PENSOTTI DK2-3, User Manual

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9-1-2009 6
PIPING
Prior to connecting the Quatech to an existing piping system certain procedures must be
followed. The system should be flushed to insure that scale and sludge will not be
introduced to the boiler. This is a must when replacing a gravity open system. The Quatech
is a low mass boiler requiring low water content and steps must be taken to insure that the
boiler is not flooded from an existing high volume standing cast iron system. If the
conversion is from a high volume system a bypass loop must be installed. If high pressure
testing of the existing system is necessary make sure the Quatech is isolated during the
testing. Manual shut off valves must be installed on both the supply line and on the boiler
bypass loop. ASME Boiler Code requires that feed or make up water be introduced to the
piping system and not directly to the boiler. Pressure reducing valves should be installed
and adjusted to 12psi cold water. The pressure relief valve must be piped from the boiler
and downward to within 6in. of the floor or to a height to meet existing code. An expansion
tank, circulating pump, and automatic air eliminators must be part of the system. The relief
valve, backflow preventer and drain valve should be piped according to code to a drain with
piping that is the same size as the relief valve. .
All piping, including heating, domestic hot water, and fuel lines, must be done in
accordance with all local codes. It is suggested that you refer to the Water Installation
Survey and Hydronics 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 degrees F for an extended
period of time can cause corrosion and boiler plugging.
Circulation Pump
A calculation for proper pump selection must be performed for all installations. The
pump(s) should not be operated at maximum working pressures above 30PSI or maximum
working temperatures above 210 degrees F and within limits advised by the manufacturer.
The pump must not be operated unless the system has been bled of all air and completely
filled with water.
Recommended locations for the circulator, expansion tank, relief valve and other trim
are shown in figure1, figure2, figure3, and figure4.
Controls
The Quatech Boiler package includes a control package with a Hydrolevel model 3250
Hydrostat with built in Low Water Cut-Off and Boiler Reset. Wiring diagrams for both
controls are included in this manual on pages 10, 11, & 12, as well as diagrams for a
powerventer application and a priority indirect application with a Taco SR503 or
equivalent. For special control systems such as outdoor reset, multiple zones, multiple
boiler installations, unit heaters, radiant heating etc. consult the respective manufacturers
manual or contact Pensotti North America.
CAUTION Safety or relief valve discharge should be piped downward to within 6in. of
the floor or to a drain. The valve must be mounted in a vertical position.