Thermal Solutions Arctic 1000 Manuel utilisateur

Form: 2435-3

Arctic Installation and Operation Manual Revision: 10

P/N 105641-01 Date: 12-1-2018

Thermal Solutions, 1175 Manheim Pike, Lancaster, PA 17601 Web: www.thermalsolutions.com

Phone: 717-239-7642 Fax: 877-501-5212 Email: s[email protected]

ARCTIC

High Efficiency, Low Emission

CONDENSING BOILER

INSTALLATION & OPERATION MANUAL

For service and repair to the boiler, call your heating contractor. When seeking information on

the boiler from the manufacturer, provide boiler model and serial number as shown on the rating

label.

Boiler Model:

Serial Number:

Installation Date:

Type System:

Heating Contractor:

Phone/Email:

Address:

Form: 2435-3

Arctic Installation and Operation Manual Revision: 10

P/N 105641-01 Date: 12-1-2018

Thermal Solutions, 1175 Manheim Pike, Lancaster, PA 17601 Web: www.thermalsolutions.com

Phone: 717-239-7642 Fax: 877-501-5212 Email: s[email protected]

Table of Contents

1 Introduction........................................................................................................................................................................6

1.1 Important Information .........................................................................................................................................6

1.2 Disclaimers and Local Codes..............................................................................................................................6

1.3 Test and Inspections..............................................................................................................................................7

1.4 Component Description .......................................................................................................................................7

2 Pre-Installation..................................................................................................................................................................9

2.1 Installation Conformance ....................................................................................................................................9

2.2 Boiler Foundation...................................................................................................................................................9

2.3 Clearances and Serviceability............................................................................................................................9

3 Installation .......................................................................................................................................................................11

3.1 Receiving The Boiler...........................................................................................................................................11

3.2 Boiler Connections ..............................................................................................................................................11

3.2.1 Flow Connection ............................................................................................................................................................11

3.2.2 Safety Relief Valves.......................................................................................................................................................11

3.2.3 Minimum Relief Valve Settings ................................................................................................................................12

3.2.4 Expansion Tank Connections ...................................................................................................................................12

3.2.5 Drain Connection...........................................................................................................................................................12

3.2.6 Condensate Drain Connection..................................................................................................................................12

3.2.6.1 ARC1000 Condensate Drain Trap................................................................................................12

3.2.6.2 ARC1500 –6000 Condensate Drain Trap ................................................................................13

3.2.7 Gas Supply Connection................................................................................................................................................13

3.2.7.1 Drip Leg ..................................................................................................................................................13

3.2.7.2 Gas Piping Leak Test .........................................................................................................................13

3.2.7.3 Venting of Gas Train Components...............................................................................................14

3.3 Combustion Air Supply System......................................................................................................................14

3.3.1 Combustion Air Openings:.........................................................................................................................................14

3.3.1.1 Two Permanent Opening Method................................................................................................14

3.3.1.2 One Permanent Opening Method.................................................................................................15

3.3.1.3 Mechanical Air Supply Systems....................................................................................................15

3.3.2 Louvers, Grilles, and Screens ....................................................................................................................................15

3.3.2.1 Louvers and Grilles:...........................................................................................................................15

3.3.2.2 Screens....................................................................................................................................................15

3.3.2.3 Motorized Louvers:............................................................................................................................15

3.3.2.4 Combustion Air Ducts.......................................................................................................................16

3.3.3 Ducted Combustion Air...............................................................................................................................................16

3.4 Venting Requirements.......................................................................................................................................16

3.4.1 Category II Venting .......................................................................................................................................................18

3.4.2 Massachusetts.................................................................................................................................................................19

3.4.3 Combustion Air and Venting Requirements for Canada ...............................................................................21

3.4.3.1 Air Supply Requirements per CAN/CSA-B149.1-05 for Appliances having an input

exceeding 400 MBH. .........................................................................................................................21

3.4.3.2 Combustion Air Supply Dampers, Louvers, and Grilles......................................................21

3.4.3.3 Mechanical Combustion Air Supply ............................................................................................22

3.4.3.4 Appliance Venting per CAN/CSA-B149.1-05 ..........................................................................22

3.5 Requirements........................................................................................................................................................22

3.5.1 Electrical............................................................................................................................................................................22

3.5.2 Gas Supply Requirements ..........................................................................................................................................23

Form: 2435-3

Arctic Installation and Operation Manual Revision: 10

P/N 105641-01 Date: 12-1-2018

Thermal Solutions, 1175 Manheim Pike, Lancaster, PA 17601 Web: www.thermalsolutions.com

Phone: 717-239-7642 Fax: 877-501-5212 Email: s[email protected]

iii

3.5.3 Sound Pressure Levels.................................................................................................................................................24

3.5.4 Pump and Piping Requirements..............................................................................................................................24

3.5.4.1 Water Flow Rates (Variable Primary Pumping Systems)..................................................24

3.5.4.2 Water Flow Rates (Primary / Secondary Systems)..............................................................25

3.5.4.3 Water Flow Rates (Constant Volume Primary Pumping Systems)................................26

3.5.4.4 Water Flow Rates for Glycol...........................................................................................................26

3.6 Before Placing Boiler In Operation...............................................................................................................26

3.6.1 Pre-Boil Out Flushing Of System .............................................................................................................................26

3.6.2 Boil Out Procedure........................................................................................................................................................27

3.6.3 Replacement Boiler Installations............................................................................................................................27

3.7 Draining and refilling the boiler & system ................................................................................................28

3.7.1 Filling The System .........................................................................................................................................................28

3.7.2 Hydrostatic Test Of Boilers And System ..............................................................................................................28

3.8 Boiler Water Treatment....................................................................................................................................28

3.8.1 Purpose of water treatment......................................................................................................................................28

3.8.2 Objectives..........................................................................................................................................................................29

3.8.3 Water softener................................................................................................................................................................29

3.8.4 Continuous Monitoring ...............................................................................................................................................29

4 SYSTEM START-UP .......................................................................................................................................................30

4.1 Concert Boiler Control Display Navigation –This Section applies ONLY to the ARC1000

through ARC3000 ................................................................................................................................................30

4.2 System Check:........................................................................................................................................................31

4.3 Power the Boiler: .................................................................................................................................................31

4.4 Power the Circulators:.......................................................................................................................................31

4.5 Pressurize the Fuel System: ............................................................................................................................31

4.6 Boiler Commissioning: This Section applies ONLY to the ARC1000 through ARC3000 ........31

4.7 Finish Commissioning the Boiler: This Section applies ONLY to the ARC1000 through

ARC3000..................................................................................................................................................................33

4.8 Re-Starting After Prolonged Shutdown......................................................................................................33

4.9 Testing of Controls and Safety Devices.......................................................................................................34

4.10 Ignition Failure ........................................................................................ Error! Bookmark not defined.

5 Service, Maintenance, and Inspection...................................................................................................................35

5.1 General Maintenance: ........................................................................................................................................35

5.1.1 DAILY:.................................................................................................................................................................................36

5.1.2 WEEKLY: ...........................................................................................................................................................................36

5.1.3 MONTHLY:........................................................................................................................................................................36

5.1.4 ANNUALLY:......................................................................................................................................................................36

5.2 Ignition Assembly Cleaning .............................................................................................................................37

5.3 Burner Assembly Cleaning...............................................................................................................................37

5.4 Heat Exchanger Cleaning..................................................................................................................................37

5.5 Tube Replacement Procedure ........................................................................................................................38

5.6 Safety and Operating Controls .......................................................................................................................42

5.7 Troubleshooting...................................................................................................................................................43

Appendix A Sizing Gas Piping...........................................................................................................................................46

Appendix B Vent and Combustion Air Pressure Drop Data.................................................................................48

Appendix C Installation & Startup Report...................................................................................................................50

Appendix D Venting Diagrams .........................................................................................................................................51

Appendix D.1 Typical Horizontal Vent Piping.......................................................................................................51

Appendix D.2 Typical Vertical Pressurized Venting ...........................................................................................52

Form: 2435-3

Arctic Installation and Operation Manual Revision: 10

P/N 105641-01 Date: 12-1-2018

Thermal Solutions, 1175 Manheim Pike, Lancaster, PA 17601 Web: www.thermalsolutions.com

Phone: 717-239-7642 Fax: 877-501-5212 Email: s[email protected]

Appendix E Combustion Air Diagrams .........................................................................................................................53

Appendix E.1 Typical Horizontal Air Intake Piping ............................................................................................53

Appendix E.2 Typical Vertical Air Intake Piping ..................................................................................................54

Appendix F Boiler Piping Diagrams –Typical Layout for all Boiler Models (Boilers may look

different than pictured) ....................................................................................................................................55

Appendix F.1 Single Boiler, Primary / Secondary ...............................................................................................55

Appendix F.2 Multiple Boilers, Primary Reverse-Return Piping...................................................................56

Appendix F.3 Multiple Boilers, Primary / Secondary Reverse Return Piping .........................................57

Appendix F.4 Multiple Boilers, Primary / Secondary Piping ..........................................................................58

Appendix F.5 Multiple Boilers, Primary / Secondary Piping, Heating with Domestic Hot Water...59

Appendix F.6 Multiple Boilers, Primary / Secondary Piping, Heating with Domestic Hot Water

(continued).............................................................................................................................................................60

Appendix G Water Flow Pressure Drops .....................................................................................................................61

Appendix H Wiring Diagrams...........................................................................................................................................63

Appendix H.1 ARC1000 Wiring Diagram ................................................................................................................63

Appendix H.2 ARC1500 To ARC3000 115 VAC Single Phase Wiring Diagram........................................65

Appendix H.3 ARC1500 To ARC3000 208 –230 VAC Single Phase Wiring Diagram ...........................67

Appendix H.4 ARC2000 To ARC3000 208-460 VAC Three Phase Wiring Diagram ..............................69

Appendix H.5 ARC3500 To ARC6000 208-460 VAC Three Phase Wiring Diagram ..............................71

Tables

Table 1 Water Flow Switch Settings ...............................................................................................................7

Table 2: Clearances and Serviceability ..........................................................................................................11

Table 3: Typical Condensate Flow Rate .......................................................................................................12

Table 4: Combustion Air and Flue Gas Requirements ..............................................................................19

Table 5: Electrical Requirements...................................................................................................................23

Table 6: Gas Supply Requirements ...............................................................................................................24

Table 7 Sound Pressure Levels ......................................................................................................................24

Table 8 Minimum Water Flow Rates for Variable Primary Pumping......................................................25

Table 9 Maximum Water Flow Rates for Variable Primary Pumping .....................................................25

Table 10 Water Flow Rates for Primary / Secondary Pumping 20F ΔT ................................................25

Table 11 Water Flow Rates for Primary / Secondary Pumping 40F ΔT ................................................26

Table 12: Water Flow Rates for Constant Volume Primary Pumping.....................................................26

Table 13 GPM Increase for Glycol Systems................................................................................................26

Table 14: Chemical Agents and Effects........................................................................................................29

Table 15 Recommended Feed Water Limits ...............................................................................................29

Table 16: Safety Device Test..........................................................................................................................34

Table 17: Safety and Operating Controls .....................................................................................................42

Table 18: General Troubleshooting ..............................................................................................................43

Table 19: Maximum Gas Capacity Of Schedule 40 Pipe ...........................................................................46

Table 20: Equivalent Lengths Of Standard Pipe Fittings And Valves.....................................................47

Table 21: Specific Gravity Correction Factors ............................................................................................47

Form: 2435-3

Arctic Installation and Operation Manual Revision: 10

P/N 105641-01 Date: 12-1-2018

Thermal Solutions, 1175 Manheim Pike, Lancaster, PA 17601 Web: www.thermalsolutions.com

Phone: 717-239-7642 Fax: 877-501-5212 Email: s[email protected]

Figures

Figure 1: ARC1000 External Boiler Connections and Components .........................................................8

Figure 2: ARC1500 - 3000 External Boiler Connections and Components .............................................8

Figure 3: ARC3500 - 6000 External Boiler Connections and Components ............................................9

Figure4: Clearances and Serviceability ..........................................................................................................10

Figure5: ARC 1000 Condensate Drain Trap ...............................................................................................13

Figure 6: ARC1500 - 6000 Condensate Drain Trap ...................................................................................13

Figure 7: High Fire Adjustment on the Main Gas Valve Regulator.........................................................33

Figure 8: Ignition Assembly ...........................................................................................................................37

Figure 9: Panel Removal in Preparation for Tube Inspection - ARC1000 .............................................39

Figure 10: Panel Removal in Preparation for Tube Inspection - ARC1500-ARC3000 .......................41

Figure 11: Panel Removal in Preparation for Tube Inspection - ARC3500-ARC6000.........................42

Figure 12: Tube Puller Insertion....................................................................................................................41

Form: 2435-3

Arctic Installation and Operation Manual Revision: 10

P/N 105641-01 Date: 12-1-2018

Thermal Solutions, 1175 Manheim Pike, Lancaster, PA 17601 Web: www.thermalsolutions.com

Phone: 717-239-7642 Fax: 877-501-5212 Email: s[email protected]

1Introduction

1.1 Important Information

The following terms are used throughout this

manual to bring attention to the presence of

hazards of various risk levels, or to important

information concerning product life. It is

critical that all personnel read and follow all

the information provided in the boxes marked

DANGER, WARNING, CAUTION, and

NOTICE.

DANGER

Indicates an imminently hazardous

situation, which, if not avoided, will result

in death, serious injury or substantial

property damage

WARNING

Indicates a potentially hazardous

situation, which, if not avoided, could

result in death, serious injury or

substantial property damage.

CAUTION

Indicates a potentially hazardous

situation, which, if not avoided, may result

in moderate or minor injury or property

damage.

NOTICE

Indicates specific instructions on

installation, operation, or maintenance,

which are important but not related to

personal injury hazards.

1.2 Disclaimers and Local Codes

Installation must conform to the requirements

of the authority having jurisdiction. In the

absence of such requirements, installation

must conform to the National Fuel Gas Code,

NFPA 54/ANSI Z223.1, and/ or

CAN/CGA B149 Installation Codes. Where

required by the authority having jurisdiction,

the installation must conform to the Standard

for Controls and Safety Devices for Automatically

Fired Boilers, ANSI/ ASME CSD-1.

Installation, start-up, and maintenance of this

equipment can be hazardous and requires

trained, qualified installers and service

personnel. Do not install, operate, service or

repair any components of this equipment

unless you are qualified and fully understand

all requirements and procedures. Trained

personnel refer to those who have completed

Thermal Solutions Service School training

specific to this product.

The boiler heat exchanger is manufactured

and stamped in accordance with ASME Boiler

and Pressure Vessel Code, Section IV for a

maximum allowable working pressure and

operating temperature of 160 psig (1103 kPa)

and 210 F(99 C) respectively. Aqua-stat is

factory set at 200 F (93 C).

NOTICE

Post these instructions and maintain in

legible condition.

Form: 2435-3

Arctic Installation and Operation Manual Revision: 10

P/N 105641-01 Date: 12-1-2018

Thermal Solutions, 1175 Manheim Pike, Lancaster, PA 17601 Web: www.thermalsolutions.com

Phone: 717-239-7642 Fax: 877-501-5212 Email: s[email protected]

1.3 Test and Inspections

Upon the completion of boiler installation,

final air-fuel adjustments are to be made by

factory trained service personnel. The

emissions data and the O2 levels at minimum

and maximum input rate can be found on the

back side of the front-boiler’s door, which can

be referenced in the future by the boiler

operator(s) when troubleshooting and

servicing the boiler. In addition, the following

tests and inspections are made on each boiler

at the factory to ensure it meets our highest

safety and functionality standards.

ASME hydrostatic test inspection

Electrical components inspection

Operating & efficiency test

Final engineering inspection

Crating inspection

Danger

DO NOT store or use gasoline or other

flammable vapors or liquids in the vicinity

of this or any other appliance.

If you smell gas vapors, DO NOT try to

operate any appliance—DO NOT touch

any electrical switch or use any phone in

the building. Immediately, call the gas

supplier from a remotely located phone.

Follow the gas supplier’s instructions or if

the supplier is unavailable, contact the fire

department.

1.4 Component Description

1. Touchscreen display. (Used on ARC1000

–ARC3000) The display provides easy

access for viewing and adjusting boiler

operational parameters, monitoring

historical performance characteristics and

annunciating boiler alarm/lockout

conditions.

2. Boiler On/Off switch. (Used on

ARC1000 –ARC3000)

3. Manual gas shutoff valve. The boiler is

equipped with two manual gas shut off

valves, one located on the incoming gas

supply line outside of the boiler, and the

other downstream of the main gas valve.

4. Main gas supply connection.

5. Pressure relief valve. The pressure relief

protects the heat exchanger from an over-

pressure condition.

6. Ducted combustion air flange.

7. Flue gas vent outlet. The boiler comes

with a standard AL 29-4C® stainless steel

vent connection.

8. Boiler water flow switch. The boiler

water flow switch is adjustable within the

parameters listed in Table 1.

Settings

Mode Of Operation

Switch

Closed

Switch

Open

Minimum

Maximum

Table 1 Water Flow Switch Settings

9. Return water connection. A 3” diameter

Victaulic grooved connection is provided

on the ARC1000. A 3”, 150# class, flange

is provided on the ARC1500 –3000. A

6”, 150# class, flange is provided on the

ARC3500-6000.

10. Cleanout and inspection. The ARC1000

has a 3” diameter Victaulic grooved

connection is provided for inspecting and

cleaning sediment from the heat

exchanger. The ARC1500-6000 has a 1”

npt pipe for blow down to clean sediment

from the heat exchanger and a 3”

removable plug for inspecting.

Form: 2435-3

Arctic Installation and Operation Manual Revision: 10

P/N 105641-01 Date: 12-1-2018

Thermal Solutions, 1175 Manheim Pike, Lancaster, PA 17601 Web: www.thermalsolutions.com

Phone: 717-239-7642 Fax: 877-501-5212 Email: s[email protected]

11. Supply water connection. A 3” diameter

Victaulic grooved connection is provided

on the ARC1000. A 3”, 150# class, flange

is provide on the ARC1500 –3000. A 6”,

150# class, flange is provided on the

ARC3500-6000.

12. Air vent. The boiler is provided with an

internal dip tube that traps liberated air

from the boiler water. The air vent allows

the trapped air to escape from the boiler.

13. Boiler reset push button.

14. Boiler water temperature gauge.

15. Boiler water pressure gauge.

References 16 to 18 are only used on

ARC3500 –ARC6000

16. Boiler Hand/Off/Auto

17. Push Button Display. The display

provides easy access for viewing and

adjusting boiler operational parameters

and provides alarm/lockout codes.

18. Temperature Display. Provides for

temperature set points and actual

temperature.

Figure 1: ARC1000 External Boiler

Connections and Components

Figure 2: ARC1500 - 3000 External Boiler

Connections and Components

Form: 2435-3

Arctic Installation and Operation Manual Revision: 10

P/N 105641-01 Date: 12-1-2018

Thermal Solutions, 1175 Manheim Pike, Lancaster, PA 17601 Web: www.thermalsolutions.com

Phone: 717-239-7642 Fax: 877-501-5212 Email: s[email protected]

Figure 3: ARC3500-6000 External Boiler

Connections and Components

2Pre-Installation

The customer should examine the equipment

for any damage. It is the responsibility of the

installer to ensure all parts supplied with the

equipment are fitted in a correct and safe

manner.

WARNING

This boiler requires regular maintenance

and service to operate safely. Follow the

instructions contained in this manual.

WARNING

Improper installation, adjustment,

alteration, service, or maintenance can

cause property damage, personal injury or

loss of life. Read and understand the

entire manual before attempting

installation, start-up operation, or service.

Only an experienced, skilled installer or

service agency must perform installation

and service.

WARNING

This boiler must be properly vented.

WARNING

This boiler needs fresh air for safe

operation and must be installed so there

are provisions for adequate combustion

and ventilation air.

2.1 Installation Conformance

Installation must conform to the requirements

of the authority having jurisdiction. In the

absence of such requirements, installation

must conform to the National Fuel Gas Code,

NFPA 54/ANSI Z223.1, and/ or CAN/CGA

B149 Installation Codes. Where required by

the authority having jurisdiction, the

installation must conform to the Standard for

Controls and Safety Devices for Automatically

Fired Boilers, ANSI/ ASME CSD-1.

2.2 Boiler Foundation

Before uncrating, the boiler location should

be prepared. The boiler should set upon a

good level concrete floor. If the boiler is not

level or the floor is not in good condition, a

concrete foundation should be built, the

dimensions being larger than the outside

dimensions of the boiler base. A 4” high

housekeeping pad is suggested.

WARNING

Do not install boiler on combustible

flooring.

2.3 Clearances and Serviceability

See Figure 4 and Table 2 for minimum

clearances to walls, ceilings, or obstructions.

These clearances are intended as a general

Form: 2435-3

Arctic Installation and Operation Manual Revision: 10

P/N 105641-01 Date: 12-1-2018

Thermal Solutions, 1175 Manheim Pike, Lancaster, PA 17601 Web: www.thermalsolutions.com

Phone: 717-239-7642 Fax: 877-501-5212 Email: s[email protected]

recommendation only. Local codes must be

applied to specific installations and the

minimum clearances established accordingly.

Provisions must also be made for service,

accessibility and clearance for piping and

electrical connections. Do not obstruct

combustion air and ventilation openings with

piping or any other construction. All boilers

must be installed in a space that is large

compared to the boiler.

Figure 4: Clearances and Serviceability

Boiler

Flue Gas

Vent

Boiler

Ce manuel convient aux modèles suivants

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