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Absolute ABS-1500 Installation And Operating Manual

Gas-fired condensing hot water boiler
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Gas-Fired Condensing Hot Water Boiler
ABS - 1500
ABS - 2000
ABS - 2500
ABS - 3000
ABS - 4000
- 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 NO
Standard
x
- Fully Packaged CSA/ASME Boilers
Innovative Industrial Inc.
Document # 2050-20
Installation and Operating Manual
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 qualified installer,
service agent.
Hamilton, Ontario, Canada L8l 3R5
ABS 1500-2000-2500-3000-4000/V.01/4/2016
Innovative Industrial Inc.
122 Burton Street

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Summary of Contents for Absolute ABS-1500

  • Page 1 Gas-Fired Condensing Hot Water Boiler Installation and Operating Manual ABS - 1500 ABS - 2000 ABS - 2500 ABS - 3000 ABS - 4000 - Cast Aluminum Sectional Heat Exchanger - 10 to 1 Turndown CAUTION - Honeywell Sola Boiler Control System Please read this manual and retain a copy for future - Compact Light Weight Packaged Boiler reference.
  • Page 2 Absolute Boilers ABS 1500-2000-2500-3000-4000 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.

  • Page 3: Table Of Contents

    Absolute Boilers ABS 1500-2000-2500-3000-4000 Contents 1. SAFETY INSTRUCTIONS 1.2 Symbols 1.2 General safety notes 1.3 Lighting Instructions 2.2 Operational principal of boiler 2.3 View of boiler for service connections 3. Technical Data 3.1 Boiler Version 3.2 Technical Data Sheet 3.3 Absolute Boiler Specifications: 3.4 Ordering options:...
  • Page 4 Absolute Boilers ABS 1500-2000-2500-3000-4000 4.5 Condensate drain connection and trap 4.6 Water connection 4.6.1 Water pressure 4.6.2 Safety valve 4.6.3 Water treatment 4.6.4 Water Flow 4.6.5 Typical water system layout 4.6.6 Frost Protection 5. Electrical 5.1 General 5.2 Main power voltage 5.2.1 Sola Model R7910A-1027...
  • Page 5 Absolute Boilers ABS 1500-2000-2500-3000-4000 8. Operator Interface Display 8.1 Honeywell Sola Control Programming/Configuration 8.2 Programming Access: 9. COMMISSIONING 9.1 Pre operational checks 9.2 Safety checks and lighting instructions 9.3 Commissioning Steps 9.4 IMPORTANT SAFETY WARNING: 10 Commission report 10.1 Installation and Location details 11 Maintenance 11.1 General Maintenance...

  • Page 7: Safety Instructions

    Absolute Boilers ABS 1500-2000-2500-3000-4000 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. Indicates a potentially hazardous situation which, if ignored, may result in minor injury or product/ CAUTION property damage.

  • Page 8: General Safety Notes

    Absolute Boilers ABS 1500-2000-2500-3000-4000 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 specific precautions included in these instructions.

  • Page 9: Lighting Instructions

    Absolute Boilers ABS 1500-2000-2500-3000-4000 1.3 Lighting Instructions FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life This appliance does not have a pilot. It is equipped phone.
  • Page 10 Europe. The cast aluminum provides a robust corrosion resistant heat exchanger that allows for ultra-high efficiencies with the added benefit of a small, light weight boiler foot print. The ABSOLUTE “ABS SERIES” heat exchanger also provides additional efficiencies with large water ways, reducing the pressure drop through the boiler! We are so confident in our heat exchanger, we provide an industry leading warranty.
  • Page 11 The Honeywell and the Sola controls cannot override the standard flame safety controls. External controls or commands can modulate the boiler as required by the BMS. All Absolute boilers are fully test fired after assembly to ensure the boiler and controls comply with our strict quality policy.

  • Page 12: Operational Principal Of Boiler

    Absolute Boilers ABS 1500-2000-2500-3000-4000 2.2 Operational principal of boiler Combustion air is drawn into the inlet connection from the plant room (room ventilated version) or from outside via the air inlet pipe. On the inlet side of the fan is a specially designed chamber which takes gas from the multi-block and mixes it in the correct proportions with the incoming air.

  • Page 13: Technical Data

    Absolute Boilers ABS 1500-2000-2500-3000-4000 3. Technical Data 3 /4 ” 7 /8 ” 1 /2 ” 2 /16 ” Boiler Control Panel 7 /16 ” 5 /16 ” Boiler Supply (150 ANSI Flanged) 4” Boiler Exhaust Connection 10” ID Combustion Air Inlet 10”...

  • Page 14: Boiler Version

    Absolute Boilers ABS 1500-2000-2500-3000-4000 3.1 Boiler Version...
  • Page 15 Absolute Boilers ABS 1500-2000-2500-3000-4000 The service side of the boiler (with the heat exchanger inspection cover) is the front. 1. Pressure Relief valve. 13. Gas Connection 26. Honeywell Touch Screen (manual gas valve by Other) 2. Air Vent. 14. Boiler Drain 27.

  • Page 16: Technical Data Sheet

    Absolute Boilers ABS 1500-2000-2500-3000-4000 3.2 Technical Data Sheet Specifications Unit ABS 1500 ABS 2000 ABS 2500 ABS 3000 ABS 4000 General Firing Sequence Operation Full modulation Minimum Fuel Input MBH[kW] 150 [43.9] 200 [58.6] 250 [73.2] 300 [87.9] 400 [117.2]...

  • Page 17: Absolute Boiler Specifications

    Absolute Boilers ABS 1500-2000-2500-3000-4000 3.3 Absolute Boiler Specifications: Fully assembled cast aluminum floor standing sectional hot water boilers. Premix burner with stainless steel cylinder with perforated holes for precise air-fuel mixture and velocity with a stainless tube with woven steel fiber for stable flame and heat insulation.

  • Page 18: Ordering Options

    Absolute Boilers ABS 1500-2000-2500-3000-4000 3.4 Ordering options: Available in inputs from 1500, 2000, 2500, 3000 and 4000 MBH, 5 models Control options: Honeywell Sola control with touch screen control BMS- available with Sola control/touch screen Service kits for heat exchanger...

  • Page 19: Installation

    CSA & NEC electrical codes Other Regulations WARNING All Absolute boilers are CSA certified, and must not be modified or installed in any way contrary to these “Installation and operations manual. Delivery and installation The Absolute boiler is supplied fully assembled, plastic wrapped and crated on a pallet. The Unit should be completely inspected for evidence of shipping damage and shipping completeness at time of receipt.

  • Page 20: Site Preparation

    Absolute Boilers ABS 1500-2000-2500-3000-4000 4.2.1 Site preparation Ensure that the site selected for the installation has the following: Access to AC input power of 120 VAC for ABS 1500, ABS 2000 and ABS 2500. Access to AC input power of 230 VAC 3 phase for two models ABS 3000 and ABS 4000 Access to a natural gas line at a minimum gas line pressure of 3.5 inch W.C.

  • Page 21: Multiply Boiler Arrangements

    Absolute Boilers ABS 1500-2000-2500-3000-4000 4.2.3 Multiply boiler arrangements Front 36” Back 24” Back 24” Front 36” Front 36” 6” Minimum between boilers Front 36”...
  • Page 22 Absolute Boilers ABS 1500-2000-2500-3000-4000 4.2.4 Setting the boiler in place It is recommended that a house keeping pad 4 to 6 inches high be installed to ensure proper condensate drainage. If anchoring the boiler is required due to local codes for seismic activities potential, ensure 4 holes ¾ diameter by 4 inches deep are drilled in the house keeping pad as per the dimension shown in figure# 4 The boiler frame has been drilled with 4 holes of 7/8 diameter, allowing for a ¾...

  • Page 23: Flue Gas Discharge And Air Supply

    DANGER PVC or CPVC should never be used in the Absolute Boiler. PVC and CPVC is not rated for the potential flue temperatures and failure of this venting material can cause severe personnel injury or death! Use AL 29-4C or stainless steel equivlent venting.

  • Page 24: Venting Options

    Each Absolute boiler is supplied with a ½ inch NPT port to house a flue gas temperature sensor. Each Absolute boiler is supplied with a ¼ NPT test port for a combustion probe. Ensure the test port in sealed after combustion analysis.

  • Page 25: Room Combustion Air Supply Requirements

    Absolute Boilers ABS 1500-2000-2500-3000-4000 WARNING The flue gas vent pipe must be airtight and watertight. Horizontal sections of the venting must slope downward towards the boiler ½” per linear foot [12mm] and adequate vent support must be provided. 4.4.4 Room combustion air supply requirements: The boiler must be provided with an adequate combustion air supply, the combustion air supply requirements must be determined and sized in accordance to national and local codes having jurisdiction.
  • Page 26 Absolute Boilers ABS 1500-2000-2500-3000-4000 WARNING The boiler should never be operated in a negative building pressure. Caution should be exercised with exhaust fans, air handling & other devices, that could affect the buildings air pressure or combustion air supply. All venting must be arranged to avoid and prevent the accumulation of flue gas condensation.
  • Page 27 Absolute Boilers ABS 1500-2000-2500-3000-4000 runs of the venting must slope towards the boiler ¼ to½” per linear foot Chimney applications: This venting system uses a single vent to discharge all flue gases to the outside vertically, combustion air provided with the boiler room, the air source must be sized in accordance to national codes CSA B149 &...

  • Page 28: Co-Venting - Retrofitting

    Absolute Boilers ABS 1500-2000-2500-3000-4000 Application Note: In all applications the venting must be between the minimum and maximum equivalent vent lengths shown in table 5a-b. For values not shown in the chart, consult your local sales representative 4.4.6 Co-venting – Retrofitting:...
  • Page 29 Absolute Boilers ABS 1500-2000-2500-3000-4000 Instructions: Adjust thermostat so appliance will operate continuously. Test for spillage near and around the each of the gas appliances after 5 minutes of main burner operation. After determining that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return all doors, windows, exhaust fan, fireplace dampers and any other gas burning appliance to their normal positions.

  • Page 30: Vent Terminations Installation Precautions

    Absolute Boilers ABS 1500-2000-2500-3000-4000 4.4.7 Vent terminations installation precautions: [Consult national & local codes for other requirements] All exhaust terminations for conventional chimney must be finished with a finishing cone with tapered end, with a bird/ rodent screen. All sidewall, direct vent systems must be finished with a tee termination, the combustion air inlet must be a 90°...

  • Page 31: Condensate Drain Connection And Trap

    4.5 Condensate drain connection and trap The Absolute boiler is fitted with a 1 ¼ NPT drain port near the back and bottom face of the condensate pan. Discharge the condensate directly into a drain. Only use synthetic material for the connecting pipe-work because of the acidity of the condensate (pH 2-5) and allow a min.

  • Page 32: Water Connection

    4.6 Water connection The Absolute boiler is supplied with 4 inch # 150 ANSI flanges for both the inlet and outlet manifolds. It is advisable to install a shut off valve for the both the supply and return to allow removal of the boiler in the future. All water connections should be in compliance with national and local code requirements.

  • Page 33: Water Pressure

    Absolute Boilers ABS 1500-2000-2500-3000-4000 4.6.1 Water pressure The boiler is suitable for a maximum working pressure of 160 psi [10.8 bar], the system pressure shall be at least 12 psi [0.8 bar] 4.6.2 Safety valve A safety relief valve NB certified with V or HV symbol as supplied must be installed on the boiler supply piping without any obstructions.

  • Page 34: Water Treatment

    Absolute Boilers ABS 1500-2000-2500-3000-4000 4.6.3 Water treatment The heat exchanger is manufactured from aluminum alloys which will provide many years of excellent service, if maintained properly. All heat exchangers require proper water conditions to remain efficient and function properly. Failure to do so will lead to premature failures within the heat exchanger. The system should be filled with mains, cold water (this will usually have a pH of between 7 and 8).

  • Page 35: Water Flow

    Absolute Boilers ABS 1500-2000-2500-3000-4000 4.6.4 Water Flow See the chart below for proper water flow requirements. Incorrect flow may cause eventual damage or premature boiler failure that may not be covered under the warranty Proper flow rates may be achieved through a combination of primary and secondary flow loops. Multiple zones and pumps may result in different flow rates at different times Consideration must be given to all possible conditions and their consequences.

  • Page 36: Typical Water System Layout

    Absolute Boilers ABS 1500-2000-2500-3000-4000 4.6.5 Typical water system layout The piping diagram illustrates the minimum boiler system controls needed, the by-pass system is not necessary, but can be used in multiple heating temperature circuits. Consult all national, local and building codes having jurisdiction for other requirements regarding the boiler system.

  • Page 37: Frost Protection

    5.1 General The Absolute Boiler is supplied with an electronic flame ionization safety control, as standard equipment. A specially designed microprocessor is at the heart of the system. The boiler is pre-wired as shown in the wiring diagram in 12.
  • Page 38 Absolute Boilers ABS 1500-2000-2500-3000-4000 Model Voltage/phase Fuse sizes ABS1500 120/60/1 15A fused disconnect ABS2000 120/60/1 15A fused disconnect ABS2500 120/60/1 15A fused disconnect ABS3000 230/60/3 10A fused disconnect ABS4000 5.2.1 Sola Main Control Voltage: 120V AC 60 Hz +10% -15%...
  • Page 39 Absolute Boilers ABS 1500-2000-2500-3000-4000...
  • Page 40 Absolute Boilers ABS 1500-2000-2500-3000-4000 LWCO...
  • Page 41 Absolute Boilers ABS 1500-2000-2500-3000-4000...
  • Page 42 Absolute Boilers ABS 1500-2000-2500-3000-4000 S7999D 8 PIN Plug Connector COM1 COM2 POWER...
  • Page 43 Absolute Boilers ABS 1500-2000-2500-3000-4000...
  • Page 44 Absolute Boilers ABS 1500-2000-2500-3000-4000...
  • Page 45 Absolute Boilers ABS 1500-2000-2500-3000-4000...
  • Page 46 Absolute Boilers ABS 1500-2000-2500-3000-4000...
  • Page 47 Absolute Boilers ABS 1500-2000-2500-3000-4000...

  • Page 48: Power Consumption

    5.4 Limit Controls 5.4.1 Temperature control The Absolute boiler is equipped with an electronic temperature limit control based on flow, return, and flue gas temperature sensors. The flow temperature is adjustable between 68-200°F [20- 93°C]. 5.4.2 Low water level protection (LWCO) (flow and content) The Absolute boiler is equipped with low water protection based on temperature differences (ΔT) between flow and...

  • Page 49: High Gas Pressure Switch (Hgp)

    Absolute Boilers ABS 1500-2000-2500-3000-4000 5.4.5 High gas pressure switch (HGP) The boiler is equipped with a gas pressure switch that is mounted directly on the air intake housing. The gas pressure switch is pre set at the factory and should not be adjusted.

  • Page 50: Gas Connection

    6.1 Gas connection The Absolute boiler is suitable for use with natural gas only. The gas connection is at the back left side of the boiler . The boiler is fitted with a gas filter which is mounted within the mono block gas valve as standard to prevent dirt from contaminating the gas valve or burner assembly.

  • Page 51: Gas Line Piping To Boiler

    Absolute Boilers ABS 1500-2000-2500-3000-4000 6.1.3 Gas line piping to boiler Ensure pipe sizing capability follows the recommend values based on an overall length of pipe from the meter plus the equivalent length of all fittings. Approximate sizing may be based on 1 cubic foot of natural gas supply per 1,000 BTU/ hour input.

  • Page 52: Gas / Air Ratio Control

    Absolute Boilers ABS 1500-2000-2500-3000-4000 6.3 Gas / air ratio control The boiler has a pressure differential gas/air ratio control. This gas/air ratio control maintains the correct balance of gas and air quantities to the burner at a constant level under variable loads. This ensures clean and reliable combustion and high part load efficiency across the entire load range.
  • Page 53 Absolute Boilers ABS 1500-2000-2500-3000-4000 To adjust low fire: Required tools- 2.5 mm hex wrench and combustion analyzer Start the boiler and observe proper settings for the system. Set the boiler to low fire, to achieve minimum firing rate of the boiler.
  • Page 54 Absolute Boilers ABS 1500-2000-2500-3000-4000 Electrical DIN Connector Upstream Flange G1/8 inlet test port Filter Valve Body Coil Test port connection #2, G 1/8 between V1 and V2; both sides. Test port connection #3, G1/8 downstream of V2; both sides. Regulator outlet pressure adjustment screw; both side 10.

  • Page 55: Commissioning

    Absolute Boilers ABS 1500-2000-2500-3000-4000 7. Commissioning: DANGER If you do not follow the commissioning instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. 7.1 Pre operational checks Check power supply ensure fused and service disconnect provided as required by local code or authorities having jurisdiction.

  • Page 56: Combustion Setting And Adjustment

    Absolute Boilers ABS 1500-2000-2500-3000-4000 7.3 Combustion setting and adjustment Factory combustion readings Chart 8 Set point High fire ABS 1500 ABS 2000 ABS 2500 ABS 3000 ABS 4000 9.58 CO ppm 9.58 Factory combustion readings Chart 8 Set point Set point...
  • Page 57 Absolute Boilers ABS 1500-2000-2500-3000-4000 Flue port for combustion analyzer WARNING The installation of the boiler is not completed until all controls and safety device have been tested and verified for correct function and operation. It is the sole responsibility of the installer to ensure that all safety control systems...

  • Page 58: Operator Interface Display

    Absolute Boilers ABS 1500-2000-2500-3000-4000 8. Operator Interface Display Warning Explosion Hazard. Improper configuration can cause fuel buildup and explosion. Operators of this display may move fuel and/ or air actuators to positions that can create hazardous burner conditions. Improper user operation may result in PROPERTY LOSS, PHYSICAL INJURY or DEATH.

  • Page 59: Honeywell Sola Control Programming/Configuration

    Absolute Boilers ABS 1500-2000-2500-3000-4000 8.1 Honeywell Sola Control Programming/Configuration The Honeywell control has been fully programmed and configured by the factory for most installations, in most installation no adjustments or configurations are required, please note that optional items like, Outdoor reset, DHW production and lead/lag systems require configuration, see separate instruction provide with the kits.
  • Page 60 Absolute Boilers ABS 1500-2000-2500-3000-4000 Step 2: From the Configuration window, use the slide bar on the right had side and select the group by touching the group name. Step 3: Verify in correct group and view setting, determine the parameter in the group you wish to either view (confirm) or change, if changes to a group parameter is needed, a service password will have to be entered.

  • Page 61: Commissioning

    Absolute Boilers ABS 1500-2000-2500-3000-4000 9. COMMISSIONING Warning If you do not follow the commissioning instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. 9.1 Pre operational checks Check power supply ensure fused and service disconnect provided as required by local code or authorities having jurisdiction.

  • Page 62: Commissioning Steps

    Absolute Boilers ABS 1500-2000-2500-3000-4000 9.3 Commissioning Steps NOTE Commissioning can only be performed with the Honeywell S7999D 1006 color touch screen display All units are fully factory tested, due to varying field conditions, boiler must be tested on final site for safety shutdown, operation, and combustion limits.
  • Page 63 Absolute Boilers ABS 1500-2000-2500-3000-4000 Touch the Diagnostics test button, screen changes to the Modulating Test window Press the Maximum Modulation button (High fire position), this will force the boiler into the High fire position. Once in the High fire postion and stable conditions are reached check the following: Check combustion (see table) for factory and field combustion limits Adjust main flow (High fire) as necessary via shutter adjustment slotted screw ±...

  • Page 64: Important Safety Warning

    Note: Absolute is supplied with a number of factory default settings that should be correct for most installations. If there setting values are required: The following operating situations are now possible:...
  • Page 65 Absolute Boilers ABS 1500-2000-2500-3000-4000 Local operation via internal set point, The output of the boiler modulates on the basis of the flow temperature. Remote operation via external signal (4-20mA) for output or temperature set-point Lead/Lag (Cascade master control) communicates directly to each boiler via Modbus communication protocol.
  • Page 66 Absolute Boilers ABS 1500-2000-2500-3000-4000 High gas/Vent Safety pressure switch calibration and check Check for leaks around the piping of high gas pressure switch for gas leaks Command boiler on, while starting turn dial to minimum setting or until the boiler shutdown on LCI (operating interlocks), the switch is equipped with a LED indication when switch has activated.

  • Page 67: Commission Report

    Absolute Boilers ABS 1500-2000-2500-3000-4000 10 Commission report 10.1 Installation and Location details Absolute Boilers- ABS Series Boiler Start-up Form Installation & Location Details Project Name Sart-up Date: Address Start-up Tech. City/Town Prov/State Equipment Installer Contact Info. Country Postal/Zip Code Equipment Information...

  • Page 68: Maintenance

    If during the annual inspection combustion results indicate that the boiler is no longer operating at the optimum level additional maintenance should be carried out as follows: The Absolute Mini boiler or any of its components does not contain any crystalline silica. Warning Electrical Shock Hazard: Please label all wires prior to disconnecting when servicing this boiler.

  • Page 69: Cleaning The Fan

    Absolute Boilers ABS 1500-2000-2500-3000-4000 11.1.3 Cleaning the fan Use compressed air or a synthetic brush to clean the fan, be careful not to disturb the balance clips on the vanes. Clean this area Warning Ensure the balancing clips in the impeller stay in place! 11.1.4 Cleaning the heat exchanger...

  • Page 70: Cleaning The Burner Assembly

    Absolute Boilers ABS 1500-2000-2500-3000-4000 11.1.5 Cleaning the burner assembly CAUTION Turn electrical off, then ensure gas has been shut off at the main shut off valve. Next purge all gas in the system as per code. The burner may be hot, allow enough time to allow the boiler to cool before removing the burner tube.

  • Page 71: Cleaning/Replacing The Ignition/Ionization Rod

    Absolute Boilers ABS 1500-2000-2500-3000-4000 11.1.7 Cleaning/replacing the ignition/ionization CAUTION Turn electrical off, then ensure gas has been shut off at the main shut off valve. Next purge all gas in the system as per code. The ignition/ionization rod may be hot, allow enough time to let boiler cool before removing the ignition/ionization rod.

  • Page 72: Sight Glass Cleaning

    Absolute Boilers ABS 1500-2000-2500-3000-4000 11.1.9 Sight glass cleaning CAUTION Turn electrical off, then ensure gas has been shut off at the main shut off valve. Next purge all gas in the system as per code. The ignition/ionization rod may be hot, allow enough time to let boiler cool before removing the ignition/ ionization rod.

  • Page 73: Maintenance Schedule

    Absolute Boilers ABS 1500-2000-2500-3000-4000 12.Maintenance Schedule Description Schedule System pressure Monthly Control functioning Monthly Seals or evidence of leaks Monthly Unobstructed combustion air supply, no chemicals, garbage, gasoline, combustible Monthly materials, flammable liquids are stored near the boiler. Check for water on the floor – around relief, vent and other parts and piping of the...
  • Page 74 Innovative Industrial Inc. Innovative Industrial Inc. 122 Burton Street Hamilton, Ontario, Canada L8l 3R5...

This manual is also suitable for:

Abs-2500Abs-4000Abs-3000Abs-2000

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