Thermal Solutions Arctic 1000 Manuals

Form: 2435-3 Arctic Installation and Operation Manual Revision: 10 P/N 105641-01 Date: 12-1-2018 Thermal Solutions, 1175 Manheim Pike, Lancaster, PA 17601 Web: www.thermalsolutions.com Phone: 717-239-7642 Fax: 877-501-5212 Email: [email protected] 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: Address: Form: 2435-3 Arctic Installation and Operation Manual Revision: 10 P/N 105641-01 Date: 12-1-2018 Thermal Solutions, 1175 Manheim Pike, Lancaster, PA 17601 Web: www.thermalsolutions.com Phone: 717-239-7642 Fax: 877-501-5212 Email: [email protected] ii Table of Contents 1 Introduction ........................................................................................................................................................................ 6 1.1 Important Information ......................................................................................................................................... 6 1.2 Disclaimers and Local Codes .............................................................................................................................. 6 1.3 Test and Inspections .............................................................................................................................................. 7 1.4 Component Description ....................................................................................................................................... 7 2 Pre-Installation .................................................................................................................................................................. 9 2.1 Installation Conformance .................................................................................................................................... 9 2.2 Boiler Foundation ................................................................................................................................................... 9 2.3 Clearances and Serviceability ............................................................................................................................ 9 3 Installation ....................................................................................................................................................................... 11 3.1 Receiving The Boiler ........................................................................................................................................... 11 3.2 Boiler Connections .............................................................................................................................................. 11 3.2.1 Flow Connection ............................................................................................................................................................ 11 3.2.2 Safety Relief Valves ....................................................................................................................................................... 11 3.2.3 Minimum Relief Valve Settings ................................................................................................................................ 12 3.2.4 Expansion Tank Connections ................................................................................................................................... 12 3.2.5 Drain Connection ........................................................................................................................................................... 12 3.2.6 Condensate Drain Connection .................................................................................................................................. 12 3.2.6.1 ARC1000 Condensate Drain Trap ................................................................................................ 12 3.2.6.2 ARC1500 – 6000 Condensate Drain Trap ................................................................................ 13 3.2.7 Gas Supply Connection ................................................................................................................................................ 13 3.2.7.1 Drip Leg .................................................................................................................................................. 13 3.2.7.2 Gas Piping Leak Test ......................................................................................................................... 13 3.2.7.3 Venting of Gas Train Components ............................................................................................... 14 3.3 Combustion Air Supply System ...................................................................................................................... 14 3.3.1 Combustion Air Openings: ......................................................................................................................................... 14 3.3.1.1 Two Permanent Opening Method ................................................................................................ 14 3.3.1.2 One Permanent Opening Method................................................................................................. 15 3.3.1.3 Mechanical Air Supply Systems .................................................................................................... 15 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 Ducts ....................................................................................................................... 16 3.3.3 Ducted Combustion Air ............................................................................................................................................... 16 3.4 Venting Requirements ....................................................................................................................................... 16 3.4.1 Category II Venting ....................................................................................................................................................... 18 3.4.2 Massachusetts ................................................................................................................................................................. 19 3.4.3 Combustion Air and Venting Requirements for Canada ............................................................................... 21 3.4.3.1 Air Supply Requirements per CAN/CSA-B149.1-05 for Appliances having an input exceeding 400 MBH. ......................................................................................................................... 21 3.4.3.2 Combustion Air Supply Dampers, Louvers, and Grilles ...................................................... 21 3.4.3.3 Mechanical Combustion Air Supply ............................................................................................ 22 3.4.3.4 Appliance Venting per CAN/CSA-B149.1-05 .......................................................................... 22 3.5 Requirements ........................................................................................................................................................ 22 3.5.1 Electrical ............................................................................................................................................................................ 22 3.5.2 Gas Supply Requirements .......................................................................................................................................... 23 Form: 2435-3 Arctic Installation and Operation Manual Revision: 10 P/N 105641-01 Date: 12-1-2018 Thermal Solutions, 1175 Manheim Pike, Lancaster, PA 17601 Web: www.thermalsolutions.com Phone: 717-239-7642 Fax: 877-501-5212 Email: [email protected] iii 3.5.3 Sound Pressure Levels................................................................................................................................................. 24 3.5.4 Pump and Piping Requirements .............................................................................................................................. 24 3.5.4.1 Water Flow Rates (Variable Primary Pumping Systems) .................................................. 24 3.5.4.2 Water Flow Rates (Primary / Secondary Systems) .............................................................. 25 3.5.4.3 Water Flow Rates (Constant Volume Primary Pumping Systems) ................................ 26 3.5.4.4 Water Flow Rates for Glycol........................................................................................................... 26 3.6 Before Placing Boiler In Operation ............................................................................................................... 26 3.6.1 Pre-Boil Out Flushing Of System ............................................................................................................................. 26 3.6.2 Boil Out Procedure ........................................................................................................................................................ 27 3.6.3 Replacement Boiler Installations ............................................................................................................................ 27 3.7 Draining and refilling the boiler & system ................................................................................................ 28 3.7.1 Filling The System ......................................................................................................................................................... 28 3.7.2 Hydrostatic Test Of Boilers And System .............................................................................................................. 28 3.8 Boiler Water Treatment .................................................................................................................................... 28 3.8.1 Purpose of water treatment ...................................................................................................................................... 28 3.8.2 Objectives .......................................................................................................................................................................... 29 3.8.3 Water softener ................................................................................................................................................................ 29 3.8.4 Continuous Monitoring ............................................................................................................................................... 29 4 SYSTEM START-UP ....................................................................................................................................................... 30 4.1 Concert Boiler Control Display Navigation – This Section applies ONLY to the ARC1000 through ARC3000 ................................................................................................................................................ 30 4.2 System Check: ........................................................................................................................................................ 31 4.3 Power the Boiler: ................................................................................................................................................. 31 4.4 Power the Circulators: ....................................................................................................................................... 31 4.5 Pressurize the Fuel System: ............................................................................................................................ 31 4.6 Boiler Commissioning: This Section applies ONLY to the ARC1000 through ARC3000 ........ 31 4.7 Finish Commissioning the Boiler: This Section applies ONLY to the ARC1000 through ARC3000 .................................................................................................................................................................. 33 4.8 Re-Starting After Prolonged Shutdown ...................................................................................................... 33 4.9 Testing of Controls and Safety Devices ....................................................................................................... 34 4.10 Ignition Failure ........................................................................................ Error! Bookmark not defined. 5 Service, Maintenance, and Inspection ................................................................................................................... 35 5.1 General Maintenance: ........................................................................................................................................ 35 5.1.1 DAILY: ................................................................................................................................................................................. 36 5.1.2 WEEKLY: ........................................................................................................................................................................... 36 5.1.3 MONTHLY: ........................................................................................................................................................................ 36 5.1.4 ANNUALLY: ...................................................................................................................................................................... 36 5.2 Ignition Assembly Cleaning ............................................................................................................................. 37 5.3 Burner Assembly Cleaning ............................................................................................................................... 37 5.4 Heat Exchanger Cleaning .................................................................................................................................. 37 5.5 Tube Replacement Procedure ........................................................................................................................ 38 5.6 Safety and Operating Controls ....................................................................................................................... 42 5.7 Troubleshooting ................................................................................................................................................... 43 Appendix A Sizing Gas Piping ........................................................................................................................................... 46 Appendix B Vent and Combustion Air Pressure Drop Data ................................................................................. 48 Appendix C Installation & Startup Report ................................................................................................................... 50 Appendix D Venting Diagrams ......................................................................................................................................... 51 Appendix D.1 Typical Horizontal Vent Piping ....................................................................................................... 51 Appendix D.2 Typical Vertical Pressurized Venting ........................................................................................... 52