PENSOTTI DK2 Series Installation And User Manual Download Page 3

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START UP PROCEDURE

Testing Safety & Control Devices

SERVICE INFORMATION HOMEOWNER

MAINTENANCE – SERVICEMAN

Clean Boiler

Clean Fuel System and Burner

Perform Combustion Test

PENSOTTI HEATLINE QUATECH SERIES BOILER SPECIFICATIONS

PENSOTTI HEATLINE QUATECH/RIELLO BURNER SPECIFICATIONS

PENSOTTI BOILER PARTS LIST AND DIAGRAM

Summary of Contents for DK2 Series

Page 1: ...Installation and User Guide DK2 Series Cast Iron Boiler Assembly Operating and Maintenance Instructions ...

Page 2: ...s 7 Filling of the System With a Sealed Expansion Tank 7 Boiler Replacement Service Caution 7 General Requirements for Piping Circuits 7 Circulation Pump 8 Installation Diagrams 9 WIRING 13 Special Control Systems 13 Electrical Hazard 14 Typical Wiring Diagrams 14 VENTING REQUIREMENTS 18 Natural Draft Applications 18 Mechanical Draft Applications 19 Draft Regulator 19 Neutral Point Pressure Adjust...

Page 3: ...ON HOMEOWNER 26 MAINTENANCE SERVICEMAN 26 Clean Boiler 26 Clean Fuel System and Burner 26 Perform Combustion Test 26 PENSOTTI HEATLINE QUATECH SERIES BOILER SPECIFICATIONS 27 PENSOTTI HEATLINE QUATECH RIELLO BURNER SPECIFICATIONS 27 PENSOTTI BOILER PARTS LIST AND DIAGRAM 35 ...

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Page 6: ...stem will deliver only the amount of heat required to match your actual home s heating demand We want to provide you with the maximum comfort level achievable combined with the highest fuel cost savings The following are useful bits of information presented under a series of sub headings Annual Fuel Utilization Efficiency AFUE The A F U E is a measure of the estimated ability of a heating applianc...

Page 7: ...ater load if the unit is to be used for this purpose Most heating systems are oversized In fact recent US Government DOE and HUD surveys found existing equipment in the field to be as much as 400 oversized Reducing the firing rate of the boiler results in longer burner on times increased A F U E and provides significant savings for the consumer The improved A F U E of the Pensotti Heatline Quatech...

Page 8: ...e delivering carrier not PNA Inc and request inspection of the damaged equipment Do not destroy the carton The inspector from the freight company will need this to determine the reason for the damage Normally claims for any damages should be filed with the freight company within 5 working days after receipt of shipment It is the responsibility of the consignee to file claim with the delivering car...

Page 9: ... construction At least 20 inches free space should be present at the right or the left hand sides of the boiler Minimum clearances for proper service are as follows 8 from the front of the oilburner 18 from the back of the unit 20 from the other side The minimum installation clearances to combustible materials are 8 from the front of the oilburner 18 from the back of the unit 20 from either side 1...

Page 10: ...ractices have resulted in many people insulating and caulking their homes to a level where the fresh air required for efficient combustion is not always readily available Particularly if you choose to isolate your Pensotti Heatline Quatech Series boiler in an enclosed area of your home a fresh air intake must be installed in this area Air for Combustion The Pensotti Heatline Quatech Series boiler ...

Page 11: ...he jacket and controls in place it is ready for piping and connection to the heating and domestic water systems fuel system room thermostat and 110 Volt 60 cycle AC current Assemble and install the oilburner to manufacturer specifications and apply a bead of RTV silicone between air tube and flange Mount and level burner and fully tighten all mounting nuts Piping Heat Distribution System Before co...

Page 12: ...t efficient boilers sometimes called low mass can cause problems from corrosion being produced with low operating water temperatures Combustion by products in fuels produce acidic sulfur oxides that corrode cast iron and steel surfaces when the oxides condense in a water solution on the boiler surfaces The water dewpoint on the inside surfaces of a boiler is 120 F 49 C for fuel oil burning and 140...

Page 13: ...i stored buildings or multiple zone control systems and the pump capacity must be checked for proper operation The pump s should not be operated at maximum working pressures above 30 PSI and maximum working temperatures above 210 F or as advised by the pump manufacturer The pump s should not be operated unless the entire system has been completely filled with water and properly bled of all air Ins...

Page 14: ... Figure 1 Figure 2 Figure 3 and Figure 4 The relief valve backflow preventer and drain valve should be piped according to code and should be piped to discharge safely If the Pensotti Heatline Quatech Series is to be used with a storage type domestic hot water system other than provided by PNA Inc connect and wire according to manufacturer s instructions Flow Check Drain Valve Piped to Floor or Cod...

Page 15: ...ucing Valve Boiler Feed Piped to Code Purge Valve Air Separator Air Vent Flow Check Circulator SUPPLY RETURN TO SYSTEM BOILER Burner Control Valve in By Pass Line Figure 2 Figure 2 shows a typical installation with no domestic hot water and with a by pass loop installed The control valve should be either a needle or throttling valve ...

Page 16: ...tor Air Vent Heating Circulator SUPPLY RETURN TO SYSTEM Control Valve in By Pass Line Domestic Circulator Burner BOILER INDIRECT HOT WATER HEATER Figure 3 Figure 3 shows a typical installation with domestic hot water supplied by an indirect heater and with a by pass loop installed The control valve should be either a needle or throttling valve ...

Page 17: ...iler Feed Piped to Code Purge Valve Air Separator Air Vent Heating Circulator SUPPLY RETURN TO SYSTEM BOILER Burner Domestic Circulator INDIRECT HOT WATER HEATER Figure 4 Figure 4 shows a typical installation with domestic hot water supplied by an indirect heater and with no by pass loop installed ...

Page 18: ...ld 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 The Pensotti Heatline Quatech Series boiler should be equipped with a burner that includes a 15 second pre purge control This will ensure smooth quiet starts and proper perform...

Page 19: ...ed in place at al times except during maintenance and servicing Figure 5 Typical wiring for line voltage oil burner with Honeywell L7248 and one heating zone Caution If using a multiple switching relay run low voltage wire from the XX terminals to the TT terminals on the L7248 relay You will not be able to use the circulator relay in the L7248 ...

Page 20: ...BURNER CIRCUIT CIRC PUMP T T 5 6 4 3 1 2 T T1 R1 WC1 CARLIN 90000B E Z TEMP R1 Relay R845A or equiv TT1 Low Voltage Thermostat WC1 Low Water Cutoff white white red white black black Figure 6 Typical wiring for line voltage burner oil or gas with one heating zone ...

Page 21: ...v TT1 Low Voltage Thermostat WC1 Low Water Cutoff WC1 Factory Pre Wired Controls Sideshot Terminal Strip Tjernlund SideShot Shown for Reference Only Any Listed Model may be used CARLIN 90000B E Z TEMP black white red white white black Figure 7 Typical wiring for line voltage burner oil or gas with one heating zone and power venter ...

Page 22: ...hermostat TT2 Low Voltage Thermostat DHW Water Heater Control WC1 Low Water Cutoff WC1 ZONE 1 ZONE 3 ZONE 2 ZC X ZONE 1 ZONE 3 ZONE 2 CIRC PUMP DHW PUMP TT1 TT2 R1 X ZR POWER CARLIN 90000B E Z TEMP white red white white black Figure 8 Typical wiring for line voltage burner oil or gas with two heating zones and indirect hot water heater ...

Page 23: ...ate draft that is in accordance with local regulations and NFPA 211 and NFPA31 Before using the boiler it must be connected to an independent chimney flue Insufficient and shared flue pipes should be avoided Never use an adjustable damper in the chimney or flue pipe The internal diameter of the chimney flue should be at least 6 inch For connection of the boiler flue outlet to the chimney a 6 inch ...

Page 24: ...rs in a mechanical draft application the following basic guidelines should be observed according to the venting system in use In addition it is strongly recommended that the applicable precautions for Natural Draft Applications be used For additional information on venting see NFPA211 Draft Regulator The Pensotti Heatline Quatech Series boiler does not normally require a barometric damper but it m...

Page 25: ... the adjuster in its final position make sure that the final firing rate has been set and that all draft settings have been made and are final Roof Clearances Standard roof clearances apply It is the responsibility of the installer to ensure they are adequate Mechanical Draft Applications When using Pensotti Heatline Quatech Series boilers in a mechanical draft application the following basic guid...

Page 26: ...nt it from sagging Follow the national codes for the installation of oil burning equipment in USA NFPA 31 in Canada CAN CSA B139 and local regulations Figure 10 Do not install vent terminals on prevailing wind wall side of structure Moisture and ice may form around terminal Make sure the surface is in good repair and protected from damage Power Venter Applications When using a power venter all of ...

Page 27: ... a two stage fuel unit or a device like the Tigerloop is recommended when the oil supply is located ten feet 10 below the burner The use of double filtration is recommended to ensure maximum longevity of the pump and nozzle The use of a low micron paper filter is also recommended The filter s should be properly sized to the Total Gear Suction Capacity TGSC of the pump in use Leave the existing fil...

Page 28: ...inimum Make certain that correct voltages have been applied to all circuits Check to make sure that oil storage tank is filled with clean 1 or 2 heating oil Make sure that all manual shutoffs are open in the system Set operating controls to desired or recommended settings Following the burner manufacturer s instructions set the oil burner for proper light off and starting Using accurate combustion...

Page 29: ...rs recommendations outlined in the instructions furnished with the control or burner assembly Testing should include a Safe start safety check b Ignition failure c Flame failure d Power failure If the boiler is equipped with a low water cutoff the cutoff should be checked according to manufacturers instructions When no instructions are present follow the guidelines in ASME CSD 1 or as follows 1 Se...

Page 30: ... recommend how often your Pensotti Heatline Quatech Series boiler should be serviced If a problem occurs please check the following before calling your Pensotti Heatline Quatech Series Dealer Be sure there is oil in the tank and that all oil valves are open Be sure the thermostat is set above the room temperature Be sure all switches are on and that fuses are not blown DO NOT TAMPER ANY FURTHER WI...

Page 31: ...ns of the cleaning covers if necessary Re fit the cleaning covers and the fiberglass insulation on the front cleaning cover 6 Re fit the front casing Clean Fuel System and Burner Fuel system and burner must be properly serviced to ensure safe and efficient operation Check burner manual for proper servicing of burner supplied and that the following items are covered Service fuel filter s and fuel u...

Page 32: ...0 98 83 74 85 2 5 x 18 DK2 4 1 00 140 121 106 86 5 6 x 18 DK2 5 1 25 175 151 131 85 6 6 x 18 DK2 6 1 39 194 167 148 86 7 7 x 18 DK2 7 1 60 224 195 171 86 9 7 x 18 DK2 8 1 80 252 222 193 87 1 7 x 18 Pensotti Heatline Quatech Series Burner Specifications PENSOTTI HEATLINE QUATECH SERIES RIELLO SPECIFICATIONS BOILER MODEL BURNER MODEL NOZZLE SIZE PUMP PRESSURE psi TURBULATOR SETTING AIR GATE SETTING ...

Page 33: ...Pensotti Heatline Quatech Series 28 DIRECT VENTING GUIDE ...

Page 34: ... for the installation of oil burning equipment in USA NFPA 31 in Canada CAN CSA B139 and local regulations Installing The Joint Assembly 1 Loosen the gear clamps attached to the adapter sleeve and slide the adapter sleeve over the vent pipe Figure 12 and Figure 13 2 Pull the corrugated inner tube out of the vent pipe for easy access to insert the adapter 3 Apply sealant around the corrugated end o...

Page 35: ... 1 4 diameter hole through the wall slightly larger than the O D of the terminal 3 Pull apart the inner and the outer terminal sections 4 Slide the outer wall plate over the outer section of the terminal until it rests against the bead 5 From the outside of the building insert the outer section through the hole until it rests against the wall 6 From the inside of the building Figure 13 slide the i...

Page 36: ...ction with the aluminum tape and secure using air intake clamp Beaded end of the air intake clamp should go first over the air intake collar 9 Seal the gap between the vent pipe and the inner section with silicone sealant Connections To Appliance Using Figure 18 Figure 19 Figure 20 and Figure 21 complete the following steps 1 Connect the appliance adapter to the vent pipe as per joint assembly 2 A...

Page 37: ...ine Quatech Series 32 Maintenance PNA and Flex L International Inc recommends the entire heating system including the appliance and vent to be checked annually by a qualified heating professional Figure 16 Figure 17 ...

Page 38: ...Pensotti Heatline Quatech Series 33 Figure 18 Figure 19 Figure 20 Figure 21 ...

Page 39: ... Length CFV204 CeraFlex Appliance Adapter w Pt 6 4 CFAA64P CeraFlex Terminal Adapter 4 4 CFAT44 CeraFlex Vent Terminal 4 CFT4 CeraFlex Air Intake Flex 10 x4 L10 04 CeraFlex Air Intake Flex 15 x4 L15 04 CeraFlex Air Intake Flex 4 L20 04 CeraFlex Air Intake Clamp 4 CFGC4 Riello BF Air Adapter 3 4 CFBA34 RL CeraFlex Sealant 70ml XMM SC5 NOTE Other components may be available upon request ...

Page 40: ...Pensotti Heatline Quatech Series 35 ...

Page 41: ...ASS B WASHER A10 5 22a SIGHTGLASS FRAME INSULATION C NUT M10 22b SIGHTGLASS INSULATION D STUD M10 X 40 24 FRONT DOOR REFRACTORY E NUT M8 25 27 29 2ND PASS RETARDERS F WASHER A8 4 26 28 3RD PASS RETARDERS G SETSCREW M5 X 15 30 DELIVERY STUB PIPE H NUT M6 31 RETURN STUB PIPE J WASHER A6 4 44 BLANK FLANGE K STUD M6 X 22 47 SMOKEHOOD DIA 150 MM L SELF TAPPING SCREW S6 3 X 30 50 SMOKEHOOD CLEANING COVE...

Page 42: ...RTHER TECHNICAL INFORMATION CONTACT PNA Inc 242 Miller Street PO Box 8085 Bangor ME 04402 207 942 3636 This manual was prepared by FIREDRAGON ENTERPRISES 132 Lowell Street Arlington MA 02474 2756 781 646 2584 Copyright 1997 2006 George Lanthier ...

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