Quest Engineering CHH-300 Installation, Operation And Maintenance Instructions

Quest Gas-Fired CHH-300

Installation, Operation and Maintenance Instructions

Installation, Operation and Maintenance Instructions

– Read and Save These Instructions –

– Read and Save These Instructions –

Warning: If the information in these instructions are not followed exactly, a re or

explosion may result causing property damage, personal injury or death.

- Do NOT store or use gasoline or other ammable vapors and liquids in the vicinity of

this or any other appliance.

- WHAT TO DO IF YOU SMELL GAS

• Do NOT try to light any appliance.

• Do NOT touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call the re department.

- Installation and service must be performed by a qualied installer, service agency or the

gas supplier.

“Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect

the electrical supply to the pump. Instead, shut off the gas supply at a location external to
the appliance.”

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TS-720

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Quest Gas Fired CHH-300 Installation, Operation and Maintenance Instructions

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This appliance is equipped with a Blocked-Flue shutoff device. If any part of the ue-gas
passageway in the combustion chamber, exhaust pipe or rain cap should become blocked or
adversely restricted, a pressure sensing switch (Fig.22 pg.12) will break the electrical control circuit
and not allow the burner to run or the gas valve to open. There is a “Manual Reset” button on this
switch that will have to be reset before re-ring can occur. If the burner fails to start after resetting
once, call a qualied service technician to clean the ue passageways and/or replace the switch.
Cleaning instructions can be found in Section (6.1 G) of the Maintenance section of this manual.

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Table of Contents

1. System Description & Features ................................5

1.1 Description .....................................................5

1.2 Features ..........................................................6

2. Safety ......................................................................6

2.1 General Safety Guidelines ............................... 6

2.2 Safety Devices and Clearances ......................... 7

2.3 Heat Transfer Fluid ..........................................7

3. Specications .......................................................... 7

3.1 Construction Specications ............................. 7

3.2 Dimensions & Capacities Chart ....................... 8

3.3 Propane Burner & Fuel Specications .............8

3.4 Natural Gas Burner & Fuel Specications ........9

3.5 Circulation Pump ............................................ 9

3.6 Electrical Requirements for Complete System 1 0

3.7 Gauges & Indicator Lights ............................. 1 1

3.8 Controls & Electrical ..................................... 1 1

3.9 Controls, Switches, & Gauges Identication .. 1 3

4. Setup ..................................................................... 14

4.1 Positioning Equipment on the job .................... 1 4

4.2 Hose & Accessory Connections ..................... 1 4

4.3 Charging the Fluid System ............................. 1 6

4.4 Propane Gas Burner Installation & Setup ....... 1 7

4.5 Natural Gas Burner Installation & Setup ........ 1 8

5. Operation .............................................................. 1 8

5.1 Startup .......................................................... 1 8

5.2 Shutdown ...................................................... 1 9

6. Maintenance ......................................................... 1 9

6.1 Service Instructions and Checks .................... 1 9

6.2 Maintenance Frequency Chart ....................... 2 3

7. Troubleshooting .................................................... 2 3

7.1 Fault Determination ...................................... 2 3

7.2 Burner Internal Faults .................................... 2 5

7.3 Electrical Schematics ..................................... 2 6

Warranty ....................................................... 2 9

Page

Serial No. __________________________________

Purchase Date ______________________________

Dealer’s Name ______________________________

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Quest Gas Fired CHH-300 Installation, Operation and Maintenance Instructions

1. System Description & Features

2: CHH-300, Burner End1: CHH-300, Pump End

1.1 Description

• The CHH is a fuel burning appliance, designed to heat uid “on demand” and provide pumped
circulation of the uid for use in various portable hydronic applications.

• The CHH provides a central source of hot “heat transfer uid” (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.

• The CHH gas-red units can be equipped with either of 2 burners, each dedicated to burn one of the

following:

-Natural Gas.

-Propane Gas.

• Pumping and combustion control are achieved with electrical components. The CHH-300 requires a
120 volt, 20 amp, 3-wire grounding circuit.

• The CHH is designed for consistently-efcient outdoor operation.

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1.2 Features

• All exposed components are made of non-corrosive materials such as stainless steel, brass or aluminum.

• The “HTF” circuit includes an open, atmospherically-vented expansion tank, which effectively eliminates
the system from pressure vessel classication.

• 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, pump, lters and “HTF” tank ller
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.

• Burners approved for use with the system, come with a permanently installed pressure gauge to simplify
adjustment of gas pressure when setting up the burner.

• Door handles and hose connection couplers for the external HTF circuit are recessed so as not to create
“snag-points” when moving, shipping or delivering the unit.

2. Safety

2.1 General Safety Guidelines:

CAUTION! This is a fuel burning appliance.

• Some surfaces will become extremely HOT!

• When using propane or natural gas, the chance of FIRE or EXPLOSION always exists!
Always follow safe-operating practices and comply with local re and gas 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, certied work boots and hard hat when working with or operating this
equipment.

• Keep children, pets and all untrained by-standers clear from the heater and accessories.

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2.2 Safety Devices and Clearances

• 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.

• The ue-gas exhaust pipe and rain-cap requires a minimum of 6” (152 mm) clearance,
from any type of combustible material.

• Clearance from any obstructive objects must be maintained to a minimum of 36” (914
mm) from both ends of the hydronic heater.

• Do not allow anything to obstruct the “Combustion Air Intake”.

2.3 Heat Transfer Fluid

Precautions and measures to follow when working with “heat transfer uid” (Inhibited aqueous propylene

glycol).

• Ventilation - Good general ventilation should be sufcient for most conditions.

• Respiratory protection - No respiratory protection should be needed.

• Skin protection - For brief contact, no precautions other than clean body-covering clothing should be

needed.

• Use impervious gloves when prolonged or frequently repeated contact should occur.

• Eye protection - Use safety glasses.

First aid measures.

• Eyes - Flush eyes with plenty of water.

• Skin - Wash off in owing water or shower.

• Ingestion - Induce vomiting if large amounts are ingested. Consult medical personnel.

• Inhalation - Remove to fresh air if effects occur. Consult a physician.

• Note to physician - No specic antidote. Supportive care. Treatment based on judgement of the physician

in response to reactions of the patient.

3 Specications

3.1 Construction Specications

• The “CHH” includes an aluminum “enviro-containment” base, with fork-lift pockets.

• The exterior enclosure panels are made of stainless steel.

• The framework for the enclosure and the base are built of structural aluminum. A top center hoisting hook

is included.

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• Primary access for operation and service is provided for through hinged, lockable doors at the two ends

of the enclosure.

• Both side panels and both roof panels are fastener-attached for potential removal.

• Then combustion chamber/heat exchange section is fabricated from stainless steel.

• Access for cleaning the chamber is from the burner end with minimal disassembly required. The
procedure consists of removing the burner and inside chamber section.

• Temperature turn-down and condensing within the chamber can not harm the chamber.

• The exhaust ue for the burner exits through the roof of the enclosure. The exposed roof ashing is made
from aluminum. The rain cap and ue pipe are made of stainless steel.

3.2 Dimensions and Capacities

Length of Cabinet inches (millimeters) 72 (1829)
Width of Cabinet inches (millimeters) 22 (559)
Height of Cabinet inches (millimeters) 48 (1219)
Height to Top of Rain Cap inches (millimeters) 58 (1473)
Heat Transfer Fluid Capacity US gallons (liters) 20 (76)
Weight: with heat transfer uid pounds (kilograms) 600 (272)

3.3 Propane Gas Burner and Fuel Specications (Fig. 3)

• The “Gas Burner” is a power, forced-draft, type with direct spark ignition, manufactured by Riello
Burners.

• A CSA/UL version gas train is factory installed in units equipped for either propane or natural gas. The gas
train works with either burner.

• Two gauges are mounted to pressure-tap ports on the gas train for use in setting the burner and
monitoring performance(Fig. 24) .

Riello Burner Model Propane 40-G400-LP

Operational Mode single stage

Electrical Characteristics V / A / Hz / Ph 120 / 2.2 / 60 / 1
Orice: factory equipped # 1.5
Diaphragm: factory equipped # C14
Gas Supply Pressure: Minimum “WC (KPa) 8 (1.99)
Gas Supply Pressure: Maximum “WC (KPa) 13 (3.24)
Gas Manifold Pressure ( P): factory set “WC (KPa) 5.0 (1.25)
Heat Setting: factory set # 1
Air Gate Setting: factory set # 3.0
Heat Input B/tu/H (Watts) 250,000 (73,250)
Heat Output: @ 80% net efciency B/tu/H (Watts) 200,000 (58,600)

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3: Gas Burner, LP or Natural Gas Train

3.4 Natural Gas Burner and Fuel Specications (Fig. 3)

• The “gas burner” is a power, forced-draft, type with direct spark ignition, manufactured by Riello Burners.

• A CSA/UL version gas train is factory installed in units equipped for either natural gas or propane. The gas train
works with either burner.

• Two gauges are mounted to pressure-tap ports on the gas train for use in setting the burner and monitoring
performance (Fig. 24).

Riello Burner Model Natural Gas 40-G400-NG

Operational Mode single stage

Electrical Characteristics V / A / Hz / Ph 120 / 2.2 / 60 / 1
Orice: factory equipped # 2.2
Diaphragm: factory equipped # C4
Gas Supply Pressure: Minimum “WC (KPa) 7 (1.74)
Gas Supply Pressure: Maximum “WC (KPa) 10.5 (2.61)
Gas Manifold Pressure ( P): factory set “WC (pascals) 3.8 (946)
Heat Setting: factory set # 1
Air Gate Setting: factory set # 3.5
Heat Input B/tu/H (Watts) 300,000 (87.9)
Heat Output: @ 80% net efciency B/tu/H (Watts) 240,000 (70,320)

3.5 Circulation Pump (Fig. 4)

• The HTF circulation pump is a stainless steel, direct drive centrifugal type.

• The pump is located inside the enclosure at the opposite end to the burner and can be accessed through a
hinged lockable door (Fig. 1).

• A panel-mounted pressure gauge is connected to the output side of the HTF pump by means of a 1/8” ID
hydraulic hose and ttings (Fig. 23).

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Quest Gas Fired CHH-300 Installation, Operation and Maintenance Instructions

Goulds Pump Model 1ST1E4C4
Impeller Diameter inches (millimeters) 5.1875 (132)
Motor Horsepower HP (Watts) 1.0 (746)
Voltages pump can run on Volts 120/240
Full Load Amp Rating - Franklin motor Amps 10.4/5.2

- Emerson motor Amps 12.3/6.2
System Design Flow Rate USGPM (liters/sec) 30 (1.89)
System Design Operating Pressure PSI (kilopascals) 35 (241)

4: Fluid circulation Pump

3.6 Electrical Requirements for Complete System

Supply Voltage Volts 120
Circuit Amperage Amps 20
Hertz HZ 60
Phase PH single
Control Circuit Voltage Volts 120
Power Inlet - NEMA Twistlock L5-20P

5: Power Inlet Plug

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3.7 Gauges and Indicator Lights

• A cluster of gauges and status-indicator lights are located inside the UL approved control panel. This panel
is located behind the burner access door near the top (Fig. 2). These gauges and lights are visible from the

exterior through plexi-glass windows in the access door and the control panel door.

• A digital gauge (Fig. 12) monitors each of the following:

- HTF supply temperature.

-HTF return temperature.

• A digital hours meter (Fig. 12) logs system run-time.

• A series of 6, LED indicator lights (Fig. 13) illuminate in sequence as each of the following scenarios is
proven:

-#1 - 115 volt control power is present - clear lens.

-#2 - HTF level is adequate in reservoir - green lens.

-#3 - High temp auto switch has not interrupted the circuit - green lens.

-#4 - High temp limit control has not interrupted the circuit - green lens.

-#5 - High pressure switch has not interrupted the circuit - green lens.

#6 - Aquastat is calling for heat - green lens.

6: Control Panel, Outer 7: Control Panel, Inner

3.8 Controls and Electrical

• The UL approved electrical box, located inside the enclosure, above the burner, houses specic electrical
components, besides the lights and gauges, and serves as a junction box for cords going to and from remote
electrical components (Fig. 6 & Fig. 7).

• The following components are part of and are located in or on the UL approved box:

-Main power disconnect (Fig. 9).

-Pump ON/OFF switch (Fig. 10).

-Burner circuit ON/OFF switch (Fig. 11).

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-Main system breaker (Fig. 14).

-Pump circuit breaker (Fig. 14).

-Burner circuit breaker (Fig. 14).

-Power disconnect switch (Fig. 15).

-Temperature gauge transformers 6VDC (Fig. 16).

-LED lights - 120 volt (Fig. 13).

-Hours meter - 120 volt (Fig. 12).

-Terminal blocks (Fig. 18).

-Contactors (Fig. 17).

-Electronic operating thermostat (Fig. 8).

• The following items are remotely connected to cords that exit from the control panel: (see chart below
for details of these components)

-Main power male inlet-plug (twist lock) (Fig. 5).

-Low water cut-off switch (mounted on HTF reservoir) (Fig. 19).

-High Temp Auto switch (mounted in HTF plumbing circuit) (Fig. 20).

-High Temp Limit switch (mounted in HTF plumbing circuit) (Fig. 21).

-High Pressure Limit switch (Fig. 22).

-HTF circulating pump (Fig. 4). (see pump chart above for details)

-Burner (Fig. 3). (see burner chart above for details)

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3.9 Controls, Switches & Gauges Identication

• Mounted on Control Panel

8: Operator, Digital 9: Main Power Switch Knob 10: Pump Switch 11: Burner Switch

• Mounted Behind Control Panel

12: Temperature Gauges & Hour Meter 13: LED Indicator Lights

• Mounted Remotely

14: Circuit Breakers 15: Main Power Switch Body 16: Transformers for Digital Temp. Gauges

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17: Contactors 18: Terminal Blocks

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• Pump and Gas Pressure Gauges

19: Low Water Cutoff 20: High Temp Auto Switch 21: High Temp Limit Switch 22: High Pressure Switch

23: Pump Pressure Gauge (PSI) 24: Gas Pressure Gauges (“WC)

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 should be placed at a central position that will minimize and equalize the lengths
of hoses. This helps to ensure maximized and equalized HTF ow.

• Convenient access to a suitable electrical connection, if site power is to be used. 120V, 1PH, 60Hz,
20A, 3-wire grounding is required.

• Convenient access to bulk truck re-fueling in the case of propane systems.

• Do not locate in the path of job site trafc.

• Avoid locations that will expose the CHH to intense dust or other sources of air contamination. Clean
owing air is essential 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 uid, it is necessary to lay out a circuit of hoses to; distribute the hot uid,
transfer it’s heat to another medium and return the cooled uid to the CHH for re-heating (Fig. 25).

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• Primary 1” hoses are used from the CHH quick-connect couplings (Fig. 26) to feed a manifold for either
multiple fancoils in air heating situations (Fig. 28) or multiple 5/8” hose circuits for ground thawing,
concrete curing, slab heating or snow melting (Fig. 29).

• 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 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 trafc of any kind and at the same time
minimize the overall circuit length.

• Provide protection from “Kinking” of hoses that would restrict ow.

• When connecting quick couplers, ensure that the connections are “Fully Engaged” and snapped into
place or ow 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-300 and the exterior building wall. Special “Insulating Wraps” are available for this

purpose.

25: Layout for Fluid Distribution

1. Central Hydronic Heating Unit

2. Burner& Heat Exchanger

3. Circulating Pump

4. Reservoir for Expansion & Filling

5. Primary Fluid Hoses, 1”

6. Secondary Fluid Hoses, 3/4” or 1”

7. Manifold for Multiple Connections

8. Fancoil Heat Exchanger

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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

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26: Hoses Connected to CHH Unit 27: Fancoil Connected to CHH Unit

28: Manifolds for Fancoils - Supply & Return 29: Manifold for Thaw & Cure

4.3 Charging the Fluid System

30: HTF Level Gauge & Vented Filler Cap 31: HTF Circuit Valves, Y-strainer & High Temp. Limit

• The CHH-300, all hose and all accessories are shipped pre-charged with the “approved blend” of heat
transfer uid (HTF). The required uid is a 50% blend of Inhibited propylene glycol and de-mineralized
neutral PH (#7)water. (Freeze protection to -29ºF). 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.

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Quest Gas Fired CHH-300 Installation, Operation and Maintenance Instructions

• Check the HTF level gauge (Fig. 30). The reservoir should be ¼ to ½ full when the system is cold. Add
approved uid, if necessary, at the vented ller cap (Fig. 30).

• Connect all primary hoses from the CHH-300 to the distribution manifold.

• Place all fancoils in the desired locations and route all the hoses to them OR lay out all hose grid circuits

for ground thaw or concrete curing.

• Connect hoses from the manifold to ONE fancoil or ONE thaw/cure loop ONLY.

• Open 2 HTF circuit valves (Fig. 31).Turn ON the circulating pump switch (Fig. 10) and let the uid
circulate until all the air is eliminated from the rst branch circuit. Air has been purged when steady
pressure of 30 to 35 PSI is observed at the glycol pressure gauge (Fig. 22).

• Connect each fancoil or thaw/cure loop, in turn, one at a time, in the same manner as above. When all

are connected and the pressure gauge maintains steady pressure, the system is charged and ready for
use.

• Check the HTF level again and top up if necessary (¼ to ½ full).

4.4 Propane Burner Installation and Setup (Fig. 3)

• Refer to the Riello Burner 40-G400 manual (which is included with this package) for detailed

information and instruction.

• Specic propane gas burner settings for the CHH-300 are as follows.

Riello Burner Model 40-G400
Orice: # 1.5
Diaphragm: # C14
Gas Supply Pressure: Minimum “WC (KPa) 8 (1.99)
Gas Supply Pressure: Maximum “WC (KPa) 13 (3.24)
Gas Manifold Pressure ( P): factory set “WC (KPa) 5.0 (1.25)
Head Setting: factory set # 1
Air Gate Setting: factory set # 3.0
Heat Input B/tu/H (Watts) 250,000 (73,250)
Heat Output: @ 80% net efciency B/tu/H (Watts) 200,000 (58,600)

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Quest Gas Fired CHH-300 Installation, Operation and Maintenance Instructions

4.5 Natural Gas Burner Installation and Setup (Fig. 3)

• Refer to the Riello Burner 40-G400 Manual (which is included with this package) for detailed

information and instruction.

• Specic natural gas burner settings for the CHH-300 are as follows.

Riello Burner Model 40-G400
Orice: # 2.2
Diaphragm: # C4
Gas Supply Pressure: Minimum “WC (KPa) 7 (1.74)
Gas Supply Pressure: Maximum “WC (KPa) 10.5 (2.61)
Gas Manifold Pressure ( P): factory set “WC (KPa) 3.8 (0.95)
Head Setting: factory set # 1
Air Gate Setting: factory set # 3.5
Heat Input B/tu/H (Watts) 300,000 (87,900)
Heat Output: @ 80% net efciency B/tu/H (Watts) 240,000 (70,320)

5. Operation

5.1 Startup

• Make sure the CHH-300 is connected to a correct, stable power source (120V, 20A, 60Hz, 3-wire
Grounding) and proper gauge chords are used (12 gauge minimum).

• Verify adequate and correct fuel supply for the burner as it is equipped on the system (propane or
natural gas). Open all valves in the respective fuel-supply lines.

• Make sure at least one circuit of HTF hose is connected to the CHH-300 to provide adequate circulation
(see hose and accessory connections section 4.2).

• At the control panel (Fig. 6), remove 2 thumb screws to open and expose the inner panel (Fig. 7), turn
ON the three breakers located behind the light panel (Fig. 14). Close and refasten the panel.

• Turn ON the main power switch (Fig. 9). The white unit power light (Fig. 13) will come on, as well as the
two digital temperature gauges and hour meter (Fig. 12).

• Turn ON the pump switch (Fig. 10) and check the pump pressure gauge (Fig. 22). Steady pressure
around (30 to 35 PSI), indicates that no air remains in the uid circuit.

• Once a stable pump pressure is achieved, turn ON the burner switch (Fig. 11). The following sequence
should now occur: Observe the LED light cluster (Fig. 13).

-The glycol level light will turn on (indicating that there is a sufcient amount of HTF in the system).

-The high temp auto light will turn on (This indicates that the high temp auto safety switch has not

broken the circuit).

-The high temp limit light will turn on. (This indicates that the high temp limit safety switche has not

broken the circuit).

-The high pressure limit switch light will turn on. (This indicates that the blocked ue high pressure

safety switch has not broken the circuit).

-A few seconds later, the stat light will come on and the burner fan will purge the combustion

chamber for a few seconds.

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Quest Gas Fired CHH-300 Installation, Operation and Maintenance Instructions

-The burner should light following the pre-purge. If air is still present in the gas lines, the burner
may not light and will lock out. It might be necessary to push the red reset button on the burner
module 2 or 3 times until gas reaches the burner head and ignition takes place.

• Make sure the stat (Fig. 8) is set at the desired temperature. DO NOT Operate at temperatures above
200ºF, or damage to inline controls and certain accessory components 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 uid

temperature.

• Once the setpoint temperature has been reached, the burner will cycle off and on as needed.

5.2 Shutdown

• Turn OFF the burner switch (Fig. 11). The burner will no longer recycle but the circulation pump will

continue to run.

• It is recommended that the uid be allowed to continue circulating until it has cooled down to 100ºF or

lower.

• Turn OFF the pump switch (Fig. 10). If any fancoils and hoses have been placed at a higher elevation
than the CHH-300, the primary hoses should be immediately disconnected from the CHH-300 (Fig. 26).
This will prevent uid from draining back and overowing at the HTF reservoir vent (Fig. 30).

• Turn OFF the main power switch (Fig. 9).

• Turn OFF manual gas supply valves.

• If the system is to be de-commissioned, it is now safe to disconnect the power supply, the natural gas or
propane supply (if applicable) and all HTF circulation hoses, manifolds and accessories.

6. Maintenance

6.1 Service Instructions and Checks

“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” must be used to verify
clean combustion. Perform the following checks while the burner is ring. Must be performed by a trained
service technician ONLY. Refer to the Riello burner Manual for burner adjustment instructions. This check
should be performed, every time, when putting the system into operation on a new project and a minimum

of once yearly.

a. Ensure that the gas manifold pressure is at 3.5”WC for propane red units or 3.8”WC for natural gas

red units. Adjust if necessary.

b. Regulation of combustion air ow is made by adjustment of the manual air adjustment plate. Initial
suggested setting is (3.5) for natural gas and (3.0) for propane gas.

c. Final position of the air adjustment plate must be set based on instrument readings of not greater
than 12.0% CO2 for propane-red systems and 10% CO2 for natural gas systems. Final readings must
be taken with all service-access doors closed.

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B. After 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. Disconnect the electrical wire which connects the “Ionization Probe” to the burner’s control box.
The wire has a clip-together connector for convenience.

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 ionization probe’s lead wire disconnected, consult the operator’s manual for troubleshooting

procedures.

d. To put the unit back in standard operating mode, turn OFF the burner circuit power switch, re-

connect the electrical wire which connects the “Ionization Probe” to the burner’s control box and turn
ON the “Burner Circuit” power switch.

C. Examine the ue 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 technician ONLY. The low water cutoff switch is located in plain view at the
same end of the CHH-300 as the circulating pump and is identied 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 switch, the control will restore function to the burner circuit as long as there is
uid 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-300 as the circulating pump and are identied with labels. One of these
switches re-sets itself automatically and is set at a slightly lower temperature (about 5ºF) than the other which
must be manually re-set after its set point has been reached.

a. With the burner ring, set the main digital operating stat to a temperature value that is at least 5ºF
higher than the set point of the manual re-set high temperature limit switch.

b. When the uid temperature reaches the set point of the automatic re-set limit switch, it should shut
down the burner. As the uid cools down 2 or 3 degrees, the burner should re-re. This automatic re-set
limit switch should function like a second thermostat and will take over as operator of the burner.

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 re 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 uid 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 5ºF lower than the manual re-set limit.

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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-ue) 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 identied with a label.

a. Remove the chimney rain cap.

b. With the burner ring, cover the chimney ue 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 under 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 ue gas passageways. This procedure should be performed in the event of

blockage in the ue gas 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 ue gas passageway. Must be performed by a trained service

technician ONLY.

a. Shut off and disconnect external gas supply and electrical power supply.

b. Drain the heat transfer uid from the system.

c. Exterior cabinet side panels and the cabinet door & framing members, at the burner end of the
cabinet, should be removed, to facilitate access to the combustion chamber. The control panel should
be loosened from its mounting frame. These are all bolt-on components.

d. Once access to the chamber has been gained, disconnect the burner electrical supply line and
gas supply line and remove the burner. Two bolts will need to be removed that hold the burner to its
mounting ange.

e. Disconnect the ue gas vent pipe by removing screws and clamping bands. Remove the pipe and
rain cap assembly and clean its interior thoroughly.

f. Two hoses are connected to 1” ttings that protrude through the front ange plate disk of the
combustion chamber. These hoses will need to be disconnected by loosening the hose clamps and
pulling the hose off the insert barbs.

g. Remove 8 bolts that hold the chamber ange 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. All ue gas contact surfaces are now exposed and can be easily cleaned with vacuum cleaner,
brushes or other cleaning utensils.

i. To re-assemble the unit, replace components in reverse order to which they were removed.

j. Reconnect gas and power supply to the unit and when re-starting the system perform all safety and

service checks as outlined above.

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H. The CHH-300 will produce condensate while operating, at any time that the circulating uid is cooler
than approximately 130ºF (54ºC). A clear poly-tube is connected to a tting 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.

I. Flame inspection is recommended on a frequent basis (about once per month under normal continuous

service) and a ame inspection port is available for this. It is located just above the burner on the front ange
plate disk of the combustion chamber. A 3/8” NPT plug must be removed to see into the inner chamber
while the burner is red. Be sure that the plug is replaced when this check is complete. Must be performed
by a trained service technician ONLY.

a. Normal ame for natural gas or propane should be blue with slight orange tips at the cone of the
ame.

b. Although visual inspection is benecial. We strongly recommend that instruments be used to check
combustion quality. This procedure is outlined in (#.1), above.

J. On a daily basis, the area around this system must continue to be kept clear and free from combustible
materials, gasoline and all other ammable vapors and liquids.

K. At the circulation pump end of the CHH-300 cabinet, Louvers are stamped into the access door to
provide intake air for combustion and ventilation. Check on a daily basis to ensure that nothing is allowed to
obstruct this free-ow of air.

L. Check heat transfer uid level daily. Maintain between ¼ and ¾ level during normal operation. If
excessive uid loss occurs check all hoses and connections for leaks. Top-up only with approved HTF.

M. Verify that all gauges are maintaining within their desired operating ranges with respect to setpoint.

N. For propane systems ONLY. 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 the Y-strainer before each set up, at least once per year or as required due to uid
contamination. To clean the Y-strainer (Fig. 31) close the ball valve, immediately adjacent to the Y-strainer
and disconnect the adjacent quick-coupler connection at the alcove manifold (Fig. 26), on the outside of
the cabinet. This will isolate the Y-strainer. The cap on the Y-branch can now be removed so the cylindrical
screen can also be removed. Clean the screen with compressed air or a small wire brush. Put the screen
back in place, replace the cap, re-connect the quick coupler connection and open the valve.

For further service assistance

Call the manufacturer toll free at: 1-866-413-5214 to speak to a Hydronic Service Specialist

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6.2 Maintenance Frequency Chart

7. Troubleshooting

7.1 Fault Determination

The CHH-300 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 fails:

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If all switches have been turned ON and the system has been operating 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.9) still turned on?

b. Are the circuit breakers (Fig. 14) still turned on?

c. Verify external power supply (120V) to inlet plug (Fig. 5).

#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. 16) should show 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) burner control circuit (Fig. 19).

a. Check uid level in reservoir. Should be at least to the ¼ level. Add if necessary.

b. Check, with a multi-meter, for 120V in and out of LWCO switch. If uid 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 pump
from running with no uid in the system.

#2 LWCO Light, (plus #1) are ON indicates.

A. LWCO switch (Fig. 19) is sensing sufcient glycol in the reservoir and power is going through the switch.

B. There is no power going through the high temperature auto switch (Fig. 20).

a. Check the set points on the high temperature auto switch (Fig. 20) and digital stat (Fig. 8). If the set
point of the stat is equal to or higher than the set point of the high temperature auto switch (Fig. 20), the
high temperature auto switch will be functioning like a stat and cycling the burner off and on. Light #3
will be cycling in-step with the burner. The digital stat should always be set (maximum 200ºF), a few
degrees lower than the high temperature auto switch (about 210ºF).

b. With the actual uid 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. 20). If there is
power in but not out, replace the high temperature auto switch.

#3 High Temp Auto Light, (plus #1 & #2) are ON indicates.

A. Fluid supply temperature is below the set-point of the high temperature auto switch (Fig. 20) and power
is going through the switch.

B. There is no power going through the high temperature Limit switch (Fig. 21).

a. Check the set points on the high temperature Limit switch (Fig. 21), the high temperature auto switch
(Fig. 20) and digital stat (Fig. 8). If the set points of both the high temperature auto switch and the stat are

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equal to or higher than the set point of the high temperature limit switch (Fig. 21), 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 (210ºF), the high temp limit switch (220ºF) and the digital stat (maximum 200ºF).

b. With the high temp limit switch re-set and actual uid temperature well below the set points of both
high temp switches, check, with a multi-meter, for 120V in and out of the high temp limit switch (Fig.

21). If there is power in but not out, replace the high temp limit switch.

#4 High Temp. Limit Light, (plus #1, #2 & #3) are ON indicates.

A. Fluid supply temperature is below the set-point of the high temp limit switch (Fig. 21) and power is
going through the switch.

B. There is no power going through the NC contacts of the high pressure switch (Fig. 22)

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 briey but it trips again, blockage may have occurred in the ue gas
passage way. Clean the ue 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 & #4) are ON indicates.

A. Pressure in the combustion chamber and ue pipe has not risen above the high limit cutoff point. Power

is going through the NC contacts of the high pressure switch (Fig. 22). Indicates no blockage in any of the
ue gas passages.

B. There is no power going through the digital stat switch contacts (Fig. 8).

a. The actual supply uid temperature may have risen high enough that the operator has cycled off. A
call-for-heat will be re-established once the supply uid temperature has dropped to 5ºF below set point.

b. If the actual supply uid temperature is well below the set point of the stat (at least 10ºF lower),
check, with a multi-meter, for 120V in and out of the stat. If there is power in but not out, replace the

stat and its sensor.

#6 Stat Light, (plus #1, #2, #3, #4 & #5) are ON indicates.

A. The digital stat (Fig. 8) is calling for heat. The burner should be engaged.

B. If the burner is not functioning, a fault lies within the burner.

7.2 Burner Internal Faults

Gas Burner, (Natural Gas and Propane Gas)

Below is a list of scenarios and possible causes for burner failure.

A. The burner goes through the prepurge period normally. The ame ignites, but the burner goes to lockout
within ve seconds.

a. The phase/neutral lines are reversed. Correct polarity is critical.

b. The wiring to ground is absent or ineffective.

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c. The ionization probe is grounded, or not in contact with the ame, or the circuit to the control box
is broken.

d. The spark interferes with the ame signal due to incorrect setting of the electrode.

B. The burner goes to lockout after the prepurge period because the ame does not ignite.

a. Air has not been fully bled from the gas lines.

b. The gas valve is passing too little gas.

c. The spark is irregular or not present.

C. The burner does not start when the thermostat calls for heat.

a. The 24 volt switching relay is defective.

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.

f. The air pressure switch is not in the normally closed position.

D. The burner does not go through prepurge, and the control module goes to lockout. The air pressure

switch does not change over from normally closed to normally open contacts. This condition exists because
there is insufcient air pressure in the combustion head.

E. For additional information refer to the Riello Manual, 40-G400, included in your data package.

7.3 Electrical Schematics

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Riello Burner Wiring:

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Quest CHH-300 Limited Warranty

Warrantor:

Therma-Stor LLC

4201 Lien Rd.
Madison, WI 53704
Telephone: [phone]

Who Is Covered: This warranty extends only to the original end-user of the Quest CHH-300 and may
not be assigned or transferred.

One Year Warranty: Therma-Stor LLC warrants that, for one (1) year the Quest CHH-300 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 Therma­Stor 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, modication, unauthorized or improper repair or installation, accident, acts of
nature or any other cause beyond Therma-Stor LLC’ reasonable control.

Limitations and Exclusions: If any Quest CHH-300 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-300 Desiccant
Dehumidier is out of service while awaiting covered warranty service).

UPON THE EXPIRATION OF THE WRITTEN WARRANTY APPLICABLE TO THE QUEST CHH­300 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-300 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 specic legal rights, and you may also have other rights which
vary from state to state.

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