1 ARCTIC Rev. 6 08/14/15 High Efficiency, Low Emission CONDENSING BOILER INSTALLATION & OPERATION MANUAL
2 INTRODUCTION Important Information The following terms shown on the right hand side of this page 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. 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). Post these instructions and maintain in legible condition. 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 O 2 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 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. 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.
3 Component Description 1. Communication Interface (display screen) The Arctic condensing boiler is equipped with a touchscreen display which 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 3. Manual gas 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. Supply gas line This is the connection to the incoming gas supply that delivers gas to the main gas valve and burner. 5. Pressure relief valve The pressure relief valve protects the heat exchanger from an over-pressure condition. Boiler comes with a 50 psi standard relief valve, and optional settings are available. 6. Combustion air intake This provides a pathway for combustion air to enter the boiler by a means of positive suction created by the blower. Replaceable filter (included) prevents debris from entering the boiler. 7. Exhaust vent connection The Arctic boiler comes with a standard AL 29-4C stainless steel vent connection. The vent pipe is used to convey combustion products to a safe point of discharge. Figure 1A: External Boiler Connections and Components 8. Water flow switch In the event of insufficient water flow, the boiler will shut down by the action of the flow switch. 9. Inlet /return water connection A 3 diameter steel manifold with a Victaulic grooved connection conveys the return water from the system to the boiler. 10. Boiler drain A 3 diameter steel manifold provides a capped clean-out opening and 1 drain valve. 11. Outlet /supply water connection A 3 diameter steel manifold with a Victaulic grooved connection conveys the supply water from the boiler to system 12. Air Vent An air vent allows entrapped air to escape from the heat exchanger.
4 PRE-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. 1. 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. Check building specification for permissible floor loading. 3. The boiler is not design certified for installation on combustible flooring. The boiler must not be installed on carpeting. 4. Provide clearance between boiler jacket and combustible material in accordance with local fire ordinance. Refer to page 7 of this manual for minimum listed clearance from combustible material. 5. Install on level floor. For basement installation, provide concrete base if floor is not perfectly level or if water may be encountered on the floor around boiler. Floor must be able to support weight of boiler, water, and all additional system components. 6. Protect gas ignition system components from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, condensate trap service, control replacement, etc.). 7. Provide combustion and ventilation air in accordance with applicable provision of local building codes or: USA-National Fuel Gas Code, NFPA 54/ ANSI Z223.1, Section 5.3, Air for Combustion and Ventilation; Canada-Natural Gas Installation Code, CAN/CGA- B149.1, or Propane Installation Code, CAN/CGA-B149.2, Part 5, Venting Systems and Air Supply for Appliances. WARNING This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. 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. Installation and service must be performed only by an experienced, skilled installer or service agency. This boiler must be properly vented. This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air. The interior of the venting and air intake system must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions. Clean and unobstructed venting and air intake systems are necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler s efficiency. The following guideline is based on the National Fuel Gas Code, NFPA 54/ANSI Z223.1. 1. Determine volume of space (boiler room). Rooms communicating directly with space (through openings not furnished with doors) are considered part of space. Volume [ft 3 ] =Length [ft.] x Width [ft.] x Height [ft.]
5 2. Determine Total Input of all appliances in space. Round result to nearest 1,000 Btu per hour (Btuh). 3. Determine type of space. Divide Volume by Total Input. a. If result is greater than or equal to 50 ft 3 per 1,000 Btuh, space is considered an unconfined space. b. If result is less than 50 ft 3 per 1,000 Btuh, space is considered a confined space. 4. Determine building type. A building of unusually tight construction has the following characteristics: a. Walls and ceiling exposed to outside atmosphere have a continuous water vapor retarder with rating of 1 perm or less with openings gasketed and sealed, and; b. Weather-stripping has been added on open-able windows and doors, and; c. Caulking or sealants applied in joints around window and door frames, between sole plates and floors, between wall-ceiling joints, between wall panels, at plumbing and electrical penetrations, and at other openings. 5. For boiler located in an unconfined space in a building of other than unusually tight construction, adequate combustion and ventilation air is normally provided by fresh air infiltration through cracks around windows and doors. 6. For boiler located within an unconfined space in a building of unusually tight construction or within a confined space, provide outdoor air through two permanent openings which communicate directly or by duct with the outdoors, or space (crawl or attic) freely communicating with the outdoors. Locate one opening within 12 inches of top of space. Locate remaining opening within 12 inches of bottom of space. Minimum dimension of air opening is 3 inches. Sizing each opening per the following; a. Direct communication with the outdoors. Minimum free area of 1 square inch per 4,000 btu per hour input of all equipment in space. b. Vertical ducts. Minimum free area of 1 square inch per 4,000 Btu per hour input of all equipment in space. Duct cross- sectional area shall be same as opening free area. WARNING This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative. This boiler contains very hot water under high pressure. Do not unscrew any pipe fitting, nor attempt to disconnect any component of this boiler without positively assuring the water is cool and has no pressure. Always wear protective clothing and equipment when installing, starting up or servicing this boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler. This boiler contains components which become very hot when the boiler is operating. Do not touch components unless they are cool. Boiler materials of construction, products of combustion, and the fuel, contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/ or other toxic or harmful substances which can cause death or serious injury, and which are known to the state of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing or working nearby the appliance. Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions, including all those contained in component manufacturer s manuals which are provided with the boiler before installing, starting up, operating, maintaining or servicing.
6 7. Alternate method for boiler located within confined space. Use indoor air if two permanent openings communicate directly with additional space(s) of sufficient volume such that combined volume of all spaces meet criteria for unconfined space. Size each opening for minimum free area of 1 square inch per 1,000 Btu per hour input of all equipment in spaces, but not less than 100 square inches. 8. Ventilation Duct Louvers and Grilles. Equip outside openings with louvers to prevent entrance of rain and snow, and screens to prevent entrance of insects and rodents. Louvers and grilles must be fixed in open position or interlocked with equipment to open automatically before burner operation. Screens must be smaller than ¼ inch mesh. Consider the blocking effect of louvers, grilles and screens when calculating the opening size to provide the required free area. If free area of louvers or grilles is not known, assume wood louvers have 20-25 percent free area and metal louvers and grilles have 60-75 percent free area. Unpacking the Boiler A. Move boiler to approximate installed position. WARNING Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors or liquids. All cover plates, enclosures and guards must be in place at all times. This product must be installed by a licensed plumber or gas fitter when installed within the Commonwealth of Massachusetts. Do not install boiler where gasoline or other flammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used or stored. B. Remove all packing fasteners. C. Open outside packing and remove all inside protective spacers and bracing. NOTICE Boiler packaging is equipped with a tip & tell label. If the label indicates boiler has been tipped over during shipping, remove packaging and inspect before trucker leaves. Due to the low water content of the boiler, incorrect sizing of the boiler with regard to the heating system load will result in excessive boiler cycling and accelerated component failure. Thermal Solutions DOES NOT warrant failures caused by incorrectly sized boiler applications. Do NOT oversize the boiler to the system. Modular boilers greatly reduce the likelihood of boiler oversizing.
7 Water Treatment Prior to installing the boiler, flush the system to remove sediment. Do not use petroleum-based cleaning agents in the boiler system. The quality of water used in the heating system is essential for the successful operation and longevity of the system components. A successful water treatment plan will help to maintain efficiency, reduce the regularity of repair and/or replacement, and extend the working life of the boiler and other system equipment. If left untreated, poor water quality could cause a number of problems including, but not limited to, oxidation, scaling, corrosion, and fouling. See Table 2A for examples of typical chemical agents found in untreated water along with their potential effects. Table 2A: Chemical Agents and Effects Compound Effect Calcium Carbonate, (CaCO3) Soft Scale Calcium Bicarbonate (CaHCO3) Soft scale, CO2 Calcium Sulphate (CaSO4) Hard Scale Calcium Chloride (CaCl2) Corrosion Magnesium Carbonate (MgCO3) Soft Scale Magnesium Bicarbonate (MgHCO4) Corrosion, Scale Magnesium Sulphate (MgSO4) Corrosion Silicon Dioxide (SiO2) Hard Scale Since the condition of water varies from location to location, it is impossible to prescribe a one-size-fits-all treatment plan for the system water. In order to develop an effective water treatment plan, it will be necessary to gain knowledge of the impurities dissolved in the water. Once all the impurities are identified, the proper treatment plan can be established. Therefore, it will be essential to obtain the expertise of a qualified industrial water treatment professional for establishing a treatment plan. CAUTION The water shall have a maximum water hardness of 8.5 grains/gal or 150 ppm. The recommended ph range is 8.3 to 10. However, other aspects of water quality can affect boiler operation and longevity. A qualified water treatment expert should be consulted to develop a complete water treatment plan. Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Thermal Solutions Standard Warranty does not cover problems caused by oxygen contamination of boiler water. Proper water treatment and boiler maintenance is required to avoid scale build-up on the inside of the boiler. Thermal Solutions Standard Warranty does not cover problems caused by scale build-up. When using Glycol products, all Glycol manufacturers requirements, including rust inhibitors, must be adhered. Max 50% Glycol. A periodic testing/sampling plan should be developed. The intent of the plan should be to: ensure the protection of the boiler and system equipment, (2) prevent an unforeseen system failure, (3) provide information for use in addressing water quality, and (4) to confirm the proper concentration of chemicals in use. Clearances and Serviceability 1. Strictly follow all local and national codes for proper clearances and serviceability when installing the boiler. 2. Maintain adequate clearances around the equipment front, back, side and top for ease of access for serviceability and maintenance purpose. See Figure 2B. WARNING Chemicals used in treating boiler water are toxic and/or harmful. Always use protective clothing and equipment when working with/near chemicals. Contact local authorities to determine if treated boiler water can be discharged into local waste water system.
Figure 2A: Boiler Dimensions, Clearances and Capacity Data 8
9 INSTALLATION Ensure all labels on the boiler will be fully visible for maintenance and inspection. Do not change or modify any boiler accessories or parts, or jump-out any safety limit devices. Venting Requirements In order to properly vent this boiler, the installer must select and install a venting system that meets all requirements specified in this section (VENTING REQUIREMENTS), as well as following the instructions provided by the venting system manufacturer. a. The venting system shall be designed and constructed in accordance with the National Fuel Gas Code, NFPA 54 / ANSI Z223.1 and applicable local building codes to develop a positive flow adequate to convey flue or vent gasses to the outdoors. b. If this boiler is being installed in Massachusetts, follow the Massachusetts Code Instructions printed later in this section. c. Consult the vent pipe manufacturer s instructions for vent system assembly and system specific installation requirements. d. Vent pipe system shall be acceptable for use with boiler fuel type. e. Vent pipe system shall be compatible either by directly connecting, or by using an adaptor, to the boiler vent connection. i. This boiler is shipped with an AL 29-4C Heat-Fab Saf-T-Vent connection. ii. Alteration of the boiler vent connection is prohibited. f. Do not reduce the diameter of the vent pipe. The vent pipe must not be smaller than the vent connector on the boiler. g. Vent pipe system must be adequately supported at intervals no less than five (5) feet apart. The completed vent system must be rigid and able to withstand impacts without collapse. h. The boiler s venting is Category IV (positive vent pressure, flue condensing), with regards to the National Fuel Gas Code, NFPA 54 / ANSI Z223.1. i. Vent pipe system must be fully sealed. j. Atmospheric venting is prohibited. k. For multiple boiler installations, each boiler must have its own independent vent system. Common venting with additional or any other appliances is prohibited. l. Direct venting applications: For direct vent (ducted combustion air) installations, the maximum vent length is 100 equivalent feet. The vent length is equal to the total length of straight pipe plus the equivalent length of vent fittings. m. Non-direct vent applications: For non-direct vent installations (those without ducted combustion air), design the vent system so that the pressure measured at the outlet of the boiler is between 0 w.c. and 0.3 w.c. at high fire. n. If any point of the vent pipe system is higher than the boiler flue outlet, the vent system must have an adequate condensate drain loop(s) to prevent condensate from running back into the boiler. o. It is permissible to run vent pipe through a vertical or horizontal chase provided minimum clearances to combustible materials are maintained. p. The minimum clearance to combustible material is six (6) inches unless otherwise specified by the manufacturer. q. Horizontal vent pipe must slope no less than one inch in four (4) feet of run. For sidewall venting, slope pipe toward vent termination if possible.
10 r. The vent termination location is restricted as follows: 1. Minimum twelve (12) inches above grade plus normally expected snow accumulation or seven (7) feet above grade if located adjacent to public walkways. DO NOT INSTALL over public walkway where local experience indicates condensation or vapor from the boiler creates a nuisance or hazard. 2. Minimum three (3) feet above any forced air inlet located within ten (10) feet of the vent termination. 3. Minimum four (4) feet below, four (4) feet horizontally or one foot above any door, window or gravity air inlet. 4. Minimum four (4) feet horizontally from electric meters, gas meters, regulators and relief valves. This distance may be reduced if equipment is protected from damage due to condensate or vapor by enclosure, overhangs, etc. s. Use appropriately designed thimbles when passing through combustible walls or roofs. t. Install fire-stops where vent passes through floors, ceilings or framed walls. The fire-stop must close the opening between the vent pipe and the structure. u. Enclose vent passing through occupied or unoccupied spaces above the boiler with materials having a fire resistance rating at least equal to the rating of the adjoining floor or ceiling. Maintain minimum clearance to combustible materials. v. Locate vent terminal above combustion air intake terminal (if used) and no closer than foot horizontally. w. Vertical venting requires flashing and a storm collar to prevent moisture from entering the structure. x. Vertical vent termination must be at least two (2) feet plus the expected snow accumulation above roof penetration height. y. This boiler has been certified with AL29-4C venting. Select a vent material that is approved for use with condensing flue gasses. z. Install vent system before installing air intake, water, gas or electrical connections. aa. For instances where the vent system manufacturer s instructions do not make a specification, refer to the below points. 1. Make sure pipe and fittings are clean by swabbing with alcohol. Use Dow Corning 736 or 732 RTV, Polybar # 500 RTV or Sil-Bond 4500 or 6500 or seal vent pipe. 2. Refer to the appropriate drawings in this section of this manual to determine common acceptable configurations of vent system. WARNING Improper venting may result in property damage and the release of flue gasses which contain deadly carbon monoxide (CO) into the building, which can cause severe personal injury and/ or death. Vent pipe system must be made of materials approved for use with condensing flue gasses at the expected stack temperatures. Do not use vent dampers or barometric damper with this boiler.
11 Massachusetts The commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 to 5.00 for installation of side-wall venting gas appliance as follow: For all side wall horizontally vented gas fueled equipment installed in very dwelling, building or structure used in whole or in part for residential purpose, including those owned or operated by Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied. 1. INSTALLATION OF CARBON MONOXIDE DETECTORS: At the time of installation of the side wall venting gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wire carbon monoxide detractor with an alarm is installed on each additional level of dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the service of a qualified licensed professional for the installation of hard wired carbon monoxide detectors. a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detectors with alarm and battery back-up may be installed on the next adjacent floor level. b. In the event that the requirements of this subdivision cannot be met at the time of completion of installation, the owner shall have a period of (30) days to comply with the above requirements; provided, however, that during said (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed. 2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector, as required in accordance with the above provisions, shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCIONS. 4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspections, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4. A. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1. The equipment listed in chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board; and 2. Product Approved side wall horizontally vented fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes. B. MANUFACTURER REQUIREMENTS- GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by manufacturer for installation of the equipment and the venting system shall include:
12 1. Detailed instructions for the installation of the venting system design or the venting system components; and 2. A complete parts list for the vent system design or venting system. C. MANUFACTURER REQUIREMENTS- GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies special venting systems, the following requirements shall be satisfied by the manufacturer: 1. The referenced special venting system instructions shall be included with the appliance or equipment installation instructions; and 2. The special venting systems shall be Product Approved by the Board, and the instructions for the system shall include a parts list and detailed installation instructions. D. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with appliance or equipment at the completion of the installation instructions.
Figure 3A: Typical Horizontal Vent Piping 13
Figure 3B: Alternative Horizontal Vent Piping 14
Figure 3C: Typical Vertical Pressurized Venting 15
16 Combustion Air 1. Sufficient combustion air must be supplied to the boiler room in accordance with local codes and NFPA 54/ANSI Z223.1, Section 5.3, Air for Combustion and Ventilation. 2. The boiler may be operated with inside or outside air. 3. Refer to combustion air pipe drawing (Figure 1D) in this section of the manual for proper outside air installation details. 4. Combustion air conduit can be galvanized smoke pipe, PVC, CPVC or flexible aluminum conduit. 5. The maximum air inlet length is one hundred (100) equivalent feet. Air inlet length is equal to the total length of straight pipe plus the equivalent length of fittings. Consult conduit manufacturer for equivalent length of fittings and pipe. 6. Consult intake pipe manufacturer s instructions for proper method of sealing vent pipe sections and fittings. Do not use other adhesives or sealants except as expressly permitted by the vent pipe manufacturer s instructions. 7. Air intake termination must be located at least twelve (12) inches above grade plus the expected snow accumulation. WARNING Do not reduce size of air intake pipe. Read, understand and follow combustion air instructions and restrictions contained in the Pre- Installation instructions of this manual. Do not locate air intake where petroleum distillates, CFCs, detergents, volatile vapors or any other chemicals are present. Severe boiler corrosion and failure will result. Thermal Solutions does not warrant failure caused by contaminated air. Do not locate air intake termination where natural convection or wind conditions cause the boiler exhaust to be drawn into the air intake. 8. Boiler may be installed with vertical venting and sidewall combustion air inlet or visa versa. 9. The air intake pipe must be adequately supported with straps or supports no more than five (5) feet apart. The completed air intake pipe system must be rigid and able to withstand impacts without collapse. 10. Combustion air opening must never be blocked or obstructed in any manner. 11. The boiler room must be at a positive or neutral pressure relative to the outdoors. A negative pressure in the boiler room will result in downdraft problems and incomplete combustion due to the lack of air.
Figure 3D: Typical Horizontal Air Intake Piping 17
Figure 3E: Typical Vertical Air Intake Piping 18
19 Hydronic Piping and Trim 1. Design and install boiler and system piping to prevent oxygen contamination of boiler water and frequent water additions. a. There are many possible cause of oxygen contamination such as: i. Addition of excessive make-up water as a result of system leak. ii. Absorption through open takes and fittings. iii. Oxygen permeable materials in distribution system. b. In order to ensure long periodic life, oxygen sources must be eliminated. This can be accomplished by taking the following measures: i. Repairing system leaks to eliminate the need for addition of make-up water. i. Eliminating and/or repairing fittings which allow oxygen absorption. ii. Using of non-permeable materials in the distribution system. iii. Isolating the boiler from the system water by installing a heat exchanger. iv. Using properly designed and operating air elimination devices in water piping. 2. Remove protective cap from the boiler inlet, outlet, and drain line. Connect system supply and return piping to the boiler. 3. Refer to Table 3A for pressure drop, flow rates, and temperature rise (ΔTs). WARNING Failure to operate the unit with proper water flow rate can lead to appliance failure. Always verify proper water flow switch operation so that the unit stops operating if improper water flow is present. Safety relief valve discharge piping must be piped such that the potential of server burns is eliminated. DO NOT pipe in any area where freezing could occur. DO NOT install any shut-off valves, plugs or caps. Consult Local Codes for proper discharge piping arrangement. Do not install valves, plugs or caps in safety relief valve piping. Safety relief valve piping must be terminated such that in the event the safety relief valve opens, the discharge will not cause personal injury or damage. Do not operate the boiler with flow rates in excess of the maximum flow rates listed in Table 1B. Tube erosion, pitting or component failure will occur. Do not operate boiler below flow rates listed in Table 1B. Thermal Solutions Standard Warranty does not cover problems caused by excessive water flow rates. * Maximum allowable flow rate ** Minimum allowable flow rate 4. Install air eliminating device to remove air from system. 5. Connect drain line to the boiler drain valve located at the bottom rear, left side of the boiler. WARNING Do not install boiler and circulation pump on the same fused disconnect.
20 6. If this boiler is used in connection with a refrigeration system, the boiler must be installed so that the chilled medium is piped in parallel with the boiler using appropriate valves parallel with the boiler, using appropriate valves to prevent the chilled medium from entering the boiler. Also, consult I=B=R Installation and Piping Guides. If this boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air, the boiler piping must be equipped with flow control valves to prevent gravity circulation of boiler water during operation of the cooling system. 7. If the boiler is installed in a closed water supply system, such as one having a back flow preventer in the cold water supply line, means should be provided to control thermal expansion. Contact water supplier to local plumbing inspector on how best to control this situation. 8. A pressure relief valve is supplied with each boiler. NO valve is to be placed between the relief valve and the appliance. a. Pipe the safety relief discharge to a suitable place for disposal when relief occurs. b. Do not install reducing coupling or other restrictive devices in the safety relief discharge line. c. The safety relief discharge line must allow for complete drainage of both the valve and line. 9. If the relief valve discharges periodically, this may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation. DO NOT PLUG THIS RELIEF VALVE.
Figure 3F: Near Boiler Piping-Single Boiler, Primary/Secondary-Heating Only 21
Figure 3G: Near Boiler Piping-Single Boiler, One Pipe System-Heating Only 22
Figure 3H: Near Boiler Piping-Multiple Boilers, Reverse/Return Piping-Heating Only 23
Figure 3I: Near Boiler Piping-Multiple Boilers, Primary/Secondary Piping-Heating Only 24
Figure 3J: Near Boiler Piping-Multiple Boilers, Primary/Secondary Piping-Heating with Domestic Hot Water 25
Figure 3J: Near Boiler Piping-Multiple Boilers, Primary/Secondary Piping-Heating with Domestic Hot Water (continued) 26
27 Condensate Drain A condensate drain trap is shipped loose with the boiler. It is the installer s responsibility to examine all loosely shipped items upon receiving them, for damage. 1. Connect 1 NPT condensate drain trap to the boiler drain line located on the lower right rear of the boiler (see Figure 3K). 2. Ensure that the condensate drain trap is filled with water prior to running the boiler as to prevent flue gas emission to the boiler room. Table 3B: Typical Condensate Flow Rate at Given Conditions 3. It is recommended that the personnel responsible for running and maintaining the boiler periodically check the water level in the condensate drain trap bend, especially, when the boiler is operating in a non-condensing condition for an extended period of time. 4. In addition, the condensate drain trap should be flushed with water as part of your boiler maintenance schedule to remove any debris that might have accumulated over time. 5. Use continuous Teflon, high temperature silicone tubing, or other tubing material compatible with flue gas condensate, for condensate piping. 6. A common condensate pump/sump may be used. Run separate piping from each condensate drain to the sump. A common drain may be used to discharge condensate from the sump. Consult pump/sump materials of construction. If a common sump is used, individual drain lines should be connected such that one drain cannot back feed into another drain. 7. Consult local authorities regarding disposal of flue gas condensate into public waste water system. Some jurisdictions require that condensate be buffered before discharge. This buffering is commonly achieved by draining the condensate through a limestone bed. The condensate will be slightly acidic and range between 3-5 on the ph scale. Consult Thermal Solutions or a chemical treatment company for buffering system. Figure 3K: Condensate Drain Trap 1. Union Connection to the boiler condensate drain line 2. Removable cleaning plug 3. Condensate drain outlet connection
28 Gas Piping 1. Blower The boiler uses a variable speed blower designed for pre-mix applications. 2. Swirl plate: This integrated baffle is located at the combustion air inlet to the blower. It acts as a signal amplifier and permits safe operation over the modulation range. 3. Manual gas shut-off valve: This manual gas shut-off valve is located between the main gas valve and the blower. 4. High gas pressure switch: The boiler is equipped with a high gas pressure switch that monitors pressure and shuts off the electrical control circuit when pressure rises above the set point. 5. Low gas pressure switch: The boiler is equipped with a low gas pressure switch that monitors pressure and shuts off the electrical control circuit when pressure drops below the set point. 6. Main gas valve regulator: This a combined regulator and safety valve with variable air/gas ratio control. Figure 3L: Gas Train and Blower Assembly 7. Sediment trap: This prevents unwanted particles/debris from entering the main gas valve/regulator or main burner assembly. 8. Manual gas shut-off valve: This manual gas shut-off valve is located outside of the boiler jacket. It is used to prevent the supply gas from entering the gas train in the event of an emergency. 9. Supply gas connection: Gas supply line should be connected to the boiler by a licensed professional only. 10. Supply gas pressure tapping: Use this pressure tapping for measuring supply gas pressure entering the boiler. See recommended supply gas pressure in Table 3C.
29 1. Size gas piping. Design system to provide an adequate gas supply to boiler. Consider these factors: a. Allowable pressure drop from point of delivery to the boiler. Refer to Table 3C for minimum and maximum boiler gas train inlet pressure. If gas supply pressure is higher than maximum as listed in Table 3C, an additional field supplied pressure regulator will be required. Table 3C: Inlet Gas Pressure Requirements b. Maximum gas demand. Table 3D lists boiler input rate. Also consider existing and expected future gas utilizing equipment (i.e., water heater, cooling equipment). Table 3D: Rated Input c. Length of pipe and number of fittings. Refer to Table 3E for maximum capacity of schedule 40 pipe. Table 3G lists equivalent pipe length for standard fittings. i. Given the specific gravity of gas at the boiler s location, a correction factor can be found on Table 3F and multiplied by the Capacity in Cubic Feet of Gas Per Hour on Table 3E. ii. For gas piping material other than schedule 40 pipes, refer to the National Fuel Gas Code, NFPA 54/ANZI Z223.1 and/or CAN/CGA B149 Installation codes. WARNING Failure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure. Always assure gas piping is absolutely leak free and of the proper size and type for the connection load. An additional gas pressure regulator may be needed. Consult gas supplier. Failure to use proper thread compounds on all gas connectors may result in leaks of flammable gas. Gas supply to the boiler and system must be absolutely shut off prior to installing or servicing boiler gas piping. Use an additional gas pressure regulator where the gas pressure is greater than the maximum specified in Table 3C. Using one additional regulator for multiple boilers may result in unsafe boiler operation. The additional regulator must be able to properly regulate gas pressure flow at the lowest input of a single boiler. If the regulator cannot do this, two or more additional regulators are required. Consult regulator manufacturer s instructions for minimum gas flow rate. Table 3D lists gas inputs at sea level to 2000 feet altitude. Reduce gas input four percent (4%) for each additional 1000 feet above sea level. DANGER Do not use matches, candles, open flames or other ignition sources to check for leaks.
2. If step down regulator is required, it must be used in conjunction with factory supplied regulator and be located as far away from the boiler as possible to prevent nuisance shutdowns. The minimum and maximum inlet gas pressures must not exceed the values specified in Table 3C. 3. Install field supplied sediment trap, ground-joint union and manual non-displaceable shut-off valves upstream of factory supplied shut-off valve outside of the boiler jacket. Use methods and materials in accordance with Local Codes and requirements of gas supplier. In the absence of such requirement follow National Fuel Gas Codes, NFPA /ANSI Z 223.1 and/or CAN/CGA B149 Installation Codes. 30 4. Use threaded joint compound resistant to the action of liquefied petroleum gas. 5. Pressure test. The boiler and its gas connection must be leak tested before placing boiler in operation. a. Protect boiler gas control valve. For all testing over ½ psig, boiler and its individual shutoff valve must be disconnected from gas supply piping. For testing at ½ psig or less, isolate boiler from gas supply piping by closing boiler s individual manual shutoff valve. b. Locate leak using approved combustion gas detector, soap and water, or similar nonflammable solutions.
Install sediment trap in the supply gas line, and also connect the supply gas line to the boiler s gas train with a union so that the gas train can easily be removed for service. 31 ELECTRICAL 1. Install wiring and ground boiler in accordance with authority having jurisdiction, or in absence of such requirements, National Electrical Code, ANSI/NFPA 70 and/or CSA C22.1 Electrical Code. 2. A separate electrical circuit must be run from the main electrical service with an over-current device/disconnect in the circuit. A service switch is recommended and may be required by some local jurisdictions. Locate the service switch such that the appliance can be shut off without exposing personnel to danger in the event of an emergency. 4. Connect field supplied safety limits or devices using proper terminals provided in boiler electrical cabinet. Refer to wiring diagram supplied with boiler for wiring information. 5. The following pages have sample wiring diagrams. Contact a Thermal Solutions Representative or visit the website (www. thermalsolutions.com) for current wiring options. 6. An as-built wiring diagram is included with every boiler when it ships. 3. Connect the main power supply and ground from fuse disconnect to proper boiler electrical leads located in the junction box at the rear of the boiler. Refer to electrical consumption plate on boiler jacket.
32 Line Voltage Connections 1. Connect 120 VAC power wiring to the line voltage connections in the junction box, shown in Figure. 4A. DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING Electrical power may be supplied from more than one service. Make sure all power is off before attempting any electrical work. Figure 4A: Line Voltage Connection, Junction Box Rear of Boiler The wiring diagrams contained in this manual are for reference purposes only. Each boiler may be wired differently according to the specifications given to Thermal Solutions at the time the boiler was purchased. Always use the wiring diagram provided with the boiler. If the wiring diagram provided with the boiler is unavailable, STOP all wring work and contact Thermal Solutions for a replacement diagram. Do not directly connect low voltage (24 volt, milliamp, etc.) controls to this boiler. If low voltage controls are desired, isolating relays must be used. Never jump out or bypass any safety controls. Never jump out or make inoperative any safety or operating controls. Each boiler must be protected with a properly sized over-circuit device.
33 CONTROLS Control Panel The control panel is designed to be easily accessible for service and maintenance. All of the primary controls/electronics are mounted on the control panel located behind the front door of the boiler. Component description: 1. 24 VDC power supply for the control display 2. 24 VAC control transformer 3. 5 amp circuit breaker 4. Low water cut-off reset box 5. Concert Boiler Control 6. Din-rail terminal block Vestibule Panel Figure 5B: Control Panel Components All of the safety components mounted on the vestibule panel can be accessed through the front door of the boiler, or by removing either the right or left side boiler jacket panel. Component description: 1. Aquastat/high temperature limit (auto reset) 2. Maximum air pressure switch/high burner pressure 3. Minimum air proving switch/low air pressure 4. Blower (combustion fan) 5. Ignition transformer Figure 5A: Vestible Panel Components 6. Blocked condensate switch
34 Concert Boiler Control Flame Rod Fan Communication Ground Neutral Line Voltage System Pump or Fresh Air Damper Boiler Pump DHW Pump or Fresh Air Damper Ignition Transformer Gas Valve Minimum Burner Pressure Switch Lockout Alarm External limit Fresh Air Damper Proving On/Off Switch Water flow switch High Limit Auto Reset LWCO (Low Water Cut Off) Blocked Condensate (Float Switch) Vestibule & Burner Thermal Fuses High and Low Gas Pressure Switches Maximum Burner Pressure Switch 12 11 10 9 8 7 6 5 4 3 2 1 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 LCI A1 A2 J4 J5 J6 Power Flame Alarm Reset J1 L1 L2 7 6 A3 5 A4 4 A5 J7 3 A6 J3 2 A7 1 MB1 MB2 ECOM A8 A B C A B C 1 2 3 J2 1 4 4 3 2 5 2 1 3 6 J8 J9 J10 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 + Flame Strength - + - + 4-20 ma + 0-10 Vdc - ma/vdc return Optional Honeywell Wireless Outdoor Air Reset Adaptor pn 105766-01 24vAC Control Transformer External Enable/Disable Input Return Temperature Sensor External Control (EMS) (4-20mAdc) Modulation or Setpoint Input Supply Temperature Sensor Header Temperature Sensor, Or Outside Air Temperature Sensor DHW Temperature Sensor Or DHW Demand Switch Stack Temperature Sensor Time of Day (TOD) Input Firing Rate Output to BAS J10 4 to J10 6 = 4-20 madc Or J10 5 to J10 6 = 0-10 Vdc 1 2 3 Wireless Receiver Module Wireless Outdoor Sensor LINE TYPES: Wiring Legend Factory Wiring Field wiring (optional) Sola Screw Terminal Boiler to Boiler Sequence Master Communication Figure 5C: Control Terminal Layout and Wiring Notes
A B C 35 Communication Terminals 7 Inch Display Rear View SDI Card Slot and Battery located behind door SLAVE USB USB Connection for Parameter Update and Historical Data Collection + - DC Only COM 3 COM 2 COM 1 COM Pin Detail (Typical for Com 1, 2 & 3) 5 4 3 2 1 9 8 7 6 24vdc Power Supply Control To Energy Managment System (EMS) RS485 Modbus Communication From Control J3 Terminal EMS RS485 Modbus Communication RJ 45 Module PN: 1375191-3 MB2 Boiler to Boiler Sequence Master Communication Mounting Box PN: 1116697-x Connects to Up to 8 boilers Note The Sequence Master communicates to all networked boilers using the MB2 Connection on each boiler. Seperately the Display COM 3 port on each boiler is used to communicate RS485 Modbus to the Energy Management System (EMS). These communications are electrically seperate from each other and make the connection between boilers using a common RJ45 Module and Ethernet Cable. Note Display to EMS wiring ; Function COM 3 Terminal RJ45 Module Terminal RS485 (+) Pin 1 A Green/White RS485 (-) Pin 6 A Orange/White Ground Pin 5 A Green Note Control to Peer-to-peer wiring ; FunctionJ3 Terminal RJ45 Module Terminal RS485 (+) MB2 A Brown RS485 (-) MB2 B White/Brown Ground MB2 C A Green Figure 5D: Display Terminal Layout and Wiring Notes
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Figure 5E: Typical Ladder Diagram 37
38 Concert Boiler Control Display Navigation The Arctic boiler is equipped with a color touch screen display, which presents information and control options in a page manner. Pages are arranged in a tree structure through which the user navigates up and down to arrive at the desired function. The page descriptions and a complete list of the available control parameters are provided in a separate instruction manual for the Concert boiler control (Also supplied with the boiler). Most pages have a Home button in the top-left corner of the screen. The Home Home page to view real time operation of the boiler. button returns the user to the Refer to the Concert Boiler Control manual for detailed instructions on the use of the hydronic control and display. Figure 5C: Display Home Screen The back button returns the user to the previous page. A padlock icon will be shown on the screens that require the user to enter a password to change the parameter. An unlocked padlock indicates the correct password has been entered to change the parameter. The user can access the following icons from the Home screen: Menu, Info, Status, Adjust, and Help. It is important that the user become familiar in accessing additional icons which are not shown on the home screen page.
39 SYSTEM START-UP A. System Check: Verify that the venting, water piping, gas piping and electrical system are installed properly. Refer to installation instructions contained in this manual. 1. Confirm all electrical, water and gas supplies are turned off at the source and the chimney/vent is clear of obstructions. If boiler is controlled by an external control system, this system must be temporarily disconnected. The local boiler controls should be allowed to operate the boiler. 2. Confirm that all manual shut-off valves between the boiler and gas supply are closed. See Figure 3L. B. Pressurize the Hydronic System: Fill entire heating system with water and vent air from system. Use the following procedure on a Series Loop or multi-zoned system installed to remove air from the system while filling. 1. Close full port ball valve in boiler supply piping. 2. Isolate all zones by closing zone valves or shut-off valves in supply and return of each zone(s). 3. Attach a hose to the hose bib in system piping and terminate hose in a five gallon bucket at a suitable floor drain or outside area. 4. Starting with one circuit at a time, open zone valve or shut-off valve in system supply and return piping. a. Open hose bib. b. Open fill valve (Make-up water line should be located directly after full port valve in system piping between air scoop and expansion tank). c. Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds. d. Close the opening zone valve or shut-off valve for the zone being purged of air, then open the zone valve or shut-off valve for the next zone to be purged. Repeat this step until all zones have been purged. At completion, open all zone valves or shut-off valves. 5. Close hose bib, continue filling the system until the pressure gauge indicates required system operating pressure. Close fill valve. 6. Open isolation valve in boiler supply piping. 7. Remove hose from hose bib. 8. Confirm that the boiler and system have no water leaks WARNING Completely read, understand and follow all instructions in this manual, Concert Boiler Control manual, and all other component manuals supplied with this boiler before attempting start- up. The maximum allowable operating pressure of this boiler is 160 psig. Never exceed this pressure. This boiler was supplied with a safety relief valve with a pressure relief setting specified at the time of purchase. This relief valve setting must be above the maximum operating pressure of the system. Consult Thermal Solutions if the desired system operating pressure is above the safety relief valve pressure setting. Do not plug or change safety relief valve. WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Thermal Solutions Standard warranty does not cover problems caused by oxygen contamination of boiler water. Proper water treatment is required to avoid scale build-up on the inside of the boiler. Thermal Solutions Standard warranty does not cover problems caused by scale build-up. On an existing or retrofit system, a filter or strainer must be installed on the system return prior to the boilers.
40 C. Power the Boiler: Turn on the electrical supply to the boiler and circulation system at fused disconnect switch. Ensure that the circuit breaker switch is in the ON position. D. Power the Circulators: Turn system circulators on and purge air from the boiler and system piping. E. Pressurize the Fuel System: Turn on gas supply to the boiler gas piping. 1. Open the manual gas shut-off valves located upstream of the field supplied gas regulator. Do not open manual gas valve directly outside the boiler jacket. 2. Use soap solution or similar non-combustible to solutions, electronic leak detectors or other approved method to check that the system gas piping, valves, regulators, and all other components are leak free. Eliminate any leaks. 3. Purge gas line of air. 4. Open manual ball valve outside boiler jacket. Confirm that the supply pressure to the manual ball valve tapping outside the boiler jacket conforms to Table 3C for maximum and minimum supply pressure. 5. Repeat steps 2 and 3 for boiler gas train components. 6. Reset low gas pressure safety switch. F. Select Operational Mode: Refer to the Concert Boiler Control manual to select the desired control features. Allow the boiler to complete its standard startup procedure (pre-purge, pre-ignition, and light-off), and once again using the gas leak detector, inspect the fuel gas train both inside and outside of the boiler for gas leakage. G. Begin Commissioning the Boiler: Measure gas pressure at tapping on manual gas valve at boiler inlet and confirm that the inlet gas pressure is within the acceptable range found in Table 3C at high and low fire. 1. Confirm that Oxygen (O 2 ) level in the boiler s flue gas is within 3.8 to 4.2% at high fire and 4.3 to 4.7% at low fire. Refer to Figure 6A for throttle adjustment. Turn throttle clockwise to increase gas. Turn throttle counter clockwise to decrease gas. For high and low fire adjustments, perform ½ turn forward and then back ¼ turn. After each adjustment, close all jacket panels and doors and wait until O 2 level has stabilized before making any additional adjustments. This may take approximately 15 minutes. 2. Confirm the high and low gas pressure switches are functioning and are adjusted to prevent over firing or under-firing of the boiler. 3. Verify that all safety and operating limits and flame controls are operating properly. DANGER Failure to properly adjust excess air will result in unsafe level of carbon monoxide. Variations in venting or combustion air pressure and temperature will change excess air. Adjust excess air levels so that variation in venting or combustion air pressures and temperatures caused by change of seasons, wind conditions, opening or closing of boiler room doors or windows do not cause the boiler to operate with carbon monoxide concentration above 400 parts per million. WARNING Failure to properly adjust gas input rate will result in over firing or under firing of the appliance. Improper and unsafe boiler operation may result. Do not start the burner with combustion chamber full of gas or with very hot combustion chamber. CAUTION A proper water treatment and monitoring program will extend the life of the boiler. The water shall have a maximum water hardness of 8.5 grains or 150 ppm. The recommended ph range is 8.3 to 10. However, other aspects of water quality can affect boiler operation and longevity. A qualified water treatment expert should be consulted to develop a complete water treatment plan.
41 4. With boiler running, front door closed and all jacket panels attached, measure oxygen (O 2 ) and carbon monoxide (CO) concentrations in the flue gas and flue gas temperature. Compare results with values given on factory fire test report supplied with boiler. 5. Repeat if necessary. J. Finish Commissioning the Boiler: Reconnect any wires from the external control system, if applicable. 1. Test function of external control system. 2. Place system control back in normal operation, if necessary. DANGER This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service. More than one gas shut-off valve and electrical disconnect switch are used on the boiler. Assure that all gas valves and electrical disconnect switches are off before attempting any disassembly or service. Do not attempt any service work if gas is present in the air in the vicinity of the boiler. Never modify, removed or tamper with any control device. Do not use matches, candles, open flames or other ignition source to check for leaks. WARNING This boiler must be only be serviced and repaired by skilled and experienced service technicians. If any controls are replaced, they must be replaced with identical models supplied by Thermal Solutions. Read, understand and follow all the instructions and warnings contained in all the sections of this manual. The instructions and warnings contained in all of the component instruction manuals. Reminder Figure 6A: High and Low Fire adjustments on the Main gas valve regulator Ensure that the temperature differential across the boiler does not exceed 100 0 F. Refer to Table 3A for acceptable water flow rates and temperature differentials. If any electrical wires are disconnected during service, clearly label the wire and ensure that the wires are reconnected properly. Never jump out or bypass any safety or operating control or components of this boiler. Assure that all safety and operating controls and components are operating properly before placing boiler back in service.
42 Re-Starting After Prolonged Shutdown Use the following recommendations prior to re-starting the heating system after prolonged shutdown. 1. Perform Pre-Start-Up Inspection by checking all gas, water, air intake and venting connections to ensure proper, leak-free connections and that the water and gas lines has been cleaned completely. 2. Ensure that combustion air piping, vent piping, and terminations are free of obstructions. 3. Inspect the boiler for damage and loose wire connections. 4. Remove all flammable material present in the vicinity of the boiler. Testing of Controls and Safety Devices Prior to placing the boiler in operation, the installing contractor or other responsible personnel must perform safety and control device limit tests to ensure proper operation of the appliance. Refer to Table 6A for recommended method(s) of carrying out these safety limit devices tests. Ignition Failure Table 6A: Safety Device Tests After the first ignition failure, the boiler goes into a hard lockout and a manual reset of the Concert Boiler Control is required to restart the boiler. The boiler will then attempt to light-off after it has completed its post-purge process. However, if ignition failure reoccurs more than three (3) times after initially resetting the main boiler control, contact the boiler manufacturer or a qualified heating service technician.
43 Sequence of Operation Boiler Sequence Status is shown on both the Home screen and the Status Screen. Once limits have been established the boiler start/stop sequence progresses as shown in the graph below: Figure 6B: Central Heat Start Sequence (Typical for Domestic Hot Water)
44 SERVICE, MAINTENANCE AND INSPECTION General Guidelines: 1. Follow any checks and/or inspections that may be required as specified in the component manufacturers instruction manuals. 2. Repair or replace any defective components immediately. 3. The following service procedures are required for proper and safe boiler operation. DAILY: 1. Make visual inspection of gauges, monitors, and indicators and record readings in boiler log. 2. Make visual check of instrument and equipment settings against factory recommended specifications. 3. Check operation of probe type low water cutoff(s) to ensure control is functioning. 4. Check gas train for gas leaks and water piping for any leaks. 5. Confirm boiler area is free of combustible materials and that there is nothing obstructing air intake and vent. WEEKLY: 1. Check combustion safety controls for flame failure (or other alarm messages. 2. Check all limit controls and low water cutoff as described above. 3. Check condensate drains for any obstructions. 4. Check carbon monoxide level in flue products. MONTHLY: 1. Check high and low gas pressure interlocks. Refer to manufacturer's instructions for correct procedure. 2. Check proper operation of safety relief valve. 3. Check water quality and correct if needed. 4. Inspect boiler air filter. ANNUALLY: 1. The flue gas passages and the exterior surfaces of the boiler tubes should be inspected at least once annually. Any accumulation of soot or debris should be thoroughly cleaned out. 2. If inspection of the boiler tube surfaces reveals a build-up of soot (carbon), the tube surfaces should be thoroughly brushed. Failure to do so may result in reduced efficiency, fire and asphyxiation hazards. 3. The boiler pressure vessel and piping should be checked annually. 4. Inspect flame and ignition rods for carbon build up. 5. Replace air filter. Use the following recommendations when shutting down the boiler for an extended period of time. 1. Disconnect supply power to the boiler. 2. Drain the boiler completely. 3. Shut off main manual gas supply valve. 4. Remove air intake and vent piping, and cover the air intake and vent connections to prevent debris from entering the boiler. WARNING The service instructions contained in this manual are in addition to the instructions provided by the manufacturer of the boiler components. Follow component manufacturer s instructions. Component manufacturer s instructions were provided with the boiler. Contact component manufacturer or Thermal Solutions for replacement if instructions are missing. Do not install, start up, operate, maintain or service this boiler without reading and understanding all of the component instructions. Do not allow the boiler to operate with altered, disconnected or jumpered components. Only use replacement components identical to those originally supplied by Thermal Solutions. All cover plates, enclosures, and guards must be in place at all times, except during maintenance and servicing.
45 Ignition Assembly Cleaning Disconnect power and shut off the external manual gas valve to the boiler prior to removing the ignition assembly. When removing either the igniter or the flame sensor rod, extra caution must be taken to prevent damaging the ceramic insulator. Remove any excess oxide deposits from the surface of the igniter and flame sensor rod with steel wool or emery cloth. Do not use sandpaper. Inspect the ceramic insulators for cracks, and if necessary, replace the igniter and flame sensor rod. After each inspection of the igniter and flame sensor rod, replace gasket and apply anti-seize compound to mounting screws prior to reinstalling them. F i g u r e WARNING Label all wires prior to disconnecting them to service or inspect any safety control components on the boiler. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. Do not use any acid or alkali products for the purpose of cleaning the heat exchanger tubes. 7 A : Ignition Assembly Ensure that igniter electrode spacing is within 1/8 inch. When reinstalling either the igniter or the flame sensing rod after inspecting them, make sure there is a 3/8 inch gap between the igniter and flame sensing rod and the burner surface. Burner Assembly Cleaning After disconnecting power to the boiler, remove the boiler s furnace door. For part identification, refer to the Repair Parts section of this manual. Clean around the burner assembly by blowing compressed air over the surface of the burner to remove lint and debris accumulation. Be careful when cleaning the burner assembly, to avoid damaging the metal mesh burner surface. If the burner or the burner gasket shows any visual deterioration or corrosion signs, replace it immediately. After replacing the burner or burner gaskets, check for proper operation by performing combustion analysis, as well as checking for gas leakage around the burner mounting and blower transition pieces. Heat Exchanger Cleaning Perform visual inspection of both boiler flue passes, and remove any debris from the surfaces of the heat exchanger. If necessary, brush the tubes of the heat exchanger using non-abrasive, non-metallic bristle brush. Be careful not to damage or disturb the insulation inside of the heat exchanger.
46 Tube Replacement Procedure Reminder: Performing a regular boiler inspection will prolong the life of the heat exchanger, and ensure optimal function and energy efficiency. For best practices, adhere to the general guidelines outlined in the service and maintenance section of this manual. 1. Inspect the boiler. Use the following steps to identify a potential tube leak and to minimize possible damage to the boiler and other equipment as a result of tube failures: Shut off power to the boiler immediately from the external, dedicated electrical disconnect. Confirm that any water leakage is not the result of a blocked condensate drain line. Remove the boiler s left side jacket panels and flue collector access panels as shown in Figure 7B. Visually inspect the burner and furnace pass insulation for water damage. If significant water damage to the insulation or burner is observed, contact the manufacturer. Identify any leaking tubes. Isolate and drain the boiler completely. 2. Use the proper tools. Use the following tools to remove and replace leaking boiler tubes: Tube Puller (P/N 106019-02) Tube Driver (P/N 106019-01) Sledgehammer (steel head, approximately 3 lb) Figure 7B: Panel Removal in Preparation for Tube Inspection
47 3. Loosen tube-ends. Insert tube puller between the tube-end and header. Apply pressure to the puller and strike the side of the tube two or three times with a hammer to help loosen the tube-end in the upper and lower header. 4. Pull lower tube end. Wedge the tube puller under the flange of the tube. Drive the tube puller with several blows with a hammer on the end of the handle. Alternate with downward blows to lift tube-end. 5. Clear tube-end from the header. Continue driving wedge under and leveraging flange up until it pops the end of the tube free from the hole in the header. 6. Pull upper tube-end. Repeat the procedure to the pull the tube-end of the same tube from the upper header. WARNING If a leak is detected after a replacement tube has been installed, pressure in the boiler must be reduced to zero before adjusting tube(s). Adjusting tubes under pressure could result in serious personal injury. CAUTION Do Not Overdrive Tubes! Overdriving tubes can cause damage to the tubes and boiler header holes. Use only approved Thermal Solutions tube driver and specified hammer. The endformed tube fitting is designed to deform if overdriven to minimize damage to the vessel tube holes. Figure 7C: Tube Puller Insertion 7. Prepare the headers and replacement tubes. Before placing a new tube into the header, clean the holes by wiping gently with emery cloth to be sure that there are no burrs. Clean the replacement tube-ends of any rust or debris. With a small brush, apply a thin coating of gray pipe dope around the inside of the hole. Pipe dope may also be applied to the tube-end. Cutting oil may be mixed with the pipe dope for easier application.
8. Insert both ends of the tubes into the headers. Insert the lower tube-end into the bottom header first. Then insert the top tube-end into the top header. Insert all replacement tubes before driving them. 9. Drive the upper and lower tube-ends. DO NOT drive the tube-ends down to the flange. With the driver tool positioned on the flange, strike the end of the driver with hammer. After a few hits, the feel of the strike will become solid. The tone will also change from a ting sound to more of a tong sound. This indicates the tube has seated. 10. Reinstall the tube clamps. Replace the nuts and flat washers if damaged in any way. Use brass nuts only! Tighten the nuts until snug. Do not try to compress the tube-ends into the holes with the clamps, because the clamps might break or the stud might shear. 11. Refill the boiler. Fill the unit with water and ensure that there is no leakage at the replacement tube-ends before reinstalling the flue collector panels. 12. Reinstall all flue access doors, door clamps, an jacket panels. 13. Perform startup check prior to putting boiler back into operation. 48
49 Safety and Operating Controls All of the safety control devices listed in Table 7A are logically linked to the Concert Boiler Control which supervises the sequence of operation of the boiler for safe and efficient operation. It does so by ensuring proper light-off and firing of the main burner and if need be, will immediately cut-off gas supply to the main burner when gas pressure, water temperature, water flow or another critical attribute is outside of the operational settings. It also varies the combustion rate in real time to meet the desired load of the system. 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 should refer to those who have completed Thermal Solutions Service School training specific to this product. Table 7A: Safety and Operating Controls
50 TROUBLESHOOTING Refer to the troubleshooting section in the Concert Boiler Control manual on how to navigate the Limit String Status screen which shows an active safety limit status and for an in-depth guide to all the possible lockouts as well as recommended corrective actions for restore boiler operation.
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52 REPAIR PARTS All Arctic boiler Repair Parts may be obtained through your local authorized Thermal Solutions Representative. Should you require assistance in locating a Thermal Solutions representative in your area, or have questions regarding the availability of Thermal Solutions products or repair parts, please contact Thermal Solutions Customer Service at (717)-239-7642 or Fax (877)-501-5212. HEAT EXCHANGER