Bryan Boilers Triple-Flex 150 Service manual

Date: 8-4-2010
Revision: 0
Form: 2396
Bryan Steam LLC
Installation and Operating Service Manual
Triple-Flex
High Efficiency Boilers

Date: 8-4-2010
Revision: 0
Form: 2396
INSTALLATION AND OPERATION SERVICE MANUAL
Triple-Flex 150, 200, 250, & 300
High Efficiency Boilers
Bryan Steam LLC
783 North Chili Avenue * Peru, IN 46970
Phone [phone] • Fax [phone]
E-mail: [email protected] Internet: www.bryanboilers.com

Date: 8-4-2010
Revision: 0
Form: 2396
Table of Contents
Bryan Steam LLC ..............................................................................................................................i
Installation and Operating Service Manual........................................................................................i
Table of Contents ............................................................................................................................ iii
Tables ...............................................................................................................................................v
Figures..............................................................................................................................................v
Section 1 Installation Instructions– Triple-Flex High Efficiency Boilers........................................... 1
1.1 Boiler Foundation................................................................................................................... 2
1.2 Clearances............................................................................................................................. 2
1.2.1 Minimum Clearances to Combustible Surfaces............................................................... 2
1.3 Receiving The Boiler.............................................................................................................. 2
1.4 Boiler Connections................................................................................................................. 3
1.4.1 Flow Connection .............................................................................................................. 3
1.4.2 Safety Relief Valves......................................................................................................... 3
1.4.3 Expansion Tank Connections .......................................................................................... 3
1.4.4 Drain Connection ............................................................................................................. 3
1.4.5 Condensate Drain Connection......................................................................................... 3
1.4.6 Gas Supply Connection ................................................................................................... 3
1.4.7 Drip Leg............................................................................................................................ 3
1.4.8 Gas Piping Leak Test....................................................................................................... 3
1.4.9 Venting Of Gas Train Components.................................................................................. 4
1.5 Electrical Requirements ......................................................................................................... 4
1.6 Combustion Air Supply .......................................................................................................... 4
1.6.1 Combustion Air Openings: ............................................................................................... 5
1.6.2 Louvers, Grilles, and Screens.......................................................................................... 5
1.7 Flue Gas Venting System ...................................................................................................... 6
1.7.1 Design & Installation ........................................................................................................ 6
1.7.2 Combustion Air and Venting Requirements for Canada.................................................. 7
1.7.3 Marking Of Gas Vents...................................................................................................... 8
1.8 Before Placing Boiler In Operation ........................................................................................ 8
1.8.1 Hydrostatic Test Of Boilers And System.......................................................................... 9
1.8.2 Test Of Gas Piping........................................................................................................... 9
Section 2 Start-Up and Operation Triple-Flex High Efficiency Boilers .......................................... 10
2.1 Boiler Assembly ................................................................................................................... 11
2.1.1 Triple-Flex Front View.................................................................................................... 11
2.1.2 Triple-Flex Rear View .................................................................................................... 12
2.1.3 Triple-Flex Left Side View .............................................................................................. 13
2.1.4 Triple-Flex Right Side View............................................................................................ 13
2.1.5 Triple-Flex Behind the Cabinet Door.............................................................................. 13
2.1.6 Pilot Spark Igniter Assembly .......................................................................................... 15
2.1.7 Triple-Flex Left Flue Collector View............................................................................... 15
2.1.8 Triple-Flex Right Flue Collector View............................................................................. 16
2.2 SOLA Hydronic Control System .......................................................................................... 16
2.2.1 Power-up Validation....................................................................................................... 16
2.2.2 Home Page .................................................................................................................... 16
2.2.3 Page Navigation............................................................................................................. 17
2.2.4 Keyboard........................................................................................................................ 17
2.2.5 Status Page.................................................................................................................... 18
2.2.6 Configuration Page ........................................................................................................ 18
2.2.7 Configuration Password................................................................................................. 19
2.2.8 Change Parameter Settings........................................................................................... 20
2.2.9 Safety Verification .......................................................................................................... 20
2.2.10 Fault/Alarm Handling ................................................................................................... 21

Date: 8-4-2010
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Form: 2396
2.2.11 Operation Page............................................................................................................ 22
2.2.12 Annunciation Page....................................................................................................... 23
2.2.13 Modulation Configuration............................................................................................. 23
2.2.14 Firing Rate Control Page ............................................................................................. 23
2.2.15 Advanced Setup........................................................................................................... 24
2.2.16 System Time ................................................................................................................ 24
2.2.17 Calibrate Touch Screen ............................................................................................... 24
2.2.18 Reset / Reboot Display ................................................................................................ 25
2.2.19 Outdoor Reset.............................................................................................................. 25
2.2.20 Remote Setpoint (4 – 20 mA) ...................................................................................... 26
2.2.21 Central Heat Configuration .......................................................................................... 27
2.2.22 Sound Pressure Levels................................................................................................ 27
2.2.23 Modbus Communication .............................................................................................. 29
2.2.24 Alert Codes .................................................................................................................. 29
2.3 Boiler Commissioning .......................................................................................................... 35
2.3.1 Modulation...................................................................................................................... 35
2.3.2 Test Setup...................................................................................................................... 35
2.3.3 Pre Checks And Setup................................................................................................... 35
2.3.4 Dry Run .......................................................................................................................... 36
2.3.5 Pilot Adjustment ............................................................................................................. 36
2.3.6 Initial Light Off ................................................................................................................ 37
2.3.7 Adjusting Boiler Maximum Input .................................................................................... 37
2.3.8 Adjusting Boiler Minimum Input ..................................................................................... 37
2.3.9 Gas Meter Readings ...................................................................................................... 38
2.4 Troubleshooting ................................................................................................................... 39
Section 3 Care and Maintenance .................................................................................................. 50
3.1 Cleaning The Boiler And System – New Systems............................................................... 51
3.1.1 Pre-Boil Out Flushing Of System................................................................................... 51
3.1.2 Boil Out Procedure......................................................................................................... 51
3.1.3 Draining The System ..................................................................................................... 52
3.2 Replacement Boiler Installations: Protection Against Corrosion And Sediment.................. 52
3.3 Boiler Water Treatment........................................................................................................ 52
3.4 External “Fire-Side” Cleaning............................................................................................... 53
3.5 Suggested Maintenance Schedule ...................................................................................... 53
Section 4 Lead Lag........................................................................................................................ 55
4.1 General Description Of The Lead Lag Application .............................................................. 56
4.2 Lead Lag (Ll) Master General Operation ............................................................................. 56
4.3 System Wiring Hookup ........................................................................................................ 58
4.4 Lead-Lag Operation ............................................................................................................. 59
4.5 Slave Operation And Setup ................................................................................................. 60
4.6 Slave Parameters ................................................................................................................ 60
4.7 Ll Master Operation And Setup ........................................................................................... 61
4.7.1 Overall Control ............................................................................................................... 61
4.7.2 Periodic Data Polling messages .................................................................................... 62
4.7.3 Slave Status Manager.................................................................................................... 62
4.7.4 Master Active Service .................................................................................................... 65
4.7.5 Modulation Sensor ......................................................................................................... 65
4.7.6 Demand and Rate.......................................................................................................... 66
4.7.7 Rate Adjustment............................................................................................................. 67
4.7.8 Implementation............................................................................................................... 67
4.7.9 Rate Allocation............................................................................................................... 68
4.7.10 Burner Demand............................................................................................................ 70
iv
4.7.11 Lead Drop-Stage On Error - LDSE: ............................................................................. 73

Date: 8-4-2010
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Form: 2396
Tables
Table 1 Minimum Clearance............................................................................................................ 2
Table 2 Electrical Requirements...................................................................................................... 4
Table 3 Boiler Draft.......................................................................................................................... 7
Table 4 Water Flow Switch Settings.............................................................................................. 14
Table 5 Gas Limiting Orifice Rough Settings ................................................................................ 15
Table 6 Sound Pressure Readings................................................................................................ 28
Table 7 Modbus Terminals............................................................................................................ 29
Table 8 Alert Codes....................................................................................................................... 29
Table 9 Approximate Boiler Settings ............................................................................................. 38
Table 10 Gas Pressure Correction................................................................................................ 38
Table 11 Gas Temperature Correction.......................................................................................... 38
Table 12 R7910A Lockout and Hold Codes .................................................................................. 39
Figures
Figure 1 Minimum Clearances......................................................................................................... 2
Figure 2 Main Gas Inlet Connection................................................................................................ 4
Figure 3 Triple-Flex Front View ..................................................................................................... 11
Figure 4 Triple-Flex Rear View...................................................................................................... 12
Figure 5 Triple-Flex Left Side View ............................................................................................... 13
Figure 6 Triple-Flex Right Side View............................................................................................. 13
Figure 7 Triple-Flex Behind the Cabinet Door............................................................................... 13
Figure 8 Air Flow Switch................................................................................................................ 14
Figure 9 Pilot Spark Igniter Assembly ........................................................................................... 15
Figure 10 Triple-Flex Left Flue Collector View .............................................................................. 15
Figure 11 Triple-Flex Right Flue Collector View............................................................................ 16
Figure 12 Home Page ................................................................................................................... 16
Figure 13 Keyboard ....................................................................................................................... 17
Figure 14 Status Page................................................................................................................... 18
Figure 15 Configuration Menu Page.............................................................................................. 18
Figure 16 Sample Configuration Page .......................................................................................... 19
Figure 17 Change Parameter Dialog............................................................................................. 20
Figure 18 Safety Parameter Verification ....................................................................................... 20
Figure 19 Safety Parameter User Confirmation ............................................................................ 21
Figure 20 Safety Parameter Reset................................................................................................ 21
Figure 21 Home Page Lockout...................................................................................................... 22
Figure 22 Status Page Lockout ..................................................................................................... 22
Figure 23 History Dialog ................................................................................................................ 22
Figure 24 Lockout History Page .................................................................................................... 22
Figure 25 Operation Page ............................................................................................................. 22
Figure 26 Annunciation Page ........................................................................................................ 23
Figure 27 Modulation Configuration .............................................................................................. 23
Figure 28 Firing Rate Control Page............................................................................................... 23
Figure 29 Advanced Setup ............................................................................................................ 24
Figure 30 System Time ................................................................................................................. 24
Figure 31 Display Diagnostics....................................................................................................... 24
Figure 32 Reset / Reboot Display.................................................................................................. 25
Figure 33 Outdoor Reset............................................................................................................... 25
v
Figure 34 Outdoor Reset Curve .................................................................................................... 26

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Figure 35 Outdoor Reset Sensor Configuration ............................................................................ 26
Figure 36 Air / Gas Ratio Tappings ............................................................................................... 35
vi
Figure 37 LL / Multi-Boiler Field Wiring ......................................................................................... 58

Date: 8-4-2010
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Form: 2396
1
Section 1 Installation Instructions–
Triple-Flex High Efficiency Boilers

Date: 8-4-2010
Revision: 0
Form: 2396
Note:
Please read and save for future reference the
entire instruction manual before attempting
installation of or starting the unit. Insurance and
local or state regulatory codes may contain
additional or more stringent requirements than
those contained in this manual. Installation must
conform to these codes and any other authority
having jurisdiction. This instruction manual shall
be posted and maintained in a legible condition.
1.1 BOILER FOUNDATION
Before uncrating, the boiler location should be
prepared. The boiler should set upon a good
level concrete floor. If the boiler is not level or
the floor is not in good condition, a concrete
foundation should be built, the dimensions being
larger than the outside dimensions of the boiler
base. A 4” high housekeeping pad is
suggested.
WARNING:
Do not install boiler on combustible
flooring.
1.2 CLEARANCES
See Table 1 for minimum clearances to walls,
ceilings, or obstructions. The clearances in
Table 1 are intended as a general
recommendation only. Local codes must be
applied to specific installations and the minimum
clearances established accordingly. Provisions
must also be made for service, accessibility and
clearance for piping and electrical connections.
Do not obstruct combustion air and ventilation
openings with piping or any other construction.
All boilers must be installed in a space that is
large compared to the boiler.
NOTE:
These boilers should be installed in a room that
is large compared to the size of the boiler. They
are not intended for alcove installation and are
suitable for installation on non-combustible
flooring only. Adhere to all applicable local
codes regarding boiler installation and
clearances.
1.2.1 MINIMUM CLEARANCES TO
COMBUSTIBLE SURFACES
Figure 1 Minimum Clearances
DIM. Description Triple-Flex
150 - 300
A Clearance Above Top of
Boiler 18”
B Right Side 18”
C
From Chimney or Vent
Collector Measured
Horizontally
18”
D
Left Side – Tube Access
Side On Standard
Construction
27”
E
From Chimney or Vent
Collector Measured
Vertically
18”
F Front of Boiler – Gas Train
& Control Panel End 48”
G
Rear of Boiler Opposite
Gas Train & Control Panel
End
18”
Table 1 Minimum Clearance
1.3 RECEIVING THE BOILER
2
The boiler is shipped from the factory with (4)
shipping feet/legs bolted to the skids. These are
provided to facilitate unloading/moving with a
forklift. Lifting lugs are also provided to enable
over-head lifting. The shipping feet/legs MUST

Date: 8-4-2010
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Form: 2396
BE REMOVED after the boiler is set in-place on
its concrete foundation before any
piping/electrical connections are made. It is
recommended that the plastic protective cover
be left on as long as possible to reduce finish
damage from the installation.
1.4 BOILER CONNECTIONS
Do not run any pipes along the tube access
panel side of the boiler. Maintain clearances as
shown on the dimensional drawing for servicing
of the boiler tubes. Provide at least 48" from the
front of the boiler, unless a larger dimension is
indicated on the dimensional. All piping should
be designed and installed to avoid any loadings
on the boiler connections or piping.
1.4.1 FLOW CONNECTION
The system supply and return flow connections
are shown on Figure 3 and Figure 4
respectively. A gate valve should be installed on
the boiler outlet and inlet lines. This allows the
boiler to be isolated from the heating system for
draining and servicing.
1.4.2 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. Avoid over-
tightening as this can distort valve seats. All
piping from the safety relief valve(s) must be
independently supported with no weight carried
by the valve.
1.4.3 EXPANSION TANK
CONNECTIONS
Connection(s) to an expansion tank are to be
provided by others in the system piping separate
from the boiler.
1.4.4 DRAIN CONNECTION
A drain valve must be installed on the boiler
drain connection, the same pipe size as this
connection, to allow draining of the boiler.
1.4.5 CONDENSATE DRAIN
CONNECTION
A 1” MPT connection is provided to drain the
condensed products of combustion from a trap
located beneath the boiler. This must be run to
a drain using stainless steel or PVC piping. The
condensate temperature should never exceed
212o F and the pH of the condensate should
never be greater than 3.5. NO VALVE is to be
installed in this line from the boiler to point of
discharge.
1.4.6 GAS SUPPLY CONNECTION
The installation must conform completely to the
requirements of the authority having jurisdiction,
or in the absence of such, requirements shall
conform in the U.S. to the current National Fuel
Gas Code, ANSI Z223.1-1984, or in Canada to
the current Natural gas and propane installation
code (CAN/CSA B149.1-05), and applicable
regional regulations for the class; which should
be followed carefully in all cases. Authorities
having jurisdiction should be consulted before
installations are made.
1.4.7 DRIP LEG
A drip leg, or sediment trap, must be installed in
the gas supply line. See Fig. 1.5A. The gas line
must be connected to a supply main at least as
large as the gas train connection at the boiler.
This connection should be made with a union so
that the boiler gas train components and burner
may be easily removed for service.
1.4.8 GAS PIPING LEAK TEST
Leaks shall be checked using a soap and water
solution.
3
After completion of the gas-piping hookup, the
installation must be checked for leaks. All joints
up to the main motorized gas valve shall be
checked. A pressure gauge shall be installed
down stream of the 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

Date: 8-4-2010
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Form: 2396
valve shall be tested for leaks.
1.4.9 VENTING OF GAS TRAIN
COMPONENTS
Figure 2 Main Gas Inlet Connection
Normally open vent valves (when supplied) -
These valves must be piped to outdoors using
pipe no smaller than that of the valve.
Gas pressure switches – All gas pressure
switches provided are of the VENTLESS type
and do not require venting to atmosphere.
Gas pilot pressure regulator – A vent limiter for
the pilot pressure regulator is provided
eliminating the need to run a vent line to
atmosphere. NOTE:
Do not use Teflon tape for threaded joints in gas
piping.
1.5 ELECTRICAL REQUIREMENTS
WARNING:
All electrical connections must
conform to the National Electrical
Code and to all other applicable State
and Local Codes. See boiler wiring
diagram and equipment list for specific
voltage requirements.
Model TF300/250 TF200/150
200 V – 240 V / 60 Hz / 3 Ph
Blower Motor
KW (HP) 3 (4.02) N/A
Full Load
Amps115.6 N/A
Service Fuse (3) 20 Amp N/A
400 V – 480V / 60 Hz / 3 Ph
Blower Motor
KW (HP) N/A N/A
Full Load
Amps1N/A N/A
Service Fuse N/A N/A
200 V – 240 V / 60 Hz / 1 Ph
Blower Motor
KW (HP) N/A 1.05 (1.41)
Full Load
Amps1N/A 6
Service Fuse N/A (2) 7 Amp
Table 2 Electrical Requirements
Equipment Grounding
The boiler must be grounded in accordance with
the current American National Standard
Electrical Code, ANSI/NFPA #70.
1.6 COMBUSTION AIR SUPPLY
Combustion Air:
For proper combustion it is necessary to provide
the boiler room with appropriate openings for
fresh air supply. Temporary air intakes such as
windows and doors should be avoided since
they may be closed. In addition to air needed
for combustion, sufficient air must be supplied
for ventilation as well as other air consuming
equipment that may be present in the boiler
room. Often when personnel are working in the
boiler room, combustion air openings are closed
due to the temperature of the outside air. THIS
MUST BE AVOIDED AT ALL COSTS!
Provisions should be made to heat the outside
combustion air, if necessary, for personnel
comfort.
Positive means for supplying an ample amount
of outside air, allowing for the complete
combustion of the gas, must be provided.
Movable combustion air dampers, automatic or
manually adjustable, must be electrically
4
1Full load Amps include blower and control
circuit.

Date: 8-4-2010
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Form: 2396
interlocked with the boiler to prevent boiler
operation if the dampers are closed.
Combustion air openings must never be blocked
or obstructed in any manner.
The boiler room must be at a positive or neutral
pressure relative to the outdoors. A negative in
the boiler room will result in downdraft problems
and incomplete combustion due to the lack of
air.
WARNING!
Failure to provide an adequate air
supply will result in boiler damage and
hazardous conditions in the building
(fire and asphyxiation hazard as well
as equipment damage).
1.6.1 COMBUSTION AIR OPENINGS:
The design of combustion air openings MUST
comply with local and/or State codes or the
authority having jurisdiction. As a minimum,
combustion air openings to the boiler room shall
be provided as follows:
Note:
Combustion air provided solely from an indoor
source is discouraged. No dimension for a
round or rectangular opening shall be less than
3”.
Two Permanent Opening Method
One opening starting within 12” of the top of the
boiler room and one starting within 12” of the
bottom of the boiler room shall be provided. The
openings shall be open directly to the outside or
ducted directly to the outside.
When directly open to the outside or ducted to
the outside by vertical ducts, each opening or
duct shall have a minimum fee open area of 1
in2per 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 in2per 2000 BTU total
input rating of the boiler(s) in the room.
One Permanent Opening Method
One opening commencing within 12” of the top
of the room shall be provided. The opening
shall be directly to the outside or shall be ducted
to the outside with a horizontal or vertical duct.
The opening or duct shall have a minimum free
area of:
1 in2/ 3000 BTU /hour of the total input ratting of
all appliances (boilers) in the room.
Not less than the sum of the areas of all vent
connectors in the room. A “vent connector” is
defined as the pipe or duct that connects a fuel
burning appliance to a vent or chimney.
Additional area must be provided for other air
consuming equipment in the room.
Mechanical Air Supply Systems
The combustion air supply may be provided by a
mechanical air supply system. If utilized, the
combustion air must be provided from the
outside at a minimum rate of 0.35 ft3/min. for
every 1000 Btu/hr. input for all appliances
located in the space.
If exhaust fans are utilized, additional air shall be
provided to replace the exhausted air.
Each boiler and other appliance must be
interlocked to prevent operation when the
mechanical air supply system is not in operation.
If the combustion air is provided by a buildings
mechanical ventilation system, the system shall
be sized to provide the specified combustion air
in addition to the ventilation air requirements.
1.6.2 LOUVERS, GRILLES, AND
SCREENS
Louvers and Grilles:
5
The required size of openings for combustion,
ventilation, and dilution air shall e based on the
net free area of each opening. Where the free
area through a design of louver, grille, or screen
is know, it shall be used in calculating the size
opening required to provide the free area

Date: 8-4-2010
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Form: 2396
specified. Where the louver and grille design
and free area are not know, it shall be assumed
that wood louvers have a 25 percent free area,
and met louvers and grilles have 75 percent free
area. Non-motorized louvers and grilles shall be
fixed in the open position.
Screens
Minimum Screen Mesh Size:
Screens shall not be smaller than 1/4 “ mesh.
Motorized Louvers:
Motorized louvers shall be interlocked with the
appliance so they are proven in the full open
position prior to main burner ignition and during
main burner operation. Means shall be provided
to prevent the main burner from igniting should
the louver fail to opening during burner startup
and to shut down the main burner if the louver
close during burner operation.
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 combustion air to the
appliances.
Ducts shall serve a single space.
Ducts shall not serve both upper and lower
combustion air openings where both such
openings are used. The separation between
ducts serving the upper and lower combustion
air openings shall be maintained to the source of
combustion air.
Ducts shall not be screened where terminating
in an attic space.
Horizontal upper combustion air ducts shall not
slope downward toward the source of
combustion air.
For informational purposes, there are several
codes that address the amount of air and/or size
of the opening(s) in walls for combustion air.
NFPA 54, National Fuel Gas Code (ANSI
Z223.1)
ASME CSD-1, Controls and Safety Devices for
Automatically Fired Boilers
ASME Section VI, Recommended Rules for
Care and Operation of Heating Boilers
BOCA, National Mechanical Code
WARNING:
Do not locate air intakes where
petroleum distillates, CFC’s,
detergents, volatile vapors or any
other chemicals are present. Severe
boiler corrosion and failure will result.
1.7 FLUE GAS VENTING SYSTEM
Triple-Flex boilers are Category IV appliances
that vent with a positive exhaust vent pressure
and with a temperature that is likely to cause
condensation. Any venting system used with
the Triple-Flex boiler must comply with the
requirements for Special Gas Vents per UL
Category Code (CCN) DGSH, which are UL
Listed per UL 1738 or UL Category Code
DGSH7, which are cUL Listed (Canada) per UL
1738.
WARNING:
The Triple-Flex boiler is NOT certified
for use with other types of venting
excepting Special Gas Vents. Use of
any other types of venting may cause
vent failure resulting in serious injury
or death.
1.7.1 DESIGN & INSTALLATION
6
A qualified venting professional experienced in
venting system designs should design the boiler
vent system. The vent size must be NO LESS
THAN 8” IN DIAMETER and sized such that the
pressure drop between the boiler and the point
of discharge does not exceed 0.20” WC. While
the vent must be UL Listed Special Gas Vent
per Category Code DGSH or DGSH7 for
Canada, Bryan Steam, LLC recommends the
use of venting components fabricated from
AL29-4C® material. The vent installation must
be in strict compliance with the vent
manufacturers requirements. Clearances to
combustible materials and supporting
requirements, per the vent manufacturers
installation instructions, must be maintained.

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Form: 2396
Horizontal sections of the flue vent system must
be pitched back towards the boiler at ¼ inch per
foot to avoid condensate pooling and allow for
proper drainage. Venting may be horizontal,
through the wall installation or vertical, through
the roof installation. The vent system, including
terminus, must be sized in accordance with the
flue gas flow(s) and pressure drop(s) per Table 3.
Boiler Model
Flue Gas
Flow,
ACFM
@40%X
SA
200oF
Comb Air
Req.
SCFM
@40%XS
A60oF
Permissible
∆P Thru
Venting
TF-150 452 330
0.2” WC
(Max)
TF-200 603 441
0.2” WC
(Max)
TF-250 753 550
0.2” WC
(Max)
TF-300 904 661
0.2” WC
(Max)
Table 3 Boiler Draft
Note:
NFPA 54-2009 (ANSI Z223.1-2009) paragraph
12.7.3.3 states, “The sizing of gas vents for
Category II, Category III, and Category IV
Appliances shall be in accordance with the
appliance manufacturers instructions.”
WARNING:
Do not use a barometric damper with
this boiler. This is a positive pressure
system. The use of a barometric
damper may cause flue gases to leak
into the boiler room.
The boiler vent must not be connected to any
portion of another vent system without
consulting the vent manufacturer. The boiler
shall not be connected to any part of a vent
system serving a Category I or Category II
appliance, nor shall a Category I or Category II
appliance be connected to the vent system
serving this boiler. Improper connection of
venting systems may result in leakage of flue
gases into building spaces.
Note:
An existing masonry chimney may be utilized
PROVIDING that the existing chimney is lined
with Special Gas Vent material(s), primarily
AL29-4C®. There are venting manufacturers
that have these products available.
1.7.2 COMBUSTION 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 combustion air, excess air, flue gas dilution
air, primary air, secondary air, and ventilation
air. The air supply requirements below are a
summation of Clause 8.4 specific to the Triple-
Flex boiler.
Air Supply Requirements per CAN/CSA-
B149.1-05 for Appliances having an input
exceeding 400 MBH.
Ventilation Air: an opening for ventilation air at
the highest point that opens to the outdoors shall
provide Ventilation of the space. The cross
sectional area of this opening shall be at least
10% of the area required for combustion air, but
in no case shall the cross-sectional area be less
that 10 in2(6500mm2).
Combustion Air: For combustion air where the
air supply is provided by natural airflow from
outdoors, in addition to the opening for
ventilation air, there shall be permanent opening
having a total cross-sectional free area of not
less than 1 in2for each 30,000 BTU/hr. (70 mm2
for each kW) of the total rated input of the
boiler(s). The location of the opening(s) shall
not interfere with the openings for ventilation air.
Please refer to CAN/CSA-B149.1-05, Para.
8.4.4, for combustion air openings if there are
natural draft, fan assisted or power draft
assisted equipment in the space.
When an air supply duct is used to supply
combustion air, it’s discharge opening shall be
located where there is no possibility of cold air
affecting steam or water lines or other
temperature sensitive equipment.
7

Date: 8-4-2010
Revision: 0
Form: 2396
Combustion Air Supply Dampers, Louvers,
and Grilles
The free area of the combustion air supply
opening shall be calculated by subtracting the
blockage area of all fixed louvers, grilles or
screens from the gross area of the opening.
Openings in a fixed louver, grille, or screen shall
have no dimension smaller than ¼” (6 mm).
No manually operated damper or manually
operated adjustable louvers are permitted.
A motorized damper or louvers shall be
interlocked so the burner(s) cannot operate
unless the damper or louver is in the fully open
position.
Mechanical Combustion Air Supply
When combustion air is supplied by mechanical
means, an airflow sensing device shall be
installed and wired into the safety limit circuit of
the primary safety control to shut off the gas in
the even a an air supply failure.
Appliance Venting per CAN/CSA-B149.1-
05
Paragraph 8.9 of CAN/CSA-B149.1-05 addresses
“Appliance Venting”. Paragraphs 8.9 through 8.31
address many facets of flue gas vents, many of which
do not apply to the Triple-Flex boiler, which is a
Category IV listed appliance requiring the use of
special venting systems as previously described.
NOTE:
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 strongly suggested. The final
approval of all system designs must be
acceptable to the authority having jurisdiction.
• Venting for Category IV appliances shall
be as specified or furnished by the
manufacturer of the listed appliance.
The Triple-Flex boiler is a Category IV
appliance requiring the use of special
vent that is certified.
• A special venting system shall be
installed in accordance with the terms of
it’s listing and the vent manufacturers
certified installation manual.
• A flue gas vent or a vent connector shall
not be installed in either a duct or a
shaft used for return air, hot air,
ventilating air, or combustion air.
• An appliance that operates at a positive
vent pressure shall not be connected to
a venting system serving any other
appliance. The Triple-Flex boiler
operates at a positive vent pressure.
• A factory-built chimney used for venting
an appliance shall be certified.
Vent Sizing
• A vent or chimney serving a single
appliance shall provide effecting venting
and shall be sized so that it’s effective
area is not less than that of the flue
outlet diameter of the boiler and in
accordance with engineering venting
tables acceptable to the authority having
jurisdiction.
• A vent or chimney serving more than
one appliance shall provide effective
venting and shall be sized in
accordance with good engineering
practice, such as by the use of
engineering venting tables acceptable to
the authority having jurisdiction.
1.7.3 MARKING OF GAS VENTS
Where solid and liquid fuels are used, gas vents,
must be plainly and permanently identified by a
label. The label should read, "This gas vent is
for appliances that burn gas only. Do not
connect to incinerators or solid or liquid fuel
burning appliances."
This label must be attached to the wall or ceiling
at a point near where the gas vent connector
enters the wall, ceiling or chimney.
The authority having jurisdiction must determine
whether their area constitutes such a locality.
Solid Fuel Appliance Vents
Gas appliances shall not be vented to a vent or
a chimney that serves a solid-fuel burning
appliance.
8
1.8 BEFORE PLACING BOILER IN
OPERATION

Date: 8-4-2010
Revision: 0
Form: 2396
1.8.1 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 should be gradually increased to a
pressure just below the setting of boiler safety
relief valve(s).
Remove the boiler tube access panels (see
dimensional drawing in the boiler manual).
Inspect the tube to header joints to be certain
that all tube fittings are sealed. This is
necessary because, although the boiler is
hydrostatically tested at the factory, minor leaks
in fittings and at attachments can develop from
shipping vibration or from installation
procedures. It is often necessary to retighten
such fittings after installation and after the boiler
has been operated for some time. Replace tube
access panels before proceeding to start boiler.
1.8.2 TEST OF GAS PIPING
9
Reference the gas system test under paragraph
Gas Supply Connection, in this manual.

Date: 8-4-2010
Revision: 0
Form: 2396
10
Section 2 Start-Up and Operation
Triple-Flex High Efficiency Boilers

Date: 8-4-2010
Revision: 0
Form: 2396
WARNING:
Improper servicing and start-up of this
equipment may create a potential
hazard to equipment, operators, or
persons in the building.
Only fully trained and qualified
personnel should do servicing and
start-up.
WARNING:
Before disconnecting or opening any
fuel line, cleaning or replacing parts of
any kind take the following
precautions.
Turn OFF the main fuel shutoff valves,
including the pilot gas cock if
applicable.
Turn OFF all of the electrical
disconnects to the burner, boiler and
any other equipment or systems
electrically interlocked with the burner
or boiler.
All cover plates, enclosures, and
guards must be in place at all times
except during maintenance and
servicing.
2.1 BOILER ASSEMBLY
The Triple-Flex boiler is a fully integrated
assembly consisting of a Metal Fiber Pre-Mix
Burner Head and the necessary fittings, valves,
and safety devices. The boiler equipment list
provided in the boiler manual lists the
components supplied for the boiler assembly.
Refer to the boiler dimensional for location
dimensions. A description of the major
components follows. For additional information
refer to the manufactures literature provided in
the boiler manual.
2.1.1 TRIPLE-FLEX FRONT VIEW
Figure 3 Triple-Flex Front View
1. The boiler cabinet door provides easy
access to boiler and burner components.
This door should remain closed during
normal operation to ensure proper flow of air
around the boiler flue collector.
2. The boiler supply water connection provides
heated water to the system. This
connection is a standard ANSI 150# class 3”
flange.
3. The boiler water pressure gauge is 2”
diameter and will have a range not less than
1-1/2 nor more than 3-1/2 times the
pressure setting of the boiler safety relief
valve.
4. The boiler water temperature gauge is 2”
diameter and is located so that it will indicate
the boiler water temperature at the supply
water connection of the boiler.
5. The boiler touch panel display provides a
human interface for controlling the boiler.
Controlling the boiler with the touch panel
display will be explained in section 2.2.
11
6. The boiler on / off switch will turn on or off
the 120 volt ac control voltage for every
electrically connected device. This includes

Date: 8-4-2010
Revision: 0
Form: 2396
the touch panel display. There is a soft
switch (paragraph 2.2.11) provided with the
SOLA hydronic control that will put the boiler
into standby for an indefinite period of time.
WARNING:
The boiler on / off switch will not turn
off the 3 phase high voltage power to
the motor.
7. The boiler lockout reset button is a push
button used to reset the hydronic control
after a boiler failure.
8. The power on light will be white in color and
indicates that there is 120 volts ac being
supplied to electrically connected devices.
9. The enabled light will be green in color and
indicates that the boiler is enabled. Enabled
is a state in which the boiler is allowed to
operate within the boiler’s predefined
parameters.
10. The fuel on light will be amber in color and
indicates that the boiler is firing and
producing heated water.
11. The boiler lockout light will be red in color
and indicates that the boiler has failed. The
SOLA control will have additional
information displayed on the touch panel
display. These failures will be explained in
section 2.3.9.
2.1.2 TRIPLE-FLEX REAR VIEW
Figure 4 Triple-Flex Rear View
1. The flue gas vent is 8” diameter and
exhausts products of combustion. Refer to
section 1.7 for installation details.
2. The rear jacket access panel provides
access to the combustion air blower for
servicing.
3. The boiler return water connection receives
cooled water from the system. This
connection is a standard ANSI 150# class 3”
flange.
12
4. The drain connection is 1” NPT and provides
a means for draining water from the boiler.
For installation details refer to paragraph
1.4.4.

Date: 8-4-2010
Revision: 0
Form: 2396
2.1.3 TRIPLE-FLEX LEFT SIDE VIEW
Figure 5 Triple-Flex Left Side View
1. This jacket access panel will permit access
to the primary air-to-air exchanger.
2. This jacket access panel will permit access
to the primary air-to-air exchanger and the
boiler convection tube access panels.
3. These jacket access panels will permit
access to the convection and furnace tube
access.
4. Flame observation port. This port provides
visual access to observe the pilot and main
flame during operation and service.
5. This jacket access panel will permit access
to the majority of the boiler devices.
WARNING:
The flame observation port will
become very hot during normal
operation. Burn injuries can occur if
come in contact with the skin.
2.1.4 TRIPLE-FLEX RIGHT SIDE VIEW
Figure 6 Triple-Flex Right Side View
1. Main gas inlet connection. This connection
is a 2” male national pipe thread.
2. Condensate Drain Connection. This
connection is a 1” male national pipe thread.
For installation details refer to paragraph
1.4.5.
3. This jacket access panel will permit access
to the majority of the boiler devices.
4. These jacket access panels will permit
access to the flue collector. There is no
practical reason for the removal of these
panels.
5. This jacket access panel will permit access
to the condensate trap. The condensate
trap is provided with a ½” NPT plugged
connection for cleanout purposes.
6. This jacket access panel will permit access
to the primary air-to-air exchanger.
2.1.5 TRIPLE-FLEX BEHIND THE
CABINET DOOR
Figure 7 Triple-Flex Behind the Cabinet Door
1. Auxiliary gas shutoff valve actuator.
2. Low fire displacement adjustment that can
be adjusted by removing the cap and
rotating the slotted screw clockwise to
increase gas flow and counter-clockwise to
decrease gas flow.
13
Fig. 2.1.2 Triple-Flex Rear View

Date: 8-4-2010
Revision: 0
Form: 2396
NOTE:
The low fire displacement final adjustment
should be made at low fire only.
3. Main gas pressure regulating and shutoff
valve actuator. The pressure regulating
actuator provides slow opening fast closing
safety shutoff and air/gas ratio control. The
actuator controls the pressure difference
across the gas limiting orifice valve (Figure 7
item 26) as a function of the pressure
difference across the furnace section so that
the air to gas ratio remains constant
irrespective of air volume changes. There is
no need for an upstream constant pressure
regulator when the supply gas pressure
does not exceed 56 inches of water column.
A minimum of 14 inches of water column
must be supplied at the gas inlet connection
(Figure 6 item 1). The supply pressure can
be measured at the test port (Figure 7 item
28).
NOTE:
The supply pressure is not static. The supply
pressure is at the maximum full flow of gas
through the burner.
4. Manual main gas shutoff valve.
5. Pilot ignition transformer.
6. Manual pilot gas shutoff valve.
7. Pilot gas pressure regulator. This regulator
provides a constant gas pressure to the pilot
when the solenoid valve is energized. The
pressure can be adjusted by removing the
cap and adjusting the slotted screw
clockwise to increase the pressure and
counter-clockwise to decrease the pressure.
The pilot gas supply is taken upstream of
the main gas cock so the pilot may be
lighted and adjusted with the main gas cock
closed.
8. Low pilot gas pressure switch (Manual
Reset)
9. Pilot spark igniter assembly. For further
detail see Figure 9.
10. Pilot gas solenoid valve.
11. Flame scanner.
12. Main gas manifold pressure test port (1/4”
NPT).
13. Main high gas pressure switch (Manual
Reset). This switch should be set 1” of
water column above the maximum gas
manifold pressure.
14. Pilot gas pressure test port (1/4” NPT). This
port is also used to record the furnace
pressure.
15. Boiler water flow switch. The boiler water
flow switch is adjustable within the
parameters listed in the table.
Mode Of Operation
Settings Switch
Closed
Switch
Open
Minimum 30 gpm 12 gpm
Maximum 52.1
gpm
46.1
gpm
Table 4 Water Flow Switch Settings
16. Low Water Cutoff (Manual Reset Probe
Type).
17. Combustion air-flow switch. An airflow
switch is provided to prove that air is being
provided to the burners before main flame
can be established. The airflow switch can
be adjusted by turning the screw (Figure 8
item A) clockwise to increase the pressure
setting and counter-clockwise to decrease
the pressure setting. The switch will open
on pressure drop. When the blower is
running there should be continuity between
the common and the normally open contacts
(Figure 8 item B and C). When the blower is
interrupted the switch should open and
cause a safety shutdown.
A
B
C
Figure 8 Air Flow Switch
18. High burner air pressure switch manual
reset. This switch will trip when the air
pressure in the burner rises above the set-
point, indicating that the burner has become
plugged with dust or other foreign matter.
19. Gas and air mixer assembly.
14
20. Main 3-phase power connection and fuse