electrical shock hazard can cause personal injury or loss of life including property damage...

Page 38: ...120 60 1 15A fused disconnect ABS2500 ABS3000 ABS4000 120 60 1 15A fused disconnect 230 60 3 10A fused disconnect 5 2 1 Sola Main Control Voltage 120V AC 60 Hz 10 15 Safety time is 3 seconds Control voltage 24 Volt AC 5 2 2 Honeywell Sola Display Honeywell Sola control with Touch screen S7999D 1006 display Voltage 24V Powered ...

Page 39: ...ries Model s 750 2500 Internal Factory Wiring 120 24v SIZE Drawn by DWG NO REV 11x17 Craig H 4 ABS SOL 001 0 SCALE NTS 4 6 2016 SHEET 3 OF 15 ST1 Connector G L1 L N OFF OFF 1 2 P3 P3 ON ON P1 P2 P2 OD OD TT 24v N V1 V2 L V1 N L V2 P1 N COM NO NC IAS 1 2 3 4 5 6 7 8 J2 J1 S7999D 1006 Touch Screen Display F1 24v 120v 24v T1 Supply Outlet Temp Sensor ST1 ST2 See sheet 3 PIN 1 Vdc L 120v DHW DHW DHW R...

Page 40: ...5 4 3 2 1 J6 8 7 6 5 4 3 2 1 J7 7 6 5 4 3 2 1 J9 1 2 3 4 5 6 7 1 J8 2 3 4 5 6 7 8 9 10 11 12 J10 1 2 3 4 5 6 7 8 J11 1 2 3 4 5 6 7 A C B A C B 1 3 2 J3 socket Honeywell R7910A 1027 Control PCB 3 4 POWER FLAME ALARM RESET 2 4 5 1 6 2 3 1 G L1 L N OFF OFF 2 1 P3 P3 ON ON P1 P2 P2 V1 V2 L V1 N L V2 P1 N COM NO NC IAS J2 J1 F2 G3 G250 MW72 01 connections See sheet 5 L2 L3 F2 Tach 20v PWM Gnd L3 L2 L3 ...

Page 41: ...Models TACO McDonnell Miller Mfr Model MR CSD 1 compliant MR CSD 1 compliant Features DL1E1 IAS Interrupted Air Switch All ABS Models Dungs Krom Schroder Mfr Model Working Range AA A1 0 2 0 08 0 40 inch w 0 16 to 1 20 inch w c Set Point 0 20 0 1 w c C6097B 1028 DG50HT 3N Honeywell Dungs Kromschroder Mfr Model Working Range GMH A4 4 4 1 20 inch w c 1 20 inch w c 3 21 0 inch w c ABS 1500 6 0 0 25 w ...

Page 42: ...g Connector Data Data Common 24v power 18 awg 2 c shielded 48 inches black red black red white HMI 18awg 3 c shielded cord 48 inches TB2 1 COM1 COM2 24V POWER 2 3 4 5 6 7 8 Remote Communication Native RS 485 ModBus or Gateway Install clamp filters Wrap power and communication wires as shown above STEP 1 STEP 2 Clamp filter Clamp filter Clamp filter 18Awg 2 c cord shielded By Others 18Awg 3 c 105 C...

Page 43: ...ctions Black 120v 24v LED fuse holder Green Yellow Ground Terminal L N 120v 15A Fused max Service Un fused local disconnect Service switch Pump Contact dry 5A max Each contact H O A Pump A starter H O A Pump B starter H O A Pump C starter Pump A Boiler Pump Pump B CH pump Pump C System Pump All pumps configurable Caution No don t apply power Sensor Wiring Only Main 24v Power Control Display Remote...

Page 44: ...und Terminal L N 120v 15A Fused max Service Un fused local disconnect Service switch Pump Contact dry 5A max Each contact H O A Pump A starter H O A Pump B starter H O A Pump C starter Pump A Boiler Pump Pump B CH pump Pump C System Pump All pumps configurable Caution No don t apply power Sensor Wiring Only Main 24v Power Control Display Remote Automatic Connections 120V Safety Circuit T2 L N Wiri...

Page 45: ...v 15A Fused max Service Un fused local disconnect Service switch Pump Contact dry 5A max Each contact H O A Pump A starter H O A Pump B starter H O A Pump C starter Pump A Boiler Pump Pump B CH pump Pump C System Pump All pumps configurable Caution No don t apply power Sensor Wiring Only Main 24v Power Control Display Remote Automatic Connections 120V Safety Circuit T2 L N Wiring Legend Power wiri...

Page 46: ...Contact dry 5A max Each contact H O A Pump A starter H O A Pump B starter H O A Pump C starter Pump A Boiler Pump Pump B CH pump Pump C System Pump All pumps configurable Caution No don t apply power Sensor Wiring Only Main 24v Power Control Display Remote Automatic Connections 120V Safety Circuit T2 L N Wiring Legend Power wiring min 18awg Sensor wiring shielded type Pump Control Dry contacts rat...

Page 47: ...Caution No don t apply power Sensor Wiring Only Main 24v Power Control Display Remote Automatic Connections Wiring Legend Power wiring min 18awg Sensor wiring shielded type Pump Control Dry contacts rated 5A max Remote BMS 24v enable disable 120v safety contact 1 2 3 Single sensor Non safety Dual sensor Safety Supply DHW Flue Return Outdoor Common Sensor Hot Water Storage Tank DHW Sensor 3 c shiel...

Page 48: ...required as the Sola control system will monitor these conditions and reduce the boiler output finally shutting down until flow conditions improve As a result the boiler is virtually unaffected by low water flow Although boiler flow and content protection is provided does not safeguard the entire heating system additional low water content and temperature safety controls maybe needed in certain ju...

Page 49: ...ake housing The gas pressure switch is pre set at the factory and should not be adjusted High gas pressure switch Low gas pressure switch 5 4 6 Low gas pressure switch LGP The boiler is equipped with a low gas pressure switch that is mounted directly on the mono block of the gas valve The gas pressure switch is pre set at the factory and should be checked per commissioning ...

Page 50: ...enting to the atmosphere other regulators and safety shutoff valves may require venting and relief piping to the atmosphere consult their documentation Install a sediment trap drip leg and a union connection ahead of any primary manual shut off valve Gas piping should be installed in accordance with the National Fuel Gas code ANSI Z223 1 latest edition and any other local codes which may apply in ...

Page 51: ... 3 7700 5300 4300 3700 3250 2650 2280 4 4 026 10 1 20 2 15000 10900 8800 8800 6700 5500 4600 6 2 Gas pressures The boiler has been factory test fired and adjusted for proper combustion The boilers main gas valve are certified and can accept a maximum inlet pressure up to psi or 14 w c 35 mbar but MUST provided with a min of 3 5 w c 8 mbar at the gas filter inlet test point when the boiler is opera...

Page 52: ...ratio of the valve being used according to the procedures below To adjust High fire Required tools Flat head screw driver and combustion analyzer Start the boiler and observe the proper operating parameters for the system Set the boiler to high fire to achieve maximum firing rate of the boiler Check combustion readings using the combustion analyzer If combustion readings are not within the range s...

Page 53: ...rl Dungs gas valve B Turn the offset screw located in the bottom center of the side of the valve in the direction indicated on the label to increase or decrease the natural gas flow Increasing the gas decreases the O2 while decreasing the gas increases the O2 There will be a slight delay of 30 seconds from the time the adjustment is made until the gas combustion reads alter It is best to make smal...

Page 54: ...ion 2 G 1 8 between V1 and V2 both sides 8 Test port connection 3 G1 8 downstream of V2 both sides 9 Regulator outlet pressure adjustment screw both side 10 Vent less regulator vent connection is G1 8 threaded The brass vent limiting orifice is 0 2mm in diameter 11 Downstream flange 12 Test port connection 1 G1 8 upstream of V1 both sides 13 Offset adjustment cover ...

Page 55: ...utralizer used ensure no obstructed flow through neutralizer to drain Ensure all piping of condensate is gravity feed to drain 9 Check water connections to the system are correct and all isolation valves are open 10 Check to ensure boiler drain connection is provided 11 Ensure boiler has been installed and properly mounted to the boiler pad if provided anchoring of boiler per local codes and seism...

Page 56: ...an electronic CO2 gauge on the basis of O2 and a gas pressure gauge Note that the opening see fig 23 around the measuring probe is sealed properly during measurement Note also that measuring the O2 levels in the flue gas is necessary because direct mea surement of CO2 can lead to inaccuracies due to varying CO2 levels in the natural gas Connect the gas pressure meter between measuring point PG on ...

Page 57: ...lation of the boiler is not completed until all controls and safety device have been tested and verified for correct function and operation It is the sole responsibility of the installer to ensure that all safety control systems and gas ignition systems and any the associated safety control are tested ...

Page 58: ...D contains software that incorporates many features that are designed to guide you safely through the commissioning process Safety however is your responsibility Read all documentation carefully and respond appropriately to all error messages Be aware that as you command the R7999 to open and close actuators the R7999 is designed to prevent you from opening or closing them too rapidly When any of ...

Page 59: ...ser no password or login required A OEM Factory access by authorized factory personnel only B Service trained installers operators Access to configure optional items lead lag etc C User end user or operator limited access In the configuration menu the User no password required has access to view all parameters but user cannot change unless either a Service or OEM password is entered Login only req...

Page 60: ...ither view confirm or change if changes to a group parameter is needed a service password will have to be entered Step 4 Enter service password Serial by touching the locked padlock icon near the top right hand corner this will bring you to the login screen enter service password serial The locked padlock icon will change to an unlock padlock icon and return back to the configuration menu select t...

Page 61: ... trap assembly if Ph neutralizer used ensure no obstructed flow through neutralizer to drain Ensure all piping of condensate is gravity feed to drain 9 Check water connections to the system are correct and all isolation valves are open 10 Check to ensure boiler drain connection is provided 11 Ensure boiler has been installed and properly mounted to the boiler pad if provided anchoring of boiler pe...

Page 62: ...ully factory tested due to varying field conditions boiler must be tested on final site for safety shutdown operation and combustion limits The display maybe in a screen saver mode or in the home position Sola control icon 1 Start main screen touch the Sola control this will bring you to the Operation Overview window 2 Touch the diagnostics button screen changes to the I O Status window ...

Page 63: ...s necessary via shutter adjustment slotted screw c Measure breeching vent draft condition d Check flame signal on operation overview window and observe flame condition via sight glass 5 Press the Minimum Modulation button this will force the boiler into the Low fire position Once in the Low fire postion and stable conditions are reached check the following a Check combustion see table for factory ...

Page 64: ... Unit Range Part Load 20 Full Load 100 CO2 Range 6 9 5 8 0 9 0 O2 Range 8 0 4 0 7 0 5 0 CO Limit ppm 100 Gas Pressure Readings Full Load 100 Part Load 20 Δp in w c Δp mbar Δp in w c Δp mbar EPN EPAW1050 EPN EPAW1600 EPN EPAW2080 9 4 IMPORTANT SAFETY WARNING The installation of the boiler is not completed until all controls and safety device have been tested and verified for correct function and op...

Page 65: ...rm correct operation 7 Low gas pressure calibration and check manual reset a Check for leaks around the surface mount of low gas pressure switch for gas leaks b Command boiler on while starting turn dial to the maximum setting or until boiler shutdown on LCI operating interlocks the switch is equipped with a LED indication when switch has activated c Set switch setting back to 3 5 w c press the re...

Page 66: ... leaks b Command boiler on while starting turn dial to minimum setting or until the boiler shutdown on LCI operating interlocks the switch is equipped with a LED indication when switch has activated c Set switch setting back to SEE TABLE press the reset on switch and observe boiler shall start again automatically d Connect a manometer to the test point and observe pressure reading ...

Page 67: ...ssure sw High Fuel Pressure sw Air pressure sw Vent Switch Lockout Setting Tested Vent Type Height or Length Size ø Air Supply Boiler Burner Control Serial SW Tested Air filter Setting Tested TFI FRT Specific Site Note Unit Fuel Train Leakage Test Local Remote switch function Setting Tested Boiler pressure P Trap filled High fire Full load Low fire Part load Volts L Gnd Volts N Gnd Amps High fire ...

Page 68: ...n and dry for re assembly Following maintenance cleaning the boiler should be re assembled in the reverse order re placing gaskets and joints where found necessary All general cleaning should be carried out with compressed air a soft brush or damp cloth to avoid damaging components Solvents must not be used Remove front and end casing panels lift casing panel slightly upwards and tilt toward you l...

Page 69: ...iff bristle bottle type brush or use the special cleaning tool supplied optional Care should be taken when using water in the confined space of the boiler casing to avoid contaminating the electrical controls Compressed air can also be used but care should be taken to ensure disturbed dust etc does not contaminate the rest of the boiler and controls Replace the heat exchange plate after cleaning a...

Page 70: ...as been done to the tube from heat If the burner is in good condition clean the burner assembly by using compressed air only between 30 70 psi 2 5 bar with the nozzle positioned a min of 3 8 10mm away and towards the face of the burner If there is any damage to the mesh or tube the burner must be replaced Check the retaining bolts are tight If the burner is removed from the front plate ensure burn...

Page 71: ...essary then discard screws and gasket and fit replacement assembly c w new gasket and screws making sure that the earth connection is in good condition and in contact with the base plate and refit safety bracket Ensure a gap of 1 8 inch exists 3 mm 11 1 8 Filter maintenace and filter replacement The filter shall be replaced under the following conditions 1 The filter has been in service for more t...

Page 72: ...ng screws on the inspection glass holder clean and replace Re assemble boiler in reverse order check front plate gasket and insulation piece replace if required Also check the gasket on fan and on gas valve replace if necessary Ensure that all cables are routed correctly using existing clips and ties were possible to ensure that they do not touch any hot parts of the boiler CAUTION Ensure that wir...

Page 73: ...xhaust terminals for ice snow or debris buildup Monthly Check air inlet filter Shall be done weekly if unit is operating in a construction zone Monthly Check and test pressure relief safety valve Annually Test temperature Hi limit functions Annually Checks for system leaks Annually Check all auxiliary and other safety limit for function and correct operation Monthly Check system water quality refe...

Page 74: ...Innovative Industrial Inc Innovative Industrial Inc 122 Burton Street Hamilton Ontario Canada L8l 3R5 ...

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