Traid Triumph 1000 Operating And Maintenance Manual Download

Page: 2 / 67

TRIAD Boiler Systems, Inc.

West Chicago, IL

www.triadboiler.com

Contents

FORWARD ...................................................................................................................................................... 6

Documents Unique to your boiler ............................................................................................................. 7

Supplimentary Manuals ............................................................................................................................. 7

Definitions, Standards, & Sources ............................................................................................................. 8

Introduction to safety ................................................................................................................................ 8

What to do if you smell gas ....................................................................................................................... 9

Approvals & Recordkeeping .................................................................................................................... 10

Applicable Regulations in the U.S. market .............................................................................................. 10

Warnings ...................................................................................................................................................... 11

1 Labeling, Signage, Handling Options ........................................................................................................ 12

2.0 Boiler Component Identification ........................................................................................................... 17

2.1 Boiler Specifications and Dimensions .................................................................................................... 18

2.1.1 Cutaway of Combustion Chamber and Heat Exchanger………………………………………………………………….23

2.2 Typical basic water level and temperature controls ............................................................................. 24

2.3 Burner Mount ........................................................................................................................................ 25

2.4 Gas Train…………………………………………………………………………………………………………………………………………..26

2.5 Example fuel train schematics ............................................................................................................... 26

2.6 Example wiring diagrams ....................................................................................................................... 27

3.0 Specifications ......................................................................................................................................... 28

4.0 Boiler Installation ................................................................................................................................... 29

4.1 Receiving the boiler ............................................................................................................................... 29

4.2 Unloading the boiler-burner unit .......................................................................................................... 30

4.3 Boiler unloading instructions ................................................................................................................. 30

4.4 The boiler room ..................................................................................................................................... 31

Fresh & Ventilation air ............................................................................................................................. 31

Lighting .................................................................................................................................................... 31

4.5 Installing the Boiler ................................................................................................................................ 31

Flue .......................................................................................................................................................... 32

Condensate Drain .................................................................................................................................... 32

Water Connections .................................................................................................................................. 32

Inverting Door Aperture (Model 300 & 500) ........................................................................................... 30

Inverting Door Aperture (Models 750 - 2000) ......................................................................................... 33

Pressurized Boiler Connection ................................................................................................................. 33

Furnace Drawer ...................................................................................................................................... 34

Summary of Contents for Triumph 1000

Page 1: ...TRIUMPH SS SERIES High Efficiency Condensing Boiler 300MBH 2000MBH OPERATING AND MAINTENANCE MANUAL TRIAD Boiler Systems Inc West Chicago IL 6018 888 526 5245 1 26 2014 ...

Page 2: ...utaway of Combustion Chamber and Heat Exchanger 23 2 2 Typical basic water level and temperature controls 24 2 3 Burner Mount 25 2 4 Gas Train 26 2 5 Example fuel train schematics 26 2 6 Example wiring diagrams 27 3 0 Specifications 28 4 0 Boiler Installation 29 4 1 Receiving the boiler 29 4 2 Unloading the boiler burner unit 30 4 3 Boiler unloading instructions 30 4 4 The boiler room 31 Fresh Ven...

Page 3: ...ctions 39 5 2 Boiler connections general 39 5 3 Water connections 39 5 4 Hot water boilers supply return connections 40 5 5 Drains 40 5 6 Drain connections 40 5 7 Safety relief valves SRV 41 5 8 SRV discharge piping 41 6 Boiler start up 42 6 1 Operating data 42 6 2 Start up guidelines 42 6 3 Tools gauges 43 6 4 Fuel guidelines 43 6 5 Cleaning and filling a new boiler 43 6 6 Firing a new boiler 44 ...

Page 4: ...intenance on temperature limiting controls 51 7 5 Example of control set point adjustment procedure 52 7 7 Water level controls 52 7 7 1 Electric probe type low water fuel cutoffs 52 7 7 2 Low water fuel cutoff and water feeder maintenance 52 7 7 3 Pushbutton Shunt 53 7 7 4 LWCO 53 7 7 5 Water level manual reset 53 7 8 Water level operations 53 7 8 1 Maintaining Proper Water Level 53 7 9 Water Tre...

Page 5: ...59 8 3 Detailed Empty inspection 60 Safety Checklist for Inspection 61 Water Side Checklist 61 Fire Side Checklist 61 Look for corrosion of pressure parts 61 Look for erosion 62 External Checklist 62 8 4 Limit control tests 62 8 4 1 High Low gas pressure switch limit test adjustment 62 For setting and testing the gas pressure switches 63 8 4 2 Electrical Limit Controls 63 9 TROUBLESHOOTING 63 To s...

Page 6: ...ncy higher operating costs sooting frequent cleaning and high carbon monoxide CO output The successful long term operation of the boiler is dependent on the quality of its water Failure to provide suitable water will result in corrosion and the build up of scale and mud sludge sediment causing inefficient thermal transfer an associated loss of efficiency higher operating costs and eventually lead ...

Page 7: ...ed specific to each end user A list of exact components and information about them are appended to this manual All of these documents and devices work together to safely operate your boiler Documents Unique to your boiler Triad documents are created unique to each boiler and are appended to this manual Document of pages Page Location Specification sheets 4 Appendix 1 Ratings and dimension drawing ...

Page 8: ...ater temperature control device BHP Boiler horse power is equivalent to 33 475 Btu Hr PSI Pounds per square inch PSIG PSI gage reading In WC Inches of water column Units of pressure where one 1 PSI 28 In WC 28 WC UL Underwriters Laboratories Inc UL Mark Signage on the boiler designating UL approval UL 795 Commercial Industrial Gas Heating Equipment UL 353 Limit Controls cUL Verification to Canadia...

Page 9: ...expressly for each installation by the manufacturers service engineers and qualified personnel from the operating organization before and during the commissioning period These procedures are based on actual experience and often include invaluable information on what the equipment is expected to do Limitations critical to safe and reliable operations are also given Control systems vary in complexit...

Page 10: ...the CSA 22 1 Canadian Electrical Code Part I The installation of the unit shall be in accordance with the regulations of the authorities having jurisdiction APPLICABLE REGULATIONS FOR US MARKET NFPA54 National Fuel Gas Code NFPA70 National Electrical Code IFGC International Fuel Gas Code All drawings wiring diagrams schematic arrangements manufacturers descriptive literature and spare parts lists ...

Page 11: ...s in the sector of heating system components INCORRECT INSTALLATION MAY CAUSE DAMAGE TO PERSONS ANIMALS OR OBJECTS FOR WHICH THE MANUFACTURER CANNOT BE HELD RESPONSIBLE At the first start up all regulation and control devices positioned on the control panel should be checked for efficiency The guarantee shall be valid only upon compliance with the instruction given in this manual IMPORTANT This bo...

Page 12: ... triadboiler com 1 0 BOILER LABELING AND SIGNAGE Supply Water Label Low Temperature Return Water Label Medium Temperature Return Water Label Warning plate Every boiler includes this warning mounted on the front doors of the boiler close to eye level ...

Page 13: ...Line this up with the primary level mark on the LWCO ASME Drum stamping The ASME H Stamp is riveted directly to the boiler frame when ASME approval is given and is located above the medium temperature return to the left Load Bearing Point sticker Besides the lifting lugs this shows the only locations the boiler should be lifted from ...

Page 14: ...14 TRIAD Boiler Systems Inc West Chicago IL www triadboiler com Handling Options ...

Page 15: ...15 TRIAD Boiler Systems Inc West Chicago IL www triadboiler com Baffle Warning Label UL and CUL boiler stickers ...

Page 16: ...16 TRIAD Boiler Systems Inc West Chicago IL www triadboiler com 2 0 Boiler Component Identification ...

Page 17: ...17 TRIAD Boiler Systems Inc West Chicago IL www triadboiler com 2 1 Boiler Specifications and Dimensions Model 300 500 Model 750 1000 ...

Page 18: ...valve probe 17 Thermometer 18 Regulation thermostat n 1 19 Regulation thermostat n 2 20 Manual reset safety thermostat 21 Shock absorbing pipe 22 Safety valve n 1 the 2 nd has a heating capacity above 580 kW 23 Fuel shut off valve 24 Manual shut off valve 25 Manual shut off valve for gas 26 Expansion vessel 27 Level probe glow plug optional 28 System flow 29 Probe sleeves inside the boiler 30 Gas ...

Page 19: ...276 384 307 093 279 796 98 5 109 Triumph 1400 464 052 515 234 470 876 98 5 109 Triumph 2000 580 065 644 896 590 301 98 5 109 Pressure losses flue gas side Heat loss thru chimney For condensing temp flow return 50 86F Heat loss thru casing For condensing temp flow return 50 86F Heat loss with burner off For condensing temp flow return 50 86F Flue gas temp at output air 20c For condensing temp flow ...

Page 20: ...20 TRIAD Boiler Systems Inc West Chicago IL www triadboiler com Model 300 500 Model 750 1000 ...

Page 21: ...0 2000 N1 Boiler flow N2 Medium temperature return N3 Safety Valve fitting N4 System filling drainage N5 Safety valve s fitting N6 Immersion wells not used N7 Boiler condensation drain N8 Inspection well N9 Low temperature return T Inspection Plug See Dimensions on next page ...

Page 22: ...P14 L2 L6 in in in in in in in in in in in in Triumph 300 38 98 34 69 26 38 12 52 13 78 12 68 7 9 11 8 4 33 27 95 Triumph 500 52 36 48 07 39 76 12 52 7 87 31 97 7 9 11 8 5 71 27 95 Triumph 750 61 02 51 02 39 53 12 72 6 89 41 42 9 8 11 8 8 27 32 05 5 91 Triumph 1000 61 02 51 02 39 53 12 72 6 89 41 42 9 8 11 8 8 27 32 05 5 91 Triumph 1400 71 54 62 09 47 44 12 76 8 66 38 31 9 8 11 8 5 91 5 91 10 63 3...

Page 23: ...23 TRIAD Boiler Systems Inc West Chicago IL www triadboiler com Cutaway Images of Combustion Chamber and Heat Exchanger ...

Page 24: ...d 1000 Low water cutoff probe connection 2 Spool piece from boiler outlet High Limit control connection Firing Rate control connection Operating control connection Temperature Pressure gauge connection 2 5 Spool piece from boiler outlet Low water cutoff probe connection High Limit control connection Firing Rate control connection Operating control connection Temperature Pressure gauge connection ...

Page 25: ...umph SS 1400 and 2000 2 3 Burner Mount 1 4 3 2 1 Burner 2 Thermo insulating material 3 Burner Draft Tube Hole 4 Gasket P 6 Øb Temperature Pressure gauge connection Low water cutoff probe connection High Limit control connection Firing Rate control connection Operating control connection ...

Page 26: ...ple Fuel Train Schematics 1 Pilot Shutoff Cock 2 Pilot Regulator 3 Pilot Valve 4 Main Gas Shutoff Cock 5 Main Gas Pressure Regulator 6 Low Gas Pressure Switch 7 Leak Test Cock 8 Main Gas Valve with Proof of Closure 9 Main Gas Leak Test Cock 10 Butterfly Valve 11 High Gas Pressure Switch ...

Page 27: ...27 TRIAD Boiler Systems Inc West Chicago IL www triadboiler com 2 6 Example wiring diagrams ...

Page 28: ... There are several slits in the bottom of the furnace which lead to the condensing section The condensing section is a series of vertical plates surrounded on both sides by water The plates have a pattern of indentations to increase the heat transfer area The plates are located at the bottom of the boiler near the return water inlet This counterflow arrangement leads to lower stack temperatures an...

Page 29: ...e the flue gas outlet If only one nozzle is used always use the low temperature return Recirculation pump connections and re circulating pumps may be added to one or both sides of the boiler to isolate the boiler from the hot water system and reduce temperature differential across the boiler The boiler shall have a drain connection 4 0 BOILER INSTALLATION 4 1 Receiving the boiler During the constr...

Page 30: ... and can damage the boiler Before lifting the boiler check all of the transport tie downs to insure that they have been removed and will not interfere with the lifting of the boiler Check the lifting cables to insure that they are positioned properly and will not cause any damage to the boiler Check all electrical enclosure doors and attached piping to insure that they are firmly secured Carefully...

Page 31: ...nd inspection of all piping supplied with the boiler After the boiler has been set in place ensure it is level Fresh Ventilation air The boiler room must have an adequate air supply to permit clean safe combustion and to minimize soot formation An unobstructed air opening should be provided It may be sized on the basis of 1 sq in free area per 1000 Btu hr maximum fuel input of the combined burners...

Page 32: ...r is not supplied with acid condensate neutralizer a siphon must be fitted on the condensate drain to avoid flue gas leakage Water Connections Make sure that the water pressure downstream of the water supply pressure reducer is lower than the working pressure shown on the boiler data plate During operation the water in the heating system increases in pressure make sure therefore that the maximum p...

Page 33: ...mise correct boiler operation Check the maximum combustion chamber pressure as shown in the technical characteristics table Make the following checks 1 Check the internal and external fuel supply system for any leaks 2 Adjust the fuel supply rate as to the required boiler heat rating 3 Check that the boiler is supplied with the type of fuel for which it has been arranged 4 Check that the fuel supp...

Page 34: ...re insulation rope is provided with the boiler If this is not suited to the specific burner fitted use a rope of another diameter of the same type of material Furnace Drawer A drawer has been fitted inside the furnace in order to increase thermal exchange and efficiency of the boiler See picture below If removed it is necessary to refit it considering that The open side with fin supports 1 must st...

Page 35: ...ecommends a desiccant product called Boiler Lizard These tubes of desiccant can be opened and placed in the water side of a boiler The boiler lizards can remain in the water side of the boiler to be dissolved by water The desiccant and tubular bags are water soluble dissolving the first time water is added to the boiler Desiccant placed in other locations should be removed prior to placing the boi...

Page 36: ...cal disconnect switch must be in the OFF position There may be more than one disconnect switch Lock out and tag switch with a suitable warning label The exact configurations of electrical panels vary Additional small junction boxes are used when needed If for repair purposes wiring is run to any probes that wiring shall be sufficient for 150 F Grounding of some components is conducted through the ...

Page 37: ...ontrols when used shall provide proper sequencing of the above controls to insure that all conditions necessary for proper burner operation are satisfied Included in a programmed control are pre purge and post purge cycles to remove accumulated gases Flame Safeguard When installation is complete Safety Controls will stop fuel flow in the cases of ignition failure main flame interruption mechanical...

Page 38: ... can dramatically impact the adjustment of your burner on a seasonal basis Draft values and draft control vary depending on the configuration of your stack weather conditions firing rate of your boiler and many other variables 4 11 Vent material selection TRIAD recommends the use of type L UL listed ducting systems installed by a professional contractor Type L is a UL listing category The L stands...

Page 39: ...GC AS APPROPRIATE 5 1 Fuel supply connections Gas piping shall be of adequate pressure at capacity for your applications in accordance with NFPA 54 UL cUL listed boilers have the required fuel pressures and flow rates on the rating plate 5 2 Boiler connections general The configuration of the supplied piping is documented on your R D drawing The piping on a boiler should be kept leak proof A small...

Page 40: ...g shall be held in place by a guard or gland The design pressure of all valves used in water headers should equal or exceed the design pressure of the boilers they are attached to 5 5 Drains Unobstructed floor drains properly located in the boiler room will facilitate proper cleaning of the boiler room Floor drains that are used infrequently should have water poured into them periodically to preve...

Page 41: ...al cross sectional area shall be not less than the full area of the valve outlet or of the total of the valve outlets discharged therein shall be as short and straight as possible and so arranged as to avoid undue stress on the valve or valves A union may be installed in the discharge piping close to the valve outlet When an elbow is placed on a safety or safety relief valve discharge pipe it shal...

Page 42: ...and the entire contents of this manual prior to any startup or adjustment made to the boiler and related components Installation and service must be performed by a qualified installer service agency or the fuel supplier 6 1 Operating data Whenever a new boiler is placed in service operating data should be recorded compared to predicted performance and saved for future reference This information is...

Page 43: ...er to measure flame signal A stack velocity meter if you need to verify stack flow 6 4 Fuel guidelines Do not attempt to relight the pilot or start burner with the combustion chamber full of gas or with very hot combustion chamber Do not use gasoline crankcase drainings or any oil containing gasoline NEVER BURN GARBAGE OR PAPER IN THE UNIT AND NEVER LEAVE COMBUSTIBLE MATERIAL AROUND IT Review all ...

Page 44: ...arting up the burner When tuning the flame in your new boiler the flame should not be allowed to impinge upon the back of the furnace A boiler tuned with flame continuously impinging upon the back of the furnace will void the warranty Also see the boil out instructions and start up procedures for details on firing the boiler for the first time 6 7 Boil out procedure All new boilers must be boiled ...

Page 45: ...nine 9 if necessary NOTE Plates near the sidewalls are usually the last to boil out because the temperature of the flue gas passing over them is lower 11 All inspection plugs and any other openings shall be closed except a vent line Fill the boiler immediately to prevent flash corrosion Fire boiler until water is heated to at least 180ºF to drive off any dissolved gases that may corrode the metal ...

Page 46: ...er pressure regulator and turn circulator pumps on electrically 10 Check temperature controls for proper settings 11 Check manual reset button on low water fuel cutoff and high limit temperature control 12 Set manual fuel supply valves in open position 13 Place circuit breaker or fused disconnect switch in ON position 14 Place all boiler emergency switches in On position 15 Place boiler control st...

Page 47: ...ny purpose without properly balancing the heating system and properly adjusting the burner 2 The burner must be adjusted to avoid short term cycling This will help eliminate the problems connected with rapid expansion and contraction associated with short cycling when the burner is not modulating continuously 3 The firing rate of the unit must not be exceeded 4 A circulation flow switch when a cir...

Page 48: ... all shutdown controls in the event of an emergency and there should be at least two people present Care should be taken to protect those present from escaping steam All safety relief valves are to be documented including the date into your log book Excessive hand lifting will shorten the life of the valve 7 1 2 Safety relief valve tests Try Lever Test 1 Check the safety relief valve discharge pip...

Page 49: ...g pressure of the safety relief valve 8 The temperature at the start of the test is below the normal operating temperature as recommended it will not be necessary to change or jumper out the operating or high limit temperature controls If the water temperature is at normal operating temperature it may be necessary to readjust these limits upward to allow the burner to remain on long enough to reac...

Page 50: ... 7 2 2 Pressure gauge range The gauge range should be selected so that the gauge will normally operate in the middle of the scale For example if the operating pressure is 50 psi then a 100 psi gage should be used 7 2 3 Pressure gauge accuracy The gauge accuracy is expressed in percent of full scale reading For example if a 100 psi gage is 2 accurate then it will be within 2 psi of the actual press...

Page 51: ...ilers are protected from over temperature by two temperature operated controls The high limit and operator temperature controls are installed as aquastats in the boiler s outlet water spool 7 3 1 High limit Water boilers have a high temperature limit control that cut off fuel supply to prevent water outlet temperature from exceeding its maximum fixed set point This control is constructed to preven...

Page 52: ...her too high or too low Control settings are determined by observing the water temperature gauge at the point of switch function as opposed to relying on the pointer indication on the scale plate There is no benefit in adjusting the manual reset high limit and operating control set points too close to each other This practice can lead to nuisance tripping and lockout of the high limit 7 7 Water le...

Page 53: ...e This ensures the operator is aware that the LWCO is not operating as designed If your LWCO is a probe type the reset button is located on the boilers junction box located near the water column mounted on the boiler 7 7 5 Water level manual reset Probe type water level controls have the reset button located on either on the junction box or on the probe holder 7 8 Water level operations 7 8 1 Main...

Page 54: ...oiler water treatment The exact chemistry of water varies so much from one area to another there is no such thing as one treatment being effective in all areas Treatment must be provided to prevent scale formation oxygen corrosion excess acidity control of total dissolved solids prevent caustic embrittlement and so forth We therefore recommend that you contact a reputable boiler treatment company ...

Page 55: ...oilers Water treatment in a heating boiler is usually not a problem because the same water is used over and over Treatment is primarily to eliminate corrosion and pitting cause by alkalinity and oxygen It is usually necessary to treat the water in a heating boiler once a year at the beginning of the heating season TRIAD recommends you consult a competent water consultant to determine your water tr...

Page 56: ... has been custom made to match with your burner No maintenance other than replacement after seven years should be required 7 10 2 Refractory Refractory is part of the burner mount The refractory typically has a life of about seven 7 years TRIAD recommends that you order one of each once you see any spauling of refractory After ten 10 years even if the refractory looks good it should be replaced By...

Page 57: ...ted here is a good place to start Over time you can determine exactly how often each items needs to be checked Examples of maintenance logs are provided however the end user is responsible to create log sheets that match with the specifics of your system A permanent log book should be provided in each boiler room to record maintenance work inspection certain tests and other pertinent data Brief de...

Page 58: ...el valves are closing within specified timings check valve position indicators 11 If boiler is equipped with modulating burner verify that adequate differential exists between operating and modulating controls to prevent short cycling 12 If you have chemicals being introduced directly into the boiler check chemical feed equipment against the check list supplied by your water treatment professional...

Page 59: ... This is very important To assist cool down use the Test Run or Check Run switch located on the programmer to run the blower 2 Remove all the nuts from the front door pry the door loose from the boiler and swing it away on the davit arm 3 Clean the combustion chamber 4 Clean the sight port glass replace if required 5 Clean Adjust pilot Assembly This will be covered in the burner manual 6 Re calibr...

Page 60: ...rmine if high limit control functions correctly Remove jumper wire when finished 5 Bypass both operating and high limit controls under manually controlled low load condition Gradually bring boiler pressure up to safety relief valve set point 70 to 300 valves may vary by three percent 3 6 Remove gas line strainer basket and clean 7 Flame failure detection system pilot turn down test 8 10 Replace sc...

Page 61: ...anges 5 Note location and type of deposits in boilers that have previously been in operation and collect samples for analysis Fire Side Checklist 1 All combustion air and flue gas passages such as the furnace ductwork and fans should be free of extraneous material 2 It is especially important to remove all combustible material that might ignite burn and trigger the explosion of unburned fuel if ig...

Page 62: ...er to service 6 Safety relief valve outlets should be piped so they cannot discharge on people or any property that may be damaged The discharge piping should be supported so that loads piping weights and dynamic forces during operation transmitted to the relief valves are minimized The weight supported by the valve should not exceed the weight of a short elbow and drip pan or comparable weight of...

Page 63: ... of the high gas pressure switch If the high gas pressure switch HGPS is located downstream of the metering valve adjustment and testing of the HGPS is performed at high fire If the HGPS is located upstream of the metering valve then adjustment and testing is performed at low fire Cycle the burner to firing rate and take gas pressure reading Slowly adjust the switch until it breaks and shuts down ...

Page 64: ...the LWCO is always showing low water you could have a collapsed float ball Probe style switches common LWCO can give a false closed switch signal because of contamination Clean water side of probe holder Leaking If water starts coming out of the smoke box doors this is common during initial cold start up If this does happen during start up but stops after the boiler has warmed up this is ok If thi...

Page 65: ...vice When a boiler is taken out of service it should be laid up using either the wet or dry procedure NOTE TRIAD does not warranty boilers out of operation that are not properly laid up for extended periods of time If the boiler could be subject to freezing temperatures when out of service the boiler must be laid up dry If draining the boiler is not practical the laid up wet procedure may be used ...

Page 66: ...ot used for extended periods of time This will prevent oxidization of the metal Care should be taken to avoid putting oil on the firebox thermal blankets 9 Place desiccant on wooden or plastic trays in the fireside of the boiler Do not fill the trays more than half way Also place small amount of desiccant in the junction box and burner control panel 10 Close up all opening to the boiler preventing...

Page 67: ...RIAD Boiler Systems Inc West Chicago IL www triadboiler com 6 See the start up section of this manual Boil out procedures do not need to be repeated unless inspection finds oil buildup inside the water side ...

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