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Date: 8-4-2010
Revision: 0
Form: 2396
Bryan Steam LLC
Installation and Operating Service Manual
Triple-Flex
High Efficiency Boilers
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Date: 8-4-2010 Revision: 0 Form: 2396 INSTALLATION AND OPERATION SERVICE MANUAL Triple-Flex 150, 200, 250, & 300 High Efficiency Boilers Bryan Steam LLC 783 North Chili Avenue * Peru, IN 46970 Phone 765.473.6651 • Fax 765.473.3074 E-mail: inquiry@bryansteam.com Internet: www.bryanboilers.com
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Date: 8-4-2010 Revision: 0 Form: 2396 Table of Contents Bryan Steam LLC ..............................................................................................................................i Installation and Operating Service Manual........................................................................................i Table of Contents ............................................................................................................................ iii Tables .
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Date: 8-4-2010 Revision: 0 Form: 2396 2.2.11 Operation Page............................................................................................................ 22 2.2.12 Annunciation Page....................................................................................................... 23 2.2.13 Modulation Configuration............................................................................................. 23 2.2.14 Firing Rate Control Page ...........................
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Date: 8-4-2010 Revision: 0 Form: 2396 Tables Table 1 Minimum Clearance............................................................................................................ 2 Table 2 Electrical Requirements...................................................................................................... 4 Table 3 Boiler Draft.......................................................................................................................... 7 Table 4 Water Flow Swi
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Date: 8-4-2010 Revision: 0 Form: 2396 Figure 35 Outdoor Reset Sensor Configuration............................................................................ 26 Figure 36 Air / Gas Ratio Tappings ............................................................................................... 35 Figure 37 LL / Multi-Boiler Field Wiring ......................................................................................... 58 vi
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Date: 8-4-2010 Revision: 0 Form: 2396 Section 1 Installation Instructions– Triple-Flex High Efficiency Boilers 1
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Date: 8-4-2010 Revision: 0 Form: 2396 Note: 1.2.1 MINIMUM CLEARANCES TO Please read and save for future reference the COMBUSTIBLE SURFACES entire instruction manual before attempting installation of or starting the unit. Insurance and local or state regulatory codes may contain additional or more stringent requirements than those contained in this manual. Installation must conform to these codes and any other authority having jurisdiction. This instruction manual shall be p
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Date: 8-4-2010 Revision: 0 Form: 2396 BE REMOVED after the boiler is set in-place on 1.4.5 CONDENSATE DRAIN its concrete foundation before any CONNECTION piping/electrical connections are made. It is recommended that the plastic protective cover be left on as long as possible to reduce finish A 1” MPT connection is provided to drain the damage from the installation. condensed products of combustion from a trap located beneath the boiler. This must be run to a drain using st
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Date: 8-4-2010 Revision: 0 Form: 2396 valve shall be tested for leaks. Model TF300/250 TF200/150 200 V – 240 V / 60 Hz / 3 Ph Blower Motor 3 (4.02) N/A KW (HP) 1.4.9 VENTING OF GAS TRAIN Full Load 15.6 N/A 1 COMPONENTS Amps Service Fuse (3) 20 Amp N/A 400 V – 480V / 60 Hz / 3 Ph Blower Motor N/A N/A KW (HP) Full Load N/A N/A 1 Amps Service Fuse N/A N/A 200 V – 240 V / 60 Hz / 1 Ph Blower Motor N/A 1.05 (1.41) KW (HP) Full Load N/A 6 1 Amps Service Fuse N/A (2) 7
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Date: 8-4-2010 Revision: 0 Form: 2396 interlocked with the boiler to prevent boiler One Permanent Opening Method operation if the dampers are closed. One opening commencing within 12” of the top Combustion air openings must never be blocked of the room shall be provided. The opening or obstructed in any manner. shall be directly to the outside or shall be ducted to the outside with a horizontal or vertical duct. The boiler room must be at a positive or neutral pressu
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Date: 8-4-2010 Revision: 0 Form: 2396 specified. Where the louver and grille design BOCA, National Mechanical Code and free area are not know, it shall be assumed that wood louvers have a 25 percent free area, and met louvers and grilles have 75 percent free WARNING: area. Non-motorized louvers and grilles shall be fixed in the open position. Do not locate air intakes where petroleum distillates, CFC’s, Screens detergents, volatile vapors or any Minimum Screen Mesh Size:
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Date: 8-4-2010 Revision: 0 Form: 2396 Horizontal sections of the flue vent system must Note: be pitched back towards the boiler at ¼ inch per An existing masonry chimney may be utilized foot to avoid condensate pooling and allow for PROVIDING that the existing chimney is lined proper drainage. Venting may be horizontal, with Special Gas Vent material(s), primarily through the wall installation or vertical, through AL29-4C®. There are venting manufacturers the roof installation
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Date: 8-4-2010 Revision: 0 Form: 2396 shaft used for return air, hot air, Combustion Air Supply Dampers, Louvers, ventilating air, or combustion air. and Grilles • An appliance that operates at a positive vent pressure shall not be connected to The free area of the combustion air supply a venting system serving any other opening shall be calculated by subtracting the appliance. The Triple-Flex boiler blockage area of all fixed louvers, grilles or operates at a positive vent
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Date: 8-4-2010 Revision: 0 Form: 2396 1.8.1 HYDROSTATIC TEST OF BOILERS AND SYSTEM After completing the boiler and burner installation, the boiler connections, fittings, attachments and adjacent piping must be inspected for leaks by filling the unit with water. The pressure should be gradually increased to a pressure just below the setting of boiler safety relief valve(s). Remove the boiler tube access panels (see dimensional drawing in the boiler manual). Inspect the tube
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Date: 8-4-2010 Revision: 0 Form: 2396 Section 2 Start-Up and Operation Triple-Flex High Efficiency Boilers 10
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Date: 8-4-2010 Revision: 0 Form: 2396 2.1.1 TRIPLE-FLEX FRONT VIEW WARNING: Improper servicing and start-up of this equipment may create a potential hazard to equipment, operators, or persons in the building. Only fully trained and qualified personnel should do servicing and start-up. WARNING: Before disconnecting or opening any fuel line, cleaning or replacing parts of any kind take the following precautions. Turn OFF the main fuel shutoff valves, including the pilot ga
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Date: 8-4-2010 Revision: 0 Form: 2396 the touch panel display. There is a soft 2.1.2 TRIPLE-FLEX REAR VIEW switch (paragraph 2.2.11) provided with the SOLA hydronic control that will put the boiler into standby for an indefinite period of time. WARNING: The boiler on / off switch will not turn off the 3 phase high voltage power to the motor. 7. The boiler lockout reset button is a push button used to reset the hydronic control after a boiler failure. 8. The power on light
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Date: 8-4-2010 Revision: 0 Form: 2396 1. Main gas inlet connection. This connection 2.1.3 TRIPLE-FLEX LEFT SIDE VIEW is a 2” male national pipe thread. 2. Condensate Drain Connection. This connection is a 1” male national pipe thread. For installation details refer to paragraph 1.4.5. 3. This jacket access panel will permit access to the majority of the boiler devices. 4. These jacket access panels will permit access to the flue collector. There is no practical reason for
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Date: 8-4-2010 Revision: 0 Form: 2396 port is also used to record the furnace pressure. NOTE: 15. Boiler water flow switch. The boiler water The low fire displacement final adjustment flow switch is adjustable within the should be made at low fire only. parameters listed in the table. 3. Main gas pressure regulating and shutoff Mode Of Operation valve actuator. The pressure regulating Settings Switch Switch actuator provides slow opening fast closing Closed Open sa
