Thermal Solutions EVCA SERIES Installation, Operating And Service Instructions

Price - $3.00

H

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS

EVCA SERIES CONDENSING BOILER

A

S

M

E

File Number MH25585

For service and repairs to the heating plant, call your heating contractor. When seeking information on the
boiler from the manufacturer, provide boiler model and serial number as shown on rating label.

Boiler Model Installation Date

EVCA -

Heating Contractor

Your Local Thermal Solutions Representative:

Serial Number

Type System

Phone NumberAddress

814EVC003 R4-11/12

1

IMPORTANT INFORMATION - READ CAREFULLY

NOTE: Post these instructions and maintain in legible condition.

NOTE: e equipment shall be installed in accordance with those installation regulations required in the area where the

installation is to be made. ese regulations shall be carefully followed in all cases. Authorities having jurisdiction
shall be consulted before installations are made.

All wiring on boilers installed in the USA shall be in accordance with the National Electrical Code and/or local regulations.

All wiring on boilers installed in Canada shall be in accordance with the Canadian Electrical Code and/or local regulations.

e following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to
important information concerning product life.

DANGER

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.

Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.

Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.

CAUTION

NOTICE

DANGER

DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other

appliance.

If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use
any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the gas

supplier’s instructions or if the supplier is unavailable, contact the re department.

2

WARNING

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained

in this manual.

Improper installation, adjustment, alteration, service, or maintenance can cause property damage, personal
injury or loss of life. Read and understand the entire manual before attempting installation, start-up,
operation, or service. Installation and service must be performed only by an experienced, skilled installer
or service agency.

This boiler must be properly vented.

This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate

combustion and ventilation air.

The interior of the venting and air intake systems must be inspected and cleaned before the start of the
heating season and should be inspected periodically throughout the heating season for any obstructions.
Clean and unobstructed venting and air intake systems are necessary to allow noxious fumes that could

cause injury or loss of life to vent safely and will contribute toward maintaining the boiler’s efciency.

This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start
without service - If damage due to frozen pipes is a possibility, the heating system should not be left
unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating
system to prevent damage if the boiler is inoperative.

This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings nor attempt

to disconnect any components of this boiler without positively assuring the water is cool and has no

pressure. Always wear protective clothing and equipment when installing, starting up or servicing this

boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.

Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals,
carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause
death or serious injury and which are known to the state of California to cause cancer, birth defects and

other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing

or working nearby the appliance.

Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions,
including all those contained in component manufacturers manuals which are provided with the boiler
before installing, starting up, operating, maintaining or servicing.

Keep boiler area clear and free from combustible materials, gasoline and other ammable vapors or
liquids.

All cover plates, enclosures and guards must be in place at all times.

This product must be installed by a licensed plumber or gas tter when installed within the Commonwealth

of Massachusetts.

NOTICE

This boiler has a limited warranty, a copy of which is printed on the back of this manual. It is the responsibility
of the installing contractor to see that all controls are correctly installed and are operating properly when the
installation is complete.

3

Table of Contents

I. Pre-Installation........................................... 8

II. Unpacking the Boiler ................................ 9

III. Installation ................................................ 10

A. Venting ................................................ 10

B. Combustion Air ................................. 15

C. Water Treatment ................................ 17

D. Water Piping and Trim ...................... 18

E. Gas Piping ........................................... 21

F. Electrical ............................................. 24

G. Modular Systems ................................31

H. Condensate Drains ............................ 40

IV. System Start-up ........................................ 41

V. Lighting Instructions ...............................44

VI. Boiler Operational Sequence ..................46

VII. Service/Maintenance ............................... 48

A. Safety and Operating Controls......... 49

B. Troubleshooting .................................50

C. Periodic Maintenance........................52

D. Inspection & Cleaning Procedure ... 53

VIII. Repair Parts .............................................56

IX. ermal Solutions Boiler Control™

(TSBC™) ...................................................85

A. Introduction .......................................85

B. Front Panel Display ........................... 86

C. Security Menu .................................... 88

D. Setup Menu .........................................89

E. Boiler Conguration Menu...............92

F. System Conguration Menu .............93

G. Setpoints Menu ..................................94

H. Communication Menu ..................... 95

I. Manual Mode Menu ...........................96

X. Warranty ................................... Back Cover

Minimum Clearance to Combustible Materials

Left Side Right Side Front Rear Top Flue Connector

6" 6" 24" 6" 6" 18"

Recommended Clearance for Service

Boiler Size Left Side or Right Side Front and Rear Top

750/1000 24" 24" 24" 24" 16"

1500 24" 24" 24" 24" 19"

2000 24" 24" 24" 24" 31"

3000 24" 24" 36" 36" 26.5"

NOTES:

1. When 3 or more units are mounted side-by-side, the front service clearance
increases by 12" and the rear service clearance increases by 24".

2. Verify clearances with local codes.

3. Net AHRI Ratings

A. The Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1.15.

B. The manufacturer should be consulted before selecting a boiler for installations having unusual piping and
pickup requirements, such as intermittent system operation, extensive piping systems, etc.

C. The ratings have been determined under the provisions governing forced draft boiler-burner units.

4

Notes:

1. Piping removed for visual clarity.

2. See notes concerning Net AHRI Ratings on page 4.

MOUNTED LOW

31.0

[787.4]

60.9
[1547.8]

28.3

[717.6]

WATER CUT-OFF

SHUT-OFF VALVE

19.5

[495.3]

[1169.5]

MANUAL

46.0

56.5

[1435.1]

63.9
[1623.1]

REQUIREMENT

FOR BURNER

REMOVAL

WATER INLET

2.5 NPT

GAS VENT .75

NPT PIPE

14.5

[368.7]

SUPPLY TO
SYSTEM, 2"
VICTAULIC

FLUE OUTLET Ø4

SAF-T-VENT

16.7

13.0

[424.9]

4.6

[116.7]

16.0
[406.4]

[330.9]

5.1

[128.4]

[239.7]

14.2

[360.0]

9.4

CAPACITIES

BOILER MODEL

NUMBER

INPUT
(MBH)

GROSS

OUTPUT

(MBH)

NET AHRI

RATING

2

(MBH)

WATER

VOLUME

(gallons)

DRY WEIGHT

(lbs.)

WET WEIGHT

EVCA-750 750 699 608 16.7 1,401 1,672

12.0

[304.8]

3.0

[76.2]

GAS PILOT
Ø.25 TUBE

GAS SUPPLY

INLET AIR Ø6
GALVANIZED

DUCT

CONDENSATE DRAINS TO BE

PIPED TO AN EXTERNAL TRAP

1 NPT

BOILER DRAIN

1 NPT PIPE

2.5
[63.5]

21.8
[552.9]

16.0
[406.3]

(lbs.)

29.6
[751.1]

EVCA-1000 1,000 939 817 18.4 1,518 1,868

BOILER MODEL

RANGE

750/1000

65.2

SUPPLY (volts/Hz/phase) blower motor (hp) pump motor (hp) Nominal power draw (amps)

120/60/1

208/60/1 9.1

230/60/1 9.0

208/60/3 7.4

230/60/3 7.3

460/60/3 6.3

MANUAL SHUT-OFF

19.5

[495.3]

VALVE

46.0

[1169.5]

[1435.1]

MOUNTED LOW

31.0

[787.4]

[1655.8]

28.3

[717.6]

WATER CUT-OFF

ELECTRICAL

1 1/2 1/4

REQUIREMENT

FOR BURNER

REMOVAL

68.2
[1732.3]

56.5

16.0

GAS VENT .75 NPT

PIPE

14.5

[368.7]

SUPPLY TO SYSTEM,

2" VICTAULIC

FLUE OUTLET Ø6

SAF-T-VENT

WATER INLET

2.5 NPT

18.6
[472.7]

13.0
[330.9]

4.6

[116.7]

14.5

12.0

[304.8]

[406.4]

5.1

[128.4]

14.2

[360.0]

9.4

[239.7]

[76.2]

GAS PILOT
Ø.25 TUBE

GAS SUPPLY

1.5 NPT

INLET AIR Ø6

GALVANIZED DUCT

CONDENSATE DRAINS TO BE

PIPED TO AN EXTERNAL TRAP

BOILER DRAIN

1 NPT PIPE

2.5
[63.5]

3.0

21.8
[552.9]

34.5
[877.4]

16.0
[406.3]

Figure 1a: Dimensions and Capacities EVCA 750 & 1000

5

[304.8]

GAS PILOT

Ø.25 TUBE

GAS SUPPLY

1.5 NPT

CONDENSATE DRAINS TO BE

PIPED TO AN EXTERNAL TRAP

BOILER DRAIN

1 NPT PIPE

2.5

Notes:

1. Piping
removed for
visual clarity.

2. See notes
concerning
Net AHRI
Ratings on
page 4.

82.1
[2085.3]

REQUIREMENT

FOR BURNER

REMOVAL

SUPPLY TO SYSTEM,

FLUE OUTLET Ø6

GALVANIZED DUCT

16.5
[418.8]

6.2

19.0

GAS VENT .75 NPT

PIPE

14.5

[368.7]

2" VICTAULIC

SAF-T-VENT

WATER INLET

2.5 NPT

INLET AIR Ø8

4.6

[116.7]

[157.2]

[482.6]

21.8

[552.5]

14.2

[360.0]

[239.7]

9.4

MANUAL SHUT-OFF

19.5

[495.3]

VALVE

46.0

[1169.5]

56.5

[1435.1]

MOUNTED LOW

31.0

[787.4]

79.1
[2009.1]

28.3

[717.6]

WATER CUT-OFF

CAPACITIES

BOILER MODEL

NUMBER

INPUT
(MBH)

GROSS

OUTPUT

(MBH)

NET AHRI

RATING

2

(MBH)

WATER

VOLUME

(gallons)

DRY WEIGHT

(lbs.)

EVCA-1500 1,500 1,420 1,235 19.8 1,704 1,994

12.0

3.0

[76.2]

21.8
[552.9]

46.4
[1177.8]

26.5
[672.8]

[63.5]

WET WEIGHT

(lbs.)

EVCA-2000 2,000 1,900 1,652 21.2 1,897 2,163

BOILER MODEL

RANGE

1500/2000

SUPPLY (volts/Hz/phase) blower motor (hp) pump motor (hp) Nominal power draw (amps)

120/60/1

208/60/1 11.9

230/60/1 11.8

208/60/3 9.3

230/60/3 9.0

460/60/3 7.2

MANUAL SHUT-OFF

31.0

[787.4]

91.8
[2331.7]

MOUNTED LOW

WATER CUT-OFF

VALVE

1 1/2 3/4

ELECTRICAL

REQUIREMENT

FOR BURNER

REMOVAL

92.8
[2357.1]

31.0

GAS VENT

.75 NPT PIPE

15.1

[384.0]

SUPPLY TO SYSTEM,

2" VICTAULIC

FLUE OUTLET Ø6

SAF-T-VENT

WATER INLET

2.5 NPT

[787.4]

19.3

12.0

[304.8]

3.0

[76.2]

GAS PILOT
Ø.25 TUBE

GAS SUPPLY

1.5 NPT

CONDENSATE DRAINS TO BE

PIPED TO AN EXTERNAL TRAP

21.8
[552.9]

51.9
[1318.5]

28.3

[717.6]

Figure 1b: Dimensions and Capacities EVCA 1500 & 2000

19.5

[495.3]

44.5

[1131.0]

53.0

[1346.2]

BOILER DRAIN

[239.7]

1 NPT PIPE

30.4
[771.7]

9.4

2.5
[63.5]

INLET AIR Ø8

GALVANIZED DUCT

17.1
[433.6]

4.6

[116.7]

6.2
[157.2]

21.8

[552.5]

14.2

[360.0]

6

40.8

[1036.3]

MOUNTED LOW

WATER CUT-OFF

REQUIREMENT

FOR BURNER

REMOVAL

SUPPLY TO SYSTEM,

4 Victaulic

MANUAL SHUT-OFF

26.5
[673.1]

VALVE

20.9
[531.8]

GAS SUPPLY

2 NPT

84.5
[2146.3]

Notes:

38.1

[968.2]

FRONT VIEW

BOILER DRAIN

1 NPT PIPE

1.9

26.0

[660.3]

[47.3]

64.5

[1638.1]

80.5

[2044.1]

86.1

FLUE OUTLET Ø8

[2188.1]

SAF-T-VENT

WATER INLET

4 NPT

29.9
[760.1]

16.1
[410.1]

4.4

[112.8]

INLET AIR Ø8

GALVANIZED DUCT

10.9
[275.9]

CONDENSATE DRAINS TO BE

PIPED TO AN EXTERNAL TRAP

1. Piping removed for visual
clarity.

2. See notes concerning Net
AHRI Ratings on page 4.

CAPACITIES

BOILER MODEL

NUMBER

INPUT
(MBH)

GROSS

OUTPUT

(MBH)

NET AHRI

RATING

2

(MBH)

WATER

VOLUME

(gallons)

HEAT

TRANSFER

AREA (sq.ft.)

DRY WEIGHT

(lbs.)

EVCA-3000 3,000 2,910 2,530 53.9 1,426 3,354 3,803

29.9
[760.1]

WET

WEIGHT

(lbs.)

60.2
[1528.3]

BOILER MODEL

SUPPLY (volts/Hz/phase) blower motor (hp) pump motor (hp) Nominal power draw (amps)

208/60/3

EVCA-3000

230/60/3 13.9

460/60/3 7.0

Figure 1c: Dimensions and Capacities EVCA 3000

ELECTRICAL

14.6

2 2

7

I. Pre-Installation

WARNING

Carefully read all instructions before installing
boiler. Failure to follow all instructions in proper
order can cause personal injury or death.

A. Installation must conform to the requirements of

the authority having jurisdiction. In the absence of
such requirements, installation must conform to the
National Fuel Gas Code, NFPA 54/ANSI Z223.1, and/
or CAN/CGA B149 Installation Codes. 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
CSD-1.

B. e boiler is not design certied for installation on

combustible ooring. e boiler must not be installed
on carpeting.

C. Provide clearance between boiler jacket and combustible

material in accordance with local re ordinance. Refer
to page 4 of this manual for minimum listed clearance
from combustible material.

D. Install on level oor. For basement installation provide

concrete base if oor is not perfectly level or if water
may be encountered on oor around boiler. Floor
must be able to support weight of boiler, water and all
additional system components.

E. Protect gas ignition system components from water

(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap
service, control replacement, etc.).

1. Determine volume of space (boiler room). Rooms
communicating directly with space (through
openings not furnished with doors) are considered
part of space.

Volume [³] = Length [] x Width [] x Height []

2. Determine Total Input of all appliances in space.
Round result to nearest 1,000 Btu per hour (Btuh).

3. Determine type of space. Divide Volume by Total
Input.

a. If result is greater than or equal to 50 ³ per 1,000

Btuh, space is considered an unconned space.

b. If result is less than 50 ³ per 1,000 Btuh, space is

considered a conned space.

4. Determine building type. A building of unusually
tight construction has the following characteristics:

a. Walls and ceiling exposed to outside atmosphere

have a continuous water vapor retarder with a
rating of 1 perm or less with openings gasketed
and sealed, and;

b. Weather-stripping has been added on openable

windows and doors, and;

c. Caulking or sealants applied in joints around

window and door frames, between sole plates and
oors, between wall-ceiling joints, between wall
panels, at plumbing and electrical penetrations,
and at other openings.

5. For boiler located in an unconned space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally
provided by fresh air inltration through cracks
around windows and doors.

NOTICE

F. Provide combustion and ventilation air in accordance

with applicable provisions of local building codes or:
USA - National Fuel Gas Code, NFPA 54/ANSI Z223.1,
Section 5.3, Air for Combustion and Ventilation;
Canada - Natural Gas Installation Code, CAN/CGA

- B149.1, or Propane Installation Code, CAN/CGA

- B.149.2, Part 5, Venting Systems and Air Supply for
Appliances.

WARNING

Adequate combustion and ventilation air must

be provided to assure proper combustion.

e following guideline is based on the National Fuel

Gas Code, NFPA 54/ANSI Z223.1.

Boilers operated with sealed combustion are
exempt from needing provisions for combustion
air from the room, provided air intake piping is
installed per code and the instructions in this
manual.

6. For boiler located within unconned space in

building of unusually tight construction or within
conned space, provide outdoor air through two

permanent openings which communicate directly or by
duct with the outdoors or spaces (crawl or attic) freely
communicating with the outdoors. Locate one opening
within 12 inches of top of space. Locate remaining
opening within 12 inches of bottom of space. Minimum
dimension of air opening is 3 inches. Size each opening
per the following:

8

a. Direct communication with outdoors. Minimum

free area of 1 square inch per 4,000 Btu per hour
input of all equipment in space.

b. Vertical ducts. Minimum free area of 1 square

inch per 4,000 Btu per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.

c. Horizontal ducts. Minimum free area of 1

square inch per 2,000 Btu per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.

Alternate method for boiler located within conned

space. Use indoor air if two permanent openings
communicate directly with additional space(s) of
sucient volume such that combined volume of all
spaces meet criteria for unconned space. Size each
opening for minimum free area of 1 square inch per
1,000 Btu per hour input of all equipment in spaces,
but not less than 100 square inches.

7. Ventilation Duct Louvers and Grilles. Equip outside
openings with louvers to prevent entrance of rain
and snow, and screens to prevent entrance of insects
and rodents. Louvers and grilles must be xed in
open position or interlocked with equipment to
open automatically before burner operation. Screens
must not be smaller than ¼ inch mesh.

Consider the blocking eect of louvers, grilles and

screens when calculating the opening size to provide
the required free area. If free area of louver or grille
is not known, assume wood louvers have 20-25
percent free area and metal louvers and grilles have
60-75 percent free area.

DANGER

Do not install boiler where gasoline or other

ammable vapors or liquids, or sources

of hydrocarbons (i.e. bleaches, cleaners,
chemicals, sprays, paint removers, fabric
softeners, etc.) are used or stored.

NOTICE

Due to the low water content of the boiler,
incorrect sizing of the boiler with regard to the
heating system load will result in excessive
boiler cycling and accelerated component
failure. Thermal Solutions DOES NOT warrant
failures caused by incorrectly sized boiler
applications. DO NOT oversize the boiler to
the system. Modular boilers greatly reduce the
likelihood of boiler oversizing.

II. Unpacking the Boiler

NOTICE

Boiler crate is equipped with a tip & tell label.

If label indicates boiler has been tipped over
during shipping, remove crate and inspect
before trucker leaves.

CAUTION

Do not drop boiler. Do not bump boiler jacket

against oor.

A. Move boiler to approximate installed position.

B. Remove all crate fasteners.

C. Open outside container and remove all inside protective

spacers and bracing.

D. Remove all boiler hold-down fasteners.

WARNING

Installation of this boiler should be undertaken
only by trained and skilled personnel from a

qualied service agency.

E. Remove unit from shipping skid (if provided.)

1. Tilt the boiler to one side and slide a small roller
under the raised base.

2. Tilt the boiler to the other side and slide another

roller under the base.

3. Place a larger pipe roller on oor behind the skid.

4. Roll the boiler forward or backward o the skid and

onto the pipe roller.

F. Move boiler to its permanent location.

WARNING

Boiler air vent is shipped loose for EVCA 750-

2000. Refer to water piping and trim section prior

to lling the boiler with water.

9

III. Installation

A. VENTING

WARNING

Improper venting may result in property damage

and the release of ue gasses which contain

deadly carbon monoxide (CO) into the building,
which can cause severe personal injury and/or
death.

1. Venting Requirements

In order to properly vent this boiler, the installer

must select and install a vent system that meets all
requirements specied in this section (VENTING) as
well as following the instructions provided by the vent
system manufacturer.

a. e vent system shall be designed and constructed in

accordance with the National Fuel Gas Code/NFPA
54 ANSI Z223.1 and applicable local building codes to
develop a positive ow adequate to convey ue or vent
gasses to the outdoors.

b. If this boiler is being installed in Massachusetts, follow

the Massachusetts Code instructions printed later in this
section.

c. Consult the vent pipe manufacturer’s instructions for

vent system assembly and system specic installation
requirements.

g. Vent pipe system must be adequately supported at

intervals no less than ve (5) feet apart. e completed
vent system must be rigid and able to withstand impacts
without collapse.

h. is boiler’s venting is Category IV (positive vent

pressure, ue condensing), with regards to National Fuel
Gas Code/NFPA 54 ANSI Z223.1.

i. Vent pipe system must be fully sealed.

j. Atmospheric venting is prohibited.

k. For multiple boiler installations, each boiler must have

its own independent vent system. Common venting
with additional or any other appliances is prohibited.

WARNING

Do not use vent dampers or barometric dampers
with this boiler.

l. Direct vent applications: For direct vent (ducted

combustion air) installations, the maximum vent length
is 50 equivalent feet. e vent length is equal to the total
length of straight pipe plus the equivalent length of vent
ttings.

m. Non-direct vent applications: For non-direct vent

installations (those without ducted combustion air),
design the vent system so that the pressure measured at
the outlet of the boiler is between 0”w.c. and 0.3”w.c. at
high re.

WARNING

Vent pipe system must be made of materials

approved for use with condensing ue gasses.

d. Vent pipe system shall be acceptable for use with boiler

fuel type.

e. Vent pipe system shall be compatible either by directly

connecting, or by use of an adapter, to the boiler vent
connection.

i. is boiler is shipped with an AL 29-4C® Heat-Fab

Saf-T-Vent connection.

ii. Alteration of the boiler vent connection is

prohibited.

f. Do not reduce the diameter of the vent pipe. e vent

pipe must not be smaller than the vent connector on the
boiler.

n. If any point of the vent pipe system is higher than the

boiler ue collar, the vent system must have adequate
condensate drain loop(s) to prevent condensate from
running back into the boiler.

o. It is permissible to run vent pipe through a vertical

or horizontal chase provided minimum clearances to
combustible materials are maintained.

p. e minimum clearance to combustible material

is six (6) inches, unless otherwise specied by vent
manufacturer.

q. Horizontal vent pipe must slope no less than one (1)

inch in four (4) feet of run. For sidewall venting, slope
pipe toward vent termination if possible.

r. e vent termination location is restricted as follows:

i. Minimum twelve (12) inches above grade plus

normally expected snow accumulation or seven (7)
feet above grade if located adjacent to public walkways.
DO NOT INSTALL over public walkway where local
experience indicates condensation or vapor from the
boiler creates a nuisance or hazard.

10

ii. Minimum three (3) feet above any forced air inlet

located within ten (10) feet of the vent termination.

iii. Minimum four (4) feet below, four (4) feet

horizontally or one (1) foot above any door, window or
gravity air inlet.

iv. Minimum four (4) feet horizontally from electric

meters, gas meters, regulators and relief valves. is
distance may be reduced if equipment is protected from
damage due to condensation or vapor by enclosure,
overhangs, etc.

v. Minimum twelve (12) inches from corners of

building.

3. IMPORTANT

e Commonwealth of Massachusetts requires

compliance with regulation 248 CMR 4.00 and 5.00 for
installation of side-wall vented gas appliances as follows:

(a) For all side wall horizontally vented gas fueled

equipment installed in every dwelling, building or
structure used in whole or in part for residential
purposes, including those owned or operated by the
Commonwealth and where the side wall exhaust
vent termination is less than seven (7) feet above
nished grade in the area of the venting, including
but not limited to decks and porches, the following
requirements shall be satised:

s. Use appropriately designed thimbles when passing

through combustible walls or roofs.

t. Install re-stops where vent passes through oors,

ceilings or framed walls. e re-stop must close the
opening between the vent pipe and the structure.

u. Enclose vent passing through occupied or unoccupied

spaces above the boiler with materials having a re
resistance rating at least equal to the rating of the
adjoining oor or ceiling. Maintain minimum clearance
to combustible materials.

v. Locate vent terminal above combustion air intake

terminal (if used) and no closer than one (1) foot
horizontally.

w. Vertical venting requires ashing and a storm collar to

prevent moisture from entering the structure.

x. Vertical vent termination must be at least two (2)

feet plus the expected snow accumulation above roof
penetration height.

2. General Guidelines

a. is boiler has been certied with AL29-4C® venting.

Select a vent material that is approved for use with
condensing ue gasses.

b. Install vent system before installing air intake, water, gas

or electrical connections.

c. For instances where the vent system manufacturer’s

instructions do not make a specication, refer to the
below points.

1. INSTALLATION OF CARBON MONOXIDE
DETECTORS. At the time of installation of the side wall
horizontal vented gas fueled equipment, the installing
plumber or gastter shall observe that a hard wired
carbon monoxide detector with an alarm and battery
back-up is installed on the oor level where the gas
equipment is to be installed. In addition, the installing
plumber or gastter shall observe that a battery
operated or hard wired carbon monoxide detector
with an alarm is installed on each additional level of
the dwelling, building or structure served by the side
wall horizontal vented gas fueled equipment. It shall
be the responsibility of the property owner to secure
the services of qualied licensed professionals for the
installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally vented

gas fueled equipment is installed in a crawl space or an
attic, the hard wired carbon monoxide detector with
alarm and battery back-up may be installed on the next
adjacent oor level.

b. In the event that the requirements of this

subdivision can not be met at the time of completion of
installation, the owner shall have a period of thirty (30)
days to comply with the above requirements; provided,
however, that during said thirty (30) day period, a
battery operated carbon monoxide detector with an
alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS.
Each carbon monoxide detector as required in
accordance with the above provisions shall comply
with NFPA 720 and be ANSI/UL 2034 listed and IAS
certied.

i. Make sure pipe and ttings are clean by swabbing

with alcohol. Use Dow Corning 736 or 732 RTV,
Polybar #500 RTV or Sil-bond 4500 or 6500 to seal vent
pipe.

ii. Refer to the appropriate drawings in this section

of this manual to determine common acceptable
congurations of venting system.

3. SIGNAGE. A metal or plastic identication plate shall be
permanently mounted to the exterior of the building at a
minimum height of eight (8) feet above grade directly in
line with the exhaust vent terminal for the horizontally
vented gas fueled heating appliance or equipment. e
sign shall read, in print size no less than one-half (1/2)
inch in size, “GAS VENT DIRECTLY BELOW. KEEP
CLEAR OF ALL OBSTRUCTIONS”.

11

4. INSPECTION. e state or local gas inspector of the
side wall horizontally vented gas fueled equipment shall
not approve the installation unless, upon inspection,
the inspector observes carbon monoxide detectors and
signage installed in accordance with the provisions of
248 CMR 5.08(2)(a)1 through 4.

B. EXEMPTIONS: e following equipment is exempt

from 248 CMR 5.08(2)(a)1 through 4:

1. e equipment listed in Chapter 10 entitled

“Equipment Not Required To Be Vented” in the
most current edition of NFPA 54 as adopted by the
Board; and

2. Product Approved side wall horizontally vented

gas fueled equipment installed in a room or
structure separate from the dwelling, building or
structure used in whole or in part for residential
purposes.

C. MANUFACTURER REQUIREMENTS - GAS

EQUIPMENT VENTING SYSTEM PROVIDED.
When the manufacturer of Product Approved side
wall horizontally vented gas equipment provides a
venting system design or venting system components
with the equipment, the instructions provided by the
manufacturer for installation of the equipment and the
venting system shall include:

1. Detailed instructions for the installation of

the venting system design or the venting system
components; and

2. A complete parts list for the venting system

design or venting system.

D. MANUFACTURER REQUIREMENTS - GAS

EQUIPMENT VENTING SYSTEM NOT PROVIDED.
When the manufacturer of a Product Approved side
wall horizontally vented gas fueled equipment does
not provide the parts for venting the ue gases, but
identies “special venting systems”, the following
requirements shall be satised by the manufacturer:

1. e referenced “special venting system”

instructions shall be included with the appliance or
equipment installation instructions; and

2. e “special venting systems” shall be Product

Approved by the Board, and the instructions for
that system shall include a parts list and detailed
installation instructions.

E. A copy of all installation instructions for all Product

Approved side wall horizontally vented gas fueled
equipment, all venting instructions, all parts lists
for venting instructions, and/or all venting design
instructions shall remain with the appliance or
equipment at the completion of the installation.

12

Figure 2: Typical Sidewall Pressurized Venting

Figure 3: Typical Sidewall Pressurized Venting (Optional)

13

Figure 4: Typical Vertical Pressurized Venting

14

B. COMBUSTION AIR - See Figures 5 and 6

1. e boiler may be operated with inside or outside
air.

2. Refer to combustion air piping drawings in this
section of this manual for proper outside air
installation details.

3. Combustion air conduit can be galvanized smoke
pipe, PVC, CPVC, or exible aluminum conduit.

4. e maximum air inlet length is y (50) equivalent
feet. Air inlet length is equal to the total length of
straight pipe plus the equivalent length of ttings.
Consult conduit manufacturer for equivalent length
of ttings and pipe.

5. Consult intake pipe manufacturer's instructions
for proper method of sealing vent pipe sections
and ttings. Do not use other adhesives or sealants
except as expressly permitted by the vent pipe
manufacturer's instructions.

WARNING

Do not reduce size of air intake pipe.

Read, understand and follow combustion air
instruction restrictions contained in the Pre­Installation instructions of this manual.

WARNING

Do not locate air intake where petroleum
distillates, CFCs, detergents, volatile vapors
or any other chemicals are present. Severe
boiler corrosion and failure will result.
Thermal Solutions does not warrant failures
caused by contaminated air.

Do not locate air intake termination where
natural convection or wind conditions may
cause the boiler exhaust gases to be drawn
into the air intake.

6. Air intake termination must be located at least
twelve (12) inches above grade plus the expected
snow accumulation.

7. Boiler may be installed with vertical venting and
sidewall combustion air inlet or visa versa.

8. e air intake pipe must be adequately supported
with straps or supports no less than ve (5) feet
apart. e completed air intake pipe system must be
rigid and able to withstand impacts without collapse.

CAUTION

Dirty, contaminated or dusty air used for
combustion will decrease the useful life of

the boiler air lter. Use outside air if inside
air quality is questionable. Use outside air if

the boiler is installed in manufacturing plants,
laundries, dry cleaners or other locations with
heavy particulates in the air.

15

Figure 5: Horizontal Air Intake Piping

Figure 6: Vertical Air Intake Piping

16

C. WATER TREATMENT

e quality of water used in the heating system is essential
for the successful operation and longevity of the system
components. A successful water treatment plan will help
to maintain eciency, reduce the regularity of repair and/
or replacement, and extend the working life of the boiler
and other system equipment. If le untreated, poor water
quality could cause a number of problems including, but not
limited to, oxidation, scaling, corrosion, and fouling. See
Table 1A for examples of typical chemical agents found in
untreated water along with their potential eects.

Table 1A: Chemical Agents and Effects

Compound Effect

Calcium Carbonate

Soft Scale

(CaCO3)
Calcium Bicarbonate

Soft Scale, CO

2

(CaHCO3)
Calcium Sulphate (CaSO4) Hard Scale
Calcium Chloride (CaCl2) Corrosion
Magnesium Carbonate

Soft Scale

(MgCO3)
Magnesium Bicarbonate

Corrosion, Scale

(MgHCO3)
Magnesium Sulphate

Corrosion

(MgSO4)
Silicon Dioxide (SiO2) Hard Scale

CAUTION

The water shall have a maximum water hardness
of 8.5 grains or 150 ppm. The recommended
pH range is 8.8 to 9.2. However, other aspects

of water quality can affect boiler operation and
longevity. A qualied water treatment expert

should be consulted to develop a complete
water treatment plan.

Oxygen contamination of boiler water will cause
corrosion of iron and steel boiler components,
and can lead to boiler failure. Thermal Solutions
Standard Warranty does not cover problems
caused by oxygen contamination of boiler water.

Proper water treatment and boiler maintenance

is required to avoid scale build-up on the inside

of the boiler. Thermal Solutions Standard
Warranty does not cover problems caused by
scale build-up.

When using Glycol products, all Glycol

manufacturers' requirements, including rust

inhibitors, must be adhered. Max 50% Glycol.

Since the condition of water varies from location to location,
it is impossible to prescribe a one-size-ts-all treatment plan
for the system water. In order to develop an eective water
treatment plan, it will be necessary to gain knowledge of the
impurities dissolved in the water. Once all the impurities
are identied, the proper treatment plan can be established.
erefore, it will be essential to obtain the expertise of
a qualied industrial water treatment professional for
establishing a treatment plan.

In addition, a periodic testing/sampling plan should be
developed. e intent of the plan should be to: (1) ensure the
protection of the boiler and system equipment, (2) prevent
an unforeseen system failure, (3) provide information for
use in addressing the water quality, and (4) to conrm the
proper concentration of chemicals in use.

17

D. WATER PIPING AND TRIM

CAUTION

WARNING

For EVCA 750-2000, the boiler air vent is shipped
loose. Prior to connecting system piping to

boiler, or lling the boiler with water, remove

protective cap from the tagged elbow at the top
of the loop piping. Install supplied air vent to

boiler elbow using teon tape.

CAUTION

Failure to properly pipe boiler may result in
improper operation and damage to boiler or
structure.

All piping, either new or existing, must be
cleaned with a tri sodium (TSP) solution to
remove mill scale and oils from the system.
Failure to do so could result in premature failure
of the heat exchanger (not covered by Thermal
Solutions warranty.

On an existing or retrot system, a lter or

strainer must be installed on the system return
prior to the boilers.

When using Glycol products, all Glycol

manufacturers' requirements, including rust

inhibitors, must be adhered.

1. Design and install boiler and system piping to
prevent oxygen contamination of boiler water
and frequent water additions.

a. ere are many possible causes of oxygen

contamination such as:

i. Addition of excessive make-up water

as a result of system leaks.

ii. Absorption through open tanks and ttings.

iii. Oxygen permeable materials in the

distribution system.

b. In order to insure long product life, oxygen

sources must be eliminated. is can be
accomplished by taking the following measures:

i. Repairing system leaks to eliminate the need

for addition of make-up water.

ii. Eliminating and/or repairing ttings which

allow oxygen absorption.

iii. Using of non-permeable materials in the

distribution system.

iv. Isolating the boiler from the system water by

installing a heat exchanger.

v. Using properly designed and operating air

elimination devices in water piping.

Support weight of system piping adequately.

Boiler loop piping is not designed to support
system piping weight.

2. Connect system supply and return piping to boiler.

a. Refer to Figure 8.

b. Consult I=B=R Installation and Piping Guides.

c. Maintain ½" minimum distance between water

piping and combustible material.

d. Consult ermal Solutions for unusual system

requirements.

3. Remove protective cap from boiler drain line located
in the rear of the boiler (EVCA-750 through 2000)
or the right side of the boiler (EVCA-3000).

4. For EVCA-3000, install a 10" minimum or longer 1"
diameter nipple into hole in right side of base and
thread into drain elbow underneath the boiler.

5. Install drain valve in the boiler drain line at bottom
rear or right side of the boiler.

6. If this boiler is used in connection with refrigeration
systems, the boiler must be installed so that the
chilled medium is piped in parallel with the boiler
using appropriate valves to prevent the chilled
medium from entering the boiler. Also consult
I=B=R Installation and Piping Guides. If this boiler
is connected to heating coils located in air handling
units where they may be exposed to refrigerated air,
the boiler piping must be equipped with ow control
valves to prevent gravity circulation of boiler water
during operation of the cooling system.

7. Install optional low water cut-o in system piping
above the boiler, if not shipped with boiler. On
EVCA-750 through -2000 boilers, a low water cut­o may be installed on the boiler at the factory as
an option. A factory-mounted low water cut-o is
standard on all EVCA-3000 boilers.

8. Install an air eliminating device to remove air from
the system.

18

Figure 8: Schematic Boiler Piping

19

WARNING

Failure to operate the unit with the proper water

ow rate can lead to appliance failure. Always
verify proper water ow switch operation so that
the unit stops operating if improper water ow is

present.

Safety relief valve discharge piping must be
piped such that the potential of severe burns
is eliminated. DO NOT pipe in any area where
freezing could occur. DO NOT install any shut­off valves, plugs or caps. Consult Local Codes
for proper discharge piping arrangement.

If a high head system pump is installed, ensure
that the boiler relief valve and system piping are
capable of operating properly at the combined

pressure of the system ll pressure plus the

pump static head pressure.

Do not install valves, plugs or caps in safety
relief valve piping.

Safety relief valve piping must be terminated
such that in the event the safety relief valve
opens, the discharge will not cause personal
injury or damage.

Do not operate the boiler with ow rates in
excess of the maximum ow rates listed in Table

1B Tube erosion and pitting will occur. Thermal
Solutions Standard Warranty does not cover

problems caused by excessive water ow rates.

supplier or local plumbing inspector on how best to
control this situation.

12. A pressure relief valve is supplied with each boiler.
No valve is to be placed between the relief valve and
appliance.

a. Pipe the safety relief discharge to a suitable place

for disposal when relief occurs.
b. Do not install reducing couplings or other

restrictive devices in the safety relief discharge
line.

c. e safety relief discharge line must allow for

complete drainage of both the valve and line.

13. If the relief valve discharges periodically, this may be
due to thermal expansion in a closed water supply
system. Contact the water supplier or local plumbing
inspector on how to correct this situation. DO NOT
PLUG THE RELIEF VALVE.

9. Refer to Table 1B for pressure drop, ow rates, and
temperature rise (ΔTs).

10. e factory supplied circulator is not intended to
replace the boiler supply circulator or the system
supply circulator. It provides a constant ow to the
primary heat exchanger.

11. If the boiler is installed in a closed water supply
system, such as one having a back ow preventer in
the cold water supply line, means shall be provided
to control thermal expansion. Contact the water

Table 1B- EVCA BOILER FLOW AND PRESSURE DROP

BOILER

MODEL

(Ft. hd)

EVCA-750 32.4 70 17.8 47 11.6 35 8.3 28 6.3 23 5.0 20

EVCA-1000 36.9 94 20.9 63 13.9 47 10.2 38 7.9 31 6.4 27

EVCA-1500 53.7 142 27.3 95 16.9 71 11.7 57 8.6 47 6.7 41

EVCA-2000 67.8 190 36.0 127 23.0 95 16.2 76 12.2 63 9.6 54

EVCA-3000 29.2 291 15.2 194 9.6 146 6.7 116 5.0 97 3.9 83

Note: * Indicates maximum allowable ow rate.

*20°F ∆T 30°F ∆T 40°F ∆T 50°F ∆T 60°F ∆T 70°F ∆T

DP

GPM

DP

(Ft. hd)

GPM

DP

(Ft. hd)

GPM

DP

(Ft. hd)

GPM

DP

(Ft. hd)

GPM

DP

(Ft. hd)

GPM

20

E. GAS PIPING

WARNING

Failure to properly pipe gas supply to boiler may
result in improper operation and damage to the
boiler or structure. Always assure gas piping is
absolutely leak free and of the proper size and
type for the connected load.

An additional gas pressure regulator may be
needed. Consult gas supplier.

1. Size gas piping. Design system to provide adequate
gas supply to boiler. Consider these factors.

a. Allowable pressure drop from point of delivery

to boiler. Refer to Table 2 for minimum and
maximum boiler gas train inlet pressure. If gas
supply pressure is higher than maximum as listed
in Table 2, an additional eld supplied pressure
regulator will be required.

be located as far away from the boiler as possible to
prevent nuisance shutdowns.

a. e minimum and maximum inlet gas pressure

must not exceed the value specied in Table 2.

3. Install eld supplied sediment trap, ground-joint
union and manual non-displaceable shut-o valve
upstream of factory supplied shut-o valve outside
the boiler jacket. Use methods and materials in
accordance with Local Codes and requirements of
gas supplier. In absence of such requirements, follow
National Fuel Gas Code, NFPA 54/ANSI Z223.1
and/or CAN/CGA B149 Installation Codes.

4. Use thread joint compound resistant to the action of
liqueed petroleum gas.

WARNING

Failure use proper thread compounds on all gas

connectors may result in leaks of ammable gas.

TABLE 2 - BOILER GAS TRAIN

INLET PRESSURE

BOILER

MODEL

MIN ("w.c.) MAX (psig)

EVCA-750 7.0 5
EVCA-1000 7.0 5
EVCA-1500 7.0 5
EVCA-2000 9.0 5
EVCA-3000 6.0 5

b. If a lower minimum gas pressure is needed,

the low gas pressure build can be used. e
minimum gas pressure on all of the low gas
pressure builds is 4.0 in. w.c. Consult factory if
this option is desired. is option is not available
on the EVCA-3000.

c. Maximum gas demand. Table 6 lists boiler input

rate. Also consider existing and expected future
gas utilization equipment (i.e., water heater,
cooking equipment).

d. Length of piping and number of ttings. Refer

to Table 3 for maximum capacity of schedule
40 pipe. Table 5 lists equivalent pipe length for
standard ttings.

i. Given the specic gravity of gas at your

location, a correction factor can be found on
Table 4 and multiplied by the "Capacity in
Cubic Feet of gas Per Hour" on Table 3.

ii. For gas piping material other than schedule

40 pipe, refer to the National Fuel Gas Code,
NFPA 54/ANSI Z223.1 and/or CAN/CGA
B149 Installation codes.

MODULATION

5. All above ground gas piping upstream from eld
supplied manual gas valve must be electrically
continuous and bonded to a grounding electrode.
Do not use gas piping as grounding electrode. Refer
to National Electrical Code, ANSI/NFPA 70 and /or
CSA C22.1 Electrical Codes.

WARNING

Gas supply to boiler and system must be
absolutely shut off prior to installing or servicing
boiler gas piping.

WARNING

Use an additional gas pressure regulator where
the gas pressure is greater than 5 psig. Using
one additional regulator for multiple boilers
may result in unsafe boiler operation. The
additional regulator must be able to properly

regulate gas pressure ow at the lowest input of

a single boiler. If the regulator cannot do this,

two or more additional regulators are required.

Consult regulator manufacturer's instructions for

minimum gas ow rate.

NOTICE

The EVCA-3000 is shipped with the gas line
regulator in the downward position. During
installation loosen the union behind the regulator
and rotate gas inlet to horizontal orientation.
Remove cap and reattach 1/4" regulator tubing to
regulator.

2. If step down regulator is required, it must be used in
conjunction with the factory supplied regulator and

21

6. Pressure test. e boiler and its gas connection must
be leak tested before placing boiler in operation.

a. Protect boiler gas control valve. For all testing

over ½ psig, boiler and its individual shuto
valve must be disconnected from gas supply
piping. For testing at ½ psig or less, isolate
boiler from gas supply piping by closing the
boiler's individual manual shuto valve.

b.. Locate leaks using approved combustible

gas detector, soap and water, or similar
nonammable solution.

Do not use matches, candles, open ames or

other ignition source to check for leaks.

DANGER

TABLE 3: MAXIMUM GAS CAPACITY OF SCHEDULE 40 PIPE.

(Based on Gas Pressure less than 2 psi, pressure drop of 0.3 in w.c. and 0.6 specic gravity.)

Pipe Length in

Pipe Size (in.)

Equivalent Feet

3/4 1 1-1/4 1-1/2 2 2-1/2 3 4

Capacity in Cubic Feet of Gas Per Hour
10 273 514 1060 1580 3050 4860 8580 17500
20 188 353 726 1090 2090 3340 5900 12000
30 151 284 583 873 1680 2680 4740 9660
40 129 243 499 747 1440 2290 4050 8270
50 114 215 442 662 1280 2030 3590 7330
60 104 195 400 600 1160 1840 3260 6640

70 95 179 368 552 1060 1690 3000 6110
80 89 167 343 514 989 1580 2790 5680
90 83 157 322 482 928 1480 2610 5330

100 79 148 304 455 877 1400 2470 5040
125 70 131 269 403 777 1240 2190 4460
150 63 119 244 366 704 1120 1980 4050
175 58 109 224 336 648 1030 1820 3720

200 54 102 209 313 602 960 1700 3460

TABLE 4 – SPECIFIC GRAVITY

CORRECTION FACTORS

Specic
Gravity

0.50 1.10 1.10 0.74

0.55

0.60

0.65

0.70

0.75

0.80

0.85

0.90

1.00

Correction

Factor

Specic
Gravity

1.04 1.20 0.71

1.00 1.30 0.68

0.96 1.40 0.66

0.93 1.50 0.63

0.90

0.87

0.84

0.82

0.78

1.60 0.61

1.70 0.59

1.80 0.58

1.90 0.56

2.00 0.55

Correction

Factor

22

TABLE 5 - EQUIVALENT OF STANDARD PIPE FITTING & VALVES

Valves Fully Open (Screwed,

Pipe

Size

1/2"
3/4"

1"

1-1/4"

1-1/2"

2"

2-1/2"

3"

4"
6"

Equivalent lengths are for standard screwed ttings and for screwed, anged, or welded valves relative

to schedule 40 steel pipe.

I.D.

Inches

0.622

0.824

1.049

1.380

1.610

2.067

2.469

3.068

4.026

6.065

Flanged, Welded)

Gate Globe Angle

0.36

0.48

0.61

0.81

0.94

1.21

1.44

1.79

2.35

3.54

17.3

22.9

29.1

38.3

44.7

57.4

68.5

85.2

112
168

8.65

11.4

14.6

19.1

22.4

28.7

34.3

42.6

56

84.1

Swing

Check

4.32

5.72

7.27

9.58

11.2

14.4

17.1

21.3

28.0

42.1

Schedule 40, Screwed Fittings

90°

Elbow

(threaded)

1.55

2.06

2.62

3.45

4.02

5.17

6.16

7.67

10.1

15.2

45°

Elbow

(threaded)

0.73

0.96

1.22

1.61

1.88

2.41

2.88

3.58

4.70

7.07

90° Tee, Flow

through Branch

(threaded)

3.10

4.12

5.24

6.90

8.04

10.3

12.3

15.3

20.2

30.4

WARNING

Table 6 lists gas inputs at sea level to 2000 feet altitude. Reduce gas input four percent (4%) for each
additional 1000 feet above sea level.

TABLE 6: RATED INPUT

BOILER
MODEL

EVCA-750 750 300 1

EVCA-1000 1000 400 1-1/2

EVCA-1500 1500 600 1-1/2

EVCA-2000 2000 800 1-1/2

EVCA-3000 3000 1200 2

RATED CAPACITY (CFH)

NATURAL LP/PROPANE

GAS CONNECTION SIZE (inch dia.)

23

F. ELECTRICAL

1. General. Install wiring and ground boiler in
accordance with authority having jurisdiction or in
absence of such requirements National Electrical
Code, ANSI/NFPA 70 and/or CSA C22.1 Electrical
Code.

WARNING

Failure to properly wire electrical connections to
the boiler may result in serious physical harm.
DO NOT ATTACH ADDITIONAL J-Box to back or
top of boiler jacket.

DANGER

Positively assure all electrical connections are
unpowered before attempting installation or
service of electrical components or connections
of the boiler or building. Lock out all electrical
boxes with padlock once power is turned off.

2. A separate electrical circuit must be run from
the main electrical service with an over-current
device/disconnect in the circuit. A service switch
is recommended and may be required by some
local jurisdictions. Locate the service switch such
that the appliance can be shut o without exposing
personnel to danger in the event of an emergency.

3. Connect the main power supply and ground from
fused disconnect to proper boiler electrical leads
located in the junction box at the rear of the boiler.
Refer to electrical consumption plate on boiler
jacket.

4. Protection for the factory installed circulator is
provided by the factory. Install a separate fused
disconnect switch for each additional circulator
installed (i.e. boiler and system circulators).

5. Connect eld supplied safety limits or devices
using proper terminals provided in boiler electrical
cabinet. Refer to wiring diagram supplied with
boiler for wiring information. Refer to Figures 9a ­9f for typical wiring diagrams. Refer to Figure 1, for
electrical requirements for boiler.

WARNING

Electrical power may be supplied from more than
one service. Make sure all power is off before
attempting any electrical work.

The wiring diagrams contained in this manual are
for reference purposes only. Each boiler may be

wired differently according to the specications

given to Thermal Solutions at the time the boiler
was purchased. Always use the wiring diagram
provided with the boiler. If the wiring diagram
provided with the boiler is unavailable, STOP all
wiring work and contact Thermal Solutions for a
replacement diagram.

Do not directly connect low voltage (24 volt,
milliamp, etc.) controls to this boiler. If low
voltage controls are desired, isolating relays
must be used.

Never jump out any safety controls.

Never jump out or make inoperative any safety
or operating controls. Each boiler must be
protected with a properly sized over-circuit
device.

6. e following pages have sample wiring diagrams.
Contact ermal Solutions Representative or visit
website (www.thermalsolutions.com) for current
wiring options.

7. An as-built wiring diagram is included with every
boiler when it ships.

CAUTION

Each boiler must be protected with a dedicated
properly sized fused disconnect.

24

Figure 9a: 208/230/480V - 1PH/3PH - 60HZ Supply Power Wiring Schematic

25

Figure 9b: 120V - 1PH - 60HZ Supply Power Wiring Schematic

26

Figure 9c: Control Wiring Schematic (EVCA-750/2000)

27

PUMP MOTOR STARTER

AND OVERLOAD RELAY

BLOCKED AIR FILTER

SWITCH AND LIGHT

115V TO 24V

TRANSFORMER

MIXING VALVE

1 2 3

LINE TYPES:

120V-1PH-60HZ

SEE FIGURES 9a&9b FOR
SUPPLY POWER WIRING

ALARM SILENCE

PUSH BUTTON

ALARM BELL

TO VSD
TERMS.
1&2

M

96 95

LT

ACTUATOR

FACTORY WIRING, LINE VOLTAGE

FACTORY WIRING, LOW VOLTAGE (SEE NOTE 2)

FACTORY WIRING, SPECIAL IGNITER

FIELD WIRING, LINE VOLTAGE

FIELD WIRING, LOW VOLTAGE

OPTIONAL WIRING

GND TO

CHASSIS

(2)

(1)

DRY CONTACTS

FOR BOILER

STATUS

INDICATION

A1A2

BOILER PUMP

5 9

CRA3

NO

115V TO 24V

TRANSFORMER

GND TO

CHASSIS

OUTLET

SENSOR

INLET

SENSOR

PROG. SPARE OUTPUT

(COLD AIR DAMPER,

SYSTEM PUMP BACKUP

LOCKOUT INDICATOR

G

L2

L1

29

2

30

31

32

33

34

35

36

37

38

39

40

41

43

44

45

46

3

2

3

C

2

3

3

47

48

49

2

50

OR ALARM)

SYSTEM PUMP

SPARE

CONTROL RELAY OPTIONS

G

2

FUSE

K3

3

K5

K5

K3

K4

K6

K2

REMOTE CONTROL

REMOTE SETPOINT

(VALID INPUT SIGNAL RANGE IS 1-9VDC)

4

5

6

21

9

8

10 28

G

F

0

2

9

13 14

CRA

1

5

9

13 14

CRA

2

5

13 14

CRA

3

9

13 14

CRA

4
5
9

13 14

CRA

5
5

OR

0-10 VDC INPUT

SEE NOTE 6

Q7800H1009 INTERNAL WIRING

4

SENSE

ALARM RELAY K2

K2

LINE VOLTAGE ALARM

K3

BLOWER MOTOR

K5

AUXILIARY RELAY

K4

K6

MAIN FUEL

VALVE(S)

HONEYWELL Q7800H

FLAME SAFEGUARD SUBBASE

AND

PROGRAMMER CONTROL

RM7896D 1027

24VAC -

24VAC +

C

FUSE

PR

BO

BC

BI

C

C

C

SO

SP

BP

VI

LO

1

R

MS

m

h

o

0

0

5

MR

C-

C+

RJ11

GND TO

CHASSIS

K1 K1

SENSE

LOW WATER CUTOFF

SENSE

BURNER ON/OFF

SWITCH

SENSE

WATER FLOW SWITCH

SENSE

GAS PRESS SWITCHES

SENSE

HIGH LIMIT

SENSE

COMBUSTION AIR

FLOW

SENSE

MAIN FUEL VALVE

THERMAL SOLUTIONS

BOILER CONTROL

(TSBC)

CA HL GP WF
OO V- V+ P- P+

12 VDC

0.5A MAX TOTAL
FOR SO, SP, BP,
V1, & LO

4-20 mA DC

CONVERTED TO

2-10 VDC

(FIELD SUPPLIED

CONTACTS/SWITCHES)

CALL FOR

HEAT

24VAC -

24VAC +

Pin 6

Pin 1

K1

11

10

9

8

7

6

5

Pin 7

Pin 1

12 VDC

2

3

10

11

12

13

14

15

16

17

18

19

20

21

22

237

24

25

26

2

42

27

2

2

12

3

11

10

9

8

7

6

5

4

2

1

AL

CS

10

9

8

7

6

5

4

3

2

1

LC

CH

O+

O+

O-

O-

R+

R+

R-

R-

DP

LR

RO

C

SI

C

RJ45

BURNER

THERMAL FUSE

OPTIONAL

SEE NOTE 3

HIGH LOW

HIGH LIMIT OPERATING LIMIT

NC

MANUAL AUTO

PRIMARY SECONDARY

GAS RATIO

GAS

ACTUATOR

VALVE

L

E/H

N

2

1

4

3

REMOTE

LOCAL

P

2

1

BURNER ON/OFF SWITCH

WATER FLOW SWITCH

HIGH AND LOW GAS
PRESSURE SWITCHES

HIGH LIMIT AND OPERATING
TEMPERATURE SWITCHES

UNUSED OPERATING LIMIT

COMBUSTION AIR FLOW
SWITCH

VENT VALVE
(OPTIONAL)

INTERRUPTED
IGNITION PILOT
GAS VALVE

UV SCANNER

2

5

OUTSIDE AIR

RESET OPTION

3

5

IGNITION XFMR

IGNITION PILOT

COMBUSTION BLOWER
SPEED CONTROL
CIRCUIT

REMOTE SYSTEM
SENSOR

VESTIBULE

THERMAL FUSE

CNO

CNC

L

N

CNO

NC

CC

CNO

GND TO
CHASSIS

VARIABLE

SPEED DRIVE

AC Tech SCF

1

12

2

2

OUTSIDE AIR
SENSOR

DOMESTIC HOT WATER PRIORITY
DOMESTIC HOT WATER PRIORITY

LOCAL/REMOTE(REMOTE CONTROL OR REMOTE SETPOINT)
LOCAL/REMOTE(REMOTE CONTROL OR REMOTE SETPOINT)

REMOTE ON/OFF(ENABLE/DISABLE)
SEE NOTE 5

SPARE INPUT
SPARE INPUT

MM 750-

MT-120

LOW WATER

CUTOFF

OPTION

(SEE NOTE 1)

(38)

(37)

TO K3
RELAY ON
FLAMESAFEGUARD
SUBBASE
TERM. 37 & 38

Figure 9d: Ladder Wiring Diagram (EVCA-750/2000)

28

Figure 9e: Control Wiring Schematic (EVCA-3000)

29

120V-1PH-60HZ
SEE FIGURES 9a&9b FOR
SUPPLY POWER WIRING

PUMP MOTOR STARTER

AND OVERLOAD RELAY

BLOCKED AIR FILTER

SWITCH AND LIGHT

115V TO 24V

TRANSFORMER

ALARM SILENCE

PUSH BUTTON

ALARM BELL

TO VSD
TERMS.
1&2

A1A2

M

96 95

LT

TRANSFORMER

(2)

(1)

BOILER PUMP

115V TO 24V

GND TO

CHASSIS

DRY CONTACTS

FOR BOILER

STATUS

INDICATION

5 9

CRA3

NO C

G

L2

FUSE

L1

K3

29

2

30

31

K5

32

33

34

35

K5

36

37

K3

38

39

K4

40

41

43

44

45

K6

46

3

2

3

2

3

3

47

K2

48

49

2

50

Q7800H1009 INTERNAL WIRING

G

2

AND

24VAC -

24VAC +

K1 K1

SENSE

LOW WATER CUTOFF

SENSE

BURNER ON/OFF

SWITCH

SENSE

WATER FLOW SWITCH

SENSE

GAS PRESS SWITCHES

SENSE

HIGH LIMIT

SENSE

COMBUSTION AIR

FLOW

SENSE

MAIN FUEL VALVE

K1

CALL FOR

HEAT

11

10

9

8

7

6

5

12

11

10

Pin 7

Pin 1

4

SENSE

ALARM RELAY K2

K2

3

LINE VOLTAGE ALARM

K3

4

BLOWER MOTOR

5

K5

AUXILIARY RELAY

6

21

K4

K6

9

MAIN FUEL

VALVE(S)

8

10 28

G

F

HONEYWELL Q7800H

FLAME SAFEGUARD SUBBASE

0

2

PROGRAMMER CONTROL

RM7896D 1027

2

3

10

11

12

13

14

15

16

17

18

19

20

21

22

237

24

25

26

2

42

27

2

2

3

9

8

7

6

5

4

2

1

VESTIBULE

THERMAL FUSE

HIGH LOW

CNC

HIGH LIMIT OPERATING LIMIT

NC

MANUAL

PRIMARY SECONDARY

GAS RATIO

GAS

ACTUATOR

VALVE

L

E/H

N

N

L

NC

AUTO

GND TO
CHASSIS

P

2

1

MM 750­MT-120

3

LOW WATER

CUTOFF

5

BURNER ON/OFF SWITCH

WATER FLOW SWITCH

CNO

HIGH AND LOW GAS
PRESSURE SWITCHES

CNO

HIGH LIMIT AND OPERATING
TEMPERATURE SWITCHES

CC

UNUSED OPERATING LIMIT

COMBUSTION AIR FLOW
SWITCH

CNO

VENT VALVE
(OPTIONAL)

INTERRUPTED
IGNITION PILOT
GAS VALVE

UV SCANNER

IGNITION XFMR

IGNITION PILOT

G G0 Y

LINE TYPES:

MIXING VALVE

ACTUATOR

FACTORY WIRING, LINE VOLTAGE

FACTORY WIRING, LOW VOLTAGE (SEE NOTE 2)

FACTORY WIRING, SPECIAL IGNITER

FIELD WIRING, LINE VOLTAGE

FIELD WIRING, LOW VOLTAGE

OPTIONAL WIRING

GND TO
CHASSIS

OUTLET

SENSOR

INLET

SENSOR

PROG. SPARE OUTPUT

COLD AIR DAMPER,

SYSTEM PUMP BACKUP

OR ALARM

SYSTEM PUMP

SPARE

LOCKOUT INDICATOR

CONTROL RELAY OPTIONS

9

13 14

CRA

1

5

9

13 14

CRA

2

5

13 14

CRA

3

9

13 14

CRA

4
5
9

13 14

CRA

5
5

REMOTE CONTROL

OR

REMOTE SETPOINT

0-10 VDC INPUT

(VALID INPUT SIGNAL RANGE IS 1-9VDC)

SEE NOTE 2

THERMAL SOLUTIONS

BOILER CONTROL

(TSBC)

C

FUSE

PR

BO

BC

BI

C

C

C

SO

SP

12 VDC

0.5A MAX TOTAL
FOR SO, SP, BP,
V1, & LO

BP

VI

LO

MS

MR

C-

C+

RJ11

GND TO

CHASSIS

24VAC -

24VAC +

Pin 6

CA HL GP WF
OO V- V+ P- P+

Pin 1

(FIELD SUPPLIED

CONTACTS/SWITCHES)

12 VDC

AL

CS

10

9

8

7

6

5

4

3

2

1

LC

CH

O+

O+

O-

O-

R+

R+

R-

R-

DP

LR

RO

C

SI

C

RJ45

LOCAL

2

1
4

3

REMOTE

VARIABLE

SPEED DRIVE

AC Tech SCF

1

12

2

2

OUTSIDE AIR
SENSOR

DOMESTIC HOT WATER PRIORITY

DOMESTIC HOT WATER PRIORITY

LOCAL/REMOTE(REMOTE CONTROL OR REMOTE SETPOINT)

LOCAL/REMOTE(REMOTE CONTROL OR REMOTE SETPOINT)

REMOTE ON/OFF(ENABLE/DISABLE)

REMOTE ON/OFF(ENABLE/DISABLE)
SEE NOTE 3

SPARE INPUT

SPARE INPUT

2

5

COMBUSTION BLOWER
SPEED CONTROL
CIRCUIT

OUTSIDE AIR

RESET OPTION

(38)

(37)

REMOTE SYSTEM
SENSOR

TO K3
RELAY ON
FLAMESAFEGUARD
SUBBASE
TERM. 37 & 38

Figure 9f: Ladder Wiring Diagram (EVCA-3000)

30

G. MODULAR SYSTEMS

1. General Guidelines

a. Read and follow all venting, combustion

air, water piping, gas piping and electrical
instructions contained in this manual unless
otherwise instructed in this section.

b. Modular systems are complex. Design and

installation of modular systems should only
be undertaken by skilled and knowledgeable
engineers and contractors.

c. Consult Local Building Codes, National Fuel Gas

Code, or NFPA 54/ANSI Z223.1 for restrictions
and instructions for modular boilers.

d. Refer to the Pre-Installation section for further

warnings, cautions, notices and instructions.

2. Module Sizing

Consult factory for recommended number and

size of boilers for a given input.

3. Venting

a. Refer to Venting Section for sidewall and vertical

venting guidelines.

b. Each boiler requires an individual vent pipe.

c. e minimum horizontal distance between

vent terminations is one (1) foot. Additional
horizontal distance is desirable to avoid frost
damage to the building. Vent terminations must
be at least twelve (12) inches above the ground
plus the expected snow accumulation.

d. IMPORTANT: Refer to the Venting section

for further warnings, cautions, notices and
instructions.

4. Air Intake Piping

a. Consult intake pipe manufacturer for common

air intake pipe sizing.

b. Refer to Figures 10 and 11 for common air intake

guidelines for modular boilers.

c. Individual air intake pipes may be used in lieu of

common air intake piping.

d. Common air intake straight lengths and ttings

should be assumed to have the equivalent length
the same as an individual air intake pipe, used for
a given boiler intake pipe diameter.

e. Position horizontal air intake termination center

line below horizontal vent termination's center
line.

f. Vertical air intake pipe must terminate at least

two (2) feet above the closest portion of the roof.

g. IMPORTANT: Refer to the Combustion Air

section for further warnings, cautions, notices
and instructions.

5. Water Piping

a. Refer to Figure 12 for the recommended piping

arrangement on modular boiler systems. Refer
to Figures 13, 14, 15, 16 or 17 for alternate piping
arrangements on modular boiler systems.

b. Installing a low water cut-o in the system piping

is highly recommended and may be required by
Code, if not factory-mounted on boiler.

c. Refer to Table 1b for pressure drop for each

boiler.

d. Consult I=B=R Installation and Piping Guide.

e. Maintain ½" minimum distance between water

piping and combustible material.

f. Refer to Water Piping and Trim Section

for further warnings, cautions, notices and
instructions.

NOTICE

The pressure drop given in Table 1B is for the
boiler only. The pressure drop of each system

tting and component must be added to the

boiler pressure drop to determine the system

pressure head requirement. See Table 5 for
tting and component equivalent lengths.

CAUTION

Proper water treatment is required. The water

shall have a maximum water hardness of 8.5
grains or 150 ppm. The recommended pH range
is 8.8 to 9.2.

6. Gas Piping

a. Refer to National Fuel Gas Code, Local Codes

and Tables 2 through 6 for gas pipe sizing.

b. Refer to Gas Piping Section for further warnings,

cautions, notices and instructions.

31

Figure 10: Modular System Horizontal Air Intake Piping

32

Figure 11: Modular System Vertical Air Intake Piping

33

Figure 12: Modular System: Typical One Pipe Water Piping

34

Figure 13: Modular System: Typical Primary/Secondary Water Piping

35

Figure 14: Modular System: Typical Primary/Secondary without System Pump

36

Figure 15: Modular System: Typical Reverse - Return Water Piping

37

Figure 16: Modular System Reverse - Return with System Pump Only

38

Figure 17: Modular System: Typical Primary/Secondary with Reverse-Return

39

7. Electrical

a. Each boiler must be provided with a dedicated

fused disconnect.

b. Install wiring and ground boiler in accordance

with requirements of authority having
jurisdiction. In absence of such requirements,
reference the National Electrical Code, ANSI/
NFPA 70 and/or CSA C22.1 Electrical Code.

c. Refer to Figure 1 for electrical data for each size

boiler.

d. Refer to the Electrical Section for further

warnings, cautions, notices and instructions.

NOTICE

Do not install boiler and circulator pump on the
same fused disconnect.

8. Condensate Piping

a. Each boiler requires separate condensate drains.

In addition, most venting congurations require
separate condensate drains in the vent system.

H. CONDENSATE DRAINS

1. Each boiler has two condensate drains - one from
the primary heat exchanger, and one from the
secondary heat exchanger. In addition, most vent
congurations require a drain tee located in the vent
piping. Pipe each condensate drain separately to a
oor drain or condensate pump/sump. See Table 7
for maximum condensate ow rates.

2. Use continuous Teon, high temperature resistant
silicone tubing, or other tubing material compatible
with ue gas condensate for condensate piping.

CAUTION

Failure to properly pipe condensate system will
greatly reduce boiler life. Do not install plugs,
caps or valves on condensate piping.

Do not manifold boiler condensate drains or vent
drains together.

Do not crimp condensate lines or reduce drain
line inner diameter size.

Each condensate drain must contain a siphon/

pigtail or trap to prevent ue gas ow through

the condensate piping. The height of the top of
the siphon/pigtail loop or trap shall not exceed
the height of the condensate drain outlet.

3. A common condensate pump/sump may be used.
Run separate piping from each condensate drain
to the sump. A common drain may be used to
discharge condensate from the sump. Consult
pump/sump manufacturer for compatibility of
pump/sump materials of construction. If a common
sump is used, individual drain lines should be
connected such that one drain cannot back feed into
another drain.

4. Consult local authorities regarding disposal of ue
gas condensate into public waste water system.
Some jurisdictions require that the condensate
be buered before discharge. is buering is
commonly achieved by draining the condensate
through a limestone bed. e condensate will be
slightly acidic and range between 3 - 5 on the pH
scale. Consult ermal Solutions or a chemical
treatment company for buering systems.

TABLE 7: MAXIMUM CONDENSATE
FLOW

Boiler

Model

Condensate Flow (gal/hr)

EVCA-750 3.4
EVCA-1000 4.5
EVCA-1500 6.8
EVCA-2000 9.1
EVCA-3000 18.6

Maximum

CAUTION

Do not use material that is not approved for use

with ue gas condensate for condensate piping.

40

IV. System Start-up

CAUTION

Failure to properly pipe boiler may result in
improper operation and damage to boiler or
structure.

Oxygen contamination of boiler water will cause
corrosion of iron and steel boiler components,
and can lead to boiler failure. Thermal Solutions
Standard Warranty does not cover problems
caused by oxygen contamination of boiler water.

Proper water treatment is required to avoid scale

build-up on the inside of the boiler. Thermal
Solutions standard warranty does not cover
problems caused by scale build-up.

All piping either new or existing must be cleaned
with a tri sodium phosphate (TSP) solution to
remove mill scale and oils from the system.
Failure to do so could result in premature failure
of the heat exchanger (not covered by Thermal
Solutions warranty).

On an existing or retrot system, a lter or

strainer must be installed on the system return
prior to the boilers.

When using Glycol products, all Glycol manu-

factures' requirements, including rust inhibitors,

must be adhered. Max 50% Glycol.

A. System Check

1. Verify that the venting, water piping, gas piping and
electrical system are installed properly. Refer to
installation instructions contained in this manual.

WARNING

Completely read, understand and follow all

instructions in this manual, Honeywell ame

safeguard, and all other component manuals
supplied with this boiler before attempting start
up.

2. Conrm all electrical, water and gas supplies are

turned o at the source and that chimney/vent
is clear of obstructions. If boiler is controlled by
an external control system, this system must be
temporarily disconnected. e local boiler controls
should be allowed to operate the boiler.

3. Remove the upper front jacket panel.

WARNING

Prior to pressurizing the boiler water supply
system, be sure the boiler piping air vent is
properly installed. Refer to water piping section
of this manual.

CAUTION

This boiler contains a manual gas shut-off valve
inside of the upper front jacket panel

B. Pressurize the Hydronic System - ll entire heating

system with water and vent air from system. Use the
following procedure on a Series Loop or multi-zoned
system installed to remove air from the system while
lling.

1. Close full port ball valve in boiler supply piping.

2. Isolate all zones by closing zone valves or shut-o
valves in supply and return of each zone(s).

3. Attach a hose to the hose bib in system piping and
terminate hose in a ve gallon bucket at a suitable
oor drain or outside area.

4. Starting with one circuit at a time, open zone valve
or shut-o valve in system supply and return piping.

a. Open hose bib.

b. Open ll valve (Make-up water line should be

located directly aer full port ball valve in system
supply piping between air scoop and expansion
tank).

c. Allow water to overow from bucket until

discharge from hose is bubble free for 30 seconds.

d. Close the opened zone valve or shut-o valve for

the zone being purged of air, then open the zone
valve or shut-o valve for the next zone to be
purged. Repeat this step until all zones have been
purged. At completion, open all zone valves or
shut-o valves.

5. Close hose bib, continue lling the system until the
pressure gauge indicates required system operating
pressure. Close ll valve.

(Note - if make-up water line is equipped with

pressure reducing valve, system will automatically
ll to set pressure. Follow ll valve manufacturer's
instructions).

6. Open isolation valve in boiler supply piping.

7. Remove hose from hose bib.

8.

Conrm that the boiler and system have no water leaks.

4. Conrm that all manual shut-o gas valves between

the boiler and gas supply are closed.

CAUTION

For the EVCA-3000, do not open or adjust mixing
valve actuator rotating knob at the top of the
actuator. This will affect proper boiler operation.

41

WARNING

The maximum operating pressure of this boiler
is 160 psig. Never exceed this pressure. This
boiler was supplied with a safety relief valve with

a pressure relief setting specied at the time of

purchase. The relief valve setting must be above
the maximum operating pressure of the system.
Consult Thermal Solutions if the desired system
operating pressure is above the safety relief
valve pressure setting. Do not plug or change
safety relief valve.

C. Power the boiler - Turn on electrical supply to the

boiler and circulation system at fused disconnect
switches. Note that there is electrical power at certain
components even with the power switch o. See wiring
diagrams in Figures 9a-9f.

D. Power the Circulators - Turn system circulators on

and purge air from the boiler and system piping.

1. Conrm motor rotation on boiler and system
circulators.

2. Conrm that water ow switch is operating properly.

E. Pressurize the Fuel System - Turn on gas supply to the

boiler gas piping.

1. Conrm that the supply pressure to the gas regulator
supplied with the boiler conforms to Table 2 for
maximum and minimum supply pressures.

2. Open the manual gas shut-o valves located
upstream of the gas regulator supplied with the
boiler. Do not open manual gas valve inside of boiler
jacket.

DANGER

Do not use matches, candles, open ames or

other ignition source to check for leaks.

3. Using soap solution, or similar non-combustible
solution, electronic leak detector or other approved
method, check that boiler gas piping valves,
regulators and all other components are leak free.
Eliminate any leaks.

4. Purge gas line of air.

5. Reset low gas pressure safety switch.

F. Select Operational Mode - Refer to the ermal

Solutions Boiler ControlTM (TSBCTM) Instruction
Manual to select the desired control features.

G. Check Blower Rotation - Remove air lter to expose

the fan blades.

1. Allow boiler to enter the sequence of operation.

2. While in Pre-Purge, position the ame control to the

test position.

3. Conrm proper blower motor rotation.

4. Shut boiler o and position the ame control back to
run. Reinstall air lter.

H. Flame Safeguard Operation Check - Turn boiler

operating switch to the ON position.

1. Allow boiler to complete prepurge and trial for
ignition period. Once pilot ame is recognized by
controller, position ame control switch to TEST
position.

2. Look through the boiler sight glass and conrm
that pilot ame is blue and steady and that the ame
signal is steady and between 1.5 and 5.0 volts DC.
On some boiler sizes, the pilot ame may not be
visible. In these cases, conrm proper ame signal
(as indicated above.)

3. Adjust pilot gas regulator until proper pilot manifold
gas pressure is achieved per retest report label.
Pilot ame should be blue with very little yellow.

4. Turn the boiler o, place ame control switch in
"run" position, and repeat Steps H.1 and H.2 at least
ve times until reliable pilot ignition and signal is
achieved and conrmed.

5. With the pilot operating properly, allow boiler to
continue to trial for main ame. Conrm that the
ame control locks out on main ame failure.

6. Open the manual main gas shut-o valve located
inside the boiler jacket. Using the procedure detailed
in Step E.3, leak test gas piping and valves inside of
jacket. Eliminate any leaks.

7. Reset ame safeguard and allow boiler to run
through prepurge, trial for pilot and trial for main
ame.

8. Conrm that main ame ignites smoothly.

9. Observe main ame and conrm that burner
element is evenly orange without ickering.

10. Observe ame signal and conrm signal is steady
and between 1.5 and 5.0 volts DC.

11. Using the procedure detailed in step E.3, leak test
gas piping and valves inside of jacket. Eliminate any
leaks.

12. Turn boiler o and repeat Steps H.7-H.10 at least
ve times to conrm proper main burner operation.

I. Begin Commissioning the boiler - With main ame

on, at high re, measure gas pressure upstream and
downstream of the main gas valves

1. Adjust the manifold pressure to match the pressure
indicated on the factory retest label.

2. Reassure that the inlet gas pressure is within the
acceptable range found in Table 2. Adjust if
necessary.

42

WARNING

Failure to properly adjust gas input rate will

result in over ring or under ring of the

appliance. Improper and unsafe boiler operation
may result.

temperature operating control, manual reset water
temperature safety limit, vestibule fuseable link,
mixer fuseable link, high and low gas pressure
switches. Refer to manuals for these components for
proper start-up and operating instructions. Follow
all instructions contained in these manuals. is
manual was provided with the boiler.

3. Conrm that high and low gas pressure switches are

functioning and are adjusted to prevent over ring
or under ring of the boiler.

4. Adjust setting of air lter ow switch by rotating

knob on switch counter clockwise until change
lter light switch is illuminated. Turn switch knob
clockwise ¼ turn past the point where the change
lter light goes out. Replace upper front jacket
panel.

5. With boiler running and all panels attached,

measure oxygen (O2) and carbon monoxide
(CO) concentrations in the ue gas and ue gas
temperature. Compare results with values given on
factory retest report supplied with the boiler.

DANGER

Failure to properly adjust excess air will result
in unsafe levels of carbon monoxide. Variations
in venting or combustion air pressure and
temperature will change excess air. Adjust
excess air levels so that variation in venting
or combustion air pressures and temperatures
caused by change of seasons, wind conditions,
opening or closing of boiler room doors or
windows do not cause the boiler to operate with
carbon monoxide concentrations above 400
parts per million.

J. Finish Commissioning at the Boiler - Reconnect any

wires from the external control system, if applicable.

1. Test function of external control system.

2. Place system control back in normal operation, if

necessary.

K. Water Treatment - Contact reputable chemical

treatment company for recommendations on proper
water treatment for the installation. Each installation
is dierent and must be analyzed based on local water
conditions and boiler operating schedule.

e treatment chemicals must be compatible with

copper, bronze, steel and cast iron materials of
construction.

6. Verify that all safety and operating limits and ame

controls are operating properly. ese controls
and limits include combustion air switch, water

CAUTION

A proper water treatment and monitoring program will extend the life of the boiler. The water shall have
a maximum water hardness of 8.5 grains or 150 ppm. The recommended pH range is 8.8 to 9.2. However,

other aspects of water quality can affect boiler operation and longevity. A qualied water treatment expert

should be consulted to develop a complete water treatment plan.

WARNING

Chemicals used in treating boiler water are toxic and/or harmful. Always use protective clothing and

equipment when working with/near chemicals. Contact local authorities to determine if treated boiler water

can be discharged into local waste water system.

43

V. Lighting Instructions

FOR YOUR SAFETY, READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, a re or explosion may result

causing property damage, personal injury, or loss of life.

A. is appliance is equipped with an ignition device

which automatically lights the pilot. Do NOT try to
light the pilot by hand.

B. BEFORE OPERATING smell all around the appliance

area for gas. Be sure to smell next to the oor because
some gas is heavier than air and will settle on the oor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric 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.

OPERATING INSTRUCTIONS

1. STOP! Read all the safety information (warnings,
cautions etc.) in this manual.

2. Turn o all electric power to the appliance.

3. Set the system control so that there is no call for heat
to the appliance.

4. is appliance is equipped with an ignition device
which automatically lights the pilot and main
burner. Do not try to light the pilot or main ame
by hand.

5. Remove front door panel.

6. Locate the gas pilot valve at the rear of the appliance.

7. Locate the gas main valves at the rear of the
appliance and at the end of the gas supply pipe inside
the appliance.

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

C. Do not use this appliance if any part has been under

water. Immediately call a qualied service technician
to inspect the appliance and to replace any part of the
control system and any gas control which has been
under water.

10. Rotate gas shuto valves counterclockwise
from "OFF" to "ON". Make sure handle rests against
stop. Do not force.

12. Turn on all electric power to the appliance.

13. Set thermostat to desired setting.

14. If the appliance will not operate, follow
the instructions " TO TURN OFF GAS TO
APPLIANCE" and call your service technician or
gas supplier.

15. Move the switch to the "ON" position.

8. Rotate gas shuto valves clockwise from
"ON" position to "OFF". Make sure handle rests
against stop.

9. Wait ve (5) minutes to clear out any gas. en smell
for gas, including near the oor. If you smell gas,
STOP! Follow "B" in the safety information above on
this label. If you do not smell gas, go to the next step.

16. Set system control so that there is a call for heat
from the system.

17. Observe prepurge, pilot ignition and main ame
ignition.

18. If pilot or main ame ignition does not occur
during initial attempt, remove the upper front jacket
panel of the appliance. If the appliance pilot and
main ame light, go to step 20.

44

OPERATING INSTRUCTIONS CONTINUED

19. Reset the burner control by pressing the reset button
located on the burner control. If you do not know
where the control reset button is, do not touch any
part of the control system or wiring. Turn all gas
and electrical power o to the appliance and call a
qualied service technician.

20. Replace the upper front jacket panel.

To Turn Off Gas To Boiler

21. Observe several on and o cycles of the water heater.
If any light os are excessively noisy or rough, or any
questionable boiler operation is noticed, immediately
turn o all gas and electrical power and call qualied
service technician.

22. Should overheating occur or the gas supply fail
to shut o, turn o the manual gas control to the
appliance.

1. Set the thermostat to lowest setting.

2. Turn o electric power to the appliance if service is to
be performed.

3. Remove front door.

4. Rotate gas main shuto valves, located inside the
appliance, clockwise from "ON" position to
"OFF". Make sure handle rests against stop.

5. Replace front door.

6. At the rear of the unit, rotate the pilot and main gas
valves clockwise from "ON" position to
"OFF". Make sure handle rests against stop.

45

VI. Boiler Operational Sequence

Product Features

Boiler Sequence

Start/Stop Sequence StatesPre-Sequence States

BOILER STATE

LCD Displa y

Boiler Disable or Remote On/Off

Warm Weather Shutdown Setpoint

Domestic Hot Water Priority

System Pump Feedback

(LC, OO, WF , GP and HL inputs)

Limits

Inp uts

(Combustion Air Flow (CA Input))

(Manual Reset Required)

Parame ter / Notes

Outdoor Air Temp >

Low Fire Hold

Fuel Valve Energized

Flame Safeguard Alarm

Call For Heat

Recycling Li mits

Non-Recyclin g Limi ts

Call For Heat Relay

Lockout Indi cator

Spare Output

Terminal Number

RO

O+,O-

DP

SI

CS

AL

SI

R+,R-

OR

BO,BC

LC , OO ,WF,

GP ,H L

CA

CH

LO

VI

-

44 ,30 ,

75

20 ,74

9

-

-

9

70 ,71 ,

72

8,27,

28

-

-

-

-

Parameter/Note

Boiler Disable

Warm Weather

Sh ut do wn

Lockout

b &ca aa

Pump P urg e

Standby

Purge / Pilot Ignition

Limit Hold

-3/d - - -53 4/d

-

Main Ignition

Low Fire / Ignition

Low Fire Hold

Boiler Running

Pump Cooldown

Fan Post Purge

54/d

Boiler Enable/Disable On

Domestic Hot Water Demand Monitored

System Pump Feedback Monitored

Call For Heat

Recycling Limits Made

Non-Recycling Limits Made

Call For Heat Relay On

Spare Output On

Boiler Pump

System Pump

Relay Outputs Interlock Inputs

System Pump Backup Pump

Combustion Air Damper

System Ala rm

Mixing Valve Output

MS,MR

Blower High Speed

Purge %

Modulation

Firing Rate

Modulation Outputs

Low Fire %

Blower 0 Volts

BP

SP

SO

SO

SO

V+,V-,

P+,P -

V+,V-,

P+,P -

V+,V-,

P+,P -

V+,V-,

P+,P -

V+,V-,

P+,P -

2,30

25 ,30

10

10 ,27 /

e

10

6,79,

80

49

52

-

9,51/f

50

Boiler Pump On

System Pump On

Starts in response to System Pump Feedback Input SI

Combustion Air Damper Open

Alarm Status is Monitored

Modulate

Notes

a. Boiler Pump is “On” when the Boiler Pump is set to “On Always” or the boiler is lead boiler and Boiler Pump is set to “On Lead”.
b. Boiler Pump is "On" when the Boiler Pump is set to "On Always" and WWSD is set to "WWSD of System Pump" or “Off”.
c. System Pump is "On" when the System Pump is set to “yes” and WWSD is set to either "WWSD of Boiler" or "Off".
d. Boiler pump is "On" during Prepurge and Post Purge when Boiler Pump is set to "Purge" or boiler is lead & Boiler Pump is set to “On Lead”.
e. Combustion Air Damper Spare Output is maintained “On” for 2 minutes after the Call For Heat is removed.
f. Modulation rate is held at purge % when low fire input is not provided.

46

Product Features

Boiler Sequence (Continued)

Pre-Sequence States

BOILER

STATE

LCD Display

Boiler

Disabled

Warm

Weather

Shutdown

Lockout Any Mode

Standby

CONTROL MODE

LCD Display

Any Mode

(Except for

Remote Control)

Any Mode

(Except for

Manual Mode)

Outlet Sensor &

Local SP Mode

Remote Sensor

& Local SP

Mode

Outlet Sensor &

Remote SP

Mode

Remote Sensor

& Remote SP

Mode

Remote Control

Mode

Manual

Operation Mode

Description

Boiler is prevented from starting, Remote On/Off (Enable) (Terminal RO) Input is not
energized.

Boiler is prevented from starting, Warm Weather Shutdown (WWSD) is enabled and
outside air temperature is above the WWSD Setpoint.

Boiler is prevented from starting, Flame Safeguard lockout is present. A Flame
Safeguard manual reset is required.
Control monitors boiler outlet temperature, a Call For Heat is initiated when boiler
outlet temperature is below the Operational Setpoint.

Control monitors Remote System Temperature, a Call For Heat is initiated when
Remote System Temperature is below the Operational Setpoint.

Control monitors boiler outlet temperature, a Call For Heat is initiated when boiler
outlet temperature is below the Remote Setpoint Input (Terminal C+,C- or Modbus
Interface).
Control monitors Remote System Temperature, a Call For Heat is initiated when
Remote System Temperature is below the Remote Setpoint Input (terminal C+,C- or
Modbus Interface).
Control monitors Remote On/Off (Enable) input (Terminal RO or Modbus Interface), a
Call For Heat is initiated when input is energized.

A Call For Heat is initiated when Manual Mode Menu item Boiler On/Off is set to On.

Start/Stop Sequence States

BOILER

STATE

LCD Display

CONTROL MODE

LCD Display

Any Mode

Pump Purge

(Except

Manual Mode)

Limit Hold Any Mode

Purge / Pilot

Ignition

Low Fire /

Ignition

Any Mode

Any Mode

Main Ignition Any Mode

Low Fire

Hold

Boiler

Running

Fan Post

Purge

Pump

Cooldown

Any Mode The modulation output is held at the Low Fire for the Low Fire Hold time.

Any Mode

Any Mode

Any Mode

Description

Once a Call For Heat is initiated and Boiler Pump Purge is selected, the pump output
is energized until the Pump Prepurge Time is complete. If the Call For Heat condition
still exists at the end of the Prepurge Time (the temperature of the water at the sensor
may rise with boiler water flowing passed it) the pump will continue to operate and the
Call For Heat Relay is energized.
Power is applied to the safety limit string. If any limits does not pass power (is not
energized), the alarm LED and LCD display shows the reason the start sequence is
on Hold. Refer to Trouble shooting section for explanation of individual lockout and
alarm messages.
After the limit string passes power, the fan is started, the modulation output is set to
Purge Rate. When the purge period is complete, the flame safeguard sequences on
the ignition transformer and pilot.
When the Spare Input Low Fire is selected, modulation output is set to the Low Fire
Speed when the Spare Input is energized.
The main gas valve input is energized and the modulation output is held constant for
an ignition stabilization period.

When this Low Fire Hold time is complete, the modulation output is released to
modulate.
When water temperature is above setpoint, there is a Flame Safeguard or Limit fault,
the Call For Heat is ended and the modulating output is set to Purge Rate for the Post
Purge Time.
When Boiler Pump Purge is selected, the boiler pump remains “on” until the boiler
outlet temperature is less than the Post Purge Delta (default is 5 F) above the Boiler
Inlet Temperature.

47

VII. Service/Maintenance

GENERAL GUIDELINES

1. A thorough and complete boiler inspection and check must be conducted a minimum of one (1) time per year.

2. Follow any checks and/or inspections that may be required as specied in the component manufacturer's

instruction manuals.

3. Repair or replace any defective compontents immediately.

4. The following service procedures are required for proper and safe boiler operation.

DANGER

This boiler uses ammable gas, high voltage electricity, moving parts, and very hot water under high

pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool
before attempting any disassembly or service.

More than one gas shut-off valve and electrical disconnect switch are used on the boiler. Assure that all
gas valves and electrical disconnect switches are off before attempting any disassembly or service.

Do not attempt any service work if gas is present in the air in the vicinity of the boiler.
Never modify, remove or tamper with any control device.

WARNING

This boiler must only be serviced and repaired by skilled and experienced service technicians.

If any controls are replaced, they must be replaced with identical models.

Read, understand and follow all the instructions and warnings contained in all the sections of this
manual.

If any electrical wires are disconnected during service, clearly label the wires and ensure that the wires
are reconnected properly.

Never jump out or bypass any safety or operating control or component of this boiler.

Read, understand and follow all the instructions and warnings contained in ALL of the component
instruction manuals.

Assure that all safety and operating controls and components are operating properly before placing the
boiler back in service.

The service instructions contained in this manual are in addition to the instructions provided by the
manufacturer of the boiler components. Follow component manufacturer’s instructions. Component
manufacturer’s instructions were provided with the boiler. Contact component manufacturer for
replacement if instructions are missing. Do not install, start up, operate, maintain or service this
boiler without reading and understanding all of the component instructions. Do not allow the boiler
to operate with altered, disconnected or jumpered components. Only use replacement components
identical to those originally supplied by Thermal Solutions.

USE caution when servicing components behind upper front jacket panel. Filter/mounting bracket may
cause head injury.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and
dangerous operation.

Verify proper operation after servicing.

CAUTION

48

A. SAFETY AND OPERATING CONTROLS. OPERATION AND SHUT DOWN

Component Function

Circuit Board Fuse

Power Switch

Operating Aquastat

Manual Reset High

Limit Aquastat

Flow Switch

Pressure (Safety)

Relief Valve

Mixer Fuseable Link

If the power draw of the control circuit exceeds approximately 5 amps, the circuit board
fuse trips and prevents the boiler from operating until the fuse is replaced.

If this switch is in the off position, power is interrupted to the control circuit of the boiler,
which prevents the boiler from operating. If the switch is in the on position, power is
supplied to the control circuit.

If the boiler water temperature exceeds the adjustable set point, power is interrupted to
the control circuit of the boiler, which prevents the boiler from operating. When the boiler
water temperature drops below the set point minus the adjustable differential setting, power
is again supplied to the control circuit.

If the boiler water temperature exceeds the adjustable set point, power is interrupted to the
control circuit of the boiler, which prevents the boiler from operating. Power is interrupted
until the control is manually reset by pressing the control’s reset button. When the button
is depressed, power will again be supplied to the control circuit.

If the water ow through the boiler drops below the xed ow rate required to move the

control’s paddle enough to close the controls contacts, power is interrupted to the control

circuit, which prevents the boiler from operating. When the water ow rate is increased,

the paddle closes the control’s contacts and power is supplied to the control circuit.

If the pressure inside the appliance exceeds the xed set point, the valve opens

mechanically and discharges water. The valve remains open until the pressure inside the
appliance drops below the set point.

If the temperature in the interior of the burner exceeds the xed set point, The contacts of

the switch open and power is interrupted to the control circuit, which prevents the boiler
from operating. Power is interrupted until the switch is replaced.

Vestibule Fuseable

Link

High and Low Gas

Pressure Switches

Combustion Air Flow

Switch

Flame Safeguard

Control

Variable Frequency

Drive (VFD)

Thermal Solutions

Boiler Control™

(TSBC)™

If the temperature in the interior of the vestibule enclosure exceeds the xed set point, the

contacts of the switch open and power is interrupted to the control circuit, which prevents
the boiler from operating. Power is interrupted until the switch is replaced.

If the gas pressure reaches a point below the adjustable set point, or above the adjustable
set point, the contacts of the switch open and power is interrupted to the control circuit,
which prevents the boiler from operating. Power is interrupted until gas pressure is
between the high and low set points and the control is manually reset by moving the switch
to the reset position. The switches will not reset until the gas pressure is within the set
point parameters.

If the differential air pressure drops below the xed set point, the contacts of the switch

open and power is interrupted to the control circuit, which prevents the boiler from

operating. Power is interrupted until air ow increases so that the contacts close.

Refer to the manual supplied with the boiler.

The variable frequency drive’s primary function is to vary the rotational speed of the blower
fan based on the air requirements of the boiler combustion process. The VFD responds to
a 0-10 VDC signal from the TSBC.

The Thermal Solutions Boiler Control™ (TSBC™) is a complete boiler and automation
system. It provides advanced boiler modulation control, operating control, diagnostics,
multiple boiler lead lag and auxiliary device control. Refer to the TSBC manual shipped
with the boiler to learn more about these features and functions.

49

B. TROUBLESHOOTING GUIDE

Alarm Messages

Alarm Messages are shown one at a time in priority order. The message closest to the top of this list is displayed rst.

Following messages are not shown until the higher priority message has cleared. All alarm messages are also stored
in the Fault History.

LCD Display

Alarm Message

Low Water Level

Off Switch Turn Burner Switch On

Low Water Flow

Fuel Limit

High Temp Limit

Low Air Flow

FSG Fault

Outlet Temp Fail

Inlet Temp Fail

OA Temp Fail

Remote Temp Fail

Recommended

Action

Manually Reset the Low

Water Cutoff

Ensure Boiler Pump is

Running and Boiler

Water Flow is

Unobstructed

Manually Reset the Fuel

Pressure Switch

Manually Reset the

High Temperature

Aquastat

Check Combustion Air

Blower and Air

Pressure Switch

Settings and Wiring

Manually Reset

Required, Refer to

Flame Safeguard

Manual

Corrective Actions

Check Wiring and

Sensor

Check Wiring and

Sensor

Check Wiring and

Sensor

Check Wiring and

Sensor

Explanation

Low Water Cutoff Switch

When this option is congured and an instrument is installed, the manual reset

low water safety relay is preventing the boiler from starting. If terminal (LC) does
not receive power and the Call For Heat output (CH) is powered, the “Low Water
Level” Message is displayed.

Burner Switch is Off

Control switch is in the OFF position and is preventing the boiler from starting. If
terminal (OO) does not receive power and the Call For Heat output (CH) is pow­ered the “OFF Switch” Message is displayed.

Low Water Flow Switch

Low water ow is preventing the boiler from starting. If terminal (WF) does not

receive power and the Call For Heat output (CH) is powered, the “Low Water
Flow” Message is displayed.

Low or High Gas Pressure Switch

The low or high gas pressure switch is preventing the boiler from starting. If
terminal (GP) does not receive power and the Call For Heat output (CH) is
powered, the “Fuel Limit” Message is displayed.

High Limit Temperature

The high temperature limit (HL) (and operational temperature limit when
provided) aquastat is preventing a boiler start. If terminal (HL) does not receive
power and the Call For Heat output (CH) is powered, the “High Temp Limit”
Message is displayed.

Low Air Flow or Blocked Vent Switch Not Made

The air ow (and blocked vent switch when installed) is preventing a boiler start.

If terminal (CA) does not receive power and the Call For Heat output (CH) is
powered, the “Low Air Flow” Message is displayed.

Flame Safeguard Fault

The Flame Safeguard is preventing a boiler start. If terminal (AL) receives power
at any time, the “Flame Failure” Message is displayed.

Boiler Outlet Temperature Sensor Fail

The boiler outlet temperature sensor is not connected or is reading above or
below a valid range. When the boiler outlet sensor fails and the Outlet Sensor
mode was selected, the control will transfer to Lost Sensor Blind Mode.

Boiler Inlet Temperature Sensor Fail

The boiler inlet temperature sensor is not connected or is reading above or below
a valid range. When the boiler inlet sensor fails, the mixing valve output will drive
to 0% and low temperature alarm and maximum water differential (boiler outlet
minus boiler inlet) temperature hold are disabled.

Outside Air Temperature Sensor Fail

The outside air sensor is congured and is not connected or is reading above or

below a valid range. When the outside air sensor fails, the warm weather shut­down (WWSD) and outside air reset control logics are disabled.

Remote System Temperature Sensor Fail

The remote system temperature sensor is congured and is not connected or is

reading above or below a valid range. If Remote System Temperature Sensor
mode was selected, the control will transfer to Boiler Outlet Sensor Mode.

50

TROUBLESHOOTING GUIDE (CONTINUED)

LCD Display

Alarm Message

Remote Input Fail

Comm Failure

Recommended

Action

Check Wiring and

Remote System

Conrm each boiler has

a unique address

Check Wiring and

Remote System

Explanation

Remote Control Input Fail

The Remote Control Input is congured and is not connected or is above or be­low a valid range. When the remote control input fails, the following control mode
changes are taken automatically:

Selected Modes Resulting Control Mode
Remote Mod Outlet Sensor and Local Setpoint
Remote Mod & Remote Sensor Remote Sensor and Local Setpoint
Remote SP Outlet Sensor and Local Setpoint
Remote SP & Remote Sensor Remote Sensor and Local Setpoint

Communication Failure

The Modbus or Peer-To-Peer network has failed. When the Modbus network fails
the following control mode changes are taken automatically:

Selected Modes Resulting Control Mode
Modbus Mod Outlet Sensor and Local Setpoint
Modbus Mod & Remote Sensor Remote Sensor and Local Setpoint
Modbus SP Outlet Sensor and Local Setpoint
Modbus SP & Remote Sensor Remote Sensor and Local Setpoint
After a Modus communication failure, the ‘Comm Failure’ alarm is not cleared
until communication is restored and successfully writes to both the Remote On
/ Off Modbus Command (00004) and Remote Firing Rate or Remote Setpoint
(40006) points have been completed, power is cycled or the protocol parameter is
changed to Peer-To-Peer and then back to Modbus.

Low Inlet Temp

Memory Failure

Check return water

temperature. Consider

system or operational

changes to avoid low

temperature events

Check wiring and

sensor

Call Factory Reset

all memories in

System menu:

Clr BIT History

Clr Alarm Hist

Clr Run Time Cnt

Clr Cycle Cnt

Factory Defaults

(Factory Level

Password is required)

When a Peer-To-Peer network has failed the boilers begin operation as stand
alone boilers using the selected parameters.

After a Peer-To-Peer communication failure the ‘Comm Failure’ alarm is not
cleared until communication is restored and the boiler rejoins a network with at
least one other boiler, power is cycled or the protocol parameter is changed to
Modbus and then back to Peer-To-Peer.

Low Boiler Inlet Temperature
If the boiler inlet temperature is below the Low boiler inlet temperature setpoint,
the “Low Inlet Temp” Message is displayed and the boiler inlet temperature
history is stored.

Memory Failure

New software has been installed in the Thermal Solutions Boiler Control (TSBC)
or a power interruption has caused a memory failure. The Call For Heat will be
prevented until the condition is cleared.

51

C. PERIODIC MAINTENANCE RECOMMENDED CHECK LIST

Frequency Component/Item Recommended Test

Inspect the area to assure proper clearance to combustible materials,

gasoline, and other ammable vapors and liquids.

Make visual inspection and record readings.

Check combustion properties as specied in section VII, part D.

Make visual inspection of burner ame as stated in section VII, part D.

Test low draft, fan, air pressure, and damper position interlocks
according to instructions if so equipped.

Make visual inspection, check ame signal strength; log.

Read and log ame signal meter, read for both pilot and main ames.

Close manual fuel supply for (1) pilot, (2) main fuel cock, and/or

valve(s); check safety shutdown timing. Refer to section VII, Part D.

Check ring rate control, place TSBC™ in manual mode and check
high and low ring settings for proper operation.

Open limit switch and make aural and visual check; check valve
position indicators and check fuel meters if so tted.

Test low-water fuel cutoff device and alarm according to
manufacturer’s instructions.

Conrm that components are gas tight and free from obstructions to
ow.

Test high and low gas pressure interlocks.

Test condition of water, correct condition as needed.

Recalibrate all indicating and recording gauges.

Check components.

Check drain tubes have liquid in trap and condensate is properly
directed.

Check air lter as specied in section VII, Part D.

Check piping and wiring of all interlocks and shut off valves if so
equipped.

Maintain according to manufacturers' instructions.

Conrm that components are gas tight and free from obstructions to
ow.

Check combustion properties as specied in section IV, Part I, Step 5.

Conduct pilot turndown test according to manufacturer’s instructions.

This test is required annually and after any adjustments to ame

scanner mount or pilot burner.

Check all coils and diaphragms; test other operating parts of all safety

shutoff and control valves.

Perform leakage test on pilot and main gas and/or oil fuel valves, in
accordance with instructions.

Test purge timing according to manufacturer’s instructions.

Replace

Remove lower front jacket panel and check for any signs of corrosion
and leaks.

Check and clean if dirty. Refer to section VII, Part D.

Test proper operation.

Test proper operation. Refer to section VII, Part D.

Recondition or replace.

Test safety relief valves in accordance with ASME Boiler and Pressure
Vessel Code, Sections VI and VII.

Daily

Maintenance

Weekly

Maintenance

Monthly

Maintenance

Semi-Annual

Maintenance

Annual

Maintenance

As-Required

Boiler surroundings

Gauges, monitors, and indicators

Combustion Properties

Burner ame

Low Draft, fan air pressure, and damper
position interlocks

Igniter

Flame signal strength

Flame failure detection system

Firing rate control

Pilot and/or main fuel valves

Low-water fuel cutoff

Flue, vent, stack, condensate drains,
and outlet dampers
Gas pressure interlocks

Water condition

Gauges, monitors, and indicators

Flame failure detection system

Condensate drain tubes

Air lter

Interlocks and valves

Circulators and system pumps

Flue, vent, stack, or outlet dampers

Combustion Properties

Flame failure detection system

Pilot and/or main fuel valves

Pilot and/or main fuel valves

Flame safeguard
Air Filter

Boiler trim

Secondary Heat Exchanger

High limit and operating temp. controls

Mixing Valve

Low-water fuel cutoff

Safety relief valves

52

D. INSPECTION AND CLEANING PROCEDURES

Daily Boiler Inspection & Check

1. Inspect the area to assure proper clearance from
combustible materials, gasoline, and other ammable
vapors and liquids.

2. Observe burner color. See "Pilot and Main Flame"
instructions later in this section

3. Check ame control for proper operation and shutdown.

4. Check vent and air intake piping for any obstructions.

5. Check for any water leaks in the entire boiler assembly.
a.) For leaks in the boiler secondary Victaulic® piping:
i) Disassemble the leaking coupling
ii) Clean and lubricate the gasket. Clean all surfaces
mating to the gaskets prior to reassembly.
iii) See www.victaulic.com for specic details about
the QuickVic® style 107 couplings.

NOTICE

Victaulic® brand water-based Vic-Lube shall be

used to lubricate all coupling and ange gaskets

prior to reassembly. Oil-based lubricants shall
not be used.

6. Check for any gas leaks.

7. Check condensate drains for any obstructions.

8. Clean any debris or trash from area.

9. Check the low dra, fan, air pressure, and damper position
interlocks, according to the manufacturer's instructions,
if so equipped.

10. Check gauges, monitors, and indicators to assure they are
functioning properly.

11. Log that the above maintenance was completed in an
appliance log. Maintain log near appliance location.

Weekly Boiler Inspection & Check

1. Check ame strength for both pilot and main ames; log.

2. Check ignitor.

3. Check operation of the ame failure detection system for
both pilot and main ame.

4. Check ring rate control for proper operation.

5. Check pilot and main fuel valves:
Open limit switch and make aural and visual inspection,
check valve position indicators and fuel meters, if provided.

6. Check the low water cuto device and alarm according
to the manufacturer's instructions.

Monthly Safety and Operating Control Checks

1. Check proper operation of all boiler system safety and
operating controls including ame safeguard.

2. Check proper operation safety relief valve.
3 Check condition of water (pH, alkalinity, hardness).
Correct water condition as needed.

4. Check carbon monoxide level in ue products.

5. Check venting/air intake and condensate drain tubes for
obstructions.

6. Repair or replace any inoperative or damaged components.

7. Low water cuto, oat type (if so equipped):
Monthly blowo. During the heating season, if an
external oat type low water cuto is above the boiler,
the blowo valve should be opened once per month (use
greater frequency where conditions warrant), to ush out

the sediment chamber so the device will be free to
function properly.

8. Inspect and replace air lter as needed.

9. Check high and low gas pressure switch interlocks.

10. Log service procedure in appliance log.

Semi-Annual "Tune-Up"

1. Inspect condensate drain tubes for deterioration,
cracking, etc.

2. Inspect air intake and exhaust pipes for leaks, deterioration,
scale, etc.

3. Measure fuel input, oxygen and carbon monoxide in ue
products.

4. Adjust burner to obtain values noted in retest report.

5. Complete safety and operating control checks.

6. Repair or replace any inoperative or damaged components.

7. Log service procedures in water appliance log.

Annual Boiler Inspection and Check

1. Replace air lter.

2. Remove and inspect pilot assembly.

3. Remove lower front jacket panel and check for any signs
of corrosion and leaks.

4. Remove pipe plugs in header and inspect inside of copper
tubes and header.

5. Flush boiler and mechanically remove any scale.

6. Remove, inspect, and clean water ow switch and low
water cutos.

7. Complete "tune-up" procedures (See previous instructions).

8. Log service procedures in appliance log.

9. Repair or replace any inoperative or damaged components.

10. Vent/Air Intake System. Inspect for obstructions, soot
accumulation, proper support, and deterioration of pipe,
ttings, and joints.
a.) Clean terminal screens. Terminals must be
free of obstruction, undamaged, with screens
securely in place.
b.) Terminal and wall thimbles (if used) must be
weathertight.
c.) Pipe must be full round shape, and show no
damage from impact or excessive temperature.
d.) Pipe must be supported at minimum (5) foot
intervals and must not sag.
e.) All vent joints must be secure and watertight.
f.) Horizontal vent tee drain or vertical vent tee
drain (if used) must have minimum 6 inch trap and
allow condensate to ow freely.
To clean:
i.) Disconnect drain tube from drain tting
ii.) Flush drain tube with water. Fill trap with water.
iii) Securely fasten drain tube to drain tting,
providing gas-tight and watertight seal.
g.) If pipe must be disassembled for removal of
obstructions or resealing of joint, see VENTING
section of the manual.

11. Low Water Cuto (if so equipped)
a.) Float type low water cutos should be dismantled
annually by qualiied personnel, to the extent necessary
to ensure freedom from obstructions and proper
functioning of the working parts.

i.) Inspect connecting lines to boiler for accumulation

of mud, scale, etc. and clean as required.

53

ii.) Examine all visible wiring for brittle or

worn insulation and make sure electrical

contacts are clean and that they function

properly. Give special attention to solder
joints on bellows and oat when this type of
control is used.
iii.) Check oat for evidence of collapse and
check mercury bulb (where applicable) for
mercury separation or discoloration.
b.) Probe Type: Probe type LWCO should be
removed once a year and cleaned of any dirt
accumulations to assure proper operation.
Do not attempt to repair mechanisms in
the eld. Complete replacement
mechanisms, including necessary gaskets and
installation instructions, are available from the
manufacturer.

12. Verify proper operation aer servicing.

Air Filter

A. Perform a visual inspection of air lter and replace
as necessary.

1. Remove upper front panel.

2. Remove tube from nipple on lter assembly.

3. Remove wing nut.

4. Remove lter assembly from boiler. For the
EVCA-3000: to facilitate assembly removal, loosen
the two top screws on the lower front panel and
lean the lower front panel forward. Remove the
blower lter front plate, if necessary.

5. Remove foam prelter and wash with soap and
water.

6. Replace primary lter as necessary.

Pilot and Main Flame

A. Perform a visual inspection of pilot burner ame.

1. Refer to the ame safeguard instruction manual
and conduct a pilot turndown test.

2. Observe pilot operation and record pilot signal.
Flame should be steady medium hard blue.
B. Pilot cleaning and maintenance

1. Shut o gas supply and disconnect electrical
service.

2. Disconnect scanner, ignition electrode, loosen
and remove pilot gas line and combustion air
line from fan.

3. Remove mounting fasteners and pull pilot
assembly from heat exchanger.

4. Examine pilot electrode and set gaps to 1/8" if
needed. Clean as required.

5. Reassemble in reverse order using a new gasket
available from ermal Solutions.
C. Perform a visual inspection of main burner ame

1. Observe main ame and record ame signal.
Flame color should be steady deep orange in color

with dark blue checkerboard pattern throughout.

2. Main burner requires no cleaning or annual
maintenance.

Check Combustion and Safety Controls

A. Check ame failure detection system with system
operating.

1. Pilot
a.) Refer to the ame safeguard instruction
manual.
b.) Manually close pilot fuel supply and verify
lock out of primary control.

2. Main Flame
a.) Refer to the ame safeguard instruction
manual.
b.) Close manual main fuel shut-o valve and

CAUTION

Do not attempt to remove or service burner.
Damage to the burner may result. Consult
boiler manufacturer.

Secondary Heat Exchanger

A. Remove vent pipe from stack adapter
B. See Figure 18. Use ashlight to inspect the ns of
the heat exchanger through stack adapter opening.
C. If excessive deposits are found, refer to the
following section for cleaning instructions.
D. Re-install vent on stack adapter.

Cleaning Secondary Heat Exchanger for EVCA
Units:

A. Remove vent pipe from stack adapter.
B. See Figure 18. Using the opening in the stack
adapter (1) as a point of entry, remove foreign
matter from the secondary heat exchanger (2) by
sprayng an industrial coil cleaner as specied by
the manufacturer.
C. Reinstall vent on stack adapter.

Mixing Valve:

A. Set TSBC to control the mixing valve manually.
B. Stroke the valve from 0-100%, periodically
stopping to check for proper positioning and valve
seizures.
C. Troubleshoot control signals and valve actuator for
positioning errors.
D. Replace valve body if seizure occurs.

1. When removing/servicing the mixing valve,
never li by the mixing valve actuator. Li the
valve body.

54

2

1

Figure 18: Cleaning Secondary Heat Exchanger

55

This page intentionally left blank

56

VIII. Repair Parts

EVCA Series repair parts can be ordered through your nearest ermal Solutions Representative for delivery from Lancaster, PA.

e Representatives can also advise as to the availability of product and repair parts from local sources.

Contact ermal Solutions for your Representative at:

ermal Solutions Products LLC

1175 Manheim Pike

Lancaster, Pennsylvania 17601

Telephone [phone]

Fax [phone] (toll free)

www.thermalsolutions.com

WARNING

The repair parts noted in this section are for a standard EVCA Series boiler. Different contents and

components may have been supplied due to the request of the equipment end user. Consult Thermal

Solutions for repair parts on non-standard controls and components.

57

Figure 19: Boiler Combustion Chamber

58

BOILER COMBUSTION CHAMBER

Key
No.

Description

EVCA-750 EVCA-1000 EVCA-1500 EVCA-2000

1. COMBUSTION CHAMBER ASSEMBLY

1A Heat Exchanger

(1)

603EVC07510

1B Base

1F Tube Bafe

1G Sight Tube Bafe

Combustion Pan Sup-

1H

port
Heat Exchanger Wrap-

1I

per

1J Heat Exchanger Bafe

(31)

70356215

(1)

70356223

(4)

603562041

(1)

804EVC2003

(1)

70356236

1K Condensate Drain Tube

1L 1” Fiber Gasket

Sight Glass Lens Re-

1M

tainer

1N Sight Glass Gaskets

(Quantity) Part Number

(1)

603EVC01000

61556024

(31)

70356216

(1)

70356224

(4)

603562051

(1)

804EVC2004

(1)

70356237

(1)

806EVC01

(14 LF)

9206032

603EVC01500

(1)

(31)

70356217

70356225

603562061

804EVC2005

70356238

(1)

7186019

(2)

8206039

(1)

(1)

(4)

(1)

(1)

(1)

6035630061

(31)

70356218

(1)

70356226

(4)

603562071

(1)

804EVC2006

(1)

70356239

8065601

EVCA-

3000

(1)

104057-01

(1)

103078-01

(41)

70356317

(1)

70356320

(6)

60356210

(1)

103081-02

(1)

70356242

(1)

(19.5)

9206032

1Q Sight Glass Lens

1R Wrapper Banding

1S Banding Buckle

Temperature Probe (not

1T

shown)

8026082

(24 LF)

92466028

80860946

101935-01

(1)

(25.5 LF)

92466028

(4)

(2)

59

TOP

VIEW

FRONT

VIEW

Figure 20: Burner Assembly

60

Key

No.

Description

2. BURNER/ FAN ASSEMBLY

2A Fan (three phase)

2B Air Filter

Pilot Assembly - Natural

2C

-OR- Pilot Assembly -LP

BURNER ASSEMBLIES

(Quantity)

Part Number

EVCA-750 EVCA-1000 EVCA-1500 EVCA-2000 EVCA-3000

81156018

(1)

81156011

(1)

(1)

81156012

See Figure 27

(1)

81156300

(1)

81156101

Mixer Assembly - Natural

2D

Mixer Assembly - LP

2E Burner Element

2F Air Orice Gasket

2G Air Orice

2H Pilot Gasket

2J Burner Gasket

Burner Mounting Flange

2K

Gasket
Burner Thermal Fuse

2L

Assembly

(1)

60256209

(1)

60256213

(1)

TS750CF-

GBNR

80256235

(1)

60256210

(1)

60256214

(1)

TS1000CF-

GBNR

(1)

60256211

60256215

TS1500CF-

GBNR

(2)

8205603

80256236

(1)

82056041

(1)

8205605

(1)

6025601

(1)

(1)

(1)

(1)

(1)

8205608

(1)

60256212

(1)

60256216

(1)

TS2000CF-

GBNR

(1)

80256237

(1)

62156300

(1)

62156300

(1)

TS3000CF-

GBNR

(2)

8205666

N/A

(1)

82056501

(1)

8205665

N/A

61

Figure 21a: UL/FM/CSD-1 Main Gas Train Assembly (EVCA-750/2000)

62

UL/FM/CSD-1 GAS TRAIN - MAIN AND PILOT

Key

No.

Description

EVCA-750 EVCA-1000 EVCA-1500 EVCA-2000

3. MAIN AND PILOT GAS TRAIN (UL/FM/CSD-1)

Main Gas Valve Body, 1"
NPT

(1)

816634041

3A

Main Gas Valve Body, 1½"
NPT

Manual Gas Valve with Pilot
Tapping, 1" NPT

---

(1)

806603055

3B

Manual Gas Valve with Pilot
Tapping, 1½" NPT

Air/Gas Ratio Controller,

3C

Siemen's SKP75

Solenoid Valve
V4295A1031, 1" NPT

(1)

806603053

(1)

81660207

3D

Solenoid Valve
V4295A1056, 1½" NPT

---

3E Manual Gas Cock, ¼"

3F Pilot Gas Regulator

3G High Gas Pressure Switch

3H Low Gas Pressure Switch

(Quantity) Part Number

--- --- ---

(1)

81663404

--- --- ---

(2)

806603053

(1)

81663408

--- --- ---

(1)

81660205

(3)

822758

(1)

822702

(1)

80160333

(1)

80160332

63

Figure 21b: UL/FM/CSD-1 Main Gas Train Assembly (EVCA-3000)

64

UL/FM/CSD-1 Gas Train - Main and Pilot

Key No. Description

Main and Pilot Gas Train (UL/FM/CSD-1)

3A Main Gas Valve Body, 2" NPT

3B

3C

3D

Manual Gas Valve Body with Pilot

Tapping, 2" NPT

Air/Gas Ratio Controller, Siemens

SKP75

Solenoid Valve V4295A1064, 2"

NPT

3E Manual Gas Cock, 1/4"

3F Pilot Gas Regulator

3G High Gas Pressure Switch

3H Low Gas Pressure Switch

(Quantity)

Part Number

EVCA-3000

(1)

816634043

(2)

806604691

(1)

81663408

(1)

816602051

(3)

822758

(1)

822702

(1)

80160333

(1)

80160322

65

Figure 22a: DB&B Gas Train (750)

Figure 22b: DB&B Gas Train (1000-2000)

66

Key

No.

Description

3. MAIN AND PILOT GAS TRAIN

Main Gas Valve Body 1" NPT (1)

3A

Main Gas Valve Body, DBL,
1-1/2" NPT

Manual Gas Valve with Pilot
Tapping, 1" NPT

3B

Manual Gas Valve with Pilot
Tapping, 1-1/2" NPT

DB&B Actuator/Regulator

3C

Ratio Valve, Siemens SKP75
(max 5 PSI)

3D DB&B Solenoid Valve

3E Manual Gas Cock, 1/4"

3F Pilot Gas Regulator

3G High Gas Pressure Switch

3H Low Gas Pressure Switch

3I Normally Open Vent Valve

DB&B – MAIN AND PILOT

(Quantity) Part Number

EVCA-750 EVCA-1000 EVCA-1500 EVCA-2000

816634041

—

(1)

806603055

(1)

806603053

— — —

(1)

81663404

— — —

(2)

806603053

(1)

81663408

(1)

81660207

(1)

81660205

(3)

822758

(1)

822702

(1)

80160333

(1)

80160332

(1)

81660748

67

Figure 22c: DB&B w/POC Gas Train (750)

Figure 22d: DB&B w/POC Gas Train (1000-2000)

68

Key

No.

Description

3. MAIN AND PILOT GAS TRAIN

Main Gas Valve Body 1" NPT

3A

Main Gas Valve Body, DBL,
1-1/2" NPT

Manual Gas Valve with Pilot
Tapping, 1" NPT

3B

Manual Gas Valve with Pilot
Tapping, 1-1/2" NPT

DB&B w/POC Actuator/

3C

Regulator Ratio Valve,
Siemens SKP75 (max 5 PSI)

3D

DB&B w/POC Actuator,
Siemens SKP15

3E Manual Gas Cock, 1/4"

3F Pilot Gas Regulator

3G High Gas Pressure Switch

3H Low Gas Pressure Switch

3I Normally Open Vent Valve

DB&B W/POC – MAIN AND PILOT

(Quantity) Part Number

EVCA-750 EVCA-1000 EVCA-1500 EVCA-2000

(2)

816634041

— — —

—

(1)

806603055

— — —

(1)

806603053

81663409

81663407

80160333

80160332

81660748

(1)

81663404

(2)

806603053

(1)

(1)

(3)

822758

(1)

822702

(1)

(1)

(1)

69

Figure 22e: DB&B Gas Train (EVCA-3000)

Figure 22f: DB&B w/POC Gas Train (EVCA-3000)

70

DB&B AND DB&B W/POC -

MAIN AND PILOT

Key
No.

3. MAIN AND PILOT GAS TRAIN

Main Gas Valve Body, DB&B,
2" NPT

3A

Main Gas Valve Body, DB&B
w/POC, 2" NPT

Manual Gas Valve with Pilot

3B

Tapping
DB&B Actuator/Regulator

Ratio Valve, Siemens SKP75
(max 5 psi)

3C

DB&B w/POC Actuator/Regu­lator Ratio Valve Siemens
SKP75 (max 5 psi)

DB&B Solenoid Gas Valve,
Honeywell

3D

DB&B w/POC Actuator, Sie­mens SKP15

3E Manual Gas Cock

3F Pilot Gas Regulator

3G High Gas Pressure Switch

3H Low Gas Pressure Switch

3I Normally Open Vent Valve

Description

(Quantity)

Part Number

EVCA-3000

(1)

816634043

(1)

816634051

(2)

80660491

(1)

81663408

(1)

81663409

(1)

8016602051

(1)

81663407

(3)

822758

(1)

822702

(1)

80160333

(1)

80160332

(1)

816607501

71

Figure 23: Jacket

72

Key

Description (Quantity) Part Number

No.

4. JACKET ASSEMBLY

4A Jacket Lower Front Panel

4B Jacket Upper Rear Panel

Jacket Center Rear

4C

Panel

JACKET

EVCA-750 EVCA-1000 EVCA-1500 EVCA-2000 EVCA-3000

(1)

60456342

---

(1)

60456343

70456279

(1)

60456344

(1)

704562471

(1)

(1)

60456345

(1)

104002-01

(1)

704563002

(1)

104001-01

4D Jacket Panel Left Side

4E Jacket Top Panel

4F Jacket Vestibule Panel

4G Jacket Upper Front Panel

4H Jacket Panel Right Side

4I Handle

4K Observation Port Lens

4L Observation Port Gasket

Observation Port Lens

4M

Retainer

4N Latch

Power Switch w/Filter

4P

Light

(1)

604563291

(1)

604563231

(1)

604563301

704562541

604563021

70456280

(1)

604563241

(1)

604563311

(1)

(1)

(1)

(1)

604563251

8056256

8026082

8206039

7186019

80861722

8136363

(2)

(1)

(2)

(1)

(2)

(1)

(1)

604563321

(1)

604563261

(1)

6045603010

(1)

704563000

(1)

604563000

(1)

104023-01

(1)

6045603020

73

Figure 24: EVCA-750, 1000 and 1500 Secondary Heat Exchanger and Housing

74

EVCA-750/1500 SECONDARY HEAT EXCHANGER AND HOUSING

Key

No.

Description

4. Secondary Heat Exchanger Housing

4A Secondary Heat Exchanger

4B Secondary Heat Exchanger Drain Pan

4C Secondary Heat Exchanger Wrapper

(Quantity) Part Numbe

EVCA-750 EVCA-1000 EVCA-1500

(1)

803EVC10750

(1)

803EVC11000

(1)

703EVC211

(1)

703EVC2003

(1)

703EVC2004

r

803EVC11500

703EVC2005

4D Secondary Heat Exchanger Top Pan (1) 703EVC20021

4E Stack Adapter (1) 811EVC004 (1) 811EVC006

4F 2” Trim Ring (2) 70456271

4G 2” Trim Ring Gasket (2) 8205643

4H 2-1/2” Trim Ring (2) 704EVC001

4I 2-1/2" Trim Ring Gasket (2) 8205676

4J Stack Adapter Gasket (1) 8205641 (1) 8205642

(1)

(1)

4K Stack Adapter Trim Ring (1) 70456121 (1) 70446129

Secondary Heat Exchanger Jacket

4L

Bottom Panel

4M

Secondary Heat Exchanger Jacket
Side Panel

Secondary Heat Exchanger Jacket

4N

Back Panel

Secondary Heat Exchanger Jacket Top

4O

Panel

4P Stack Trim Ring Gasket

604EVC220401

(2)

604EVC22010

604EVC22011

(1)

604EVC22020

604EVC22021

(1) 604EVC2203

(

1) 820EVC01 (1) 820EVC02

(1)

(2)

604EVC22012

(1)

604EVC22022

01

4Q 1/2" Condensate Trim Ring (1) 704EVC002

4R 1/2" Condensate Trim Ring Gasket (1) 8205677

4S 3" Trim Ring (2) 704EVC004 (2) 70456272

4T 3" Trim Ring Gasket (2) 8205644

4U Jacket Center Rear Panel

Secondary Heat Exchanger Left

4V

Mounting Bracket

Secondary Heat Exchanger Right

4X

Mounting Bracket

(1)

604EVC21010

(1)

703EVC26

(1)

703EVC22

(1)

604EVC21011

(1)

703EVC27

(1)

703EVC23

604EVC21012

703EVC28

703EVC24

(2)

(1)

(1)

(1)

(1)

4Y Air Inlet Trim Ring (1) 81156106 (1) 81156108

4Z Air Inlet Trim Ring Gasket (1) 82056106 (1) 82056108

75

4U

4F

4G

4W

4O

4D

4T

4S

4X

4M

4H

4G

4H

4J

4K

4Y

4G

4P

4E

4N

4M

4Z

4R

4Q

4C

4B

4L

4A

Figure 25a: EVCA-2000 Secondary Heat Exchanger and Housing

76

EVCA-2000 SECONDARY HEAT EXCHANGER AND HOUSING

Key Number Description

(Quantity)

Part Numbe

EVCA-2000

r

4. EVCA-2000 Secondary Heat Exchanger Housing

-

-

Boiler Drain Trim Ring, 1" (not shown) (1) 70456136

Boiler Drain Trim Ring Gasket, 1" (not shown) (1) 8205651
4A Secondary Heat Exchanger (1) 803EVC12000
4B Secondary Heat Exchanger Drain Pan (1) 703EVC21

4C Secondary Heat Exchanger Wrapper (1) 703EVC2006
4D Secondary Heat Exchanger Top Panel (1) 703EVC2002

4E Stack Adapte

r

(1) 811EVC006

4F Modied 2-1/2” Trim Ring (1) 704EVC003

4G 2-1/2” Trim Ring Gasket (4) 8205676
4H 2-1/2” Trim Ring (3) 704EVC001

4J Stack Adapter Gasket (1) 8205642

4K Stack Adapter Trim Ring (1) 70456129

4L Secondary Heat Exchanger Jacket Bottom Panel (1) 604EVC22040
4M Secondary Heat Exchanger Jacket Side Panel (2) 604EVC22013
4N Secondary Heat Exchanger Jacket Rear Panel (1) 604EVC22023
4O Secondary Heat Exchanger Jacket Top Panel (1) 604EVC22030

4P Stack Adapter Gasket (1) 820EVC02
4Q Condensate Drain Trim Ring, 1/2" (1) 704EVC002
4R Condensate Drain Trim Ring Gasket, 1/2" (1) 8205677

4S Water Trim Ring, 3" (2) 70456272

4T Water Trim Ring Gasket, 3" (2) 8205644
4U Jacket Center Rear Panel (1) 604EVC21013
4W Secondary Heat Exchanger Left Mounting Bracket (1) 703EVC29

4X Secondary Heat Exchanger Right Mounting Bracket (1) 703EVC25

4Y Air Inlet Ring, 8" (1) 81156108

4Z Air Inlet Ring Gasket, 8" (1) 82056108

77

Figure 25b: EVCA-3000 Secondary Heat Exchanger and Housing

78

EVCA-3000 SECONDARY HEAT EXCHANGER AND HOUSING

Key

No.

Description

(Quantity) Part Numbe

EVCA-3000

4. Secondary Heat Exchanger Housing

4A Secondary Heat Exchanger (1) 104019-01
4B Secondary Heat Exchanger Drain Pan (1) 103083-02

4C Secondary Heat Exchanger Wrapper (1) 104018-01

4D Secondary Heat Exchanger Top Pan (1) 104017-01
4E Stack Adapter (1) 811EVC008

4F 3-1/2” Trim Ring (4) 70456150
4G 3-1/2” Trim Ring Gasket (4) 8205678
4H Stack Adapter Trim Ring (1) 70456128

4J Stack Adapter Trim Ring Gasket (1) 8205660

4K Air Inlet Trim Ring (1) 81156108

4L Air Inlet Trim Ring Gasket (1) 82056108

4M Secondary Heat Exchanger Jacket Side Panel (2) 104004-01
4N1 Secondary Heat Exchanger Jacket Rear Panel, Water Side (1) 103099-01
4N2 Secondary Heat Exchanger Jacket Rear Panel, Intake Side (1) 103098-01

4O Secondary Heat Exchanger Jacket Top Panel (1) 104005-01
4P Stack Trim Ring Gasket (1) 820EVC03
4Q Secondary Heat Exchanger Pan Support Brace (2) 103079-01
4R Condensate Line Brace (1) 104022-01
4S 4" Trim Ring (2) 70456131

4T 4" Trim Ring Gasket (2) 8205661
4U Jacket Panel, Lower Rear (1) 104001-01
4V Secondary Heat Exchanger Support Brace, Horn Side (1) 104015-01
4X Secondary Heat Exchanger Support Brace, Closed Side (1) 104016-01
4Y Condensate Line Trim Ring (1) 104020-02

4Z Condensate Line Trim Ring Gasket (1) 104021-02

4AA 5/8" Condensate Line Extension (not shown) (1) 104025-01
4AB 1/2" Condensate Line Hose (not shown) (1) 103302-02
4AC 5/8" Condensate Line Extension Fitting (not shown) (1) 104026-01

r

79

Figure 26: Control Panel Assembly

80

Controls

Key

No.

Description (Quantity) Part Numbe

5. Controls and Components

RM7896D1027 Flame Safeguard Control for UL/FM/CSD-1/DB&B (1) 80160212
RM7840L1075 Flame Safeguard Control for DB&B w/POC/LFP (1) 801602303

5A

Modbus Module for 5A (optional - not shown) (1) 80160909

Display Module for 5A (optional - not shown) (1) 80160640

5B Amplier Card (not shown) R7849A1023 (1) 80160243

Purge Card (not shown) ST7800A1039, UL/FM/CSD-1/DB&B/LFP (1) 8136362

5C

Purge Card (not shown) ST7800A1005, DB&B w/POC (1) 81363621

5D Power Switch w/Filter Light (not shown) (1) 8136363

5E Operating Limit L4008A1015 (Auto Reset) (1) 80160626

5F High Limit L4008E 1313 (Manual Reset - Max 240F) (1) 80160667
5G Water Flow Switch FS4-3 (not shown) (1) 80160175
5H Vestibule Fuse Switch (not shown) (1) 80160209

5I Contact Relay 12V DC (1) 80160768

5J Blocked Filter Switch (1) 80160295

5K Combustion Air Flow Switch (1) 102382-02

5L Ignition Transformer (1) 80160018

Variable Frequency Drive 208/230 volt input (1) 80160940

5M

Variable Frequency Drive 460 volt input (1) 80160941
Variable Frequency Drive 115/120 volt input (1) 80160933

5N Control Transformer (1) 80160820

5P Fuses and Fuse Block, for 208/230/460V Application (2) 8136426, (2) 8136427
5Q Overload Relay See Table Below
5R Transformer AT140B1206 (2) 801600502

5S Contactor 3PH 120 Volt Coil (see table below for permutations) See Table Below

5T Q7800H1109 Board for Thermal Solutions Boiler Control (TSBCTM) (1) 101182-01
5U Thermal Solutions Boiler Control (TSBC) Assembly (not shown) (1) 101171-03

5V Resistor, 1K ohm, 25 watt (LFP boiler only) (1) 103577-01

5W Delay Timer (LFP boiler only) (1) 80160675

r

Description 5Q 5S

120V - 1 Phase, EVCA-750/1000 813EVC60004 813EVC60001

208/230V - 1 Phase, EVCA-750/1000 813EVC60003 813EVC60001

208/230 - 3 Phase, EVCA-750/1000 813EVC60002 813EVC60001

120V - 1 Phase, EVCA-1500/2000 813EVC60009 813EVC60007

208/230V - 1 Phase, EVCA-1500/2000 813EVC60004 813EVC60001

208/230V - 3 Phase, EVCA-1500/2000 813EVC60003 813EVC60001

460V - 3 Phase, EVCA-750/1000 813EVC60008 813EVC60001

460V - 3 Phase, EVCA-1500/2000 813EVC60002 813EVC60001

208/230V - 3 Phase, EVCA-3000 813EVC60005 813EVC60001

460V - 3 Phase, EVCA-3000 813EVC60003 813EVC60001

81

Figure 27: "Bishop" Pilot Assembly

82

PILOT ASSEMBLY

Key

No.

Description

6. Pilot Assembly

Pilot Assembly Natural Gas,
ULX2

--­Pilot Assembly Propane,

ULX2

7A Ultraviolet Sensor

Pilot Orice Natural Gas

7B

Pilot Orice Propane

7C Pilot Air Orice

7D Cast-Iron Body

7E Ignitor Assembly, ULX2

7F Nipple, 1/2” NPT X Close

Pilot Ignition Cable (not

7G

shown)

Pilot Solenoid Valve

7H

V4048C1047 (not shown)

7I O-Ring

(Quantity) Part Number

EVCA-750 EVCA-1000 EVCA-1500 EVCA-2000 EVCA-3000

(1)

62356110

(1)

62356210

(1)

8026145

(1)

722606

(1)

722605

(1)

722607

(1)

82361581

(1)

82356009

(1)

806600040

(1)

103827-01

(1)

81660204

(1)

8206054

83

EVCA LOOP PIPING - MAJOR COMPONENTS

Key
No.

Description

8. EVCA Loop Piping

1-Phase 120/208/230V
¼ HP Pump

3-Phase 208/230/460V
¼ HP Pump

1-Phase 120/208/230V

8A

¾ HP Pump
3-Phase 208/230/460V

¾ HP Pump
3-Phase 208/230/460V

2 HP Pump

8B Temperature Probe

8C 3-Way Valve

8D 3-Way Valve Actuator

3-Way Valve and Actuator

8E

Assembly

(Quantity) Part Number

EVCA-750 EVCA-1000 EVCA-1500 EVCA-2000 EVCA-3000

(1)

805622005

(1)

805622006

—

—

— —

— —

— —

(1)

805622007

(1)

805622008

—

—

(1)

104033-02

(1)

101935-01

(1)

102653-01

(1)

101894-01

—

—

—

(1)

104032-01

84

IX. Thermal Solutions Boiler Control™ (TSBC™)

A. INTRODUCTION - e intent of this section is to briey summarize the controllers capabilities, familiarize the user with its

basic features and to list the factory supplied default settings. Read the additionally supplied Factory Instruction Manual for
the TSBC to learn more about the controllers features and capabilities.

1. Thermal Solutions Boiler Control™ Overview
e ermal Solutions Boiler Control™ (TSBC™) is a complete boiler monitoring and automation system. e TSBC™

provides advanced boiler modulation, operating control, diagnostics, multiple boiler lead-lag and auxiliary device control.
e TSBC™ provides advanced control features in an easy to use package.

2. Flexible, Field Selectable Control
Control modes, water system, boiler auxiliary

and modulating lead/lag control features are
menu selectable without the need for external
programmers, lap tops or down loads. Every boiler
is shipped with factory defaults that make eld
menu selections unnecessary unless you are applying
additional control features.

3. Boiler Monitoring and Diagnostic Displays
e TSBC™'s two line by sixteen character LCD

display may be used for monitoring boiler inlet and
outlet, remote system and outside air temperatures,
modulation rate setpoint and modulating percent
and mixing valve demand percent. Additionally,
the display automatically presents boiler sequence
messages, alarms, hold and lockout messages. A
diagnostic menu is included that provides the last
10 alarm messages and boiler inlet temperature
alarm history. Boiler inlet temperature alarm history
includes time and date, the lowest inlet temperature
reached and the amount of time the water
temperature dropped below the alarm setpoint.

4. Modulation Rate and On/Off Modes
e TSBC™ may simply control boiler modulation

and on/o output based on the boiler water outlet
temperature and an operator adjusted setpoint.
However, using parameter selections, the TSBC™
allows the boiler modulation and on/o output
to respond to remote system water and outside
air temperatures, Domestic Hot Water Priority
(DHWP) input or Energy Domestic Hot Water
Priority (EMS) modulation rate demand, remote
setpoint or remote start/stop commands. Parameter
selections of remote system water temperature and
remote mode determine the choice of one of six
dierent control modes.

5. Advanced Availability
e above control modes are menu selectable

options. However, if a selected sensor fails, the
TSBC™ automatically changes to a control mode
that will allow continued automatic operation of
the boiler. For example, in the event of a remote
system temperature sensor failure, the TSBC™ will
automatically switch to boiler outlet temperature
sensor based control.

6. Outdoor Air Reset
When selected the modulation rate setpoint

is automatically adjusted based on outside air
temperature. Outdoor air "reset" setpoint saves
fuel by adjusting the water temperature of a heating
boiler lower as the outside air temperature increases.

7. Warm Weather Shutdown (WWSD)
Some boilers are used primarily for heating

buildings, and the boilers can be automatically
shutdown when the outdoor air temperature is
warm. When outside air temperature is above the
WWSD setpoint, this function will prevent the
boiler, boiler pump and/or the system pump from
starting.

8. Domestic Hot Water Priority (DHWP)
Some boilers are used primarily for building space

heating, but also provide heat for the domestic hot
water users. When the outdoor temperature is
warm, the outdoor reset setpoint may drop lower
than a desirable domestic hot water temperature.
When enabled and a DHWP contact input is
detected, the hot water setpoint is adjusted to be
greater than a eld adjustable DHWP Setpoint.

9. Water Side Control Outputs
In order to maximize the life and availability of a

hot water systems it may be desirable to automate
mixing valves, boiler pumps, system pumps, and
standby system pumps. e TSBC™ makes this
type of automation totally integrated and cost
eective. e control of these devices is eld
selectable through simple yes/no menu selections.

10. Combustion Air Side Control Outputs
Boiler room Combustion air dampers (fresh air

dampers) and Vent Inducer control outputs are eld
selectable options.

11. Peer-To-Peer Network
e TSBC™ includes state-of-the-art modulating

lead-lag sequencer for up to eight (8) boilers capable
of auto rotation, outdoor reset and peer-to-peer
communication. e peer-to-peer network is truly
"plug and play". Communication is activated by
simply connecting a RJ11 telephone line between
boilers. e TSBC™ provides precise boiler
coordination by sequencing boilers based on

85

both remote system water temperature and boiler
modulation rate. For example, the lead boiler can be
congured to start a lag boiler aer operating above
90% modulation rate for longer than an adjustable
time. e boilers are modulated in "unison"
(parallel) modulation rate to ensure even heat

B. FRONT PANEL DISPLAY

distribution.

12. Modbus Communication Interface
A factory congured RS485 Modbus interface is

available for Energy Management System (EMS) or
SCADA system monitoring and control.

B. Thermal Solutions Boiler ControlTM (TSBCTM) Wiring

When wiring to the ermal Solutions Boiler Control (TSBC™) terminals, see the terminal layout drawing on the following

page or the terminal jacket label, located on the inside surface of the boiler jacket upper front panel. e TSBC™ terminals are
removable for easier eld wiring connection.

86

C

R-

O-

LC

CH

RJ-45

(8 pin)

O+

O+

O-

R+

R+

R-

DP

LR

RO

SI

C

Alternate Connection For

Outside Air Temperature and

(TSBC™)

Remote System Temperature

(10k ohm Thermister, 5 Vdc)

Low Water Cutoff Switch Input

24

WARNING:

Vac

Call For Heat Output

NOTE:

Outside Air Temperature

(10k ohm Thermister, 5 Vdc)

CA - Low Combustion Air Flow

Local / Remote

12 Vdc Common

Remote On / Off (Enable)

Remote System Temperature

(10k ohm Thermister, 5 Vdc)

Domestic Hot Water Priority

12

P-, P+ - Firing Rate Demand (0-10 Vdc, PWM)

V-, V+ - Firing Rate Demand (0-10 Vdc)

HL - Operating or High Limit

GP - Gas Pressure Switch

WF - Low Water Flow Switch

OO - Burner On/Off Switch

Vdc

Spare Input (Programmable)

CA

GPWF HL

Fuel Valve Energized

OO

V-V+P-P+

(24 Vac)

24

Vac

12 Vdc,

(24 Vac)

Flame Safeguard Alarm

Power Supply (+24 Vac)

SP and SO

for LO, VI, BP,

0.5 A max total

Thermal Solutions Boiler Control™

TERMINAL LAYOUT GUIDE

(Terminal connections as viewed from front of boiler)

See boiler wiring diagram for details.

All connections have different inputs and outputs.

Valid signal range for terminals C+ and C- is 1-9VDC.

Refer to connections on diagrams for individual inputs/outputs.

Power Common (-24 Vac)

C PR AL CS

Communication

Boiler Peer-To-Peer

Network

(10k ohm Thermister, 5 Vdc) Common

Boiler Outlet Temperature

Boiler Inlet Temperature

RJ-11

Label 101175-04

(6 pin)

BC

BO

BI

12Vdc Common

C

C

C

Spare Output (Programmable)

SO

System Pump Start/Stop

SP

Boiler Pump Start/Stop

BP

Spare Output Start/Stop

VI

Lockout Indicator

LO

Mixing Valve Output

MR

(4-20 mAdc)

MS

Remote Firing Rate or

C-

Setpoint Input (0-10 Vdc)

(See Note)

C+

87

C. SECURITY MENU

1. Press and hold the MENU button to enter menu mode.

2. Access parameters and set password.

a. In MENU mode page through to the SECURITY menu and press ENTER.

b. Page down to the "Enter Password" parameter and press ENTER.

c. Use the arrow buttons to change the password value to the desired password and hold ENTER until the screen ashes.

3. e access level will reset to Basic aer one hour if no key is pressed, or if power is removed.

PASSWORD

Access Level Enter Password Description

Basic 0 (NONE)

Supervisor 15

Factory

Consult Thermal Solutions Boiler Control (TSBC) Instruction manual for operation guidance and a detailed list of parameters

and their associated access levels.

This is the default access level. The user can view many parameters, but is only
allowed to edit a small sub-set of the parameters that are visible.

This password is set at the factory but can be changed in the eld. The user can

view and edit most parameters that are visible. Note: Not all parameters will be vis­ible at the Supervisor Access Level.

All relevant internal parameters in the system will be visible and programmable.
Please consult Thermal Solutions for the factory access level password.

88

D. SETUP MENU

EVCA Modulating Fire Test Procedures and Specifications

APPENDIX D (Cont…) - TSBCTM SETUP Menu

Factory

Trigger

Boiler

Delay

The Net Start Dwell Time Delay specifies the length of time the peer-to-peer network

The Limit Fault time Delay specifies the length of time the peer-to-peer network will

Specifies number of hours (cumulative) a lead boiler runs before passing the lead to

satisfying a DHWP request

Rotation

Specifies number of hours (cumulative) a lead boiler runs before passing the lead to

Display

Settings

WWSD Off

LL Start

Trigger

LL Stop

Boiler

On Delay

Off

%FR On

Delay

%FR Off

Delay

High Fire

Limit

Deg/Min
Hold Off

Cutback
Setpoint

90 50 to 100 %

25 0 to 50 %

120 0 to 900 (s)

30 0 to 900 (s)

1 1 to 30 (m)

1 1 to 30 (m)

100 40 – 100 %

1 1-10 F

Boiler

220

Range/Choices Description

Specifies Warm Weather Shut-Down (WWSD) control of boiler and/or system pump.

Off

WWSD of Boiler

WWSD of Sys

Pump

Both

100 to 240 F

Off: Ignores Warm Weather setpoint
WWSD of boiler: When Outside Air Temperature (OAT) is higher than the

WWSD of Sys Pump: When OAT is higher than the WWSD setpoint de-energize

Both: When OAT is higher than the WWSD setpoint, inhibit Call

Specifies the percent of maximum modulation rate the running boiler(s) must reach
before calling upon additional boilers for help.
Specifies the percent of modulation rate that the running boiler(s) must be below
before shutting down a lag boiler
Time Delay after On Point setpoint has been reached before starting the next boiler.
Short time delay to prevent nuisance starts due to momentary temperature and
modulation rate swings.
Time Delay after the Off Point setpoint before stopping the next boiler. Short time
delay to prevent nuisance stops due to momentary temperature and modulation rate
swings.
Time Delay after the modulation rate is above the LL Start Trigger before starting the
next boiler. Shorten time delay to avoid temperature going below setpoint as a result of
a slow process change.
Time Delay after the modulation rate is below the LL Stop Trigger before stopping
the next boiler. Shorten time delay to avoid temperature going above setpoint as a
result of a slow process change.
High modulation rate limit for all boilers on the peer-to-peer network as long as at
least one boiler is still not running. After the last boiler has started the modulation
rate is released up to 100.
Specifies a temperature rate of change that inhibits the next boiler being started or
stopped. If the temperature is increasing faster than this rate of change, the next
boiler is not started. Also, if the temperature is decreasing faster than this rate of
change, the next boiler is stopped.
Boiler outlet temperature above the Cutback Setpoint causes the modulation rate to
be reduced proportionally to help avoid a high temperature limit lockout. This
parameter is significant while the modulation rate of the boiler is controlled
according to the remote system temperature sensor, remote input (C+, C-) or Modbus
(40006).

WWSD setpoint, inhibits boiler start

System Pump output (SO)

for Heat and de-energized system pump output (SO)

Net Start

Dwell

Limit

Fault
Time

Rotation Disable

After

120 16 to 420 (s)

5 3 to 120 (s)

Disable

Enable

168 8-720 (hr)

will wait for the Main Fuel Valve Energized input (CS) to be energized after a boiler
call for heat. If the Net Start Dwell time is exceeded before the main fuel valve is
open, the next boiler Call for Heat is immediately initiated.

wait for the boiler limits input (CA) to be energized after a boiler Call for Heat. If the
Limit Fault time is exceeded before the limits are energized, the next boiler Call for
Heat is immediately initiated.

another boiler.
Lead role will be surrendered earlier if the lead boiler is placed into manual mode, is
run remotely (mode 6), fails to start, is “blind” (all input sensors failed), or is

another boiler.

89

D. SETUP MENU (continued)

EVCA Modulating Fire Test Procedures and Specifications

APPENDIX D (Cont…) - TSBCTM SETUP Menu

Display

Outdoor

Sensor

Outdoor

Set Up

Boiler

Set Up

Outdoor

Design

Boiler

Design

Factory

Settings

No

55 40 F to 100 F

140 80F to 180 F

30 -20 F to 50 F

180 80F to 220 F

Range/Choices Description

Enables the Outside Air Temperature sensor display and control logic.
No: Outside Air Input (O+O-) is ignored.

No

Display Only

Outdoor Reset

Display Only: Do Not

Outdoor Reset: Calculate the temperature setpoint based on outdoor

The Outdoor Set Up temperature is the outdoor temperature at which the
Boiler Set Up temperature is supplied.
Only visible when Outdoor Sensor is set to Outdoor Reset .

The Boiler Set Up Temperature is the starting boiler water temperature of the
reset ratio. If the building feels cool during mild outdoor conditions, the
Boiler Set Up setting should be increased.
Only visible when Outdoor Sensor is set to Outdoor Reset.

The Outdoor Design Temperature is the outdoor temperature at which the
Boiler Design temperature is supplied.
Only visible when Outdoor Sensor is set to Outdoor Reset.

The Boiler Design setting is the water temperature required to satisfy the
building heat loss during the Outdoor Design temperature. If the building feels
cool during cold outside conditions, the Boiler Design setting should be
increased.
Only visible when Outdoor Sensor is set to Outdoor Reset.

Calculate setpoint based on outdoor temperature,

Display Outside Air Temperature.

temperature using a reset curve defined by Outdoor Set Up,
Boiler Set Up, Outdoor Design and boiler Design
parameters.

Blower

SPD

High

Blower

SPD
Low

Low Fire

Spd

Fan

Purge

Spd

Percent of (0 - 10 vdc output (V+, V-) output that represents a 100%

100 0 to 100 %

0 0 to 100 %

50 0 to 100 % Modulation % used for Low Fire Hold and Low Fire Start conditions.

See

Description

0 to 100 %

modulation rate. This scaling factor allows the controller to display 100%
when the blower is at rated boiler output.

Percent of (0 - 10 vdc output (V+, V-) output that represents a 0% modulation
rate. This scaling factor allows the controller to display 0% when the blower is
at minimum boiler output.

Percent of blower operating range that the blower should be run during Fan
Purge (at ignition).

Build

Standard 100 100 100 100 55
Low fire proving 25 24 23 26 55
Venturi 100 100 23 26 N/A

750 1000 1500 2000 3000

Boiler model

90

EVCA Modulating Fire Test Procedures and Specifications

APPENDIX D (Cont…) - TSBCTM SETUP Menu

D. SETUP MENU (continued)

Display

Low
Fire

Hold

Post

Purge

Time

Local

Pid

P

Local

PID

I

Local

PID

D

Remote

PID

P

Remote

PID

I

Remote

PID

D

Mixing

Valve

P

Mixing

Valve

I

Mixing

Valve D

Max

Delta T

P

Max

Delta T

I

Max

Delta T

D

Factory

Settings

20 10 to 1200 (s)

30 0 to 600 (s)

20 0 to 10000

30 0 to 10000

0 0 to 10000

20 0 to 10000

30 0 to 10000

0 0 to 10000

10 0 to 10000

60 0 to 10000

0 0 to 10000

10 0 to 10000

60 0 to 10000

0 0 to 10000

Range Description

Time modulation rate is held at present value (Low Fire Spd or Fan Purge Spd
depending on the state and configuration of spare input) after the Fuel Valve
Energized Input (CS) is energized.

Time modulation rate is held at Fan Purge Spd after the Fuel Valve Energize Input
(CS) is de-energized.

Proportional Gain value for boiler outlet temperature sensor control Modes. A larger
gain value results in tighter, more active, PID control. Gain is the primary PID
modulation rate tuning adjustment and provides the immediate modulation rate
response.
Integral gain value for boiler outlet temperature sensor control Modes. A smaller
value makes the Integral ramp in less time (i.e., faster). Integral is a secondary PID
modulation rate tuning adjustment that ramps the output over time (typically
minutes).
The Derivative gain value for boiler outlet temperature sensor control Modes. A
larger Derivative gain value produces a larger PID output contribution proportional to
the rate of change of the error (Setpoint – Boiler Outlet Temperature). When set
equal to zero it has no effect on the output.

Proportional Gain value for Remote System Temperature sensor control Modes.
Refer to Local PID P for explanation.

Integral Gain Term for Remote System Temperature sensor control Modes. Refer to
Local PID I for explanation.

Derivative Gain Term for Remote System Temperature sensor control Modes. Refer
to Local PID D for explanation.

Proportional Gain value for boiler Inlet temperature sensor control mode. A larger
gain value results in tighter, more active, PID control. Gain is the primary PID
modulation rate tuning adjustment and provides the immediate mixing valve
modulation response.
Only visible when mixing valve = yes.
Integral gain value for boiler inlet temperature sensor control mode. A smaller value
makes the Integral ramp in less time (i.e., faster). Integral is a secondary PID
modulation rate tuning adjustment that ramps the output over time (typically
minutes).
Only visible when mixing valve = yes.
The Derivative gain value for boiler inlet temperature sensor control mode. A larger
Derivative gain value produces a larger PID output contribution proportional to the
rate of change of the error (Setpoint – Boiler Inlet Temperature). When set equal to
zero it has no effect on the output.
Only visible when mixing valve = yes.

Proportional Gain value for boiler differential (boiler outlet minus inlet temperature
sensor) temperature control mode. Refer to Local PID P for explanation.
Only visible when mixing valve = yes.

Integral Gain value for boiler differential (boiler outlet minus inlet temperature
sensor) temperature control mode. Refer to Local PID I for explanation.
Only visible when mixing valve = yes.
Derivative Gain Term for boiler differential (boiler outlet minus inlet temperature
sensor) temperature control mode. Refer to Local PID D for explanation.
Only visible when mixing valve = yes.

91

E. BOILER CONFIGURATION MENU

EVCA Modulating Fire Test Procedures and Specifications

APPENDIX D (Cont…) - TSBCTM BOILER CONFIG Menu

N

Display

Display

Units

Factory

Setting

Deg F

Boiler

Pump

Purge

Pump

Prepurge

Postpurge

Delta

Inlet

Sensor

Mixing

Valve

Set

Time/Date

Spare

Input

15 0 to 600 (s)

5

Yes

Yes

-

Off

Range/

Choices

Deg F
Deg C

None

Always On

Purge

Lead On

0 to 20

(C or F)

No

Yes

No

Yes

hour : minute

Month / day /

year

Off

Sys Pump

FB

Low Fire

Description

Selects how temperature parameter values are displayed.

None: No Boiler Pump.
Always On: Pump Runs Continuously.
Purge: Pump Runs during pump pre/post purge operations and during call

for heat and then turns off.

Lead On: Lead boiler’s pump runs continuously when the boiler is the lead

boiler and reverts to “Purge” operation when it is a lag boiler.

Sets length of time the boiler pump will be run prior to closing the “Call for Heat”
relay (CH).
Only visible when Boiler Pump does not equal None.

Defines the temperature above BIT that BOT must be at or below before turning off
the boiler pump during pump post purge (Pump Cooldown State).

Only visible when Boiler Pump does not equal None.

Enables the inlet temperature display and control logic.

Enables the mixing valve control output and user display.

Sets the time and date of the boiler’s real time clock. This item also displays the
time and date.

Sets the function of the Spare Input Terminal (SI).
Off: Ignore.
Sys Pump Feedback: Input (SI) should be wired to a flow switch inserted in the flow

path of the primary system pump. Input (SI) indicates the
primary system pump is operating. If output (SP) is set to
System Backup Pump, system pump output (SP) is
energized and System pump Feedback is de-energized the
System Backup Pump output (SP) is energized.

Low Fire: When the Fuel Valve Energized input (CS) is not energized

and Input (SI) is energized the modulation rate is set to the
“Low Fire Spd” setpoint. When input (SI) is not energized
the modulation rate is set to “Fan Purge Spd” setpoint.
When the fuel valve energized input (CS) is energized input
(SI) is ignored.

Fuel limit

Spare
output

Yes

Off

o

Yes

Off

CAD

System

Pump BU

Soft Alarm

Specifies whether high and low gas pressure switches are connected to input (GP).
Enables Fuel Limit Hold and alarm messages.

Sets the function of the Spare Output Terminal (SO).
Off: Never close output (SO).
CAD: Closes SO relay with a call for heat, Opens SO relay 2

minutes after call for heat has been de-activated.

System Pump BU: Closes when System Pump output is activated but the

System Pump Feedback indicates the Primary System
Pump is not operating.

Soft Alarm: Closes when a any alarm is active.

92

F. SYSTEM CONFIGURATION MENU

EVCA Modulating Fire Test Procedures and Specifications

APPENDIX D (Cont…) – TSBCTM SYSTEM CONFIG Menu

Display

Factory

Settings

Range

Description

Enables Domestic Hot Water Priority (DHWP) control feature. When input (DP) is

Off

Isolated

DHWP Off

Remote
Control

No

Demand

Shared

Demand

No

Remote

SP

Modbus

SP

Remote

Mod

Modbus

Mod

energized DHWP becomes active as selected.
Off: No DHWP.
Isolated Demand: Boiler that receives the input (DP) drops off the Peer-To-Peer

network and it’s temperature setpoint is adjusted above the DHWP
Setpoint. The PID output is based on boiler outlet temperature and
setpoint. If Remote SP or Remote System temperature sensors were
selected, control is switched to the Boiler Outlet Sensor.

Shared Demand: If the lead boiler receives the input (DP) the temperature setpoint for

all boilers on the peer-to-peer network is adjusted above the DHWP
Setpoint.

Sets the remote (Energy Management System) control mode as follows.
No: Local setpoint and modulation rate is used. Modbus and remote

input (C+,C-) are ignored.

Remote SP: Remote Input (C+, C-) is used as the temperature setpoint.

Parameter 22 & 23 may be used to adjust the signal range.
Modbus SP: RS485 Modbus (40006) is used as the temperature setpoint.
Remote Mod: Remote Input (C+, C-) is used as the modulation rate.
Modbus Mod: RS485 Modbus (40006) is used as the modulation rate.

Remote

1.0 volt =

Remote

9.0 volt =

Remote

Sensor

System

Pump
LWC

or

CAD

“Low

Water

Level”

140

220

Control

No

Yes

(If

applicable)

“Low

Water

Level”

60 F to

170 F

150 F to

220 F

No

Display

Only

Control

No

Yes

No

Yes

16 Text

Characters

Sets the temperature corresponding to input (C+,C-) 1V. Voltage below 1V is
considered invalid, (failed or miss wired sensor).

Only visible when Remote Control equals Remote SP.

Sets the temperature corresponding to input (C+,C-) 9 Volts. Voltage above 9V is
considered invalid, (failed or miss wired sensor).

Only visible when Remote Control equals Remote SP.

Enables the Remote System Temperature sensor display and control logic.
No: Remote Sensor Input (R+.R-) is ignored.
Display Only: Remote Sensor Input (R+,R-) is used for display only.
Control: Remote Sensor Input (R+,R-) is compared with the temperature

setpoint to establish a modulation rate.

Enables the System Pump output (SP).

Specifies a Low Water Cut-off Switch or Combustion Air Damper (Fresh Air Damper).
Open switch is connected to input (LC). Enables Limit Hold and Alarm Messages.

Only visible if LWC or CAD is selected. The Limit hold and Alarm message displayed
corresponding to the sensor connected to input (LC). The “Enter” key and “Up” and
“Down” arrow keys are used to change the text message.

93

G. SETPOINTS MENU

EVCA Modulating Fire Test Procedures and Specifications

APPENDIX D (Cont…) - TSBCTM SETPOINTS Menu

The Warm Weather Shutdown (WWSD) Setpoint used to disable boiler and or

Only visible when WWSD does not equal Off.

modes

Display

Operational

SP

On Point -5 0 to 99 F

Off Point 15 0 to 99 F

High Temp

Stop

Factory

Settings

180 60 to 230 F

Boilers

230

Range/Choices Description

Setpoint used in Local Setpoint Mode when not servicing a Domestic Hot Water
Priority (DHWP) request

The boiler starts when the water temperature drops ‘On Point’ degrees below the
setpoint.

The boiler stops when the water temperature rises ‘Off Point’ degrees above the
setpoint.

60 to 230 F

The boiler stops when water temperature is above the High Temperature Stop
setpoint. This setpoint is active in every control mode.

The Domestic Hot Water Priority (DHWP) Setpoint is active when DHW Input
(DP) closes and “DHWP” parameter is set to “yes” and Local SP Mode is

DHWP

Setpoint

WWSD

Setpoint

180

70 40 to 90 F

140 to 230 F

selected. When the contact is closed, the boiler outlet is maintained at, or above,
the DHW Setpoint.

Only visible when DHWP equals Yes.

system pump operation when enabled by setting the “WWSD” parameter to
“WWSD of Boiler”, “WWSD of Sys Pump” or “Both”

Max SP

Min SP 70 60 to 230 F

Min BIT 120 110 to 235 F Low Boiler Inlet Temperature alarm and event setpoint.

Min In H2O

Temp

Max H2O

Delta T

Max

Delta T

Hold

Boilers

230

130 110 to 180 F

50 20 to 50 F

50 20 to 50 F

140 to 230 F The Maximum Operational Setpoint for all possible Local and Remote modes

The Minimum Operational Setpoint is the lower limit for all Local and Remote

Minimum Inlet Water Temperature setpoint used as the Mixing Valve inlet
temperature setpoint.

Only visible when Mixing Valve equals Yes.

Maximum Water Differential (Boiler Outlet minus Boiler Inlet) Temperature
setpoint used as the Mixing Valve differential temperature setpoint.

Only visible when Mixing Valve equals Yes.

Maximum Water Differential (Boiler Outlet minus Boiler Inlet) Temperature used
to hold modulation rate at low fire.

94

H. COMMUNICATION MENU

EVCA Modulating Fire Test Procedures and Specifications

APPENDIX D (Cont…) – TSBCTM COMMUNICATIONS Menu

Display

Protocol

Modbus
Address

Baud
Rate

Parity Odd

Timeout 30 1 to 120 Only visible when Protocol equals Modbus.

Messages
Rcvd

Messages
Sent

Factory

Settings

Peer to
Peer

1 1 to 247

19.2

Range/Choices

Peer to Peer
Modbus

9.6

19.2

38.4

Odd
Even
None

Description

Selects between Peer-To-Peer (multiple boiler Lead/Lag control network) and a
Modbus slave communication.

Each boiler must be given a unique address.

Only visible when Protocol equals Modbus.

Units are 1000 Bits Per Second (KBPS).

Only visible when Protocol equals Modbus.

Only visible when Protocol equals Modbus.

Diagnostic tool used to confirm wiring and Modbus master configuration.

Only visible when Protocol equals Modbus.

Diagnostic tool used to confirm wiring and Modbus master configuration.

Only visible when Protocol equals Modbus.

Boiler
Address

Online
Status

1 1 to 8

xxxxxxxx

Each boiler must be given a unique address. The boiler address assignment
determines the boiler sequencing order. A value of 0 disables the network
communications.

Only visible when Protocol equals Peer to Peer.

Each space can be either the boiler address or a ‘ - ‘ depending on whether there
is a boiler of that address on-line.

Example: - - 6 - - - 321 indicates that boilers 6,3,2 and 1 are online

Only visible when Protocol equals Peer to Peer.

.

95

I. MANUAL MODE MENU

EVCA Modulating Fire Test Procedures and Specifications

APPENDIX D (Cont…) - TSBCTM MANUAL MODE Menu

Display

Boiler

Man/Auto

Modulation

Rate

Boiler

On/Off

Mixing

Valve

M/A

Mixing

Valve

Factory

Settings

Auto

Varies 0 to 100

Varies

Auto

Varies 0 to 100

Range/Choices Description

Man
Auto

On,

Off

Man
Auto

Man: Remain in Manual Mode.
Auto: Return to Boiler Mode specified by parameter/boiler conditions.

Activated only when in Supervisor Mode.

Sets the modulation rate to be used for boiler when in Manual Mode.

Activated only when in Supervisor Mode and Boiler Man/Auto = Man.

Sets the boiler start/stop status when in Manual Mode.
No: Turn off boiler if running, otherwise remain off.
Yes: Turn on boiler if off, otherwise remain on.

Activated only when in Supervisor Mode and Boiler Man/Auto = Man.

Man: Remain in Manual Mode.
Auto: Return to Control Mode specified by parameter/boiler conditions.

Activated only when in Supervisor Mode.

Sets the Mixing Valve % Open to be used for valve when in Manual
Mode.

Activated only when in Supervisor Mode and Mixing Valve M/A equals
Man.

96

NOTES

97

NOTES

98

NOTES

99

X. Warranty

ermal Solutions

LIMITED WARRANTY

LIMITED WARRANTY

Subject to the terms and conditions herein and except
as provided below with respect to products or parts not
manufactured by ermal Solutions, Seller warrants to the
original owner at the original installation site that products
manufactured by Seller (“Products”) comply, at the time of
manufacture, the primary heat exchanger with recognized
hydronics industry regulatory agency standards and
requirements then in eect and will be free from defects in
materials and workmanship for a period of 5 years from date
of shipment (the “Warranty Period”). e secondary heat
exchanger is also covered under the limited warranty for 3 years
and the burner for 10 years from the date of shipment (the
"Warranty" Period). For products or parts not manufactured
by ermal Solutions, the warranty obligations of ermal
Solutions shall, in all respects, be limited to one year.

REMEDY

A. e sole remedy for breach of this warranty is expressly

limited to the repair or replacement of any part found to
be defective under conditions of normal use within the
Warranty Period. Labor for removal and/or installation is
not included.

B. Warranty - e owner must notify the original installer of

the Product and Seller (Attention: ermal Solutions, P.O.
Box 3244, Lancaster, PA 17604-3244), in writing, within
the Warranty Period, providing a detailed description of
all claimed defects. Transportation to a factory or other
designated facility for repairs of any products or items
alleged defective shall, in all events, be the responsibility
and at the cost of the owner.

EXCLUSIONS

Seller shall have no liability for and this warranty does not
cover:

A. Incidental, special or consequential damages, such as

loss of the use of products, facilities or production,
inconvenience, loss of time or labor expense involved in
repairing or replacing the alleged defective Product.

B. e performance of any Product under conditions varying

materially from those under which such Product is usually
tested under industry standards as of the time of shipment.

C. Any damage to the Product due to abrasion, erosion,

corrosion, deterioration, abnormal temperatures or the
inuence of foreign matter or energy.

D. e design or operation of owner’s plant or equipment

or of any facility or system of which any Product may be
made a part.

E. e suitability of any Product for any particular

application.

F. Any failure resulting from misuse, modication not
authorized by Seller in writing, improper installation or

lack of or improper maintenance.

("seller")

G. Equipment furnished by the owner, either mounted or

unmounted, or when contracted for by the owner to be
installed or handled.

H. Leakage or other malfunction caused by:

1. Defective installations in general and specically, any
installation which is made:

a. in violation of applicable state or local plumbing

housing or building codes,
b. without a certied ASME, pressure relief valve, or
c. contrary to the written instructions furnished with

the unit.

2. Adverse local conditions in general and, specically,
sediment or lime precipitation in the tubes and/or
headers or corrosive elements in the atmosphere.

3. Misuse in general and, specically, operation and
maintenance contrary to the written instructions
furnished with the unit, disconnection, alteration or
addition of components or apparatus, not approved by
seller, operation with fuels or settings other than those
set forth on the rating plate or accidental or exterior
damage.

I. Production of noise, odors, discoloration or rusty water.

J. Damage to surrounding area or property caused by leakage

or malfunction.

K. Costs associated with the replacement and/or repair

of the unit including: any freight, shipping or delivery
charges, any removal, installation or reinstallation charges,
any material and/or permits required for installation
reinstallation or repair, charges to return the boiler and or
components.

Seller’s liability under this warranty shall not in any case exceed
the amount paid for the Product found to be defective.

THIRD-PARTY WARRANTIES

For goods or components not manufactured by Seller, the
warranty obligations of Seller shall, in all respects, conform and
be limited to one year from the date of shipment

SEVERABILITY

To the extent that any provision of this warranty would be void
or prohibited under applicable law, such provisions shall be
limited in eect to the minimum extent necessary to render the
remaining provisions hereof enforceable.

100