PENSOTTI DK2 Series Installation And User Manual
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PENSOTTI DK2 Series Installation And User Manual

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Installation and User Guide
DK2 Series Cast Iron Boiler
Assembly, Operating and Maintenance Instructions

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Summary of Contents for PENSOTTI DK2 Series

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

  • Page 2: Table Of Contents

    PENSOTTI HEATLINE QUATECH BOILER MANUAL TABLE OF CONTENTS Page WARRANTY Inside front Cover JACKET ASSEMBLY INSTRUCTIONS GENERAL INSTRUCTIONS Selection of Boiler Size Receiving Shipment Boiler Location Clearances for Service & Combustible Materials Leveling Unit Burner Tube Insertion COMBUSTION AIR & VENTILATION...
  • Page 3 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...

  • Page 6: General Instructions

    When you purchase a Pensotti Heatline Quatech Series home comfort system your new appliance will be sized on the basis of the new heat loss calculation. This will ensure that your new Pensotti Heatline Quatech Series home comfort system will deliver only the amount of heat required to match your actual home’s heating demand.

  • Page 7: Selection Of Boiler Size

    The correct boiler is selected by matching the boiler's Net I-B-R Rating to the actual heat loss of the building. If the calculated load exceeds the capacity of the largest size Pensotti Heatline Quatech Series boiler, two or more units may be installed. Modular installations can be a sound investment leading to an increase in fuel efficiency.

  • Page 8: Receiving Shipment

    Pensotti Heatline Quatech Series All Pensotti Heatline Quatech Series boilers must be properly sized to provide domestic hot water. Use the water heater manufacturer's charts to determine the correct BTU requirements for domestic hot water service. Alternatively, the ‘K’ factor sizing method, which uses past energy consumption, based on the efficiency of the old appliance and local weather data may also be used.

  • Page 9: Leveling Unit

    Combustion Air and Ventilation If a Pensotti Heatline Quatech Series boiler is being used for a retrofit and is installed in a full basement with adequate infiltration for combustion air it may be installed in the usual way following accepted industry guidelines and good industry practices.

  • Page 10: Air For Combustion

    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.

  • Page 11: Combustion Air Supply With No Barometric Damper

    The Pensotti Heatline Quatech Series is a low mass boiler and care should be taken to ensure that a high volume of water should not be allowed to flood the boiler from a high volume standing cast iron system.

  • Page 12: Assembly Instructions

    The rapid production of corrosion and cold flame temperatures can lead to rapid boiler plugging. The following step-by-step procedure should be followed for connecting the Pensotti Heatline Quatech Series boiler to the existing heat distribution system:...

  • Page 13: Circulation Pump

    The by-pass loop is a must on all standing cast iron radiation systems. This eliminates flooding (cold return) on a low mass boiler and gravity flow during off cycles. If the Pensotti Heatline Quatech Series Boiler is to be used with large water content systems, or the boiler will be placed into use in a low water temperature system such as a converted gravity circulation system, a full size bypass loop is recommended.

  • Page 14: Installation Diagrams

    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.
  • Page 15 Pensotti Heatline Quatech Series Purge Valve Air Vent Air Separator Circulator Flow Check Boiler Feed Piped to Code Pressure Reducing Valve Diaphragm Relief Valve Expansion Tank Control Valve By-Pass Line BOILER Flow Check Burner Drain Valve Piped to Floor (or Code) Figure 2 Figure 2 shows a typical installation with no domestic hot water and with a by-pass loop installed.
  • Page 16 Pensotti Heatline Quatech Series Purge Valve Air Vent Air Separator Heating Circulator Domestic Circulator Relief Valve INDIRECT Boiler Feed Piped to WATER Code Control Valve HEATER By-Pass Line BOILER Flow Check Burner Piped to Drain Valve Floor (or Code) Figure 3 Figure 3 shows a typical installation with domestic hot water supplied by an indirect heater and with a by-pass loop installed.
  • Page 17 Pensotti Heatline Quatech Series Purge Valve Air Vent Air Separator Heating Circulator Domestic Circulator Relief Valve INDIRECT Boiler Feed Piped to WATER Code HEATER BOILER Flow Check Burner Piped to Drain Valve Floor (or Code) Figure 4 Figure 4 shows a typical installation with domestic hot water supplied by an indirect heater and...

  • Page 18: Wiring

    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 performance. Although a post-purge period is not required, a one minute post-purge will make for better operation.

  • Page 19: Electrical Hazard

    Pensotti Heatline Quatech Series Electrical Hazard All electrical devices shall have cover plates, enclosures and guards that must be maintained 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.
  • Page 20 Pensotti Heatline Quatech Series 120Vac 60Hz T T1 R1 = Relay (R845A or equiv.) TT1 = Low Voltage Thermostat WC1 = Low Water Cutoff red/white CARLIN 90000B white TEMP black Line Voltage CIRC. BURNER PUMP CIRCUIT Figure 6 Typical wiring for line voltage burner, oil or gas, with one heating zone.
  • Page 21 Pensotti Heatline Quatech Series CARLIN R1 = Relay (R845A or equiv.) red/white TT1 = Low Voltage Thermostat 90000B WC1 = Low Water Cutoff TEMP black white white 120Vac 60Hz CIRC. PUMP Tjernlund SideShot Line Shown for Reference Only Voltage Any Listed Model may be used...
  • Page 22 Pensotti Heatline Quatech Series Line Voltage BURNER CARLIN CIRCUIT 90000B TEMP white white black 120Vac 60Hz ZONE 1 ZONE 2 ZONE 3 ZONE 1 ZONE 2 ZONE 3 POWER R1 = Relay-TACO SR504 or SR506 TT1 = Low Voltage Thermostat...

  • Page 23: Venting Requirements

    Oil fired appliances shall be connected to flues or vents having sufficient draft at all times to ensure safe and proper operation of the appliance. When venting the Pensotti Heatline Quatech Series boilers, all installations should conform to all national, local and state codes and authorities having jurisdiction.

  • Page 24: Mechanical Draft Applications

    • Chimney connectors should be free of as many 90° degree turns as possible, and be pitched upwards towards the vent. It is important to note that due to the high efficiency of the Pensotti Heatline Quatech Series boilers condensing temperatures in the chimney connector and venting system may be reached.

  • Page 25: 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 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.

  • Page 26: Mechanical Draft Application Diagram

    Pensotti Heatline Quatech Series • At least 1' from any roof soffit or ridge vent. • At least 7' above any public walkway. • All of the vent construction consists of suitable materials, and terminates at an approved stainless steel hood.
  • Page 27 Pensotti Heatline Quatech Series Fuel System Enclosed with each burner are the pump manufacturers' specifications, which the fuel system piping should conform to. In addition the following suggestions are highly recommended. • All fuel system piping must meet local codes and ordinances.

  • Page 28: Start Up Procedure

    Pensotti Heatline Quatech Series CRANKCASE OIL, WASTE OIL, OR GASOLINE SHOULD NEVER BE USED! The danger of explosion and personal injury is VERY HIGH when GASOLINE is present in fuel source! Never attempt to burn garbage or paper in the heating unit and remove all paper and rags from around the unit.
  • Page 29 Pensotti Heatline Quatech Series 1. Set controls with burner service switch turned 'OFF'. 2. Set room thermostat at least 10 °F above room temperature. 3. Set operating limit to maximum. Turn on the burner. After the burner has started and the boiler reaches a temperature of at least 140 °F turn down the operating limit and make sure that it shuts off the burner.
  • Page 30 Pensotti Heatline Quatech Series Service Information - Homeowner Have your Pensotti Heatline Quatech Series boiler, oil burner, flue and venting system serviced at regular intervals by your Pensotti Heatline Quatech Series Dealer. Your dealer will recommend how often your Pensotti Heatline Quatech Series boiler should be serviced.

  • Page 31: Maintenance – Serviceman

    Pensotti Heatline Quatech Series Maintenance - Serviceman Cleaning Of The Boiler Sections: These operations must be carried out when the boiler is out of service: Remove the front casing pulling it up and front wards. 2. Remove the two bolts and open the front swing door to expose the chamber area, second and third passes.

  • Page 32: Pensotti Heatline Quatech Series Boiler Specifications

    86.7 7” x 18’ DK2-7 1.60 86.9 7” x 18’ DK2-8 1.80 87.1 7” x 18’ Pensotti Heatline Quatech Series Burner Specifications PENSOTTI HEATLINE QUATECH SERIES / RIELLO SPECIFICATIONS BOILER BURNER NOZZLE PUMP TURBULATOR AIR GATE MODEL MODEL SIZE PRESSURE...

  • Page 33: Direct Vent Applications

    Pensotti Heatline Quatech Series DIRECT VENTING GUIDE...

  • Page 34: Installing The Joint Assembly

    Pensotti Heatline Quatech Series Figure 11 In addition to all of the previous stated information regarding Natural Draft Applications and Mechanical Draft Applications the following additional instructions for Direct Vent Applications must be followed while referencing Figure 11; • That the maximum wall thickness is no more than 14". Contact PNA for recommendations in case of a thicker wall.

  • Page 35: Installing The Outside Terminal

    Pensotti Heatline Quatech Series 5) Seal around edge of vent pipe inner tube. 6) Slide the adapter sleeve back onto adapter and tighten the gear clamps to complete the connection. 7) If the vent requires cutting to length, a fine toothed hacksaw can be used. Remove any burrs and flare out the end of the inner vent tube for easy installation of the adapter.

  • Page 36: Connections To The Outside Terminal

    Pensotti Heatline Quatech Series 8) Seal with a weatherproof sealant around the bead and edge of the outer wall plate to prevent water from getting inside. Connections To Outside Terminal Using Figure 16 and Figure 17 complete the following steps: 1) Slide the inner section over the vent pipe.
  • Page 37 Pensotti Heatline Quatech Series 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 Figure 18 Figure 19 Figure 20 Figure 21...

  • Page 39: Cera Flex Components

    Pensotti Heatline Quatech Series Ceraflex Components List: Components - 4" Dia. System Part No. CeraFlex Vent Pipe 10' Length CFV104 CeraFlex Vent Pipe 15' Length CFV154 CeraFlex Vent Pipe 20' Length CFV204 CeraFlex Appliance Adapter w/Pt 6"-4" CFAA64P CeraFlex Terminal Adapter 4"-4"...
  • Page 40 Pensotti Heatline Quatech Series...
  • Page 41 Pensotti Heatline Quatech Series Numbe Number PART NAME PART NAME QUATECH PNA - POCKET FOR SENSING DK2 FRONT SECTION BULBS DK2 INTERMEDIATE SECTION TAPPING WITH AIR RELIEF VALVE DK2 REAR SECTION REAR CASING NIPPLE SPECIAL PIN FOR CASING ASSEMBLY STAYBOLTS FIBRE-GLASS ROPE DIA.
  • Page 42 Pensotti Heatline Quatech Series FOR FURTHER 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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