Thermal Solutions SOLARIS Installation, Operating And Service Instructions

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

SOLARIS

Gas-Fired Boiler

For service or repairs to boiler, call your heating contractor. When seeking information on boiler,
provide Boiler Model Number and Serial Number as show on Rating Label.

Boiler Model Number
SOL __ __ __ __ - __ __ __

Heating Contractor Phone Number

Address

814SOL0010-8/09

Boiler Serial Number
6 __ __ __ __ __ __ __

Installation Date

Price - $5.00

1

IMPORTANT INFORMATION - READ CAREFULLY

NOTE: The equipment shall be installed in accordance with those installation regulations enforced 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 made in accordance with the National Electrical Code and/or local regulations.

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

The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas Fitter.

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 dam-

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

CAUTION

age.

WARNING

Indicates a potentially hazardous situation
which, if not avoided, could result in death,
serious injury or substantial property dam­age.

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

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.

Manufacturer’s Contact Information:
Thermal Solutions
1175 Manheim Pike
Lancaster, PA 17601
717-239-7642
www.thermalsolutions.com

2

WARNING

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

contained in this manual.
Improper installation, adjustment, alteration, service or maintenance can cause property dam-

age, 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.
A clean and unobstructed venting system is 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.

Installation is not complete unless a pressure relief valve is installed into the tapping located on
top of appliance. - See the Water Piping and Trim Section of this manual for details.

This boiler is supplied with safety devices which may cause the boiler to shut down and not re­start 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 Com-

monwealth of Massachusetts.

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.

NOTICE

3

Table of Contents

I. Pre-Installation ................................................. 6

II. Unpack Boiler ...................................................7

III. Venting/Air Intake Piping ................................ 8

A. Vent Guidelines Due to Removal of an

Existing Boiler .............................................8

B. General Guidelines ..................................... 9

C. Supplemental Vent Terminal Location

Instructions ................................................10

D. Separate Horizontal Venting

System ........................................................ 11

E. Optional Horizontal Vent Terminal

Mounting .................................................... 14

F. Conventional Venting........ ........................15

G. Air Intake Piping ......................................15

H. Separate Vertical Venting System ...........17

IV. Water Piping and Trim .................................. 20

V. Gas Piping .......................................................24

VI. Electrical .........................................................26

VII. Modular Installations ....................................29

VIII. System Start-up ...........................................39

IX. Service and Maintenance ............................... 46

A. Periodic Maintenance ..............................46

B. Safety & Operating Controls .................... 49

C. Trouble Shooting ........................................50

X. Sage Boiler ControlTM (SBCTM)......................52

A. Introduction ............................................... 52

B. Front Panel Display ...................................53

C. Setup Menu ................................................54

 D.BoilerCongurationMenu ......................56

 E. SystemCongurationMenu ....................57

F. Setpoints Menu ..........................................58

G. Communication Menu ..............................59

H. Manual Mode Menu .................................. 59

I. Security Menu............................................60

XI. Repair Parts ....................................................61

XII. Service Record .............................................. 71

XIII. Refractory Ceramic Fiber ..........................74

XIV. Warranty .......................................................75

Minimum Clearance to Combustible Materials

Left Side Right Side Front Rear Top Flue Connector

1” 1” 24” 3” 1” 6”

Recommended Clearance for Service

Model Left Side or Right

Front Rear Top

Side
SOL-300 24” 24” 24” 16”
SOL-750 24” 24” 24” 16”
SOL-1000 24” 24” 24” 19”
SOL-1250 24” 24” 24” 31”
SOL-1500 24”

Note: Verify clearance with jurisdiction having authority and local codes.

4

(Amps)

REAR VIEW

TOP VIEW

SIDE VIEW

L

(TYP.)

L

(TYP.)

C

2.71

E

D

B

K

A

13.00

H

M VENT

OUTLET

F OULET

WATER

F INLET

WATER

G INLET GAS

J

M VENT

INLET

Amp Draw

Rated Blower

(HP)

Rated Motor

Horse Power

Electrical Supply

(Voltz/Hertz/Phase)

Wet

(lbs.)

Weight

Dry

(lbs.)

Weight

Water

Volume

(Gallons)

BTU

(MBH)

Output

General Ratings and Capacities

(MBH)

BTU Input

Boiler

Model

SOL-300 300 252 1.1 288.5 297.7 3/4 8.5

SOL-500 500 420 1.3 316.0 326.8 3/4 8.5

SOL-750 750 637.5 2.4 508.5 528.5 120/60/1 3/4 8.0

SOL-1000 1000 850 2.6 548.5 570.2 3/4 8.0

SOL-1250 1250 1062.5 2.9 620.0 644.2 1-1/8 12

SOL-1500 1500 1275 3.3 713.0 740.5 1-1/8 12

Dimensions

‘A’ ‘B’ ‘C’ ‘D’ ‘E’ ‘F’ ‘G’ ‘H’ ‘J’ ‘K’ ‘L’ ‘M’

Boiler

Model

SOL-300 27.8 32.6 28.1 25.9 15.0 2.0 1.00 4.1 29.3 17.0 4.1 4.0

SOL-500 42.6 32.6 28.1 28.0 15.0 2.0 1.00 7.2 27.8 17.0 4.1 6.0

SOL-750 41.4 36.9 31.8 32.4 13.0 3.0 1.00 3.5 32.1 23.6 6.2 8.0

SOL-1000 49.4 36.9 31.8 32.4 13.0 3.0 1.25 3.5 32.1 21.6 6.2 8.0

SOL-1250 61.6 36.9 31.8 32.4 13.0 3.0 1.25 3.5 32.1 26.5 6.2 10.0

Figure 1: Dimensions

SOL-1500 73.9 36.9 31.8 32.4 13.0 3.0 1.50 3.5 32.1 25.6 6.2 10.0

5

I. Pre-Installation

WARNING

If you do not follow these instructions ex-

actly, a re or explosion may result causing

property damage or personal injury.

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

E. Protect gas ignition system components from water

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

F. Provide combustion and ventilation air in accordance

with sections 5.3 of the National Fuel Gas code,
ANSIZ223.1/NFPA 54, or sections 7.2, 7.3, or 7.4 of
CAN/CSA B149.1, Natural Gas and Propane Installa­tion code, or applicable provisions of the local building
codes.

WARNING

Adequate combustion and ventilation air

must be provided to assure proper combus­tion.

Due to the low water content of the boiler,
mis-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 mis-sized boiler
applications. DO NOT oversize the boiler
to the system. Modular boiler installations
greatly reduce the likelihood of boiler over­sizing.

A. Installation must conform to the requirements of the

authority having jurisdiction. In the absence of such
requirements, installation must conform to the Na-
tional Fuel Gas Code, NFPA 54/ANSI Z223.1, and/or
CAN/CGA B149 Installation Codes. Where required
the installation must conform to the standard for con-

trols and safety devices for automatically red boilers,

ANSI/ASME CSD-1.

B. Appliance is design certied for installation on combus-

tible ooring. Do not install boiler on carpeting.

C. Provide clearance between boiler jacket and combus-

tible material in accordance with local re ordinance.

Refer to Figure 1 for minimum listed clearance from
combustible material. Recommended service clearance
is 24 inches from left side, right side and front. Rec­ommended service clearance is 36” at rear of unit. Ser­vice clearances may be reduced to minimum clearances
to combustible materials.

The following guideline is based on the National Fuel Gas
Code, NFPA 54/ANSI Z223.1.

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]

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 sill plates and

oors, between wall-ceiling joints, between wall

panels, at plumbing and electrical penetrations,
and at other openings.

D. Install on level oor. Floor must be able to support

weight of boiler, water and all additional system com­ponents.

6

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.

6. For boiler located within unconned space in

building of

within equate 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 commu­ nicating with the outdoors. Locate one opening
within twelve (12) inches of top of space. Locate
remaining opening within twelve (12) inches of
bottom of space. Minimum dimension of air
opening is three (3) inches. Size each opening
per following:

a. Direct communication with outdoors. Minimum

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

b. Vertical ducts. Minimum free area of one (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 one (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.

unusually tight construction, or

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 one (1) square inch per 1,000 Btu per hour
input of all equipment in spaces, but not less than
100 square inches.

7. Combustion Air/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.

CAUTION

Avoid operating this boiler in an environment where saw dust, loose insulation bers, dry wall

dust, etc. are present. If boiler is operated under these conditions, the burner interior and ports
must be cleaned and inspected daily to insure proper operation.

II. Unpack Boiler

CAUTION

Do not drop boiler. Do not bump boiler

jacket against the oor.

A. Move boiler to approximate installed position.

B. Remove all crate fasteners.

C. Lift and remove outside container. Save two of the

wooden slats from the container sleeve for use in Steps
E and F.

D. Remove all boiler hold-down fasteners.

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

from a qualied service agency.

E. Tilt the boiler to its front side or back side and slide a

wooden slat under the raised feet.

F. Tilt the boiler in the opposite direction and slide another

wooden slat under the raised feet.

G. Slide the boiler left or right off the skid using the two

wooden slats as runners.

H. Move boiler to its permanent location.

WARNING

7

III. Venting / Air Intake Piping

WARNING

Do not use this boiler with galvanized, non metallic or any other venting material that is not de-

signed for condensing ue gas applications.

Do not use a drafthood with this appliance.
Do not use vent dampers with this boiler.
Moisture and ice may form on surfaces around termination. To prevent deterioration, surfaces

should be in good repair (sealed, painted, etc.).
This appliance needs fresh air for safe operation and must be installed so there are provisions

for adequate combustion and ventilation air.

Do not reduce size of air intake pipe.
Read, understand and follow combustion air instruction restrictions contained in the Pre-Installa-

tion instructions of this manual.

Do not operate appliance 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, stored and/or present in the air.

When installing vent pipe through chimney, no other appliance can be vented into the chimney.
Do not exceed maximum vent/air intake lengths. Refer to Table 1.

A. Vent Guidelines Due to Removal of an Ex-

isting Boiler

For installations not involving the replacement of an

existing boiler, proceed to Step B.

When an existing boiler is removed from a common

venting system, the common venting system is likely to
be too large for proper venting of the remaining appli­ances. At the time of removal of an existing boiler, the
following steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances remain­ing connected to the common venting system are not in
operation:

1. Seal any unused openings in the common venting
system.

2. Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion, and

other deciencies which could cause an unsafe

condition.

3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system.
Turn on any exhaust fans, such as range-hoods
and bathroom exhausts, so they will operate at

8

maximum speed. Do not operate a summer exhaust

fan. Close replace dampers.

4. Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.
Adjust thermostat so appliance will operate
continuously.

5. Test for spillage at the draft hood relief opening

after ve (5) minutes of main burner operation. Use
the ame of a match or candle, or smoke from a

cigarette, cigar or pipe.

6. After it has been determined that each appliance
remaining connected to the common venting
system properly vents when tested as outlined

above, return doors, windows, exhaust fans, re

place dampers and any other gas burning appliance
to their previous conditions of use.

7. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, NFPA
54/ANSI Z223.1 and/or CAN/CSA B149.1 Natural
Gas and Propane Installation Code. When resizing
any portion of the common venting system, the
common venting system should be resized to ap­proach the minimum size as determined using the
appropriate tables in Part 11 of the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA
B149.1 Natural Gas and Propane Installation Code.

B. General Guidelines

1. Vent system installation must be in accordance with
Part 7, Venting of Equipment of the National Fuel
Gas Code, ANSI Z223.1/NFPA 54, or Section 7,
Venting Systems and Air Supply for Appliances of
the CAN/CSA B149.1, Natural Gas and Propane In­stallation Code, or applicable provisions of the local
building codes.

2. Contact local building or re ofcials about restric­tions and installation inspection in your area.

3. Refer to the appropriate drawings in this section of

this manual to determine the proper conguration of

venting system. Figures 2 thru 11. The vent system
shall be installed in accordance with the instructions
listed in this manual.

4. This appliance requires a Special Gas Vent. The
product is designed to use AL 29-4C® Stainless
Steel or other Stainless Steel material approved for

condensing ue gas applications. The boilers are

shipped with AL 29-4C® vent adapter to directly
connect to Heat Fab Saf-T-Vent. The use of alter­nate manufacturer’s venting systems will require
adapters and vent terminal. These adapters are not
supplied with this unit and should be obtained from
the supplier of alternate venting system.

5. The venting system must be installed so as to
prevent accumulation of condensate. Horizontal
vent pipe must maintain a minimum ¼ inch per foot
slope down towards boiler.

a. Do not manifold condensate drains.

b. A common condensate pump/sump may be used.

Run separate condensate piping from each vent
drain to the sump. A common drain may be used
to discharge condensate from the sump.

Consult pump/sump manufacturer for compat-

ibility of materials of construction with ue gas

condensate. If a common pump/sump is used,
individual vent drain lines must be connected
such that one drain pipe cannot back feed into
another vent drain.

c. 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 bed. Consult chemical
treatment company for buffering systems.

6. Use noncombustible ¾ inch pipe strap to support
horizontal runs and maintain vent location and
slope while preventing sags in pipe. Do not restrict
thermal expansion or movement of vent system.

Maximum support spacing is ve (5) feet. Do not

penetrate any part of the vent system with fasteners.

7. Vent length restrictions are based on equivalent
length of vent/air pipe (total length of straight

pipe plus equivalent length of ttings). Maximum

vent/air lengths are listed in Table 1. Do not exceed

Table 1: Vent & Air Intake Length

Vent/Air Intake

Pipe Dia.Min Max

Boiler Model

SOL-300 5 50 4

SOL-500 5 78 6

SOL-750 5 50 8

SOL-1000 5 50 8

SOL-1250 5 50 10

SOL-1500 5 50 10

maximum vent/air intake lengths. Refer to vent
manufacturer’s recommendations for the equivalent

length of ttings.

8. Provide and maintain vent pipe minimum clearances
to combustible materials. Vent pipe minimum clear­ance to combustible material is four (4) inches when
vent is installed in a fully enclosed (chase) applica­tion or three (3) inches when vent is installed with
at least one side open, similar to a joist bay applica­tion. Use double wall thimble when penetrating a
combustible wall. Some examples of Wall thimble
manufactures are American Metal Products, Hart &
Cooley, and Metal Fab.

9. Do not install venting system components on the ex-

terior of the building except as specically required

by these instructions. The vent termination location
is restricted as follows:

a. The minimum distance from adjacent public

walkways, adjacent buildings, openable win
dows and building openings shall not be less

than those values specied in the National Fuel

Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/
CSA B149.1, Natural Gas and Propane Installa
tion Code.

b. Minimum twelve (12) inches above grade plus

normally expected snow accumulation level, or
seven (7) feet above grade if located adjacent to
public walkway. Do not install over public walk­way where local experience indicates appliance

ue gas vapor or condensate creates a nuisance

or hazard.

c. Minimum three (3) feet above any forced air

inlet located within ten (10) feet.

d. Power Vent - Minimum four (4) feet below, four

(4) feet horizontally from, or four (4) feet above
any door, window, or gravity air inlet.

ft. ft. In.

9

e. Minimum of four (4) feet horizontally from, and

in no case above or below, unless a 4 foot hori­zontal distance is maintained from electric me­ters, gas meters, regulators and relief equipment.
This distance may be reduced if equipment is
protected from damage due to condensation or
vapor by enclosure, overhangs, etc.

f. Minimum twelve (12) inches from overhang or

corner of building.

g. The vent termination shall be located such that

no damage to building materials will occur from

Figure 2: Vent Therminal Location

NOTICE

Cut must be square with pipe and led or

sanded smooth before joining. Carefully
ensure roundness of cut pipe by hand with
gloves before installing. Seal joint with RTV

specied in this manual.

ue gasses degradation.

10. Enclose vent passing through occupied or unoccu
pied spaces above the boiler with material having a

re resistance rating of at least equal to the rating
of the adjoining oor or ceiling. Maintain minimum

clearances to combustible materials. See page 4.

11. Plan venting system to avoid possible contact with
plumbing or electrical wires. Start at vent connector
on top of boiler and work towards vent terminal.

12. Once a vent pipe manufacturer and system is cho­sen never mix and match vent systems.

13. Field Supplied Vent Terminations (One per boiler)
a. Horizontal - Use Saf-T Vent mitered termination
with screen or equivalent

b. Vertical - Use Saf-T Vent rain cap or equivalent

C. Supplemental Vent Terminal Location In-

structions (Massachusetts Code Only)

The Commonwealth of Massachusetts requires compli-

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

(a) For all side wall horizontally vented gas fueled equip-

ment 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 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 install-

ing 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 even 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”.

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,

10

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 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 gasses, 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.

D. Separate Horizontal Venting System. See

Figures 3, 4 and 5.

1. Vent Piping –

a. Do not exceed maximum vent/air intake

lengths. Refer to Table 1.

b. Recommended horizontal installation consists

of vent being sloped down ¼ inch per foot
toward boiler.

c. Use appropriate designed thimbles when

passing through combustible walls (thimble
use optional for noncombustible walls). Insert
thimble through wall from outside. Secure

outside ange to wall with nails or screws, and

seal ID, OD and vent holes with sealant

material. Install inside ange to inside wall,

secure with nails or screws, and seal with
sealant material.

d. For noncombustible wall application when
thimble is not used, size opening such that bell
with locking band attached cannot pass
through.
e. Join vent terminal to vent pipe. Locate vent
pipe such that vent terminal is between six (6)
inches and twenty-four (24) inches from wall
when joined to inside vent piping. See Figure
3 or 4.
f. Insert vent pipe through thimble/opening from
outside and join to vent system. Apply seal­ ant between vent pipe and opening/thimble to
provide weathertight seal.

2. Side Vent Installation. See gure 5.

a. Horizontal vent/air intake runs with no
vertical rise in piping allowed.
b. Do not exceed maximum vent/air intake
lengths. Refer to Table 1.
c. Recommended Horizontal Installation only
consists of vent/air intake sloped down 1/4
inch per foot toward termination.
d. Thimbles, same as “C” above in section D.1
e. same as “D” above in section D.1
f. same as “E” above in section D.1
g. same as “F” above in section D.1

Figure 3: Side Top Vent

11

12

Figure 4: Recommended Separate Horizontal - Vent/Air Intake Installation

Figure 5: Side Vent

13

E. Optional Separate Horizontal Vent Terminal Mounting – See Figure 6

1. Do not exceed maximum vent/air intake lengths.

Refer to Table 1.

2. This installation will allow a maximum of ve (5)

feet vertical exterior run of the vent/air intake piping
to be installed on separate horizontal venting and
indoor air horizontal venting.

Note: Exterior run to be included in equivalent vent/

air intake lengths.

3. Install vent piping.

a. Install vent piping for desired venting system.

Refer to specic section for details for vent pipe

installation.

b. After penetrating wall/thimble, install a 90°

elbow so that elbow leg is in the up direction.

c. Install maximum of ve (5) feet of vent pipe.

Refer to Sections C through E for proper proce-

dures for joining vent pipe and ttings.

d. At top of vent pipe length install a 90° elbow so

that elbow leg is opposite the building’s exterior
surface.

e. Install 45° elbow to upper 90° elbow so that leg

of 45° is in down direction (see Figure 6). If not
using indoor air, proceed to Step f.

f. Install horizontal vent terminal.

g. Brace piping if required.

4. Air Intake Piping (not required for indoor air).

a. Install air intake piping for desired venting sys-

tem. Refer to specic section for details for air

intake installation.

b. After penetrating wall, install a corrosion re-

sistant 90o elbow so that elbow leg is in the up
direction.

c. Install maximum of ve (5) feet of corrosion

resistant air intake pipe.

d. At top of air intake pipe install air intake termi

nal (provided with boiler).

e. Brace piping if required.

-

14

Figure 6: Optional Indoor Air – Vent Terminal Installation

F. Conventional Venting (Negative Draft) – See Figure 7

a. The minimum chimney height is 15 feet.

b. The chimney must be protected from down

drafts, rain and debris by using a chimney cap or
star.

c. Start installing vent at vent cap and continue

installation toward the boiler.

d. The ue connector and chimney ue diameter

may need to be increased or decreased depend
ing on the dimensions of the boiler. Consult the
National Fuel Gas Code or Local Codes for siz-

ing. Boiler input, ue connector lateral distance
and chimney height affect the ue connector or
chimney ue diameters.

e. A double acting barometric damper with integral

ue spillage interlock switch must be used when

the boiler is vented conventionally.

f. The chimney and ue connector must be sized

and congured to provide a minimum - 0.04 inch

w.c. draft at the vent outlet of the boiler.

g. Maintain a minimum vertical pitch of one (1)

inch in four (4) feet of vent connector run.

G. Air Intake Piping - See Figure 4 & 8

1. Locate air intake termination on the same wall as the
vent termination if possible, to prevent nuisance boiler
shutdowns. However, boiler may be installed with verti­cal venting and sidewall combustion air inlet or vice
versa, if installation conditions do not allow alternate
arrangement.

2. Do not exceed maximum air intake length. See Table 1.

3. Use single wall metal pipe and ttings or thin wall PVC

available at most heating distributors.

4. Air intake termination must be located: Horizontal - At
least twelve (12) inches above grade plus the expected
snow accumulation.

5. Start at collar on burner enclosure (inside boiler jacket)
and work towards the air intake terminal.

6. Maintain minimum of 1/4 inch per foot slope on
horizontal runs. Slope towards air inlet terminal when
possible. If not, slope towards boiler.

7. The air intake pipe must be adequately supported with

straps or supports no less than ve (5) feet apart on

horizontal runs. The complete air intake piping system
must be rigid and able to withstand minor impacts with­out collapse.

8. Inlet air pipe penetration: Horizontal - Size wall pen­etration to allow easy insertion of air inlet piping. Seal
around pipe with sealant to form weathertight exterior
joint.

9. Seal all joints airtight, using silicone caulk or self-adhe­sive aluminum tape.

10. Install Air Intake Terminal.

Figure 7: Conventional Venting (Negative Draft)

15

16

SEE TABLE 1.

Figure 8: Separate Horizontal – Vent/Air Intake Terminal Conguration

H. Separate Vertical Venting System - See Figures 9, 10, and 11.

Vertical Venting –

1. Do not exceed maximum vent lengths. Refer to
Table 1.

2. Slope horizontal runs minimum ¼ inch per foot
down towards boiler.

3. 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.
Fire stop manufacturers are Air-Jet, American Metal
Products, Metal-Fab, and Simpson Dura-Vent.

4. Whenever possible, install vent straight through the
roof. Refer to Figure 9 if offset is necessary. Main­tain minimum clearance to combustible
materials.

5. Install Vent Terminal.

a. Size roof opening to maintain minimum clear-

ance from combustible materials.

b. Extend vent pipe to maintain minimum vertical

and horizontal distance of twelve (12) inches
from roof surface. Allow additional vertical dis­tance for expected snow accumulation. Provide
brace as required. Refer to Figure 11.

c. Vertical venting requires use of the roof ashing

and storm collar to prevent moisture from enter­ing the structure.

d. Install storm collar on vent pipe immediately

above ashing. Apply Dow Corning Silastic 732

RTV Sealant between vent pipe and storm collar
to provide weathertight seal.

e. Attach vent terminal.

Vertical Air Intake Piping –

1. Do not exceed maximum air intake length. Refer to
Table 1.

2. Locate air intake termination on the same roof loca
tion as the vent termination if possible, to prevent
nuisance boiler shutdowns. However, boiler may be
installed with vertical venting and sidewall combus­tion air inlet or vica versa, if installation conditions
do not allow alternate arrangement.

-

8. Inlet air pipe penetration:

9. Seal all joints airtight, using silicone caulk or self -
adhesive aluminum tape.

10. Install Air Intake Terminal:
Vertical - Insert intake piping into intake terminal
collar. Secure terminal to intake piping and seal
joint with silicone caulk.

with straps or supports no less than ve (5) feet

apart on horizontal runs. The complete air intake
piping system must be rigid and able to withstand
minor impacts without collapse.

Vertical - Size roof opening to allow easy insertion
of inlet piping and allow proper installation of ash­ing and storm collar.

a. Use appropriately designed vent ashing when

passing through roofs. Follow ashing manufac-

turers’ instructions for installation procedures.
Flashing manufacturers are Air-Jet, American
Metal Products, Metal Fab, and Simpson Dura­Vent.

b. Extend air intake pipe to maintain minimum

vertical and horizontal distance of twelve (12)
inches from roof surface. Allow additional verti­cal distance for expected snow accumulation.
Provide brace as required. Refer to Figure 11.

c. Vertical air intake requires ashing and a storm

collar to prevent moisture from entering the
structure.

d. Install storm collar on air intake pipe immediate-

ly above ashing. Apply Dow Corning Silastic

732 RTV Sealant between air intake pipe and
storm collar to provide weathertight seal.

3 Use single wall metal pipe and ttings or thin wall

PVC available at most heating distributors.

4. Air intake termination must be located:
Vertical - At least twelve (12) inches above the roof
surface plus the expected snow accumulation.

5. Start at collar on burner enclosure (inside boiler
jacket) and work towards the air intake terminal.

6. Maintain minimum of 1/4 inch per foot slope on
horizontal runs. Slope down towards boiler.

7. The air intake pipe must be adequately supported

17

18

Figure 9: Vertical Vent Installation

Figure 10: Attic Offset

Figure 11: Indoor Air - Horizontal / Vertical Vent Terminal Installation

Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve
(12) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation.

19

IV. Water Piping and Trim

CAUTION

iii. Oxygen permeable materials in the distribu-

tion system.

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

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

CAUTION

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 or scale

(lime) build-up cause by frequent addition of

water.

CAUTION

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

CAUTION

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

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

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 non-permeable materials in the distri-

bution system.

iv. Isolating the boiler from the system water by

installing a heat exchanger.

vi. Using properly designed and operating air

elimination devices in water piping.

2. Design and install system piping to prevent return
water temperatures below 130°F. Refer to Table 2

for boiler ow and pressure drop requirements.

3. Connect system supply and return piping to boiler.
Refer to Figure 12. Also consult I=B=R Installation

CAUTION

Return water temperature below 130°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.

WARNING

CAUTION

When using Glycol products, all Glycol

manufacturers’ requirements, including

rust inhibitors, must be adhered. Max 50%
Glycol.

a. There are many possible causes of oxygen con-

tamination such as:

i. Addition of excessive make-up water as a

result of system leaks.

ii. Absorption through open tanks and ttings.

20

Supply and return water temperature differ­ences greater than 40°F can lead to boiler
failure. Thermal Solutions Standard War­ranty does not cover problems caused by
temperature difference greater than 40°F.

and Piping Guides. Maintain ½” minimum distance
between water piping and combustible material.
Consult Thermal Solutions for unusual system
requirements.

4. A pressure relief valve is supplied with each appli­ance. No valve is to be placed between the relief
valve and appliance. No reducing coupling or other
restriction shall be installed in the discharge line.

See Figure 13.

compatible with local environmental regulations.

a. Pipe the safety relief discharge to a suitable place

for disposal when relief occurs.

b. Do not install reducing couplings for 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.

5. 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.

6. Install the drain valve provided with the appliance at
the lowest elevation. See Figure 13.

7. 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, see gure 13A.

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 circulation, the boiler piping must be
equipped with ow control valves or other auto­matic means to prevent gravity circulation of boiler
water during operation of the cooling system.

8. Install water ow switch. Water ow switch must
be located such that water ow disruptions do not

affect switch operation. Maintain maximum practi-

cal straight piping before and after ow switch to

minimize water disruptions. Refer to manufactures’
instructions for proper paddle length.

9. A low water cutoff is required to protect a hot water
boiler when any connected heat distributor (radia­tion) is installed below the top of the hot water

boiler (i.e. baseboard on the same oor level as the

boiler). In addition, some jurisdictions require the
use of a LWCO with a hot water boiler. If a low
water cutoff is required, it must be mounted in the
system piping above the boiler. The minimum safe
water level of a hot water boiler is just above the
highest water containing cavity of the boiler; that is,
a hot water boiler must be full of water to operate
safely.

10. Oil, grease, and other foreign materials which
accumulate in new hot water boilers and a new or
reworked system should be boiled out, and then

thoroughly ushed. A local qualied water

treatment chemical specialist is a suggested source
for recommendations regarding appropriate
chemical compounds and concentrations which are

11. After the boiler and system have been cleaned and

ushed, and before relling the entire system add

appropriate water treatment chemicals, if necessary,
to bring the pH between 8.8 and 9.2.

12. If it is required to perform a long term pressure

test of the hydronic system, the boiler should rst

be isolated to avoid a pressure loss due to the
escape of air trapped in the boiler.

To perform a long term pressure test including the

boiler, ALL trapped air must rst be removed from

the boiler.

A loss of pressure during such a test, with no

visible water leakage, is an indication that the
boiler contained trapped air.

WARNING

Failure to operate the unit with the proper

water ow rate can lead to appliance failure.
Always install water ow switch 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 shut-off valves, plugs or caps.
Consult Local Codes for proper discharge
piping arrangement.

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

Table 2. Boiler tube erosion and pitting will
occur. Thermal Solutions Standard War­ranty does not cover problems caused by

excessive water ow rates.

If a high head system pump is installed, as­sure 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.

21

Table 2 - Solaris Boiler Flow and Pressure Drop

20° ΔT (max) 40° ΔT (min)

Boiler

Model

SOL-300 0.8 24 0.5 12 2

SOL-500 6.9 41 1.4 20 2

SOL-750 6.5 64 1.5 32 3

SOL-1000 16.1 85 3.7 43 3

SOL-1250 23.5 106 6.9 53 3

SOL-1500 29.1 128 10.6 64 3

Flow

(GPM) Δ P (ft)

Flow

(GPM)

Supply/Return

Pipe (in. dia.)Δ P (ft)

Figure 12: Water Piping (Single Boiler)

22

Figure 13: Safety & Drain Valve Installation

Figure 13 A: Recommended Piping for Combination

Heating & Cooling (Refrigeration) System

23

V. Gas Piping

WARNING

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

A. Size gas piping. Design system to provide adequate gas

supply to boiler. Consider these factors:

1. Allowable pressure drop from point of delivery to
boiler. Maximum allowable system pressure is ½
psig. Actual point of delivery pressure may be less;
contact gas supplier for additional information. The
minimum and maximum gas valve inlet pressure is
stamped on the rating label and can be found in table

3.

2. Maximum gas demand. Refer to the boiler’s input
found in Figure 1 or as printed on it’s rating label.
Also consider existing and expected future gas
utilization equipment (i.e. water heater, cooking
equipment).

3. Length of piping and number of ttings. Refer to

Table 5 for maximum capacity of Schedule 40 pipe.
Table 6 lists equivalent pipe length for standard t­tings.

Table 3: Gas Ratings

Maximum

Boiler

Model

SOL-300 14 4.5 3.5

SOL-500 14 4.5 1.3

SOL-750 14 4.5 2.3

SOL-1000 14 4.5 1.9

SOL-1250 14 4.5 1.5

SOL-1500 14 4.5 1.3

Gas Pressure

(in. w.c.)

Minimum

Gas Pressure

(in. w.c.)

Manifold

Pressure

(in. w.c.)

4. Specic gravity of gas. Gas piping systems for
gas with a specic gravity of 0.70 or less can be

sized directly from Table 5, unless authority having

jurisdiction species a gravity factor be applied.
For specic gravity greater than 0.70, apply gravity
factor from Table 4. If exact specic gravity is not

shown choose next higher value.

Table 4: Specic Gravity Correction Factors

Specic

Gravity

0.50 1.10 1.10 0.74

0.55 1.04 1.20 0.71

0.60 1.00 1.30 0.68

0.65 0.96 1.40 0.66

0.70 0.93 1.50 0.63

0.75 0.90 1.60 0.61

0.80 0.87 1.70 0.59

0.85 0.84 1.80 0.58

0.90 0.82 1.90 0.56

1.00 0.78 2.00 0.55

For materials or conditions other than those listed above, re-

fer to National Fuel Gas Code, NFPA54/ANSI Z223.1,
or size system using standard engineering methods
acceptable to authority having jurisdiction.

Correction

Factor

Specic

Gravity

Correction

Factor

B. Connect boiler gas valve to gas supply system.

1. Use methods and materials in accordance with local
plumbing codes and requirements of gas supplier. In
absence of such requirements, follow National Fuel
Gas Code, NFPA 54/ANSI Z223.1.

2. Use thread (joint) compounds (pipe dope) resistant

to action of liqueed petroleum gas.

3. Install sediment trap, ground-joint union and manual
shut-off valve upstream of boiler gas control valve
and outside jacket. See Figure 14.

4. All above ground gas piping upstream from manual
shut-off valve must be electrically continuous and
bonded to a grounding electrode. Do not use gas
piping as grounding electrode. Refer to National
Electrical Code, NFPA 70.

USA boilers built for installation at altitudes greater than 2,000 feet above sea level have been

specically oriced to reduce gas input rate 4 percent per 1,000 feet above sea level per the

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

24

C. Pressure test. The boiler and its gas connection must be

NOTICE

Table 5: Maximum Capacity of Schedule 40 Pipe in CFH* for Gas Pressures of 0.5 psig or Less

MANUAL
SHUT-OFF
VALVE

GROUND-JOINT

UNION

TEE

CAP

3" MIN.

0.3 inch w.c. Pressure Drop 0.5 inch w.c. Pressure Drop

Length (Feet)

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

10 273 514 1060 1580 360 678 1390 2090

20 188 353 726 1090 247 466 957 1430

30 151 284 583 873 199 374 768 1150

40 129 243 499 747 170 320 657 985

50 114 215 442 662 151 284 583 873

60 104 195 400 600 137 257 528 791

70 95 179 368 552 126 237 486 728

80 89 167 343 514 117 220 452 677

90 83 157 322 482 110 207 424 635

100 79 148 304 455 104 195 400 600

* 1 CFH of Natural Gas is approximately equal to 1 MBH.

leak tested before placing boiler in operation.

1. Protect boiler gas control valve. For all testing over

DANGER

½ psig, boiler and its individual shutoff valve must
be disconnected from gas supply piping. For test­ing at ½ psig or less, isolate boiler from gas supply

Do not use matches, candles, open ames

or other ignition source to check for leaks.

piping by closing boiler’s individual manual shutoff
valve.

2. Locate leaks using approved combustible gas detec­tor, soap and water, or similar nonammable solu­tion.

WARNING

Failure to use proper thread compounds
on all gas connectors may result in leaks of

ammable gas.

WARNING

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

Table 6: Equivalent Lengths of Standard Pipe Fittings & Valves

VALVES FULLY OPEN

Figure 14: Recommended Gas Piping

Pipe Size I.D. Gate Globe Angle Swing 90° Elbow 45° Elbow 90° Tee, Flow 90° Tee, Flow

1/2” 0.622 0.35 18.6 9.3 4.3 1.6 0.78 1.0 3.1

3/4” 0.824 0.44 23.1 11.5 5.3 2.1 0.97 1.4 4.1

1” 1.049 0.56 29.4 14.7 6.8 2.6 1.23 1.8 5.3

1-1/4” 1.380 0.74 38.6 19.3 8.9 3.5 1.60 2.3 6.9

25

VI. Electrical

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.

WARNING

Failure to properly wire electrical connections to the boiler may result in serious physical harm.
Electrical power may be from more than one source. Make sure all power is off before attempt-

ing any electrical work.
Each boiler must be protected with a properly sized over-current device.
Never jump out or make inoperative any safety or operating controls.
The wiring diagrams contained in this manual are for reference purposes only. Each boiler is

shipped with a wiring diagram attached to the front door. Refer to this diagram and the wiring
diagram of any controls used with the boiler. Read, understand and follow all wiring instructions
supplied with the controls.

A. General. Install wiring and electrically ground boiler

in accordance with authority having jurisdiction or, in
the absence of such requirements, follow the National
Electrical Code, NFPA 70, and/or CSA C22.1 Electrical

Code.

B. 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. Install
the service switch in the line voltage “Hot” leg of the
power supply. Locate the service switch such that the
boiler can be shut-off without exposing personnel to
danger in the event of an emergency. Connect the main
power supply and ground to the three (3) boiler wires
(black, white and green) located in the junction box at
the back of the boiler jacket.

C. Refer to Figures 15 and 16 for details on the internal

boiler wiring.

D. When installed, the boiler must be electrically bonded

to ground in accordance with the requirements of the
authority having jurisdiction or, in the absence of such
requirements, with the National Electric Code, ANSI/
NFPA70 and/or the Canadian Electrical Code Part 1,
CSA C22.1, Electrical Code.

NOTICE

This boiler is equipped with a high water temperature limit located inside the internal wiring of the

boiler. This limit provides boiler shutdown in the event the boiler water temperature exceeds the

set point of the limit control. Certain Local Codes require an additional water temperature limit. In

addition, certain types of systems may operate at temperatures below the minimum set point of
the limit contained in the boiler.

If this occurs, install an additional water temperature limit (Honeywell L4006 Aquastat) located in

the system piping as shown in the Water Piping and Trim Section of this manual. Wire as indi­cated in the Electrical Section of this manual.

26

SAGE

CONTROLLER

Solaris

Ladder Diagram

LOW WATER

CUTOFF
OPTION

(SEE NOTE 1)

WATER FLOW SWITCH

BURNER ON/OFF SWITCH

HIGH LIMIT AND OPERATING
TEMPERATURE SWITCHES

HIGH AND LOW GAS
PRESSURE SWITCHES

CNO

CNC

CC

CNO

MM 750-

MT-120

IGNITION PILOT

IGNITION XFMR

IGN

.

LEAD

2

1

P

GR

INTERMITTENT
PILOT
GAS VALVE

3

5

COMBUSTION AIR FLOW
SWITCH

CNO

BLOCKED VENT

GN

RD

10

18

17

20

19

22

21

237

K1 K1

26

27

FUSE

G

2

10 28

8

9

11

12

13

14

16

15

7

8

9

11

10

3

2

5

SENSE

MAIN FUEL VALVE

6

SENSE

COMBUSTION AIR

FLOW

SENSE

HIGH LIMIT

SENSE

GAS PRESS SWITCHES

SENSE

WATER FLOW SWITCH

SENSE

BURNER ON/OFF

SWITCH

SENSE

LOW WATER CUTOFF

6

2

2

2

L1

L2

G

TO DISCONNECT (BY

OTHERS). GROUND

UNIT TO TECHNICAL

EARTH GROUND

120V-1PH-60HZ

43

31

32

34

35

33

36

K5

K5

29

37

38

K3

2

40

39

K4

41

4

4

5

3

K3

K5

K2

K3

SENSE

ALARM RELAY K2

K4

K6

51

52

1

2

1

4

1

5

0-10 VDC

TO

135 OHM

(+)

(-)

HONEYWELL Q7800H

FLAME SAFEGUARD SUBBASE

AND

PROGRAMMER CONTROL

RM7897A-1002

CALL FOR

HEAT

LC

CA

42

47

48

49

K2

2

3

3

2

3

50

2

0

30

K6

45

46

3

2

44

Flame

Rod

F

O+

O-

R+

R-

DP

LR

RO

SI

C

OUTSIDE AIR
SENSOR

REMOTE SYSTEM
SENSOR

OUTSIDE AIR

RESET OPTION

SYSTEM

TEMPERATURE

CONTROL OPTION

OUTLET

SENSOR

INLET

SENSOR

RJ45

MULTIPLE BOILER OUTSIDE AIR AND
REMOTE SYSTEM TEMPERATURE
SENSOR SHARING

C

SP

BP

VI

LO

SO

SYSTEM PUMP

COLD AIR DAMPER,

SYSTEM PUMP BACKUP

OR ALARM

BOILER PUMP

SPARE

LOCKOUT INDICATOR

CONTROL RELAY OPTIONS

MIXING VALVE

ACTUATOR

C-

C+

MR

MS

OR

1-9 VDC

24VAC +

24VAC -

2

12

7

5

4

6

8

9

1

11

10

3

K1

CS

AL

PR

C

LC

CH

FUSE

24VAC +

24VAC -

2

3

7

5

4

6

8

9

1

10

OO V

- V+

P-P

+

CA HL GP WF

Pin 6

Pin 1

Pin 7

Pin 1

BC

BO

BI

V+

V-

COMBUSTION BLOWER
SPEED CONTROL
CIRCUIT (0-10VDC)

COMBUSTION BLOWER

120 VAC CIRCUIT

GND TO

CHASSIS

GND TO

CHASSIS

2

1

3

GND TO

CHASSIS

2

1

3

GND TO

CHASSIS

MAIN
GAS VALVE

115V TO 24V

TRANSFORMER

L2

L1

C

C

C

O+

O-

R+

R-

RJ11

SAGE CONTROLLER PEER-TO-PEER

COMMUNICATION

GND TO

CHASSIS

CNC

NC NC

LINE VOLTAGE ALARM

BLOWER MOTOR

AUXILIARY RELAY

AUXILIARY RELAY

MAIN FUEL VALVE(S)

20

HIGH LIMIT OPERATING LIMIT

HIGH LOW

GND TO
CHASSIS

FACTORY WIRING, LINE VOLTAGE

LINE TYPES:

FIELD WIRING, LINE VOLTAGE

FACTORY WIRING, LOW VOLTAGE(SEE NOTE 3)

FACTORY WIRING, SPECIAL IGNITER

FIELD WIRING, LOW VOLTAGE

25

24

CS AL CH C PR

OO WF GP HL

THERMAL FUSE

(SEE NOTE 2)

BOILER

STATUS

12 VDC

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

REMOTE ON/OFF

(ENABLE/DISABLE)

SPARE INPUT

DOMESTIC HOT
WATER PRIORITY

LOCAL/REMOTE

(REMOVE JUMPER IF USED)

12 VDC

REMOTE CONTROL

REMOTE SETPOINT

OPTIONAL WIRING

CRA1

CRA2

CRA3

CRA4

CRA5

NOTES:

1. IF LOW WATER CUTOFF (LWCO) IS NOT USED, WIRE #P2 10/THERMAL
FUSE MUST BE WIRED FROM TERMINAL TO THE THERMAL FUSE.

2. IF THE HIGH AND LOW GAS PRESSURE SWITCHES ARE NOT USED, A
WIRE MUST BE INSTALLED BETWEEN TERMINAL AND .

3. FACTORY WIRING, LOW VOLTAGE IS 24VAC UNLESS OTHERWISE INDICATED.

10

16

17

GND TO

CHASSIS

Figure 15: Internal Boiler Wiring Ladder Diagram

27

E. System Controls and Wiring

E1

W7W6W5W4W3W2W1

250V T5A

SIZE 3AG

W15

W14 W11

W10 W12

W13

W8

W9

K2

K6

K4K3

K5

K1

24V

COIL

CAUTION

HAZARD OF ELECTRIC SHOCK.

MORE THAN ONE DISCONNECT

SWITCH MAY BE REQUIRED TO

DE-ENERGIZE THE DEVICE

FOR SERVICING.

GND

L2 L1

120VAC POWER

SUPPLY

2

3 10

11 12

13

14

15 16

17

18 19 20

21 2

28

2272

2625

24

23

22

2923031323334353637383940414243444546

32323

3

4748492505152

P8

176

12

RJ11

RJ45

BC

BO

BI

CCC

SO

SP

BPVILO

MR

MS

C-

C+

LC

CH

O+

O+

O-

O-

R+

R+

R-

R-

DP

LR

RO

SI

C

C

CPRALCS

WF

P+P-V+V-OO

CA HL GP

HLPR

C

CHWF

GP

AL

CS

CA

LC

OO

G

L2

3456789

10

F

1213141516171819202122

3 5

SWITCH

ON/OFF

BURNER

NO

NC

C

CNO CNC

GAS PRESSURE SWITCH

LOW HIGH

MANUAL

SWITCH

AIR FLOW

COMBUSTION

TRANSFORMER

IGNITION

PILOT

INGITION

FLAME ROD

OR ALARM

SYSTEM PUMP BACKUP

COLD AIR DAMPER,

SYSTEM PUMP

BOILER PUMP

SPARE

LOCKOUT INDICATOR

AUXILIARY EQUIPMENT

AIR SENSOR

OUTSIDE

SYSTEM TEMPERATURE CONTROL OPTION

OUTSIDE AIR RESET OPTION

WATER PRIORITY

DOMESTIC HOT

(ENABLE/DISABLE)

REMOTE ON/OFF

SPARE INPUT

^WE

^WE

^BK

^BK

WE

BNBNBNBNBN

YW

BN

^BK

^WE

WE

BK

GN

WE

BK

WE

BK

YW

OE

OE

BN

WE

BN

WE

BN

WE

BE

YWYWYWYWYWYWYWYWYW

YW

NC C

NC C

RESET HIGH LIMIT

AUTO

TRANSFORMER

NEC

LOAD

R

C

YW

YW

YW

YW

YW

YW

YW

YW

YW

YW

YW

BE

YW

BE

YW

YW

BE

BE

YW

YW

YW

^WE

^BK

YW

YW

YW

YW

IGN LEAD

SWITCH OPTION

LOCAL REMOTE

(SEE NOTE 3)

BLOCKED

VENT

SWITCH

P1 P2

P3

P5

P4

P6

P7

104 GN

YW

OE

SWITCH

FLOW

WATER

LOW

F1

F2

125V T5A

SIZE 5MM X 20MM

CHASSIS

GND TO

GROUND

L2

L1

TO DISCONECT,

(BY OTHERS)

GROUND UNIT TO

TECHINCAL EARTH GND.

208/230/460V-3PH-60HZ

GN

WE

BK

CHASSIS

GND TO

OE

2

1

3

CHASSIS

GND TO

2

1

3

CHASSIS

GND TO

GAS VALVE

IGNITION PILOT

GAS VALVE

MAIN

WIRE COLORS:

BE = BLUE

BK = BLACK

BN = BROWN

GN = GREEN

OE = ORANGE

PK = PINK

RD = RED

VT = VIOLET

WT = WHITE

YW = YELLOW

RELAY/SWITCH TERMINALS:

C = COMMON

NC = NORM. CLOSED

NO = NORM. OPEN

WIRE TYPES:

(BLACK COLOR SHOWN, TYPICAL FOR ALL COLORS)

FACTORY WIRING, LINE VOLTAGE, 12 AWG, 105°C

FACTORY WIRING, LINE VOLTAGE, 18 AWG, 105°C

FACTORY WIRING, LOW VOLTAGE, 18 AWG, 105°C

FACTORY WIRING, LOW VOLTAGE, 18 AWG, SHIELDED

FACTORY WIRING, SPECIAL IGNITER, NOT IN HARNESS

OPTIONAL WIRING, LINE VOLTAGE, NOT IN HARNESS, 18AWG, 105°C

OPTIONAL WIRING, LOW VOLTAGE, NOT IN HARNESS

^BK

BK

BK

*BK

WE

BK

CHASSIS

GND TO

BLOWER

VARIABLE SPEED

PIN 6

PIN 1

PIN 7

PIN 1

BK

WE

(SEE NOTE 2)

(CRA1)

(CRA2)

(CRA3)

(CRA4)

(CRA5)

STANDARD FACTORY WIRING, LINE VOLTAGE, NOT IN HARNESS, 18AWG, 105°C

STANDARD FACTORY WIRING, LOW VOLTAGE, NOT IN HARNESS

STANDARD FACTORY WIRING, NOT IN HARNESS, 16AWG, 200°C

FUSE

^BK

^WE

NO

C

C

NC

THERMAL FUSE

(SEE NOTE 1)

(INSTALL IGNITION TERMINAL,

RAJAH MODEL AEBF)

(REMOVE)

(REMOVE)

(REMOVE)

(REMOVE)

(REMOVE)

(REMOVE JUMPERS 11, 12, & 15)

NOTES:

1. IF THE LOW WATER CUTOF F(LWCO) IS USED, DISCONNECT WIRE LABELED

P2 10/THERMAL FUSE FROM THE THERMAL FUSE AND CONNECT IT TO

LWCO TERMINAL 3. ALSO, CONNECT LWCO TERMINAL 5 TO THE THERMAL FUSE.

2. IF GAS PRESSURE SWITCHS ARE USED, INSTALL WIRING BETWEEN P16 AND

P17 TO INCLUDE THE PRESSURE SWITCH(S) AS SHOWN. IF NO GAS PRESSURE

SWITCH IS REQUIRED, INSTALL A JUMPER BETWEEN TERMINALS P16 AND

P17 AS SHOWN.

3. IF THE REMOTE ON/OFF FUNCTION IS DESIRED, REMOVE JUMPER WIRE BETWEEN

TERMINALS RO & C AND WIRE AS SHOWN. NOT TO BE DONE AT FACTORY.

THERMAL SOLUTIONS SAGE CONTROLLER™ (SBC™)

PART NO. 801SOL0001

(BACK VIEW)

P12

LOW WATER

CUTOFF (LWCO)

OPTION

WE

GN

HONEYWELL

PROGRAMMER CONTROL

RM789A-1002

HONEYWELL Q7800H

PART NO. 101182-01

CHASSIS

GND TO

1. Refer to National Electric Code or Local Electric Codes for proper size and type of wire required. Follow Code.

2. Use anti-short bushings on all wiring passing through boiler jacket, junction boxes and/or control boxes.

3. Use armored cable (BX) over all exposed line voltage wiring.

28

Figure 16: Schematic Diagram

VII. Modular Installation

A. General Guidelines

1. Read and follow all venting, combustion air, water
piping, gas piping and electrical instructions con­tained in this manual unless otherwise instructed in
this section.

2. Consult Local Building Codes or National Fuel Gas
Code, NFPA 54/ANSI Z222.3 for restrictions and
instructions on modular boiler installations.

3. Modular systems are complex. Design and installa­tion of modular systems should only be undertaken
by skilled and knowledgable engineers and contrac­tors.

4. Use stainless steel vent material approved for con-

densing ue gass applications.

B. Module Sizing

Thermal Solutions recommends sizing each boiler in a

modular system to provide 20 % of the combined heat­ing load where ever possible. If the combined load ex-

ceeds the output of ve (5) boilers, install the minimum

number of boilers to meet the load requirements.

C. Venting

1. Horizontal/Vertical Venting
a. Use Stainless Steel vent material approved for

condensing ue gas applications.

WARNING

CAUTION

Installing multiple vent terminations close
together promotes frost buildup 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 terminations.

f. Refer to the cautions, notices, and warnings in

Section III.

2. Conventional Venting (Negative Draft)

a. Refer to Figure 17 for conventional venting

guideline for modular boilers.

b. 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.

c. A single double acting barometric damper can

be utilized on the common venting when venting
according to Figure 17.

d. Slope common venting a minimum of one (1)

inch in four feet of run towards boilers.

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

chimney.

f. Refer to cautions, notices, and warnding in Sec-

tion III.

Do not manifold vent components of a
boiler without correcting to negative draft.

b. See Table 1 for the maximum vent length of each

size boiler.

c. Refer to Section III of this manual for guidelines

on venting of modular boilers individually. Each
boiler requires an individual vent pipe.

d. The minimum horizontal distance between vent

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

e. Multiple vertical vent pipes may be piped

through a common conduit or chase so that one
roof penetration may be made. Each vent termi­nation must be one (1) foot from other termina­tions. A minimum of at least six (6) inches from
the common conduit to combustible material
must be maintained unless otherwise instructed
by the conduit manufacturer.

D. Air Intake Piping

1. Locate air intake termination on the same wall as
the vent termination if possible, to prevent nuisance
boiler shutdowns. However, boiler may be installed
with vertical venting and sidewall combustion air
inlet (or visa versa) if installation conditions do not
allow alternate arrangement.

2. Refer to Figures 18 and 19 for common air intake
guidelines for modular water heaters.

3. Individual air intake pipes may be used in lieu of
common air intake piping. If so desired, refer to
Figures 4 and 8.

4. Refer to Table 1 for the maximum air intake length.

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.

5. Position horizontal air intake termination center line
below horizontal vent termination’s center line.

6. Vertical air intake pipe must terminate at least two
(2) feet above teh closest portion of the roof.

7. Refer to the cautions, notices, and warnings in the
Combustion Air Section of this manual.

29

E. Water Piping

1. Refer to Figures 20 through 25 for typical water pip
ing installation details for modular boilers.

2. Installing a low water cutoff in the system is highly
recomended and may be required by code.

3. Refer to Table 2 for pressure drop and ow require­ments for each boiler.

4. Refer to the instructions, cautions, notices, and
warnings in Section IV.

F. Gas Piping

1. Refer to National Fuel Gas Code, Local Codes and
Tables 5 and 6 for gas pipe sizing.

2. Each boiler must be piped as shown in Figure 14.

3. Refer to the instructions, catuions, notices, and

warnings in Section V.

G. Electrical

WARNING

If gas pressure in the building is above 1/2
psig, an additional gas pressure regulator is

required. Using one additional regulator for

multiple boilers may result in unsafe boiler
operation. The additional regulator must be
able to properly regulate gas pressure at
the input of the smallest boiler. If the regula­tor cannot do this, two or more additional

regulators are required. Consult regulator

manufacturer and/or local gas supplier for

instructions and equipment ratings.

-

1. Each boiler must be provided with a fused discon
nect and service switch.

2. Install wiring in accordance with requirements of
authority having jurisdiction. In the absence of such
requirements, follow the National Electric Code,
NFPA 70 and/or CSA C22.1 Electric Code.

3. Refer to Figure 2 for electrical data for each boiler
size.

4. Refer to the instructions, cautions, notices, and
warnings found in Section VI.

30

-

Figure 17: Modular Boiler Conventional Venting

Figure 18: Modular Boiler Horizontal Air Intake Piping

31

LISTED IN TABLE 1.

Figure 19: Modular Boiler Vertical Air Intake Piping

32

Figure 20: Modular System: Typical One Pipe Water Piping

33

34

Figure 21: Modular System: Typical Primary/Secondary Water Piping

Figure 22: Modular System: Typical Primary/Secondary without System Pump

35

36

Figure 23: Modular System: Typical Reverse - Return Water Piping

Figure 24: Modular System Reverse - Return with System Pump Only

37

38

Figure 25: Modular System: Typ Primary/Secondary with Reverse-Return

VIII. System Start-up

A. Safe operation and other performance criteria were met

with gas manifold and control assembly provided on

boiler when boiler underwent tests specied in Ameri­can National Standard for Gas-Fired Low-Pressure

Steam and Hot Water Boilers, ANSI Z21.13.

B. Verify that the venting, water piping, gas piping and

electrical system are installed properly. Refer to instal­lation instructions contained in this manual.

C. Conrm all electrical, water and gas supplies are turned

off at the source and that vent is clear of obstructions.

D. Conrm that all manual shut-off gas valves between the

boiler and gas source are closed.

WARNING

Completely read, understand and follow all
instructions in this manual before attempt­ing start up.

E. FILL 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.

WARNING

3. Attach a hose to the vertical hose bib located prior to
the full port ball valve in the system supply piping.

(Note - Terminate hose in ve gallon bucket at a
suitable oor drain or outdoor area).

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

5. Open hose bib.

6. 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).

7. Allow water to overow from bucket until discharge

from hose is bubble free for 30 seconds.

8. 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.

9. 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).

10. Open isolation valve in boiler supply piping.

The maximum operating pressure of this
boiler is 150 psig. Never exceed this pres­sure. Do not plug or change pressure relief
valve.

NOTICE

If it is required to perform a long term pres­sure test of the hydronic system, the boiler

should rst be isolated to avoid a pressure

loss due to the escape of air trapped in the
boiler.
To perform a long term pressure test includ-

ing the boiler, ALL trapped air must rst be

removed from the boiler.
A loss of pressure during such a test, with
no viable water leakage, is an indication
that the boiler contained trapped air.

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).

11. Remove hose from hose bib.

F. Conrm that the water ow switch is operating prop-

erly.

G. Turn on the electrical supply to the boiler and circula-

tion system at the fused disconnect.

H. Conrm that water ow switch is operating properly.

I. Prepare to check operation.

1. Obtain the gas heating value (in Btu per cubic feet)
from the gas supplier.

2. Connect a monometer to the pressure taping
upstream V1 on the main gas valve. Use the G 1/8

test nipple provided. Reference item 7 on gure 28.

3. Temporarily turn off all other gas-red appliances.

4. Turn on gas supply to the boiler gas piping.

5. Purge the gas line of air.

6. Reset the low gas pressure switch.

7. Conrm that the supply pressure to the gas valve is

14 in. w.c. or less. Refer to Table 3 for the minimum
supply pressure.

39

DANGER

Do not use matches, candles, open ames

or other ignition source to check for leaks.

8. Open the eld installed manual gas shut-off valve

located upstream of the gas valve on the boiler.

9. Check that boiler gas piping, valves, and all other
components are leak free using a soap solution or
a similar non-combustible solution, electronic leak
detector or other approved method. Eliminate any
leaks.

J. Follow the operating instructions to place the boiler

into operation. Reference Figure 27.

K. Sequence of operation. See Figure 29. If boiler fails to

operate properly, see Trouble shooting Guide in Section
IX.

L. Select Desired Operating Mode. Refer to the Sage

Boiler Control ™ (SBC ™) instructional manual sup­plied with the boiler.

M. Set operating limits. Refer to the (SBC ™) instructional

manual supplied with the boiler.

Figure 26: Pilot Burner/Main Burner Flame

N. Check Ignition control module shut-off.

1. Rotate the manual gas shut-off valves clockwise
from “ON” to “OFF” position.

2. Turn on the boiler-operating switch located on the
left side of the unit.

3. Allow boiler to complete prepurge and pilot trial for

ignition (PTIF) sequence. Conrm that the ame
control locks out on pilot ame failure.

4. Rotate the manual shut off valve for the pilot to al-

low gas ow to the pilot valve.

5. Allow the boiler to complete the pre-purge, PTIF,

and main trial for ignition (MTFI). Conrm that the
ame control locks out on main ame failure.

6. Rotate the manual shut off valves for the main gas

valve to allow gas ow to the main gas valve. Con­rm that the ame control locks out on main ame

failure.

7. Disconnect the pilot lead wires from the pilot gas
valve. If the burners do not shutdown, determine the
cause of the malfunction. Replace necessary items
and check operation.

40

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING:

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.

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

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

OPERATING INSTRUCTIONS

1.

STOP! Read the safety information above on this label.

2.

Set the thermostat to lowest setting.

3.

Turn off all electric power to the appliance.

4.

This appliance is equipped with an ignition device, which
automatically lights the pilot. Do not try to light the pilot
by hand.

Inlet Gas

5.

Remove front door.

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

C.

Use only your hand to push in or turn the gas control knob.
Never use tools. If the knob will not push in or turn by hand,

don’ttrytorepairit,callaqualiedservicetechnician.
Forceorattemptedrepairmayresultinareorexplosion.

D.

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.

7.

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

8.

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.

9.

Rotate gas shutoff valves counterclockwise from
“OFF” to “ON”. Make sure handle rest against stop. Do not
force.

6.

Locate the gas pilot & main
shutoff valves at the end
of the gas supply pipe
inside the boiler.

Gas Shut Off Valves

TO TURN OFF GAS TO APPLIANCE

1.

Set the thermostat to lowest setting.

2.

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

3.

Remove front door.

Figure 27: Operating Instructions

10.

Replace front door.

11.

Turn on all electric power to the appliance.

12.

Set thermostat to desired setting.

13.

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

4.

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

5.

Replace front door.

814SOL0001

41

1 Electrical connection for valves (DIN EN 175 301-803) 10 Setting screw Ratio V

2 Input ange 11 Vent nozzle G 1/8

3 Pressure connection G 1/8 upstream of lter 12 G 1/8 pressure connection Burner pressure p

4 Filter 13 Output ange

Test point connection G 1/8 upstream of V1, possible

5 Type plate 14

both sides

6 Cover 15 G 1/8 pressure connection blower pressure p

Test point connection G 1/8 upstream of V1, possible

7

on both sides 16 G 1/8 pressure connection for pF furnace pressure

Test point connection G 1/8 downstream of V2

8

possible on both sides 17 Optional: Pulse line pBr

9 Setting screw Zero point adjustment N * G 1/8: 1/8” Iso Parallel Threads

Figure 28: Main Gas Valve

Br

L

42

Figure 29: Sequence of Operation

43

O.Checkthepilotandmainburnerames.Allow the

boiler to complete pre-purge, PTIF, and MTFI. Look
through the boiler sight glass and check the pilot and

main burner ames. Reference Figure 26 for ame ap­pearance. The ames should have a clearly dened in-

ner cone with no yellow tipping. Orange-yellow streaks
should not be confused with true yellow tipping. If the

ames do not meet the criteria in gure 26, adjust the

gas valve settings as described in step R.

WARNING

c. Use the N setting (Item 9 on Figure 28) on the

main gas valve to adjust the gas manifold pres-

sure at low re. Turn the screw setting clockwise

to increase counterclockwise to decrease the
manifold pressure.

3. Clock the gas meter for at least 30 seconds. Use

table 7 to determine the gas ow rate in cubic feet

per hour.

4. Determine the input rate. Multiply the gas ow rate

by the gas heating value.

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.

P. Check low water cut-off (if so equipped).

1. Adjust setpoint to highest setting.

2. With boiler operating, open the drain
valve and slowly drain the boiler.

3. Main burners and pilot burner will extinguish and
blower will stop when the water level drops below
the low water cutoff probe. Verify limit, thermostat
or other controls have not shut off the boiler.

4. Adjust the setpoint to the desired value and rell

the boiler.

Q. Verify that all safety and operating limits are operat-

ing properly. These controls and limits include differ-

ential air switch, water temperature operating control,
manual reset water temperature safety limit, and the
high and low gas pressure switches (if provided). Refer
to the individual manuals, provided with the boiler, for
these components to obtain proper start-up and operat­ing instructions. Follow all instructions contained in
these manuals. Refer to section IX to view a description
of the safety and operating controls.

R. Adjust the gas input rate to the boiler.

1. Administer a call for heat and allow the boiler to
operate.

2. Check the manifold pressure at high re and low
re. See table 3 or the rating label located in the

boiler’s vestibule compartment.

a. Connect manometer to pressure tapping

downstream V1 on main gas valve. See item 8 on
Figure 28.

b. Use the V setting (Item 10 on Figure 28) on

the main gas valve to adjust the gas manifold

pressure at high re. Turn the screw setting

clockwise to increase and counterclockwise to
decrease the manifold pressure.

WARNING

Failure to properly adjust gas input will

result in over ring or under ring of the

appliance. Improper and unsafe operation
may result.

5. Compare the measured input rate to the input rate
stated on the rating plate.

a. The boiler must not be over red. Reduce the

input rate by decreasing the manifold pressure as
described in step R. Do not reduce more than 0.3

inch w.c. If the boiler is still over red, contact

your Thermal Solutions representative.

b. If the measured value is less than 98% of the

rating plate input, increase the input rate by
increasing the manifold gas pressure described
in step R. Do not increase the manifold pressure
more than 0.3 inch w.c. Contact your Thermal
Solutions representative if the measured rate is
still less than 98% of the rated input.

WARNING

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. Measure the percent oxygen (%O2), the carbon

monoxide concentrations in the ue gas (CO ppm),
and the ue gas temperature. Compare the results

44

with the values given on the factory re test report

supplied with the boiler.

7. Return gas red appliances to previous conditions of

use.

S. Review user’s information manual and system Op-

eration with owner or operator.

Table 7: Gas Flow Rate in Cubic Feet Per Hour

Size of Gas Meter Dial

Seconds

for One

30 60 120 240

32 56 113 225

34 53 106 212

36 50 100 200

38 47 95 189

40 45 90 180

42 43 86 172

44 41 82 164

46 39 78 157

48 37 75 150

50 36 72 144

52 35 69 138

54 33 67 133

56 32 64 129

58 31 62 124

60 30 60 120

One-Half

Cu. Ft.

One

Cu. Ft. Two Cu. Ft.

45

IX. Service and Maintenance

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.

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 assure that the

wires are reconnected properly.
Never jump out or bypass any safety or operating control or component of this boiler.
Read, understand and follow all the instructions and warnings contained in ALL of the compo-

nent instruction manuals.
Assure that all safety and operating controls and components are operating properly before plac-

ing the boiler back in service.

CAUTION

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

Verify proper operation after servicing.

ATTENTION

Au moment de l’entretien des commandes, étiqueteztous les ls avant de les débrancher. Des
erreurs de câblage peuvent entraîner un fonetionnement inadéquat et dangereux.

S’assurer que l’appariel fonctionne adéquatement une fois l’entretien terminé.

A. Periodic Maintenance. Inspection and service should

be conducted periodically. Turn off electrical power and
gas supply while conducting service or maintenance.
Follow instructions TO TURN OFF GAS TO APPLI­ANCE. See Figure 27.

1. General

a. Keep the area around the boiler free from com-

bustible materials, gasoline and other ammable

vapors and liquids.

b. Keep the area around the combustion air inlet

terminal free from contaminates.

c. Keep the boiler room ventilation openings open

and unobstructed.

2. Low water cutoff (if so equipped).

a. Probe Type (Annual Service). Probe type

LWCO should be removed once a year, exam­ined and cleaned of any dirt accumulations to as­sure proper operations. Do not attempt to repair

mechanisms in the eld. Complete replacement

mechanisms, including necessary gaskets and
installation instructions, are available from the
manufacturer.

3. Vent/Air Intake System. Inspect for obstructions,

soot accumulation, proper support, deterioration of

46

pipe, ttings, and joints.

a. Clean terminal screens. Terminals must be free

of obstruction, undamaged, with screens securely
in place.

b. Inspect and clean the air lter as needed. The

lter can be cleaned using water. See Figure 39,

Item 11, for location.

c. Terminal Wall thimbles (if used) must be weath-

ertight.

d. Pipe must be full round shape, and show no dam-

age from impact or excessive temperature.

e. Ensure that there is nothing obstructing the ow

of combustion air and/or ue gas.

f. Inspect and clean piping with soft bristle brush

and vacuum to remove any lint, soot, or other
dirt.

g. Replace immediately if any signs of deterioration

or corrosion are present.

h. Pipe must be supported at minimum ve (5) foot

intervals and must not sag.

i. All vent joints must be secure and watertight.

j. All air intake joints must be secure and airtight.

k. Horizontal vent tee drain or vertical vent tee

drain (if used) must have minimum 6 inch trap

and allow condensate to ow freely. To Clean:

i. Disconnect drain tube from drain tting.

ii. Flush drain tube with water. Fill trap with

water.

iii. Securely fasten drain tube to drain tting,

providing gas-tight and watertight seal.

1/2 inch of sensing probe. If ame is yellow and

lazy, follow instructions TO TURN OFF GAS
TO APPLIANCE (see Figure 27), and contact

qualied agency.

e. Check main burner ames. See Figure 26. Flame

should have clearly dened inner cone with no

yellow tipping. Orange-yellow streaks caused
by dust should not be confused with true yellow

tipping. If yellow ames are observed, follow

instructions TO TURN OFF GAS TO APPLI-

ANCE (see Figure 27), and contact qualied

service agency.

6. Combustion Chamber/Burners . Inspect for

blockage or soot accumulation (annually).

a. Remove Main Burners. See Figure 30.

1. Remove front door.

2. Remove air box cover.

3. Disconnect ignition wire, sensor wire,
ground wire and gas valve wiring.

4. Disconnect manifold unions at pilot valve
and main gas inlet on right side of air box.

5. Remove attachment screws holding air box
to front of combustion chamber.

6. Remove burner/fuel train assembly from
combustion chamber.

7. Inspect and clean burners with soft bristle
brush and vacuum to remove any dirt and
lint.

l. If pipe must be disassembled for removal of

obstructions or resealing of joint, see Section III,
Paragraph B.

4. Inspect Condensate Drain Trap and
Drain Line (Monthly)

a. Inspect condensate trap water level. If low, add

water to bring level to trap discharge.

b. Ensure condensate can ow freely to drain.

5. Inspect Pilot and Main Burner Flames

(Monthly).

a. Remove jacket front panel.

b. View ames through Flame Observation Port.

c. Adjust thermostat to highest setting.

d. Check pilot ame. See Figure 26. The pilot pro-

duces three (3) ames. The center ame should

be steady, medium hard blue enveloping 3/8 to

8. If burners show signs of deterioration or cor­rosion, replace immediately.

9. Check gas orices for dirt and lint. Clean as

necessary.

10. Inspect heat exchanger and combustion
chamber. Clean heat exchanger with
straight handle wire brush and vacuum heat
exchanger and combustion chamber.

1. Exercise care during vacuuming to
avoid damaging base insulation.

11. Inspect combustion chamber/burner assem­bly gaskets and replace if required.

12. Install burner/fuel train assembly and secure
with original fasteners.

13. Connect manifold unions, ignition wire, sen-

47

sor wire, ground wire and gas valve wiring.

WIRE BRUSH

SOFT BRISTLE BRUSH

14. Install air box cover and attachment hard­ware.

15. Install front door.

6. Check Operation . Follow steps from Section VIII
for system start-up.

Figure 30: Cleaning Boiler Flue Passages

48

B. 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
Sage Boiler Control™
(SBC)™

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 operat-

ing. 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 on Modulat-

ing boilers responds to a 0-10 VDC or 4-20 ma signal from the Digital Temperature Control­ler.

The Thermal Solutions Sage Boiler Control™ (SBC™) 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 SBC manual shipped with
the boiler to learn more about these features and functions.

49

C. Trouble Shooting Guide

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

messages are not show 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 provided) is preventing a boiler start.

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

Flame Safeguard Fault

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

Boiler Outlet Temperature Sensor Fail

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

Boiler Inlet Temperature Sensor Fail

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

Outside Air Temperature Sensor Fail

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

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

Remote System Temperature Sensor Fail

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

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

50

Trouble Shooting Guide (continued)

LCD Display
Alarm Message

Remote Input Fail

Comm Failure

Recommended
Action

Check Wiring and

Remote System

Check Wiring and

Remote System

Conrm each boiler has

a unique address

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 wiring and

sensor

Check return water

temperature. Consider

system or operational

changes to avoid low

temperature events

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. See following page for additional information on low boiler inlet
temperature history storage and retrieval.

Memory Failure

New software has been installed in the SBC™ or a power interruption has caused
a memory failure. The Call For Heat will be prevented until the condition is
cleared.

51

X. Sage Boiler ControlTM (SBCTM)

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

1. Sage Boiler Control Overview
The Sage Boiler Control (SBC) is a complete boiler
monitoring and automation system. The SBC pro­vides advanced boiler modulation, operating control,
diagnostics, multiple boiler lead-lag and auxiliary
device control. The SBC provides advanced control
features in an easy to use package.

Flexible, Field Selectable Control.

2.
Control modules, water system, boiler auxiliary and
modulating lead/lag control features are menu se­lectable without the need for external programmers,
laptops or downloads. 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 SBC’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.

Modulation Rate and On/Off Modes

4.
The SBC 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 SBC
allows the boiler modulation and on/off output to
respond to remove 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 deter­mining 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 rails, the SBC
automatically changes to a control mode that will
allow continued automatic operation of the boiler.
For example, in the event of a remote system tem-

52

perature sensor failure, the SBC will automatically
switch to boiler outlet temperature sensor based
control.

6. Outdoor Air Reset
When selected the modulation rate setpint 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 system it may be desirable to automate
mixing valves, boiler pumps, system pumps, and
standby system pumps. The SBC 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 SBC includes state-of-the-art modulating lead­lag 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 SBC provides precise boiler coordination by
sequencing boilers based on both remote system
water temperature and boiler 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.

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. FRONT PANEL DISPLAY

POWER LED (Steady On Green LED) indicates power is available down
stream of the Electronic Control Module’s on board fuse.
(Flashing On Green LED) indicates manual mode operation for
boiler modulation, Call For Heat, and/or mixing valve modula
tion.
ALARM LED (Steady On Red LED) indicates an alarm is active. (Flashing
On Red LED) indicates a lockout alarm is active and a manual

reset may be required.

SCREEN 2 line by 16 character display provides operational, alarm,

sequence status, conguration and diagnostic user interface

ENTER The ENTER key has no function in display mode. The ENTER
key is used to select menus, menu items and save edited pa
rameters as follows:
Select Mode (steady text): Press ENTER to change into Edit
Mode or select a menu or menu item
Edit Mode (blinking text): Press ENTER to save the current
value. Press MENU to cancel the current editing operation.

UP, DOWN Select Mode (steady text): Press UP, DOWN to change the
selected display and move up and down menu items.
Edit Mode (blinking text): Press UP, DOWN to increase or de
crease the value of the number being edited, or scrolls through
a list of choices.

MENU Press and hold MENU to change to the Main Menu screen.
When in a sub menu screen, press MENU to move to the next
higher menu. When in Edit Mode (blinking text) Press MENU to
cancel the current editing operation.

53

C. SETUP MENU

Display

WWSD Off

LL Start

Trigger

LL Stop

Trigger

Boiler On

Delay

Boiler Off

Delay

High Fire

Limit

Rotation Disable

Rotation

After

Outdoor

Sensor

Outdoor

Set Up

Boiler Set

Up

Outdoor

Design

Boiler

Design

Local

PID P

Factory

Settings

90 50 to 100

25 0 to 50

120 0 to 900

30 0 to 900

100 40 to 100

168 8 to 720

No

55°F 40°F to 100°F

140°F 80°F to 180°F

30°F -20°F to 50°F

180°F 80°F to 220°F

20 0 to 10000

Range/Choices

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

Both

Disable
Enable

No Outside Air Input (O+O-) is ignored.

Display Only Do Not Calculate setpoint based on outdoor temperature, Display Outside Air Temperature

Outdoor Reset

Description

WWSD

Species Warm Weather Shut-Down (WWSD) control of boiler and/or system pump:

When OAT is higher than the WWSD setpoint de-energize System Pump output (SO)

When OAT is higher than the WWSD setpoint, inhibit Call for Heat and de-energized system pump
output (SO)

LL Start Trigger

Species the percent of maximum modulation rate the running boiler(s) must reach before calling

upon additional boilers for help.

LL Stop Trigger

Species the percent of modulation rate that the running boiler(s) must be below before shutting

down a lag boiler.

Boiler On Delay
Time Delay after the On Point setpoint before starting the next boiler. Short time delay to prevent
nuisance starts due to momentary temperature and modulation rate swings.

Boiler Off Delay
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.

High Fire Limit
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%.

Rotation

Species number of hours (cumulative) a lead boiler runs before passing the lead to another boiler.

Lead rote will be surrendered earlier if the lead boiler is placed into manual mode, is running remotely

(mode 6), fails to start, is “blind” (all input sensors failed), or is satisfying a DHWP request.

Rotate After

Species number of hours (cumulative) a lead boiler runs before passing the lead to another boiler.

Outdoor Sensor
Enables the Outside Air Temperature sensor and display and control logic:

Calculate the temperature setpoint based on outdoor temperature using a reset curve dened by

Outdoor Set Up, Boiler Set Up, Outdoor Design and boiler Design parameters.

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

Boiler Set Up
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.

Outdoor Design
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

Boiler Design

The Boiler Design setting is the water temperature required to satisfy the building heat loss during

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

Local PID P
Promotional 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.

54

C. Setup Menu (Continued)

Display

Local
PID I

Local

PID D

Remote

PID P

Remote

PID I

Remote

PID D

Mixing

Valve P

Mixing
Valve I

Mixing

Valve D

Max ΔT P 10 0 to 10000

Max ΔT I 60 0 to 10000

Max ΔT D 0 0 to 10000

Factory

Settings

30 0 to 10000

20 0 to 10000

30 0 to 10000

10 0 to 10000

60 0 to 10000

Range/Choices Description

0 0 to 10000

0 0 to 10000

0 0 to 10000

Local PID I
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).

Local PID D
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.

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

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

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

Mixing Valve P
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.

Mixing Valve I
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 minuets).

Mixing Valve D
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.

Max ΔT P

Promotional 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.

Max ΔT I

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.

Max ΔT D

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.

55

D. Boiler Conguration Menu

Display

Display

Units

Boiler

Pump

Pump

Prepurge

Postpurge

ΔT

Inlet Sen-

sor

Mixing

Valve

Set Time/

Date

Spare

Input

Spare

Output

Factory

Setting

°F

None

15 0 to 600

Yes

No

____

Off

Off

Range/Choices Description

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

5 0 to 20

hour : minute
Month / day /

Sys Pump FB

Low Fire

System Pump BUCloses when System Pump output is activated but the System Pump Feedback indicates the Primary

Soft Alarm Close when any alarm is active.

°F
°C

None No Boiler Pump.

No

Yes

No

Yes

year

Off Ignore

Off Never close output (SO).

CAD

Display Units
Selects how temperature parameter values are displayed.

Boiler Pump

Lead boiler’s pump runs continuously when the boiler is the lead boiler and revers to “Purge” opera­tion when it is a lag boiler.

Pump Prepurge
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.

Postpurge ΔT
Denes 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.

Inlet Sensor
Enables the inlet temperature display and control logic.

Mixing Valve
Enables the mixing valve control output and user display.

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

Spare Input
Set the function of the Spare Input Terminal (SL):

Input (SI) should be wired to a ow switch inserted in the ow of the 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.

When the Fuel Valve Energized input (SC) 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.

Spare Output
Sets the function of the Spare Output Terminal (SO):

Closes SO relay with a call for heat, Opens SO relay 2 minutes after call for heat has been deacti­vated.

System Pump is not operating.

56

E. System Conguration Menu

Display

DHWP Off

Remote

Control

Remote

1.0 volt =

Remote

9.0 volt =

Remote

Sensor

System

Pump

LWC or

CAD

Alarm

Message

Factory

Setting

140°F 60°F to 170°F

220°F 150°F to 220°F

16 Text

Charac-

Range/Choices Description

Off No DHWP.

Isolated

Demand

Shared Demand

No No

No Remote Sensor Input (R+,R-) is ignored.

No

No

No

ters

Display Only Remote Sensor Input (R+,R-) is used for display only.

Control

No

Yes

No

Yes

“Low Water

Level”

DHWP
Enables Domestic Hot Water Priority (DHWP) control feature. When input (DP) is energized DHWP
becomes active as selected:

Boiler that received the input (DP) drops off the Peer-To-Peer network and its 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 sensor were selected, control is switched to the
Boiler Outlet Sensor.

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.

Remote Control
Sets the remote (Energy Management System) control mode as follows:

Local setpoint and modulation rate is used. Modbus and remote input (C+,C-) are ignored.

Remote 1.0 Volt =
Sets the temperature corresponding to the input (C+,C-) 1 Volt. Voltage below 1V is considered
invalid, (failed or miswired sensor.)

Remote 9.0 Volt =
Sets the temperature corresponding to the input (C+,C-) 9 volts. Voltage above 9V is considered
invalid (failed or miswired sensor.)

Remote Sensor
Enables the Remote System Temperature sensor display and control logic:

Control Remote Sensor Input (R+,R-) is compared with the temperature setpoint to establish a modu­lation rate.

System Pump
Enables the System Pump Output (SO)

LWC or CAD

Species 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. Limit hold display message is
described by parameter 28.

Alarm Message
Limit Hold and alarm message displayed corresponding to sensor connected to input (LC).
The “ENTER” key and “up” and “Down” arrow keys are used to change the text message.

Only visible when parameter 27 equals Yes.

57

F. Setpoints Menu

Display

Opera-

tional SP

On Point -5°F 0°F to -99°F

Off Point 15°F 0°F to 99°F

High

Temp

Stop

DHWP

Setpoint

WWSD

Setpoint

Max SP 230°F 140°F to 230°F

Min SP 140°F 60°F to 230°F

Min In

H2O

Temp

Max H2O

Delta T

Max

Delta T

Hold

Factory

Setting

180°F 60°F to 230°F

200°F 60°F to 230°F

180°F 140°F to 230°F

70°F 40°F to 90°F

130°F 110°F to 180°F

40°F 20°F to 50°F

50°F 20°F to 50°F

Range/Choices Description

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

request.

On Point
The boiler starts when the water temperature drops “On Point” degrees below the setpoint.

Off Point
The boiler stops when the water temperature rises “Off Point” degrees above the setpoint.

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

DHWP Setpoint
The Domestic How 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.

WWSD Setpoint
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”

Max SP
The Maximum Operational Setpoint for all possible Local and Remote Modes.

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

Min In H2O Temp.
Minimum Inlet Water Temperature Setpoint used as the Mixing Valve inlet temperature setpoint.

Only visible when Mixing Valve equals Yes.

Max H2O Delta T
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.

Max Delta T Hold
Maximum Water differential (Boiler Outlet minus Boiler Inlet) Temperature used to hold modulation

rate at low re.

58

G. Communication Menu

Display

Protocol

Modbus
Address

Baud

Rate

Parity Odd

Timeout 30 1 - 120

Messag-

es Rcvd

Messag-

es Sent

Boiler

Address

Online
Status

Factory

Setting

Peer-To-

Peer

19.2

Range/Choices Description

Peer-To-Peer

1 1 - 247

1 1 to 8

Modbus

9.6

19.2

38.4

Odd

Even

None

XXXXXXXX

Protocol
Selects between Peer-To-Peer (Multiple boiler lead/lag control network) and a Modbus slave commu­nication.

Modbus Address

Each boiler must be given a unique address.
Only visible when Protocol equals Modbus.

Baud Rate
Units are 1000 Bits Per Second (KBPS).

Only visible when Protocol Equals Modbus.

Parity

Only visible when Protocol equals Modbus.

Timeout

Only visible when Protocol equals Modbus.

Messages Rcvd

Diagnostic tool used to conrm wiring and Modbus master conguration.
Only visible when Protocol equals Modbus.

Messages Sent

Diagnostic tool used to conrm wiring and Modbus master conguration.
Only visible when Protocol equals Modbus.

Boiler Address

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.

Online Status
Each space can be either the boiler address or a “-” depending on whether there is a boiler of that
address online.
Example: _ _ 6 _ _ _ 321 indicates that boilers 6, 3,2, and 1 are online.

Only visible when Protocol equals Peer-To-Peer

H. Manual Mode Menu

Display

101 Auto

102 Varies 0 to 100

103 Varies

104 Auto

105 Varies 0 to 100

Factory

Setting

Range/Choices Description

Man

Auto

On
Off

Man

Auto

Boiler Man/Auto
Man: Remain in Manual Mode

Auto: Return to Boiler Mode specied by parameter/boiler conditions.

Activated only when in Supervisor Mode.

Modulation Rate
Sets the modulation rate to be sued for boiler when in Manual Mode.
Activated only when in Supervisor Mode and Boiler Man/Auto = Man.

Boiler On/Off
Sets the boiler start/stop status when in Manual Mode.
No: Turn of 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.

Mixing Valve M/A
Man: Remain in Manual Mode

Auto: Return to Control Mode specied by parameter/boiler conditions

Activated only when in Supervisor Mode.

Mixing Valve
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.

59

I. Security Menu

Passwords
There are three Access Levels in the system: Basic, Supervisor, and Factory.

At the BASIC Access Level, the user can view many parameters, but is only allowed to edit a

•
small sub-set of the parameters that are visible.
At the SUPERVISOR Access Level, the user can view and edit most parameters that are vis-

•
ible. Not all parameters will be visible at the Supervisor Access Level.
At the FACTORY Access Level, all relevant internal parameters in the system will be visible

•
and programmable.

The Basic Access Level is the access level at power-up if the system password parameter is not

equal to zero. The Supervisor Access Level is the access level at power-up if the system pass­word parameter is equal to zero. If the system password is non-zero, the Supervisor Access Level

may be reached by entering the correct password in the Enter Password parameter.

The Factory Access Level can be reached by entering the factory password in the Enter Password
parameter and holding the Enter key for at least two seconds when accepting the value entered.
The display will jump to the Access Level parameter menu when the system has entered the Fac­tory Access Level. Note that the Access Level parameters value will indicate “Supervisor”.

To exit either of the privileged access levels (Factory or Supervisor), change the value of the Ac­cess Level parameter from “Supervisor” to “Basic”. Also, if no key is pressed for ~ 1 hour, the ac­cess level will automatically revert to Basic.

Factory

No.

Setting Range/Choices Parameter and Description

Access Level

Basic

Supervisor

Basic: Select Basic Level Access to parameters/variables
Supervisor: Select Password Level Access to parameters/
variables.

Enter Password

0 to 9999

Allows user to enter password to gain access to both Su­pervisor Access and Factory Access Levels.

Set Password

15 0 to 9999

Holds the user-dened password for the boiler. A password

= ) means no password protection. Access Level will de­fault to Supervisor Level at power-up.

60

XI. Repair Parts

2

3

10

7

7

9

1

6

5

4

8

All Solaris® Series Repair Parts may be obtained through your local Thermal Solutions

representative. Should you require assistance in locating a Thermal Solutions representative in
your area, or have questions regarding the availability of Thermal Solutions products or repair parts,

please contact Thermal Solutions Customer Service at [phone] or Fax [phone].

Figure 31: Combustion Chamber

Key
No. Description Part Number

1. Combustion Chamber SOL-300 SOL-500 SOL-750 SOL-1000 SOL-1250 SOL-1500

1 Base/Bottom Panel 618SOL0204 618SOL0504 618SOL0704 618SOL1004 618SOL1204 618SOL1504

2 Left Side Panel Assembly 618SOL0021 618SOL00211

3 Right Side Panel Assembly 618SOL0031 618SOL00311

4 Air Box Cover 718SOL0203 718SOL0503 718SOL0703 718SOL1003 718SOL1203 718SOL1503

5 Air Box Assembly 618SOL02051 618SOL05051 618SOL07051 618SOL10051 618SOL12051 618SOL15051

6 Canopy Assembly 618SOL0210 618SOL0510 618SOL0710 618SOL1010 618SOL1210 618SOL1510

7 Side Insulation 820SOL0020 820SOL0021

8 Front Insulation 820SOL0203 820SOL0503 820SOL0703 820SOL1003 820SOL1203 820SOL1503

9 Bottom Insulation 820SOL0200 820SOL0500 820SOL0700 820SOL1000 820SOL1200 820SOL1500

10 Back Insulation 820SOL0202 820SOL0502 102504-01 102504-02 102504-03 102504-04

61

Figure 32: Burner Tray

2

1

3

4

Key

No. Description Part Number

1. Burner Tray

1 3 Burner Assembly 102017-01

2 Ignitor Assembly 812SOL0010

3 Gasket, Burner Mounting Plate 820SOL0004

4 Gasket, Ignitor Assembly 820SOL0005

62

6

3

5

4

2

1

3

7

Figure 33: Gas Train (SOL-300)

(Reference Table 8)

63

3

9

6

5

4

7

1

10

8

3

SIDE VIEW OF

GAS VALVE

2 2

11

Figure 34: Gas Trains (SOL-500 through SOL-1500)

64

(Reference Table 8)

Gas Trains: Reference Figures 33 & 34

SOL-300 SOL-500 SOL-750 SOL-1000 SOL-1250 SOL-1500

Main Gas Valve Flange(s) 3/4” NPT (1) 102281-01 — — — — —

Main Gas Valve Body (1)816SOL0006 (1)816SOL0510 (1) 816SOL0005

Key Description (Quantity) Part Number

1

Main Gas Valve Flange(s) 1” NPT — (2) 816SOL0503 (2) 102281-02 — —

Main Gas Valve Flange(s) 1-1/4” NPT — — — — (2) 102281-03 —

Main Gas Valve Flange(s) 1-1/2” NPT — — — — — (2) 102281-04

2

Manual Gas Valve 1” NPT (2) 816SOL0015 — —

Manual Gas Valve 1-1/4” NPT — — — — (2) 816SOL0016 —

Manual Gas Valve 1-1/2” NPT — — — — — (2) 816SOL0017

3

4 Pilot Gas Valve (1) 816SOL0501

5 Pilot Gas Valve Flange 1/2” NPT (1) 816SOL0502

6 Manual Gas Valve 1/2” NPT (1) 816SOL0010

7 Insulation Grommet (1) 820SOL0001

8 High Gas Pressure Switch (Optional) — (1) 816SOL0005

9 Low Gas Pressure Switch (Optional) — (1) 816SOL0006

10 G18 Test Nipple — (2) 816SOL0001

Table 8: Gas Train Components

11 Hose Barb — (2) 816SOL0002

65

1

2

Manifold Orice Assembly

Key

No. Description

1 Manifold Orice Assembly 812SOL0200 812SOL0500 812SOL0700 812SOL1000 812SOL1200 812SOL1500

2a Natural Gas Prejet 812SOL0034

2b Liquid Propane (LP) Gas Prejet 812SOL0001

Figure 35: Manifold Orice Assembly

66

Boiler Model

SOL-300 SOL-500 SOL-750 SOL-1000 SOL-1250 SOL-1500

3

5

2

3

4

1

6

Heat Exchanger Assembly (SOL-300 & 500)

Key No. Description Quantity

1 Heat Exchanger 1 603SOL0210 603SOL0510

2 Immersion Well 2 80160456

3 Inlet/Outlet Temp. Sensor 2 801SOL0010

4A Temp/Pressure Gauge 0-100PSI 1 8056248

4B Temp/Pressure Gauge 0-200PSI 1 8056249

4C Temp/Pressure Gauge 0-240PSI 1 8056250

5 Water Flow Switch 1 80160175

6 Tube Bafes 10 718SOL0219 718SOL0519

Part Number

SOL-300 SOL-500

Figure 36: Heat Exchanger Assembly (SOL-300 & 500)

67

Key No. Description

1 Heat Exchanger 102499-01 102499-02 102499-03 102499-04

2 Tube Bafe 718SOL0719 718SOL1019 718SOL1219 718SOL1519

3 Inlet/Outlet Temp Sensor 801SOL0010

4 Hose Banding 924660281

5 Hose Clamp 80860491

6 Fiberglass Tape Gasket 9206032

Figure 37: Heat Exchanger Assembly (SOL-750 through 1500)

68

Part Number

SOL-750 SOL-1000 SOL-1250 SOL-1500

7

9

6

5

3

4

1

2

8

Key No. Description Quantity Part Number

1. Electrical Panel

1 Q7800H1009 Electrical Side Panel 1 704SOL0006

Q7800H1009 Honeywell Relay Module Circuit

2

board 1 101182-01

3 Relay Module Honeywell RM7897A1002 1 801602121

4 Flame Rectication Amplier 1 80160207

5 Purge Card 1 8136362

6 Keyboard Display Module 1 80160640

7 Transformer, 120V Primary, 24V Secondary 1 801600502

8 Combustion Airow Switch 1 102382-03

Figure 38: Electrical Panel

69

SOL-300 SOL-500 SOL-750 SOL-1000 SOL-1250 SOL-1500

7

4

10

1

2

5

9

11

6

3

8

12

Part Number

Figure 39: Boiler Jacket Assembly

1 Base Panel Assembly 604SOL0211 604SOL0511 604SOL0711 604SOL1011 604SOL1211 604SOL1511

2 Jacket, Rear Panel Assembly 604SOL0203 604SOL0503 604SOL0703 604SOL1003 604SOL1203 604SOL1503

3 Exhaust CV Assembly 618SOL0000 618SOL0001 618SOL0701 618SOL1001 618SOL1201 618SOL1501

4 Jacket, Right Side Panel Assembly 604SOL0204 604SOL0504 604SOL0704 604SOL1004 604SOL1204 604SOL1504

5 Jacket, Left Side Panel Assembly 604SOL0205 604SOL0505 604SOL0705 604SOL1005 608SOL1205 604SOL1505

No. Description

Key

6 Jacket, Top Panel Assembly 604SOL0206 604SOL0506 604SOL0706 604SOL1006 604SOL1206 604SOL1506

7A Jacket. Front Panel (Left Side SOL-1250 & 1500) 704SOL0202 704SOL0502 604SOL0702 604SOL1002 704SOL0090 704SOL0091

8 Insulation Box 820SOL0032 820SOL0032 820SOL0033 820SOL0033 820SOL0033 820SOL0033

9 Intake Corner Vent Assembly 604SOL0208 604SOL0508 604SOL0708 604SOL0708 604SOL1208 604SOL1208

7B Jacket, Front Panel (Right Side SOL-1250 & 1500) — — — — 704SOL0092 704SOL0093

10 Exhaust Corner Vent 704SOL0207 704SOL0507 704SOL0707 704SOL0707 704SOL1207 704SOL1207

11 Air Inlet Filter 811SOL0020 811SOL0020 811SOL0022 811SOL0022 811SOL0022 811SOL0022

70

SERVICE RECORD

Date Service Performed

71

SERVICE RECORD

Date Service Performed

72

SERVICE RECORD

Date Service Performed

73

Important Product Safety Information

Refractory Ceramic Fiber Product

Warning:

This product contains refractory ceramic bers (RCF). RCF has been classied as a pos­sible human carcinogen. After this product is red, RCF may, when exposed to extreme-

ly high temperature (>1800F), change into a known human carcinogen. When disturbed
as a result of servicing or repair, RCF becomes airborne and, if inhaled, may be hazard­ous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace previously red RCF (combustion chamber insulation, tar­get walls, canopy gasket, ue cover gasket, etc.) or attempt any service or repair work

involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH) approved
respirator

2. Long sleeved, loose tting clothing

3. Gloves

4. Eye Protection

• Take steps to assure adequate ventilation.

• Wash all exposed body areas gently with soap and water after contact.

• Wash work clothes separately from other laundry and rinse washing machine

after use to avoid contaminating other clothes.

• Discard used RCF components by sealing in an air tight plastic bag.

First Aid Procedures:

• If contact with eyes: Flush with water for at least 15 minutes. Seek immedi­ate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water. Seek
immediate medical attention if irritation persists.

• If breathing difculty develops: Leave the area and move to a location with
clean fresh air. Seek immediate medical attention if breathing difculties

persist.

74

Thermal Solutions

(seller)

LIMITED WARRANTY

LIMITED WARRANTY

Subject to the terms and conditions herein and except as pro­vided below with respect to products or parts not manufactured
by 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
3 years from date of shipment (the “Warranty Period”). The
burner is also covered under the limited warranty for 1 year
from date of shipment (the “Warranty” Period). SPECIAL
NOTE: The warranty of any boiler found to be operating as a
“Water Heater” shall revert back to Thermal Solution’s stan­dard water heater warranty.

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, corro

sion, 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 applica

tion.

-

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.

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