Install Instructions

ManualsBrandsSlant/Fin ManualsBoilers80,000 BTU Q3 Series High Efficiency 3-Pass Oil Boiler (Chimney Vent)

TABLE OF CONTENTS

CONTENTS.......................................................................3

1. INTRODUCTION ...............................................................4

2. SAFETY INFORMATION...................................................5

3. BEFORE YOU START.......................................................6

4. RATINGS & CAPACITIES .................................................7

5. LOCATING THE BOILER ..................................................8

6. INSTALLATION REQUIREMENTS....................................9

7. FRESH AIR FOR COMBUSTION....................................10

8. BOILER ASSEMBLY .......................................................12

9. BOILER SYSTEM PIPING ..............................................16

10. HYDRONIC PIPING ........................................................17

11. FUEL SUPPLY PIPING ...................................................20

12. ANTIFREEZE IN THE SYSTEM......................................21

13. ELECTRICAL CONNECTIONS .......................................22

14. CHIMNEY AND VENTING CONNECTIONS ...................23

15. FILLING BOILER.............................................................26

16. OPERATING THE BOILER - SYSTEM START-UP.........27

17. OIL BURNER, NOZZLE, & AIR SETTINGS ....................31

18. MAINTENANCE ..............................................................32

19. OIL BOILER / BURNER CLEANING INSTRUCTIONS ...34

20. TROUBLESHOOTING ....................................................36

21. EQUIPMENT AND ACCESSORIES ................................38

MODELS Q3-4, Q3-5, Q3-6 and Q3-7

INSTALLATION, OPERATION & MAINTENANCE MANUAL

IMPORTANT

READ ALL OF THE FOLLOWING WARNINGS AND STATEMENTS

BEFORE READING THE INSTALLATION INSTRUCTIONS

This manual

must be left

with owner and

should be hung

on or adjacent

to the boiler

for reference.

High Efficiency 3-Pass

Oil Fired Hot Water Boiler

©Slant/Fin Corp. 2017 •

917 • PN 473900000 • PUBLICATION Q3-40

Heating Contractor

Address

Phone Number

Boiler Model Number

Boiler Serial Number

Installation Date

DANGER

Danger Sign: Indicates a hazardous situation which,

if not avoided, WILL result in serious injury or death.

Indicates a hazardous situation which, if not

avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could

result in minor or moderate injury.

Used to address practices not related

to personal injury

Installations of boilers and venting shall be done only by a

qualified expert and in accordance with this manual. Installing

or venting a boiler or any other oil appliance with improper

methods or materials may result in serious injury or death due

to fire or to asphyxiation from poisonous gases such as

carbon monoxide which is odorless and invisible.

WARNING

CAUTION

NOTICE

WARNING

SEE ALL WARNINGS AND NOTICES ON PAGES 4 & 5

FOR U.S. SALES ONLY

Summary of content (40 pages)

PAGE 1
FOR U.S. SALES ONLY ® Q3 US This manual must be left with owner and should be hung on or adjacent to the boiler for reference. High Efficiency 3-Pass Oil Fired Hot Water Boiler MODELS Q3-4, Q3-5, Q3-6 and Q3-7 INSTALLATION, OPERATION & MAINTENANCE MANUAL IMPORTANT READ ALL OF THE FOLLOWING WARNINGS AND STATEMENTS BEFORE READING THE INSTALLATION INSTRUCTIONS ! DANGER ! WARNING ! CAUTION Danger Sign: Indicates a hazardous situation which, if not avoided, WILL result in serious injury or death.
PAGE 2
DIMENSIONS DIMENSIONS 7⅝" Top panel removed to shown boiler control located under top panel. 1-1/4" NPT Supply Relief Valve TOP OF BOILER 32⅛" 2¼" 5⅝" 4¾" 29⅛" 17¾" 25⅛" 20¼" 10½" 3½" ¾" "DIM A" 15" 3/4" NPT For Drain Valve 3½" 1-1/4" NPT Return FRONT VIEW RIGHT SIDE VIEW REAR VIEW DIMENSIONS Model Q3-4 Q3-5 Q3-6 Q3-7 Dimension "A" Inches (cm) Flue Size Inches (cm) 5 5 5 6 (13) (13) (13) (15) 18 21 24 28 2 ⅜ (46.6) ⅝ (54.8) ⅞ (63.1) ⅛ (71.
PAGE 3
TABLE OF CONTENTS 1 - INTRODUCTION......................................................................................................... 4 2 - SAFETY INFORMATION................................................................................................ 5 3 - BEFORE YOU START.................................................................................................... 6 4 - RATINGS & CAPACITIES..............................................................................................
PAGE 4
1 - INTRODUCTION ! WARNING NOTICE Installations of boilers and venting shall be done only by a qualified expert and in accordance with this manual. Installing or venting a boiler or any other oil appliance with improper methods or materials may result in serious injury or death due to fire or to asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible. Surface rust on cast iron sections may be attributed to manufacturing process as well as condensation during storage.
PAGE 5
2 - SAFETY INFORMATION 2.1 General ! WARNING Boiler installation shall be completed by qualified agency. Construction materials of appliance and products of combustion and fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and /or other toxic or harmful substances which can cause death or serious injury and which are known to the State of California to cause cancer, birth defects and other reproductive harm.
PAGE 6
3 - BEFORE YOU START 3.1 Installation and Operation 3.2 Prior To Installing The Boiler 1. Do not operate unit if any control, switch, components 2. 3. 4. 5. 6. 7. 8. 9. 10. • Verify you have selected right size boiler with proper capacity. AHRI rating of boiler selected should be greater than or equal to calculated peak heating load (heat loss) for building or area(s) served by boiler and associated hot water heating systems. Use heat loss calculations based on approved methods. See Table 1, Page 7.
PAGE 7
4 - RATINGS & CAPACITIES Table 1 - RATINGS & CAPACITIES OIL-FIRED HOT WATER BOILERS Model Number of Sections Firing Rate [GPH] Input [Mbh] Q3-4 4 0.75 105 Q3-5 5 1.00 140 Q3-6 6 1.30 182 Q3-7 7 1.65 231 Net AHRI Rating [Mbh] *MAWP Water [psi] AFUE [%] 92 80 65 87.0 92 5 123 107 65 87.0 123 5 160 139 65 87.0 160 5 202 176 65 87.0 202 6 Heating Capacity [Mbh] Min. relief Flue Valve Size Capacity [Inches] [Mbh] GPH = U.S.
PAGE 8
5 - LOCATING THE BOILER 7. Fresh air for combustion and ventilation must be ! WARNING Fire hazard. Do not be install on carpeting. Failure to follow these instructions could result in death or serious injury. 8. 1. Boiler is suitable for installation on combustible flooring. Do not install boiler on carpeting. 9. 2. Locate boiler in front of final position before removing 3. 4. 5. crate. Locate unit so vent pipe connection to chimney will be short and direct.
PAGE 9
6 - INSTALLATION REQUIREMENTS Figure 2 - General Requirements For A Typical Installation RELIEF VALVE CHECK LOCAL CODES FOR MAXIMUM DISTANCE FROM FLOOR, OR OTHER ALLOWABLE SAFE POINT OF DISCHARGE. NOTICE Shut off manual fuel supply valve if burner is shut down for extended period of time.
PAGE 10
7 - FRESH AIR FOR COMBUSTION ! WARNING Alternate method for boiler located within confined space: Use indoor air if two permanent openings communicate directly with additional space(s) of sufficient volume such that the combined volume of all spaces meet criteria for unconfined space. Size each opening for minimum free area of 1 square inch per 1,000 BTU per hour input of all equipment in spaces, but not less than 100 square inches. Asphyxiation, fire hazard.
PAGE 11
7 - FRESH AIR FOR COMBUSTION Fresh Air Duct Capacities For Ducts Supplying Fresh Air To Boiler In Tightly Constructed Houses Table 3 - FRESH AIR DUCT CAPACITIES THROUGH LOUVERS ¼” Mesh Screen Wood Louvers Metal Louvers (Btuh)* (Btuh)* (Btuh)* 3 ½” x 12” 144,000 36,000 108,000 8” x 8” 256,000 64,000 192,000 8” x 12” 384,000 96,000 288,000 8” x 16” 512,000 128,000 384,000 Fresh Air Duct Size *Btuh = British Thermal Units per hour based on opening covered by ¼” mesh screen , wood louver
PAGE 12
8 - BOILER ASSEMBLY 1. Remove Crate Figure 5 - Reversible Hinge A. Remove all fasteners at crate skid. B. Lift outside container and remove all other inside protective spacers and bracing. Remove burner and miscellaneous parts boxes. 2. Remove Boiler from skid. Boiler is secured to base with 4 screws. Remove all securing hardware. 3. Move boiler into permanent position by sliding or walking into place. 4. Do not drop boiler. Do not bump boiler jacket against floor. 5.
PAGE 13
8 - BOILER ASSEMBLY 12. Check installation of liners and baffles (Not all ! WARNING models). See Table 4, Page 14. A. Check oval (4 section) or V-shaped (6 and 7 section) liner. See Figures 9 & 10. Liner should be flush with front edge of heat exchanger fins. B. Flue way baffles (4, 5, 6 section only) are factory installed in 3rd pass. Insure baffles are inserted in flue way such that position tab touches casting between 2nd and 3rd Pass flue way. See Figure 11, Page 14. Burn and scald hazard.
PAGE 14
8 - BOILER ASSEMBLY B. Use hand wrench to tighten door hardware and start with non-hinged side. Use alternating tightening method from non-hinged side to hinged side to tighten door equally until sealed without applying excessive torque. Never tighten hinged side flange bolt first or tighten either piece of hardware 100% without using alternating tightening method described above. Figure 9 - Oval Liner NOTICE When securing burner swing door, make sure door is drawn-in equally on both sides.
PAGE 15
8 - BOILER ASSEMBLY Figure 12 - Circulator Wiring BLACK TO YELLOW WHITE TO WHITE NOTICE Ensure all conduit is secured to prevent contact with flue pipe Figure 13 - Drain Valve DRAIN VALVE 15 PN 473900000
PAGE 16
9 - BOILER SYSTEM PIPING 9.1 Connect System Supply And Return Piping To Boiler 9.2 Bypass Piping Connect system supply and return piping to correct boiler fittings. Bypass piping may be required for applications listed below. Failure to do so may cause damage due to thermal shock and sustained condensation within the boiler. See Piping Diagrams for illustrations for this section. Size system circulator to supply sufficient flow (GPM) to allow 20°F temperature differential in system.
PAGE 17
10 - HYDRONIC PIPING Figure 14 - Standard Near Boiler Piping Piping Diagram Legend 17 PN 473900000
PAGE 18
10 - HYDRONIC PIPING Figure 15 Bypass Piping (Fixed Low Temperature Only) Adjust two throttling valves to maintain at least 130°F - 140°F in boiler return.
PAGE 19
10 - HYDRONIC PIPING Figure 17 - Bypass Piping (4-Way Valve Option With Circulator On Supply Side) TO SYSTEM FROM SYSTEM WATER INLET EXPANSION TANK BOILER ALTERNATE CIRCULATOR LOCATION Figure 18 - Recommended Piping for Combination Heating and Cooling (Refrigeration) System CIRCULATOR PRESSURE REDUCER VALVE SHUT-OFF VALVE CHECK VALVE BALL VALVE AIR SEPARATOR WATER CHILLER 4-WAY MIXING VALVE HOSE BIB FLOW CONTROL VALVE BOILER SHUT OFF VALVES SHUT OFF VALVES AIR CUSHION TANK CIRCULATOR RETUR
PAGE 20
11 - FUEL SUPPLY PIPING 11.1 Installation of oil tank and piping shall conform to requirements of authority having jurisdiction or in absence of such requirements National Board of Fire Underwriters. In addition, refer to NFPA 31 (U.S.). Installation of oil storage tank, vent, fill pipe and caps shall conform to requirements of authority having jurisdiction. Figure 20 - Double Pipe Oil Line • In no case should vent pipe be smaller than 1¼" I.P.S. • Fill pipe should not be less than 2" I.P.S.
PAGE 21
12 - ANTIFREEZE IN THE SYSTEM 12.1 Antifreeze added to boilers must be nontoxic, and must be of type specifically intended for use in closed hydronic heating systems. Under no circumstances should automotive antifreeze be used. Antifreeze used in any boiler may reduce capacity by 10% or more and increase fuel consumption. See Table 6 and 7. Table 7 - PIPING WATER VOLUMES Table 6 - BOILER WATER VOLUMES Number of Boiler Section 4 5 6 7 Total Volume (Gallons) 3.6 4.3 5.1 5.
PAGE 22
13 - ELECTRICAL CONNECTIONS ! WARNING 13.1 Electrical wiring shall conform to requirements of authority having jurisdiction or in absence of such requirements ANSI/NFPA No. 70. Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury. Run separate electrical circuit from entry box with fused disconnect switch in this circuit.
PAGE 23
14 - CHIMNEY AND VENTING CONNECTIONS 14.1 Chimney Venting Oil fired boilers with connections to vents or chimneys, vent installation shall conform to requirements of authority having jurisdiction or in absence of such requirements NFPA 31 Installation Of Oil Burning Equipment (U.S.) and applicable provisions of local building codes.
PAGE 24
14 - CHIMNEY AND VENTING CONNECTIONS 1. Chimney connector should be kept as short as possible. 2. 3. • Over-fire Draft - Measure pressure at 1/4” NPT test port. Three pass boilers have higher pressure drop than single pass. Table 9 shows expected pressure drop between over-fire and breech. Total pressure drop is difference between over-fire draft and breech draft. For example, if over-fire draft = 0.05 INWC and breech draft = - 0.05, total pressure drop = 0.05 - (-0.05) = 0.10 INWC.
PAGE 25
14 - CHIMNEY AND VENTING CONNECTIONS Figure 21 - Proper Draft Regulator Locations Figure 23 - Pressure Tapping for Checking Draft Figure 22 - Typical Chimney Locations Minimum height must be at least 3 Ft higher than highest part of passage through roof. Must be at least 2 FT higher than any neighboring object within 10 Ft. Must have unobstructed top opening. 1/4”NPT TEST PORT FOR OVER-FIRE MEASUREMENT Must be at least 4 inches thick and be tight.
PAGE 26
15 - FILLING BOILER ! WARNING NOTICE Boiler maximum operating pressure is posted on ASME data label located on front lower leg of boiler. Never exceed this pressure. Do not plug relief valve. Fire, burn, asphyxiation hazard. Turn off service switch to boiler to prevent accidental firing of burner outside combustion chamber. Disconnect burner power cord from wire harness in front jacket. Tighten swing door fastener completely when service is complete.
PAGE 27
16 - OPERATING THE BOILER - SYSTEM START-UP 16.1 Setting The Limit Control Figure 24 - Limit Setting can be verified using TEST/SETTINGS button. See Page 28. 16.2 Setting High Limit To adjust, turn HI TEMP dial A until desired setting is displayed. See Figure 24. Overall range of High limit setting is from 100°F to 220°F (82° C to 104° C). High limit (HL) on limit control is factory set at 190°F. Temperature setting may be varied to suit requirements of installation.
PAGE 28
16 - OPERATING THE BOILER - SYSTEM START-UP 16.6 Activating Thermal Pre-Purge (optional) Figure 26 - LED Legend Activation of this feature is not recommended for boilers with tankless coils. • Limit has thermal pre-purge feature to maximize efficiency. When activated, control will purge higher boiler temperatures down to 135°F at start of any thermostat call and supply latent energy in boiler to heating zone calling. • During purge cycle, display will indicate PUR.
PAGE 29
16 - OPERATING THE BOILER - SYSTEM START-UP ! WARNING 6 ECONOMY TARGET Economy feature is active, limit control continually sets target temperatures below high limit setting to maximize fuel efficiency. When boiler water reaches target temperature, LED illuminates and burner shuts down. Boiler water will continue to circulate and heat the house as long as thermostat call continues.
PAGE 30
16 - OPERATING THE BOILER - SYSTEM START-UP 4. Final Burner Adjustments: Final burner adjustments must be made using combustion test instruments. A. Check breech draft to verify between 0.00” WC and -0.05” WC, or otherwise adjust draft to -0.05” WC (or less than zero.) B. After operating 10 minutes to warm up boiler, use combustion test equipment to take smoke reading in flue pipe between boiler and draft regulator. Smoke reading should be zero to trace (Shell Bacharach Scale). C.
PAGE 31
17 - OIL BURNER, NOZZLE, & AIR SETTINGS Figure 27 - Riello Electrode Setting Figure 28 -Riello Turbulator Setting Turbulator Setting A. Loosen nut (1) turn SCREW (2) until INDEX MARKER (3) is aligned with correct index number as per Burner Settings Table. B. Tighten RETAINING NUT (1). NOTE: Zero and four are scale indicators only. From left to right, first line is 4 and last line 0. On some models, scale indicators are 0 and 3.
PAGE 32
18 - MAINTENANCE ! DANGER 18.3 Relief Valve • Test relief valve for proper operation. Refer to valve manufacturer’s instructions packaged with relief valve. Before servicing, turn off electrical power to boiler at service switch. Turn off fuel supply to burner Failure to comply will result in death or serious injury. 18.4 Conventional Expansion Tank See “Equipment And Accessories” section. NOTICE 18.5 Diaphragm Expansion Tank See “ Equipment And Accessories” section.
PAGE 33
18 - MAINTENANCE • Continue to circulate water for few hours. • Stop firing boiler. • Drain system in a manner and to a location that hot water can be discharged safely. • Remove plugs from all available returns and wash water side of boiler as thoroughly as possible, using high-pressure water stream. • Refill system with fresh water. Steps to inspect, clean and/or replace control well: 1. Turn off electric service to boiler controls. 2. Drain boiler water to level below tapping for control well. 3.
PAGE 34
19 - OIL BOILER / BURNER CLEANING INSTRUCTIONS 2. Clean combustion chamber and baffles. Use wire ! DANGER or fiber bristle brush to clean surfaces of combustion chamber and baffles. Vacuum all of loose debris in bottom of combustion chamber. 3. After cleaning: Vacuum all remaining debris as necessary. Inspect burner swing door insulation, and rope gasket for signs of damage. If damaged, replace as needed. 4. Re-assemble boiler. A. Insert liner and baffles (if equipped) into correct flue way.
PAGE 35
19 - OIL BOILER/BURNER CLEANING INSTRUCTIONS Figure 29 - Cleaning the Boiler FLUE BRUSH 3RD PASS VACUUM HOSE FLUE BRUSH BRISTLE BRUSH VACUUM HOSE FRONT VIEW COMBUSTION CHAMBER & 2ND PASS 35 PN 473900000
PAGE 36
20 - TROUBLESHOOTING 20.1 Combustion A. Nozzles- See “17 - Oil Burner, Nozzle, & Air Settings” on page 31. B. Fuel leaks - Any fuel leak between pump and nozzle is detrimental to good combustion results. Look for wet surfaces in air tube, under ignitor, and around air inlet. Repair any such leaks as they may cause erratic burning of fuel and in extreme case may become fire hazard. C. Dirt - Fuel filter is required to prevent clogging nozzle or nozzle strainer and produce poor spray pattern from nozzle. D.
PAGE 37
20 - TROUBLESHOOTING IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . . POSSIBLE CAUSE WHAT TO DO Thermostat is not set correctly Reset thermostat Burner is not operating properly Adjust burner per instructions. No electric power to boiler Check over-current protection. Check to be sure electric power supply circuit is “ON”. There may be as many as 3 safety shut-off switches installed. Look for a red plate which may be on the service switch.
PAGE 38
21 - EQUIPMENT AND ACCESSORIES 21.1 Limit Relay Control (provided) 21.6 Conventional Expansion Tank (Not Provided) Water temperature limit control in limit relay is adjustable. See Limit instructions for how to set limit temperature. In a properly assembled system, expanding water flows into an expansion tank. 21.
PAGE 39
NOTES 39 PN 473900000
PAGE 40
IMPORTANT In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.