Atlas Triton T-80, Triton-100, Triton-150, Triton-200 Operating Manual

Triton Series™

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High Efﬁ ciency Boiler

Models: T80 - T200

Installation, Operating & Maintenance Manual

T-200

• Designed and Manufactured in Accordance with ASME Code Section IV

• ETL Tested and Listed: ANSI Z21.13-2010 / CSA 4.9-2010

• AHRI IBR Listing per BTS 2000

• ASME Section IV H-Stamped

• SCAQMD 1146.2

• CRN

“Quality, value and service since 1919”

Contents

A. Introduction ............................................................. 1

A.1. Standard Features & Bene ts .......................... 1

A.2. Miscellaneous ................................................... 1

B. Pre-Installation ........................................................ 3

B.1. Determining Unit Location ................................ 3

B.2. Connection Information .................................... 4

B.3. Combustion and Ventilation Air ......................... 4

B.4. Conventional Flue Venting ................................ 6

C. Installation ................................................................ 9

C.1. Product Inspection ............................................ 9

C.2. Rating and Certi cations ................................ 10

C.3. Installation Codes ............................................11

C.4. Preparing the Boiler ........................................11

C.5. Water System Piping .......................................11

C.6. Gas Supply .................................................... 12

C.7. Pump Installation ............................................ 13

C.8. Electrical ......................................................... 13

C.9. Flue Venting ................................................... 14

C.10. Condensate Drains ..................................... 15

C.11. Modular System Installations ....................... 15

D. Start Up Instructions ............................................ 18

D.1. Water Quality and Treatment ......................... 18

D.2. Filling The System ......................................... 18

D.3. Factory Test Report (FTR) .............................. 19

D.4. Veri cation ...................................................... 19

D.5. Start-Up Detail ............................................... 19

D.6. Start Up And Maintenance Tests ................... 19

D.7. Startup Component Adjustments ................... 22

D.8. Shutting Down The Unit................................. 23

D.9. After Startup Checklist ................................... 23

E. Maintenance .......................................................... 25

E.1. Maintenance Detail ........................................ 25

E.2. Maintenance Log ........................................... 27

F. Troubleshooting ..................................................... 28

F.1. Controller lockout and hold codes. .................. 28

F.2. Controller alert codes. ..................................... 37

G. Warranty ............................................................... 42

A 1

A. INTRODUCTION

Congratulations on choosing the Atlas™ Triton Series™ high ef ciency boiler! The Triton Series™ combines solid engineering and innovative design with all the quality and features you would expect from a company with a proud 100 year tradition of building safe, reliable, high quality products in the USA.

Your Triton boiler is E.T.L. tested, certi ed and listed and is constructed and stamped in accordance with Section IV of the ASME Code. The boiler is also AHRI IBR Listed per BTS 2000.

A.1. STANDARD FEATURES & BENEFITS

A.1.a. Compact Water Tube Design

The Triton is a compact, vertically  red water tube boiler utilizing a double row, high  nned copper tube design to maximize ef ciency while minimizing the boiler footprint. The gasketless cast iron headers are a 4-pass con guration.

A.1.b. Quality Construction Built in the USA.

Triton Series™ boilers are 100% designed and manufactured in the USA in accordance with ASME Code Section IV. The  nest quality components are used for many years of trouble free service.

A.1.c. Advanced Pre-mix Gas Delivery and

Combustion System

Triton Series™ boilers provide clean, ef cient combustion with very low emission levels. The gas delivery system is powered by a combustion blower which forces air and gas into the venturi which pre-mixes the gas before entering the combustion chamber. The Triton burner is a knit metal alloy  ber design which optimizes heat transfer, minimizes surface temperatures, and is resistant to clogging.

A.1.f. Ease of Installation and Maintenance

Triton Series™ boilers include a heavy steel base with pallet jack access for ease of installation and movement. Routine maintenance and service are made simple with easy access to all components front and rear. The entire heat exchanger is easily removable and replaceable using hand tools only, without performing welding or cutting operations and without the use of gaskets.

A.1.g. Smart Boiler Control System

Triton Series™ boilers are factory equipped to accept the

accessory Smart Boiler Control System™. The Ace Heating

accessory Smart Boiler Control System™. The Ajax Boiler

Solution, LLC proprietary Smart Boiler Control is a web-based

Inc. proprietary Smart Boiler Control is a web-based system

system providing 24/7 access to the boilers operational

providing 24/7 access to the boilers operational perfor-

performance from any computer or smart phone with an internet

mance from any computer or smart phone with an internet

connection. The system allows personnel to conveniently

monitor critical boiler information including inlet/ outlet

temperatures, stack temperatures, firing rates, cycle counts

and much more can be easily accessed and analyzed, to

maximize boiler performance and safety

maximize boiler performance and safety.

A.2. MISCELLANEOUS

This manual covers installation, maintenance, and operat-

This manual covers installation, maintenance, and operating

ing instructions for Atlas™ Triton Series™ High Ef ciency

instructions for Atlas™ Triton Series™ High Efficiency

hot water boilers. Please review the entire manual carefully

before installation or operation, and keep it in legible condi-

before installation or operation, and keep it in legible

tion with the boiler at all times for reference. If this manual

condition with the boiler at all times for reference. If this

is misplaced or lost, check the Ajax Boiler Inc. website,

manual is misplaced or lost, check the Ace Heating

www.ajaxboiler.com to print an electronic copy or contact

Solutions, LLC. website, www.aceheatingllc.com to print an

your local Ajax Boiler Inc. representative.

electronic copy or contact your local Ace Heating Solutions, LLC. representative. The following terms and signs are used

The following terms and signs are used throughout this

throughout this manual to bring attention to the presence of

manual to bring attention to the presence of hazards of

hazards of various risk levels, or to important information

various risk levels, or to important information concerning

concerning product life.

product life.

DANGER:

A.1.d. Controls

The Triton Series™ uses the advanced Honeywell SOLA control system and high-resolution color LCD touch screen Operator Interface display. This system provides the user clear, quick and easy access to all of the system’s features and capabilities from a single, user-friendly interface. Up to 8 Triton Series™ boilers can be operated in a lead-lag installation using standard controls.

A.1.e. Heavy Duty, Solid Steel Cabinet

Triton Series™ boilers include a solid, 18 gauge steel cabinet. The cabinet is  nished inside and out with a tough UV rated, outdoor quality powder coat paint.

Indicates an imminently hazardous situation

which, if not avoided, will result in death, serious

injury or substantial property damage.

WARNING:

Indicates a potentially hazardous situation which,

if not avoided, could result in death, serious injury

or substantial property damage.

A 2

CAUTION:

Indicates a potentially hazardous situation which,

if not avoided, may result in moderate or minor

injury or property damage.

NOTE:

Indicates special instructions on installation,

operation, or maintenance which are important

but not related to personal injury hazards.

WARNING: If the information in this manual is not followed exactly, a  re or explosion may result causing property damage, personal injury or loss of life.

- Do not use or store gasoline or other  ammable vapors and liquids in the vicinity of this or any other appliance.

- 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.

• Immidiately call your gas supplier from a neighbors phone. Follow the gas suppliers instructions.

• If you cannot reach your gas supplier, call the  re department.

- Installation and service must be performed by a quali ed installer, service agency or the gas supplier.

Touch Screen

T-200

Control Display

Front Door

Panel

Gas Inlet

Valv e

Return Water

Inlet

Front Panel Rear Panel

Pallet Jack

Base

Rear Door

Panel

Pressure

Flow

Switch

Hot Water

Outlet

Condensate

Drain

Relief

Valv e

Combustion

Main System

FRONT REAR SIDE

Temp./

Pressure

Gauge

Manifold

Side Panel (L)

Flue

Collar

Air Inlet

Drain

Gas Inlet

Valv e

Figure A.1.1. Features and Components

B 3

B. PRE-INSTALLATION

ce Heating Solutions, LLC. strongly recommends that this

Ajax Boiler Inc. strongly recommends that this manual be

manual be

reviewed thoroughly before installing your Triton Series™

high ef ciency boiler. The factory warranty does not apply

high efficiency boiler. The factory warranty does not apply

to boilers that have been improperly installed or operated

(Refer to the warranty in chapter 8). If, after reviewing this

manual, you still have questions not covered in this manual,

manual, you still have questions not covered in this

please contact the manufacturer or your local Ajax Boiler

manual,

Inc. representative.

please contact the manufacturer or your local Ace Heating Solutions, LLC representative.

This section is intended to provide guidance in planning,

design, construction and preparing the space prior to physi-

design, construction and preparing the space prior to

cal installation of the boiler, its venting, and the necessary

physical

electrical and plumbing connections.

installation of the boiler, its venting, and the necessary electrical and plumbing connections.

NOTE:

The installation must conform to the requirements of the authority having jurisdiction or, in the absence of

REAR SIDE

Figure A.2. Dimensions

such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1.

The boiler must not be installed on carpeting.

Local and state codes requiring greater clearances supersede these minimum clearances.

• Multiple appliances may be installed side by side with 6” clearance between adjacent appliances to allow suf cient air for the pilot blower. It is recommended to maintain 16” clearance between adjacent boilers to allow access for service to the rear of the unit.

• The minimum clearance between a Triton Series™ boiler and a storage tank is 6”. For alcove installations, the minimum clearance to combustible construction is 6” to side, 24” to rear walls and 22” from top of the unit to the ceiling. The front alcove shall remain open. This will allow boiler to be serviced in its location without movement or removal of the unit.

B.1. DETERMINING UNIT LOCATION

The boiler should be mounted on a level, structurally sound surface. The boiler is not approved for mounting on a combustible surface and Gas fueled equipment installed in enclosed parking garages must be located at least 18” above the  oor.

A: Total Height

B: Total Width

C: Base Height

D: System Drain Height

E: Condensate Drain Ht.

F: Air Intake Height

G: Flue Collar Height

H: Inlet/ Outlet Height

J: Syst. Drain Clearance

K: Air Intake Clearance

L: Flue Collar Clearance

M: Gas Valve Clearance

N: Manifold Clearance

P: Inlet/ Outlet Clearance

Q: Drain/ Flue Center

R: Air Intake Center

S: Gas Valve Height

T: Gas Valve Center

The optimal location for the boiler is as close to an exterior

MODEL

T-80 T-100 T-150 T-200

60 11/16 60 11/16 68 11/16 76 11/16

31 1/2 31 1/2 31 1/2 31 1/2

3 3/8 3 3/8 3 3/8 3 3/8

2 1/4 2 1/4 2 1/4 2 1/4

10 11/16 10 11/16 10 11/16 10 11/16

15 11/16 15 11/16 16 3/4 16 3/4

20 7/16 20 7/16 22 23 15/16

32 13/16 32 13/16 40 13/16 48 13/16

4 5/8 4 5/8 4 5/8 4 5/8

1111

7 1/8 7 1/8 7 1/8 7 1/8

6 3/8 6 3/8 6 3/8 6 3/8

12 3/4 12 3/4 12 3/4 12 3/4

16 16 16 16

15 3/4 15 3/4 15 3/4 15 3/4

6 11/16 6 11/16 6 11/16 6 11/16

39 7/8 39 7/8 47 7/8 55 7/8

9 15/16 9 15/16 9 15/16 9 15/16

Table A.2. Triton Dimensions (inches).

All measurements are approximate and subject to change.

wall as possible to reduce vent loss and to minimize costly stainless steel  ue venting. Maintain minimum speci ed clearances for adequate operation. All installations must allow suf cient space behind the boiler to service vent connections, water pipe connections, piping and other auxiliary equipment, as well as the appliance.

MODEL

Top Clearance: 18” 18” 18” 18”

Front Clearance: 36” 36” 36” 36”

Side Clearance: 6” 6” 6” 6”

Bottom Clearance: 0” 0” 0” 0”

Figure B.1.1. Triton Minimum Clearances Chart.

T-80 T-100 T-150 T-200

B 4

CAUTION:

• Locate the unit so that the condensate can be treated and piped to meet city and local code requirements.

• The boiler shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler operation or service (circulator replacement, control replacement, etc.)

• Keep the area around the unit(s) free from combustibles and  ammable liquids.

• It is highly recommended that you allow suf cient space in front and the rear of the unit for replacement and adjustment of all parts requiring such attention.

B.1.a. Outdoor Installations (Optional)

CAUTION:

Triton Series™ boilers are available for certi ed outdoor installations.

• Boilers must not be installed under an overhang that is less than 3’ from the top of the vent terminal.

• Three sides must be open in the area under the overhang.

• Roof water drainage must be diverted away from boiler(s) installed under overhangs.

B.1.b. Installations at Elevation.

Rated inputs are suitable for up to 2,000 ft.. elevation without de-rating. Consult the factory for installations over 2,000 ft.. above sea level. No hardware changes are required to the unit. (Adjustments may be required).

B.2. CONNECTION INFORMATION

NOTE:

The boiler, when used in connection with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler.

The boiler piping system of a hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with  ow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.

All plumbing and electrical connections are conveniently made at the rear of the boiler without the need to remove any panels or components.

MODEL

Inlet Temp.

Outlet Temp.

Rec. Flow Rate (gpm)

Pressure Drop For Rec. Flow

Min. Flow Rate (gpm)

Max. Flow Rate (gpm)

Cold Water Inlet

Combustion Air Inlet

MODEL

Gas Connection: 1” 1” 1” 1 1/4”

Water Connection (In): 3” MPT 3” MPT 3” MPT 3” MPT

Water Connection (Out): 3” FPT 3” FPT 3” FPT 3” FPT

Vent Intake: 8” 8” 8” 8”

Exhaust Vent: 6” 6” 8” 8”

System Drain 1 1/4” 1 1/4” 1 1/4” 1 1/4”

Condensate Drain 1/2” 1/2” 1/2” 1/2”

Figure B.2.1. Piping Connection Sizing Chart.

T-80 T-100 T-150 T-200

34-69 43-85 65-129 85-172

Table A.1. Triton Recommended Flow Rates.

Electrical Connection

Gas Inlet

Hot Water Outlet

Exhaust Vent

Condensate Drain

System Drain

Figure B.2.1. Connection Locations

T-80 T-100 T-150 T-200

B.3. COMBUSTION AND VENTILATION AIR

WARNING:

• The lack of adequate combustion air is the single biggest operating problem encountered with gas ﬁ red water boilers.

B 5

• Use of the boiler in construction areas where  ne particulate matter, such as concrete dust or drywall dust, is present may result in damage to the boiler that is not covered by the warranty. If operated in a construction environment, a clean source of combustion air must be provided directly to the boiler.

• Your Triton Series™ boiler is equipped with a  lter to help prevent such an occurrence above and must be checked at least every month. A single replacement  lter is located inside the control box.

B.3.a. Indoor Units (Standard)

The boiler must be supplied with suf cient quantities of non–contaminated air to support proper combustion and equipment ventilation. Triton Series™ boiler combustion air can be taken using the boiler room air or may be vented directly outside.

It is generally recommended to take combustion air from a well ventilated boiler room whenever possible. However when using direct combustion air venting, the boiler is capable of up to 30 ft. of equivalent venting. If more than 30 ft. of equivalent venting is required, an enlarged vent diameter may be used to extend maximum vent lengths, but must be properly sized to allow for suf cient combustion air to be supplied to the boiler.

All installations must comply with the requirements of the National Fuel Gas Code, NFPA 54, Canada B149, and all local codes.

• Note: All additional gas  red equipment should be considered when calculating the necessary air supply.

B.3.b. Direct Vent (Ducted Combustion Air)

If outside air will be drawn through the intake vent directly to this unit for combustion:

• The exhaust vent must be installed with a slight upward slope of not more than ¼ inch per foot of horizontal run to vent terminal.

• The exhaust vent must be insulated through the length of the horizontal run.

• Intake and exhaust vents with vertical termination should have a rain cap installed.

• It is recommended to install a drain on the exhaust vent.

In cold climates, and to mitigate potential freeze up,

• In cold climates, and to mitigate potential freeze up,

ce Heating Solutions, LLC highly recommends the

Ajax Boiler Inc. highly recommends the installation of a

installation of a motorized sealed damper to prevent

motorized sealed damper to prevent circulation of cold

circulation of cold air through the boiler during the non –

air through the boiler during the non – operating hours.

operating hours. When installing motorized damper

When installing motorized damper actuator with switch

actuator with switch contacts, prove the damper is fully

contacts, prove the damper is fully open to prevent unit

open to prevent unit from firing when damper is not fully

from  ring when damper is not fully open.

open.

B.3.c. Conventional Combustion Air Supply

U.S. Installations

All Air from inside the building

NOTE:

• In calculating free area, the required size of the opening for combustion, ventilation, and dilution air shall be based on net free area of each opening. If free area through a design of louver or grill is known, it shall be used in calculating the size opening required to provide the free area speci ed. For additional information, refer to the latest NFGC code requirements.

• Provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1. In Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.

• In order to protect electrical components, the boiler room ambient air temperature shall not exceed 100

• The equipment room MUST be provided with properly sized openings to assure adequate combustion and ventilation air when unit is installed with a basic Category IV venting system.

If all combustion air is drawn from inside the building and the mechanical equipment room does not receive air from outside, the following applies:

• The mechanical room must be provided with two permanent openings communicating directly with additional room(s) of suf cient volume so that the combined volume of all spaces meets the criteria for an uncon ned space. (An uncon ned space is de ned as a space whose volume is more than 50 cubic feet per 1,000 BTUH of the aggregate input rating of all appliances installed in that space. (NFGC).

• Each opening must have a minimum free area of 1 sq. in. per 1,000 BTUH of the total input rating of all

gas utilization equipment in the mechanical room.

• One opening must commence within 12” of the top, and one opening must commence within 12” of the bottom of the room.

B 6

NOTE:

Ajax Boiler Inc. recommends that one opening shall com-

ce Heating Solutions, LLC recommends that one opening

mence with 6” from the top and one opening shall com-

shall commence with 6” from the top and one opening shall

mence 6” from the bottom. The combined area of the two

commence 6” from the bottom. The combined area of the two

openings should not be less than 200 sq. in. for the  rst

openings should not be less than 200 sq. in. for the first

100,000 BTUH boiler input, and 100 sq. in. for each ad-

100,000 BTUH boiler input, and 100 sq. in. for each additional

ditional 100,000 BTUH boiler input.

100,000 BTUH boiler input.

All Air from Outdoors

If all the combustion air is drawn from the air outside the building, and the mechanical equipment room directly communicates with outdoor air, either of the following methods can be used:

Louvers and grilles.

NOTE:

The required size openings for combustion, ventilation and dilution air shall be based on the net free area of each opening. Where free area through a louver or grille design is known, it shall be used in calculating the size opening required to provide the free area speci ed. Where the louver and grille design, and free area are not known, it shall be assumed that wood louvers will have 25% free area, and metal louvers and grilles will have 75% free area (NFGC).

Canadian Installations

Method 1

• The mechanical equipment room must be provided with two permanent openings. One commencing within 12” of the top and one commencing within 12” from the bottom of the room.

• The openings must communicate directly, or by ducts, with the outdoors

• Each opening must have a minimum free area of 1 sq. in. per 4,000 BTUH of all equipment in the room when the opening is communicating directly with the outdoors or through vertical ducts. The minimum free area required for horizontal ducts is 1 sq. in. per 2,000 BTUH of the total input rating to all the equipment in the room.

(For addition information, refer to the latest NFGC)

Method 2 (normally applied in cold climate regions):

• The mechanical equipment room must be provided with at least one permanent opening, commencing within 12” of the top of the enclosure.

• The opening must communicate directly or by ducts with the outdoors.

• The opening must have a minimum free area of 1 sq. in. per 3,000 BTUH of the total input rating of all equipment in the room, or no less than the sum of the areas of all vent connectors in the con ned space.

CAUTION:

All combustion air must be drawn from the outside air of the building; the mechanical equipment room must communicate directly with outdoor air.

WARNING:

Care must be taken to ensure that the equipment room is

not under negative pressure conditions.

• Ventilation of the space occupied by the boiler shall be provided by an opening(s) for ventilation air at the highest practical point communicating with the outdoors. The total cross-sectional area of such an opening(s) shall be at least 10% of the area required in (2) below, but no less than 10 sq. in.

• For boilers using a barometric damper vent system there shall be a permanent air supply opening(s) having a cross section area of not less than 1 sq. in. per 7,000 BTUH up to and including 1 million BTUH, plus 1 sq. in. per 14,000 BTUH in excess of 1 million BTUH. This opening(s) shall be located at or ducted to a point no more than 18” nor less than 6” above  oor level. The duct can also “goose neck” through the roof. The duct is preferred to be straight down and terminated 18” from the  oor, but not near the piping. This air supply opening requirement shall be in addition to the air opening for ventilation air required in (1). (above)

(For additional information, refer to the latest NFGC)

WARNING:

Do not use the “one permanent opening” method if the

equipment room is under negative pressure conditions or the equipment is common vented with other gas  red appliances.

For additional information, refer to CGA, B149

B.4. CONVENTIONAL FLUE VENTING

CAUTION:

Proper  ue venting is critical for the safe and ef cient

operation of the boiler.

B 7

Deﬁ nition of ANSI Categories for High Efﬁ ciency Appliances

• Boilers are divided into four vent type categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent. Atlas™ Triton Series™ Boilers require Category IV venting. (See NFGC, NFPA 54, Section 7 “Venting Equipment” for more detailed information).

• Category IV: A boiler which operates with a positive

vent pressure and with a gas temperature that may cause excessive condensate production in the vent.

NOTE:

This de nition applies to the appliance and does not necessarily re ect the performance of the connected vent system.

• For additional information on appliance categorization, see appropriate ANSI Z21 Standard and the NFGC (US), or CGA (Canada) B149, or applicable provisions of local building codes.

• Triton Series™ boilers are designed to operate with a chamber pressure of 0 to +0.5” WC. The boiler is capable of 100 feet of vertical equivalent exhaust when equipped with the standard exhaust vent. When more than 100 feet of exhaust venting is used, the chamber pressure could increase beyond the maximum designed +0.5” WC. An optional enlarged vent may be used to increase vent runs in case more than the 100 ft. maximum is needed, however venting must be designed by a professional engineer to ensure the boiler chamber pressure stays within the designed range. Boiler vents must be constructed of AL29-4C or similar suitable material acceptable for use with exposure to condensate.

WARNING:

Using improper venting materials can result in per-

sonal injury, death or property damage.

U.S. Installations

Refer to the latest edition of the National Fuel Gas Code.

• Vent must terminate at least 4 ft. below, 4 ft. horizontally from, or 1 ft. above any door, window or gravity air inlet to the building.

• The vent must not be less than 7 ft. above grade when located adjacent to public walkways.

• Terminate the vent at least 3 ft. above forced air inlet located within 10 ft..

• The vent must terminate at least 4 ft. horizontally, and in no case above or below unless 4 ft. horizontal distance is maintained, from electric meters, gas meters, regulators, and relief equipment.

• Terminate the vent at least 6 ft. away from adjacent walls.

• Do not terminate vent closer than 5 ft. below roof overhang.

• Terminate vent at least 1 ft. above grade, including snow line.

• Multiple direct vent installations require a 4 ft. clearance between the ends of vent caps located on the same horizontal plane.

WARNING:

Canadian Installations

Refer to the latest edition of CGA, B149 Installation

Code.

• A vent shall not terminate directly above a paved sidewalk or driveway which is located between two single family dwellings and serves both dwellings.

• A vent shall not terminate less than 7 ft. above a paved sidewalk or paved driveway located on public property.

• A vent shall not terminate within 6 ft. of a mechanical air supply inlet to any building.

• A vent shall not terminate above a meter/regulator assembly within 3 ft. horizontally of the vertical center line of the regulator.

• A vent shall not terminate within 6 ft. of any gas service regulator.

• A vent shall not terminate less than 1 ft. above grade level.

• A vent shall not terminate within 3 ft. of a window or door which can be opened in any building, any non – mechanical air supply inlet of any other appliance.

• A vent shall not terminate underneath a verandah, porch or deck, unless the verandah, porch or deck is fully open on a minimum of two sides beneath the  oor, and the distance between the top of the vent termination and the underside of the verandah, porch or deck is greater than 1 ft..

Vent Termination Location

NOTE:

During winter months check the vent termination cap and make sure no blockage occurs from buildup of snow and ice. Condensate can freeze on the cap. Frozen condensate on the vent cap can result in a blocked  ue.

• Give special attention to the location of the vent termination to avoid possibility of property damage or personal injury.

B 8

• Gases may form a white vapor plume in the winter. The plume could allow hazardous  ue gas in through an open window or obstruct a window view if the termination is installed near windows.

• Prevailing winds, in combination with below freezing temperatures, can cause freezing of condensate and water/ice build up on building, plants or roofs.

• The bottom of the vent terminal and air intake shall be located at least 12” above grade, including normal snow line.

• Non-insulated single wall Category IV metal vent pipe shall not be used outdoors in cold climates for venting gas– red equipment without insulation.

• Through-the-wall vents for Category IV appliances shall not terminate over public walkways or over an area where condensate or vapor could be detrimental to the operation of regulators, relief valves, or other equipment.

• Locate and guard vent termination to prevent accidental contact by people or pets.

• Do not terminate vent in a window well, stairwell, alcove, courtyard or other recessed area.

• Do not terminate above any door, window, or gravity air intake. Condensate can freeze, causing ice formations.

• Locate or guard vent to prevent condensate from damaging exterior  nishes. Use a rust resistant sheet metal backing plate against brick masonry surfaces.

• Do not extend exposed vent pipe outside of building beyond minimum distance required for vent termination. Condensate could freeze and block vent pipe.

C. INSTALLATION

For Your Safety:

C 9

WARNING:

• Altering any Atlas™ Triton Series™ boiler’s pressure

ltering any Atlas™ Triton Series™ boiler’s pressure

vessel by installing replacement heat exchangers,

tube bundles, coils or any ASME parts not manufac-

tube bundles, coils or any ASME parts not manufactured

tured and/or approved by Ajax Boiler Inc. will instantly

and/or approved by Ace Heating Solutions, LLC will

void the ASME and E.T.L. rating of the vessel and

instantly void the ASME and E.T.L. rating of the vessel

any warranty on the vessel. Altering the ASME or

and any warranty on the vessel. Altering the ASME or

E.T.L. ratings of the vessel also violates national,

state, and local codes.

• Installation and service must be performed by a quali ed installer, service agency or gas supplier.

• Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury, loss of warranty, exposure to hazardous materials or loss of life. Review the information in this manual carefully.

• Make sure the gas on which the boiler will operate is the same as that speci ed on the boiler rating plate (natural gas/propane).

• Caution when servicing gas train components. Propane (LPG) is heavier than air and may be trapped in pipes, vents, combustion chamber, or other areas. Always handle with care.

• Should overheating occur or if the gas supply valve fails to shut, do not turn off or disconnect the electrical supply to the boiler. Instead, shut off the gas supply at a location external to the boiler.

• Do not use this boiler if any part has been under water. Immediately call a quali ed service technician to inspect the boiler and to replace any part of the control system or any gas control which has been under water.

• To minimize the possibility of improper operation, serious injury,  re, or damage to the boiler:

1. Always keep area around the unit(s) free of chlorine, combustible materials, gasoline, and other  ammable liquids and vapors.

2. Water to be heated in the boiler should be free or have low levels of chlorine or other chemicals or water conditions that would be harmful to the copper heat exchanger. Boiler room ambient temperature shall not exceed 100 degrees F.

3. Boiler should never be covered or have any blockage to the  ow of fresh air to the boiler.

• Risk of electrical shock. More than one disconnect switch may be required to de–energize the equipment

before servicing.

• When servicing ceramic  ber based refractory or insulation blanket, gloves and respirators should be worn to reduce exposure to airborne refractory ceramic  bers.

Do not store or use gasoline or other  ammable vapors and liquids or other combustible materials in the vicinity of this or any other appliances. To do so may result in an explosion or  re.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance

• Open any windows and secure area

• 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  re department.

NOTE:

• In order to meet commercial hot water needs, the high limit safety control on this hot water boiler is adjustable up to 240 degrees F. by the OEM or installer only.

• Safety and energy conservation are factors to consider when setting the temperature aquastat on the unit. The most energy–ef cient operation will result when the temperature setting is the lowest that satis es the needs of the application.

C.1. PRODUCT INSPECTION

1. Upon receipt of the boiler, visually inspect the external packaging and unit for damage. If the packaging or boiler is damaged, make a note to that effect on the Bill of Lading when signing for the shipment.

NOTE:

The boiler packaging is equipped with a tip and tell label. If label indicates boiler has been tipped over during shipping, remove crate and inspect before trucker leaves

2. Remove the shipping carton from the boiler and inspect it internally for both damage, and accuracy of the unit against the bill of lading and original purchase order. Report any damage, missing or incorrect parts, or other discrepancy to the carrier and supplier immediately.

• Claims for damages must be  led with the carrier by the consignee.

• Permission to return goods must be received from the factory prior to shipping.

• Goods returned to the factory without an authorized Return Goods Authorization number will not be accepted.

• Ajax Boiler Inc. is not responsible for any dam-

ce Heating Solutions, LLC is not responsible for

any dam-

C 10

age that the unit receives while in shipping. As each shipping company has its own procedure for  ling a claim, please contact the shipper for claim instructions.

C.1.a. Model Identiﬁ cation

• Your Atlas™ Triton Series™ Boiler carries two identi cation plates. The coil identi cation plate, which carries the ASME Code Stamping and Registration Number (when applicable), is attached to the water inlet, with a duplicate on the heat exchanger top plate. The unit’s nameplate is located on the right side of the rear panel of the unit, and lists information concerning the input and output of the unit, electrical and gas ratings, working pressure and clearance to adjacent construction  gures. In addition, the model and serial numbers are on the plate. You will need these to order replacement parts from the manufacturing representative in your area or from the factory.

• The information on the National Board plate is the same as on the nameplate with the exception of the National Board registration number, which is required in most states for installation of the unit.

C.1.b. The Boiler Name Plate

The following illustration is an accurate depiction of the nameplate found on the rear side of the boiler. You will also  nd an ASME nameplate on the inlet pipe with some of the same information.

NOTE:

• Minimum Btu/Hr. ratings apply to high-low and modulating type boilers only.

• Boiler output ratings are based on factory tests under appropriate conditions. Field results may vary.

• Maximum allowable working pressure for the boiler relief valve set pressure should not exceed the lowest MAWP of any component in your system.

• Applies to forced draft type burners only.

• Minimum and maximum gas pressure values are measured at the point of connection to the boiler gas train. Manifold gas pressures are measured after the gas train.

WARNING:

Do not remove any of these plates from the unit for any reason. Removal of these plates will void the warranty.

C.1.c The Boiler Model Number

ATLAS T 150 P - W

Brand:

• ATLAS

Boiler Type:

• T = Triton Series

Since 1919

Ace Heating Solutions, LLC

AJAX BOILER INC.

DISCRIPTION

MODEL NO. SERIAL NO. MIN. RELIEF VALVE CAP.

MAX. BTU. /HR. INPUT

MIN. BTU. /HR. INPUT

VOLTS HERTZ PH. AMPS. MOT. AMPS. CTRL. VOLT CTRL. AMP

MIN. GAS PRESS. MAX. GAS PRESS. MANIFOLD PRESS. FUEL TYPE

#2 OIL

FOR EITHER INDOOR OR OUTDOOR INSTALLATION.

NOT FOR INSTALLATION ON COMBUSTIBLE FLOORING.

9900456

BTU. /HR. OUTPUT

IF OIL FIRED, DO NOT USE OIL HEAVIER THAN #2

ETL LISTED

CONFORMS TO

UL STD 795

CERTIFIED TO

CAN STD 1-3.1

2701 S. HARBOR BLVD. SANTA ANA, CA 92704

714.437.9050 FAX 714.437.9060

H.P. HEATING SURFACE

GROSS E.D.R. M.A.W.P.

INTEGRAL GROUP

PRIMARY SAFETY

MINIMUM CLEARANCES TO

ADJACENT CONSTRUCTION

Firing Rate:

080 = 800,000 Btu/Hr 150 = 1,500,000 Btu/Hr

100 = 1,000,000 Btu/Hr 200 = 2,000,000 Btu/Hr

Fuel Type:

• G = Natural Gas

• P = Propane

Cabinet Application:

• W = Outdoor

• (No Suf x refers to Indoor Jacketing)

C.2. RATING AND CERTIFICATIONS

• All units must be installed in accordance with all state and local codes, and national codes, including but not limited to:

• ANSI Z223.1/ NFPA 54, National Fuel Code

• ANSI/ NFPA 70, National Electric Code

• All Atlas™ Boilers are National Board approved and designed–certi ed and tested by Intertek (E.T.L.), standards for the US and Canada (Can Std 1-3.1), and

UL 795. Each unit is constructed in accordance with

Section IV of the American Society of Mechanical Engineers (ASME) Boiler Pressure Vessel Code and bears the ASME “HLW” stamp or “H” stamp.

C.3. INSTALLATION CODES

• Installation of the Triton Series™ boilers must conform to the require ments of the authority having jurisdiction, or in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/ NFPA 54, and/ or Natural Gas and Propane Installation Code, CAN/CSA B149.1.

C 11

6. Move the boiler to its  nal installed position.

NOTE:

Ajax Boiler Inc. strongly recommends that you secure the

ce Heating Solutions, LLC strongly recommends that

boiler to the base pad by the mounting holes provided at

you secure the boiler to the base pad by the mounting

the base of the unit.

holes provided at the base of the unit.

C.5. WATER SYSTEM PIPING

• Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls

and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD1

Installations must also follow:

• Local, state, provincial, and national codes, laws, regulations and ordinances.

• National Electrical Code, ANSI/ NFPA 70 – latest edition (NEC).

NOTE:

• If any code listed above con ict, the stricter of the con icting codes shall be followed for installation.

• Installation and Service must be performed by a quali ed installer, service agency or the gas supplier

C.4. PREPARING THE BOILER

NOTE:

Your Atlas™ Triton boiler comes equipped with a steel pallet jack base for safe and easy movement and placement.

1. Place the boiler in its approximate installed location, on a clean, level, structurally sound surface.

CAUTION:

This boiler requires forced water circulation when burner is operating. See minimum and maximum  ow rates in Table C.3.1. below. Severe damage will occur if the boiler is operated without proper water  ow circulation. A  ow switch is used to ensure that water  ows through the boiler, but does not check for the minimum  ow rate into the boiler. Numbers are approximate and may vary depending on installation.

NOTE:

Ajax Boiler Inc. strongly recommends that you secure the

ce Heating Solutions, LLC strongly recommends that

boiler to the base pad by the mounting holes provided at

you secure the boiler to the base pad by the mounting

the base of the unit.

holes provided at the base of the unit.

All hot water outlet and return piping is connected at the rear of the boiler. Piping is to be installed per local codes and regulations. Piping for the hot water outlet and return may be connected without removing cabinet panels. Unused connections must be safely blanked off.

MODEL

Minimum Flow Rate (GPM): 34 43 65 85

Maximum Flow Rate (GPM): 69 85 129 172

Pressure Drop:

T-80 T-100 T-150 T-200

Table C.5.1. Triton Flow Rates.

2. If the boiler is in its original packaging, remove the banding, carton, corner posts and stand-offs, and discard.

3. Unpack the manifold assembly from the small carton attached to the rear of the boiler.

4. Install the manifold assembly to the hot water outlet at the rear of the boiler until tight, and such that the pressure relief valve is in the vertical, upright position at the top of the manifold.

5. Install the 2 loose wires at the rear of the boiler to

the  ow switch installed at the side of the manifold as shown in  gure C.5.1.

C.5.a. System Connections

1. Connect cold water return pipe to the primary water inlet on the boiler.

2. Connect outlet system pipe to hot water outlet at manifold.

3. Install drain valve provided in the boiler drain line at bottom rear of the boiler.

C 12

C.5.b. Pressure Relief Valve

The pressure relief valve safety is factory assembled on the safety manifold previously installed to the boiler in Section C.2. Discharge piping must be installed to the relief valve outlet to avoid potential scalding of attendants. Discharge piping should be as short and direct as possible and installed and terminated per local codes and regulations.

Pressure Relief

Valve Outlet

Manifold

Flow Switch

FRONT SIDE

Figure C.5.1. Manifold and Components

C.6. GAS SUPPLY

The boiler must be isolated from the gas supply piping system by closing its individual manual shut–off valve during any pressure testing of the gas supply piping system at test pressures equal to or more than ½ psi (3.5 kPa).

Do not use Te on tape on gas line thread. A pipe compound rated for natural and propane gases are recommended. Apply sparingly only on the male pipe ends, leaving the two end threads bare.

Gas Piping Leak Test

Upon  rst installing the Triton Series™ boiler, it is important to check the gas line leading up to the unit for gas leaks.

1. Follow the National Fuel Gas Code for instructions on proper gas line piping and gas leak tests.

2. Measuring gas pressures can help detect leaks in isolated lines. Temporarily install a manometer or pressure gauge with an upper limit of no more than 5 times the testing pressure, 5 x 14” WC = 2.6psi for Triton Series™ boiler installations between the manual gas shut off on the boiler and supply line’s regulator.

DANGER:

Make sure the gas on which the boiler will operate is the same as that speci ed on the boiler rating plate (natural gas/propane).

• The gas line should be a separate line running directly from the gas meter to the unit, unless the existing gas line is of ample capacity. Verify the capacity of the existing gas piping if it is to be used.

• The gas pipe must have a sediment trap ahead of the boiler connection controls and a manual shut–off valve located outside the boiler cabinet. It is highly recommended that a union be installed in the gas supply line adjacent to the boiler for servicing. The maximum working gas pressure for both natural gas and propane is 14” WC Keep in mind that an increase in gas pressure, without making additional adjustments, leads to an increased BTU input and a decreased ef ciency.

WARNING:

A sediment trap MUST be installed on the gas piping for

each gas line.

3. Leaving the shut off valve closed on the boiler, open the supply line momentarily until the installed manometer reads a stable pressure and record the pressure and ambient temperature.

4. Close the supply line and monitor the gas pressure for a drop in pressure. The test should be monitored for at least 10 minutes or ½ hour per each 500 ft in the testing pipe.

5. At the end of the monitoring period, record the gas pressure and temperature. If there is a drop in pressure, a gas leak may be present and should be further investigated (Note: signi cant temperature variations may cause changes in the gas pressure and should be retested).

NOTE:

Please refer to the latest National Fuel Gas Code for leak test details. If instructions differ, the Fuel Gas Code shall supersede the instructions in section D.6.a. of these instructions.

of volume

C.6.a. Testing Gas Line

CAUTION:

The boiler must be disconnected from the gas supply during any pressure testing of the gas supply at test pressures in excess of ½ psi (3.5 kPa).

C 13

C.6.b. Gas Supply Pressure

WARNING:

Relieve the pressure in the gas supply line prior to connecting the boiler and its manual shut off valve to the gas supply line. Failure to follow this procedure may damage the gas valve. Gas valves damaged by high gas pressures are not covered by the warranty.

The boiler and its gas connections must be tested for leaks before operation of the units.

Input may decrease if gas pressure falls below the values shown below. The maximum gas supply pressure is 14” WC for all Triton units. If gas pressure exceeds 14” WC an intermediate gas pressure regulator of the lockup type must be installed. If gas pressures less than those provided below are used, input may be decreased.

MODEL

Naturel Gas (“ WC) 5-14 5-14 5-14 5-14

Propane (“ WC) 5-14 5-14 5-14 5-14

If the gas pressures exceed 14” WC, a gas pressure regulator must be installed prior to the gas connection to reduce the supply pressure.

When connecting additional gas utilization equipment to the gas piping, the existing piping must be checked to determine if it is adequate for the combined load.

T-80 T-100 T-150 T-200

Table 2.3.1. Triton Gas Pressure Chart.

CAUTION:

C.7. PUMP INSTALLATION

WARNING:

Electrical Shock Hazard!

• Electrical work must be done by a quali ed electrician only.

• National Electrical codes, local codes and regulations must be followed.

• All electrical connections must be performed after the electrical supply has been switched off and secured against unauthorized switching.

• Depending on installation, the pump/motor can become extremely hot. To avoid risk of burning, handle pump with heat resistant gloves or ensure the pump is cool before handling the pump.

CAUTION:

Never operate the pump dry, the system must be  lled before starting the pump. Ensure all isolation valves are open before start up

n optional pump can be ordered through Ace

• An optional pump can be ordered through Ajax Boiler

Heating Solutions, LLC properly sized for the boiler.

Inc. properly sized for the boiler. Flange kits are also

Flange kits are also provided with the pump to fi t

provided with the pump to  t the boiler connection

the boiler connection sizes. Please contact an

sizes. Please contact an authorized Ajax Boiler repre-

authorized Ace Heating Solutions, LLC

sentative, or the factory for details.

representative, or the factory for details.

C.7.a. Pump Overload Protection

• A fused plug or circuit breaker in the power line is

required.

C.6.c. Attach Gas Line

1. Attach main gas supply line to boiler gas shut-off valve located outside at the rear of the boiler cabinet as shown below.

• The pump must be connected to the electrical supply via an external contactor/relay to provide thermal overload protection. The contactor/relay must be connected to the built-in thermal overload switch terminals P1 and P2 (potential-free normally closed contact, contact load 250 VAC/1A) to protect the pump against thermal

Safety Shut Off

Valve

overloading at all speeds.

• If the pump is protected by means of a motor starter, the starter must be set to the current consumption of the pump at the selected speed. The motor starter setting must be changed every time the pump speed is changed. The current consumption at the individual speeds is stated on the pump rating plate.

Side View

(L)

Figure C.6.1. Safety Shut Off Valve

Rear View

+ 33 hidden pages

Atlas Triton T-80, Triton-100, Triton-150, Triton-200 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual