Thermal Solutions EVO-500, EVO-1500, EVO-750, EVO-2000, EVO-1000 Installation, Operating And Service Instructions
INSTALLATION, OPERATING AND
H
SERVICE INSTRUCTIONS
EVO SERIES BOILER
ON/OFF AND MODULATION, OUTDOOR
Price - $3.00
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
EVO -
Heating Contractor
Your Local Thermal Solutions Representative:
Installation Date
Serial Number
Type System
Phone NumberAddress
104492-01R1-4/13
1
IMPORTANT INFORMATION - READ CAREFULLY
NOTE: Post these instructions and maintain in legible condition.
NOTE: The equipment shall be installed in accordance with those installation regulations required in the area where the
installation is to be made. These 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.
The 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, and
knowledgeable 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 system 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 efciency.
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 ............................... 16
C. Water Treatment .............................. 18
D. Water Piping and Trim ....................19
E. Gas Piping .......................................21
F. Electrical ......................................... 25
G. Modular Systems ............................ 28
H. Condensate Drains .......................... 38
IV. System Start-up .................................... 39
V. Lighting Instructions ............................ 42
VI. Boiler Operational Sequence................44
VII. Service .................................................. 45
VIII. Repair Parts ......................................... 52
IX. Temperature Controller Operation for
Modulating Boilers .............................. 70
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 *
Left Side or Right Side Front Rear Top
500 24" 24" 24" 16"
750 24" 24" 24" 16"
1000 24" 24" 24" 16"
1500 24" 24" 24" 19"
2000 24" 24" 24" 31"
* When 3 or more units are mounted side-by-side, front service clearance increases by 12"
and the rear service clearance increases by 24".
NOTE: Verify clearance with local codes.
Net AHRI Ratings
1. The Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1.15.
2. 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.
3. The ratings have been determined under the provisions governing forced draft boiler-burner units.
4
28.3
[717.6]
30.3
[768.4]
71.2
[1808.2]
16.0
[406.4]
REQUIREMENT
FOR BURNER
REMOVAL
11.3
[285.8]
41.1
[1044.6]
17.1
[435.0]
13.3
[336.6]
6.1
[155.6]
14.1
[358.8]
2.4
[61.9]
BOILER DRAIN
1" NPT PIPE
CONDENSATE
DRAIN
5
8
" TUBE
FLUE OUTLET
4" SAF-T-VENT
23.6
[600.1]
21.8
[552.5]
6.3
[158.8]
3.5
[88.9]
WATER RETURN
FROM SYSTEM 2" NPT
8.1
[206.4]
9.3
[235.0]
14.4
[366.7]
5.5
[139.7]
31.0
[787.4]
P&T GAUGE
WATER FLOW
SWITCH
RELIEF
VALVE
10.8
[274.3]
10.0
[254.0]
WATER SUPPLY
TO SYSTEM
2" NPT
GAS SUPPLY 1" NPT
GAS PILOT
1
4
" TUBE
GAS VENT
3
4
" NPT PIPE
30.6
[777.9]
13.9
[352.4]
7.0
[177.8]
9.6
[242.9]
2.3
[57.2]
19.0
[482.6]
6.3
[158.8]
3.5
[88.9]
4.4
[111.1]
REQUIREMENT
FOR BURNER
REMOVAL
16.0
[406.4]
17.9
[454.0]
21.8
[552.5]
23.6
[600.1]
60.9
[1547.8]
28.3
[717.6]
30.3
[768.4]
9.3
[235.0]
15.4
[392.1]
6.1
[155.6]
31.0
[787.4]
P&T GAUGE
WATER FLOW
SWITCH
RELIEF
VALVE
11.8
[298.5]
8.8
[222.3]
GAS SUPPLY 1" NPT
BOILER DRAIN
1" NPT PIPE
CONDENSATE
DRAIN
5
8
" TUBE
FLUE OUTLET
4" SAF-T-VENT
WATER RETURN
FROM SYSTEM 3" NPT
WATER SUPPLY
TO SYSTEM
3" NPT
GAS PILOT
1
4
" TUBE
GAS VENT
3
4
" NPT PIPE
EVO-500
CAPACITIES
BOILER MODEL
NUMBER
INPUT
(MBH)
GROSS
OUTPUT
(MBH)
NET AHRI
RATING
2
(MBH)
WATER
VOLUME
(gallons)
DRY WEIGHT
(lbs.)
EVO-500 500 431 375 6.1 772 823
EVO-750 750 621 540 15.9 1,097 1,230
ELECTRICAL
BOILER MODEL RANGE
SUPPLY (volts/Hz/phase) Blower Motor (hp)
Nominal power draw
(amps)
On/Off Mod.
120/60/1
8.1 4.5
208/60/1 4.4 3.5
EVO-500
230/60/1 4.4 3.4
208/60/3 2.6 3.0
1/2
230/60/3 2.52 2.9
460/60/3 1.61 1.5
120/60/1
17.7 7.5
208/60/1 9.2 6.6
EVO-750
230/60/1 9.2 6.4
208/60/3 5.2 6.0
1-1/2
230/60/3 4.96 6.0
460/60/3 2.83 3.0
Notes:
1. Piping removed
for visual clarity
(rear view).
2. See notes
concerning Net
AHRI Ratings on
page 4.
WET WEIGHT
(lbs.)
EVO-750
Figure 1a: Dimensions and capacities EVO 500 & 750
5
31.0
[787.4]
10.0
[254.0]
REQUIREMENT
FOR BURNER
REMOVAL
6.3
[158.8]
9.3
16.0
[235.0]
[406.4]
3.5
[88.9]
9.6
[242.9]
GAS PILOT
1
" TUBE
4
WATER RETURN
FROM SYSTEM 3" NPT
19.0
[482.6]
FLUE OUTLET
6" SAF-T-VENT
13.9
[352.4]
2.3
[57.2]
21.8
23.6
[552.5]
[600.1]
36.9
[938.2]
17.6
[447.7]
7.3
[184.2]
EVO-1000
GAS VENT
3
" NPT PIPE
3" NPT
CONDENSATE
5
DRAIN
BOILER DRAIN
1" NPT PIPE
4
4.4
[111.1]
6.1
[155.6]
" TUBE
8
RELIEF
WATER FLOW
67.3
[1079.8]
28.3
[717.6]
SWITCH
P&T GAUGE
30.3
[768.4]
11.8
[298.5]
15.4
[392.1]
VALVE
WATER SUPPLY
TO SYSTEM
CAPACITIES
BOILER MODEL
NUMBER
INPUT
(MBH)
GROSS
OUTPUT
(MBH)
NET AHRI
RATING
2
(MBH)
WATER
VOLUME
(gallons)
DRY WEIGHT
(lbs.)
EVO-1000 1,000 817 710 16.4 1,185 1,322
EVO-1500 1,500 1,250 1,087 17.4 1,327 1,472
ELECTRICAL
BOILER MODEL RANGE
SUPPLY (volts/Hz/phase) Blower Motor (hp)
120/60/1
Nominal power draw (amps)
On-Off Mod.
17.7 7.5
208/60/1 9.2 6.6
EVO-1000/1500
230/60/1 9.2 6.4
208/60/3 5.2 6.0
1-1/2
230/60/3 4.96 6.0
460/60/3 2.83 3.0
Notes:
1. Piping removed
for visual clarity
(rear view).
2. See notes
concerning Net
AHRI Ratings on
page 4.
WET WEIGHT
(lbs.)
EVO-1500
6.3
10.0
31.0
[787.4]
WATER FLOW
SWITCH
79.4
[2017.7]
28.3
[717.6]
P&T GAUGE
30.3
[768.4]
[254.0]
[298.5]
11.8
27.4
[696.9]
REQUIREMENT
FOR BURNER
REMOVAL
RELIEF
VALVE
WATER SUPPLY
TO SYSTEM
3" NPT
CONDENSATE
DRAIN
19.0
[482.6]
GAS VENT
3
" NPT PIPE
4
4.4
[111.1]
6.1
[155.6]
5
" TUBE
8
BOILER DRAIN
1" NPT PIPE
9.3
[235.0]
9.6
[242.9]
[158.8]
3.5
[88.9]
GAS PILOT
1
" TUBE
4
WATER RETURN
FROM SYSTEM 3" NPT
19.0
[482.6]
FLUE OUTLET
6" SAF-T-VENT
13.9
[352.4]
2.3
[57.2]
21.8
23.6
[552.5]
[600.1]
49.0
[1244.6]
17.9
[454.0]
7.0
[177.8]
Figure 1b: Dimensions and capacities EVO 1000 & 1500
6
31.0
[787.4]
10.0
[254.0]
REQUIREMENT
FOR BURNER
REMOVAL
6.3
31.0
[787.4]
9.3
[235.0]
[158.8]
3.5
[88.9]
EVO-2000
GAS VENT
3
" NPT PIPE
VALVE
TO SYSTEM
3" NPT
CONDENSATE
DRAIN
5
4
4.4
[111.1]
6.1
[155.6]
" TUBE
8
RELIEF
WATER FLOW
SWITCH
P&T GAUGE
91.8
[2332.0]
30.3
28.3
[717.6]
[768.4]
11.8
[298.5]
WATER SUPPLY
27.4
[696.9]
19.0
[482.6]
9.6
[242.9]
GAS PILOT
1
" TUBE
4
WATER RETURN
FROM SYSTEM 3" NPT
FLUE OUTLET
6" SAF-T-VENT
13.9
[352.4]
2.3
21.8
23.6
[552.5]
[600.1]
Notes:
1. Piping removed
2. See notes
61.4
[1558.9]
17.9
[454.0]
7.0
[57.2]
[177.8]
CAPACITIES
BOILER MODEL
NUMBER
INPUT
(MBH)
GROSS
OUTPUT
(MBH)
NET AHRI
RATING
2
(MBH)
WATER
VOLUME
(gallons)
DRY WEIGHT
(lbs.)
WET WEIGHT
EVO-2000 2,000 1,696 1,475 18.5 1,461 1,615
ELECTRICAL
BOILER MODEL RANGE
SUPPLY (volts/Hz/phase) Blower Motor (hp)
120/60/1
Nominal power draw (amps)
On/Off* Mod.
17.5 7.5
208/60/1 9.2 6.6
EVO-2000
230/60/1 9.2 6.4
208/60/3 5.2 6.0
1-1/2
230/60/3 4.96 6.0
460/60/3 2.83 3.0
for visual clarity
(rear view).
concerning Net
AHRI Ratings on
page 4.
(lbs.)
Figure 1c: Dimensions and capacities EVO 2000
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.
1. Determine volume of space (boiler room). Rooms
communicating directly with space (through
openings not furnished with doors) are considered
part of space.
Volume [ft³] = Length [ft] x Width [ft] x Height [ft]
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/CSA 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. The boiler is not design certied for installation on
combustible ooring. The 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.).
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/CSA - B149.1, or Propane Installation Code,
CAN/CSA - 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.
The following guideline is based on the National Fuel
Gas Code, NFPA 54/ANSI Z223.1.
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 ft³ per
1,000 Btuh, space is considered an unconned
space.
b. If result is less than 50 ft³ per 1,000 Btuh, space
is considered a conned 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 unconned space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally
provided by fresh air inltration through cracks
around windows and doors.
NOTICE
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 unconned space in
building of unusually tight construction or within
conned 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 conned
space. Use indoor air if two permanent openings
communicate directly with additional space(s) of
sufcient volume such that combined volume of all
spaces meet criteria for unconned 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 effect 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. Unpack the Boiler
NOTICE
Boiler crate is equipped with a tip and tell label. If
label indicates boiler has been tipped over during
shipping, remove crate and inspect before trucker
leaves.
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
qualied 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 off the skid and
onto the pipe roller.
F. Move boiler to its permanent location.
9
III. Installation
NOTICE
Although details for indoor installation may be
rarely applicable, Thermal Solutions recognizes
that instances may exist where such details are
required and have been included within this
manual for this purpose.
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. General Venting Requirements
In order to properly vent this boiler, the installer
must select and install a vent system that meets all
requirements specied in this section (VENTING) as
well as following the instructions provided by the vent
system manufacturer.
a. The 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 specic installation
requirements.
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. This boiler is shipped with an AL 29-4C® Heat-
Fab Saf-T-Vent connection and a screened 90° vent
termination. These items are not a complete ue ducting
system.
ii. Alteration of the boiler vent connection is
prohibited.
f. Do not reduce the diameter of the vent pipe. The vent
pipe must not be smaller than the vent connector on the
boiler.
g. Vent pipe system must be adequately supported at
intervals no less than ve (5) feet apart. The completed
vent system must be rigid and able to withstand impacts
without collapse.
h. 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.
i. It is permissible to run vent pipe through a vertical
or horizontal chase provided minimum clearances to
combustible materials are maintained.
j. The minimum clearance to combustible material is
six (6) inches, unless otherwise specied by the vent
system manufacturer.
k. Horizontal vent pipe must slope no less than one (1)
inch in four (4) feet of run.
l. The 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.
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. This
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.
m. Use appropriately designed thimbles when passing
through combustible walls or roofs.
n. Install re-stops where vent passes through oors,
ceilings or framed walls. The re-stop must close the
opening between the vent pipe and the structure.
o. 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.
10
c. The minimum chimney/vertical vent height is 15 feet.
p. Locate vent terminal above combustion air intake
terminal (if used) and no closer than one (1) foot
horizontally.
q. Vertical venting requires ashing and a storm collar to
prevent moisture from entering the structure.
r. Vertical vent termination must be at least two (2)
feet plus the expected snow accumulation above roof
penetration height.
s. This boiler’s venting may be Category IV (positive
vent pressure, ue condensing) or Category II (nonpositive vent pressure, ue condensing), with regards to
National Fuel Gas Code/NFPA 54 ANSI Z223.1.
2. Positive Pressure Venting Requirements
a. Vent pipe system must be fully sealed.
WARNING
Do not use vent dampers or barometric dampers
with positive pressure vent systems.
b. Direct vent applications: For direct vent (ducted
combustion air) installations, the maximum vent length
is 50 equivalent feet. The vent length is equal to the
total length of straight pipe plus the equivalent length of
vent ttings.
d. Install a condensate drain to collect any condensate that
may form in the lined chimney/vertical vent.
e. Install a double acting barometric damper with integral
ue spillage interlock.
f. The chimney/vertical vent and ue connector must be
sized and congured to provide a minimum - 0.04 inch
w.c. pressure (draft) at the boiler ue outlet.
g. The chimney must be protected from down drafts, rain
and debris by using a chimney cap or star.
4. General Guidelines
a. This boiler has been certied 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 specication, refer to the
below points.
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.
c. 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.
d. For sidewall venting, slope pipe toward vent
termination, if possible.
e. See Figures 2, 3 and 4 for examples of positive pressure
venting arrangements.
3. Negative Pressure (Conventional) Venting
Requirements
This section outlines requirements for conventional
venting installations, where a negative pressure at
the boiler ue outlet is achieved by means of natural
convection through a vertical length of vent pipe or
lined chimney.
a. Refer to Figure 5 for an example of a typical
conventional venting arrangement.
b. A lined chimney or vertical length of vent pipe may be
used. Chimney lining must be acceptable for use with
condensing ue gas.
ii. Refer to the appropriate drawings in this section
of this manual to determine common acceptable
congurations of venting system.
5. IMPORTANT
The 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 satised:
1. INSTALLATION OF CARBON MONOXIDE
DETECTORS. At the time of installation of the side
wall horizontal vented gas fueled equipment, the
installing plumber or gastter shall observe that
11
Figure 2: Sidewall Positive Pressure Venting
Figure 3: Sidewall Positive Pressure Venting (Optional)
12
Figure 4: Vertical Pressurized Venting
13
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 gastter 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 qualied 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 certied.
3. SIGNAGE. A metal or plastic identication 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. The 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”.
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 identies “special venting systems”,
the following requirements shall be satised by the
manufacturer:
1. The referenced “special venting system”
instructions shall be included with the appliance or
equipment installation instructions; and
2. The “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.
4. INSPECTION. The 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: The following equipment is exempt
from 248 CMR 5.08(2)(a)1 through 4:
1. The 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
14
Figure 5: Typical Negative Pressure (Conventional) Venting
15
B. COMBUSTION AIR - See Figures 6 and 7.
1. The boiler may be operated with inside or outside
air.
2. Refer to air intake piping drawings in this section
for proper outside air installation details.
3. Combustion air conduit can be galvanized smoke
pipe, PVC, CPVC, or exible aluminum conduit.
4. The maximum air intake pipe length is fty (50)
equivalent feet. Air intake pipe length is equal to
the total length of straight pipe plus the equivalent
length of ttings. Consult intake pipe manufacturer
for equivalent length of ttings and pipe.
5. Consult air 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.
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 intake air or visa versa.
8. The horizontal air intake pipe must be adequately
supported with straps or supports no less than ve
(5) feet apart. The 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.
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.
Figure 6: Horizontal Air Intake Piping
16
Figure 7: Vertical Air Intake Piping
17
C. WATER TREATMENT
The 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 efciency, reduce the regularity of repair and/or
replacement, and extend the working life of the boiler
and other system equipment. If left untreated, poor water
quality could cause a number of problems including, but not
limited to, oxidation, scaling, corrosion, and fouling. See
Table 1 for examples of typical chemical agents found in
untreated water along with their potential effects.
Table 1: 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 qualied 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 effective water treatment plan, it will be necessary to
gain knowledge of the impurities dissolved in the water.
Once all the impurities are identied, the proper treatment
plan can be established. Therefore, it will be essential to
obtain the expertise of a qualied industrial water treatment
professional for establishing a treatment plan.
In addition, a periodic testing/sampling plan should
be developed. The 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 conrm the proper concentration of chemicals in use.
18
D. WATER PIPING AND TRIM
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 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 Standard Warranty).
On an existing or retrot system, a lter or
strainer must be installed on the system return
prior to the boilers.
Return water temperature below 120°F will cause
ue gas condensation inside the boiler. Flue gas
condensate can lead to boiler failure. Thermal
Solutions Standard Warranty does not cover
problems caused by ue gas condensation.
Supply and return water temperature differences
greater than 40°F at high re can lead to boiler
failure. Thermal Solutions Standard Warranty
does not cover problems caused by temperature
differences greater than 40°F at high re.
1. Design and install boiler and system piping to
prevent oxygen contamination of boiler water and
frequent water additions.
a. There 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. This 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.
c. Maintain ½" minimum distance between water
piping and combustible material.
d. Consult Thermal Solutions for unusual system
requirements.
CAUTION
Support weight of system piping adequately.
e. Design and install system piping to prevent
return water temperatures below 120°F. Refer
to Table 2 for boiler ow and pressure drop
requirements.
3. Remove protective cap from boiler drain line
located in the rear of the boiler .
4. Install drain valve in the boiler drain line at bottom
rear of the boiler.
5. 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.
6. Install optional low water cut-off in system piping
above the boiler, if not shipped with boiler.
7. Install an air eliminating device to remove air from
the system.
2. Connect system supply and return piping to boiler.
a. Refer to Figure 8.
b. Consult I=B=R Installation and Piping Guides.
19
TABLE 2 - EVO BOILER FLOW AND PRESSURE DROP
20°DT
BOILER
MODEL
EVO-500 2.93 43 0.74 22 22 43 2
EVO-750 1.81 62 0.46 31 31 62 3
EVO-1000 3.24 82 0.81 41 41 82 3
EVO-1500 7.37 125 1.85 63 63 125 3
EVO-2000 13.27 170 3.32 85 85 170 3
(at high re)
DP
(Ft.)
(GPM)DP(Ft.)
Flow
40°DT
(at high re)
Flow
(GPM)
Minimum Flow
Rate (gpm)
Maximum Flow
Rate (gpm)
Supply/Return
Pipe
(inch dia.)
Figure 8: Water Piping (Single Boiler)
20
WARNING
E. GAS PIPING
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
2. Tube erosion and pitting will occur. Thermal
Solutions Standard Warranty does not cover
problems caused by excessive water ow rates.
.
8. There must be a minimum of ve pipe diameters
of straight horizontal run downstream of the ow
switch. Otherwise, premature failure of ow switch
paddle may occur. See ow switch instruction
manual included with boiler.
9. 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
supplier or local plumbing inspector on how best to
control this situation.
10. 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. The safety relief discharge line must allow for
complete drainage of both the valve and line.
11. 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.
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 3 for minimum and
maximum boiler gas train inlet pressure at steady
state. If gas supply pressure is higher than
maximum as listed in Table 3, an additional eld
supplied pressure regulator will be required.
b. If a lower minimum gas pressure is needed,
the low gas pressure build can be used. The
minimum gas pressure on all the low gas
pressure builds is 4.0 in. w.c. Consult factory if
this option is desired. This option is not available
on the EVO-500.
c. Maximum gas demand. Table 7 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 4 for maximum capacity of schedule
40 pipe. Table 6 lists equivalent pipe length for
standard ttings.
i. Specic gravity of gas correction factor,
to be applied to the value found in Table 4,
can be found in Table 5.
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/GCA B149
Installation codes.
2. If step down regulator is required, it must be used in
conjunction with the factory supplied regulator and
be located as far away from the boiler as possible
to prevent nuisance shutdowns. The minimum and
maximum inlet gas pressure must not exceed the
value specied in Table 3.
3. Install eld supplied sediment trap, ground-joint
union and manual non-displacable shut-off valve
upstream of factory supplied shut-off 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/CSA B149 Installation Codes.
21
4. Use thread joint compound resistant to the action of
liqueed petroleum gas.
WARNING
Failure to use proper thread compounds on all
gas connectors may result in leaks of ammable
gas.
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
boiler from gas supply piping by closing the
boiler's individual manual shutoff valve.
b. Locate leaks using approved combustible
gas detector, soap and water, or similar
nonammable solution.
DANGER
Do not use matches, candles, open ames or
other ignition source to check for leaks.
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.
6. Pressure test. The 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 shutoff
valve must be disconnected from gas supply
piping. For testing at ½ psig or less, isolate
TABLE 3 - BOILER GAS TRAIN INLET PRESSURE
Boiler Model MIN. ("w.c.) MAX.
EVO-500 5.0
EVO-750* 7.0
EVO-1000* 7.0
EVO-1500* 7.0
EVO-2000* 9.0
* Available with optional gas train with min 4" w.c. inlet gas pressure.
5 psi-NG
2 psi-LP
22
TABLE 4: 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 specic gravity.)
Pipe Length in
Equivalent Feet
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
3/4 1 1-1/4 1-1/2 2 2-1/2 3 4
Capacity in Cubic Feet of Gas Per Hour
Pipe Size (in.)
TABLE 5 – SPECIFIC GRAVITY
CORRECTION FACTORS
Specic
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
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
Specic
Gravity
1.60 0.61
1.70 0.59
1.80 0.58
1.90 0.56
2.00 0.55
Correction
Factor
23
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