Triad Triumph series Manuel utilisateur

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Installation Date: _______________________

TRIAD Boiler Systems, Inc.

1099 Atlantic Drive, Unit 2

West Chicago, IL 60185

Phone: 630.562.2700

Fax: 630.562.2800

www.triadboiler.com

Version 1.0 / 1-08-08

C.S.A Design-Certified

Complies with ANSI Z21.13/CSA 4.9

Gas-Fired Low Pressure Steam & Hot Water

Boilers

ASME Code, Section IV

C.S.A Design-Certified

Complies with ANSI Z21.13/CSA 4.9

Gas-Fired Low Pressure Steam & Hot Water

Boilers

-F

ATTENTION!!!

WATER:

ÿ The pH of the system must be between 6.0 and 8.5. Periodically check the pH!

ÿ If Glycol is used it must be approved by the chemical manufacturer for aluminum boilers!

VENTING:

ÿ This boiler is Category IV (condensing positive pressure) and is NOT certified for use with

Type “B”vent!

HEAT EXCHANGER:

ÿ Maximum operating pressure is 80 psi and maximum temperature is 200° F!

BURNER:

ÿ If the material surrounding the burner tube is ripped in any way, it MUST be replaced!

ÿ Change the spark iginiter once a year!

MANUAL RESET SERVICE CODES:

ÿ A few of the more common lockout codes: (See page 33 for all of them.)

Code Lockout Description

E 00 False flame. A flame signal is present when it shouldn’t be.

E 02 Flame failure. The burner did not light on startup, or loss of flame during run.

E 03 Gas Valve error. Check all gas valves electrical connections.

E 08 Air pressure switch open Air pressure switch failed to close to indicate sufficient air flow to start the boiler.

E 12 External limit open An external limit has opened. (High/Low Gas Pressure, High Temp, or LowWater)

ÿ If any “Manual Reset”limit device trips, DO NOT reset without determining and correcting

the cause!!

-F

1.0 INTRODUCTION ................................ ....... 2

2.0 SAFETY ................................ .................... 2

2.1 General................................ ............................ 2

2.2 Training ................................ ........................... 2

2.3 Safety Features................................ ................2

2.4 Safety Labels................................ ...................3

2.5 Safety Precautions................................ ...........3

2.5.1 Electrical Hazards................................ ...3

2.5.2 Burn, Fire, and Explosion Hazards..........3

2.5.3 Crush Hazards................................ ........4

2.5.4 Chemical Hazards................................ ...4

2.5.5 Pressure Hazards................................ ...5

2.5.6 Slip, Fall Hazards................................ ....5

3.0 INSTALLATION................................ ......... 6

3.1 Receiving and Storage................................ .....6

3.1.1 Initial Inspection................................ ......6

3.1.2 Storage Prior to Installation.....................6

3.2 Compliance with Codes................................ ....6

3.3 Setup................................ ............................... 6

3.3.1 Foundation................................ ..............6

3.3.2 Placement ................................ ..............7

3.3.3 Clearances................................ .............7

3.4 Electrical Connections................................ ......7

3.5 Combustion Air................................ ................8

3.5.1 Air Inlet Requirements............................. 8

3.6 Flue Venting................................ .....................9

3.6.1 Barometric Damper................................ .9

3.6.2 Flue Connection................................ ......9

3.6.3 Required Clearances.............................. 9

3.6.4 Vent Terminations................................ .10

3.6.5 Venting for Multiple Boilers.................... 10

3.6.6 Sealed Combustion Air/Venting System 11

3.6.7 Removing an Existing Boiler .................11

3.6.8 Intake/Exhaust Layout........................... 11

3.6.9 Intake Duct Materials and Sizes:...........12

3.6.10 Sealing the Intake Duct....................... 13

3.6.11 Intake Duct Connection to Boiler.........13

3.6.12 Intake Duct Terminations ....................13

3.6.13 Vent Elbows................................ ........13

3.7 Gas Piping................................ ..................... 13

3.7.1 Gas Supply Piping by Installer...............15

3.8 Boiler Water Piping ................................ ........15

3.8.1 Piping Design................................ ........15

3.8.2 Boiler Inlet and Outlet Connections.......16

3.8.3 Boiler Water Piping by Installer..............17

3.8.4 Water Quality, Flushing and Filling........17

3.9 Burner and Ignition System............................ 18

3.9.1 Inspection................................ .............18

3.10 Pre-Start Check List................................ .....19

3.11 Safety Checks................................ ..............19

3.11.1 Test of Ignition Safety System.............19

3.11.2 Test of Low Water Cut Off...................19

3.11.3 Test of High-Limit Control....................20

3.11.4 Test of Gas Pressure Switch...............20

3.12 Initial Adjustments................................ ........20

3.12.1 Operating Temperature Controller.......20

3.12.2 Gas Pressure Adjustment ...................25

3.12.3 Air Flow Adjustments .......................... 25

3.12.4 Gas Valve Setup and Adjustment........25

4.0 OPERATION................................ ........... 28

4.1 General................................ .......................... 28

4.1.1 Control Panel Front............................... 28

4.1.2 Tests ................................ ....................28

4.2 Normal Lighting and Shut-Down Procedures..28

4.2.1 Lighting Procedures.............................. 28

4.2.2 Normal Shut Down Procedures.............28

4.2.3 Emergency Shut-Off.............................. 28

4.3 Typical Boiler Operating Conditions................29

-F

5.0 MAINTENANCE ................................ ...... 30

5.1 Maintenance and Inspection Schedule...........30

5.1.1 Daily................................ ..................... 30

5.1.2 Weekly................................ ..................30

5.1.3 Monthly (During Operation)................... 30

5.1.4 Semi-Annually (every 6 months) ...........31

5.1.5 Annually................................ ................31

5.2 Cleaning the Burner................................ .......31

5.3 After All Repairs or Maintenance.................... 31

5.4 Sequence of Operation................................ ..32

5.5 Troubleshooting................................ .............32

5.5.1 Manual Reset Service Codes................34

5.5.2 Auto-reset Service Codes..................... 35

6.0 PARTS/TECHNICAL SUPPORT............. 36

6.1 Wiring Diagrams ................................ ............37

6.1.1 Terminal Block Assignments –High Voltage

Circuit (TB2)................................ .............37

6.1.1a Terminal Block Assignments –Low Voltage

Circuit (TB1)................................ .............38

6.1.2 Wiring Triad Series 750/900/1000.........39

6.2 Boiler Parts List................................ ..............40

6.2.1 Main Assembly ................................ .....40

6.2.2 Control Panel................................ ........41

6.2.3 Display Panel................................ ........42

6.2.4 Triad-750/900/1000 Heat Exchanger.....43

6.2.5 Triad-750/900/1000 Gas Train ..............44

7.0 LIMITED WARRANTY ............................ 45

8.0 APPENDIX................................ .............. 47

It is essential to read, understand, and follow

this manual before installing, operating, or

servicing this equipment. Failure to do so

could result in fire or explosion and serious

injury, death, and/or property damage.

The features which permit this boiler to

achieve high-efficiency performance make it

unlike most other boilers of this general size,

so it is important to understand how it

operates.

Do not store or use gasoline or other

flammables in the vicinity of this or any other

appliance. Chemicals, fuels, or other

potentially hazardous or toxic materials must

not be stored in the same room as the boiler.

Installation and service must be performed by

a qualified installer or service agency that has

been trained on the Triad TRIUMPH Boiler

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 fire department.

-F

Triad Boiler Systems, Inc –TRIUMPH Series Hot Water Boiler Page 2

1.0 INTRODUCTION

Congratulations on purchasing the highly efficient

TRIUMPH Series Gas-Fired Boilers form Triad

Boiler Systems, Inc. These boilers feature an

aluminum alloy heat exchanger capable of

operating in a fully condensing mode to provide

maximum efficiency in a very small footprint. This

is complemented by a fully modulating burner

with a variable speed combustion blower,

microprocessor controls, and modulating gas

safety shut off & control valves. The high-quality

materials and thoroughly tested design of your

boiler will provide years of trouble-free service if

the instructions in this manual are carefully

followed.

This manual covers installation of the TRIAD

TRIUMPH Series Boilers. The model numbers

may be followed by a prefix or suffix letter in

some cases to indicate special features or

options.

While details may differ slightly, basic operation is

the same for all models. Boilers may be built to

operate with natural gas or propane. Check the

rating plate for correct fuel usage and gas

pressures.

The boiler is only a part of the complete heating

system. It may be fully operational, yet because

of poor circulation, control, or other operating

characteristics, not deliver heat to the desired

location. Additional equipment such as

temperature sensors, pumps, flow switches,

balancing valves, and check valves will be

required for satisfactory operation of any system.

Triad Boiler Systems cannot be responsible for

the design or operation of such systems and a

qualified engineer or contractor must be

consulted.

2.0 SAFETY

2.1 GENERAL

The TRIUMPH Seriesgas-fired boiler must be:

∑ Installed, operated, and serviced in

accordance with instructions contained in this

manual.

∑ Installed by qualified personnel in accordance

with designs prepared by qualified facility

engineers including: structural, mechanical,

electrical, and other applicable disciplines.

∑ Operated and serviced in accordance with a

comprehensive safety program determined

and established by the customer. Do not

attempt to operate or service until such a

program has been established.

∑ Operated and serviced by qualified, properly

trained personnel in accordance with all

applicable codes, laws, and regulations.

Note: Each safety device must be maintained

and checked per the recommended schedule;

refer to Section 5.1 of this manual.

2.2 TRAINING

It is essential to read, understand, and follow the

recommendations of this manual before installing,

operating, or servicing this equipment. Failure to

do so could result in property damage, serious

injury, or death.

Proper training is the best protection against

accidents. Operating and service personnel must

be thoroughly familiar with the basic construction

of the TRIAD TRIUMPH Series boiler, the use

and locations of the controls, the operation of the

boiler, adjustment of its various mechanisms, and

all applicable safety precautions. If any of the

provisions of this manual are not fully and

completely understood, contact Triad Boiler at

630.562.2700 for assistance.

2.3 SAFETY FEATURES

It is the responsibility of the customer to maintain

the safety features, such as: guards, safety

-F

Triad Boiler Systems, Inc –TRIUMPH Series Hot Water Boiler Page 3

labels, safety controls, interlocks, lockout devices,

etc., in place and operable.

2.4 SAFETY LABELS

NOTE

Reorder No. 8032-01NHPK

When opening leak test valves,

always follow instructions in

operation and safety manual.

1998 HCS, Inc. 800-748-0241

The safety labels shown above are affixed to your

boiler. Although the labels are of high quality,

they may become dislodged or unreadable over

time. Contact Triad Boiler Systems at

630.562.2700 for replacement labels.

2.5 SAFETY PRECAUTIONS

Provide a suitable location for the boiler, away

from normal personnel traffic, with adequate

working space, adequate clearances, proper

ventilation and lighting, with a structure

sufficiently strong and rigid to support the weight

of the boiler, all piping, and accessories.

2.5.1 Electrical Hazards

∑ Shock hazard! Properly lockout/tagout the

electrical service and all other energy sources

before working on or near the boiler.

∑ Shock hazard! Do not spray water directly on

any electrical components.

2.5.2 Burn, Fire, and Explosion Hazards

General Warning

Hot Surface

NOTE

Reorder No. 8032-01NHPK

When opening leak test valves,

always follow instructions in

operation and safety manual.

1998 HCS, Inc. 800-748-0241

∑ Burn, fire, and explosion hazards!

Installation must be in strict conformance to

all applicable codes and standards including

NFPA 54, ANSI Z223.1 and CAN/CGA B.149.

Install all required vent lines for gas devices.

Refer to Section 3.7.1.

∑ Hazard from incorrect fuels! Possible fire,

explosion, overheating, and damage. Do not

use any fuels except the design fuels for the

unit.

∑ Overfire hazards! High pressure in gas or

propane supply could result in overfiring of

other devices supplied from the same source.

∑ Fire and explosion hazards! Close the main

gas shutoff before servicing boiler.

∑ Fire and explosion hazards! Do not store or

use gasoline or other flammable vapors or

liquids in the vicinity of this or any other gas

fired appliance.

∑ Burn hazard! Possible hot surfaces. Do not

touch gas vent during firing operation. Use

only factory recommended vent components.

∑ Burn hazard! Pipes, vents, and boiler

components could be hot. Do not touch piping

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Triad Boiler Systems, Inc –TRIUMPH Series Hot Water Boiler Page 4

or stack surfaces during operation or

immediately after shutdown of the boiler.

∑ Burn hazard! Hot fluids. Use caution when

servicing or draining boiler.

∑ Fire and explosion hazards! Use caution

when servicing burner. Propane (LPG) is

heavier than air and may linger in the

combustion chamber, vent lines, or

elsewhere.

∑ Gas leak hazard! Make sure the burner is

installed correctly and burner hood is securely

fastened following any maintenance

performed on them. These connections

cannot be tested after the burner is

assembled.

∑ Gas leak hazard! All threaded gas

connections must be made using a pipe

compound that is resistant to liquefied

petroleum. Do not use Teflon‰tape on

threaded gas piping.

∑ Gas leak hazard! Check entire gas train for

leaks after installation. If there is a smell of

gas, shut down the boiler and obtain

immediate assistance from trained service

personnel and/or your local fire department.

∑ Overfire hazard! Possible fire and explosion

from excess gas pressure. Make sure that

gas inlet pressure does not exceed 14 inches

W.C. to the regulator.

∑ Overfire hazard! Possible fire and explosion.

Possible malfunction of regulators and/or gas

safety shut off / control valves. Maintain all

gas train components in good condition. Do

not alter wiring connections. Annual

inspection by factory-trained personnel for

proper set-up and operation is recommended.

∑ Overfire and underfire hazards! Possible

fire, explosion, overheating, and component

failure. Do not attempt to adjust firing rate of

the boiler. The firing rate must be adjusted

only by factory trained personnel.

2.5.3 Crush Hazards

General Warning

∑ Lifting hazards! Use properly rated lifting

equipment to lift and position the boiler. The

load is unbalanced. Test balance before lifting

3 ft. above the floor. Do not allow personnel

beneath the lifted load. Refer to approximate

weights in the table below:

Boiler Size Weight in Pounds

750,000 Btu 650

900,000 Btu 700

1,050,000 Btu 750

∑ Bump hazard from overhead ductwork and

piping. Install components with adequate

vertical clearance.

2.5.4 Chemical Hazards

General Warning

∑ Chemical hazards from cleaning products.

Use caution when cleaning the system.

Consulting a professional is recommended.

Use safe procedures for the disposal of all

cleaning solutions.

∑ Combustion Condensate –a pH of

approximately 4 to 5 can be expected. Use

PVC or CPVC piping. Collection and disposal

must be in accordance with all applicable

regulations.

-F

Triad Boiler Systems, Inc –TRIUMPH Series Hot Water Boiler Page 5

2.5.5 Pressure Hazards

∑ Pressure hazard! Hot fluids. Install isolation

valves on boiler water inlet and outlet. Make

sure isolation valves are closed before

servicing boiler.

∑ Pressure hazard! Hot fluids. Annually test

safety relief valve for proper operation. Do not

operate boiler with faulty relief valve.

2.5.6 Slip, Fall Hazards

∑ Tripping hazard! Do not install piping on floor

surfaces. Maintain clear path around boiler.

∑ Slip and fall hazard! Use drip pan to catch

water while draining the boiler. Maintain dry

floor surfaces.

∑ Slip and fall hazard! Do not locate intake or

exhaust terminations directly above a

walkway; dripping of condensation can cause

icing of the walking surface.

-F

Triad Boiler Systems, Inc –TRIUMPH Series Hot Water Boiler Page 6

3.0 INSTALLATION

3.1 RECEIVING AND STORAGE

3.1.1 Initial Inspection

Upon receiving the boiler, inspect it for signs of

shipping damage. Since some damage may be

hidden, we recommend unpacking the boiler and

removing the top cover and inspecting the boiler.

Verify that the total number of pieces shown on

the packing slip agrees with those actually

received.

Important: Note any damage, suspected

potential damage, or shortage of materials on

the freight bill and immediately notify the

carrier. File all claims for shortage or damage

with the carrier. Claims for hidden damages

must be filed with your carrier within 7 days.

The boiler carton is equipped with a “Tip (N)

Tell”. If "Tip (N) Tell”arrow point is blue, that

indicates that the package has been on its

side or tipped over in transit.

3.1.2 Storage Prior to Installation

If the boiler is not installed immediately, it must be

stored in a location adequately protected from the

weather, preferably indoors. If this is not possible,

then it should remain in the shipping container

and be covered by a tarpaulin or other waterproof

covering.

Note: Controls and other equipment that are

damaged or fail due to weather exposure are

not covered by warranty.

3.2 COMPLIANCE WITH CODES

The TRIAD TRIUMPH Series Boiler with standard

components and with many options complies with

American National Standard/CSA Standard ANSI

Z21.13/CSA 4.9, latest edition, Gas-Fired Low

Pressure Steam and Hot Water Boilers.

The heat exchanger is constructed and stamped

in accordance with ASME Boiler and Pressure

Vessel Code, Section IV for 80 psig maximum

operating pressure and/or 200º F maximum

temperature.

Other codes or approvals which apply will be

labeled on the boiler.

Installation of the boiler must conform to all the

requirements of all national, state and local

codes established by the authorities having

jurisdiction or, in the absence of such

requirements, in the U.S. to the National Fuel

Gas Code, ANSI Z223.1/NFPA 54, latest edition.

In Canada, the equipment shall be installed in

accordance with the current Installation Code for

Gas Burning Appliances and Equipment,

CAN/CGA-B.149, and applicable Provincial

Regulations for the class, which should be

carefully followed in all cases. Authorities having

jurisdiction should be consulted before

installations are made.

Where required by local codes, the installation

must conform to American Society of Mechanical

Engineers Safety Code for Controls and Safety

Devices for Automatically Fired Boilers (ASME

CSD-1).

In the Commonwealth of Massachusetts (a) this

unit must be installed by a licensed pipe fitter /

plumber, (b) field installed gas cocks must be “T”

handle type, and (c) piping of condensate shall

conform with the State Plumbing Code.

3.3 SETUP

3.3.1 Foundation

Provide a firm, level foundation, preferably of

concrete.

Note: The boiler may be installed on a

combustible floor; however, the boiler must

never be installed on carpeting.

-F

Triad Boiler Systems, Inc –TRIUMPH Series Hot Water Boiler Page 7

3.3.2 Placement

The boiler must be level to function properly. To

assist in leveling the boiler, the four (4) adjustable

leg bolts (1/2"- 13 NC) must be installed. The

adjustable legs are also necessary to provide

adequate floor clearance and prevent distortion of

the cabinet, (twisting, etc.) in addition to leveling.

Adjustable Legs for Leveling and Clearance

3.3.3 Clearances

If the boiler is to be installed near combustible

surfaces, the minimum clearances shown in the

table below must be maintained.

Failure to provide for the service access

clearances, even with non-combustible surfaces,

may cause future problems servicing the boiler.

The boiler must be installed in a space large in

comparison to the boiler as described in Section

6.3 of the National Fuel Gas Code, ANSI Z223.1,

latest edition.

Minimum Clearances from Adjacent Walls, Ceiling, and

Obstructions

Dimensions (inches)Type of Surface

A B C†D

Combustible Surfaces 24 24 24 24

Non-combustible Surfaces 30 * 24 24**

†"C" Do not put pipes, ducts, etc. in this area

above the boiler.

CAUTION!

Bumping hazard from overhead ducts! Install all

components with adequate vertical clearances.

* Clearance depends upon vent configuration.

** Service access need be only on one side of a

boiler or row of boilers. Boilers may be installed

immediately adjacent to each other. However

Triad recommends this clearance between each

boiler when there is insufficient access at the

rear to allow for service and adjustment.

3.4 ELECTRICAL CONNECTIONS

The boiler is wired for 120 volts, single phase, 60

hertz. The total operating amperage is indicated

on the rating nameplate. All TRIUMPH units

require less than 8 amps. Before starting the

boiler, check to ensure that the proper electrical

service is connected to the boiler.

No pipes,

ducts, etc. in

this area.

A B

D D

Adjustable

Leg Bolts

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