Absolute ABS-750 Installation And Operation Manual Download

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Gas-Fired Condensing Hot Water Boiler

Installation and Operation Manual

ABS - 750

750

MBH

ABS - 900

900

MBH

ABS - 1050

1050

MBH

Innovative

ndustrial Inc.

ABS 750-900-1050/IOM Manual/V.01/12/2015

CATION

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 Ratio
-  Honeywell Sola Boiler Control System
-  Compact Light Weight Packaged Boiler
-  Three Models from:

ABS 750, ABS 900, ABS 1050

- Low NO

Standard

Document # 1050-20

Summary of Contents for ABS-750

Page 1: ...ent 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 In...

Page 2: ...lease read 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 sys...

Page 3: ...19 4 2 Delivery and installation 19 4 2 1 Site preparation 20 4 2 2 Hoisting the boiler 20 4 2 3 Multiply boiler arrangements 21 4 3 Flue gas discharge and air supply 23 4 4 Boiler Venting Types 23 4...

Page 4: ...3 4 Air pressure switch 50 5 3 5 High gas pressure switch HGP 51 5 3 6 Low gas pressure switch LGP 51 6 Gas connection 52 6 1 Gas connection 52 6 1 2 Manual gas valve upstream for boiler 52 6 1 3 Gas...

Page 5: ...rt trap 69 10 1 2 Cleaning the Whirlwind 69 10 1 3 Cleaning the fan 70 10 1 4 Cleaning the heat exchanger 70 10 1 5 Cleaning the burner assembly 71 10 1 6 Cleaning the siphon 71 10 1 7 Cleaning replac...

Page 6: ...installed 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 servi...

Page 7: ...on Always disconnect main service to boiler before servicing WARNING Only properly qualified personnel that hold all necceassary licenses shall work on the installation and service of this boiler Uses...

Page 8: ...ou cannot 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 tec...

Page 9: ...n our 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...

Page 10: ...ler as required by the BMS All Absolute boilers are fully test fired after assembly to ensure the boiler and controls comply with our strict quality policy The packaged boiler is constructed and appro...

Page 11: ...fter 3 attempts shut the boiler down requiring manual intervention to reset the boiler The display will indicate a flashing fault code 3 times confirming the reason for the failure The products of com...

Page 12: ...bustion air supply 8 ID B Condensate drain connection 1 1 4 NPT C Flue gas discharge 8 ID D Gas connection 1 NPT E Return connection 2 1 2 NPT F Supply connection 2 1 2 NPT A D F C G R Absolute Boiler...

Page 13: ...Sensor Return Water 1 2 5 NTC Temperature Sensor Supply Water 1 11 Boiler Drain 3 4 6 Temperature and Pressure Gauge 1 2 12 Condensate Drain 11 4 A Boiler Supply male NPT 2 1 2 D Gas Connection NPT m...

Page 14: ...Absolute Boilers 750 900 1050 14 Absolute Boilers 750 900 1050 27 6 5 7 8 9 20 19 23 28 18 11 13 24 12 15 15 26 10 17 35 32 29 2 4 1 3 16 25 14...

Page 15: ...l 5 Boiler Supply 6 NTC Temperature Sensor Supply water 7 Low Water Cut Off Manual Reset 8 Temperature and Pressure Gauge 9 Aqua stat Manual Reset 10 Boiler Return 11 NTC Temperature Sensor Return Wat...

Page 16: ...mbustion Air Vent Diameter Inch 8 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 Approved Meta...

Page 17: ...ng service and fault diagnostic capabilities Firing capabilities fully modulating 4 20MA Capable of BMS control 4 20MA Local remote switch enable disable optional Available for conventional chimney di...

Page 18: ...Air filter strongly recommended when using boiler room air Annunciation LED s audible alarms Other parameters are available 3 5 Pressure relief valve requirements Model 30 psi std 40 psi 50 psi 60 ps...

Page 19: ...t time of receipt From 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 wi...

Page 20: ...xpansion 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 servi...

Page 21: ...Absolute Boilers 750 900 1050 21 Absolute Boilers 750 900 1050 4 2 3 Multiply boiler arrangements Front 36 Rear 12 Rear 12 Front 36 Side 18 6 Side 18 Rear 12 Front 36 Front 36 Side 18 Rear 12 Side 18...

Page 22: ...the boiler 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 c...

Page 23: ...gle wall unlisted metal pipe 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...

Page 24: ...st be properly supported in a manner to prevent any sagging or low spots For Category II AND IV ensure the slope is to inch per inch towards the boiler to prevent accumulation of condensate and ensure...

Page 25: ...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 t...

Page 26: ...I Z223 1 according to appropriate tables in Part II of the above mentioned codes WARNING Do not place intake or exhaust terminations above a walkway or sidewalk as the condensation can cause icing of...

Page 27: ...iler room All combustion air is from the outdoor source The vent terminal shall discharge flue gases away from the building structure so that the flue gases do not cause damage to the building The ven...

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 th...

Page 29: ...of the venting system must be corrected so the installation conforms to either ANSI Z223 1 NFPA 54 or CAN CSA B149 1 gas installation codes When resizing any portion of the common venting system the...

Page 30: ...ndensation 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 co...

Page 31: ...rner or 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 15...

Page 32: ...not be used as pipe anchor The lower connection blue is for the return the upper connection red is the supply The supply connection tube has the following ports connections for 1 2 5 8 3 4 7 6 11 10 1...

Page 33: ...t smaller 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 o...

Page 34: ...l scale deposits 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 an...

Page 35: ...re boiler 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 differen...

Page 36: ...on system 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 ho...

Page 37: ...ection activates If the boiler is decommissioned or stored for an extended period of time where temperatures can reach below 2 C the boiler will need to be Drained De activated Electrical power must b...

Page 38: ...from ingest of water and be properly grounded and bonded according to CEC Part I CSA 22 1 NEC NFPA 70 CAUTION Label all wires prior to servicing the controls Wiring errors can cause improper and dang...

Page 39: ...50 900 1050 5 2 Control unit 5 2 1 Sola Model R7910A 1027 Voltage 120V AC 60 Hz 10 15 Safety time is 3 seconds Control voltage 24 Volt DC 5 2 2 Honeywell Sola R7910A 1027 control sheet 1 12 Honeywell...

Page 40: ...D N 24V N L 120 60 1 Power Source 15A Max COM L N NO NC LWCO 1 3 2 PWM motor PWM ST1 Main power J1 J2 J1 J2 socket details see sheet 6 A C B A C B 1 3 2 J3 socket Honeywell R7910A Control PCB J3 socke...

Page 41: ...s Inc 1090 Fountain St E Cambridge On N3E 1A3 Canada 1 800 943 6275 Absolute ABS Series Model s 750 2500 Internal Factory Wiring 120 24v SIZE Drawn by DWG NO REV 11x17 Craig H 4 ABS SOL 001 0 SCALE NT...

Page 42: ...ericas Inc 1090 Fountain St E Cambridge On N3E 1A3 Canada 1 800 943 6275 Absolute ABS Series Model s 750 2500 Honeywell Sola System R7910A J1 Flame sensor J2 PWM communication SIZE Drawn by DWG NO REV...

Page 43: ...REV 11x17 Craig H 4 ABS SOL 001 0 SCALE NTS 2 26 2016 SHEET 7 OF 15 ABS 750 MBC 1000 255749 Swirl Plate 15mm orifice Inlet flange 1 inch 221 999 1 inch Shutter 253 205 kit 255 132 ABS 900 MBC 1000 255...

Page 44: ...25 inch w c 120 60 1 10A Max N L LFM 1203S 1 751P MT 120 Low Water Control All ABS Models TACO McDonnell Miller Mfr Model MR CSD 1 compliant MR CSD 1 compliant Features DL1E1 IAS Interrupted Air Swit...

Page 45: ...AT250 1006 N a 3 16 N a L N TT TT DDR Americas Inc 1090 Fountain St E Cambridge On N3E 1A3 Canada 1 800 943 6275 Absolute ABS Series All Models Honeywell Sola 24v Wiring Details SIZE Drawn by DWG NO R...

Page 46: ...e boiler display S7999D 1006 A B C MB1 A B C MB2 1 2 3 ECOM 24v 24v S7999D 8 PIN Plug Connector Data Data Common 24v power 18 awg 2 c shielded 48 inches black red black red white HMI 18awg 3 c shielde...

Page 47: ...TT connection 120v Safety Circuit Neutral 120 24v Optional Sensor s no power Pump Output dry contacts Block Ends no connections Black 120v 24v LED fuse holder Green Yellow Ground Terminal L N 120v 15...

Page 48: ...__ 1 TT TT ON ON OFF OFF OD DHW 24 24 N DHW DHW OD FL FL FL TB2 Internal Wiring TB2 Caution No don t apply power Sensor Wiring Only Main 24v Power Control Display Remote Automatic Connections Wiring L...

Page 49: ...8 200 F 20 93 C 5 3 2 Low water level protection LWCO flow and content The Absolute boiler is equipped with low water protection based on temperature differences T between flow and return When the T 4...

Page 50: ...ded in certain jurisdictions In the event the low level is too low a RED light will flash on the low water cut off To reset this device the technician needs to press the light This limit device also h...

Page 51: ...ir intake 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 3 6 Low gas pressure switch LGP The boiler is equipped...

Page 52: ...s not require venting 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...

Page 53: ...7 67 15 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 boi...

Page 54: ...l air 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 operatin...

Page 55: ...nel of the boiler 2 Locate the Karl 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 na...

Page 56: ...onnection 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 i...

Page 57: ...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 isolati...

Page 58: ...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 be...

Page 59: ...installation 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 ensu...

Page 60: ...e S7999D 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 carefull...

Page 61: ...al c User 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...

Page 62: ...sh to either 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 t...

Page 63: ...are fully 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 hom...

Page 64: ...fire as 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 th...

Page 65: ...r 11 Downstream flange 12 Test port connection 1 G1 8 upstream of V1 both sides 13 Offset adjustment cover 8 4 IMPORTANT SAFETY WARNING The installation of the boiler is not completed until all contro...

Page 66: ...confirm 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...

Page 67: ...or gas 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 activ...

Page 68: ...LWCO control Low Fuel Pressure sw High Fuel Pressure sw Air pressure sw Vent Switch Lockout Setting Tested Vent Type Height or Length Size Air Supply Boiler Burner Control Serial SW Tested Air filter...

Page 69: ...lean 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 ca...

Page 70: ...r can be washed with clean water if badly contaminated clean with a small stiff bristle bottle type brush or use the special cleaning tool supplied optional Care should be taken when using water in th...

Page 71: ...and ensure no damage has 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...

Page 72: ...lectrode assembly if necessary 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...

Page 73: ...etaining 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...

Page 74: ...ystem is working Semi annually Check exhaust 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...

Page 75: ...Absolute Boilers 750 900 1050 75 Absolute Boilers 750 900 1050...

Page 76: ...Technical support 1 800 943 6275 9 am to 5 pm EST For service or parts contact your local sales representative...

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