Thermal Solutions EVS SERIES, EVS-500, EVS-750, EVS-1000, EVS-1500 Installation, Operating And Service Instructions

...

Download

Price - $3.00

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS

EVS™ SERIES MODULATING BOILER

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

EVS -

Heating Contractor

Your Local Thermal Solutions Representative:

Installation Date

Serial Number

Type System

Phone NumberAddress

102667-01-10/13

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.

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 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.

Table of Contents

I. Pre-Installation ....................................... 9

II. Unpacking the Boiler ...........................10

III. Installation ............................................ 11

A. Venting ............................................ 11

B. Combustion Air ............................... 17

C. Water Treatment .............................. 19

D. Water Piping and Trim ....................20

E. Gas Piping .......................................22

F. Electrical ......................................... 26

G. Modular Systems ............................ 33

H. Condensate Drains .......................... 43

IV. System Start-up .................................... 44

V. Lighting Instructions ............................ 47

VI. Boiler Operational Sequence................49

VII. Service .................................................. 51

VIII. Repair Parts ......................................... 57

IX. Thermal Solutions Boiler Control™ .......

(TSBC™) ............................................ 72

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"

2000S 24" 36" 36" 13"

2500 24" 36" 36" 20"

3000 24" 36" 36" 26.5"

* 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.

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

" 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

" TUBE

GAS VENT

" 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

" TUBE

FLUE OUTLET 4" SAF-T-VENT

WATER RETURN

FROM SYSTEM 3" NPT

WATER SUPPLY

TO SYSTEM

3" NPT

GAS PILOT

" TUBE

GAS VENT

" NPT PIPE

EVS-500

CAPACITIES

Boiler Model

Number

INPUT (MBH)

GROSS

OUTPUT

(MBH)

NET AHRI

RATING

(MBH)

WATER

VOLUME

(gallons)

DRY WEIGHT

(lbs.)

EVS-500 500 431 375 6.1 722 823

EVS-750 750 623 542 15.9 1,097 1,230

ELECTRICAL

BOILER MODEL RANGE

SUPPLY (volts/Hz/phase) Blower Motor (hp)

Nominal power draw

120/60/1

208/60/1 3.5

EVS-500

230/60/1 3.4

208/60/3 3.0

1/2

230/60/3 2.9

460/60/3 1.5

120/60/1

208/60/1 6.6

EVS-750

230/60/1 6.4

208/60/3 6.0

1-1/2

230/60/3 6.0

460/60/3 3.0

Notes:

1. Piping removed for visual clarity (rear view).

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

WET WEIGHT

(lbs.)

(amps)

4.5

7.5

Figure 1a: Dimensions and capacities EVS 500 & 750

EVS-750

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

" TUBE

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]

17.6 [447.7]

7.3 [184.2]

EVS-1000

GAS VENT

" NPT PIPE

3" NPT

CONDENSATE

DRAIN

BOILER DRAIN

1" NPT PIPE

4.4

[111.1]

6.1

[155.6]

" TUBE

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

(MBH)

WATER

VOLUME

(gallons)

DRY WEIGHT

(lbs.)

EVS-1000 1,000 819 712 16.4 1,185 1,322

EVS-1500 1,500 1,251 1,088 17.4 1,327 1,472

ELECTRICAL

BOILER MODEL RANGE

SUPPLY (volts/Hz/phase) Blower Motor (hp)

Nominal power draw

(amps)

120/60/1

208/60/1 6.6

EVS-1000/1500

230/60/1 6.4

208/60/3 6.0

1-1/2

230/60/3 6.0

460/60/3 3.0

Notes:

1. Piping removed for visual clarity (rear view).

2. See notes

36.9

concerning Net

[938.2]

AHRI Ratings on page 4.

WET WEIGHT

(lbs.)

7.5

31.0

[787.4]

EVS-1500

79.4 [2017.7]

28.3

[717.6]

WATER FLOW

P&T GAUGE

Figure 1b: Dimensions and capacities EVS 1000 & 1500

SWITCH

30.3

[768.4]

10.0

[254.0]

11.8

[298.5]

6.3

REQUIREMENT

FOR BURNER

REMOVAL

GAS VENT

" NPT PIPE

RELIEF

VALVE

WATER SUPPLY

TO SYSTEM

3" NPT

27.4 [696.9]

[111.1]

[155.6]

CONDENSATE

" TUBE

DRAIN

BOILER DRAIN

1" NPT PIPE

4.4

6.1

9.3

19.0 [482.6]

[235.0]

9.6

[242.9]

[158.8]

3.5

[88.9]

GAS PILOT

" TUBE

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]

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]

EVS-2000

GAS VENT

" NPT PIPE

3" NPT

4.4

[111.1]

RELIEF

WATER FLOW

SWITCH

P&T GAUGE

91.8 [2332.0]

VALVE

WATER SUPPLY

TO SYSTEM

19.0

[482.6]

GAS PILOT

" TUBE

WATER RETURN

FROM SYSTEM 3" NPT

21.8

23.6

[552.5]

[600.1]

Notes:

1. Piping removed for visual clarity (rear view).

2. See notes concerning Net

61.4 [1558.9]

AHRI Ratings on page 4.

17.9 [454.0]

7.0

[57.2]

[177.8]

28.3

[717.6]

30.3

[768.4]

11.8

[298.5]

FLUE OUTLET

6" SAF-T-VENT

27.4 [696.9]

[155.6]

CONDENSATE

DRAIN

" TUBE

6.1

9.6

[242.9]

13.9

[352.4]

2.3

CAPACITIES

Boiler Model

Number

INPUT (MBH)

GROSS

OUTPUT

(MBH)

NET AHRI

RATING

(MBH)

WATER

VOLUME

(gallons)

DRY WEIGHT

(lbs.)

WET WEIGHT

EVS-2000 2,000 1,696 1,475 18.5 1,461 1,615

EVS-2000S 2,000 1,732 1,506 40.1 1,835 2,169

ELECTRICAL

BOILER MODEL RANGE

SUPPLY (volts/Hz/phase) Blower Motor (hp)

120/60/1

Nominal power draw

(amps)

7.5

208/60/1 6.6

EVS-2000/2000S

230/60/1 6.4

208/60/3 6.0

1-1/2

230/60/3 6.0

460/60/3 3.0

(lbs.)

EVS-2000S

40.8

[1036.3]

70.5 [1790.7]

38.1

[968.2]

Figure 1c: Dimensions and capacities EVS 2000 & 2000S

WATER FLOW

SWITCH

P&T GAUGE

40.1

[1019.0]

10.5

[266.7]

[337.8]

GAS SUPPLY 1

19.6 [496.8]

13.3

REQUIREMENT

FOR BURNER

REMOVAL

" NPT

GAS VENT

" NPT PIPE

RELIEF

VALVE

[149.2]

WATER SUPPLY

TO SYSTEM

4" NPT

INLET AIR

8" GALVANIZED

DUCT

13.0 [330.2]

5.9

7.0

[178.6]

BOILER DRAIN

1" NPT PIPE

8.5

[215.1]

4.0

[102.4]

GAS PILOT

" TUBE

26.2

[666.7]

19.0

[481.8]

14.4

[365.9]

5.0

[126.2]

22.4

20.9 [531.8]

FROM SYSTEM 4" NPT

FLUE OUTLET

6" SAF-T-VENT

2.2 [55.5]

23.4

[569.9]

[595.3]

WATER RETURN

6.9 [174.6]

39.6

18.6 [471.4]

[1004.8]

EVS-2500

REQUIREMENT

FOR BURNER

GAS SUPPLY 2" NPT

19.6 [496.8]

13.3

REMOVAL

40.8

[1036.3]

WATER FLOW

SWITCH

77.5 [1968.5]

38.1

[968.2]

P&T GAUGE

40.1

[1019.0]

11.5

[292.1]

[337.8]

GAS VENT

1" NPT PIPE

RELIEF VALVE

WATER SUPPLY

TO SYSTEM

4" NPT

INLET AIR

8" GALVANIZED

DUCT

CONDENSATE

DRAIN

5.9

[149.2]

7.0

[178.6]

20.0

" TUBE

[508.0]

[215.1]

4.0

[102.4]

GAS PILOT

" TUBE

26.3

[666.8]

8.5

5.0

[126.2]

Notes:

20.9

22.4

23.4

19.0

[481.8]

14.4

[365.9]

[531.8]

[569.9]

WATER RETURN

FROM SYSTEM 4" NPT

FLUE OUTLET 8" SAF-T-VENT

6.9 [174.6]

2.2 [55.5]

1. Piping removed

[595.3]

2. See notes

46.6 [1182.6]

18.6 [471.4]

CAPACITIES

Boiler Model

Number

INPUT

(MBH)

GROSS

OUTPUT

(MBH)

NET AHRI

RATING

(MBH)

WATER

VOLUME

(gallons)

DRY WEIGHT

(lbs.)

EVS-2500 2,500 2,170 1,887 41.6 2,052 2,399

EVS-3000 3,000 2,610 2,270 43.1 2,193 2,552

for visual clarity (rear view).

concerning Net AHRI Ratings on page 4.

WET WEIGHT

(lbs.)

BOILER MODEL RANGE

EVS-2500

EVS-3000

84.5 [2146.3]

ELECTRICAL

SUPPLY (volts/Hz/phase) Blower Motor (hp)

208/60/1

230/60/1 7.8

208/60/3 7.4

230/60/3 7.3

460/60/3 3.7

208/60/1

230/60/1 7.8

208/60/3 7.4

230/60/3 7.3

460/60/3 3.7

REQUIREMENT

FOR BURNER

40.8

[1036.3]

38.1

[968.2]

WATER FLOW

SWITCH

P&T GAUGE

40.1

[1019.0]

11.5

[292.1]

GAS SUPPLY 2" NPT

19.6 [496.8]

13.3

[337.8]

REMOVAL

RELIEF

VALVE

WATER SUPPLY

GAS VENT

1" NPT PIPE

TO SYSTEM

4" NPT

[149.2]

[178.6]

INLET AIR

8" GALVANIZED

DUCT

CONDENSATE

DRAIN

26.5

5.9

7.0

" TUBE

[673.1]

1-1/2

8.5

[215.1]

4.0

[102.4]

GAS PILOT

" TUBE

26.2

[666.7]

19.0

[481.8]

14.4

[365.9]

Nominal power draw

(amps)

8.0

5.0

[126.2]

20.9

22.4

23.4

[531.8]

[569.9]

[595.3]

WATER RETURN

FROM SYSTEM 4" NPT

FLUE OUTLET 8" SAF-T-VENT

53.6

6.9

2.2 [55.5]

[1360.4]

[174.6]

18.6 [471.4]

Figure 1d: Dimensions and capacities EVS 2500 & 3000

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 certied 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 unconned space.

b. If result is less than 50 ft³ 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

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:

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

suf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 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. Unpacking 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

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 off the skid and onto the pipe roller.

F. Move boiler to its permanent location.

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. General 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. 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.

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 specied 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.

c. Consult the vent pipe manufacturer’s instructions for

vent system assembly and system specic 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.

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.

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.

used. Chimney lining must be acceptable for use with

condensing ue gas.

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.

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.

c. The minimum chimney/vertical vent height is 15 feet.

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 congured 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 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.

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.

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:

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

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:

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

Figure 2: Sidewall Positive Pressure Venting

Figure 3: Sidewall Positive Pressure Venting (Optional)

Figure 4: Vertical Pressurized Venting

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.

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. 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”.

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. 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 separate from the dwelling, building or structure

Figure 5: Typical Negative Pressure (Conventional) Venting

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 intake pipe sections

and ttings. Do not use other adhesives or sealants

except as expressly permitted by the intake 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

Figure 7: Vertical Air Intake Piping

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 efciency, 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

(CaHCO3) Calcium Sulphate (CaSO4) Hard Scale Calcium Choloride (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 effective 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. Therefore, 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. 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 conrm the proper concentration of chemicals in use.

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 retrot 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. On EVS-500 through -2000 boilers, a low water cutoff may be installed on the boiler at the factory as an option. A factory-mounted low water cut-off is standard on all EVS-2000S, 2500 & 3000 boilers.

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.

TABLE 2 - EVS BOILER FLOW AND PRESSURE DROP

20°DT

BOILER

MODEL

EVS-500 2.93 43 0.74 22 22 43 2

EVS-750 1.81 62 0.46 31 31 62 3

EVS-1000 3.24 82 0.81 41 44 82 3

EVS-1500 7.37 125 1.85 63 63 125 3

EVS-2000 13.27 170 3.32 85 85 170 3

EVS-2000S 4.27 173 1.36 87 87 173 4

EVS-2500 4.34 217 1.43 109 109 217 4

EVS-3000 4.41 261 1.73 131 131 261 4

(at high re)

(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)

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 EVS-500, 2000S, 2500 or 3000.

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. Specic 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 specied 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.

4. Use thread joint compound resistant to the action of

liqueed 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

nonammable 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.

EVS-500 5.0

EVS-750* 7.0

EVS-1000* 7.0

EVS-1500* 7.0

EVS-2000* 9.0

EVS-2000S 7.0

EVS-2500 6.0

EVS-3000 6.0

* Available with optional gas train with min 4" w.c. inlet gas pressure.

5 psi-NG

2 psi-LP

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 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 5 – 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

TABLE 6 - EQUIVALENT OF STANDARD PIPE FITTING & VALVES

Valves Fully Open (Screwed,

Pipe Size

1/2" 3/4"

1-1/4"

1-1/2"

2-1/2"

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

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 7 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 7 - RATED INPUT

Rated Capacity (CFH)

Boiler Model

Natural LP/Propane

EVS-500 500 200 1-1/4

EVS-750 750 300 1-1/2

EVS-1000 1000 400 1-1/2

EVS-1500 1500 600 1-1/2

EVS-2000 2000 800 1-1/2

EVS-2000S 2000 800 1/1/2

EVS-2500 2500 1000 2

EVS-3000 3000 1200 2

Gas Connection Size (inch dia.)

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.

CAUTION

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

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 off 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.

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 or bypass 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.

5. The following pages have sample wiring diagrams. Contact Thermal Solutions Representative or visit website (www.thermalsolutions.com) for current wiring options.

4. 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.

6. An as-built wiring diagram is included with every boiler when it is shipped from the factory.

Figure 9a: 208/230/460V-1/3 ph-60 Hz Supply Power Wiring Schematic

Figure 9b: 120V-1ph-60Hz Supply Power Wiring Schematic

Figure 9c: Standard UL/FM/CSD-1 Wiring Diagram (EVS 500-2000)

LINE TYPES:

120V-1PH-60HZ

SEE FIG. 9A-9B FOR

SUPPLY POWER WIRING

BLOCKED AIR FILTER

SWITCH AND LIGHT

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

ALARM SILENCE

PUSH BUTTON

ALARM BELL

TO VSD TERMS. 1&2

BOILER STATUS

TRANSFORMER

GND TO

CHASSIS

(2)

(1)

NO C

115V TO 24V

GND TO

CHASSIS

OUTLET

SENSOR

INLET

SENSOR

(COLD AIR DAMPER,

SYSTEM PUMP BACKUP

OR ALARM)

SYSTEM PUMP

LOCKOUT INDICATOR

SPARE

CONTROL RELAY OPTIONS

(VALID INPUT SIGNAL RANGE IS 1-9VDC)

Q7800H1009 INTERNAL WIRING

FUSE

SENSE

ALARM RELAY K2

LINE VOLTAGE ALARM

BLOWER MOTOR

AUXILIARY RELAY

MAIN FUEL

VALVE(S)

10 28

HONEYWELL Q7800H

FLAME SAFEGUARD SUBBASE

AND

PROGRAMMER CONTROL

RM7896D 1027

24VAC -

24VAC +

FUSE

C-

C+

RJ11

GND TO

CHASSIS

13 14

5 9

13 14

REMOTE CONTROL

REMOTE SETPOINT

0-10 VDC INPUT

CRA

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

SAGE

CONTROLLER

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

12 VDC

0.5A MAX TOTAL FOR SO, SP, BP,

V1, & LO

(FIELD SUPPLIED

CONTACTS/SWITCHES)

CALL FOR

24VAC -

24VAC +

Pin 6

Pin 1

BURNER ON/OFF SWITCH

WATER FLOW SWITCH

CNO

HIGH AND LOW GAS PRESSURE SWITCHES

CNO

HIGH LIMIT AND OPERATING TEMPERATURE SWITCHES

UNUSED OPERATING LIMIT

COMBUSTION AIR FLOW SWITCH

CNO

VENT VALVE (OPTIONAL)

INTERRUPTED IGNITION PILOT GAS VALVE

GND XFMR

TO PILOT

UV SCANNER

OUTSIDE AIR

RESET OPTION

MM 750-

MT-120

LOW WATER

CUTOFF

OPTION

(SEE NOTE 1)

IGNITION XFMR

IGNITION PILOT

COMBUSTION BLOWER SPEED CONTROL CIRCUIT

(38)

(37)

REMOTE SYSTEM SENSOR

TO K3 RELAY ON FLAMESAFEGUARD SUBBASE TERM. 37 & 38

BURNER

THERMAL FUSE

237

O+

O-

R+

R-

RJ45

OPTIONAL

PRIMARY SECONDARY GAS RATIO

ACTUATOR

E/H

LOCAL

HEAT

Pin 7

Pin 1

12 VDC

VESTIBULE

THERMAL FUSE

HIGH LOW

CNC

HIGH LIMIT OPERATING LIMIT

GAS

VALVE

GND TO CHASSIS

VARIABLE

SPEED DRIVE

AC Tech SCF

OUTSIDE AIR SENSOR

DOMESTIC HOT WATER PRIORITY

LOCAL/REMOTE(REMOTE CONTROL OR REMOTE SETPOINT)

REMOTE ON/OFF(ENABLE/DISABLE)

REMOVE JUMPER BETWEEN RO & C

WHEN SWITCH OPTION IS USED.

REMOTE

PN: 102535-01

SPARE INPUT

Figure 9d: Standard UL/FM/CSD-1 Wiring Diagram (EVS500-2000)

Figure 9e: Standard UL/FM/CSD-1 (EVS 2000S-3000)

LINE TYPES:

120V-1PH-60HZ SEE DWG 34-1136-D FOR SUPPLY POWER WIRING

BLOCKED AIR FILTER

SWITCH AND LIGHT

GND TO CHASSIS

ALARM SILENCE

PUSH BUTTON

ALARM BELL

(2) TO VSD TERMS.

(1)

1&2

DRY CONTACTS

FOR BOILER

STATUS

INDICATION

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

115V TO 24V

TRANSFORMER

GND TO

CHASSIS

OUTLET

SENSOR

INLET

SENSOR

PROG. SPARE OUTPUT

(COLD AIR DAMPER,

SYSTEM PUMP BACKUP

LOCKOUT INDICATOR

OR ALARM)

SYSTEM PUMP

BOILER PUMP

SPARE

CONTROL RELAY OPTIONS

FUSE

13 14

5 9

13 14

REMOTE CONTROL

REMOTE SETPOINT

0-10 VDC INPUT

(VALID INPUT SIGNAL RANGE IS 1-9VDC)

SEE NOTE 2

Q7800H1009 INTERNAL WIRING

SENSE

ALARM RELAY K2

LINE VOLTAGE ALARM

BLOWER MOTOR

AUXILIARY RELAY

MAIN FUEL

VALVE(S)

10 28

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

FLAME SAFEGUARD SUBBASE

PROGRAMMER CONTROL

CRA

HONEYWELL Q7800H

AND

RM7896D 1027

24VAC -

24VAC +

FUSE

C-

C+

RJ11

GND TO

CHASSIS

THERMAL SOLUTIONS

BOILER CONTROL

12 VDC

0.5A MAX TOTAL FOR SO, SP, BP,

V1, & LO

CALL FOR

HEAT

(TSBC)

24VAC -

24VAC +

Pin 6

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

Pin 1

12 VDC

(FIELD SUPPLIED

CONTACTS/SWITCHES)

Pin 7

Pin 1

237

O+

O-

R+

R-

RJ45

HIGH LOW

CNC

HIGH LIMIT OPERATING LIMIT

MANUAL AUTO

PRIMARY SECONDARY

GAS RATIO

GAS

ACTUATOR

VALVE

E/H

REMOTE

LOCAL

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

OUTSIDE AIR

RESET OPTION

IGNITION XFMR

IGNITION PILOT

COMBUSTION BLOWER SPEED CONTROL CIRCUIT

REMOTE SYSTEM SENSOR

VESTIBULE

THERMAL FUSE

CNO

GND TO CHASSIS

VARIABLE

SPEED DRIVE

AC Tech SCF

OUTSIDE AIR SENSOR

DOMESTIC HOT WATER PRIORITY

LOCAL/REMOTE(REMOTE CONTROL OR REMOTE SETPOINT)

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

SPARE INPUT

MM 750-

MT-120

LOW WATER

CUTOFF

(38)

(37)

TO K3 RELAY ON FLAMESAFEGUARD SUBBASE TERM. 37 & 38

Figure 9f: Standard UL/FM/CSD-1 Wiring Diagram (EVS 2000S-3000)

Figure 10: Modular System: Conventional Venting (Negative Pressure)

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. 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

This section outlines venting requirements for

multiple boiler installations and should be used in

addition to the “VENTING” section earlier in this

manual.

a. Positive Pressure (Sidewall and Vertical) Venting

i. Positive pressure vent systems cannot be

manifolded together.

ii. Positive pressure systems can be piped

individually through a common vertical or horizontal chase provided minimum clearances to combustible materials are maintained.

iii. Positive pressure systems can be piped

individually through a common vertical chase so that a single roof penetration can be made. Each vent termination must be one (1) foot from all other terminations.

WARNING

DO NOT manifold vent components of multiple boilers without converting to a negative pressure venting arrangement.

b. Negative Pressure (Conventional) Venting

i. Refer to Figure 10 for an example of a

typical conventional venting arrangement for modular boilers.

ii. Refer to National Fuel Gas Code to

determine required chimney diameter and common venting diameter. Note that combined input, lateral length and chimney height affect vent diameter.

iii. Install a double acting barometric damper

with integral ue spillage interlock (as

shown in Figure 10).

iv. Locate boiler(s) with lowest input closest to

chimney/vertical common vent.

v. Chimney lining must be acceptable for use

with condensing ue gases.

vi. Install a condensate drain to collect any

condensate that may form in the lined chimney or vertical common vent (refer to

gure 10).

CAUTION

Installing multiple vent terminations close together promotes frost build up on buildings. To minimize this possibility, extend the distance from the building to the end of the vent termination and increase the horizontal distance between vent terminations.

4. Air Intake Piping

a. Consult intake pipe manufacturer for common

air intake pipe sizing.

b. Refer to Figures 11 and 12 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.

6. Gas Piping

a. Refer to National Fuel Gas Code, Local Codes

and Tables 2 through 7 for gas pipe sizing.

b. Refer to Gas Piping section for further warnings,

cautions, notices and instructions.

NOTICE

The pressure drop given in Table 1 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 6 for tting and component equivalent lengths.

g. Refer to the Combustion Air section for further

warnings, cautions, notices and instructions.

5. Water Piping

a. Refer to Figures 13 thru 18 for typical water

piping for modular boilers.

b. Installing a low water cut-off in the system

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

c. Refer to Table 1 for pressure drop and ow

requirements 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.

Figure 11: Modular System Horizontal Air Intake Piping

Figure 12: Modular System Vertical Air Intake Piping

Figure 13: Modular System: Typical One Pipe Water Piping

Figure 14: Modular System: Typical Primary/Secondary Water Piping

Figure 15: Modular System: Typical Primary/Secondary without System Pump

Figure 16: Modular System: Typical Reverse - Return Water Piping

Figure 17: Modular System Reverse - Return with System Pump Only

Figure 18: Modular System: Typical Primary/Secondary with Reverse-Return

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

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 syphon/pigtail loop or trap shall not exceed the height of the condensate drain outlet.

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.

b. Refer to Section H for condensate removal

system.

H. CONDENSATE DRAINS

1. Each boiler contains a condensate drain. 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.

2. Use continuous Teon, high temperature resistant

silicone tubing, or other tubing material compatible

with ue gas condensate, for condensate piping. Do

not install valves on condensate drain lines.

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 buffered before discharge. This buffering is commonly achieved by draining the condensate through a limestone (calcium carbonate) bed. The condensate will be slightly acidic and range between 3-5 on the pH scale. Consult Thermal Solutions or a chemical treatment company for buffering systems.

CAUTION

Do not use material that is not approved for use

with ue gas condensate for condensate piping.

IV. System Start-up

CAUTION

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

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.

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 off 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. The local boiler controls should be allowed to operate the boiler.

3. Remove the upper front jacket panel.

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-off 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-off valve in system supply and return piping.

a. Open hose bib.

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

be located directly after 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-off valve for

the zone being purged of air, then open the zone valve or shut-off 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-off 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-off gas valves between

the boiler and gas supply are closed.

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.

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 off and position the ame control back to run. Reinstall air lter.

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 off. 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 3 for maximum and minimum supply pressures.

2. Open the manual gas shut-off valves located

upstream of the gas regulator supplied with the boiler. Do not open manual gas valve inside of boiler jacket.

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 off, 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.

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 Thermal

Solutions Boiler ControlTM (TSBCTM) Instruction

6. Open the manual main gas shut-off 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 off and repeat Steps H.7-H.10 at least

ve times to conrm proper main burner operation.

DANGER

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.

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.

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.

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.

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

controls are operating properly. These controls and limits include combustion air switch, water 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. This manual was provided with the boiler.

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 different and must be analyzed based on local water conditions and boiler operating schedule.

A proper water treatment and a 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.

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.

The treatment chemicals must be compatible with

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

CAUTION

WARNING

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. This 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 off all electric power to the appliance.

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

4. This 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.

• 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 shutoff 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.

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

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

9. Wait ve (5) minutes to clear out any gas. Then 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.

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

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.

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 off 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 off cycles of the water heater. If any light offs are excessively noisy or rough, or any questionable boiler operation is noticed, immediately turn off all gas and electrical power and

call qualied service technician.

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

1. Set the thermostat to lowest setting.

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

3. Remove front door.

4. Rotate gas main shutoff 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.

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

Limits

Inp uts

Parame ter / Notes

Outdoor Air Temp >

Domestic Hot Water Priority

Low Fire Hold

Fuel Valve Energized

Flame Safeguard Alarm

System Pump Feedback

Call For Heat

Recycling Li mits

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

Non-Recyclin g Limi ts

(Combustion Air Flow (CA Input))

Call For Heat Relay

Lockout Indi cator

(Manual Reset Required)

Spare Output

O+,O-

R+,R-

BO,BC

LC , OO ,WF,

GP ,H L

Terminal Number

44 ,30 ,

20 ,74

70 ,71 ,

8,27,

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

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

Low Fire Hold

Boiler Running

Pump Cooldown

Fan Post Purge

54/d

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

V+,V-, P+,P -

2,30

25 ,30

10 ,27 /

6,79,

9,51/f

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.

Product Features

Boiler Sequence (Continued)

Pre-Sequence States

BOILER

STATE

LCD Display

Boiler

Disabled

Warm

Weather

Shutdown

CONTROL MODE

LCD Display

Any Mode

(Except for

Remote Control)

Any Mode

(Except for

Manual Mode)

Lockout Any Mode

Outlet Sensor &

Local SP Mode

Remote Sensor

& Local SP

Outlet Sensor &

Remote SP

Standby

Remote Sensor

& Remote SP

Remote Control

Operation Mode

Mode

Manual

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

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

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.

VII. Service

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.

Do not attempt to remove and/or service the burner. This may result in damage to the burner.

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.

CAUTION

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

WARNING

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.

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.

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.

B. TROUBLESHOOTING GUIDE

Alarm Messages (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.

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.

Test proper operation.

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

Flame safeguard Air Filter

Boiler trim

High limit and operating temp. controls

Low-water fuel cutoff

Safety relief valves

D. INSPECTION AND CLEANING PROCEDURES

Air Filter:

A. Perform a visual inspection of air lter and

replace as necessary.

1. Remove upper front panel.

2. Remove red tube from nipple on lter assembly.

3. Remove wing nut.

4. Remove lter assembly from boiler. For the

EVS-2000S-3000: to facilitate assembly removal, loosen the two upper 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 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 clearly visible through sight glass.

B. Pilot Cleaning and Maintenance

1. Shut off 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 gap to 1/8” if needed. Clean as required.

5. Reassemble in reverse order using a new gasket available from Thermal Solutions.

Burner Flame:

A. Perform a visual inspection of main burner ame.

CAUTION

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

B. When the air lter is not properly maintained, the

burner is susceptible of clogging. Check manifold pressure during the purge cycle to test for clogging.

1. Install a pressure tting in the tapping on the gas

manifold valve inside the boiler.

2. Attach a pressure monitoring device to the

pressure tting.

3. Check the pressure while the boiler is in the purge sequence.

4. If the measured pressure is considerably higher than expected, consult factory.

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.

b. Close manual main fuel shut off valve

and verify lockout of primary control.

Heat Exchanger:

A. Remove lower front jacket panel and check for

any signs of corrosion or leaks.

B. Remove pipe plugs in header and inspect inside

of copper tubes and header.

C. Flush boiler and mechanically remove any

scale.

1. Observe main ame and record ame signal.

Flame should be steady deep orange in color with dark blue checkerboard pattern throughout.

2. Main burner requires no cleaning or annual maintenance

Main Burner:

A. When properly maintained and operated the burner

does not require servicing.

VIII. Repair Parts

EVS™ Series repair parts can be ordered through your nearest Thermal Solutions Representative for delivery from Lancaster, PA.

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

Contact Thermal Solutions for your Representative at:

Thermal Solutions Products LLC

1175 Manheim Pike

Lancaster, Pennsylvania 17601

Telephone (717) 239-7642

Fax (877) 501-5212 (toll free)

www.thermalsolutions.com

WARNING

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

components may have been supplied due to the request of the equipment and user.

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

Figure 19: Combustion Chamber Assembly

(Quantity) Part Number

COMBUSTION CHAMBER ASSEMBLY

(2) 101935-01

(24 LF) 92466028 (25.5 LF) 92466028

EVS-500 EVS-750 EVS-1000 EVS-1500 EVS-2000 EVS-2000S EVS-2500 EVS-3000

Description

No.

Key

1A Heat Exchanger (1) 103530-01 (1) 6035630031 (1) 6035630041 (1) 6035630051 (1) 6035630061 (1) 103487-01 (1) 103487-02 (1) 103487-03

1. COMBUSTION CHAMBER ASSEMBLY

1F Tube Bafe (1) 70356116 (31) 70356215 (31) 70356216 (31) 70356217 (31) 70356218 (41) 70356315 (41) 70356316 (41) 70356317

1B Base (1) 61556042 (1) 61556024 (1) 61856501

(4) 603561061 (4) 603562041 (4) 603562051 (4) 603562061 (4) 603562071 (6) 60356208 (6) 60356209 (6) 60356210

Combustion Pan

Support

1G Sight Tube Bafe (1) 70356122 (1) 70356223 (1) 70356224 (1) 70356225 (1) 70356226 (1) 70356318 (1) 70356319 (1) 70356320

(1) 70356119 (1) 70356219 (1) 70356220 (1) 70356221 (1) 70356222 (1) 70356246 (1) 70356247 (1) 70356248

Heat Exchanger

(1) 70356235 (1) 70356236 (1) 70356237 (1) 70356238 (1) 70356239 (1) 70356240 (1) 70356241 (1) 70356242

Wrapper

Heat Exchange

Bafe

Condensate Drain

(1) 8065603 (1) 8065601

Tube

Sight Glass Lens

1L 1" Fiber Gasket (9 LF) 9206032 (14 LF) 9206032 (19.5 LF) 9206032

(1) 7186019 (1) 7186019

(2) 8206039 (2) 8206039

Retainer

Sight Glass

Gaskets

(1) 8205623 (1) 8205624 (1) 82056601

Vent Connector

Gasket

1O Sight Glass Lens (1) 8026082 (1) 8026082

(12 LF)

92466028

1R Wrapper Banding

1Q Vent Connector (1) 81156027 (1) 81156016 (1) 81156017 (1) 81156028 (1) 81156029

Temperature Probe

(not shown)

1S Banding Buckle (3) 80860946 (4) 80860946 (3) 80860946

TOP

VIEW

FRONT

VIEW

Figure 20: Burner Assembly

(1)

TS3000CF

N/A

(Quantity) Part Number

BURNER ASSEMBLY

(1) 81156018 (1) 81156018 (1) 81156300

See FIgure 25

(1) 60256211 (1) 60256212 (1) 62156300

(1)

60256210

(1)

TS2500CF

(1)

TS2000SCF

(1)

TS2000CF

(1)

(1) 60256215 (1) 60256216 (1) 62156300

(1)

TS1500CF

(1)

60256214

TS1000CF

(1)

82156307

(1) 80256236 (1) 80256237 (1) 80256237

(1)

80256253

(1) 6025602

(1) 6025601 N/A

(1)

EVS-500 EVS-750 EVS-1000 EVS-1500 EVS-2000 EVS-2000S EVS-2500 EVS-3000

811560021

Description

Fan (3 phase)

2B Air Filter (1) 81156009 (1) 81156011 (1) 81156012 (1) 81156012 (1) 81156101

No.

Key

2. BURNER/FAN ASSEMBLIES

(1)

60256209

(1)

602561031

Pilot Assembly - NG

- OR -

Pilot Assembly - LP

Mixer Assembly - NG

(1)

60256213

(1)

602561061

Mixer Assembly - LP

TS750CF

2F Air Orice Gasket (2) 82056061 (2) 8205603 (2) 8205603 (2) 8205666

2E Burner Element (1) TS500CF

(1)

80256235

(1)

802561041

2G Air Orice

2I Gas Mixing Orice (1) 80256134 N/A

2H Pilot Gasket (1) 8205608

(1) 8205609 (1) 8205605 (1) 8205665

Burner Mounting Flange

Gasket

Burner Thermal Fuse

Assembly

Vestibule Fuse Assembly

2J Burner Gasket (1) 82056071 (1) 82056041 (1) 82056501

(not shown)

Figure 21: UL/FM/CSD-1 Main Gas Train Assembly

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

(Quantity) Part Number

Key No.

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

3F Pilot Gas Regulator (1) 822702

Description

Main Gas Valve Body 1" NPT

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

Main Gas Valve Body, 2" NPT

Manual Gas Valve with Pilot Tapping, 1" NPT

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

Manual Gas Valve with Pilot Tapping, 2" NPT

Air/Gas Ratio Controller, Siemens SKP75

Solenoid Valve, V4295A1031, 1" NPT

Solenoid Valve, V4295A1056, 1-1/2"

Solenoid Valve, V4295A1064, 2"

Manual Gas Cock 1/4"

High Gas Pressure Switch

Low Gas Pressure Switch

EVS-

500

(1) 816634041 -- -- -- -- -- --

-- -- (1) 81663404 -- --

-- -- -- -- -- -- (1) 816634043

(2) 806603055 -- -- -- -- -- --

-- -- (2) 806603053 -- --

-- -- -- -- -- -- (2) 806604691

(1) 81660207 -- -- -- -- -- --

-- -- (1) 81660205 -- --

-- -- -- -- -- -- (1) 816602051

EVS-

750

EVS1000

EVS-

1500

(1) 81663408

(3) 822758

(1) 80160333

(1) 80160332

EVS2000

EVS-

2000S

EVS2500

EVS3000

Figure 22a: DB&B w/POC Gas Train (500-750)

DB&B W/POC - MAIN AND PILOT

Key

No.

3. Main and Pilot Gas Train

3A Main Gas Valve Body 1" NPT (2) 816634041

Manual Gas Valve with Pilot

Tapping, 1" NPT

Actuator/Regulator Ratio

Valve, Siemens SKP75, (max 5psi), DB&B w/POC

Actuator, Siemens SKP15,

DB&B w/POC

3E Manual Gas Cock, 1/4" (3) 822758

3F Pilot Gas Regulator (1) 822702

3G High Gas Pressure Switch (1) 80160333

3H Low Gas Pressure Switch (1) 80160332

3I Normally Open Vent Valve (1) 81660262

Description

(Quantity) Part Number

EVS-500 EVS-750

(2) 806603055

(1) 81663409

(1) 81663407

Figure 22b: DB&B Gas Train (500-750)

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

Key

No.

Description

3. MAIN AND PILOT GAS TRAIN

Main Gas Valve Body 1" NPT (1)

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

Manual Gas Valve with Pilot Tapping, 1" NPT

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

DB&B Actuator/Regulator

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

EVS-500 EVS-750 EVS-1000 EVS-1500 EVS-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

Figure 22d: DB&B Gas Train (2000S-3000)

EVS Modulation DB&B

(Quantity) Part Number

Key No. Description

3A Main Valve Body (1) 81663404 (1) 816634043

3C Ratio Valve (1) 81663408

3D Actuator (1) 81660205 (1) 8016602051

3E Gas Cock (3) 822758

3F Pilot Regulator (1) 822702

3G High Pres. Switch (1) 80130333

3H Low Pres. Switch (1) 80160332

3I Vent Valve (N.O.) (1) 81660748 (1) 816607501

Manual Gas Valve

EVS-2000S

(2) 806603053 (2) 806604691

EVS-2500 to

3000

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

DB&B W/POC – MAIN AND PILOT

Key

No.

Description

3. MAIN AND PILOT GAS TRAIN

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

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

DB&B w/POC Actuator/

Regulator Ratio Valve, Siemens SKP75 (max 5 PSI)

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

EVS-1000 EVS-1500 EVS-2000

(1)

81663404

(2)

806603053

(1)

81663409

(1)

81663407

(3)

822758

(1)

822702

(1)

80160333

(1)

80160332

(1)

81660748

Figure 22f: DB&B w/POC Gas Train (2000S-3000)

EVS Modulating DB&B w/POC (Proof of Closure)

Key

No.

3A Main Valve Body (1) 81663405 (1) 816634051

3B Manual Gas Valve (2) 806603053 (2) 806604691

3C Ratio Valve (1) 81663409

3D Actuator (1) 81663407

3E Gas Cock (3) 822758

3F Pilot Regulator (1) 822702

3G High Pres. Switch (1) 80160333

3H Low Pres. Switch (1) 80160332

3I Vent Valve (N.O.) (1) 81660748 (1) 816607501

Description

(Quantity) Part Number

EVS-2000S

EVS-2500 to

3000

Figure 23: Jacket Panels

(Quantity) Part Number

(2) 8056256

(1) 81356007

(1) 8026082

(2) 8206039

(1) 7186019

(2) 80861722

(1) 81363631

(1) 70456279 (1) 704563002

EVS-500 EVS-750 EVS-1000 EVS-1500 EVS-2000 EVS-2000S EVS-2500 EVS-3000

(1) 103524-01 (1) 60456342 (1) 60456343 (1) 60456344 (1) 60456345 (1) 104002-05 (1) 104002-03 (1) 104002-01

(1) 604563041 (1) 604563051 (1) 604563061 (1) 604563071 (1) 604563081 (1) 6045612040 (1) 6045602540 (1) 6045603040

Description

Front Panel

(Modulation)

Rear Panel

No.

Key

JACKET

4. Jacket Assembly

4A Jacket Lower

4B Jacket Lower

4C Jacket Upper

(1) 704562471 (1) 704563004

(1) 604563281 (1) 604563291 (1) 604563301 (1) 604563311 (1) 604563321 (1) 6045612010 (1) 6045602510 (1) 6045603010

Rear Panel

Left Side

4D Jacket Center

4E Jacket Panel

4F Jacket Top

(1) 704562541 (1) 704563000

(1) 604563011 (1) 604563021 (1) 604563000

Panel

Vestibule Panel

4G Jacket

4H Jacket Upper

(1) 70456280 (1) 104023-01

(1) 604563221 (1) 604563231 (1) 604563241 (1) 604563251 (1) 604563261 (1) 6045612020 (1) 6045602520 (1) 6045603020

Front Panel

Right Side

4I Jacket Panel

4J Handle

4K View Port

Cover for

Flame

Safeguard

Port Gasket

4L Observation

4M Observation

Port Lens

Retainer

4N Observation

4P Latch

w/Filter Light

4Q Power Switch

R H1B - U OMRON MY2 12 V DC

R H1B - U

DC 12 V

I DE C

idec

R H1B - U

R J 1S - C D

OMRON

DC 12 V

I DE C

- D 12

MY2 12 V DC

Figure 24: Control Panel Assembly

CONTROLS

Key

No.

5. Controls and Components

RM7896D1027 Flame Safeguard Control for UL/FM/CSD-1/DB&B

RM7840L-1075 Flame Safeguard Control for DB&B w/POC

Modbus Module for 5A (optional - not shown)

Display Module for 5A (optional - not shown)

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

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

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

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

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

High Limit L4008E 1313 (Manual Reset -

Max 240F)

5G Water Flow Switch FS4-3 (not shown) (1) 80160175

5H Vestibule Fuse Switch (not shown) (1) 80160209

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

Variable Frequency Drive 460 volt input (1) 80160941

Variable Frequency Drive 115/120 volt input

5N Control Transformer (1) 80160820

Fuses and Fuse Block, for 208/230/460V

Application

5R Transformer AT140B1206 (2) 801600502

Q7800H1109 Board for Thermal Solutions

Boiler Control (TSBCTM)

Thermal Solutions Boiler Control (TSBC)

Assembly (not shown)

Description

EVS-

500

EVS-

750

(Quantity) Part Number

EVS-

1000

EVS-

1500

(1) 80160212

(1) 801602303

(1) 80160909

(1) 80160640

(1) 8136362

(1) 81363621

(1) 80160667

(1) 80160940

(1) 80160933 N/A

(2) 8136426, (2) 8136427

(1) 101182-01

(1) 101171-03

EVS-

2000

EVS-

2000S

EVS2500

EVS3000

Figure 25: Pilot Assembly (Bishop Design)

PILOT ASSEMBLY (Bishop Design)

Key

No.

Description

EVS-

500

EVS-

750

EVS-

1000

EVS1500

EVS2000

7. Pilot Assembly, Bishop

Pilot Assembly, Natural Gas, ULX2 (1) 62356110

--Pilot Assembly, Propane, ULX2 (1) 62356210

7A Ultraviolet Sensor (1) 8026145

Pilot Orice, Natural Gas (1) 722606

Pilot Orice, Propane (1) 722605

7C Pilot Air Orice (1) 722607

7D Cast Iron Body (1) 82361581

7E Ignitor Assembly, ULX2 (1) 82356009

7F Nipple, 1/2 NPT x Close (1) 806600040

7G Pilot Ignition Cable (not shown) (1) 103827-01

(Quantity) Part Number

EVS-

2000S

EVS-

2500

EVS-

3000

7H Pilot Solenoid Valve V4046C1047 (1) 81660204

7I O-Ring (1) 8206054

IX. Thermal Solutions Boiler Control™ (TSBC™)

A. INTRODUCTION - The 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

The Thermal Solutions Boiler Control™ (TSBC™) is a complete boiler monitoring and automation system. The

TSBC™ provides advanced boiler modulation, operating control, diagnostics, multiple boiler lead-lag and auxiliary device control. The 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 The 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 The TSBC™ may simply control boiler modulation

and on/off 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/off 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 different control modes.

5. Advanced Availability The 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. The TSBC™ makes this type of automation totally integrated and cost

effective. The 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 The 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. The peer-to-peer network is truly "plug and play". Communication is activated by simply connecting a RJ11 telephone line between boilers. The TSBC™ provides precise boiler coordination by sequencing boilers based on both

modulation rate. For example, the lead boiler can be

congured to start a lag boiler after operating above

90% modulation rate for longer than an adjustable time. The boilers are modulated in "unison" (parallel) modulation rate to ensure even heat distribution.

FRONT PANEL DISPLAY

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 Thermal 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. The TSBC™ terminals

are removable for easier eld wiring connection.

R-

O-

RJ-45

(8 pin)

O+

O-

R+

R-

Alternate Connection For

Outside Air Temperature and

Remote System Temperature

(10k ohm Thermister, 5 Vdc)

Low Water Cutoff Switch Input

Vac

Call For Heat Output

Outside Air Temperature

(10k ohm Thermister, 5 Vdc)

Remote System Temperature

(10k ohm Thermister, 5 Vdc)

Local / Remote

Remote On / Off (Enable)

Domestic Hot Water Priority

Vdc

Spare Input (Programmable)

GPWF HL

12 Vdc Common

V-V+P-P+

NOTE:

(TSBC™)

WARNING:

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

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

CA - Low Combustion Air Flow

HL - Operating or High Limit

GP - Gas Pressure Switch

WF - Low Water Flow Switch

OO - Burner On/Off Switch

(24 Vac)

Fuel Valve Energized

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)

12Vdc Common

Spare Output (Programmable)

System Pump Start/Stop

Boiler Pump Start/Stop

Spare Output Start/Stop

Lockout Indicator

Mixing Valve Output

(4-20 mAdc)

Remote Firing Rate or

C-

Setpoint Input (0-10 Vdc)

C+

(See Note)

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.

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.

D. SETUP MENU

EVS Fire Test Procedures and Specifications

APPENDIX D (Cont…) - TSBCTM SETUP Menu

Factory

Settings

Trigger

LL Stop

Boiler

Delay

Water

195

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

Heat is immediately initiated.

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

satisfying a DHWP request

After

another boiler.

Display

WWSD Off

LL Start

Trigger

Boiler

On Delay

Off

%FR On

Delay

%FR Off

Delay

High Fire

Limit

Deg/Min Hold Off

Cutback Setpoint

100 40 – 100 %

Boiler

220

Heater

Range/Choices Description

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

Off

WWSD of Boiler

WWSD of Sys

90 50 to 100 %

25 0 to 50 %

120 0 to 900 (s)

30 0 to 900 (s)

1 1 to 30 (m)

1 1-10 F

Pump

Both

100 to 240 F

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

WWSD setpoint, inhibits boiler start

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

System Pump output (SO)

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

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

Net Start

Dwell

Limit

Fault

Time

Rotation Disable

Rotation

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

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

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

D. SETUP MENU (continued)

EVS Fire Test Procedures and Specifications

APPENDIX D (Cont…) - TSBCTM SETUP Menu

Boiler Set Up, Outdoor Design and boiler Design parameters

Only visible when Outdoor Sensor is set to Outdoor Reset

The Boiler Design setting is the water temperature required to satisfy the

Only visible when Outdoor Sensor is set to Outdoor Reset

Low Fire

Percent of blower operating range that the blower should be run during Fan

Boiler model

500

750

1000

1500

2000

2000S

2500

3000

Standard

100

Low fire

55 Venturi

100

Display

Outdoor

Sensor

Outdoor

Set Up

Boiler

Set Up

Outdoor

Design

Boiler

Design

Factory

Settings

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.

Display Only

Outdoor Reset

Display Only: Do Not Calculate setpoint based on outdoor temperature,

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.

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

building heat loss during the Outdoor Design temperature. If the building feels cool during cold outside conditions, the Boiler Design setting should be increased.

Display Outside Air Temperature

temperature using a reset curve defined by Outdoor Set Up,

Blower

SPD

High

Blower

SPD Low

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.

Purge (at ignition)

Build

proving

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

Local

PID

Local

PID

Remote

PID

Remote

PID

Remote

PID

Mixing

Valve

Mixing

Valve

Mixing

Valve D

Max

Delta T

Max

Delta T

Max

Delta T

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.

E. BOILER CONFIGURATION MENU

EVCA Modulating Fire Test Procedures and Specifications

APPENDIX D (Cont…) - TSBCTM BOILER CONFIG Menu

Display

Units

Factory

Setting

Deg F

Boiler

Pump

None

Purge

Pump

Prepurge

Postpurge

Delta

Inlet

Sensor

Mixing

Valve

Set

Time/Date

Spare

Input

15 0 to 600 (s)

Yes

Off

Range/

Choices

Deg F Deg C

None

Always On

Purge

Lead On

0 to 20

(C or F)

Yes

hour : minute

Month / day /

year

Off

Sys Pump

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 (SO) is set to System Backup Pump, system pump output (SO) is energized and System pump Feedback is de-energized the System Backup Pump output (SO) 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

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.

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

Demand

Shared

Demand

Remote

Modbus

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

CAD

“Low

Water

Level”

140

220

Control

Yes

(If

applicable)

“Low

Water

Level”

60 F to

170 F

150 F to

220 F

Display

Only

Control

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 (SO).

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.

G. SETPOINTS MENU

EVCA Modulating Fire Test Procedures and Specifications

APPENDIX D (Cont…) - TSBCTM SETPOINTS Menu

Display

Operational

On Point -5 0 to 99 F

Off Point 15 0 to 99 F

High Temp

Stop

DHWP

Setpoint

WWSD

Setpoint

Max SP

Min SP 70 60 to 230 F

Min BIT 120 60 to 235 F Low Boiler Inlet Temperature alarm and event setpoint.

Factory

Settings

180 60 to 230 F

Boilers

230

Boilers

Water

230

Heaters

200

180

70 40 to 90 F

Boilers

230

Boilers

Water

230

Heaters

200

140

Range/Choices Description

60 to 230 F

140 to 230 F

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

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.

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

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

Only visible when DHWP equals Yes.

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

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

Only visible when WWSD does not equal Off.

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

Min In H2O

Temp

Max H2O

Delta T

Max

Delta T

Hold

130 110 to 180 F

50 20 to 50 F

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.

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.

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.

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.

NOTES

X. Warranty

Thermal Solutions

("seller")

LIMITED WARRANTY

Subject to the terms and conditions herein and except as provided below with respect to products or parts not manufactured by Thermal 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 heat exchanger with recognized hydronics industry regulatory agency standards and requirements then in effect and will be free from defects in materials and workmanship for a period of 5 years from date of shipment

(the “Warranty Period”). The burner is also covered under

the limited warranty for 10 years from date of shipment (the "Warranty" Period). For products or parts not manufactured by Thermal Solutions, the warranty obligations of Thermal Solutions shall, in all respects, be limited to one year.

REMEDY

A. The 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 - The owner must notify the original installer of

the Product and Seller (Attention: Thermal 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. The 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. The 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. The 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.

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 effect to the minimum extent necessary to render the remaining provisions hereof enforceable.

Thermal Solutions EVS SERIES, EVS-500, EVS-750, EVS-1000, EVS-1500 Installation, Operating And Service Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual