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Thermal Solutions Arctic, Installation & Operation Manual

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Thermal Solutions Arctic Installation & Operation Manual Download Page 35

 

 

Form: 2435 

 

 

Revision: 8 

Arctic Installation and Operation Manual 

 

Date: 9-19-2016 

Thermal Solutions, 1175 Manheim Pike, Lancaster, PA 17601 

Web:

  

www.

thermalsolutions

.com

 

Phone: 

717-239-7642 

Fax:

 877-501-5212 

Email:

 

[email protected] 

 

35 

5.5

 

Tube Replacement Procedure 

NOTICE 

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:  

1.

 

Shut off power to the boiler immediately from the external, dedicated electrical 

disconnect.  

2.

 

Confirm that any water leakage is not the result of a blocked condensate drain line. 

3.

 

Remove the boiler’s left side jacket panels and flue collector access panels as shown in 

Figure 8. 

4.

 

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. 

5.

 

Identify any leaking tubes.  

6.

 

Isolate and drain the boiler completely. 

2.

 

Use the proper tools.  Use the following tools to remove and replace leaking boiler tubes: 

1.

 

Tube Puller (P/N 106019-02) 

2.

 

Tube Driver (P/N 106019-01) 

3.

 

Sledgehammer (steel head, approximately 3 lb) 

 

Figure 8: Panel Removal in Preparation for Tube Inspection 

 

 

Summary of Contents for Arctic

Page 1: ... sales thermalsolutions com i ARCTIC High Efficiency Low Emission CONDENSING BOILER INSTALLATION OPERATION MANUAL For service and repair to the boiler call your heating contractor When seeking information on the boiler from the manufacturer provide boiler model and serial number as shown on the rating label Boiler Model Serial Number Installation Date Type System Heating Contractor Phone Email Add...

Page 2: ... 2 Gas Piping Leak Test 13 3 2 6 3 Venting of Gas Train Components 13 3 3 Combustion Air Supply System 13 3 3 1 Combustion Air Openings 14 3 3 1 1 Two Permanent Opening Method 14 3 3 1 2 One Permanent Opening Method 14 3 3 1 3 Mechanical Air Supply Systems 14 3 3 2 Louvers Grilles and Screens 15 3 3 2 1 Louvers and Grilles 15 3 3 2 2 Screens 15 3 3 2 3 Motorized Louvers 15 3 3 2 4 Combustion Air D...

Page 3: ... 28 4 6 Select Operational Mode 29 4 7 Begin Commissioning the Boiler 29 4 8 Finish Commissioning the Boiler 30 4 9 Re Starting After Prolonged Shutdown 30 4 10 Testing of Controls and Safety Devices 31 4 11 Ignition Failure 31 5 Service Maintenance and Inspection 32 5 1 General Maintenance 32 5 1 1 DAILY 32 5 1 2 WEEKLY 33 5 1 3 MONTHLY 33 5 1 4 ANNUALLY 33 5 2 Ignition Assembly Cleaning 33 5 3 B...

Page 4: ...ndensate Flow Rate 12 Table 3 Electrical Requirements 21 Table 4 Gas Supply Requirements 21 Table 5 Sound Pressure Levels 21 Table 6 Minimum Water Flow Rates for Variable Primary Pumping 22 Table 7 Maximum Water Flow Rates for Variable Primary Pumping 22 Table 8 Water Flow Rates for Primary Secondary Pumping 20F ΔT 23 Table 9 Water Flow Rates for Primary Secondary Pumping 40F ΔT 23 Table 10 Water ...

Page 5: ...alsolutions com v Figure 2 ARC1500 3000 External Boiler Connections and Components 8 Figure 3 Clearances and Serviceability 10 Figure 4 ARC 1000 Condensate Drain Trap 12 Figure 5 ARC1500 3000 Condensate Drain Trap 13 Figure 6 High and Low Fire Adjustments on the Main Gas Valve Regulator 29 Figure 7 Ignition Assembly 34 Figure 8 Panel Removal in Preparation for Tube Inspection 35 Figure 9 Tube Pull...

Page 6: ...tenance which are important but not related to personal injury hazards 1 2 Disclaimers and Local Codes Installation must conform to the requirements of the authority having jurisdiction In the absence of such requirements installation must conform to the National Fuel Gas Code NFPA 54 ANSI Z223 1 and or CAN CGA B149 Installation Codes Where required by the authority having jurisdiction the install...

Page 7: ...perator s when troubleshooting and servicing the boiler In addition the following tests and inspections are made on each boiler at the factory to ensure it meets our highest safety and functionality standards ASME hydrostatic test inspection Electrical components inspection Operating efficiency test Final engineering inspection Crating inspection Danger DO NOT store or use gasoline or other flamma...

Page 8: ...n over pressure condition 6 Ducted combustion air flange 7 Flue gas vent outlet The boiler comes with a standard AL 29 4C stainless steel vent connection 8 Water flow switch 9 Return water connection A 3 diameter Victaulic grooved connection is provided on the ARC1000 A 3 150 class flange is provide on the ARC1500 3000 10 Cleanout and inspection A 3 diameter Victaulic grooved connection is provide...

Page 9: ...requirements of the authority having jurisdiction In the absence of such requirements installation must conform to the National Fuel Gas Code NFPA 54 ANSI Z223 1 and or CAN CGA B149 Installation Codes Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 2 2 Boiler Foundation...

Page 10: ...ability Dim Description 1000 1500 3000 A Clearance Above Top of Boiler 6 6 B Front of Boiler Burner End 24 25 5 8 CH From Chimney or Vent Collector measured horizontally 18 18 Dim Description 1000 1500 3000 CV From Chimney or Vent Collector measured vertically 18 18 D Rear of Boiler opposite burner end 6 6 EL Left Side tube access side on standard construction 16 23 ER Right Side 6 6 Table 1 Clear...

Page 11: ...3 2 2 Safety Relief Valves Safety relief valve s are shipped loose Connections are provided in the top of the boiler for the safety relief valve s The safety relief valve discharge piping must be the same size as the safety relief valve discharge opening and run to a point of safe discharge No shutoff valves are to be placed between the relief valve and the appliance or in the discharge piping Avo...

Page 12: ...f 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 Consult Thermal Solutions or a chemical treatment company for buffering system CAUTION Failure to properly pipe the condensate system will greatly reduce boiler life Do not install plugs c...

Page 13: ...main motorized gas valve and up stream of the manual gas shutoff valve in the closed position to ensure the main motorized valves are not leaking by During commissioning the remainder of the gas train joints down stream of the main motorized gas valve shall be tested for leaks 3 2 6 3 Venting of Gas Train Components The MBC gas valve has an internal factory installed vent limiter re ANSI Z21 18 CS...

Page 14: ... or ducted to the outside by vertical ducts each opening or duct shall have a minimum fee open area of 1 in2 per 4000 BTU total input rating of the boiler s in the room If ducted to the outside through horizontal ducts each opening or duct shall have a minimum free area of 1 in2 per 2000 BTU total input rating of the boiler s in the room 3 3 1 2 One Permanent Opening Method One opening commencing ...

Page 15: ...er fail to opening during burner startup and to shut down the main burner if the louver close during burner operation 3 3 2 4 Combustion Air Ducts Combustion air ducts shall comply with the following Ducts shall be constructed of galvanized steel or a material having equivalent corrosion resistance strength and rigidity Ducts shall terminate in an unobstructed space allowing free movement of combu...

Page 16: ... vent connection a This boiler is shipped with an AL 29 4C Heat Fab Saf T Vent connection b Alteration of the boiler vent connection is prohibited 6 Do not reduce the diameter of the vent pipe The vent pipe must not be smaller than the vent connector on the boiler 7 Vent pipe system must be adequately supported at intervals no less than five 5 feet apart The completed vent system must be rigid and...

Page 17: ...ion height 22 This boiler has been certified with AL29 4C venting Select a vent material that is approved for use with condensing flue gasses 23 Install vent system before installing air intake water gas or electrical connections 24 For instances where the vent system manufacturer s instructions do not make a specification refer to the below points a Make sure pipe and fittings are clean by swabbi...

Page 18: ...rbon 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 ...

Page 19: ...ustion Air and Venting Requirements for Canada Canadian Standard CAN CSA B149 1 05 Natural gas and propane installation code specifies venting systems and air supply for appliances in Section 8 Paragraph 8 1 4 states Air supply shall be provided in accordance with Clause 8 4 when either an appliance or a combination of appliances has a total input exceeding 400 000 Btuh Air supply is defined as co...

Page 20: ...ppliance Venting Paragraphs 8 9 through 8 31 address many facets of flue gas vents many of which do not apply to the this boiler which is a Category IV listed appliance requiring the use of special venting systems as previously described NOTICE Please note that the information provided in this manual relative to the Canadian Standard is not meant to be all inclusive Reading the entire Standard is ...

Page 21: ...afety limits or devices using proper terminals provided in boiler electrical cabinet Refer to wiring diagram supplied with boiler for wiring information See Appendix G for sample wiring diagrams An as built wiring diagram is included with every boiler when it ships Contact a Thermal Solutions Representative or visit the website www thermalsolutions com for current wiring options 3 5 2 Gas Supply R...

Page 22: ...cheduled recording of the water meter register will show an indication of a potential slow system leak in addition to providing insight into any system problems Also make up water as well as water for the initial system fill should be provided through a water softener Additionally chemical treatment of the system water is advisable Contact a qualified boiler water chemical treatment company for th...

Page 23: ... ΔT 3 5 4 3 Water Flow Rates Constant Volume Primary Pumping Systems A constant volume primary pumping system shall be sized so that the flow rate specified in Table 10 can be maintained through each boiler connected to the system Model Maximum Flow Rate gpm Δ P ft High Fire Δ T ARC1000 95 12 7 20F ARC1500 143 9 2 20F ARC2000 190 16 3 20F ARC2500 238 20 20F ARC3000 285 28 7 20F Table 10 Water Flow...

Page 24: ...he safety precautions on the container s label Add chemicals slowly and in small amounts to prevent excessive heat and agitation The boil out of the boiler and system is neither difficult nor expensive The chemicals needed for cleaning are readily available Tri sodium phosphate and sodium hydroxide lye are the most commonly used chemicals Be certain the chemicals used contain NO CHLORIDES Use only...

Page 25: ...g The System WARNING Use only clean softened and treated water Chemical treatment of the raw water is essential when filling or refilling the system see section 3 8 3 7 2 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 sh...

Page 26: ...ing to Table 13 whenever the boiler is operating The boiler operator should be sure that the boiler is not operating for long periods without proper water treatment Water treatment may vary from season to season or over a period of time Therefore the water treatment procedure should be checked not less than four times a year and possibly more frequently as the local water conditions may indicate S...

Page 27: ...ded Feed Water Limits CAUTION Thermal Solutions Standard Warranty does not cover problems caused by oxygen contamination of boiler water 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 WARNING Chemicals used in treating boiler water are toxic...

Page 28: ...er 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 that are not shown on the home screen page NOTICE Refer to the Concert Boiler Control manual for det...

Page 29: ...missioning 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 4 at high and low fire 1 Confirm that Oxygen O2 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 6 for throttle adjustment Figure 6 High and Low Fire Adjustments on ...

Page 30: ... values given on factory fire test report supplied with boiler 5 Repeat if necessary 4 8 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 4 9 Re Starting After Prolonged Shutdown Use the following recommendations prior to re starting the heating ...

Page 31: ...ormal setting Hard Lockout Gas Pressure Switch Low Water Cutoff Push and hold the LWCO test button until the boiler control shuts down the main burner Manually reset the Concert Boiler Control and reset the LWCO Hard Lockout Low Water Level Auto Reset High Temp Limit Lower the setting of the limit so that the boiler control shuts down the main burner Adjust the limit to its normal setting High Lim...

Page 32: ...ice technicians only 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 If any electrical wires are disconnected during service clearly label the wire and ens...

Page 33: ...iler 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 Insp...

Page 34: ...e of the burner to remove lint and debris accumulation Be careful when cleaning the burner assembly to avoid damaging the metal mesh burner surface 3 If the burner or the burner gasket shows any visual deterioration or corrosion signs replace it immediately 4 After replacing the burner or burner gaskets check for proper operation by performing combustion analysis as well as checking for gas leakag...

Page 35: ... to the boiler and other equipment as a result of tube failures 1 Shut off power to the boiler immediately from the external dedicated electrical disconnect 2 Confirm that any water leakage is not the result of a blocked condensate drain line 3 Remove the boiler s left side jacket panels and flue collector access panels as shown in Figure 8 4 Visually inspect the burner and furnace pass insulation...

Page 36: ... 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 Figure 9 Tube Puller Insertion 7 Prepare the headers and replacement ...

Page 37: ...iving tubes can cause damage to the tubes and boiler header holes Use only approved Thermal Solutions tube driver and specified hammer The end formed tube fitting is designed to deform if overdriven to minimize damage to the vessel tube holes 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 t...

Page 38: ... again supplied to the control circuit Manual Reset High Limit Aquastat If the boiler water temperature exceeds the adjustable set point power is interrupted to the control circuit of the boiler which prevents the boiler from operating Power is interrupted until the control is manually reset pressing the control s reset button When the button is pressed power will again be supplied to the control ...

Page 39: ...SSIBLE CAUSE CORRECTIVE ACTION Boiler is not responding to a call for heat Status and Priority show Standby Boiler is not seeing Enable Disable of Domestic Demand Input Check wiring for loose connections or wiring errors If Domestic Demand is expected check the DHW Demand Modulation is selected properly Boiler is not responding to call for heat Status shows Standby and Priority shows Central Heat ...

Page 40: ...wer light on Control Control Fault The green light is connected to internal power supply The power supply is repeatedly starting and stopping not normal making the light flash The microprocessors are not running Try disconnecting all terminals except 24 Vac to power the control The green light should be steady If it is not then the control is defective If steady start plugging in all the connector...

Page 41: ...ne what adjustments may be made to reduce boiler cycling 7 Contact Manufacturer Incorrect Gas Valve Settings If combustion is too lean or rich as a result of improper gas valve settings adjust air fuel ratio to match factory O2 settings Poor Combustion Dirty Heat Exchanger Inspect heat exchanger tubes for damage and carbon build up Inspect and clean the burner assembly Refer to the Service Mainten...

Page 42: ...i e water heater cooling equipment Refer to Table 17 for maximum capacity of schedule 40 pipe Table 18 lists equivalent pipe length for standard fittings Given the specific gravity of gas at the boiler s location a correction factor can be found on Table 19 and multiplied by the Capacity in Cubic Feet of Gas Per Hour on Table 17 For gas piping material other than schedule 40 pipes refer to the Nat...

Page 43: ...7 322 482 928 1480 2610 5330 100 79 148 304 455 877 1400 2470 5040 125 70 131 269 403 777 1240 2190 4460 150 63 119 244 366 704 1120 1980 4050 175 58 109 224 336 648 1030 1820 3720 200 54 102 209 313 602 960 1700 3460 Based on gas pressures less than 2 psig and a pressure drop of 3 0 iwc and 0 6 specific gravity Table 18 Equivalent Lengths Of Standard Pipe Fittings And Valves Pipe Size nps ID in V...

Page 44: ...58 15 3 4 4 026 2 35 112 56 28 10 1 4 7 20 2 6 6 065 3 54 168 84 1 42 1 15 2 7 07 30 4 Equivalent lengths are for standard screwed fittings and for screwed flanged and welded valves relative to schedule 40 steel Table 19 Specific Gravity Correction Factors Specific Gravity Correction Factor Specific Gravity Correction Factor 5 1 1 1 2 71 55 1 04 1 3 68 6 1 0 1 4 66 65 96 Propane 7 93 1 5 63 75 9 1...

Page 45: ...0 Elbow eq ft 45 Elbow eq ft Velocity fpm 6 1 10 5 1534 8 22 2 22 1 11 863 ARC1500 Pressure Drop in Equivalent Feet Flue Vent 8 56 5 88 2 86 1296 10 174 1 75 87 829 ARC2000 Pressure Drop in Equivalent Feet Flue Vent 8 1 10 5 1728 10 31 3 125 1 56 1106 12 12 1 19 59 768 ARC2500 Pressure Drop in Equivalent Feet Flue Vent 8 1 563 16 67 8 33 2158 10 478 5 2 44 1381 12 183 1 852 92 959 ARC3000 Pressure...

Page 46: ...5212 Email sales thermalsolutions com 46 ARC2000 Pressure Drop in Equivalent Feet Combustion Air Duct 8 53 5 26 2 63 1264 10 164 1 64 82 809 12 063 63 314 562 ARC2500 Pressure Drop in Equivalent Feet Combustion Air Duct 8 83 8 3 4 17 1576 10 26 2 56 1 28 1009 12 1 98 49 701 ARC3000 Pressure Drop in Equivalent Feet Combustion Air Duct 8 1 19 12 5 5 9 1895 10 37 3 7 1 85 1213 12 14 1 41 7 842 ...

Page 47: ...ion Manual Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 47 Appendix C Venting Diagrams Appendix C 1 Typical Horizontal Vent Piping ...

Page 48: ... and Operation Manual Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 48 Appendix C 2 Typical Vertical Pressurized Venting ...

Page 49: ...ual Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 49 Appendix D Combustion Air Diagrams Appendix D 1 Typical Horizontal Air Intake Piping ...

Page 50: ...n and Operation Manual Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 50 Appendix D 2 Typical Vertical Air Intake Piping ...

Page 51: ...Manual Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 51 Appendix E Boiler Piping Diagrams Appendix E 1 Single Boiler Primary Secondary ...

Page 52: ...Operation Manual Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 52 Appendix E 2 Multiple Boilers Primary Reverse Return Piping ...

Page 53: ...tion Manual Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 53 Appendix E 3 Multiple Boilers Primary Secondary Reverse Return Piping ...

Page 54: ...d Operation Manual Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 54 Appendix E 4 Multiple Boilers Primary Secondary Piping ...

Page 55: ...al Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 55 Appendix E 5 Multiple Boilers Primary Secondary Piping Heating with Domestic Hot Water ...

Page 56: ...te 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 56 Appendix E 6 Multiple Boilers Primary Secondary Piping Heating with Domestic Hot Water continued ...

Page 57: ...79 80F 36 0 58 80F 48 1 02 70F 27 1 04 70F 41 0 75 70F 54 1 33 60F 32 1 41 60F 48 1 02 60F 63 1 81 50F 38 2 03 50F 57 1 47 50F 76 2 61 45F 42 2 51 45F 63 1 82 45F 84 3 22 40F 48 3 18 40F 71 2 30 40F 95 4 08 35F 54 4 15 35F 81 3 00 35F 109 5 32 30F 63 5 64 30F 95 4 09 30F 127 7 24 25F 76 8 13 25F 114 5 89 25F 152 10 43 20F 95 12 70 20F 143 9 20 20F 190 16 30 ARCTIC 2500 ARCTIC 3000 Delta T GPM Ft H...

Page 58: ...eration Manual Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 58 Appendix G Wiring Diagrams Appendix G 1 ARC1000 Wiring Diagram ...

Page 59: ...ion 8 Arctic Installation and Operation Manual Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 59 ...

Page 60: ...60 Appendix H Repair Parts All 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 App...

Page 61: ...llector Front Panel 1 1 105538 01 9 Flue Collector Side Panel 1 1 105540 01 10 Flue Collector Center Panel 1 1 105537 01 11 Flue Collector Top Panel 1 1 105541 01 12 Condensate Pan 1 1 105260 01 13 Horz Convection tube Access Door Clamp 2 2 105263 01 14 Horz Furnace Tube Access Door Clamp 2 2 105262 01 15 Vert Tube Access Door Clamp 3 3 105261 01 16 Bottom Reinforcement Plate 1 1 105281 01 17 Vert...

Page 62: ...00 Burner Assembly Table 21 Burner Assembly Item Number Description Quantity Part Number 1 Ultra Violet UV Scanner 1 106684 01 2 Heat Insulator 1 8026217 3 Ultra Violet UV Lens Gasket 2 107031 01 4 Ultra Violet UV Scanner Bracket 1 106685 01 5 Igniter Scanner Gasket 1 105246 02 6 Burner 1 105618 01 7 Ultra Violet UV Lens 1 107032 01 8 Igniter 1 105678 01 9 Site Glass Bushing 1 105657 01 10 Site Gl...

Page 63: ...and Operation Manual Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 63 Appendix H 3 Gas Train and Upper Vestibule Controls ...

Page 64: ...wer 1 105326 01 3B Swirl Plate 1 105327 01 3C Manual Shut Off Ball Valve 1 105325 01 3D Main Gas Valve 1 105330 01 3E High Gas Pressure Switch 1 105328 01 3F Low Gas Pressure Switch 1 105329 01 3G Ball Valve 1 1 8 Tapping 1 105324 01 3H Blower Adapter 1 105259 01 3I 1 4 NPT Plug 2 806603599 3J 1 4 NPTx1 4 Tube Compression Fitting 2 822658 3K Pressure Switch Tubing 3FT 92465560 3L Minimum Air Press...

Page 65: ...ic Installation and Operation Manual Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 65 Appendix H 4 Jacket ...

Page 66: ...le 23 Jacket Key No Description Quantity Part Number 4A Base 1 105124 01 4B Front Left Corner 1 105172 01 4C Front Right Corner 1 105172 04 4D Center Rail 1 105176 01 4E Hinges 2 105714 01 4F Front Lower Panel 1 105177 01 4G Front Door 1 105170 04 4H Front Upper Panel 1 105169 01 4J Top Panel 1 105174 04 4K Rear Panel 1 105173 02 4L Side Door 1 105178 02 4M Air Intake Filter 1 811SOL0020 Not Shown...

Page 67: ...stallation and Operation Manual Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 67 Appendix H 5 Outlet Manifold ...

Page 68: ...1 5B Top Panel Water Outlet Manifold 1 105382 01 5C 3 Victaulic Coupling 3 104035 02 5D 1 2 NPT Air Vent 1 102260 01 5E Temperature Pres sure Gauge 1 103470 01 1 103470 02 1 103470 03 5F Pressure Relief Valve 1 816603 38 1 816603 59 1 816603 75 1 816603 74 1 816603 77 1 816603 73 1 816603 78 5G 3 Cap 1 104035 03 5H LWCO Probe 1 80160592 5I Immersion Well For Auto Reset High Limit 1 105684 01 5J Br...

Page 69: ...n and Operation Manual Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 69 Appendix H 6 Miscellaneous External Components ...

Page 70: ...6D Condensate Trap 1 105432 01 6E 3 Victaulic Coupling 3 104035 02 6F 3 Cap 1 104035 03 6G Water Inlet Outlet Manifold Trim Ring and Gasket 3 105211 02 3 8205644 6H Vent Outlet Trim Ring and Gasket 1 105211 01 1 105486 01 6J J box and J box Cover 1 8136056 1 8136027 6K Water Flow Switch 1 105687 01 6L Brass Immersion Well Inlet Temperature Sensor 10Kohm 1 105684 01 1 105685 01 6M St Steel Immersio...

Page 71: ...c Installation and Operation Manual Date 9 19 2016 Thermal Solutions 1175 Manheim Pike Lancaster PA 17601 Web www thermalsolutions com Phone 717 239 7642 Fax 877 501 5212 Email sales thermalsolutions com 71 Appendix H 7 Controls ...

Page 72: ...105171 01 7B Concert Boiler Control 1 105681 01 7C 24VDC Transformer 1 105680 01 7D 120 24V Step down Transformer 1 801600502 7E Low Water Cut Off Reset Box 1 80160591 7F Display 1 105682 01 7G On Off Switch 1 105658 01 7H Ignition Transformer 1 80160208 7J Ignition Cable 1 105218 01 7K Blocked Condensate Switch 1 105659 01 Not Shown Control Limit Power Harness 1 105660 01 Not Shown Communication ...

Page 73: ...fety devices or any other improper service operation or neglect FLUE GAS CORROSION WARRANTY Subject to the terms and conditions herein Seller warrants to the original owner at the original installation site that the pressure vessel and flue collector are covered against failure due to fireside flue gas corrosion per the schedule as follows A Upper and Lower Pressure Vessel Headers 10 years from da...

Page 74: ...ressure relief valve or c Contrary to the written instructions furnished with the unit 2 Adverse local conditions in general and specifically sediment or lime precipitation in the tubes and or headers or corrosive elements in the atmosphere 3 Misuse in general and specifically operation and maintenance contrary to the written instructions furnished with the unit disconnection alteration or additio...

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