Triad Triumph series User manual

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Installation Date: _______________________
TRIAD Boiler Systems, Inc.
1099 Atlantic Drive, Unit 2
West Chicago, IL 60185
Phone: [phone]
Fax: [phone]
www.triadboiler.com
Version 1.0 / 1-08-08
C.S.A Design-Certified
Complies with ANSI Z21.13/CSA 4.9
Gas-Fired Low Pressure Steam & Hot Water
Boilers
ASME Code, Section IV
C.S.A Design-Certified
Complies with ANSI Z21.13/CSA 4.9
Gas-Fired Low Pressure Steam & Hot Water
Boilers

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ATTENTION!!!
WATER:
ÿ The pH of the system must be between 6.0 and 8.5. Periodically check the pH!
ÿ If Glycol is used it must be approved by the chemical manufacturer for aluminum boilers!
VENTING:
ÿ This boiler is Category IV (condensing positive pressure) and is NOT certified for use with
Type “B”vent!
HEAT EXCHANGER:
ÿ Maximum operating pressure is 80 psi and maximum temperature is 200° F!
BURNER:
ÿ If the material surrounding the burner tube is ripped in any way, it MUST be replaced!
ÿ Change the spark iginiter once a year!
MANUAL RESET SERVICE CODES:
ÿ A few of the more common lockout codes: (See page 33 for all of them.)
Code Lockout Description
E 00 False flame. A flame signal is present when it shouldn’t be.
E 02 Flame failure. The burner did not light on startup, or loss of flame during run.
E 03 Gas Valve error. Check all gas valves electrical connections.
E 08 Air pressure switch open Air pressure switch failed to close to indicate sufficient air flow to start the boiler.
E 12 External limit open An external limit has opened. (High/Low Gas Pressure, High Temp, or LowWater)
ÿ If any “Manual Reset”limit device trips, DO NOT reset without determining and correcting
the cause!!

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1.0 INTRODUCTION ................................ ....... 2
2.0 SAFETY ................................ .................... 2
2.1 General................................ ............................ 2
2.2 Training ................................ ........................... 2
2.3 Safety Features................................ ................2
2.4 Safety Labels................................ ...................3
2.5 Safety Precautions................................ ...........3
2.5.1 Electrical Hazards................................ ...3
2.5.2 Burn, Fire, and Explosion Hazards..........3
2.5.3 Crush Hazards................................ ........4
2.5.4 Chemical Hazards................................ ...4
2.5.5 Pressure Hazards................................ ...5
2.5.6 Slip, Fall Hazards................................ ....5
3.0 INSTALLATION................................ ......... 6
3.1 Receiving and Storage................................ .....6
3.1.1 Initial Inspection................................ ......6
3.1.2 Storage Prior to Installation.....................6
3.2 Compliance with Codes................................ ....6
3.3 Setup................................ ............................... 6
3.3.1 Foundation................................ ..............6
3.3.2 Placement ................................ ..............7
3.3.3 Clearances................................ .............7
3.4 Electrical Connections................................ ......7
3.5 Combustion Air................................ ................8
3.5.1 Air Inlet Requirements............................. 8
3.6 Flue Venting................................ .....................9
3.6.1 Barometric Damper................................ .9
3.6.2 Flue Connection................................ ......9
3.6.3 Required Clearances.............................. 9
3.6.4 Vent Terminations................................ .10
3.6.5 Venting for Multiple Boilers.................... 10
3.6.6 Sealed Combustion Air/Venting System 11
3.6.7 Removing an Existing Boiler .................11
3.6.8 Intake/Exhaust Layout........................... 11
3.6.9 Intake Duct Materials and Sizes:...........12
3.6.10 Sealing the Intake Duct....................... 13
3.6.11 Intake Duct Connection to Boiler.........13
3.6.12 Intake Duct Terminations ....................13
3.6.13 Vent Elbows................................ ........13
3.7 Gas Piping................................ ..................... 13
3.7.1 Gas Supply Piping by Installer...............15
3.8 Boiler Water Piping ................................ ........15
3.8.1 Piping Design................................ ........15
3.8.2 Boiler Inlet and Outlet Connections.......16
3.8.3 Boiler Water Piping by Installer..............17
3.8.4 Water Quality, Flushing and Filling........17
3.9 Burner and Ignition System............................ 18
3.9.1 Inspection................................ .............18
3.10 Pre-Start Check List................................ .....19
3.11 Safety Checks................................ ..............19
3.11.1 Test of Ignition Safety System.............19
3.11.2 Test of Low Water Cut Off...................19
3.11.3 Test of High-Limit Control....................20
3.11.4 Test of Gas Pressure Switch...............20
3.12 Initial Adjustments................................ ........20
3.12.1 Operating Temperature Controller.......20
3.12.2 Gas Pressure Adjustment ...................25
3.12.3 Air Flow Adjustments .......................... 25
3.12.4 Gas Valve Setup and Adjustment........25
4.0 OPERATION................................ ........... 28
4.1 General................................ .......................... 28
4.1.1 Control Panel Front............................... 28
4.1.2 Tests ................................ ....................28
4.2 Normal Lighting and Shut-Down Procedures..28
4.2.1 Lighting Procedures.............................. 28
4.2.2 Normal Shut Down Procedures.............28
4.2.3 Emergency Shut-Off.............................. 28
4.3 Typical Boiler Operating Conditions................29

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5.0 MAINTENANCE ................................ ...... 30
5.1 Maintenance and Inspection Schedule...........30
5.1.1 Daily................................ ..................... 30
5.1.2 Weekly................................ ..................30
5.1.3 Monthly (During Operation)................... 30
5.1.4 Semi-Annually (every 6 months) ...........31
5.1.5 Annually................................ ................31
5.2 Cleaning the Burner................................ .......31
5.3 After All Repairs or Maintenance.................... 31
5.4 Sequence of Operation................................ ..32
5.5 Troubleshooting................................ .............32
5.5.1 Manual Reset Service Codes................34
5.5.2 Auto-reset Service Codes..................... 35
6.0 PARTS/TECHNICAL SUPPORT............. 36
6.1 Wiring Diagrams ................................ ............37
6.1.1 Terminal Block Assignments –High Voltage
Circuit (TB2)................................ .............37
6.1.1a Terminal Block Assignments –Low Voltage
Circuit (TB1)................................ .............38
6.1.2 Wiring Triad Series 750/900/1000.........39
6.2 Boiler Parts List................................ ..............40
6.2.1 Main Assembly ................................ .....40
6.2.2 Control Panel................................ ........41
6.2.3 Display Panel................................ ........42
6.2.4 Triad-750/900/1000 Heat Exchanger.....43
6.2.5 Triad-750/900/1000 Gas Train ..............44
7.0 LIMITED WARRANTY ............................ 45
8.0 APPENDIX................................ .............. 47
It is essential to read, understand, and follow
this manual before installing, operating, or
servicing this equipment. Failure to do so
could result in fire or explosion and serious
injury, death, and/or property damage.
The features which permit this boiler to
achieve high-efficiency performance make it
unlike most other boilers of this general size,
so it is important to understand how it
operates.
Do not store or use gasoline or other
flammables in the vicinity of this or any other
appliance. Chemicals, fuels, or other
potentially hazardous or toxic materials must
not be stored in the same room as the boiler.
Installation and service must be performed by
a qualified installer or service agency that has
been trained on the Triad TRIUMPH Boiler
What to do if you smell gas:
∑ Do not try to light any appliance.
∑ Do not touch any electrical switch.
∑ Do not use any phone in your building.
Immediately call your gas supplier from a
neighbor's phone. Follow the gas
supplier's instructions.
∑ If you cannot reach your gas supplier call
the fire department.

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Triad Boiler Systems, Inc –TRIUMPH Series Hot Water Boiler Page 2
1.0 INTRODUCTION
Congratulations on purchasing the highly efficient
TRIUMPH Series Gas-Fired Boilers form Triad
Boiler Systems, Inc. These boilers feature an
aluminum alloy heat exchanger capable of
operating in a fully condensing mode to provide
maximum efficiency in a very small footprint. This
is complemented by a fully modulating burner
with a variable speed combustion blower,
microprocessor controls, and modulating gas
safety shut off & control valves. The high-quality
materials and thoroughly tested design of your
boiler will provide years of trouble-free service if
the instructions in this manual are carefully
followed.
This manual covers installation of the TRIAD
TRIUMPH Series Boilers. The model numbers
may be followed by a prefix or suffix letter in
some cases to indicate special features or
options.
While details may differ slightly, basic operation is
the same for all models. Boilers may be built to
operate with natural gas or propane. Check the
rating plate for correct fuel usage and gas
pressures.
The boiler is only a part of the complete heating
system. It may be fully operational, yet because
of poor circulation, control, or other operating
characteristics, not deliver heat to the desired
location. Additional equipment such as
temperature sensors, pumps, flow switches,
balancing valves, and check valves will be
required for satisfactory operation of any system.
Triad Boiler Systems cannot be responsible for
the design or operation of such systems and a
qualified engineer or contractor must be
consulted.
2.0 SAFETY
2.1 GENERAL
The TRIUMPH Seriesgas-fired boiler must be:
∑ Installed, operated, and serviced in
accordance with instructions contained in this
manual.
∑ Installed by qualified personnel in accordance
with designs prepared by qualified facility
engineers including: structural, mechanical,
electrical, and other applicable disciplines.
∑ Operated and serviced in accordance with a
comprehensive safety program determined
and established by the customer. Do not
attempt to operate or service until such a
program has been established.
∑ Operated and serviced by qualified, properly
trained personnel in accordance with all
applicable codes, laws, and regulations.
Note: Each safety device must be maintained
and checked per the recommended schedule;
refer to Section 5.1 of this manual.
2.2 TRAINING
It is essential to read, understand, and follow the
recommendations of this manual before installing,
operating, or servicing this equipment. Failure to
do so could result in property damage, serious
injury, or death.
Proper training is the best protection against
accidents. Operating and service personnel must
be thoroughly familiar with the basic construction
of the TRIAD TRIUMPH Series boiler, the use
and locations of the controls, the operation of the
boiler, adjustment of its various mechanisms, and
all applicable safety precautions. If any of the
provisions of this manual are not fully and
completely understood, contact Triad Boiler at
630.562.2700 for assistance.
2.3 SAFETY FEATURES
It is the responsibility of the customer to maintain
the safety features, such as: guards, safety

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labels, safety controls, interlocks, lockout devices,
etc., in place and operable.
2.4 SAFETY LABELS
NOTE
Reorder No. 8032-01NHPK
c
When opening leak test valves,
always follow instructions in
operation and safety manual.
1998 HCS, Inc. 800-748-0241
The safety labels shown above are affixed to your
boiler. Although the labels are of high quality,
they may become dislodged or unreadable over
time. Contact Triad Boiler Systems at
630.562.2700 for replacement labels.
2.5 SAFETY PRECAUTIONS
Provide a suitable location for the boiler, away
from normal personnel traffic, with adequate
working space, adequate clearances, proper
ventilation and lighting, with a structure
sufficiently strong and rigid to support the weight
of the boiler, all piping, and accessories.
2.5.1 Electrical Hazards
∑ Shock hazard! Properly lockout/tagout the
electrical service and all other energy sources
before working on or near the boiler.
∑ Shock hazard! Do not spray water directly on
any electrical components.
2.5.2 Burn, Fire, and Explosion Hazards
General Warning
Hot Surface
NOTE
Reorder No. 8032-01NHPK
c
When opening leak test valves,
always follow instructions in
operation and safety manual.
1998 HCS, Inc. 800-748-0241
∑ Burn, fire, and explosion hazards!
Installation must be in strict conformance to
all applicable codes and standards including
NFPA 54, ANSI Z223.1 and CAN/CGA B.149.
Install all required vent lines for gas devices.
Refer to Section 3.7.1.
∑ Hazard from incorrect fuels! Possible fire,
explosion, overheating, and damage. Do not
use any fuels except the design fuels for the
unit.
∑ Overfire hazards! High pressure in gas or
propane supply could result in overfiring of
other devices supplied from the same source.
∑ Fire and explosion hazards! Close the main
gas shutoff before servicing boiler.
∑ Fire and explosion hazards! Do not store or
use gasoline or other flammable vapors or
liquids in the vicinity of this or any other gas
fired appliance.
∑ Burn hazard! Possible hot surfaces. Do not
touch gas vent during firing operation. Use
only factory recommended vent components.
∑ Burn hazard! Pipes, vents, and boiler
components could be hot. Do not touch piping

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or stack surfaces during operation or
immediately after shutdown of the boiler.
∑ Burn hazard! Hot fluids. Use caution when
servicing or draining boiler.
∑ Fire and explosion hazards! Use caution
when servicing burner. Propane (LPG) is
heavier than air and may linger in the
combustion chamber, vent lines, or
elsewhere.
∑ Gas leak hazard! Make sure the burner is
installed correctly and burner hood is securely
fastened following any maintenance
performed on them. These connections
cannot be tested after the burner is
assembled.
∑ Gas leak hazard! All threaded gas
connections must be made using a pipe
compound that is resistant to liquefied
petroleum. Do not use Teflon‰tape on
threaded gas piping.
∑ Gas leak hazard! Check entire gas train for
leaks after installation. If there is a smell of
gas, shut down the boiler and obtain
immediate assistance from trained service
personnel and/or your local fire department.
∑ Overfire hazard! Possible fire and explosion
from excess gas pressure. Make sure that
gas inlet pressure does not exceed 14 inches
W.C. to the regulator.
∑ Overfire hazard! Possible fire and explosion.
Possible malfunction of regulators and/or gas
safety shut off / control valves. Maintain all
gas train components in good condition. Do
not alter wiring connections. Annual
inspection by factory-trained personnel for
proper set-up and operation is recommended.
∑ Overfire and underfire hazards! Possible
fire, explosion, overheating, and component
failure. Do not attempt to adjust firing rate of
the boiler. The firing rate must be adjusted
only by factory trained personnel.
2.5.3 Crush Hazards
General Warning
∑ Lifting hazards! Use properly rated lifting
equipment to lift and position the boiler. The
load is unbalanced. Test balance before lifting
3 ft. above the floor. Do not allow personnel
beneath the lifted load. Refer to approximate
weights in the table below:
Boiler Size Weight in Pounds
750,000 Btu 650
900,000 Btu 700
1,050,000 Btu 750
∑ Bump hazard from overhead ductwork and
piping. Install components with adequate
vertical clearance.
2.5.4 Chemical Hazards
General Warning
∑ Chemical hazards from cleaning products.
Use caution when cleaning the system.
Consulting a professional is recommended.
Use safe procedures for the disposal of all
cleaning solutions.
∑ Combustion Condensate –a pH of
approximately 4 to 5 can be expected. Use
PVC or CPVC piping. Collection and disposal
must be in accordance with all applicable
regulations.

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2.5.5 Pressure Hazards
∑ Pressure hazard! Hot fluids. Install isolation
valves on boiler water inlet and outlet. Make
sure isolation valves are closed before
servicing boiler.
∑ Pressure hazard! Hot fluids. Annually test
safety relief valve for proper operation. Do not
operate boiler with faulty relief valve.
2.5.6 Slip, Fall Hazards
∑ Tripping hazard! Do not install piping on floor
surfaces. Maintain clear path around boiler.
∑ Slip and fall hazard! Use drip pan to catch
water while draining the boiler. Maintain dry
floor surfaces.
∑ Slip and fall hazard! Do not locate intake or
exhaust terminations directly above a
walkway; dripping of condensation can cause
icing of the walking surface.

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3.0 INSTALLATION
3.1 RECEIVING AND STORAGE
3.1.1 Initial Inspection
Upon receiving the boiler, inspect it for signs of
shipping damage. Since some damage may be
hidden, we recommend unpacking the boiler and
removing the top cover and inspecting the boiler.
Verify that the total number of pieces shown on
the packing slip agrees with those actually
received.
Important: Note any damage, suspected
potential damage, or shortage of materials on
the freight bill and immediately notify the
carrier. File all claims for shortage or damage
with the carrier. Claims for hidden damages
must be filed with your carrier within 7 days.
The boiler carton is equipped with a “Tip (N)
Tell”. If "Tip (N) Tell”arrow point is blue, that
indicates that the package has been on its
side or tipped over in transit.
3.1.2 Storage Prior to Installation
If the boiler is not installed immediately, it must be
stored in a location adequately protected from the
weather, preferably indoors. If this is not possible,
then it should remain in the shipping container
and be covered by a tarpaulin or other waterproof
covering.
Note: Controls and other equipment that are
damaged or fail due to weather exposure are
not covered by warranty.
3.2 COMPLIANCE WITH CODES
The TRIAD TRIUMPH Series Boiler with standard
components and with many options complies with
American National Standard/CSA Standard ANSI
Z21.13/CSA 4.9, latest edition, Gas-Fired Low
Pressure Steam and Hot Water Boilers.
The heat exchanger is constructed and stamped
in accordance with ASME Boiler and Pressure
Vessel Code, Section IV for 80 psig maximum
operating pressure and/or 200º F maximum
temperature.
Other codes or approvals which apply will be
labeled on the boiler.
Installation of the boiler must conform to all the
requirements of all national, state and local
codes established by the authorities having
jurisdiction or, in the absence of such
requirements, in the U.S. to the National Fuel
Gas Code, ANSI Z223.1/NFPA 54, latest edition.
In Canada, the equipment shall be installed in
accordance with the current Installation Code for
Gas Burning Appliances and Equipment,
CAN/CGA-B.149, and applicable Provincial
Regulations for the class, which should be
carefully followed in all cases. Authorities having
jurisdiction should be consulted before
installations are made.
Where required by local codes, the installation
must conform to American Society of Mechanical
Engineers Safety Code for Controls and Safety
Devices for Automatically Fired Boilers (ASME
CSD-1).
In the Commonwealth of Massachusetts (a) this
unit must be installed by a licensed pipe fitter /
plumber, (b) field installed gas cocks must be “T”
handle type, and (c) piping of condensate shall
conform with the State Plumbing Code.
3.3 SETUP
3.3.1 Foundation
Provide a firm, level foundation, preferably of
concrete.
Note: The boiler may be installed on a
combustible floor; however, the boiler must
never be installed on carpeting.

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3.3.2 Placement
The boiler must be level to function properly. To
assist in leveling the boiler, the four (4) adjustable
leg bolts (1/2"- 13 NC) must be installed. The
adjustable legs are also necessary to provide
adequate floor clearance and prevent distortion of
the cabinet, (twisting, etc.) in addition to leveling.
Adjustable Legs for Leveling and Clearance
3.3.3 Clearances
If the boiler is to be installed near combustible
surfaces, the minimum clearances shown in the
table below must be maintained.
Failure to provide for the service access
clearances, even with non-combustible surfaces,
may cause future problems servicing the boiler.
The boiler must be installed in a space large in
comparison to the boiler as described in Section
6.3 of the National Fuel Gas Code, ANSI Z223.1,
latest edition.
Minimum Clearances from Adjacent Walls, Ceiling, and
Obstructions
Dimensions (inches)Type of Surface
A B C†D
Combustible Surfaces 24 24 24 24
Non-combustible Surfaces 30 * 24 24**
†"C" Do not put pipes, ducts, etc. in this area
above the boiler.
CAUTION!
Bumping hazard from overhead ducts! Install all
components with adequate vertical clearances.
* Clearance depends upon vent configuration.
** Service access need be only on one side of a
boiler or row of boilers. Boilers may be installed
immediately adjacent to each other. However
Triad recommends this clearance between each
boiler when there is insufficient access at the
rear to allow for service and adjustment.
3.4 ELECTRICAL CONNECTIONS
The boiler is wired for 120 volts, single phase, 60
hertz. The total operating amperage is indicated
on the rating nameplate. All TRIUMPH units
require less than 8 amps. Before starting the
boiler, check to ensure that the proper electrical
service is connected to the boiler.
No pipes,
ducts, etc. in
this area.
A B
C
D D
Adjustable
Leg Bolts

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An external electrical disconnect (not supplied
with the boiler) with adequate overload protection
is required. The boiler must be grounded in
accordance with local codes or in the absence of
such requirements, in the U.S. with National
Electrical Codes, ANSI/NFPA No. 70 latest
edition and in Canada to the current Canadian
Electrical Code, Part I, CSA C22.1.
Note: A dedicated earth ground (green wire) is
required to avoid nuisance shutdowns. Do not
ground through the conduit. Make sure that
proper polarity is maintained.
Note: Refer to Terminal Block Assignments
(Section 6.1.1).
Electrical Connections at Rear of Boiler
3.5 COMBUSTION AIR
Combustion air must be free from dust, lint, etc.
The presence of such materials in the air supplied
to the burner could cause nuisance "Low Air"
shutdowns, reduced capacity, or premature
burner failure. The boiler should not be operated
during construction while the possibility of drywall
dust, demolition dust, etc. exists.
The combustion air supply must be completely
free of chemical fumes which may be corrosive
when burned in the boiler. Common chemicals
which must be avoided are fluorocarbons and
other halogenated compounds, most commonly
present as refrigerants or solvents, such as freon,
trichlorethylene, perchlorethylene, chlorine, etc.
These chemicals, when burned, form acids which
quickly attack the boiler and the boiler stack.
The result is improper combustion and
premature boiler failure.
Provisions for combustion and ventilation air
must be in accordance with Section 5.3, Air for
Combustion and Ventilation, of the National Fuel
Gas Code, ANSI Z223.1, latest edition, or
applicable provisions of the local building codes.
In Canada, combustion air openings shall
comply with CSA B.149 Installation Code. The
formula is 1 sq. in. per 1,000 Btu/hr of gas input
not less than 100 sq. in. The location shall be
neither more than 18", nor less than 6" above
the floor level.
The boiler room shall be provided with two
openings to ensure adequate combustion air
and proper ventilation. One opening should be 6
to 12 inches above the floor and the other 6 to
12 inches below the ceiling, preferably on
opposite walls. The size of each opening is
determined by whether air is taken from inside or
outside the building. In Canada, ventilation air
openings shall be at least 10% of the cross
sectional area required for combustion air, but
not less than 10 square inches. It is to be
located at the highest practical point
communicating with outdoors.
WARNING!
Under no circumstances shall the boiler room
ever be under a negative pressure. Particular
care should be taken when exhaust fans,
compressors, air-handling units or other
equipment may rob air from the boiler.
3.5.1 Air Inlet Requirements
If air is taken directly from outside the building,
each opening (minimum of two) should have a
net free area of 1 square inch for each 4,000 Btu
per hour of total boiler input. For instance, 112.5
square inches are required for 450,000 Btu per
hour input.
When air is taken from the outdoors through a
vertical duct, 1 square inch per 4,000 Btu per
hour is required. If a horizontal duct is used, 1
square inch per 2,000 Btu per hour is required,
Low Voltage
Control Junction
Box
120 Volt
Electrical Control
Junction Box

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i.e., 225 square inches for 450,000 Btu per hour
input.
If air is taken from another interior space, each
opening should have a net free area of 1 square
inch for each 1,000 Btu per hour of boiler input
(450 square inches for a 450,000 Btu per hour.)
3.6 FLUE VENTING
This boiler requires a special vent system. This
boiler is Category IV (condensing –positive
pressure) as it is defined in ANSI Z21.13/CSA
4.9, latest edition. The vent material must be
listed Category IV vent pipe (316L or AL29-4C
Stainless Steel) and comply with UL 1738 or
UL103. In Canada it must comply with ULC-
S636. The exhaust vent can be run horizontally
or vertically.
This boiler is NOT certified for use with Type
"B" vent.
Vent installations shall be in accordance with Part
10, Venting of Equipment, of the National Fuel
Gas Code, ANSI Z223.1 or CSA B.149 code, or
applicable provisions of the local building codes.
The venting system and the horizontal portions of
the venting system shall be supported to prevent
sagging.
The vent must be sized according to the vent
manufacturer’s recommendations. Consult your
vent supplier for correct sizing and structural
support requirements. Design calculations should
be based on a maximum of 0.22" W.C. total
frictional resistance in the stack (measured at the
boiler flue gas discharge), with a stack
temperature of 210° F (gross) and a CO2level of
9% (natural gas) or 10.4% (propane). These
values are to be used for vent sizing calculations.
The installation of a bird screen on the vent
termination is recommended. Consult your local
vent manufacturer for proper sizing.
3.6.1 Barometric Damper
WARNING!
Do not use a barometric damper with this
boiler. (This is a positive pressure system;
combustion gas may leak into the room.)
3.6.2 Flue Connection
The connection from the boiler to the vent should
be as direct as possible and the upward slope of
any horizontal breaching should be at least 1/4
inch per linear foot. The vent connection
incorporates a slope toward the boiler to
facilitate pitching of the vent for condensate
collection. This boiler should not be connected
into any portion of another mechanical draft
system operating under positive pressure
without consulting your local venting
representative. Provisions must be made for
supports to prevent contact of the vent with
combustible surfaces.
Note: If the vent is erected directly behind the
boiler, make sure that the weight of the duct is
not supported by the boiler vent. The boiler is
not designed to support the weight of the
duct. Structural support and spacing from
combustible surfaces must be in accordance
with the vent manufacturer's requirements.
Flue Connection at Boiler
3.6.3 Required Clearances
Provide clearances between combustion air
intake, exhaust vent, roof and wall surfaces,
doors and window, and snow line as shown in
the following diagrams. The exhaust vent
termination must be 14 feet above grade when
located adjacent to a public walkway. It must

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also have a minimum 6 foot horizontal and 6 foot
vertical clearance (above or below) any electric
meters, gas meters, regulators, or relief
equipment.
WARNING!
Do not locate intake or exhaust terminations
directly above a walkway; dripping of
condensation can cause icing of the walking
surface.
Reference: ANSI Z223.1 - 2002
Sidewall Installations
Rooftop Installations
3.6.4 Vent Terminations
Vent Termination Details
The vent should extend at least three (3) feet
above the roof, or at least two (2) feet above the
highest part of any structure within ten (10) feet
of the vent.
To prevent the possible re-circulation of flue
gases, your vent designer must take into
consideration such things as prevailing winds,
eddy zones, building configurations, etc. Triad
cannot be responsible for the effects such
adverse conditions may have on the operation of
the boilers. Dimensions listed above or those
illustrated represent minimum dimensions only
and may or may not be sufficient for conditions
at a specific job site.
A tee must be of approved design and adequate
capacity.
3.6.5 Venting for Multiple Boilers
The venting instructions in this manual apply to a
single boiler.
Venting systems for multiple boilers must be
designed by qualified professionals and
verified by the stack manufacturer. The
venting system must prevent backflow of
No rain cap
required, or Tee.
Centering
Support Plate
Sealant
Outside Plate
Cover Plate
Fastener
Sealant
12" min.
Recommended
Termination
(see text below)
Mechanical draft vent
terminal
12 in.
min.
Direct vent terminal
clearance minimum 12 in.
12 in.
min
Mechanical draft
vent terminal 12 in.
min.
4 ft.
min.
Less
than
10 ft.
4 ft.
min.
Forced
air inlet
3 ft min.
Grade
10' min.
4' min.
Flue Gas
Outlet
Combustion
Air Inlet
4' min above
snow line

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exhaust gas through idle boilers which are
not operating.
3.6.6 Sealed Combustion Air/Venting System
The TRIUMPH Series Boilers are also certified for
operation with a sealed combustion air and
pressurized venting system. Such a system
employs a sealed combustion air intake duct
leading from outdoors and a sealed exhaust vent
terminating outdoors. Air flow through the system
is maintained by the fan inside the boiler
assembly.
Vent Installation Details
Installation must conform to the vent
manufacturer's instructions in all respects
including joining, clearances, fastening, fire-
stopping, and other matters.
Vent ductwork may be run horizontally or
vertically if so certified.
3.6.7 Removing an Existing Boiler
(from a common venting system)
When an existing boiler is removed from a
common venting system, the venting system will
now probably be too large for proper venting of
any remaining appliances that are still connected.
When an existing boiler is removed, complete the
following steps with each appliance remaining
connected to the common venting system (when
they are not in operation):
1. Seal any unused openings in the common
venting system.
2. Visually inspect the venting system for proper
size and horizontal pitch and determine that
there is no blockage or restriction, leakage,
corrosion or other deficiency which could
cause an unsafe condition.
3. Insofar as is practical, close all building
doors and windows and all doors between
the space in which the appliances remaining
connected to the common venting system
are located and other spaces of the building.
Turn on clothes dryers and any appliances
not connected to the common venting
system. Turn on any exhaust fans, such as
range hoods and bathroom exhausts, so
they will operate at maximum speed. Do not
operate a summer exhaust fan. Close
fireplace dampers.
4. Place the appliance being inspected in
operation. Follow the lighting instructions.
Adjust the thermostat so that the appliance
will operate continuously.
5. Test for spillage at the draft hood relief
opening after 5 minutes of main burner
operation. Use the flame of a match or
candle or smoke from a cigarette.
6. After it has been determined that each
appliance connected to the common venting
system properly vents, return windows,
doors, exhaust fans, fireplace dampers and
any other gas-burning appliance to their
previous conditions of use.
Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1 and CSA B149 Installation Code. When
resizing any portion of the common venting
system, the common vent system should be
resized to approach the minimum size as
determined using the appropriate tables.
3.6.8 Intake/Exhaust Layout
Four basic configurations for the intake/exhaust
may be used. Refer to Section 3.6.3 for
required clearances for all terminations
shown in the four following figures:

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Basic Air Inlet/Vent Configurations

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3.6.9 Intake Duct Materials and Sizes:
Material: PVC, CPVC (Schedule 40), single wall
galvanized steel, or other suitable materials.
The intake duct must be sized for a maximum
pressure drop of 0.22 inches W.C., for the SCFM
as specified below.
Btu Size Required SCFM
1050 245
900 210
750 175
The installation of a bird screen on the intake
termination is recommended.
3.6.10 Sealing the Intake Duct
Proper sealing of the intake ductwork is
necessary to prevent infiltration of air from
conditioned space. Joints in PVC or CPVC must
be cemented. For galvanized duct, wrap each
joint and seam with adhesive aluminum tape.
3.6.11 Intake Duct Connection to Boiler
Connect the air supply duct to the collar on the
back of the boiler. Fasten the duct to the collar
with sheet metal screws at 90º angles. Seal the
joint.
3.6.12 Intake Duct Terminations
The roof intake termination must be an
unrestrictive type, as shown above.
Intake Termination Details
3.6.13 Vent Elbows
The turn from horizontal to vertical should be
made with two 45º ells or with one long radius
90º ell for best operation. Do not use "short
radius" ells.
3.7 GAS PIPING
Before making the gas hook-up, make sure the
boiler is being supplied with the type of fuel
shown on the boiler nameplate.
The boiler shall be installed such that the gas
ignition system components are protected from
water (dripping, spraying, rain, etc.) during
appliance operation and service (circulator
replacement, control replacement, etc.)
The boiler is factory fire-tested and adjusted for
proper combustion with natural gas supply
pressure of 7”W.C. Typical gas pressure
supply for natural gas is 7" W.C. (11" W.C. for
propane). The gas train components are
certified to handle a maximum inlet pressure of
14" W.C. (1/2 psig.). If the available gas
pressure exceeds 14" W.C., a suitable additional
intermediate gas pressure regulator of the "lock
up" type must be provided to reduce the
pressure to less than 14" W.C.
No rain cap -
Unrestricted
Field Provided
Inlet Screens
Recommended
Termination
Centering
Support Plate
Sealant
Outside Plate
Cover Plate
Fastener
Sealant
12" min.

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WARNING!
All threaded connections must be made using a
pipe compound that is resistant to the action of
liquefied petroleum gases. Do not use Teflon
tape on gas line threads.
Gas Piping
In the Commonwealth of Massachusetts, the gas
cock must be a “T-handle type.”
Note: Install a sediment trap (drip leg) and a
union connection ahead of the primary
manual shutoff valve on the boiler. Gas
piping should be installed in accordance with
National Fuel Gas Code, ANSI Z223.1, latest
edition, and any other local codes which may
apply; in Canada see CAN/CGA-B.149.
Note: See Pipe Capacity for Natural Gas chart
on the following page for required pipe size,
based on overall length of pipe from meter plus
equivalent length of all fittings. Approximate
sizing may be based on 1 cubic foot of natural
gas per 1,000 Btu per hour input, i.e., 500,000
Btu per hour requires about 500 cubic feet per
hour. (See "Typical Boiler Operating Conditions,"
Section 4.3, for more information.)
Meter
(not supplied)
Shutoff
(on boiler)
Natural Gas
Supply By Installer
Remote Gas Shutoff
(not supplied)
Union
Drip Leg

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Pipe Capacity for Natural Gas
Equivalent Pipe Length Maximum Capacity in Cubic Feet of Natural Gas per Hour
Pressure Drop of 0.5 inch Water Column/Equivalent Length of Pipe
(in feet)
Nominal
Iron Pipe
Size
(Inches)
Internal
Diameter
(Inches) 90º Ell
(Feet)
Tee
(Feet) 20 40 60 80 100 150 200
1/2 0.622 1.55 3.1 120 82 66 57 50 40 35
3/4 0.824 2.06 4.12 250 170 138 118 103 84 72
1 1.049 2.62 5.24 465 320 260 220 195 160 135
1- 1/4 1.380 3.45 6.9 950 660 530 460 400 325 280
1- 1/2 1.610 4.02 8.04 1460 990 810 690 620 500 430
2 2.067 5.17 10.3 2750 1900 1520 1300 1150 950 800
2- 1/2 2.469 6.16 12.3 4350 3000 2400 2050 1850 1500 1280
3 3.068 7.67 15.3 7700 5300 4300 3700 3250 2650 2280
4 4.026 10.1 20.2 15800 10900 8800 7500 6700 5500 4600
3.7.1 Gas Supply Piping by Installer
The boiler and all gas piping connections should
be pressure-tested and must be checked for
leaks before being placed into service. Test with
compressed air or inert gas if possible.
The boiler must be disconnected at the boiler
manual shut-off valve (located at the end of the
supplied gas train) from the gas supply piping
system during any pressure testing of the system
at pressures in excess of 1/2 psig (14" W.C.).
During any pressure testing of the gas supply
piping system at pressures equal to or less than
1/2 psig (14" W.C.), the boiler should be isolated
from the gas supply piping system by closing the
manual shut-off.
Some leak test solutions, including soap and
water, may cause corrosion. These solutions
should be rinsed-off with water after testing.
3.8 BOILER WATER PIPING
3.8.1 Piping Design
Water Flow in System
For proper water flow requirements see below.
Incorrect flow may result in eventual damage or
premature failure of the equipment.
Model Max Flow
GPM
Min Flow
GPM
DP ft. at
max flow
T-1000 105 52 12
T-900 90 45 12
T-750 75 37 12
Contact Triad for minimum flow at other than
maximum firing rate.

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Flow vs. DP
0
2
4
6
8
10
12
14
0 20 40 60 80 100 120
Flow (gpm )
DP (ft)
Proper flow rates may be achieved through a
combination of primary and secondary flow loops.
Multiple zones and pumps may result in different
flow rates at different times. Consideration must
be given to all possible conditions and their
consequences.
Piping With Refrigeration Machines
When installed in a two-pipe system that provides
both chilled and hot water, the control system
should be configured so as to limit the time rate of
change of temperature at the boiler. Consult your
authorized Triad boiler representative for
application guidance.
Piping With Air Handling Units
The boiler piping system of a hot water heating
boiler connected to heating coils located in air
handling units, where they may be exposed to
refrigerated air circulation, must be equipped with
flow control valves or other automatic means to
prevent gravity circulation of the boiler water
during the cooling cycle.
3.8.2 Boiler Inlet and Outlet Connections
Make water connections as the application
warrants, or at a minimum as shown, but always
in compliance with the local requirements.
Note: The boiler is furnished with 2”grooved
connections for Victaulic Style 75 Couplings.
These coupling must be used with the EPDM
Victaulic seals. Isolating valves must be
installed in both water connections for ease
of service.
The bottom connection to the boiler is the INLET
and must be used for the return from the system.
The top connection to the boiler is the OUTLET
and must be connected as the supply to the
system.
* Note: Condensate Trap must be piped to drain
in accordance with all state and local codes.
750 900 1000

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3.8.3 Boiler Water Piping by Installer
Strainer
To avoid possible contamination of the boiler with
dirt, rust or sediment from the system, a strainer
near the boiler inlet is strongly recommended.
Even new systems may contain sufficient foreign
material to eventually reduce the performance of
the heat exchanger. Adequate circulation of good
clean water is essential to maximum efficiency
and long life of the boiler.
Relief Valve and Piping
Each boiler is supplied with a pressure-relief
valve sized in accordance with ASME
requirements. The relief valve should be piped to
a suitable floor drain. Reducing couplings or other
restrictions are not permitted in the discharge
line.
Low Water Cut-off
The boiler is furnished with a probe-type low
water cut-off; no field piping is required. If the
water level in the boiler drops below the probe,
the boiler will shut down and a flashing E 12
service code will be displayed on the control
panel. The low water cutoff circuit will
automatically reset when the low water condition
clears; however the boiler controls will retain the
lockout condition until the reset button on the
display is depressed.
IMPORTANT!
The low water cutout probe only prevents boiler
operation when the water level in the boiler is
insufficient. It does not detect low water
conditions in other parts of the system.
Installation of high point vents or additional low
water safety devices to protect the system should
be considered.
Installation of external limit controls may be
required by certain codes or in certain
installations. Review applicable local codes for
details.
Drain Valve and Piping
A drain valve is installed in the inlet (system
return) header connection to the boiler. Prior to
draining the boiler for maintenance or testing,
electrical power and gas supply must be turned
off to the boiler. The boiler must then be isolated
from the system at the supply and return
connections prior to draining water from the
boiler.
Note: This drain valve is installed for draining
of the boiler water only, not the entire
system. Draining of the system through the
boiler will result in depositing sediment from
the system in the boiler which will result in
poor heat transfer characteristics of the
boiler and early boiler failure.
Condensate Drain
The condensate can be slightly acidic (pH
between 3.0 and 5.0). This may be corrosive to
some building drain systems. A condensate
neutralization system may be required.
Disposal of condensate must comply with all
state and local codes.
3.8.4 Flushing and Filling
Water Quality
Because the TRIUMPH Series boiler heat
exchanger is made of an aluminum alloy it
requires special water conditions to retain
efficiency and function properly.
IMPORTANT!
Chemicals added to the system must be
approved by the chemical manufacturer for use
in aluminum boilers.
IMPORTANT!
Under no circumstances should petroleum
based cleaning or sealing compounds be used in
the boiler system.