Absolute ABS-1500 Manuale utente
Gas-Fired Condensing Hot Water Boiler
Installation and Operating Manual
Innovative Industrial Inc.
ABS 1500-2000-2500-3000-4000/V.01/4/2016
ABS - 1500
ABS - 2000
ABS - 2500
ABS - 3000
ABS - 4000
CAUTION
Please read this manual and retain a copy for future
reference. Improper Installation, adjustment, alterations,
service or maintainer can cause serious injury, property
damage or death. Refer to this manual for assistances
or additional information or consult a qualied installer,
service agent.
Innovative Industrial Inc.
122 Burton Street
Hamilton, Ontario, Canada L8l 3R5
-Cast Aluminum Sectional Heat Exchanger
- 10 to 1 Turndown
- Honeywell Sola Boiler Control System
- Compact Light Weight Packaged Boiler
- Five Models from 1,500 to 4,000 MBH
- Low NOxStandard
- Fully Packaged CSA/ASME Boilers
Document # 2050-20
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CATION
Before you install and operate this boiler, please read this manual carefully in its entirety. If for whatever reason you
are not clear of any details, please do not hesitate to contact us as shown below. Please read all safety and warnings
symbols. The installation and service manual is part of the documentation along with the boiler. The installer is to
explain the function of the boiler and heating system, before the boiler goes into full service.
For service or parts, contact your local sales representative.
Notice: In the interests of technical progress, the information in this installation and service manual is subject to change without
prior notice from Innovative Industrial Inc.
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Contents
1. SAFETY INSTRUCTIONS 6
1.2 Symbols 6
1.2 General safety notes 7
1.3 Lighting Instructions 8
2.2 Operational principal of boiler 11
2.3 View of boiler for service connections 11
3. Technical Data 12
3.1 Boiler Version 13
3.2 Technical Data Sheet 15
3.3 Absolute Boiler Specications: 16
3.4 Ordering options: 17
3.5 Pressure relief valve requirements 17
4. Installation: 18
4.1. General installation Instructions 18
4.2. Delivery and installation 18
4.2.1 Site preparation 19
4.2.2 Hoisting the boiler 19
4.2.3 Multiply boiler arrangements 20
4.3 Flue gas discharge and air supply 22
4.3.1 General 22
4.4 Boiler Venting Types 22
4.4.1 Venting options 23
4.4.2 Vent Termination Inlet/Outlets 23
4.4.3 Combustion Air Supply Requirements 23
4.4.4 Room combustion air supply requirements: 24
4.4.5 Conventional vent system clearances 24
4.4.6 Co-venting – Retrotting: 27
4.4.7 Vent terminations installation precautions: 29
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4.5 Condensate drain connection and trap 30
4.6 Water connection 31
4.6.1 Water pressure 32
4.6.2 Safety valve 32
4.6.3 Water treatment 33
4.6.4 Water Flow 34
4.6.5 Typical water system layout 35
4.6.6 Frost Protection 36
5. Electrical 36
5.1 General 36
5.2 Main power voltage 36
5.2.1 Sola Model R7910A-1027 37
5.2.2 Honeywell Sola R7910A 1027 control (sheet 1-12) 37
5.3 Power consumption 53
5.4 Limit Controls 53
5.4.1 Temperature control 53
5.4.2 Low water level protection (LWCO) (ow and content) 53
5.4.3 High limit protection 53
5.4.4 Air pressure switch 53
5.4.5 High gas pressure switch (HGP) 54
5.4.6 Low gas pressure switch (LGP) 54
6 Gas connection 55
6.1 Gas connection 55
6.1.2 Manual gas valve upstream of boiler (The manual valves supplied by others) 55
6.1.3 Gas line piping to boiler 56
6.2 Gas pressures 56
6.3 Gas / air ratio control 57
6.4 Gas valve adjustment 57
7. Commissioning: 60
7.1 Pre operational checks 60
7.2 Safety and lighting instructions 60
7.3 Combustion setting and adjustment 61
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8. Operator Interface Display 63
8.1 Honeywell Sola Control Programming/Conguration 64
8.2 Programming Access: 64
9. COMMISSIONING 66
9.1 Pre operational checks 66
9.2 Safety checks and lighting instructions 66
9.3 Commissioning Steps 67
9.4 IMPORTANT SAFETY WARNING: 69
10 Commission report 72
10.1 Installation and Location details 72
11 Maintenance 73
11.1 General Maintenance 73
11.1.1 Inspection of air box and dirt trap 73
11.1.2 Cleaning the Whirlwind 73
11.1.3 Cleaning the fan 74
11.1.4 Cleaning the heat exchanger 74
11.1.5 Cleaning the burner assembly 75
11.1.6 Cleaning the siphon 75
11.1.7 Cleaning/replacing the ignition/ionization rod 76
11.1.8 Filter maintenace and lter replacement 76
11.1.9 Sight glass cleaning 77
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1. SAFETY INSTRUCTIONS
1.2 Symbols
The following symbols are used in this document to emphasize certain instructions. This is in order to increase your
personal safety and to safeguard the technical reliability of the boiler.
CAUTION Indicates a potentially hazardous situation which, if ignored, may result in minor injury or product/
property damage.
WARNING Indicates a potentially hazardous situation which, if ignored, can result in danger, serious injury or
substantial product/property damage.
DANGER
Indicates the presence of a hazardous situation which, if ignored, will result in death, serious injury
or substantial product/property damage.
READ
Indicates recommendations made by EnerPro Boilers for the installers which help to ensure optimum
operation and longevity of the equipment.
Professional licensed heating
contractor
The assembly, installation, adjustment,
service and maintenance of this boiler must
be performed by a professional licensed
heating contractor.
Boiler Documentation
Make sure to read all documentation related
to the product before starting the installation.
The product documentation should be stored
near the boiler where it can be accessed
for future reference.
Advice for the owner
When the installation has been
completed, the heating contractor has to
familiarize the operator/owner with the
installed equipment as well as any safety
precautions and requirements, and shut-
down procedures. The heating contractor
also needs to inform the operator/owner
of the need for professional annual
servicing of the boiler prior to the heating
season.
Contaminated air
Chemicals can contaminate the air and
cause by-products during the combustion
process. These by-products are poisonous
to the occupants and very destructive to
EnerPro boilers.
Carbon monoxide
Flue products can ow into living spaces if
improperly installed, adjusted, serviced or
maintained. The ue gases contain carbon
monoxide which is poisonous.
Fresh air
Adequate ventilation and combustion air
must be provided for the equipment as it
requires fresh air for safe operation. Make
sure the equipment is installed ensuring
an adequate supply of fresh air.
Boiler venting
Always operate the boiler with an installed
vent system. Carbon monoxide poisoning
can be caused by an improperly installed
vent system. All combustion products must
be vented safely to the outdoors.
i
Some products may not be exactly as illustrated.
Information contained herein is deemed as accurate
as possible. Clarication of material supply, pipe
sizing, thread type, and typographical errors
should be noted as soon as possible. Dimensions
have been converted from the Metric standard.
Fractional rounding may aect dimensional
tolerances.
Warranty
The information in this manual and any other related
manuals must be read and proper procedures followed.
The warranty is rendered null and void if the procedures
are not followed as prescribed.
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1.2 General safety notes
Installers and operational personnel must at all times observe all safety regulations. The following warnings and cautions
are general and must be given the same attention as specic precautions included in these instructions.
The installation must conform to the requirements of their authority having jurisdiction or, in the absences of such
requirements, with the National Fuel Gas Code ANSI Z223.1/NFPA 54 and /or Natural Gas and Propane Installation
Code, CAN/CSA B149.1
Where required by the authority having jurisdiction, the installation must conform to the Standards for Control and
Safety Devices for Automatically Fired Boiler, ANSI/ASME CSD1
Product is CSD-1 complaint. Authorities having jurisdiction should be contacted before installations begin.
DANGER
Flue gas products contain carbon monoxide gas
which can cause nausea or asphyxiation, resulting
in severe personnel injury or death!
WARNING
The boiler is connected to 120 VAC 1ph and/or 230 VAC
3 ph. An improper installation or attempts to repair
electrical components or controls may result in life
threatening situation. Always disconnect main service
to boiler before servicing.
WARNING
Only properly qualied personnel that hold all necessary
licenses shall work on the installation and service of this
boiler. Unlicensed and untrained service technicians are
strictly prohibited from installing or servicing this boiler
WARNING
Do not touch the boiler; hot surfaces can be a burn hazard.
WARNING
Pressure hazard! Annually test safety relief valve for proper
operation. Do not operate boiler with faulty relief valve.
WARNING
The boiler must not be installed on carpet.
WARNING
Do not stand on top of this boiler, or place items on top
of the boiler.
WARNING
The boiler must not be modied or tted with non OEM
spare parts without the express written approval of
Innovative Industrial Inc.
WARNING
If you smell gas, turn the boiler o immediately, by
shutting o the gas supply downstream of the boiler.
Do not try to light or operate any appliances, evacuate
all people. Do not touch any electric switch; do not use
any phone in the building. If you cannot reach your gas
supplier, call the re department, using a phone outside
the building.
WARNING
Lifting hazards! Use properly rated lifting equipment to
lift and position the boiler.
WARNING
Pressure hazard! Hot uids. Install isolation valves on
boiler water inlet and outlet. Make sure isolation valves
are closed before servicing boiler.
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TO TURN OFF GAS TO APPLIANCE
Operating Instructions
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a re or explosion
may result causing property damage, personal injury or loss of life
1- STOP! Read the safety information above on this label.
2- Set thermostat or other operating control to lowest
setting.
3- Turn o all electric power to the appliance
4- This appliance is equipped with an ignition device which
A. This appliance does not have a pilot. It is equipped
with an ignition device which automatically lights the
burner. Do not try to light the burner by hand.
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the oor because
some gas is heavier than air and will settle on the oor.
WHAT TO DO IF YOU SMELL GAS
. Do not try to light any appliance.
. Do not touch any electric switch; do not use any phone
in your building.
. Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
. If you cannot reach your gas supplier, call the re
department.
C. Use only your hand to turn lever operated manual
gas shut-o valves. If the lever handle will not turn
by hand, call a qualied service technician or the gas
supplier.
D. Do not use this appliance if any part has been under
water. Immediately call a qualied service technician
to inspect the appliance and to replace any part of the
control system and any gas control which has been
under water.
automatically lights the burner. Do not try to light the
burner by hand.
5- Close main gas shut-o valve.
6- Wait ve (5) minutes to clear out any gas. Then smell
for gas, including near the oor. If you smell gas,
STOP! Follow “B” in the safety information above on
this label. If you don’t smell gas, go to the next step.
7- Open main gas shut-o valve.
8- Turn on all electric Power to the appliance.
9- Set thermostat of other operating control to desired
setting.
10- If the appliance will not operate, Follow the instructions
“To Turn O Gas To Appliance” and call your service
technician or gas supplier.
1- Set thermostat or other operating control to lowest
setting.
2- Turn o all electric power to the appliance if service
is to be performed.
3- Close main gas shut-o Valve.
Open
Manual Gas Shut-o
Closed
1.3 Lighting Instructions
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The ABSOLUTE “ABS SERIES” of hydronic heating condensing boilers is a combination of more than 35
years of North American and European engineering experience in condensing boiler technology.
The ABSOLUTE “ABS SERIES” utilizes a durable sectional cast aluminum heat exchanger engineered and
designed in Europe. The cast aluminum provides a robust corrosion resistant heat exchanger that allows for
ultra-high eciencies with the added benet of a small, light weight boiler foot print. The ABSOLUTE “ABS
SERIES” heat exchanger also provides additional eciencies with large water ways, reducing the pressure
drop through the boiler! We are so condent in our heat exchanger, we provide an industry leading warranty.
The fully water cooled combustion chamber host a knitted metal ber premix burner. A turndown ratio of
10:1 allows for ultimate combustion control and reduces short cycling of the boiler. With precise combustion
control the ABSOLUTE “ABS SERIES” is able to achieve CO2 levels that maximize condensation of the
natural gas. Low NOxand CO emissions are the standard with the ABSOLUTE “ABS SERIES”.
The ABSOLUTE “ABS SERIES” incorporated the Honeywell Sola boiler control system for ultimate boiler
control. The Sola allows for quick and easy set-up of the ABSOLUTE “ABS SERIES” of condensing boilers.
The user friendly touchscreen control ensures simplied monitoring and diagnostics along with: multiple boiler
conguration (eight boilers), remote monitoring, fault history, trend analysis, boiler status, communicates
via 3-wire RS-485 ModBus™ protocol, DHW priority.
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