MASCOT Quick Setup Guide

Transcription

1 MASCOT Quick Setup Guide

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3 Minimum Gas Pipe Sizing Guide For Black Iron pipe Refer to Sizing charts for a complete system design Mascot Models Output btu Branch Gas Line HT 330/ ,376 3/4" HT ,262 1" HT ,600 1" Linear Feet Gas Pipe BTUH in Thousands 50 ft 75 ft 100 ft 126 BTUH NG (single residential) 126 BTUH LPG (single residential) 167 BTUH NG (HT 1.45) 167 BTUH LPG (HT 1.45) 242 BTUH NG (HT 1.65) 242 BTUH LPG (HT 1.65) 334 BTUH NG (2-HT 1.45) 334 BTUH LPG (2-HT 1.45) 484 BTUH NG (2-HT 1.65) 484 BTUH LPG (2-HT 1.65) 501 BTUH NG (3-HT 1.45) 501 BTUH LPG (3-HT 1.45) 726 BTUH NG (3-HT 1.65) 726 BTUH LPG (3-HT 1.65) 3/4" 1" 1" 3/4" 3/4" 3/4" 1" 1" 1-1/4" 3/4" 3/4" 1" 1" 1-1/4 1-1/4 1" 1" 1" 1-1/4 1-1/4 1-1/2" 1" 1" 1-1/4" 1-1/2" 1-1/2" 1-1/2" 1-1/4" 1-1/4 1-1/4 1-1/2" 1-1/2" 1-1/2" 1-1/4" 1-1/4 1-1/4 1-1/2" 2" 2" 1-1/4" 1-1/2" 1-1/2"

4 HT 330 VALVE PLACEMENTS Be sure to use the supplied fiber gaskets DO NOT OVER TIGHTEN FITTINGS! Boiler Supply Valve Increase from 3/4 to 1-1/4 T&P Relief Valve This valve is vertical 3/4 Condensate Drain Increase from 5/8 to 3/4 Pot. Water Outlet- No Valve Increase from 1/2 to 3/4 Gas Supply Valve 3/4 Pot. Water Outlet- No Valve Increase from 1/2 to 3/4 Boiler Return Valve w/screen Increase from 3/4 to 1-1/4

5 HT VALVE PLACEMENTS Be sure to use the supplied fiber gaskets DO NOT OVER TIGHTEN FITTINGS! Water Feed Inlet Valve 1/2 with checkvalve Boiler Supply Valve Increase from 3/4 to 1-1/4 T&P Relief Valve This valve is vertical 3/4 Condensate Drain Increase from 5/8 to 3/4 Gas Supply Valve 3/4 Boiler Return Valve w/screen Increase from 3/4 to 1-1/4

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10 Water Pipe Sizing Guide Refer to Sizing Charts for a complete system design Water - BTU formula: GPM X Temp. Change X 500= BTUH Size (copper) 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" Maximum Flow GPM BTUH per 10º F temp. drop BTUH per 20º F temp. drop BTUH per 40º F temp. drop BTUH per 60º F temp. drop BTUH per 80º F temp. drop 1 5,000 10,000 20,000 30,000 40, ,000 40,000 80, , , ,000 80, , , , , , , , , , , , , , , , ,000 1,170,000 1,560, , ,000 1,200,000 1,800,000 2,400, , ,000 1,700,000 2,550,000 3,400,000 SAFE RULES TO FOLLOW ON THE JOB Safely figure 500BTUH per linear foot of most residential baseboard convectors. Maximum length of residential baseboard per circuit is 40ft. Maximum length of 3/4" - 1-1/4" hydronic circuit using a standard circ. Pump is 150ft. Equiv. Length (100 ft. with Mascot internal pump) Maximum concentration of antifreeze in low-mass boilers is 30% (remember antifreeze reduces efficiency and may require LARGER pumps) Outdoor reset sensors should ALWAYS be placed in a location outside the structure that will never "see" sunlight in the heating season. (typically north side under an eave). Increase the boiler intake & discharge pipe opening from 3/4" to 1-1/4" will ensure adequate flow through the Mascot residential boilers. Increase the potable water intake & discharge pipe openings from 1/2" to 3/4" will ensure adequate flow through the Mascot residential combination boilers.

11 LOW LOSS HEADER FOR MASCOT HT & HT SINGLE BOILER INSTALLATION The following instructions are essential for the correct installation of the Low loss header. The Hydronic Package and Connection Kit enables quick installation of a wall-mounted Mascot boiler by providing all necessary plumbing accessories. The assembly requires the following components: LM (Connection Kit for Hydronic package) - Delivery manifold with safety valve fitting - Elbow for safety valve - Delivery shut-off valve (two way) - Return shut-off valve (two way) - Circulator - Check valve - Gaskets: G 2 1/2 - G 1 1/2 G 1 - G 3/4 LM (Hydronic package) - Low Loss Header CA (2 adaptors) - 2 ½ British male to 2 ½ NPT male and 2 IPS female threads. The safety valve 30 p.s.i. (2.1 bar) is supplied with the boiler Figure 1: Assembly Contents 20 Industrial Way, Rochester, NH Fax Kuehner Drive, Simi Valley, CA Fax (Sales, Service) 480 S. Service Rd. West, Oakville, Ontario, Canada L6K 2H Fax Litho in U.S.A. Laars Heating Systems 0603

12 ASSEMBLY Mount the boiler to the wall with the paper template provided with the boiler itself, and following the instructions given in the boiler manual. Use the heating delivery and return fittings (see fittings legend) on the rear of the boiler and move the G 1 blind caps on the horizontal fittings (external boiler coil fittings). There must be a free space of at least 55 inches underneath the boiler. Figure 2: Installation diagram Install the kit pipes and accessories as given in the diagram in figures 2, 3 and 5. Mount the manifolds to the wall with suitable brackets (the pipes weigh 20 kg). Install the safety valve, provided in the boiler, to its fitting (ref. 1 Figure 3) with the G 3/4 elbow. Mount the safety valve outlet to a siphon drain pipe. The expansion vessel (not supplied with the kit) must be dimensioned for the overall capacity of the installation in the normal way, and connected to the check valve (ref. 2 Figure 3). The low loss header supplied with the hydronic package separates the heating plant circulation so as to keep a constant flow of water in the boiler independently of losses of load (ref. 3 Figure 3). The pump supplied with the kit pumps the water between the boiler and the manifolds. The kit includes boiler delivery and return shut-off valves which enables the system to be worked on without having to empty out the entire heating system. Figure 3: Installing components 20 Industrial Way, Rochester, NH Fax Kuehner Drive, Simi Valley, CA Fax (Sales, Service) 480 S. Service Rd. West, Oakville, Ontario, Canada L6K 2H Fax Litho in U.S.A. Laars Heating Systems 0603

13 BOILER CIRCULATOR ELECTRICAL CONNECTIONS The circulator power cable (included in the kit) connects to terminals (11) and (12) of boiler terminal block M3, which can be accessed by opening the front panel (see the boiler instruction manual). Figure 4: Boiler separator electrical connections Figure 5: exploded view showing gasket locations 20 Industrial Way, Rochester, NH Fax Kuehner Drive, Simi Valley, CA Fax (Sales, Service) 480 S. Service Rd. West, Oakville, Ontario, Canada L6K 2H Fax Litho in U.S.A. Laars Heating Systems 0603

14 MULTI-HEADER KIT FOR MASCOT HT & HT FOR CONNECTING BOILERS IN A CASCADE The following instructions are essential for the correct installation of the kit. The Multi header kit enables quick installation of a cascade of wall mounted Mascot HT & HT boilers by providing the following plumbing accessories: - Delivery/return manifolds - Delivery shut-off valve (two way) - Return shut-off valve (two way) - Check valve - Circulator - Elbow for safety valve - Gaskets: G 2 1/2 - G 1 1/2 G 1 - G 3/4 - Blind caps G 2 1/2 G 1 1/2 G 3/4 The safety valve 30 p.s.i. (2.1 bar) is supplied with the boiler. Figure 1: Kit contents Each boiler to be installed requires a separate kit (we recommend not exceeding a maximum of eight boilers in a single cascade) Industrial Way, Rochester, NH Fax Kuehner Drive, Simi Valley, CA Fax (Sales, Service) 480 S. Service Rd. West, Oakville, Ontario, Canada L6K 2H Fax Litho in U.S.A. Laars Heating Systems 0603

15 ASSEMBLY Mount the boiler to the wall with the paper template provided with the boiler itself, and following the instructions given in the boiler manual. Use the heating delivery and return fittings (see fittings legend) on the rear of the boiler and move the G 1 blind caps on the horizontal fittings (external boiler coil fittings). Proceed as follows: - Free space of at least inches underneath the boiler - Boiler spacing 31.5 inches (free space between boilers 7.8 inches). Figure 2: Installation diagram Install the kit pipes as given in the diagram in figure 2. Mount the manifolds to the wall with suitable brackets (the pipes weigh 21 kg per boiler). The main manifolds must be connected by tightening the G 2 1/2 nuts with a wrench of at least 600 mm length. Use a pipe with a G 1 1/2 fitting screwed onto one of the two free fittings on the male collector to stop it turning while doing so. Install the safety valve, provided in the boiler, to its fitting (ref. 1 Figure 3) with the G 3/4 elbow. Mount the safety valve outlet to a siphon drain pipe. The expansion vessel (not supplied with the kit) must be dimensioned for the overall capacity of the installation in the normal way, and connected to one of the fittings on the return manifolds (ref. 2 Figure 3). We recommend dividing up the required total capacity by installing an expansion vessel to the G 3/4 fittings of each boiler (ref. 3 Figure 3) on the return connections (in this case, do not use the G 3/4 cap). The heating system must be separated hydraulically from the delivery and return manifolds with a hydraulic separator (G 2 1/2 fittings). The pump supplied with the kit pumps the water between the boiler and the manifolds. The G 2 1/2 caps install on the terminating section of the left most boiler. The G 1 1/2 caps install on the free fittings of each manifold Industrial Way, Rochester, NH Fax Kuehner Drive, Simi Valley, CA Fax (Sales, Service) 480 S. Service Rd. West, Oakville, Ontario, Canada L6K 2H Fax Litho in U.S.A. Laars Heating Systems 0603

16 The G 3/4 cap installs on the free boiler return fitting (if the expansion vessel is not installed on this fitting). The kit includes boiler delivery and return shut-off valves which enable the system to be worked on without having to empty out the entire heating system, as well as allowing any single boiler to be isolated from the cascade. Figure 3: Installing components 20 Industrial Way, Rochester, NH Fax Kuehner Drive, Simi Valley, CA Fax (Sales, Service) 480 S. Service Rd. West, Oakville, Ontario, Canada L6K 2H Fax Litho in U.S.A. Laars Heating Systems 0603

17 BOILER CIRCULATOR ELECTRICAL CONNECTIONS The circulator power cable (included in the kit) connects to terminals (11) and (12) of boiler terminal block M3, which can be accessed by opening the front panel (see the boiler instruction manual). Figure 4: Boiler separator electrical connections 20 Industrial Way, Rochester, NH Fax Kuehner Drive, Simi Valley, CA Fax (Sales, Service) 480 S. Service Rd. West, Oakville, Ontario, Canada L6K 2H Fax Litho in U.S.A. Laars Heating Systems 0603

18 Doc. H LP Conversion for Mascot HT 3.30 & HT 1.33 / HT & HT The following operations must be performed before calibrating the gas valve. 1. For the HT 3.30 & HT turn the adjuster screw (V) (2.5mm hex) on the gas valve clockwise four complete revolutions. For the HT 1.450,turn the adjuster screw three complete revolutions, and for the HT 1.650, five complete revolutions. V P out K Pl P Pi 2. On the QAA73 remote control, remove the back cover and connect two field supplied thermostat wires to the black terminal block. These wires are then connected to terminals 4 and 5 of the boiler terminal strip (inside control compartment). For HT 3.30 & HT set parameters 608 to 35% and parameter 611 to 3700 rpm. For HT 1.450, leave parameter 608 at 25% and set parameter 611 to 2100 rpm. For HT 1.650, leave parameter 608 at 24% and set parameter 611 to 2000 rpm. Back Cover QAA73 Terminal Strip TO SET PARAMETERS: The editable parameters are those between 504 and 652. Proceed as follows to access these parameters. 1. Simultaneously press keys 1 and 4 on the QAA73 remote control for about 3 seconds. The message Initializing BMU parameters appears on the display. 2. Simultaneously press keys 1 and 2 for about 3 seconds. The message Initializing BMU Service appears on the display. 3. Press keys 1 or 2 to scroll through the list of parameters. 4. To change the value of a selected parameter, press key 3 or 4 to decrease or increase the value respectively. 5. Press key 5 to enter the new values and exit programming of the boiler Industrial Way, Rochester, NH Fax Kuehner Drive, Simi Valley, CA Fax (Sales, Service) 480 S. Service Rd. West, Oakville, Ontario, Canada L6K 2H Fax Litho in U.S.A. Laars Heating Systems 0603

19 Calibration mode: Proceed as follows to enter calibration mode on the boiler control panel and calibrate the gas value. 1. Turn the Mascots control knobs 6 and 7 (figure 26) fully counter-clockwise to their minimum positions as shown in figure 28A. 2. Starting in this position, quickly turn control knob 7 twice consecutively clockwise through about a ¼ turn as shown in figure 28B. Fig. 26 Note: LEDs 2 and 3 (figure 29) flash alternately and the display alternates the message SF and the boiler output temperature about every five seconds (figure 29). 3. Now turn knob 6 to adjust fan speed to a setting between minimum thermal power (0%) and maximum power (100%). Note: In calibration mode, the display alternates between the message P and the boiler output temperature about every 5 seconds. (figure 30). 4. Calibration mode remains active for 20 minutes. To exit calibration mode before this time simply turn control knob 7. Note: This function is interrupted if the central heating delivery temperature reaches its MAX. SETPOINT. Proceed as follows to calibrate the gas valve. 1. Insure your combustion analyzer is set to LPG, insert probe into flue opening on top of boiler, after removing either of the two ¼ turn plugs. 2. Calibrate maximum thermal power by turning knob 6 clockwise to max. With the boiler operating at max output, check the value for CO2 measured in the flue to 10.0 CO2. If necessary, turn the adjustment screw (V) (2.5 mm hex) on the gas valve. Turn clockwise to reduce the CO2 level or counter-clockwise to increase it. 3. Calibrate minimum thermal power. With boiler operating at minimum output by turning knob 6 counterclockwise to minimum setting. Check the CO2 value measured in the flue to 9.8 CO2. If necessary adjust screw (K) (4 mm hex) on the gas valve. Turn clockwise to increase the CO2 level or counterclockwise to reduce it. Note: Allow time between adjustments for your combustion analyzer to sense the adjusted CO2 level. The boiler is now ready for normal operation using LP gas and can be returned to the service mode by turning control knob Industrial Way, Rochester, NH Fax Kuehner Drive, Simi Valley, CA Fax (Sales, Service) 480 S. Service Rd. West, Oakville, Ontario, Canada L6K 2H Fax Litho in U.S.A. Laars Heating Systems 0603

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