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PENSOTTI DK2-3, User Manual

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PENSOTTI DK2-3 User Manual Download Page 22

9-1-2009 

21 

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Install the burner air adapter. 

-    Slide the end of the air intake flex over the burner air adapter.  Seal the connection with 

aluminum     tape and secure with the air intake clamp. The beaded end of the air intake clamp 
should go first over the burner adapter. 

-

 

The Pensotti Quatech Direct vent system does not require a vacuum relief valve or a post purge 
control on the Riello BF Series burner per UL 726 test criteria. 

 
 
 

Z FLEX COMPONENTS AND PART NUMBERS 
 

COMPONENTS – 4in. diameter system               Part Number 

Z Flex Vent Pipe 10ft. length                                                          ZFV104 
Z Flex Vent Pipe 15ft. length                                                          ZFV154 
Z Flex Vent Pipe 20ft. length                                                          ZFV204 
 
Z Flex Appliance adapter w/Pt 6in. to 4in.                                      ZFA64P 
 
Z Flex Vent Terminal 4in.                                                                ZFDV0 
 
Z Flex Terminal Adapter 4in. – 4in.                                                 ZFAT44 
 
Z Flex Air Intake Flex 10ft. by 4 in.                                                 L10-04 
Z Flex Air Intake Flex 15ft. by 4in.                                                  L15-04 
Z Flex Air Intake Flex 20ft. by 4in.                                                  L20-04 
 
Z Flex Air Intake Clamp 4in.                                                            7H372XX 
 
Riello BF Burner Air Adapter 3in. – 4in.                                          4RA43 
 
Z Flex Sealant 3 oz.                                                                           23ILUC 
 
Other components may be available.  Check with Pensotti with any needs. 

 

 
 
 

 

 
 
 
 

 

 

     

 

Summary of Contents for DK2-3

Page 1: ...AGRAMS 7 WIRING 9 GENERAL INSTRUCTIONS 9 TYPICAL WIRING DIAGRAMS 9 VENTING REQUIREMENTS 12 NATURAL DRAFT APPLICATIONS 12 CONDENSATION 13 MECHANICAL DRAFT APPLICATIONS 13 POWER VENTER APPLICATIONS 14 DIRECT VENT APPLICATIONS 15 INSTALLING THE JOINT ASSEMBLY 17 INSTALLING THE OUTSIDE TERMINAL 18 CONNECTIONS TO THE OUTSIDE TERMINAL 19 CONNECTION TO THE APPILANCE 20 Z FLEX COMPONENTS 20 FUEL SYSTEM 22...

Page 2: ...ed by comparing the heat loss calculation including domestic hot water needs with the Net I B R rating of the boiler In some cases it will be the domestic hot water need that solely determines the boiler size It is important to note that if your heat loss calculation exceeds the largest boiler in The Quatech Series a modular installation utilizing more than one boiler can be employed Consult Penso...

Page 3: ...NIMUM CLEARANCES TO COMBUSTIBLE MATERIALS COMBUSTION AND VENTILATION AIR Installations taking place in traditional unconfined settings such as basements generally have an adequate supply of both combustion and ventilation air In situations where the boiler is to be located in a confined space with all combustion and ventilation air coming from within the building two openings must be made with an ...

Page 4: ...Damper Sizing of the air inlet pipe to the burner air housing is as determined as follows PLACEMENT LEVELING OF THE UNIT The boiler should be located on a firm foundation in an easily accessible area that meets the previously discussed clearances and air requirements In situations where the floor may be uneven the Quatech may be leveled by using the leg levelers provided on the boiler or through t...

Page 5: ...9 1 2009 4 JACKET ASSEMBLY AND CONTROL INSTALLATION ...

Page 6: ...n of the jacket assembly the control unit can be mounted on the side of the boiler The boiler is now ready for piping and connection to the fuel system heating and domestic hot water thermostat and 110 Volt 60 cycle AC current ...

Page 7: ...Institute Residential Hydronic Heating Installation Design Guide All piping must be properly sized free from defect and be made of copper steel brass aluminum or PEX Test results have shown that the safest operating temperature range for modern boilers including the Quatech is 160 degrees F to 210 degrees F 90degreesC to 99degrees C Allowing the water temperature in the boiler to drop below 160 de...

Page 8: ...9 1 2009 7 ...

Page 9: ...9 1 2009 8 ...

Page 10: ...or servicing The boiler must be ground to the water piping or the main service ground Room thermostats should be installed or relocated away from cold drafts air currents lamps televisions or sunlight Set the heat anticipator on the thermostat to match the operating control Connect the thermostat leads to the circulation pump operating control or aquastat as applicable All electrical devices shall...

Page 11: ...mum operating performance The use of a post purge is recommended with mechanical draft systems Figure 5 figure 6 figure 7 and figure 8 show wiring diagrams for use of the Honeywell L7248 and the Carlin 90000B high limit controller along with installation for a powerventer application and the wiring of a priority indirect with a Taco SR503 or equivalent ...

Page 12: ...9 1 2009 11 ...

Page 13: ...ondensation of flue gasses Positive outlet draft conditions Reverse flow of flue gas during or after burner shutdown Chimney Connection To insure safe and efficient boiler operation flue gasses must be released through a clean properly sized chimney with adequate draft that meets all local codes and regulations and be in accordance with NFPA 211 and NFPA 31 Always inspect and clean the chimney to ...

Page 14: ... properly supported and be 18in from all combustible surfaces Condensation The Quatech Series boiler is a high efficiency boiler and as a result improper venting can lead to condensing temperatures in the chimney connector and the venting system If condensing temperatures of below 250 degrees F NET are reached in the chimney connector then additional steps to insure proper draft must be taken Make...

Page 15: ... the building The vent hood must be at least 4ft from any roof soffit or ridge vent The vent hood must be at least 7ft above any public walkway All venting material must consist of suitable materials and terminate at an approved steel hood All vent piping must be sealed from air leaks The vent pipe bend radius is 12in Metal support strapping must be placed every 36in to prevent the vent pipe from ...

Page 16: ...NS DIRECT VENTING IS TO BE USED FOR OIL APPLICATIONS ONLY THE USE IS LIMITED TO THREE FOUR AND FIVE SECTION BOILERS ONLY Z FLEX DIRECT VENT KITS ARE APPROVED FOR USE WITH THIS SERIES OF BOILERS ONLY RIELLO BF SERIES BURNERS MAY BE USED ...

Page 17: ... be checked annually by a qualified heating professional Maximum will thickness should not exceed 14 inches Contact Pensotti Boilers for options if your wall is thicker than 14 inches The Pensotti Z Flex system is designed for single appliance use only It is not designed for common venting unless specific approval is obtained An appliance adapter test port must be used as required by Z Flex for co...

Page 18: ...er into the vent tube Screw the adapter into the vent pipe with a counter clockwise motion The adapter should be fully inserted into the inner vent tube until it is tight The seams of both tubes must be aligned for ease of insertion If the adapter does not completely screw into the vent pipe unscrew it and repeat the same process Seal around the edge of the vent pipe inner tube Slide the adapter s...

Page 19: ...e outer section of the terminal until it until it rests against the bead From outside the building insert the outer section of the terminal through the hole until it rests against the outer wall From inside the building slide the inner wall plate over the outer terminal section and secure using 4 screws Position the outer section so that the seam on the flue collar is on top of the air intake on t...

Page 20: ...collar Slide the appliance adapter over the flue collar Tighten the terminal adapter gear clamp around the flue collar Seal the adapter seam with sealant Slide the inner section over the outer section and secure by tightening the gear clamp Stretch the air intake flex to the desired length and slide it over the air intake collar Seal the connection with aluminum tape and secure it using the air in...

Page 21: ...low the steps below to accomplish this task Connect the appliance adapter to the vent pipe as shown in the joint assembly section Apply sealant around the appliance flue collar Slide the appliance adapter over the appliance flue collar Tighten the gear clamp of the appliance adapter around the flue collar Seal the adapter seam with sealant ...

Page 22: ...criteria Z FLEX COMPONENTS AND PART NUMBERS COMPONENTS 4in diameter system Part Number Z Flex Vent Pipe 10ft length ZFV104 Z Flex Vent Pipe 15ft length ZFV154 Z Flex Vent Pipe 20ft length ZFV204 Z Flex Appliance adapter w Pt 6in to 4in ZFA64P Z Flex Vent Terminal 4in ZFDV0 Z Flex Terminal Adapter 4in 4in ZFAT44 Z Flex Air Intake Flex 10ft by 4 in L10 04 Z Flex Air Intake Flex 15ft by 4in L15 04 Z ...

Page 23: ...l Gear Suction Capacity TGSC will determine the filter size The filter normally found in the tank should be left in place while adding a high quality paper throwaway cartridge type filter or line strainer to the fuel suction line A 5 micron to 10 micron rating is recommended The paper filter or strainer should be mounted on the casing of the boiler Flexible fuel lines with adequate slack can thus ...

Page 24: ...1 131 88 4 6 x 18 DK2 6 1 39 194 167 148 88 4 7 x 18 DK2 7 1 60 224 195 171 88 5 7 x 18 DK2 8 1 80 252 222 193 88 6 7 x 18 Pensotti Heatline Quatech Series Burner Specifications PENSOTTI HEATLINE QUATECH SERIES RIELLO SPECIFICATIONS Appliance Model Burner Model Nozzle Size Pump Pressure psi Turbulator Setting Air Gate Setting DK2 3 40 F3 55 X 70 B 160 0 0 3 6 DK2 4 40 F5 85 X 60 B 140 2 0 2 8 DK2 ...

Page 25: ...ollowing sections provide information on maintenance and service related activities In the event a problem occurs consult your heating professional HOMEOWNER SERVICE CAUTION In the event of a problem with the heating system the homeowner should perform the following limited activities Check to make sure that there is fuel in the tank and that oil valves are open Set the thermostat above existing r...

Page 26: ... is out of service The following steps should be followed Remove the front casing by sliding it upwards to release and then pull to remove Open the front swing door by removing the four bolts this will expose the chamber area as well as the second and third passes Remove the stainless steel baffles With a cleaning brush clean the boiler section second and third passes Remove the insulation and smo...

Page 27: ...9 1 2009 26 PARTS LIST AND BOILER DIAGRAM ...

Page 28: ...GLASS C NUT M10 22a SIGHTGLASS FRAME INSULATION D STUD M10 X 40 22b SIGHTGLASS INSULATION E NUT M8 24 FRONT DOOR REFRACTORY F WASHER A8 4 25 27 29 2ND PASS RETARDERS G SETSCREW M5 X 15 26 28 3RD PASS RETARDERS H NUT M6 30 DELIVERY STUB PIPE J WASHER A6 4 31 RETURN STUB PIPE K STUD M6 X 22 44 BLANK FLANGE L SELF TAPPING SCREW S6 3 X 30 47 SMOKEHOOD DIA 150 MM M SERRATED WASHER A4 3 50 SMOKEHOOD CLE...

Page 29: ...9 1 2009 28 ...

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