Up to 99% Thermally Efficient Stainless Steel Heat Exchanger (13) Models: 500-4,000 mbh Hydronic Heating or Domestic Water Category 2 or 4 Natural and/or L.P. Gas Low Nox Standard Energy Management Controls Modbus, optional BACnet or Lonworks Standard or ECM Boiler Primary Pump Pg. 2 Pg. 3 Pg. 4 Pg. 5 Pg. 6 Pg. 7 Pg. 8 Pg. 9 Pg. 10 Pg. 11 Pg. 12 Pg. 13 Pg. 14 Pg. 15 Pg. 16 Pg. 17 Pg. 18 Pg. 19 Pg. 20 Pg. 21 Pg. 22 Pg. 23 Pg. 24 Pg. 25 Pg. 26 Pg. 27-28 Pg. 29 Pg. 30 Pg. 31-32 Pg. 33-35 Pg. 35-37 Pg. 38 Boiler BTUH Ranges, Burner Turndowns, Flows-Pressure Drops-Temp. Rises, Water Content Dimensions, Revit Drawings Pumps for Advantus Boilers Primary Secondary vs. Variable Primary Primary/Secondary Piping Options Variable Primary/Variable Secondary Piping Variable Primary/Variable Secondary Piping with Spirotherm QUAD Constant Primary/Variable Secondary Piping with Spirotherm QUAD Primary/Secondary Piping Form Hydraulic Separators How They Work Establishing operating Parameters for all Variable/Primary Flows Variable/Primary Full Flow Variable/Primary Full Flow with Bypass Variable/Primary Full Flow with 3-Way Valve Variable/Primary Zone Piping Piping with Domestic Water Storage Tank Domestic Water Instantaneous Piping Piping with Instantaneous Heater Instantaneous Heater Venting Categories and Sizing Vent Terminations Drain Tee Vent Terminations Side Wall, Roof Venting Materials, Operating Temperatures and Pressures Clearances: Service & to Combustibles - Electrical Requirements Electrical Control Wiring Field Control Wiring BMS and Cascade Field Wiring of Low Water Cut Off SOLA Energy Management Control Specifications boiler in Main flow Specifications with Standard Pump Specifications with ECM Pump Warranty Page 1
Up to 99% Thermally Efficient Boiler Turndowns Size Turndown 500 600 10:1 800 1800 22:1 2000 4000 25:1 Flow and pressure drops based upon water only in stainless steel heat exchanger. Consult B.G. Peterson Co. for flows and pressure drops with glycol/water solutions in stainless steel heat exchangers. Page 2
Dimensions Advantus vent connections, see venting section. Revit Drawings can be found for each appliance at www.camus-hydronics.com Page 3
Boiler Pump Recommendations 1. Contact B.G. Peterson for pump selection. Provide the Following Information: a. Boiler or Water Heater model number b. Water or Glycol and percentage c. Specify an ECM pump or Standard brushed Pump. (do not allow both) 2. BGP Co can provide a standard constant speed pump with the boiler 3. A more efficient option is an ECM pump. See below 4. Verify that the System Flow will not go below the flow requirements of the Boilers. If this should occur, a hydraulic separator or buffer tank should be used. ECM Pump Data 1. ECM pumps are on average 50% more efficient than the standard brushed motor pumps 2. The ECM pump allows the Service Technician to dial in the exact GPM required for the pump. Which means balancing valves are not required. Only isolation valves 3. The ECM pump requires a separate 208 or 230, single phase power supplied to the pump 4. The boiler will provide a dry contact that is field connected to the ECM pump for enable/disable 5. Larger boilers may require a larger pump that would require 460/60/3 power. BGP will advise if this is needed. For the Main System Pumps: Consider the Wilo Giga Series, ECM modulating pump in lieu of the standard in-line or base mounted pumps. Less Energy, Easier to Install and More Control. Page 4
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Variable Primary - Variable Secondary Piping Page 6
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Primary/Secondary Piping Consult B.G. Peterson Co. for pump sizing and selections. Flow and pressure drops based upon water only in copper primary heat exchanger. Consult B.G. Peterson Co. for flows and pressure drops with water solutions in optional stainless steel heat exchangers. Consult B.G. Peterson Co. for flows and pressure drops with glycol/water solutions in copper and stainless steel heat exchangers. Page 10
Hydraulic Air Separators Systems where the main system flow would become less than the flow of the boiler side will required a hydraulic air separator or a buffer tank. Contact B.G. Peterson Co. for help with the selection and design of this equipment. Consult B.G. Peterson Co. for pump sizing and selections. Page 11
Establish Operating Parameters for All Variable/Primary Flow Page 12
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With Storage Tank Page 16
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Positive Pressure Category 4 Individually Vented Boilers Negative Pressure Category 2 Venting Multiple Boilers Contact B.G. Peterson Co. for Category 2 commonly vented multiple boiler vent sizing. Contact B.G. Peterson Co. for sizing individual or common intake combustion air ducts. Page 20
Vent Terminations See IOM, PART 2 for Venting and Intake Guidelines 1. Vent Termination Clearances 2. Location of Rooftop Air Inlet and Vent 3. Optional Air Inlet Damper 4. Masonry Chimney Guidelines 5. Vertical Venting Terminations 6. Combined Combustion Air Inlet Sizing 7. Drain Tee Requirements 8. Air Required For Combustion Air 9. Sidewall Venting Guidelines Page 21
Vent Terminations Page 22
GUIDLEINES FOR VENT MATERIALS Based upon 100% firing (high Fire) conditions at steady state at 96% Thermal Efficiency. FLUE MATERIAL MAXIMUM OPERATING TEMPERATURES Material Flue Maximum Operating Temperatures PVC 149 F CPVC 194 F PPE 230 F AL 29 4C (Cat 3) 550 F Category 3 1,400 F Category 1 (B) 400 F Camus Boiler Model Category Advantus Single Individually Vented 4 Advantus Multiple Commonly Vented 2 Boiler Flue Material AL 29 4C PPE or CPVC AL 29 4C PPE or CPVC Combustion Air Intake Duct Material Operating Temperatures and Pressures Note: Minimum allowed return water temperature into the Advantus boiler is 40 F. Stainless Steel Heat Exchanger Boilers Controls Maximum Operating Water Temperature = 200 F Maximum High Limit Setting = 190 F Operating Pressures Minimum Operating Pressure = 30 psi Maximum Operating Pressure = 160 psi Relief Valve Selections (psi) 60, 75, 100, 125, 150, 160 Page 23
Clearances Electrical NOTE: Electrical below does not include the electrical requirements of primary boiler pumps. PRIMARY BOILER PUMPS Primary boiler pumps are field mounted and wired. Pumps with 115/1 motors 1 hp and below may be powered from the boilers pump relay. Primary boiler pumps other than 115/1 and greater than 1 hp are to be field wired separately. Primary boiler pumps must be sized for the boiler pressure drop plus the calculated field piping restrictions. Page 24
Electrical Control Wiring Typical control wiring diagram for multiple boilers being controlled by the on-board DynaForce Cascade controls. Modbus is standard. BacNet or LonWorks can be accomplished by adding a separate Protonode Converter. This should be indicated in the specifications and on the boiler schedule. PRIMARY BOILER PUMPS Primary boiler pumps are field mounted and wired. Pumps with 115/1 motors 1 hp and below may be powered from the boilers pump delay relay. Primary boiler pumps other than 115/1 and greater than 1 hp are to be field wired separately. Primary boiler pumps must be sized for the boiler pressure drop plus the calculated field piping restrictions. When Wilo ECM pumps are used, a separate 208/230/60/1 power is to be supplied to the pump. The boiler is provided with a dry contact to send an enable/disable signal to the boiler pump. Page 25
CAMUS ADVANTUS BOILERS Field Wiring BMS and Cascade P a g e 26
CAMUS ADVANTUS BOILERS Field Wiring BMS and Cascade P a g e 27
Field Wiring of LWCO Page 28
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ADVANTUS SPECIFICATIONS - BOILER PIPED IN MAIN FLOW Boilers shall be design certified by CSA International and meet the requirements of ANSI Z21.13 and CSA 4.9. The boiler shall be ASME H stamp, national board listed and include a low water cutoff and high limit with manual reset to meet ASME CSD-1. The boilers shall be fully condensing and comply with the energy efficiency requirements of the latest edition of the ASHRAE 90.1 Standard. External Jacket and Fasteners: The casing shall be of 430 stainless steel mirror finish panels, a powder coated access top cover assembled utilizing interference fit locks and minimal non-strip self tap screws for ease of removal and access to the heat exchanger and combustion air / gas control. Cabinet includes a NEMA 250 Type 1A control compartment. Combustion Chamber: The combustion chamber shall be an all welded stainless steel construction and an integral part of the heat exchanger. The combustion chamber shall incorporate an easily removable radial fired knitted fiber stainless steel burner with access to the internal combustion chamber for inspection, service, and cleaning. A window view port shall be provided for visual inspection of the boiler combustion during firing. Burner: The gas train shall consist of a pressure regulating electro-hydraulic proportional air/gas main gas actuator providing a slow opening, fast closing shutoff valve and proportional 1:1 air/gas ratio control, a fast closing safety shutoff gas pressure regulator with 1 PSI allowable static pressure, a low gas pressure switch, and a high gas pressure switch. A factory pre-set combination metering valve and orifice shall be provided for setting combustion parameters. The combustion air fan shall draw gas under negative pressure and mix it with air to generate a fine tuned air gas mixture which is delivered under positive pressure to the radial knitted stainless steel burner. Combustion modulation shall be established by either a pulse width modulation signal or variable frequency motor drive. The burner shall be a 100% stainless steel vertical mounted radial fired type with stainless knitted metal fiber construction and shall have a five year non-prorated warranty. The burner shall combust a precise amount of premixed combustion air and gas to provide equal distribution of heat for heat transfer throughout the entire heat exchanger. Combustion shall operate with a minimum ( ) burner turn down ratio while sustaining combustion characteristics throughout the entire modulating range. Operation of up to 99% thermal efficiency and shall be certified for Oxides of Nitrogen (Nox) of 9 ppm corrected to 3% oxygen. The burner combustion shall operate as proportional modulating with a minimum ( ) turndown ratio with a minimum ( %) firing rate. Multiple boiler firing algorithms shall be proportional modulation. Light off shall be at no more than 50% input to assure rumble free soft start. Combustion shall be optionally suitable for natural gas, propane and dual fuels operation as scheduled. The ignition module shall employ a proven pilot system. Trial for ignition shall proceed with 15 seconds between retrials. Ignition control shall include times for pre-purge, pre-ignition, ignition, and post purge. Heat Exchanger: The heat exchanger shall be designed, inspected, and tested to A.S.M.E. Section IV requirements. The heat exchanger shall be of fully welded construction and have a maximum working pressure of 160 psig and a minimum operating pressure of 30 psig with a 10 year non-pro-rated warranty. Configuration shall be a cylindrical, vertical, two-pass, counter-flow, fire tube design and consist of an integral combustion chamber with an inner tube bundle for primary heat transfer and an outer tube bundle for extracting latent heat from flue gases. The combustion chamber, fire tubes, and tube sheets shall be constructed of 316L stainless steel. The remainder of the heat exchanger shall be constructed of 304L stainless steel. The fire tubes shall be of an oval design with a minimum wall thickness of 0.061. The upper and lower tube sheets shall have a thickness of no less than 0.375. The heat exchanger design shall be capable of 40 o F constant system return temperatures and be fully condensing complete with condensate trap and drains. A pressure relief valve as scheduled and a pressure gauge of code range shall be furnished with the boiler. Boiler Control Panel: Each boiler shall include the same CSA certified control module with an electronic proportional integrated combination ignition limit/operator control accurate to 1 0 F (0.5 0 C) having a 4-20 ma output signal suitable for control of a variable frequency motor drive or a pulse width modulation signal output for modulating fan speeds. Energy Management: Each boiler mounted controller shall be capable of the following. a. Sequence its own boiler s modulation and/or cascade multiple boilers using a PID loop energy management firing rate tuning constant and parallel positioning of the firing rate of each boiler to track load and limit cycling to maximize all boiler operating efficiencies. b. Equalize hours of operation. c. Lead/lag. Page 30
d. Base load rate adjustment. e. Warm weather shutdown. f. Provide indoor/outdoor reset. g. Heat exchanger frost protection with sealed combustion. h. Flue gas temperature rise protection for flue material limits. i. Control shall be equipped and ready with 4-20 ma remote set point or modulating control, capable with 0-10 VDC remote set point or modulating control. j. Control shall be standard with a BMS Modbus RTU protocol ready k. When utilized BACnet or Lonworks shall be able to control and/or monitor all functions listed. l. (Optional: shall include a BACnet, LonWorks or MetasysN2 gateway protocol converter). Control shall be supplied with a factory mounted seven inch touch screen display which shall also provide for control system configuration and set up, readouts and remote monitoring of boiler target, flame signal, inlet/outlet temperatures as well as accumulated runtime, enunciator diagnostics, and firing rates. The display will be equipped with two RS485 communication ports with battery backup and a USB port to extract boiler operation parameters for troubleshooting. If utilizing cascade control and the master boiler cannot fire the master control shall continue to operate all other boilers as originally programmed. If the master boiler cannot operate altogether then all of the other boiler s controls shall automatically revert to their standalone settings. Control Panel Display: The seven inch control display shall provide full diagnostics including real time data logging and support for all of the boilers in the sequencing application. The complete control package shall be mounted on the front panel with a hinged door for easy access to all control modules. The boiler safety control string shall be furnished with controls for low gas pressure, optional high gas pressure, fan air proving, blocked flue, water pressure, high limit, stack limit and flow switch. Additional control safeties shall include flue gas stack temperature, flame rectification, fan speed, and auto recycling high limit. Boiler Requirements: Include a flow switch and a low water cutoff both shipped loose for field mounting and wiring. Boilers shall be fully factory fire tested and include all electrical and combustions tests to the owner including flue gas analyzer settings from ( %) input up through 100% input. Boilers shall be fully factory tested for ASME CSD-1 and the required test reports provided to the contractor and owner. Include factory authorized start-up service and owner training. Include field burner flue gas analyzer settings from ( %) input up through 100% input. Combustion air intake shall consist of approved material as scheduled. Exhaust flue venting shall consist of approved Category 2 or 4 venting material as scheduled. Electrical service as scheduled. Natural gas service to be 4.5 14 inches w.c. (Gas pressures above require the boiler to be supplied with high gas pressure reducing valves.) Boiler Warranty: Boiler warranty shall include: heat exchanger material and workmanship to be (10) years after initial installation, burner to be (5) years after initial installation, parts to be (1) year after installation or (18) months from date of factory shipment. Boiler ASME CSD-1: By contractor in the field: Boiler mounted locking disconnect, and ASME CSD-1 Part CE-100 Electrical Requirements, paragraph (92) (a) remote breaker switches or circuit breakers, one per boiler room door. Continued Page 31
ADVANTUS SPECIFICATIONS - PIPED PRIMARY/SECONDARY with Standard Pump Boilers shall be design certified by CSA International and meet the requirements of ANSI Z21.13 and CSA 4.9. The boiler shall be ASME H stamp, national board listed and include a low water cutoff and high limit with manual reset to meet ASME CSD-1. The boilers shall be fully condensing and comply with the energy efficiency requirements of the latest edition of the ASHRAE 90.1 Standard. External Jacket and Fasteners: The casing shall be of 430 stainless steel mirror finish panels, a powder coated access top cover assembled utilizing interference fit locks and minimal non-strip self tap screws for ease of removal and access to the heat exchanger and combustion air / gas control. Cabinet includes a NEMA 250 Type 1A control compartment. Combustion Chamber: The combustion chamber shall be an all welded stainless steel construction and an integral part of the heat exchanger. The combustion chamber shall incorporate an easily removable radial fired knitted fiber stainless steel burner with access to the internal combustion chamber for inspection, service, and cleaning. A window view port shall be provided for visual inspection of the boiler combustion during firing. Burner: The gas train shall consist of a pressure regulating electro-hydraulic proportional air/gas main gas actuator providing a slow opening, fast closing shutoff valve and proportional 1:1 air/gas ratio control, a fast closing safety shutoff gas pressure regulator with 1 PSI allowable static pressure, a low gas pressure switch, and a high gas pressure switch. A factory pre-set combination metering valve and orifice shall be provided for setting combustion parameters. The combustion air fan shall draw gas under negative pressure and mix it with air to generate a fine tuned air gas mixture which is delivered under positive pressure to the radial knitted stainless steel burner. Combustion modulation shall be established by either a pulse width modulation signal or variable frequency motor drive. The burner shall be a 100% stainless steel vertical mounted radial fired type with stainless knitted metal fiber construction and shall have a five year non-prorated warranty. The burner shall combust a precise amount of premixed combustion air and gas to provide equal distribution of heat for heat transfer throughout the entire heat exchanger. Combustion shall operate with a minimum ( ) burner turn down ratio while sustaining combustion characteristics throughout the entire modulating range. Operation of up to 99% thermal efficiency and shall be certified for Oxides of Nitrogen (Nox) of 9 ppm corrected to 3% oxygen. The burner combustion shall operate as proportional modulating with a minimum ( ) turndown ratio with a minimum ( %) firing rate. Multiple boiler firing algorithms shall be proportional modulation. Light off shall be at no more than 50% input to assure rumble free soft start. Combustion shall be optionally suitable for natural gas, propane and dual fuels operation as scheduled. The ignition module shall employ a proven pilot system. Trial for ignition shall proceed with 15 seconds between retrials. Ignition control shall include times for pre-purge, pre-ignition, ignition, and post purge. Heat Exchanger: The heat exchanger shall be designed, inspected, and tested to A.S.M.E. Section IV requirements. The heat exchanger shall be of fully welded construction and have a maximum working pressure of 160 psig and a minimum operating pressure of 30 psig with a 10 year non-pro-rated warranty. Configuration shall be a cylindrical, vertical, two-pass, counter-flow, fire tube design and consist of an integral combustion chamber with an inner tube bundle for primary heat transfer and an outer tube bundle for extracting latent heat from flue gases. The combustion chamber, fire tubes, and tube sheets shall be constructed of 316L stainless steel. The remainder of the heat exchanger shall be constructed of 304L stainless steel. The fire tubes shall be of an oval design with a minimum wall thickness of 0.061. The upper and lower tube sheets shall have a thickness of no less than 0.375. The heat exchanger design shall be capable of 40 o F constant system return temperatures and be fully condensing complete with condensate trap and drains. A pressure relief valve as scheduled and a pressure gauge of code range shall be furnished with the boiler. Boiler Control Panel: Each boiler shall include the same CSA certified control module with an electronic proportional integrated combination ignition limit/operator control accurate to 1 0 F (0.5 0 C) having a 4-20 ma output signal suitable for control of a variable frequency motor drive or a pulse width modulation signal output for modulating fan speeds. Energy Management: Each boiler mounted controller shall be capable of the following. a. Sequence its own boiler s modulation and/or cascade multiple boilers using a PID loop energy management firing rate tuning constant and parallel positioning of the firing rate of each boiler to track load and limit cycling to maximize all boiler operating efficiencies. b. Equalize hours of operation. c. Lead/lag. Page 32
d. Base load rate adjustment. e. Warm weather shutdown. f. Provide indoor/outdoor reset. g. Heat exchanger frost protection with sealed combustion. h. Flue gas temperature rise protection for flue material limits. i. Control shall be equipped and ready with 4-20 ma remote set point or modulating control, capable with 0-10 VDC remote set point or modulating control. j. Control shall be standard with a BMS Modbus RTU protocol ready k. When utilized BACnet or Lonworks shall be able to control and/or monitor all functions listed. l. (Optional: shall include a BACnet, LonWorks or MetasysN2 gateway protocol converter). Control shall be supplied with a factory mounted seven inch touch screen display which shall also provide for control system configuration and set up, readouts and remote monitoring of boiler target, flame signal, inlet/outlet temperatures as well as accumulated runtime, enunciator diagnostics, and firing rates. The display will be equipped with two RS485 communication ports with battery backup and a USB port to extract boiler operation parameters for troubleshooting. If utilizing cascade control and the master boiler cannot fire the master control shall continue to operate all other boilers as originally programmed. If the master boiler cannot operate altogether then all of the other boiler s controls shall automatically revert to their standalone settings. Control Panel Display: The seven inch control display shall provide full diagnostics including real time data logging and support for all of the boilers in the sequencing application. The complete control package shall be mounted on the front panel with a hinged door for easy access to all control modules. The boiler safety control string shall be furnished with controls for low gas pressure, optional high gas pressure, fan air proving, blocked flue, water pressure, high limit, stack limit and flow switch. Additional control safeties shall include flue gas stack temperature, flame rectification, fan speed, and auto recycling high limit. Boiler Primary Pump: Boiler pumps 115/1 with one hp motors or less shall be provided by the boiler manufacture along with necessary controls described herein and shall be field mounted and wired to the boiler s pump relay. Pumps other than 115/1 and greater than one hp shall require separate field power supply and control wiring. Factory - assembled and - tested, centrifugal, impeller mounted on stub shaft, split-coupled, single-suction pump with pump and motor shafts horizontal. Designed with an integrally cast suction diffuser in volute inlet. Pump Construction: Pump Casing: cast iron (ASTM A48, class 40), threaded gage tappings at inlet and outlet, drain plug at bottom and air vent at top of volute, and ASME B16.1, Class 125 flanged connections, and sealed via an o-ring. Integrally cast pump feet are drilled and tapped for ease of installation onto a base pad if necessary. A cataphoresis coating is applied electrostatically to prevent corrosion. Pump Cover/Motor Stool: cast iron (ASTM A48, class 40), drilled/tapped to accommodate a mechanical seal flush line which can be connected to the corresponding discharge connection or via an external source to facilitate cooling and flushing of the mechanical seal. The motor stool shall is sealed via an o-ring and also includes extra tappings for removal from pump volute by using jack screws. Impeller: Cast bronze (ASTM B427 C90700), single-suction type, statically and/or dynamically balanced and keyed to shaft. The allowable residual unbalance in the impeller rotating assembly shall conform to ANSI Grade G6.3. Trim diameter to match specified performance. Stub Shaft: Shall be AISI 316L Stainless Steel and attached to the motor shaft via a cast steel, split, balanced coupling. Mechanical Seal: Shall be an eternally flushed mechanical seal with silicium carbide seal faces, HNBR/EPDM elastomers, stainless steel spring. Split Coupling: Axial-split device capable of absorbing torsional vibration shall be employed between the pump stub and motor shafts. Coupling Guard: A dual rated ANSI B15.1, Section 8 & OSHA 1910.219 compliant coupling guard which contains viewing windows for inspection of the coupling mounted to the pump end. Boiler Requirements: Include a flow switch and a low water cutoff both shipped loose for field mounting and wiring. Boilers shall be fully factory fire tested and include all electrical and combustions tests to the owner including flue gas analyzer settings from ( %) input up through 100% input. Boilers shall be fully factory tested for ASME CSD-1 and the required test reports provided to the contractor and owner. Page 33
Include factory authorized start-up service and owner training. Include field burner flue gas analyzer settings from ( %) input up through 100% input. Combustion air intake shall consist of approved material as scheduled. Exhaust flue venting shall consist of approved Category 2 or 4 venting material as scheduled. Electrical service as scheduled. Natural gas service to be 4.5 14 inches w.c. (Gas pressures above require the boiler to be supplied with high gas pressure reducing valves.) Boiler Warranty: Boiler warranty shall include: heat exchanger material and workmanship to be (10) years after initial installation, burner to be (5) years after initial installation, parts to be (1) year after installation or (18) months from date of factory shipment. Boiler ASME CSD-1: By contractor in the field: Boiler mounted locking disconnect, and ASME CSD-1 Part CE-100 Electrical Requirements, paragraph (92) (a) remote breaker switches or circuit breakers, one per boiler room door. ADVANTUS SPECIFICATIONS - PIPED PRIMARY/SECONDARY with ECM Pump Boilers shall be design certified by CSA International and meet the requirements of ANSI Z21.13 and CSA 4.9. The boiler shall be ASME H stamp, national board listed and include a low water cutoff and high limit with manual reset to meet ASME CSD-1. The boilers shall be fully condensing and comply with the energy efficiency requirements of the latest edition of the ASHRAE 90.1 Standard. External Jacket and Fasteners: The casing shall be of 430 stainless steel mirror finish panels, a powder coated access top cover assembled utilizing interference fit locks and minimal non-strip self tap screws for ease of removal and access to the heat exchanger and combustion air / gas control. Cabinet includes a NEMA 250 Type 1A control compartment. Combustion Chamber: The combustion chamber shall be an all welded stainless steel construction and an integral part of the heat exchanger. The combustion chamber shall incorporate an easily removable radial fired knitted fiber stainless steel burner with access to the internal combustion chamber for inspection, service, and cleaning. A window view port shall be provided for visual inspection of the boiler combustion during firing. Burner: The gas train shall consist of a pressure regulating electro-hydraulic proportional air/gas main gas actuator providing a slow opening, fast closing shutoff valve and proportional 1:1 air/gas ratio control, a fast closing safety shutoff gas pressure regulator with 1 PSI allowable static pressure, a low gas pressure switch, and a high gas pressure switch. A factory pre-set combination metering valve and orifice shall be provided for setting combustion parameters. The combustion air fan shall draw gas under negative pressure and mix it with air to generate a fine tuned air gas mixture which is delivered under positive pressure to the radial knitted stainless steel burner. Combustion modulation shall be established by either a pulse width modulation signal or variable frequency motor drive. The burner shall be a 100% stainless steel vertical mounted radial fired type with stainless knitted metal fiber construction and shall have a five year non-prorated warranty. The burner shall combust a precise amount of premixed combustion air and gas to provide equal distribution of heat for heat transfer throughout the entire heat exchanger. Combustion shall operate with a minimum ( ) burner turn down ratio while sustaining combustion characteristics throughout the entire modulating range. Operation of up to 99% thermal efficiency and shall be certified for Oxides of Nitrogen (Nox) of 9 ppm corrected to 3% oxygen. The burner combustion shall operate as proportional modulating with a minimum ( ) turndown ratio with a minimum ( %) firing rate. Multiple boiler firing algorithms shall be proportional modulation. Light off shall be at no more than 50% input to assure rumble free soft start. Combustion shall be optionally suitable for natural gas, propane and dual fuels operation as scheduled. The ignition module shall employ a proven pilot system. Trial for ignition shall proceed with 15 seconds between retrials. Ignition control shall include times for pre-purge, pre-ignition, ignition, and post purge. Heat Exchanger: The heat exchanger shall be designed, inspected, and tested to A.S.M.E. Section IV requirements. The heat exchanger shall be of fully welded construction and have a maximum working pressure of 160 psig and a minimum operating pressure of 30 psig with a 10 year non-pro-rated warranty. Configuration shall be a cylindrical, vertical, two-pass, counter-flow, fire tube design and consist of an integral combustion chamber with an inner tube bundle for primary heat Page 34
transfer and an outer tube bundle for extracting latent heat from flue gases. The combustion chamber, fire tubes, and tube sheets shall be constructed of 316L stainless steel. The remainder of the heat exchanger shall be constructed of 304L stainless steel. The fire tubes shall be of an oval design with a minimum wall thickness of 0.061. The upper and lower tube sheets shall have a thickness of no less than 0.375. The heat exchanger design shall be capable of 40 o F constant system return temperatures and be fully condensing complete with condensate trap and drains. A pressure relief valve as scheduled and a pressure gauge of code range shall be furnished with the boiler. Boiler Control Panel: Each boiler shall include the same CSA certified control module with an electronic proportional integrated combination ignition limit/operator control accurate to 1 0 F (0.5 0 C) having a 4-20 ma output signal suitable for control of a variable frequency motor drive or a pulse width modulation signal output for modulating fan speeds. Energy Management: Each boiler mounted controller shall be capable of the following. a. Sequence its own boiler s modulation and/or cascade multiple boilers using a PID loop energy management firing rate tuning constant and parallel positioning of the firing rate of each boiler to track load and limit cycling to maximize all boiler operating efficiencies. b. Equalize hours of operation. c. Lead/lag. d. Base load rate adjustment. e. Warm weather shutdown. f. Provide indoor/outdoor reset. g. Heat exchanger frost protection with sealed combustion. h. Flue gas temperature rise protection for flue material limits. i. Control shall be equipped and ready with 4-20 ma remote set point or modulating control, capable with 0-10 VDC remote set point or modulating control. j. Control shall be standard with a BMS Modbus RTU protocol ready k. When utilized BACnet or Lonworks shall be able to control and/or monitor all functions listed. l. (Optional: shall include a BACnet, LonWorks or MetasysN2 gateway protocol converter). Control shall be supplied with a factory mounted seven inch touch screen display which shall also provide for control system configuration and set up, readouts and remote monitoring of boiler target, flame signal, inlet/outlet temperatures as well as accumulated runtime, enunciator diagnostics, and firing rates. The display will be equipped with two RS485 communication ports with battery backup and a USB port to extract boiler operation parameters for troubleshooting. If utilizing cascade control and the master boiler cannot fire the master control shall continue to operate all other boilers as originally programmed. If the master boiler cannot operate altogether then all of the other boiler s controls shall automatically revert to their standalone settings. Control Panel Display: The seven inch control display shall provide full diagnostics including real time data logging and support for all of the boilers in the sequencing application. The complete control package shall be mounted on the front panel with a hinged door for easy access to all control modules. The boiler safety control string shall be furnished with controls for low gas pressure, optional high gas pressure, fan air proving, blocked flue, water pressure, high limit, stack limit and flow switch. Additional control safeties shall include flue gas stack temperature, flame rectification, fan speed, and auto recycling high limit. Temperature Differential Set Point ECM Pump Speed Controller: The controller must utilize an 8-bit, 16MHz integrated microprocessor chip. Each boilers pump speed controller shall be field mounted by the contractor and wired to the boilers jacket with separate 115/1 electrical service. Two strap on temperature sensors shall be provided with the temperature controller and field mounted by the contractor under the insulation of the boiler supply and return water connections and wired into the speed controller using shielded cable. The controller shall modulate the ECM pump with a Vdc signal to vary the pumps speed to maintain a fixed temperature differential set point. The temperature differential shall be selected to meet the boiler manufacturer s requirements. The controller shall allow the programming of the minimum Vdc signal required to either allow the ECM pump to turn off when the boiler is not firing or set a minimum pump speed and flow. The controller shall allow the programming of response time to changes in temperature variation from differential set point. The controller shall have a digital display with temperature readouts of return water, supply water and differential. Programming shall be a part of the factory authorized start up service. The complete unit shall meet UL Standard 873 and be ETL Listed. Pump variable speed control based upon blower motor VFD Hz are not acceptable. Page 35
Boiler Primary ECM Pump with Separate Temperature Based Speed Controller: Boiler pumps shall be provided by the boiler manufacture along with necessary controls described herein and shall be field mounted and wired to both the field electrical service and to the boiler s pump speed controller. Circulating pumps shall be constructed with cast-iron bodies with factory applied Catephoresic coating. Shafts shall be constructed of high quality stainless steel. Motor bearings shall be metal impregnated carbon sleeve bearing type. Impellers will be constructed of a high strength, glass filled polypropylene engineered composite. Pumps shall be wet rotor, glandless inline and shall include electronic variable speed control using integrated synchronous motors with ECM technology using permanent magnetic rotors, special sensor-less control electronics and single phase electronic converters and shall not require the use of starters. The boiler controls shall enable/disable the pumps as well as vary the speed of the pumps throughout the boilers full modulating range from low fire to high fire to minimize flow and reduce electrical consumption. The circulating pumps shall have a high quality composite terminal box with NPT electrical connections and a secure, gasketed cover, Class 2 protection level. Included on the face of the terminal box cover is the single red button adjustment button, front readable graphical pump display, field adjustable for horizontal or vertical positioning of the terminal box. The display shall indicate: operation status, control mode, differential pressure or speed/set point and fault and warning signals. Pumps shall have a coded terminal strip indicating common/neutral/ground within the terminal box for field connections for single phase 230 volt, 60 Hz power. Voltage variances shall be less than +/- 10% from rated voltage with pump under load conditions. Maximum amperage not to be exceeded is indicated on the pump nameplate. Electrical power to the pump is confirmed when the face of the graphic display is lit. Pumps shall have integrated overload motor protection and shall protect the pump against over/under voltage, over temperature of motor and/or electronics, over current, locked rotor and dry run (no load condition). Fault contact terminals shall be included in the terminal box and are to be potentially free, normally closed contacts that open on the event of a failure. The circulating pump warranty shall be for a period of 2 years from date of manufacture or 1.5 years from the date of installation. Pumps using standard motors and external variable frequency drives are not acceptable. Boiler Requirements: Include a flow switch and a low water cutoff both shipped loose for field mounting and wiring. Boilers shall be fully factory fire tested and include all electrical and combustions tests to the owner including flue gas analyzer settings from ( %) input up through 100% input. Boilers shall be fully factory tested for ASME CSD-1 and the required test reports provided to the contractor and owner. Include factory authorized start-up service and owner training. Include field burner flue gas analyzer settings from ( %) input up through 100% input. Combustion air intake shall consist of approved material as scheduled. Exhaust flue venting shall consist of approved Category 2 or 4 venting material as scheduled. Electrical service as scheduled. Natural gas service to be 4.5 14 inches w.c. (Gas pressures above require the boiler to be supplied with high gas pressure reducing valves.) Boiler Warranty: Boiler warranty shall include: heat exchanger material and workmanship to be (10) years after initial installation, burner to be (5) years after initial installation, parts to be (1) year after installation or (18) months from date of factory shipment. Boiler ASME CSD-1: By contractor in the field: Boiler mounted locking disconnect, and ASME CSD-1 Part CE-100 Electrical Requirements, paragraph (92) (a) remote breaker switches or circuit breakers, one per boiler room door. Page 36
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