Instruction/ maintenance manual of the product 200 Bryan Boilers
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Date: 8-4-2010 Revision: 0 Form: 2396 Bryan S team LLC Inst allation and Operating Service Manual Triple-Flex High Efficiency Boilers.
Date: 8-4-2010 Revision: 0 Form: 2396 INSTALLATION AND OPERAT ION SERVICE MANUAL Triple-Flex 150, 200, 250, & 300 High Efficiency Boilers Bryan Steam LLC 783 North Chili Avenue * Peru, IN 46970 Phone 765.473.6651 • Fax 765.473.3074 E-mail: inquiry@bryansteam.
Date: 8-4-2010 Revision: 0 Form: 2396 Table of Contents Bryan Steam LLC .............................................................................................................................. i Installation and Operating Service Manual ........
Date: 8-4-2010 Revision: 0 Form: 2396 2.2.11 Operation Page ............................................................................................................ 22 2.2.12 Annunciation Page ......................................................
Date: 8-4-2010 Revision: 0 Form: 2396 Tables Table 1 Minimum Clearance ............................................................................................................ 2 Table 2 Electrical Requirements .....................................
Date: 8-4-2010 Revision: 0 Form: 2396 Figure 35 Outdoor Reset Sensor Config uration ............................................................................ 26 Figure 36 Air / Gas Ratio Tappings ....................................................
Date: 8-4-2010 Revision: 0 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 man ual before attempting installation of or starting th e unit. Insurance and local or state regulatory codes m ay contain additional or more stringent requi rements than those contained in this ma nual.
Date: 8-4-2010 Revision: 0 Form: 2396 BE REMOVED after the boiler is set in-place on its concrete foundation before any piping/electrical connections a re made. It is recommended that the plastic protective cover be left on as long as possible to reduce finish damage from the installation.
Date: 8-4-2010 Revision: 0 Form: 2396 valve shall be tested for leaks. 1.4.9 V ENTING O F G AS T RAIN C OMPONENTS Figure 2 Main Gas Inlet Connection Normally open vent valves (when su pplied) - These valves must be pip ed to outdoors using pipe no smaller than that of the valve.
Date: 8-4-2010 Revision: 0 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 neut ral pressure relative to the outdoors.
Date: 8-4-2010 Revision: 0 Form: 2396 specified. Where the louver and grille desig n 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 l ouv ers and grilles shall be fixed in the open position.
Date: 8-4-2010 Revision: 0 Form: 2396 Horizontal se ctions of t he flue vent system must be pitched back toward s the boiler at ¼ inch per foot to avoid condensate pooling and allow for proper drainage. Venting may be h orizontal, through the wall installation or vertical, through the roof installation.
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 are a of the opening.
Date: 8-4-2010 Revision: 0 Form: 2396 1.8.1 H YDROSTATIC T EST O F B OILERS A ND S YSTEM After completing the boiler an d burner installation, the boiler connections, fittings, attachments and adjacent pipi ng must be inspected for leaks by filling the unit with water.
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.
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.
Date: 8-4-2010 Revision: 0 Form: 2396 2.1.3 T RIPLE -F LEX L EFT S IDE V IEW 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 e xchanger and the boiler convection tube access panels.
Date: 8-4-2010 Revision: 0 Form: 2396 NOTE: The low fire displacem ent final adjustment should be made at low fire only. 3. Main gas pressure regulating and sh utoff valve actuator. The pressure regulating actuator provides slow opening fast closin g safety shutoff and air/gas ratio control.
Date: 8-4-2010 Revision: 0 Form: 2396 block. 21. Control circuit transformer. 22. 24 volt ac transformer. 23. 12 volt dc power supply. 24. SOLA hydronic and flame supervision control. 25. Repeat cycle timer. This timer will ensure that a forced shut down and pre-start sa fety check is performed at least on ce in a 24 hour period.
Date: 8-4-2010 Revision: 0 Form: 2396 Actual length and width a re 3 ⁄ 8” less than trade size shown. Filters meet UL Class 2 flame retardance requirements. Max imum temperature is 180° F. 2.1.8 T RIPLE -F LEX R IGHT F LUE C OLLECTOR V IEW Figure 11 Triple-Flex Right Flue Collector View 1.
Date: 8-4-2010 Revision: 0 Form: 2396 NOTE: The boiler name m ay be cut off on the Home page when all boilers are present for the hydronic system. The Home page also includes a System Analysis button that allo ws the user to view status information on a system-wi de (that is, multiple boiler) basis.
Date: 8-4-2010 Revision: 0 Form: 2396 2.2.5 S TATUS P AGE ► Figure 14 Status Page The status page (Figure 14) is di splayed when a boiler is selected on the Home pa ge. The status page displays the current condition of the boiler and displays some of the more important configuration settings.
Date: 8-4-2010 Revision: 0 Form: 2396 applicable for the functional group on t he page (Figure 16). Figure 16 Sample Configuration Page These parameters can be edited, and when the user is finished, control return s back to the configuration menu page.
Date: 8-4-2010 Revision: 0 Form: 2396 validates all password entry attempts with the boiler, but doesn’t conduct the validat ion itself. The boiler has sole responsibility to accept a password entry. The display gets informat ion from each boiler about the access level settings for th e status and configuration parameters.
Date: 8-4-2010 Revision: 0 Form: 2396 A verification step is required for ea ch safety parameter block that is changed. The verificatio n steps do not have to be completed immediately; the user can traver se between para meter groups before the verifications are done.
Date: 8-4-2010 Revision: 0 Form: 2396 button turns red (Figure 22 ). On all other pages and when the user i s looking at a different boiler, a notification dialog box displays indicating which boiler just locked out. Figure 21 Home Page Lockout Figure 22 Status Page Lockout Selecting the info bar will display the history dialog.
Date: 8-4-2010 Revision: 0 Form: 2396 annunciation information, and switch between heating loops (Central Heat and Domestic Hot Water), as shown in Figure 25. If a password is required to change a ny of the settings on this page, the user can p ress the Login button to enter the password.
Date: 8-4-2010 Revision: 0 Form: 2396 the user to manually control the firi ng rate while the boiler is firing. The third option can be selected to change the rpm of the blower while the boiler is off or in standby. The manual firing rate can be changed by pressin g the clear button and entering the n ew value or by using the up and down arrows.
Date: 8-4-2010 Revision: 0 Form: 2396 calibrated. When the screen i s touched in a spot and unexpected result s occur this is a good indication that the display needs to be calibrated. To calibrate the tou ch screen select the ‘ Calibrate ’ button and fo llow the on screen directions.
Date: 8-4-2010 Revision: 0 Form: 2396 (Figure 34). The normal reset curve is shown in green and the time of day is red. Figure 34 Outdoor Reset Curve ► ► CONFIGURE ► SENSOR CONFIGURATION ► (Se.
Date: 8-4-2010 Revision: 0 Form: 2396 2.2.21 C ENTRAL H EAT C ONFIGURATION ► ► CONFIGURE ► CH - CENTRAL HEAT CONFIGURATION Figure 36 Central Heat Configuration ( Central Heat Page) CH enable Dis.
Date: 8-4-2010 Revision: 0 Form: 2396 Decibel Readings Model Front Rear Tube Side Right Side TF150 55.5 58.0 59.5 58.5 TF200 62.1 65.1 66.3 65.4 TF250 77.
Date: 8-4-2010 Revision: 0 Form: 2396 2.2.23 M ODBUS C OMMUNICATION The hydronic control Global Modbus po rt is a 3- pin connector that interfaces to the following RS- 485 signals: Table 7 Modbus Term.
Date: 8-4-2010 Revision: 0 Form: 2396 30 53 Illegal Modbus read was attempted 54 Safety processor brown-out reset occurred 55 Application processor wat chdog reset occurred 56 Application processor b .
Date: 8-4-2010 Revision: 0 Form: 2396 31 129 Slow start ramp setting of zero will result in no modulation rate change 130 RESERVED 131 CH demand source was inv alid 132 CH P-gain was invalid 133 CH I-.
Date: 8-4-2010 Revision: 0 Form: 2396 32 263- 271 RESERVED 272 Abnormal Recycle: Pressure sensor fault 273 Abnormal Recycle: Safety relay drive test failed 274 Abnormal Recycle: Demand off during Pilo.
Date: 8-4-2010 Revision: 0 Form: 2396 33 323 Abnormal Recycle: Safety Relay off after 10 seconds of RUN 324 Abnormal Recycl e: Hardware flame bias 325 Abnormal Recycle: Hardware static flame 326 Abnor.
Date: 8-4-2010 Revision: 0 Form: 2396 469 Internal error: EEPROM days count address was invalid 470 Internal error: EEPROM hours count address was invalid 471 Internal error: Loc kout record EEPROM in.
Date: 8-4-2010 Revision: 0 Form: 2396 2.3 B OILER C OMMISSIONING NOTE: All of the installation inst ructions found i n section 1 must be completed before com missioning the boiler. WARNING: The following procedures must be followed carefully before putting the boiler in operation.
Date: 8-4-2010 Revision: 0 Form: 2396 WARNING: Do not open the manual main gas cock (Figure 7 item 4) before all pre checks, setups, and dry runs have been successfully completed. With a voltmeter check for the proper incomi ng main voltage and the proper control voltage from the control circuit transf ormer.
Date: 8-4-2010 Revision: 0 Form: 2396 WARNING: During pilot adjustment leave the manual main gas cock (Figure 7 item 4) closed. NOTE: Pilot gas pressures in excess of the recommended will lead to the formation of carbon hairs that will ground out the pilot igniter causing a safety shutdo wn.
Date: 8-4-2010 Revision: 0 Form: 2396 Gas Manifold Pressure (IWC) 4.4 3.6 4.0 2.0 Max RPM 6000- 7000 5100- 5500 3550- 4200 2700- 2850 Low Fire Gas Manifold Pressure (IWC) .3 .3 .2 .2 Min RPM 1200- 1600 1200- 1600 800- 950 800- 950 Table 9 Approximate Boiler Settings 2.
Date: 8-4-2010 Revision: 0 Form: 2396 2.4 T ROUBLESHOOTING To support the recommended Troubles hooting, the R7910 ha s an Alert File. Review the Alert history for possible trends that may have been occurri ng prior to the actual lockout.
Date: 8-4-2010 Revision: 0 Form: 2396 Code Description Recommended Troubl eshooting of Lockout Codes Code 15 Internal fault: Safety relay test failed due to feedback ON L 16 Internal fault: Safety rel.
Date: 8-4-2010 Revision: 0 Form: 2396 Code Description Recommended Troubl eshooting of Lockout Codes Code 32-46 Internal fault: Safety Key 0 through 14 L 47 Flame Rod to ground leakage H 48 Static flame (not flickering) 41 H 49 24VAC voltage low/ high 1.
Date: 8-4-2010 Revision: 0 Form: 2396 42 Code Description Recommended Troubl eshooting of Lockout Codes Code 68 ILK ON This lockout occurs when t he interlock string is closed before the blower starts. The airflow switch is the only device in the interlock string that will open w hen in standby.
Date: 8-4-2010 Revision: 0 Form: 2396 43 Code Description Recommended Troubl eshooting of Lockout Codes Code 2. Replace the stack sensor. 3. If previous steps are correc t and fault persists, replace the module 96 Outdoor sensor fault 1. Check wiring and correct any possible errors.
Date: 8-4-2010 Revision: 0 Form: 2396 44 Code Description Recommended Troubl eshooting of Lockout Codes Code 122 Lightoff rate proving failed L 123 Purge rate proving failed 1. Check wiring and corre ct any potential wiring errors. 2. Check VFDs ability to change sp eeds.
Date: 8-4-2010 Revision: 0 Form: 2396 45 Code Description Recommended Troubl eshooting of Lockout Codes Code 1. Check wiring and corre ct any potential wiring errors.
Date: 8-4-2010 Revision: 0 Form: 2396 46 Code Description Recommended Troubl eshooting of Lockout Codes Code 165 Block intake OFF 1. Check wiring and correct any errors. 2. Inspect the Block Intake Switch to make sure it is working correctly. 3. Reset and sequence the module.
Date: 8-4-2010 Revision: 0 Form: 2396 Code Description Recommended Troubl eshooting of Lockout Codes Code 196 Invalid ignition source settin g L 197 Invalid in terlock open response setting L 198 Inva.
Date: 8-4-2010 Revision: 0 Form: 2396 Code Description Recommended Troubl eshooting of Lockout Codes Code 219 Invalid Stack limit response setting L 220 Unconfigured Delta T limit setpoint setting L 2.
Date: 8-4-2010 Revision: 0 Form: 2396 49 Code Description Recommended Troubl eshooting of Lockout Codes Code 241- 255 RESERVED.
Date: 8-4-2010 Revision: 0 Form: 2396 50 Section 3 Care and Maintenance.
Date: 8-4-2010 Revision: 0 Form: 2396 WARNING: The boiler area should be kept free of combustible materials, gasoline and other flammable liquids. The boiler and venting system must be kept free of obstructions of the air louvers. The following procedures must be conducted as outlined to prevent damage to and assure safe operation of the boiler.
Date: 8-4-2010 Revision: 0 Form: 2396 3.1.3 D RAINING T HE S YSTEM A clean neutral hot water system sho uld not be drained, except for an emergency or when unavoidable for servicing of equipment. See Section 3.3 for wate r treatment required when refilling.
Date: 8-4-2010 Revision: 0 Form: 2396 not less than four times a year, and possibly more frequently as the l ocal water conditions may indicate. All water introduced into the boiler should be softened a nd should include a n oxygen scavenger like so dium sulfite.
Date: 8-4-2010 Revision: 0 Form: 2396 inspected at least annually. Any accumulation of soot or debris should be thoroughly cleaned out. 2. If the yearly inspection of the boiler tube surfaces reveals a build-up of soo t (carbon), the tubes surfa ces should be thoroughly brushed.
Date: 8-4-2010 Revision: 0 Form: 2396 55 Section 4 Lead Lag.
Date: 8-4-2010 Revision: 0 Form: 2396 There are parameters that are available to set the features for Lead Lag. Many of the descriptions used are internal functions or tables. The names help d efine the functions but are not controlled or selecta ble outside Sola, unless noted as a pa rameter.
Date: 8-4-2010 Revision: 0 Form: 2396 or drop a stage if the run-l imiting is providing too much heat (for exa mple if a stage is running at a higher-than command ed rate due to anti- condensatio n).
Date: 8-4-2010 Revision: 0 Form: 2396 4.3 S YSTEM W IRING H OOKUP Figure 40 LL / Multi-Boiler Field Wiring 58.
Date: 8-4-2010 Revision: 0 Form: 2396 4.4 L EAD -L AG O PERATION This is a summary of the functional capability of the embedded lead-lag on the Sola control. OEM Configurable parameters may be adjusted as part of the OEM facto ry configuration and in the field using the System Display with appropriate password perm ission s.
Date: 8-4-2010 Revision: 0 Form: 2396 Baseload common (i) “BL” for baseloa d (ii)User selection 0 – 100 % (d)Use existing timeout, Done button, and Next button functionality to enter these parameters. (e)User selections will be selected by MMI. (i) T he local display does not adhere to the PCB (OEM parameter selections used by S7999).
Date: 8-4-2010 Revision: 0 Form: 2396 algorithm. (Any Solas set to Use First will precede any that are set t o Equalize Run time.) If set to Use Last, then this burner will be used only after all Use First and Equ alize Runtime Solas have been brought online.
Date: 8-4-2010 Revision: 0 Form: 2396 off all slaves and enters an idle or standby condition. 4.7.2 P ERIODIC D ATA P OLLING MESSAG ES The LL master uses polling to discover new slave Sola devices and to periodically refresh the information it has about a kno wn slave Sola devices.
Date: 8-4-2010 Revision: 0 Form: 2396 momentary communication problem s and to act on these if they are excessive. • StatusReadFaultCounter : Used to tolerate momentary communication problem s and to act on these if they are excessive.
Date: 8-4-2010 Revision: 0 Form: 2396 LL CH DEMAND SWITCH: DISABLE, STAT, ENVIRONCOM REMOTE STAT The inputs that can function as the CH demand switch are: STAT, EnvironCOM Remote Stat. If the CH demand swit ch value is Disable , the LL master does not respond to CH d emand.
Date: 8-4-2010 Revision: 0 Form: 2396 following sources of dem and. All sources that are currently calling for he at will be true (multiple items may be true at the sa me time) except when WWSD is active, then CH demand is inhibited.
Date: 8-4-2010 Revision: 0 Form: 2396 that way until the 4- 20mA signal is stable again. LL CH 20MA WATER TEMPERATURE: TEMPERATURE OR NONE CH 4MA WATER TEMPERATURE: TEMPERATURE OR NONE These provide the 20mA and 4mA temperatures for the interpolation curve.
Date: 8-4-2010 Revision: 0 Form: 2396 algorithms are used. Additionally: 4.7.7 R ATE A DJUSTMENT When the Slave dropout/return compensation parameter specifie s a rate adjustment and a rate compensati.
Date: 8-4-2010 Revision: 0 Form: 2396 Lead Lag burner de mand will be present when Frost protection burne r demand is true, as described in the section on Frost protection. For the CH, and DHW deman d sources, Lead Lag burner demand will be true when one of these is true and also setpoi nt demand from the hysteresis block is true.
Date: 8-4-2010 Revision: 0 Form: 2396 the LL master is not asking for less heat tha n this, then the underflow rate is 0%. If it is at this location and the LL master is asking for 10% less than the threshold value, then the underflow rate is -10%. If the last stage is 5% above the threshold then the underflow rate is 5%.
Date: 8-4-2010 Revision: 0 Form: 2396 4.7.10 B URNER D EMAND The stager checks the Master’s LL burner demand. If this demand is off all slaves with SlaveStates of AddStage, SuspendStage, or Firing are set to Available by the Rate Allocator turning them all off and the StagerState is set to be Idle.
Date: 8-4-2010 Revision: 0 Form: 2396 Stager can execute an AddStage or DropStage request. Add Stage Methods Various methods can be used to determi ne when a new stage should b e added. The intern al algorithms that generate AddStageRequests are called Add-stage methods.
Date: 8-4-2010 Revision: 0 Form: 2396 that: Drop-Sta ge detection time is used with DropStageDetectTimer In the descrip tions below, the relevant parameter is referred to as LL – Dro p Stage detection time N } .
Date: 8-4-2010 Revision: 0 Form: 2396 hysteresis is ignored if one or more lag boile rs are firing. • If LDSE is enabled: The Burner Off threshold provided by LL off hysteresis is ignored also for the lead boiler when it is firing solo (i.e. when no lag boilers are firing).
Date: 8-4-2010 Revision: 0 Form: 2396 assigning an ordering numbe r and that the lowest numbers are the first to be added. • Any Available slaves that have a mode of Use First will have the lowest ordering numbers.
Date: 8-4-2010 Revision: 0 Form: 2396 StagingOrder numbers of all Firing boilers. If only one Firing boiler is found, or none are found, then this selection function returns a value that indicates no boiler may be dropped. Otherwise it returns an identifier for the boiler having the highest StagingOrder number .
An important point after buying a device Bryan Boilers 200 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Bryan Boilers 200 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Bryan Boilers 200 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Bryan Boilers 200 you will learn all the available features of the product, as well as information on its operation. The information that you get Bryan Boilers 200 will certainly help you make a decision on the purchase.
If you already are a holder of Bryan Boilers 200, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Bryan Boilers 200.
However, one of the most important roles played by the user manual is to help in solving problems with Bryan Boilers 200. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Bryan Boilers 200 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
