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T-200

Triton Series

™

High Efﬁ ciency Boiler

Models: T80 - T200

Installation, Operating & Maintenance Manual

•

Designed and Manufactured in Accordance with
ASME Code Section IV

•

ETL Tested and Listed:
ANSI Z21.13-2010 / CSA 4.9-2010

•

AHRI IBR Listing per BTS 2000

•

ASME Section IV H-Stamped

• SCAQMD

1146.2

• CRN

“Quality, value and service since 1919”

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Содержание Triton T-80

Страница 1: ...tion IV H Stamped SCAQMD 1146 2 CRN Quality value and service since 1919 S A M E H Qu Q Q Qu u Q Q Q Q Qu Q Q Q Q Q Qu Qu Q Q Q Qu Q Q ali al li li al li ali al li i i al lity y y ty ty ty y y va v va a a v va a a v va a a a va a a alue lu ue ue lue e lu ue e u lue e u ue an an a a a a a d s d d s s d d s s s serv v rv erv v rv e er r rv v v e e erv v vi ice ic ice ic c ce e ic c ce ic ce sin n nc...

Страница 2: ...y 12 C 7 Pump Installation 13 C 8 Electrical 13 C 9 Flue Venting 14 C 10 Condensate Drains 15 C 11 Modular System Installations 15 D Start Up Instructions 18 D 1 Water Quality and Treatment 18 D 2 Filling The System 18 D 3 Factory Test Report FTR 19 D 4 Veri cation 19 D 5 Start Up Detail 19 D 6 Start Up And Maintenance Tests 19 D 7 Startup Component Adjustments 22 D 8 Shutting Down The Unit 23 D 9...

Страница 3: ...l System Triton Series boilers are factory equipped to accept the accessory Smart Boiler Control System The Ajax Boiler Inc proprietary Smart Boiler Control is a web based system providing 24 7 access to the boilers operational perfor mance from any computer or smart phone with an internet connection The system allows personnel to conveniently monitor critical boiler information including inlet ou...

Страница 4: ...Jack Base Flow Switch Temp Pressure Gauge FRONT REAR SIDE Figure A 1 1 Features and Components WARNING If the information in this manual is not followed exactly a re or explosion may result causing property damage personal injury or loss of life Do not use or store gasoline or other ammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to ...

Страница 5: ... as possible to reduce vent loss and to minimize costly stainless steel ue venting Maintain minimum speci ed clearances for adequate operation All installations must allow suf cient space behind the boiler to service vent con nections water pipe connections piping and other auxiliary equipment as well as the appliance A B C D E F G H J K L M N P Q R S REAR SIDE T Figure A 2 Dimensions MODEL T 80 T...

Страница 6: ...efrigeration system must be installed so the chilled medium is piped in parallel with the boiler with appropri ate valves to prevent the chilled medium from entering the boiler The boiler piping system of a hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circu lation must be equipped with ow control valves or other automatic m...

Страница 7: ...provided with prop erly sized openings to assure adequate combustion and ventilation air when unit is installed with a basic Category IV venting system Note All additional gas red equipment should be considered when calculating the necessary air supply B 3 b Direct Vent Ducted Combustion Air If outside air will be drawn through the intake vent directly to this unit for combustion The exhaust vent ...

Страница 8: ...ion ventila tion and dilution air shall be based on the net free area of each opening Where free area through a louver or grille design is known it shall be used in calculating the size opening required to provide the free area speci ed Where the louver and grille design and free area are not known it shall be assumed that wood louvers will have 25 free area and metal louvers and grilles will have...

Страница 9: ...s Terminate the vent at least 3 ft above forced air inlet located within 10 ft The vent must terminate at least 4 ft horizontally and in no case above or below unless 4 ft horizontal dis tance is maintained from electric meters gas meters regulators and relief equipment Terminate the vent at least 6 ft away from adjacent walls Do not terminate vent closer than 5 ft below roof overhang Terminate ve...

Страница 10: ...n Through the wall vents for Category IV appliances shall not terminate over public walkways or over an area where condensate or vapor could be detrimental to the operation of regulators relief valves or other equipment Locate and guard vent termination to prevent acci dental contact by people or pets Do not terminate vent in a window well stairwell alcove courtyard or other recessed area Do not t...

Страница 11: ... reduce exposure to airborne refractory ceramic bers For Your Safety Do not store or use gasoline or other ammable vapors and liquids or other combustible materials in the vicinity of this or any other appliances To do so may result in an explosion or re WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Open any windows and secure area Do not touch any electrical switch do not use any ...

Страница 12: ...S HERTZ PH AMPS MOT AMPS CTRL VOLT CTRL AMP MIN GAS PRESS MAX GAS PRESS MANIFOLD PRESS FUEL TYPE 2 OIL IF OIL FIRED DO NOT USE OIL HEAVIER THAN 2 INTEGRAL GROUP PRIMARY SAFETY MINIMUM CLEARANCES TO ADJACENT CONSTRUCTION 2701 S HARBOR BLVD SANTA ANA CA 92704 714 437 9050 FAX 714 437 9060 AJAX BOILER INC AJAX BOILER INC Since 1919 9900456 ETL LISTED CONFORMS TO UL STD 795 CERTIFIED TO CAN STD 1 3 1 ...

Страница 13: ...of the manifold 5 Install the 2 loose wires at the rear of the boiler to the ow switch installed at the side of the manifold as shown in gure C 5 1 6 Move the boiler to its nal installed position NOTE Ajax Boiler Inc strongly recommends that you secure the boiler to the base pad by the mounting holes provided at the base of the unit C 5 WATER SYSTEM PIPING CAUTION This boiler requires forced water...

Страница 14: ... be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or more than psi 3 5 kPa Do not use Te on tape on gas line thread A pipe com pound rated for natural and propane gases are recom mended Apply sparingly only on the male pipe ends leaving the two end threads bare Gas Pi...

Страница 15: ...s must be followed All electrical connections must be performed after the electrical supply has been switched off and secured against unauthorized switching Depending on installation the pump motor can be come extremely hot To avoid risk of burning handle pump with heat resistant gloves or ensure the pump is cool before handling the pump CAUTION Never operate the pump dry the system must be lled b...

Страница 16: ...ground is proved AC 108 VAC Minimum 132 VAC Max AB 108 VAC Minimum 132 VAC Max BC 1 VAC Max C 6 b Making the Electrical Connections Verify that the circuit breaker is properly sized by referring to the boiler rating plate A dedicated circuit breaker should be provided NOTE Current draw on rating plate does not include pump current 1 Turn off all power to the boiler Verify that power has been turne...

Страница 17: ...ory IV appliance shall be determined per the NFGC US or CGA B149 Canada The diameter of the vent ue pipe should be sized according to NFGC US and Appendix B of the CGA B149 Canada The minimum ue diameter for con ventional venting using Category IV stainless steel AL29 4C vent is MODEL T 80 T 100 T 150 T 200 Flue Pipe Size 6 6 8 8 Table C 7 1 Triton Flue Pipe Sizing Chart The connections from the a...

Страница 18: ...ft horizontally from and in no case above or below unless a 4 ft horizontal distance is maintained electric meters gas meters regulators and relief equipment The minimum distance from adjacent public walkways adjacent buildings openable windows and building openings shall not be less than those values speci ed in the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or the Natural Gas and Propane Ins...

Страница 19: ...angement Positive pressure vent systems cannot be manifolded together Positive pressure systems can be piped individually through a common vertical or horizontal chase provid ed minimum clearances to combustible materials are maintained Positive pressure systems can be piped individually through a common vertical chase so that a single roof penetration can be made Each vent termination must be one...

Страница 20: ...of each system tting and component must be added to the boiler pressure drop to determine the system pressure head requirement See Table 6 for tting and component equivalent lengths Refer to National Fuel Gas Code Local Codes and Tables 2 through 7 for gas pipe sizing Refer to Gas Piping section for further warnings cau tions notices and instructions C 11 f Electrical Each boiler must be provided ...

Страница 21: ...king life of the boiler and other system equipment Since water quality and conditions will vary signi cantly depending on the local area it will be essential to obtain the expertise of a quali ed industrial water treatment pro fessional for establishing a treatment plan In addition a periodic testing sampling plan should be developed The plan should ensure a process to maintain and con rm the prop...

Страница 22: ...ives to prepurge speed Prepurge rate is veri ed with blower feedback signal and initiates 7 second prepurge After prepurge is completed the combustion blower drives to light off rate After light off rate is veri ed 10 second PFEP Pilot Flame Establishment Period is initiated During the rst half of PFEP the Pilot Valve Solenoid and Spark Transformer are both energized Spark Transformer is de energi...

Страница 23: ...l the ame signal increases to above the ame threshold value 0 8 Vdc 11 Turn the pilot hold test off and allow the Flame Safe guard to start a burner cycle During the Main Flame Establishing Period make sure the automatic main fuel valve opens Then smoothly open the manual main fuel shutoff valve and watch for the main burner ignition If the light off is not rough and the main burner ame is establi...

Страница 24: ...ty Shut Off Valve 6 Immerse the 1 4in tube vertically in in a jar of water see gure 6 2 7 Slowly open the Manual Test Valve F 8 When the rate of bubbles coming through the water stabilizes count the number of bubbles appearing during a ten second period Each bubble appearing represents a ow rate of 001 cfh See table below for allowable ow 9 Close the Upstream Manual Gas Valve A 10 Remove the Leak ...

Страница 25: ...boiler will lockout after safety shutdown Opening a safety limit switch Gas Pressure Water Flow Drain switches and Recycle Interlock during PREPURGE PILOT IGN MAIN IGN or RUN period Hold code 63 will be displayed on the Basic Panel or annunciation of opened limit switch is displayed on the Operator Interface Module Safety shutdown occurs and recycle Detection of flame 240 seconds after entry to ST...

Страница 26: ...ew To adjust fuel air ratio valve at low fire 0 1 Turn off unit by setting the burner cutoff switch to the OFF position 2 Remove aluminum protection screw on the pressure regulator 3 Using Operator Interface panel activate boiler demand by temporally adjusting setpoint about 40F above normal operating setpoint by pressing Con gure CH Central Heat Con guration CH setpoint Textbox 4 Set the burner c...

Страница 27: ...AUTION Label all wires prior to disconnection when servicing con trols Wiring errors can cause improper and dangerous operation Verify proper operation after servicing DANGER This boiler uses ammable gas high voltage electricity moving parts and very hot water under high pressure Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any di...

Страница 28: ...ner operation E 1 f Check Pilot Main Flame Signal monthly 1 Using a voltmeter plug into the ame detection port on the ame safeguard The voltage reading should be between 1 15 VDC 2 Remove the UV scanner and using soft cloth wipe the lens clean E 1 g Inspect Air Filter monthly The main burner air lter is gravity held horizontally at top of the air box as shown No tools are necessary to inspect or s...

Страница 29: ...nd Pipe Connections annually 1 Check all water pipe connections for leaks while unit is on low re 2 If a leak is present around a tting attempt to tighten the tting 3 If a leak is present in the middle of the pipe contact factory E 1q Corrosion Check annually 1 Check all gas water and air pipes to for corrosion and deterioration 2 If any corrosion or deterioration is present please contact factory...

Страница 30: ...erify Normal Boiler Sound Inspect Clean Condensate Drain Observe Main Flame Indicate P pass or F fail monthly for each category Enter actions taken in the notes area below Notes Semiannual Tests Result Date Initial Notes Gas Leak Test 1 Pilot Spark Test 1 Gas Leak Test 2 Pilot Spark Test 2 Annual Tests Result Date Initial Notes Lubricate Pilot Blower Clean Main Burner Clean HX Tubes Clean Gas Inle...

Страница 31: ...E 29 E 3 ELECTICAL WIRING DIAGRAM ...

Страница 32: ... module H 4 Internal fault Safety Relay key feedback error H 5 Internal fault Unstable power DCDC output H 6 Internal fault Invalid processor clock H 7 Internal fault Safety relay drive error H 8 nternal fault Zero crossing not detected H 9 Internal fault Flame bias out of range H 10 Internal fault Invalid Burner control state H 11 Internal fault Invalid Burner control state ag H 12 Internal fault...

Страница 33: ...ernal Fault 1 Reset Module 2 If fault repeats replace module L 59 Internal Fault Mux pin shorted L 60 Internal Fault HFS shorted to LFS L 61 Anti short cycle Will not be a lockout fault Hold Only H 62 Fan speed not proved H 63 LCI OFF 1 Check wiring and correct any faults 2 Check Interlocks connected to the LCI to assure proper function 3 Reset and sequence the module monitor the LCI status 4 If c...

Страница 34: ...dule H 92 Outlet sensor fault 1 Check wiring and correct any possible errors 2 Replace the Outlet sensor 3 If previous steps are correct and fault persists replace the module H 93 DHW sensor fault 1 Check wiring and correct any possible errors 2 Replace the DHW sensor 3 If previous steps are correct and fault persists replace the module H 94 Header sensor fault 1 Check wiring and correct any possi...

Страница 35: ...ving failed L 124 High re switch OFF 1 Check wiring and correct any potential wiring errors 2 Check High Fire Switch to assure proper function not welded or jumpered 3 Manually drive the motor to the High Fire position and adjust the HF switch while in this position and verify voltage through the switch to the HFS input with a voltmeter 4 If steps 1 3 are correct and the fault persists replace the...

Страница 36: ...module 4 During STANDBY and PREPURGE measure the voltage between Terminal J6 5 and L2 N Supply voltage should be present If not the lockout switch is defective and needs replacing 5 If the fault persists replace the relay module H or L 153 Combustion Pressure Off H or L 154 Purge Fan switch On OEM Speci c 1 Purge fan switch is on when it should be off 2 Check wiring and correct any errors 3 Inspec...

Страница 37: ...f fault repeats replace module L 185 Invalid Delta T limit enable setting L 186 Invalid Delta T limit response setting L 187 Invalid DHW high limit enable setting L 188 Invalid DHW high limit response setting L 189 Invalid Flame sensor type setting L 190 Invalid interrupted air switch enable setting L 191 Invalid interrupted air switch start check enable setting L 192 Invalid igniter on during set...

Страница 38: ...240 Invalid Outdoor connector type setting L 241 255 RESERVED Table F 1 Lockout and Hold Codes F 2 CONTROLLER ALERT CODES Code Description EE Management Faults 0 None No alert 1 Alert PCB was restored from factory defaults 2 Safety con guration parameters were restored from factory defaults 3 Con guration parameters were restored from factory defaults 4 Invalid Factory Invisibility PCB was detecte...

Страница 39: ...of range 77 Fan gain down was invalid 78 Fan gain up was invalid 79 Fan minimum duty cycle was invalid 80 Fan pulses per revolution was invalid Code Description 81 Fan PWM frequency was invalid 82 89 RESERVED 90 Modulation output type was invalid 91 Firing rate control parameter was invalid 92 Forced rate was out of range vs min max modulation 93 Forced rate was invalid vs RPM 94 Slow start ramp v...

Страница 40: ...perature was invalid Code Description 207 Lead Lag was suspended due to no enabled 208 Lead Lag slave session has timed out 209 221 RESERVED Frost Protection Faults 220 Lead Lag frost protection rate was invalid 221 Lead Lag drop stage method setting was invalid 222 CH frost protection temperature was invalid 223 CH frost protection inlet temperature was invalid 224 DHW frost protection temperatur...

Страница 41: ...Run was terminated due to interrupted air ow switch was off 312 Stuck reset switch Code Description 313 Run was terminated due to fan failure 314 Abnormal Recycle Fan failed during Drive to Purge Rate 315 Abnormal Recycle Fan failed during Measured Purge Time 316 Abnormal Recycle Fan failed during Drive to Lightoff Rate 317 Abnormal Recycle Fan failed during Pre Ignition test 318 Abnormal Recycle ...

Страница 42: ...quest to write PM status was invalid 473 Internal error PM parameter address was invalid 474 Internal error PM safety parameter address was invalid 475 Internal error Invalid record in lockout history was removed 476 Internal error EEPROM write buffer was full 477 Internal error Data too large was not written to EEPROM 478 Internal error Safety key bit 0 was incorrect 479 Internal error Safety key...

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Страница 46: ...F 44 Notes ...

Страница 47: ...ental or exterior damage I Production of noise odors discoloration or rusty water J Damage to surrounding area or property caused by leakage or malfunction Costs associated with the replacement and or repair of the unit including any freight shipping or delivery charges any removal installation or reinstallation charges any material and or permits required for installation reinstallation or repair...

Страница 48: ...m www ajaxboiler com Quality value and service since 1919 OMT 1113 2013 AJAX BOILER INC PRINTED IN U S A Made With Pride In The USA Ace Heating Solutions LLC 2701 South Harbor Blvd Santa Ana CA 92704 714 540 2230 714 540 2239 fax www aceheatingllc com OMT 1114 2014 Ace Heating Solutions LLC PRINTED IN U S A ...

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