Quest Oil-Fired CHH-980 - Quest Climate Control Equipment
Contents
1. ais QUEST Wy 1 866 413 5214 www QuestProtect com 13 Sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions 31 Hoses Connected to CHH 980 33 Manifolds for Fancoils Supply amp Return ll 35 HTF Level Gauge 36 Vented Filler Cap Reco ty A 1 866 413 5214 37 HTF Circuit Valves Y strainers amp High Temp Limits www QuestProtect com 14 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions 4 3 Filling the Fluid System e The CHH 980 all hose and all accessories are shipped pre charged with the approved blend of heat transfer fluid HTF The required fluid is a 50 blend of Inhibited propylene glycol and de mineralized neutral PH 7 water Freeze protection to 29 F The HTF provided with a new system and accessories is marketed as DowFrost Use of any other product that cannot be proven to be equal in all respects will void warranty of the system e Check the HTF level gauge Fig 35 The reservoir should be to 1 4 full when the system is cold Add approved fluid if necessary at the vented filler cap Fig 36 or use the pumping system to draw HTF from a pail or barrel If you prefer this method place the free open end of the 1 2 suction hose into a pail or barrel of HTF and position the valves as shown in Fig 38 Turn the Primary Pump Switch ON Fig 15 Once the HTF rises2. QUEST Wy 1 866 413 5214 www QuestProtect com 2 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions 1 System Description amp Features 1 CHH 980 Pump End 2 CHH 980 Burner End 1 1 Description e The CHH 980 is a fuel burning appliance designed to heat fluid on demand and provide pumped circulation of the fluid for use in various portable hydronic applications e The CHH 980 provides a central source of hot Heat Transfer Fluid HTF for use with dependent heat exchangers such as Fan coils for heating and drying of structures Multi circuit line heat exchange hose or tubing for ground thawing concrete curing snow melting and slab heating Custom hydronic heat exchange accessories and applications e The CHH 980 oil fired units are equipped with a burner that will burn either of the following 2 standard grade light heating oil or diesel fuel 1 winter grade light heating oil or diesel fuel e Pumping and combustion control are achieved with electrical components The CHH 980 requires a 120 240 volt 50 amp 4 wire grounding circuit e The CHH is designed for consistently efficient outdoor operation a Wy 1 866 413 5214 www QuestProtect com VY 3 Sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions 1 2 Features All exposed components are made of non corrosive materials such as stainles
3. Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions Read and Save These Instructions _ s a T Pa a Ni ysaausrasIiii LISTED Intertek AWARNING 3103897 This appliance is equipped with a Blocked Flue shutoff device If any part of the flue gas passageway in the combustion chamber exhaust pipe or rain cap should become blocked or adversely restricted a pressure sensing switch Fig 27 pg 11 will break the electrical control circuit and not allow the burner to run There is a Manual Reset button on this switch that will have to be reset before re firing can occur If the burner fails to start after resetting once call a qualified service technician to clean the flue passageways and or replace the switch Cleaning instructions can be found in Section 6 1 G of the Maintenance section of this manual m 4201 Lien Rd Phone 608 237 8400 o ne Therma Stor uc Madison WI 53704 Toll Free 1 866 413 5214 www QuestProtect com sales QuestProtect com WD TS 767 Specifications subject to change without notice 1 07 12 Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions Table of Contents Page 1 System Description amp Features eseese 3 tA DESTUN resien 3 UZ POOE ope E SE ieee 4 Dee S seeew ager iecrateeseencspaepenessueeeacse enenades 4 2 1 General Safety Guidelines cccccccceeeeees 4 2 2 Safe
4. As the fluid cools down 2 or 3 degrees the burner should re fire This automatic re set limit switch should function like a second thermostat and will take over as operator of the burner cy Wy 1 866 413 5214 www QuestProtect com 20 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions c If you now adjust the set point of the automatic re set limit switch to a level a few degrees higher than the set point of the manual re set limit switch the burner should continue to fire until the set point of the manual re set high limit is reached At this point the burner should be shut down and this time should not come back on as the fluid cools back down d The manual re set high limit will need to be manually re set by pushing the red re set button Adjust the operator back down to a normal operating lower setting and re adjust the automatic high limit back down to its regular set point at about 5 F lower than the manual re set limit e These controls should be tested every time when putting the system into operation on a new project or a minimum of once yearly F After placing this unit in operation the high pressure safety shutoff blocked flue device must be tested Must be performed by a trained service technician ONLY The high pressure cutoff switch is located just below and to the left of the burner and is identified with a label a Remove the chimney rain cap b With the burner
5. e If the CHH 980 is connected to a distribution system that will demand most of its capacity in terms of flow requirements and heat draw the Normal 2 pump Mode should be used e Adjust the valves as shown in Fig 40 Turn ON the Primary Pump Switch and the Secondary Pump Switch Fig 15 Normal Full Load Operation using 2 pumps Legend Valve A Open Valve B Open Valve C Closed Valve D Closed Secondary Pump Primary Pump Mode Running Mode Running 40 Normal Mode with 2 Pump Operation cy Wy 1 866 413 5214 www QuestProtect com 16 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions 4 6 4 7 a V Normal 1 Pump Mode with Light Load If the CHH 980 is connected to a distribution system that will demand only half or less of its capacity in terms of flow requirements and heat draw the Normal 1 pump Mode should be used This will provide better efficiency for the lighter load Adjust the valves as shown in Fig 41 Turn ON only the Primary Pump Switch Fig 15 Keep in mind that either pump could be used in this mode but it is imperative that the valve A or B for the pump not being used must be closed to prevent short circuiting of the fluid and greatly reduced out flow Normal Light Load Operation using only Legend Valve A Closed Valve B Open Valve C Closed Valve D Closed S
6. firing cover the chimney flue pipe so it is blocked off completely This should cause the pressure switch contacts to open and shut down the burner c Remove the cover from the pipe and replace the rain cap The burner should not try to re light since the switch must be manually re set d By pushing the reset button located on the electrical box cover of the pressure switch the control will reset and the burner should light again e This control should be tested every time when putting the system into operation on a new project or a minimum of once yearly G Procedure for cleaning flue gas passageways This procedure should be performed in the event of blockage in the flue fuel passage due to soot or any other obstruction that may occur Improper burner settings or maintenance could cause soot accumulation in the combustion chamber The following steps should be taken to clean out the chamber flue gas passageway Must be performed by a trained service technician ONLY a Shut off fuel supply and electrical power supply b Drain the heat transfer fluid from the system c The control panel should be loosened from its mounting frame d Once access to the chamber has been gained disconnect the burner electrical supply line and fuel supply lines and remove the burner 4 bolts will need to be removed that hold the burner to its mounting flange e Disconnect the flue exhaust vent pipe by removing screws Remove the pipe and rain cap as
7. once per month under normal continuous service and a flame inspection port is available for this It is located behind a flip up door at the top of the burner Must be performed by a trained service technician ONLY a Normal flame should be bright orange yellow b Although visual inspection is beneficial We strongly recommend that instruments be used to check combustion quality This procedure is outlined in 1 above J Ona daily basis the area around this system must continue to be kept clear and free from combustible materials gasoline and all other flammable vapors and liquids K At both ends of the CHH 980 cabinet Louvers are stamped into the access doors to provide intake air for combustion and ventilation Check on a daily basis to ensure that nothing is allowed to obstruct this free flow of air L Check heat transfer fluid level daily Maintain between 1 4 cold and 1 2 hot during normal operation If excessive fluid loss occurs check all hoses and connections for leaks Top up only with approved HTF See User s Manual for details M Verify that all gauges are maintaining within their desired operating ranges with respect to setpoint N Check fuel tank level daily and order fuel as required O Make sure that all access doors and panels are kept closed and locked while the system is in use P Isolate and clean both Y strainers before each set up at least once per year or as required due to fluid contamination To c
8. or flow will not take place through the coupler connection For long term building heating projects it is advised to insulate all hose sections located outdoors between the CHH 980 and the exterior building wall This also applies for the primary 1 hose circuits on a thaw or cure job to reduce fluid heat loss between the CHH 980 and the thaw cure manifold Special Insulating Wraps are available for this purpose Connect all primary 1 hoses from the CHH 980 to the distribution manifold s Three manifolds can be connected at once each to a separate pair of 1 primary hoses Place all fancoils in the desired locations and route all the secondary hose circuits to them OR lay out all hose grid circuits for ground thaw or concrete curing Connect hoses between the manifold s and the fancoils or the thaw cure loops 1 866 413 5214 www QuestProtect com 12 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions 30 Layout for Fluid Distribution Central Hydronic Heating Unit Burner amp Heat Exchanger Circulating Pump Reservoir for Expansion amp Filling Primary Fluid Hoses 1 Secondary Fluid Hoses 3 4 or 1 Manifold for Multiple Connections CON Do BWNY Fancoil Heat Exchanger 9 Heat Transfer Coil 10 Air Moving Fan 11 Heated Supply Air 12 Intake Air 13 Hose Grid Line Heat Exchanger 5 8 14 Vapor Barrier 15 Insulated Tarps
9. section is fabricated from stainless steel e Access for cleaning the chamber is from the burner end with some disassembly required The procedure consists of removing the burner and inside chamber section CA w www QuestProtect com 5 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions e Temperature turn down and condensing within the chamber can not harm the chamber e The exhaust flue for the burner exits through the roof of the enclosure The exposed roof flashing is made from aluminum The rain cap and flue pipe are made of stainless steel 3 2 Dimensions and Capacities Fig 3 3 3 Oil Burner and Fuel Specifications e The Oil Burner Fig 4 is a pressure atomization type with direct spark ignition manufactured in the USA by Wayne Combustion Systems e 1 or 2 light heating oil or diesel fuel may be used e A gauge is connected to a pressure tap port on the fuel pump of the burner to aid in setting the burner and monitoring performance e A Fuel Filter is mounted to the burner pump inlet port e Supply and return fuel lines are equipped with quick couplers for ease of connection to a fuel tank 4 CHH 980 Oil Burner 5 Oil Pressure Gauge cy Wy 1 866 413 5214 www QuestProtect com 6 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions CHH 980 Wayne Burner Model es ee ee Operational Mode
10. supply temperature HTF return temperature e A digital hour meter Fig 12 logs system run time e A series of 6 LED indicator lights Fig 18 illuminate in sequence as each of the following scenarios is proven 1 120 volt control power is present clear lens 2 HTF level is adequate in reservoir green lens 3 High temperature auto control has not interrupted the circuit green lens 4 High temperature limit control has not interrupted the circuit green lens 5 High pressure limit switch has not interrupted the circuit green lens 6 Stat is calling for heat green lens EE w7 1 866 413 5214 www QuestProtect com 8 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions 11 Control Panel 3 7 Controls and Electrical e Specific electrical components are located in and on the UL approved dual electrical panel above the burner The panel also serves as a junction box for cords going to and from remote electrical components Fig 11 e The following components are mounted on the front of the UL approved panel Hours meter 120 Volt Fig 12 Stat Electronic operating controller Fig 13 Main power disconnect Fig 14 Pump ON OFF switches Fig 15 Burner circuit ON OFF switch Fig 16 Glycol supply and return temperature gauges Fig 17 LED lights 120 Volt Fig 18 The following components are inside the UL appr
11. to the desired level turn the pump OFF and set the valve arrangement for normal operating mode Fig 40 or 41 below Tank Fill Operation using 1 pump Legend Valve A Closed Valve B Closed Valve C Closed Valve D Open Note Mode must be returned to normal operation once tank is filled to proper level 38 Filling Tank from Pail or Barrel a Wy 1 866 413 5214 www QuestProtect com VY 15 Sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions 4 4 Eliminating Air from the HTF Circuit e If there is a significant amount of air in the HTF circuit adjust the valves as shown in Fig 39 Turn the Primary Pump Switch ON Fig 15 and let the fluid circulate until all the air is eliminated from system Air has been purged when steady pressure of 35 to 40 PSI is observed at the glycol pressure gauge Fig 28 e Once all air is eliminated turn the pump OFF and set the valve arrangement for normal operating mode Fig 40 or 41 below e Check the HTF level again and top up if necessary 1 8 to 1 4 full See step 4 3 above Rapid Air Release Operation using 1 pump Legend Valve A Closed Valve B Closed Valve C Open Valve D Closed Secondary Pump Primary Pump Mode Not Running Mode Running Note Mode must be returned to normal operation once air is removed 39 Rapid Air Removal 4 5 Normal 2 Pump Mode with Full Load
12. AC NEY NEU 1 5 HP 15 6FLA ALONG WITH 24 OF SPIRAL WRAP ee ee fa 0 Neu PROVIDE 24 OF 16AWG TYPE MTW RED WHITE amp GREEN WIRE S EANES E NUU 4 NEU OPTIONAL PRE HEATER 120VAC 77 WATT TO SHEET 3 OF 5 www QuestProtect com 17 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions L1 L1 BURNER DISABLE ENABLE 3130 L1 L1 L1 CONTROL WIRING UNIT Ce Aw NEU UNIT POWER d 4 PILOT LAMP LEVEL ALARM PRI PUMP ICR OFF RUN is 3040 1 3042 fo NEU PRI PUMP ee Siar MOTOR SEC PUMP km OFF RUN m 3060 fos NEU SEC PUMP 1M QS O TO i iam NEU UNIT 2M HOURS UNIT HOURS GLYCOL LEVEL A m ay NEU w ee ta Q 3 HIGH TEMP HIGH TEMP LIMIT HIGH PRESSURE Aum MANUAL HIGH PRESS TEMP SWITCH RESET SWITCH SWITCH CONTROLLER C 3172 3174 3176 UNE Loacl 3178 orn NEU BURNER A OR 20 BURNER IES NEU a STAT Na gt NEU TEMP CONTROLLER ACTIVE Y PILOT LAMP A N L NEU NEU HIGH PRESS SWITCH NEU HIGH PRESSURE OKAY as PILOT LAMP ZTN HIGH TEMP NEU HIGH TEMP LIMIT OKAY PILOT LAMP HIGH TEMP AUTO rn NEU HIGH TEMP AUTO OKAY Y PILOT LAMP NEU GYLCO LEVEL OKAY Normally Closed Contact Normally Open Contact a2Lo Normally Closed Pushbutton oo Normally Open Pushbutton jot Light Normally Closed Time Closed Contact Norm
13. PY ON OFF Electrical Characteristics A Hz Ph 120 11 5 60 1 Nozzle Delavan Part 2 75 60 B Fuel Pump Pressure Fuel Input Rate factory set Fig 6 3 4 Circulation Pumps 2 required Fig 8 e The HTF circulation pumps are stainless steel direct drive centrifugal type e They are located inside the enclosure at the opposite end to the burner and can be accessed through a pair of hinged lockable doors Fig 1 e A panel mounted pressure gauge is connected to the output side of the HTF pump manifold by means of a 1 8 ID hydraulic hose and fittings Fig 28 e See chart Fig 7 for specifications 2 Pumps required ee CHH 980 Goulds Pump Model ee 1ST1F1B4 Impeller Diameter Fig 7 4 2 8 Fluid circulation Pumps 1 866 413 5214 www QuestProtect com 7 Sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions 3 5 Electrical Requirements for Complete System Metz o Sz o C Power Inlet Male NEMA Twistlock cs6375m2 Fig 9 10 Power Inlet Plug 3 6 Gauges and Indicator Lights e A group of gauges controls switches and status indicator lights is located on the UL approved control panel This panel is located behind the burner access doors near the top Fig 2 These gauges and lights are visible from the exterior through plexi glass windows in the access doors e A digital gauge Fig 17 monitors each of the following HTF
14. ally Closed Time Open Contact Normally Open Time Open Contact Normally Open Time Close Contact Starter Coil NS Q L Timer Coil 1 866 413 5214 pow SUPPLY 120VAC TO 6VDC Lo PS2 NOTE o 0 98 POWER SUPPLY TO 6VDC 120VAC Pst roma RETURN V Z CUSTOMER FURNISHED SAFETY DISCONNECT REQUIRED IF MAIN DISCONNECT IS NOT IN SIGHT OF EQUIPMENT POWER LUG ON THE COMPONENT TERMINAL IN REMOTE JUNCTION DEVICE BOX TERMINAL IN MAIN ENCLOSURE TERMINAL DASHED LINES INDICATE FIELD WIRING AND OR CUSTOMER SUPPLIED COMPONENTS 28 PILOT LAMP PS added NEU block 08 04 71 NEU ZN GLYCOL THIS DESIGN IS THE PROPERTY OF amr EMS INDUSTRIAL INC V Z AND MUST BE RETURNED UPON REQUES DO NOT SCALE DRAWING NEU DRAWN BY DATE BLH 04 08 11 CHECKED BY DATE DESIGN BY DATE BLH 04 08 11 WIRE COLOR CODE 120 VAC CONTROL REDO AC NEUTRAL GROUNDED WHITE DC CONTROL BLUE OVDC GROUNDED BLUE W WHITE TRACER OREIGN VOLTA GROUND OR WHITE W BLUE TRACER Yeow oo REEN OR GREEN W YELLOW TRACER FIELD WIRING TO BE COPPER WITH 75 C INSULATION www QuestProtect com sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions Wayne FH Burner INTERMITTENT IGNITION Li HOT FIGURE 1 a QUEST Wy 1 866 413 5214 www QuestProtect com 29 Sales QuestProtect com Quest Oil Fired CHH 980 Installation Op
15. chnician ONLY The low water cutoff switch is located in plain view at the same end of the CHH 980 as the circulating pumps and is identified with a label a Push the test switch on the outside of the control This will simulate a Low Water condition and open the burner circuit to prevent burner initiation b By pushing the reset button the control will restore function to the burner circuit as long as there is fluid touching the probe The electronic probe is a self cleaning type and should not require service c This control should be tested every time when putting the system into operation on a new project or a minimum of once yearly E After placing this unit in operation the high temperature limit safety shutoff device must be tested Must be performed by a trained service technician ONLY Two high temperature limit switches are located in plain view at the same end of the CHH 980 as the circulating pumps and are identified with labels One of these switches re sets itself automatically and is set at a slightly lower temperature about 5 F than the other which must be manually re set after its set point has been reached a With the burner firing set the main digital operating stat to a temperature value that is at least 5 F higher than the set point of the manual re set high temperature limit switch b When the fluid temperature reaches the set point of the automatic re set limit switch it should shut down the burner
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17. econdary Pump Primary Pump Mode Not Running Mode Running 41 Normal Mode with 1 Pump Operation Pump assisted Chamber Draining If for any reason the CHH 980 heat exchanger must be drained the primary pump can be used to simplify the draining Locate the 1 2 drainage hose at the opposite end of the unit below the burner Connect this hose to the short 1 2 suction hose at valve D in Fig 42 Garden hose fittings make this connection easy OPEN both valves on the 1 2 drainage line below the burner Prepare a short length of 1 hose with a female quick coupler on one end and the other end open Connect the female quick coupler to one of the male outlets on the side of the CHH 980 The open end should be placed in a barrel to catch the fluid It will take more than 100 gallon capacity to hold it all Adjust the valves as shown in Fig 42 Turn ON only the Primary Pump Switch Fig 15 When all fluid is pumped out shut OFF the pump switch Pump Assisted Chamber Draining Operation using 1 pump Legend Valve A Closed Valve B Closed Valve C Closed Valve D Open Connect to a Quick oupler Connect to chamber Secondary Pump Primary Pump drain located on Mode Not Running Mode Running burner end 42 Pump assisted Chamber Drain 1 866 413 5214 www QuestProtect com 17 Sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions 4 8 O
18. eration and Maintenance Instructions Quest CHH 980 Limited Warranty Warrantor Therma Stor LLC 4201 Lien Rd Madison WI 53704 Telephone 1 866 413 5214 Who Is Covered This warranty extends only to the original end user of the Quest CHH 980 and may not be assigned or transferred One Year Warranty Therma Stor LLC warrants that for one 1 year the Quest CHH 980 will operate free from any defects in materials and workmanship or Therma Stor LLC will at its option repair or replace the defective part s free of any charge End User Responsibilities Warranty service must be performed by a Servicer authorized by Therma Stor LLC If the end user is unable to locate or obtain warranty service from an authorized Servicer the end user should call Therma Stor LLC at the above number and ask for the Therma Stor Service Department which will then arrange for covered warranty service Warranty service will be performed during normal working hours The end user must present proof of purchase lease upon request by use of the warranty card or other reasonable and reliable means The end user is responsible for normal care This warranty does not cover any defect malfunction etc resulting from misuse abuse lack of normal care corrosion freezing tampering modification unauthorized or improper repair or installation accident acts of nature or any other cause beyond Therma Stor LLC reasonable control Limitations and Exclus
19. fter placing this unit in operation the ignition system safety shutoff device must be tested Must be performed by a trained service technician ONLY This check should be performed every time when putting the system into operation on a new project or a minimum of once yearly a Shut OFF the burner circuit power switch b Remove the primary control box from the burner and place a small piece of dark tape over the light sensing cad cell eye that senses the presence of flame in the combustion chamber Put the primary control back in place c Turn the power switch back ON and initiate burner lighting procedure After the short pre purge cycle the burner should light but go out in 5 seconds and lock out If the burner does not lock out with the cad cell eye covered the primary control should be replaced d To put the unit back in standard operating mode turn OFF the burner circuit power switch remove the tape cover from the burner s primary control box re insert the control and turn ON the burner circuit power switch C Examine the flue gas exhaust pipe and rain cap to be sure they are solidly attached and free from any type of obstruction Clean if necessary a This check should be performed every time when putting the system into operation on a new project or a minimum of once yearly D After placing this unit in operation the low water safety shutoff device must be tested Must be performed by a trained service te
20. gh pressure switch Fig 27 Indicates no blockage in any of the flue gas passages There is no power going through the digital stat switch contacts Fig 13 6 Stat Light plus 1 2 3 4 amp 5 are ON indicates A B CEA s The digital stat Fig 13 is calling for heat The burner should be engaged If the burner is not functioning a fault lies within the burner 1 866 413 5214 www QuestProtect com 25 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions 7 2 Burner Internal Faults Diesel Light Oil Burner Below is a list of scenarios and possible causes for burner failure A The burner goes through the prepurge period normally The flame ignites but the burner goes to lockout within five seconds a The phase neutral lines are reversed Correct polarity is critical b The wiring to ground is absent or ineffective c The electric eye light sensing switch is dirty or defective Try cleaning they eye If it still fails replace it B The burner goes to lockout after the prepurge period because the flame does not ignite a No fuel in tank or lines b Air has not been fully bled from the fuel lines c Check fuel lines The smallest leak will allow air to enter and prevent ignition d The fuel filter is dirty Replace filter e Nozzle is plugged Replace nozzle f The spark is irregular or not present Re align electrodes Check ignition transfo
21. ifolds and accessories 6 Maintenance 6 1 Service Instructions and Checks CAUTION CAUTION Label all wires prior to disconnection when servicing controls Wiring Errors can cause Improper and Dangerous Operation Verify proper operation after servicing A To achieve and ensure clean combustion from the burner a flue gas analyzer and smoke spot tester must be used to verify clean combustion Perform the following checks while the burner is firing Must be performed by a trained service technician ONLY Refer to the Wayne model FH manual for burner adjustment instructions These checks should be performed every time when putting the system into operation on a new project and a minimum of once yearly a Before starting the burner determine that the correct nozzles are in place Delavan 2 75 60 B 2 nozzles are required a Wy 1 866 413 5214 www QuestProtect com WwW 19 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions b Fire the burner and ensure that the oil pressure is at 162 PSI Adjust if necessary c Regulation of combustion air flow is made by adjustment of the manual AIR ADJUSTMENT dial Initial suggested setting is 6 0 d Final position of the air adjustment plate must be set based on instrument readings of not greater than 13 0 CO2 and a smoke spot reading of zero Final readings must be taken with all service access doors closed B A
22. il Burner Installation and Setup Fig 4 e Refer to the Wayne FH burner Manual which is included with this package for detailed information and Instruction e Specific burner settings for the CHH 980 are as follows a ee Wayne BurnerModel O O Operational Mode ONO O Electrical Characteristics Heat Input based on 140 000 Btu per USG Btu H Kw H 980 000 287 Heat Output 80 net efficiency Btu H Kw H 784 000 230 5 Operation 5 1 Startup e Make sure the CHH 980 is connected to a correct stable power source 120 240V 50A 60Hz 4 wire Grounding and proper gauge chords are used 10 gauge minimum Fuel Input Rate factory set USGPH Liters Hr 7 0265 e Verify adequate and correct fuel supply 1 or 2 light heating oil or diesel fuel Refer to the name rating plate Open all valves in the fuel supply lines e With the main power switch Fig 14 in the OFF position open the control panel door on the right Fig 11 Turn ON the three breakers Fig 19 and then close the panel e Turn ON the main power switch Fig 14 The white unit power light Fig 18 will come on as well as the two digital temperature gauges Fig 17 and hour meter Fig 12 e Ensure that the HTF circuit valves are positioned for Normal Single pump operation as in article 4 6 above e Turn ON only the primary pump switch Fig 15 and check the pump pressure gauge Fig 28 Steady pressure around 35 to 45 PSI indica
23. ions If any Quest CHH 980 part is repaired or replaced the new part shall be warranted for only the remainder of the original warranty period applicable thereto but all warranty periods will be extended by the period of time if any that the Quest CHH 980 is out of service while awaiting covered warranty service UPON THE EXPIRATION OF THE WRITTEN WARRANTY APPLICABLE TO THE QUEST CHH 980 OR ANY PART THEREOF ALL OTHER WARRANTIES IMPLIED BY LAW INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE SHALL ALSO EXPIRE ALL WARRANTIES MADE BY THERMA STOR LLC ARE SET FORTH HEREIN AND NO CLAIM MAY BE MADE AGAINST THERMA STOR LLC BASED ON ANY ORAL WARRANTY IN NO EVENT SHALL THERMA STOR LLC IN CONNECTION WITH THE SALE INSTALLATION USE REPAIR OR REPLACEMENT OF ANY QUEST CHH 980 OR PART THEREOF BE LIABLE UNDER ANY LEGAL THEORY FOR ANY SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION WATER DAMAGE THE END USER SHOULD TAKE PRECAUTIONS AGAINST SAME LOST PROFITS DELAY OR LOSS OF USE OR DAMAGE TO ANY REAL OR PERSONAL PROPERTY Some states do not allow limitations on how long an implied warranty lasts and some do not allow the exclusion or limitation of incidental or consequential damages so one or both of these limitation may not apply to you Legal Rights This warranty gives you specific legal rights and you may also have other rights which vary from state to state Dara Wy 1 866 413 5214 www QuestProtect
24. lean the Y strainers Fig 37 close the ball valves A and B immediately above the Y strainers and disconnect all the quick coupler connections at the alcove manifold Fig 31 on the outside of the cabinet This will isolate the Y strainers The caps on the Y branches can now be removed so the cylindrical screens can also be removed Clean the screens with compressed air or a small wire brush Put the screens back in place and re engage the caps quick coupler connections and valves For further service assistance Call the manufacturer toll free at 866 413 5214 to speak to a Hydronic Service Specialist Dara Wy 1 866 413 5214 www QuestProtect com 22 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions 6 2 Maintenance Frequency Chart Start of Even Star ot Heating As MAINTAINENCE TASKS Daily Project Season Necessary User Performed Tasks Sid Sr Check pressure amp temperature gauges for Normal Function Levels during operation Pv ovo fv SS E E A E Check LED lights for Correct Function during operation Nvo O yo o poo A ov E E E E C a S S E e O E E E E E E C S S E Taan Certe ssns S a a A E E E E O E E C E E E E C E E E E o O S S E E E E Perform a Flue Gas Analy sis test using instruments to confirm clean combustion oOo yvy p y ee Test lgniton Safely Shutof device on burner CCU S y i TestLow Water Cutoff Safety switch EC EC Test High Temperature Limit
25. mperature Gauges 18 LED Indicator Lights E Wy 1 866 413 5214 www QuestProtect com 10 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions e Mounted Inside Control Panel 19 Circuit Breakers 20 Main Power Switch Body 21 Transformers for Digital Temp Gauges TORR Prem 22 Contactors 23 Terminal Blocks e Controls Mounted Remotely 24 Low Water Cutoff 25 Auto reset Temp Limit 26 Man reset Temp Limit 27 High Pressure Switch e Pump Pressure and Oil Pressure Gauges 28 Pump Pressure Gauge PSI 29 Oil Pressure Gauge PSI 1 866 413 5214 www QuestProtect com 11 Sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions 4 Setup 4 1 Positioning Equipment on the Job Before choosing the location to place the central hydronic heater on a job site several factors should be considered If possible the CHH 980 should be placed at a central position that will minimize and equalize the lengths of hoses This helps to ensure maximized and equalized HTF flow Convenient access to a suitable electrical connection if site power is to be used 120 240V 1Ph 60Hz 50A 4 wire grounding is required Convenient access for bulk truck re fueling Do not locate in the path of job site traffic Avoid locations that will expose the CHH to intense dust or other sources of air contamination Clean flowing air is esse
26. multi meter for 120V in and out of the high temp limit switch Fig 26 If there is power in but not out replace the high temp limit switch 4 High Pressure Switch Light plus 1 2 amp 3 are ON indicates A Fluid supply temperature is below the set point of the high temp limit switch Fig 26 and power is going through the switch There is no power going through the NC contacts of the high pressure switch Fig 27 a Check the set point of the high pressure switch Start by turning the adjuster screw all the way counter clockwise Then turn the screw clockwise 3 full turns Push the manual reset button on the pressure switch to restore the circuit b Check the air tube connection to the pressure switch and clean if necessary Push the manual reset button on the pressure switch and the circuit should be restored If not check for 120 volts going in and out of the control If power goes in but not out replace the control c If the circuit is restored briefly but it trips again blockage may have occurred in the flue gas passage way Clean the flue gas passages in the combustion chamber see Maintenance article 6 1 G for instructions as well as the chimney pipe and rain cap Repeat step a above 5 High Pressure Switch Light plus 1 2 3 amp 4 are ON indicates lac B Pressure in the combustion chamber and flue pipe has not risen above the high limit cutoff point Power is going through the NC contacts of the hi
27. ntial to maintain clean combustion Observe all requirements listed in the Instructions for Installation document provided with this unit 4 2 Hose and Accessory Connections In order to make use of the heated fluid it is necessary to lay out a circuit of hoses to distribute the hot fluid transfer its heat to another medium and return the cooled fluid to the CHH 980 for re heating Fig 30 Up to 3 individual primary 1 hose circuits can be connected to the CHH 980 quick connect couplings Fig 31 to feed the same number of manifolds for either multiple fancoils in air heating situations Fig 33 or multiple 5 8 hose circuits for ground thawing concrete curing slab heating or snow melting Fig 34 Use only approved hose as supplied by ThermaStor Otherwise compatibility issues may arise Hoses are pre charged with the recommended mixture of water and propylene glycol HTF and are equipped with hydraulic style quick couplers Every hose has a male connector on one end and a female connector on the other end therefore any hose can be used for either the supply side or the return side of the hose circuit Route hoses to achieve minimum chance of damage from traffic of any kind and at the same time minimize the overall circuit length Provide protection from Kinking of hoses that would restrict flow When connecting quick couplers ensure that the connections are Fully Engaged and snapped into place
28. nts can result To adjust setpoint on this control just use the up and down key There is no need to go into the menu of the control to perform this function The control simultaneously displays setpoint temperature and actual supply fluid temperature e Once the setpoint temperature has been reached the burner will cycle off and on as needed e At this time you can initiate the 2 pump operating mode if the system is supporting a load of more than half its capacity See article 4 5 above for correct HTF valve positions OPEN valve A for the secondary pump and turn ON the secondary pump switch Remember that valves A or B must be open only when the corresponding pump is running 5 2 Shutdown e Turn OFF the burner switch Fig 16 The burner will shut down but the circulation pump will continue to run e It is recommended that the fluid be allowed to continue circulating until it has cooled down to 100 F or lower e Turn OFF both pump switches Fig 15 If any fancoils and hoses have been placed at a higher elevation than the CHH 980 the primary hoses should be immediately disconnected from the CHH 980 Fig 31 This will prevent fluid from draining back and overflowing at the HTF reservoir vent Fig 36 e Turn OFF the main power switch Fig 14 e Turn OFF manual fuel supply valves e If the system is to be de commissioned it is now safe to disconnect the power supply and all HTF circulation hoses man
29. oved panel Main system breaker Fig 19 Pump circuit breakers Fig 19 Burner circuit breaker Fig 19 Main power switch body Fig 20 Temperature gauge transformers 6VDC Fig 21 Contactors Fig 22 Terminal blocks Fig 23 The following items are remotely connected to cords that exit from the control panel Burner Fig 4 See burner chart above for details Fig 6 HTF circulating pump Fig 8 See pump chart above for details Fig 7 a Wy 1 866 413 5214 www QuestProtect com VY 9 Sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions Main power male inlet plug twist lock Fig 10 Low water cut off switch mounted on HTF reservoir Fig 24 Automatic reset High limit switch mounted in HTF plumbing circuit Fig 25 Manual reset High limit switch mounted in HTF plumbing circuit Fig 26 Manual reset High pressure switch Fig 27 3 8 Controls Switches amp Gauges Identification e Mounted on Control Panel see ee o PRIMARY PUMP IT SECONDARY PUMP BURNER oF i RUN OFF RUN DISABLE ENABLE QUARTZ 00007 E mnan ECR ise i110 HOURS k i j a S 14 Main Power 15 Pump Switches 16 Burner Switch Switch fm GLycoL E Salas eee suppPLY ae epee hn b 7 R ee a 7 UNIT HIGH TEMP MICH TEMP HIGH PRESS POWER 2 eae j AUTO 3 J ait SWITCH 5 wnt es _ od eon Tee 17 Glycol Te
30. ractices and comply with local fire codes Before attempting to setup or operate this equipment it is imperative that the Operator reads and understands all the information in this manual Untrained people should not attempt to operate this equipment until they receive proper Instruction Maintain instructional and safety labels Replace damaged labels Observe all posted warnings and cautions Always wear suitable protective clothing and accessories such as safety glasses leather gloves certified work boots and hard hat when working with or operating this equipment Keep children pets and all untrained bystanders clear from the heater and accessories 2 2 Safety Devices and Clearances Ee w All safety devices must be in place and functioning properly when the equipment is in operation All hydronic heater panels and doors must be kept closed when the system is operating www QuestProtect com 4 sales Questprotect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions e The flue gas exhaust pipe and rain cap requires a minimum of 6 152 mm clearance from any type of combustible material e Clearance from any obstructive objects must be maintained to a minimum of 36 914 mm from both ends of the hydronic heater for service and operating access e Do not allow anything to obstruct the Combustion Air Intakes 2 3 Heat Transfer Fluid HTF Precautions and measures to follow
31. rmer replace if defective C The burner does not start when the thermostat calls for heat a Loose wire connection at terminals L or N b Terminals on the control module are bent or loose c The motor is defective d The capacitor is defective e The control box is defective D For additional information refer to the Wayne model FH manual included in your data package Dara Wy 1 866 413 5214 www QuestProtect com 26 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions 7 3 Electrical Schematics CUSTOMER SUPPLIED 115 230V 19 60HZ 4 WIRE INCOMING POWER i a eae POWER DISTRIBUTION GND LL1LL2 INEU LARGEST MOTOR 1 5HP 8 AWG PER PHASE uy TYPE MTW 90 DEG C COPPER 12 AWG RED PER PHASE TYPE MTW 90 DEG C COPPER 2CB 25A 12 AWG RED PER PHASE TYPE MTW 90 DEG C COPPER 3CB _ 15A 12 AWG RED PER PHASE TYPE MTW 90 DEG C COPPER 4CB ae 25A TS1 TO SHEET 3 OF 5 an we 1 866 413 5214 12 AWG RED PER PHASE USE J LEADS TYPE MTW 90 DEG C COPPER JOIN 1L2 PRI PUMP 1M YELLOW VIOLET BLACK BLUE BROWN PR FOR E NEU 1L2A 120VAC S 1 5 HP 15 6FLA NEU i 14 AWG RED PER PHASE TYPE MTW 90 DEG C COPPER ia BURNER 2M SS BURNER MOTOR NEU NEU 2L2A 120VAC 8 o 8 4FLA 12 AWG RED PER PHASE USE J LEADS TYPE MTW 90 DEG C COPPER JOIN ji SEC PUMP 3M YELLOW VIOLET SEC PUMP BLACK BLUE MOTOR BROWN 120V
32. s steel brass or aluminum The HTF circuit includes an open atmospherically vented expansion tank which effectively eliminates the system from pressure vessel classification The control system includes a sequence of status indicator lights which provide a quick function check and trouble shooting aid for the operator The combustion chamber heat exchanger is completely fabricated from stainless steel and is not susceptible to corrosion Temperature turn down for prolonged periods of operation such as for concrete curing will not harm the chamber For security and environmental protection all valves controls burner pumps and HTF tank filler are either secured behind lockable access doors or are self lockable Temperature gauges pressure gauge system status indicator lights and HTF tank level gauge are visible to the operator even when the system is securely locked down The CSA UL approved burner comes with a permanently installed pressure gauge to simplify monitoring of oil pressure when setting up the burner Door handles and hose connection couplers for the external HTF circuits are recessed so as not to create snag points when moving shipping or delivering the unit 2 Safety CAUTION 2 1 General Safety Guidelines CAUTION This is a fuel burning appliance Some surfaces will become extremely HOT When using oil or diesel fuel the chance of FIRE always exists Always follow safe operating p
33. sembly and clean its interior thoroughly f Hoses will need to be disconnected by loosening the hose clamps and pulling the hose off the insert barbs g Remove all bolts that hold the chamber flange plate disk to the main chamber body h The inner section of the combustion chamber can now be pulled straight out of the main chamber body A fork lift or other machinery may be required for this procedure since the chamber is very heavy i All flue exhaust gas contact surfaces are now exposed and can be easily cleaned with vacuum cleaner brushes or other cleaning utensils a Wy 1 866 413 5214 www QuestProtect com WwW 21 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions j To re assemble the unit replace components in reverse order to which they were removed k Reconnect fuel and power supply to the unit and when re starting the system perform all safety and service checks as outlined above H The CHH 980 will produce condensate while operating at any time that the circulating fluid is cooler than approximately 130 F 54 C A 1 2 hose is connected to a fitting in the bottom of the chamber at front and is routed to the outside of the cabinet to carry condensate away This tube should be inspected and cleaned if necessary when putting the system into operation on every new project or a minimum of once yearly Flame inspection is recommended on a frequent basis about
34. step with the burner The digital stat should always be set maximum 200 F a few degrees lower than the high temperature auto switch about 210 F b With the actual fluid temperature well below the set point of the high temperature auto switch check with a multi meter for 120V in and out of the high temperature auto switch Fig 25 If there is power in but not out replace the high temperature auto switch 3 High Temp Limit Light plus 1 amp 2 are ON indicates A Fluid supply temperature is below the set point of the high temperature auto switch Fig 25 and power is going through the switch There is no power going through the high temperature Limit switch Fig 26 a Check the set points on the high temperature Limit switch Fig 26 the high temperature auto switch Fig 25 and digital stat Fig 13 If the set points of both the high temperature auto switch and the stat are equal to or higher than the set point of the high temperature limit switch Fig 26 the high temp limit switch will be locked out and the burner off Light 3 will be off It will be necessary to push the manual reset button on the front of the high temp limit switch and check the set points of all 3 The high temp auto switch 210 F the high temp limit switch 220 F and the digital stat maximum 200 F b With the high temp limit switch re set and actual fluid temperature well below the set points of both high temp switches check with a
35. switches EE CC S o i Test High Pressure Limit blocked fue swith TCT Check fue gas passageways for soot or any type of blockage and clean ifnecessay yvy V an ww 1 866 413 5214 www QuestProtect com 23 Sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions 7 Troubleshooting 7 1 Fault Determination The CHH 980 is equipped with a group of LED Indicator Lights The purpose of these lights is to aid in determining where the fault lies if the heating unit should fail to function properly The following sequence explains the function each light represents and what to look for if that function should fail UNIT O l HIGH TEMP HIGH TEMP HIGH PRESS POWER 1 coiled AUTO 3 J eve SWITCH 5 STAT 6 a a IMPORTANT If all switches have been turned ON and the system was operating correctly but has now FAILED the status of these 6 lights will help to isolate the problem All Lights OFF indicates A NO power through the main power switch Check the following a Is main power switch Fig 14 still turned on b Are the circuit breakers Fig 19 still turned on c Verify external power supply 120 240V to inlet plug Fig 10 1 Unit Power Light is ON indicates A Power is present through main switch The 2 digital temperature gauges should be ON If not use a multi meter to check the following a The 2 transformers Fig 21 should sho
36. tes that no air remains in the fluid circuit See article 4 4 above for rapid air removal e Once a stable pump pressure is achieved turn ON the burner switch Fig 16 The following sequence should now occur Observe the LED light cluster Fig 18 The glycol level light will turn on indicating that there is a sufficient amount of HTF in the system The high temp auto light will turn on This indicates that the high auto safety switch has not broken the circuit The high temp limit light will turn on This indicates that the high limit safety switches have not broken the circuit The high pressure limit switch light will turn on This indicates that the blocked flue high pressure safety switch has not broken the circuit Dara Wy 1 866 413 5214 www QuestProtect com 18 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions A few seconds later the stat light will come on and the burner fan will purge the combustion chamber for a few seconds The burner should light following the pre purge If air is still present in the fuel lines or filter the burner may not light and lock out It might be necessary to reset the burner module 2 or 3 times until fuel reaches the burner head and ignition takes place e Make sure the operator Fig 13 is set at the desired temperature DO NOT Operate at temperatures above 200 F or damage to inline controls and certain accessory compone
37. ty Devices and Clearances ccccceeeee 4 23 Fleat Transiter FUA sesei praeri r 5 Bi PEE a O a E E anmnetes 5 3 1 Construction Specifications sesssssssseeeeeee 5 3 2 Dimensions amp Capacities eeren 6 3 3 Oil Burner amp Fuel Specifications 006 6 D7 CUNEO WINS 1 sagtconceonentpetnecemetyaensaatnccess 3 5 Electrical Requirements for Complete System 8 3 6 Gauges amp Indicator Lights lt cscscasaavessasactvendes 8 3 7 Controls amp Elec TICA seisein 9 3 8 Control Switches amp Gauges Identification 10 de E e A 12 4 1 Positioning Equipment on the job 12 4 2 Hose amp Accessory COnnectionS eese 12 4 3 Filling the Fluid System sascosinntnsyscaseiesnsaenencs 15 4 4 Eliminating Air from the HTF Circuit 16 4 5 Normal 2 Pump Mode with Full Load 16 4 6 Normal 1 Pump Mode with Light Load 17 4 7 Pump assisted Chamber Draining 17 4 8 Oil Burner Installation and Setup 18 Ds PETO e a aree eee teanctar opener geen 18 Dell URC e E tence 18 2 ON ee a 19 O 12 Upc 9 vol a CG siei A 19 6 1 Service Instructions amp Checks ee 19 6 2 Maintenance Frequency Chart 00006 23 Zs MOUNE OO WIG ee E 24 ll Faut DeiermingU ON serr 24 7 2 B rner Were F QUNG ssscnncvssecieospsescsiatennsenanes 26 Serial No 7 3 Electrical Schemat CS erian n 27 Purchase Date NV UT EN E E E aceasta 30 Dealer s Name cy
38. w 120VAC in and 6VDC out If power goes in but not out replace transformer b If there is 6VDC at the digital gauge but it does not illuminate replace the temp gauge B There is no power going through the low water cutoff LWCO switch Fig 24 a Check fluid level in reservoir Should be at least 1 4 level Add if necessary b Check with a multi meter for 120V in and out of LWCO switch If fluid is adequate and there is power in but not out replace the LWCO switch c With no power going to the burner limit circuit and the burner panel switch turned ON the alarm circuit of the LWCO should be energized 120V This opens contacts in a relay that will prevent the pumps from running with no fluid in the system 2 LWCO Light plus 1 are ON indicates A LWCO switch Fig 24 is sensing sufficient glycol in the reservoir and power is going through the switch B There is no power going through the high temperature limit switches Fig 25 cy Wy 1 866 413 5214 www QuestProtect com 24 sales QuestProtect com Quest Oil Fired CHH 980 Installation Operation and Maintenance Instructions a Check the set points on the high temperature auto switch Fig 25 and digital stat Fig 13 If the set point of the stat is equal to or higher than the set point of the high temperature auto switch Fig 25 the high temperature auto switch will be functioning like a stat and cycling the burner off and on Light 3 will be cycling in
39. when working with heat transfer fluid Inhibited aqueous propylene glycol e Ventilation Good general ventilation should be sufficient for most conditions e Respiratory protection No respiratory protection should be needed e Skin protection For brief contact no precautions other than clean body covering clothing should be needed e Use impervious gloves when prolonged or frequently repeated contact should occur e ye protection Use safety glasses First aid measures e Eyes Flush eyes with plenty of water e Skin Wash off in flowing water or shower e Ingestion Induce vomiting if large amounts are ingested Consult medical personnel e Inhalation Remove to fresh air if effects occur Consult a physician e Note to physician No specific antidote Supportive care Treatment based on judgement of the physician in response to reactions of the patient 3 Specifications 3 1 Construction Specifications e The CHH 980 includes an aluminum enviro containment base with fork lift pockets e The exterior enclosure panels are made of stainless steel e The framework for the enclosure and the base are built of structural aluminum A top center hoisting hook is included e Primary access for operation and service is provided for through hinged lockable doors at the two ends of the enclosure e Side panels and roof panels are fastener attached for potential removal e The combustion chamber heat exchange
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