Bryan Boilers 250, Triple-Flex 150, & 300, 200 service manual Boil OUT Procedure

Page 57

WARNING:

The boiler area should be kept free of combustible materials, gasoline and other flammable liquids.

The boiler and venting system must be kept free of obstructions of the air louvers.

The following procedures must be conducted as outlined to prevent damage to and assure safe operation of the boiler.

All cover plates, enclosures, and guards must be in place at all times, except during maintenance and servicing.

3.1CLEANING THE BOILER AND SYSTEM – NEW SYSTEMS

3.1.1PRE-BOIL OUT FLUSHING OF SYSTEM

Much of the dirt and contamination in a new hot water system can be flushed out before the boil out of the system. First, flush the system of waste with clear water. The boiler and circulating pumps must be isolated through the successive zones of the system to waste, carrying metal shavings, dirt, pipe joint compound, etc. with it. Follow with a chemical flush. NOTE! Be CERTAIN that the chemicals used to flush and boil-out the boiler and system contain NO CHLORIDES. The boiler is fabricated with austenitic stainless steels that can be severely damaged when exposed to chlorides. The removal of pipe chips and other debris from the system before opening the isolation valves to the boiler and pumps will help to protect this equipment from damage by such debris.

In combination with system contamination, bacteria from ground water boiler water may produce objectionable odors, sometimes resembling the odorant used in natural gas. It is

51

Date: 8-4-2010

Revision: 0

Form: 2396

important to keep these fumes from air intakes that would distribute them throughout the building.

3.1.2BOIL OUT PROCEDURE

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 one type of solution in the system. The amount of chemical required will vary according to conditions, but one pound per fifty gallons of water is suggested.

Fill the system with this solution, venting all air. Then, with the circulating pump running, bring the system to design or operating temperature. After circulating water for two to three hours, the system should be drained completely, and refilled with fresh, softened water. Usually enough of the cleaning solution will adhere to the piping to result in an alkaline solution satisfactory for operation. A pH reading between 7 and 8 is preferred. If necessary, to increase the pH, a small amount of cleaner may be added.

WARNING:

The boil out procedure outlined must be performed by, or under the direct supervision of, a qualified technician. The chemicals used present a hazard of burns and physical injury if mishandled. Always use a suitable facemask, goggles, protective gloves, and garments when handling caustic chemicals. Do not permit the chemical to come into contact with skin or clothing. Always follow the safety precautions on the container's label. Add chemicals slowly and in small amounts to prevent excessive heat and agitation.

Image 57
Contents Triple-Flex High Efficiency Boilers Triple-Flex 150, 200, 250 High Efficiency Boilers Table of Contents Lead Drop-Stage On Error Ldse Figures Date Date Revision Form Clearances Boiler FoundationMinimum Clearances to Combustible Surfaces DIMBoiler Connections Safety Relief ValvesFlow Connection Expansion Tank ConnectionsElectrical Requirements Venting of GAS Train ComponentsKW HP Combustion AIR SupplyLOUVERS, GRILLES, and Screens Combustion AIR OpeningsFlue GAS Venting System Design & InstallationScfm Combustion AIR and Venting Requirements for CanadaBefore Placing Boiler in Operation Marking of GAS VentsTest of GAS Piping Hydrostatic Test of Boilers and SystemStart-Up and Operation Triple-Flex High Efficiency Boilers TRIPLE-FLEX Front View Boiler AssemblyTriple-Flex Rear View TRIPLE-FLEX Rear ViewTRIPLE-FLEX Left Side View TRIPLE-FLEX Right Side ViewTRIPLE-FLEX Behind the Cabinet Door Air Flow Switch TRIPLE-FLEX Left Flue Collector View Pilot Spark Igniter AssemblyTRIPLE-FLEX Right Flue Collector View POWER-UP ValidationHome Sola Hydronic Control SystemKeyboard NavigationStatus Configuration ConfigureSample Configuration Configuration PasswordSafety Verification Configure Verify Change Parameter SettingsSafety Parameter User Confirmation FAULT/ALARM HandlingHome Page Lockout Info BAR Lockouts Clear Lockout OperationModulation Configuration Configure Modulation Annunciation OperationFiring Rate Control Operation Firing Rate Field Advanced Setup Setup Advanced Setup System Time Setup Advanced Setup Date & TimeCalibrate Touch Screen Setup Advanced Setup Diagnostics Reset / Reboot Display Advanced Setup Display ResetOutdoor Reset Configure Configure Sensor Configuration Configure CH Central Heat ConfigurationSafety Verification Configure CH Central Heat Configuration PID Sound Pressure LevelsSound Pressure Readings Alert Codes Modbus CommunicationDHW RPMODR ILK A2D SLOHFS PIIRevision PRE Checks and Setup Test SetupBoiler Commissioning ModulationDRY RUN Pilot AdjustmentAdjusting Boiler Minimum Input Adjusting Boiler Maximum InputInitial Light OFF IWCGAS Meter Readings CFH = 3600Vc gc CFH = ft 3 hr −1 of gas Vc = ft clockedPII Or L TroubleshootingDate LCI OFF PII OFFILK OFF ILK on Weak VsnsrAre OEM Specific Fault Codes Fault CodesOFF ThroughOFF Blower LCI High Limit setpoint setting 228 Invalid Reserved Care and Maintenance Boil OUT Procedure Draining the System Do not Flush the System Through the BoilerBoiler Water Treatment Suggested Maintenance Schedule External FIRE-SIDE CleaningDate Revision Form Lead Lag Lead LAG LL Master General Operation General Description of the Lead LAG ApplicationDrop-stage method Drop-stage detection timing LL / Multi-Boiler Field Wiring System Wiring HookupLEAD-LAG Operation Slave Operation and Setup Slave Mode USE FIRST, Equalize RUNTIME, USE LastSlave Parameters Overall Control LL Master Operation and SetupSlave Status Manager Periodic Data Polling MessagesInvalid Response or no Response AbnormalFaultCounter Used to tolerate momentary abnormalityMaster Heat Demand LL CH Demand Switch DISABLE, STAT, Environcom Remote StatMaster Service Status Master Active ServiceModulation Sensor LL Modulation Sensor S5Demand and Rate Rate Adjustment Integrator CompensationImplementation Rate Allocation Base Load Common 0-100%Rate Allocation Method Parallel Commonbase Limited Overflow and Underflow Modulating StageBurner Demand Stagerstate = IdleStagerstate = Active Error Threshold ADD-STAGE Error Threshold DegreesADD-STAGE Rate Offset -100% to +100% ADD-STAGE ConditionLL ALL Boilers OFF Threshold Temperature or None DROP-STAGE Error Threshold DegreesDROP-STAGE Rate Offset -100% to +100% DROP-STAGE ConditionLead DROP-STAGE on Error LAG Selecton Method Sequence ORDER, Measured RUN TimeForce Lead Rotation Time Hhmm or None Date Revision Form Forced Lead Rotation Sequencer 1 Minute EventSlave Write Data Slave Read Data