Thermal Solutions EVA Series Installation, Operating And Service Instructions
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Thermal Solutions EVA Series Installation, Operating And Service Instructions

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INSTALLATION, OPERATING AND
INDOOR/OUTDOOR MODULATION
File Number MH25585
For Service and repairs to the heating plant, call your heating contractor. When seeking information on the boiler
from the manufacturer, provide boiler model and serial number as shown on rating label.
Boiler Model
Installation Date
EVA -
Heating Contractor
Address
Your Local Thermal Solutions Representative:
81456001
EVA/EVO boiler manual, 9/24 rev 13
SERVICE INSTRUCTIONS
EVA/EVO SERIES BOILER
Serial Number
Type System
Phone Number
1

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Summary of Contents for Thermal Solutions EVA Series

  • Page 1 Boiler Model Installation Date Serial Number Type System EVA - Heating Contractor Address Phone Number Your Local Thermal Solutions Representative: 81456001 EVA/EVO boiler manual, 9/24 rev 13...
  • Page 2 IMPORTANT INFORMATION - READ CAREFULLY NOTE: Post these instructions and maintain in legible condition. NOTE: The equipment shall be installed in accordance with those installation regulations required in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made.
  • Page 3 WARNING WARNING This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. Improper installation, adjustment, alteration, service or maintenance can cause property damage, per- sonal injury or loss of life. Read and understand the entire manual before attempting installation, start-up operation, or service.
  • Page 4 AVERTISSEMENT AVERTISSEMENT Cette chaudière exige un entretien et une maintenance régulière pour un fonctionnement sûr. Suivre les instruc- tions contenues dans ce manuel. Une installation, un réglage, une dégradation, un entretien ou une maintenance incorrecte peuvent causer des dommages matériels, des blessures corporelles ou une perte de vie. Lire et comprendre la totalité du manuel avant d’essayer d’installer, de démarrer la mise en exploitation ou de réaliser des entretiens.

  • Page 5: Table Of Contents

    Table of Contents I. Pre-Installation ..............10 II. Unpack the Boiler ............12 III. Installation ..............13 IV. System Start-up .............42 VI. Boiler Operational Sequence ........47 VII. Service/Maintenance ...........48 VIII. Repair Parts ..............55 IX. Temperature Controller Operation for Modulating Boilers ................73 Clearances to Combustible Materials (in.) Left Side Right Side Front...
  • Page 6 Notes: 1. Piping removed for visual clarity (rear view). EVA-500 2. See notes concerning Net AHRI Ratings on page 4. CAPACITIES BOILER MODEL INPUT GROSS NET AHRI WATER DRY WEIGHT WET WEIGHT NUMBER (MBH) OUTPUT RATING VOLUME (lbs.) (lbs.) (MBH) (MBH) (gallons) EVA-500...
  • Page 7 Notes: 1. Piping removed for visual clarity (rear view). EVA-1000 2. See notes concerning Net AHRI Ratings on page 4. CAPACITIES BOILER MODEL INPUT GROSS NET AHRI WATER DRY WEIGHT WET WEIGHT NUMBER (MBH) OUTPUT RATING VOLUME (lbs.) (lbs.) (MBH) (MBH) (gallons) EVA-1000...
  • Page 8 Notes: 1. Piping removed for visual clarity (rear view). EVA-2000 2. See notes concerning Net AHRI Ratings on page 4. CAPACITIES BOILER MODEL INPUT GROSS NET AHRI WATER DRY WEIGHT WET WEIGHT NUMBER (MBH) OUTPUT RATING VOLUME (lbs.) (lbs.) (MBH) (MBH) (gallons) EVA-2000...
  • Page 9 Notes: 1. Piping removed for visual clarity EVA-2500 (rear view). 2. See notes concerning Net AHRI Ratings on page 4. CAPACITIES BOILER MODEL GROSS NET AHRI WATER DRY WEIGHT NUMBER INPUT OUTPUT RATING VOLUME (lbs.) WEIGHT (MBH) (MBH) (MBH) (gallons) (lbs.) EVA-2500 2,500...

  • Page 10: Pre-Installation

    I. Pre-Installation WARNING / AVERTISSEMENT WARNING / AVERTISSEMENT WARNING / AVERTISSEMENT WARNING / AVERTISSEMENT Carefully read all instructions before installing Adequate combustion and ventilation air must be boiler. Failure to follow all instructions in proper provided to assure proper combustion. order can cause personal injury or death.
  • Page 11 Louvers and grilles must be fixed in la défaillance des composants. Thermal Solutions open position or interlocked with equipment to open NE garantit PAS les défaillances dues à des applica- automatically before burner operation.

  • Page 12: Unpack The Boiler

    II. Unpack the Boiler NOTICE / AVIS NOTICE / AVIS WARNING / AVERTISSEMENT WARNING / AVERTISSEMENT Boiler crate is equipped with a tip and tell label. If Installation of this boiler should be undertaken label indicates boiler has been tipped over during only by trained and skilled personnel from a quali- shipping, remove crate and inspect before trucker fied service agency.

  • Page 13: Installation

    III. Installation condensate drain loop(s) to prevent condensate from A. VENTING running back into the boiler. WARNING WARNING It is permissible to run vent pipe through a vertical or horizontal chase provided minimum clearances to Improper venting may result in property damage combustible materials are maintained.
  • Page 14 Venting Warnings - French AVERTISSEMENT AVERTISSEMENT AVERTISSEMENT AVERTISSEMENT Ne pas positionner l’admission d’air là où des Une ventilation incorrecte peut conduire à des distillats de pétrole, CFC, détergents, vapeurs vola- dommages matériels et le relâchement de fumées tiles ou autres produits chimiques sont présents. de combustion qui contiennent du monoxyde de Une corrosion conséquente et une défaillance de carbone (CO) mortel dans le bâtiment, ce qui peut...
  • Page 15 adjoining floor or ceiling. Maintain minimum clearance to flue spillage interlock. combustible materials. The chimney/vertical vent and flue connector must be sized and configured to provide a minimum - 0.04 inch Locate vent terminal above combustion air intake w.c. pressure (draft) at the boiler flue outlet. terminal (if used) and no closer than one (1) foot g.
  • Page 16 Figure 2: Sidewall Positive Pressure Venting Figure 3: Sidewall Positive Pressure Venting (Optional) EVA/EVO boiler manual, 9/24 rev 13...
  • Page 17 Figure 4: Vertical Pressurized Venting EVA/EVO boiler manual, 9/24 rev 13...

  • Page 18: Manufacturer Requirements - Gas Equipment Venting System Provided

    a hard wired carbon monoxide detector with an alarm used in whole or in part for residential purposes. and battery back-up is installed on the floor level c. MANUFACTURER REQUIREMENTS - GAS where the gas equipment is to be installed. In addition, EQUIPMENT VENTING SYSTEM PROVIDED.
  • Page 19 Figure 5: Typical Negative Pressure (Conventional) Venting EVA/EVO boiler manual, 9/24 rev 13...
  • Page 20 Severe Do not reduce size of air intake pipe. boiler corrosion and failure will result. Thermal Solutions does not warrant failures Read, understand and follow combustion air caused by contaminated air. instruction restrictions contained in the Pre- Do not locate air intake termination where Installation instructions of this manual.
  • Page 21 Figure 7: Vertical Air Intake Piping EVA/EVO boiler manual, 9/24 rev 13...

  • Page 22: Water Treatment

    Table 1 for examples of typical chemical agents found in corrosion of iron and steel boiler components, untreated water along with their potential effects. and can lead to boiler failure. Thermal Solutions Standard Warranty does not cover problems Table 1: Chemical Agents and Effects caused by oxygen contamination of boiler water.

  • Page 23: Water Piping And Trim

    Maintain ½" minimum distance between water WATER PIPING AND TRIM piping and combustible material. CAUTION CAUTION d. Consult Thermal Solutions for unusual system requirements. Failure to properly pipe boiler may result in improper operation and damage to boiler or CAUTION CAUTION structure.
  • Page 24 TABLE 2 - EVA BOILER FLOW AND PRESSURE DROP 20°DT 40°DT Supply/Return (at high fire) (at high fire) BOILER Minimum Flow Maximum Flow Pipe MODEL Rate (gpm) Rate (gpm) Flow Flow (inch dia.) (Ft.) (GPM) (Ft.) (GPM) EVA-500 2.93 0.74 EVA-750 1.81 0.46...
  • Page 25 à une défaillance de la chaudière. La garantie damage. standard de Thermal Solutions ne couvre pas les Do not operate the boiler with flow rates in excess problèmes causés par la condensation des fumées of the maximum flow rates listed in Table 2.

  • Page 26: Gas Piping

    Specific gravity of gas correction factor, de tube pourraient survenir. La garantie standard to be applied to the value found in Table 4, de Thermal Solutions ne couvre pas les problèmes can be found in Table 5. causés par des taux excessifs de débit d’eau.
  • Page 27 4. Use thread joint compound resistant to the action of boiler from gas supply piping by closing boiler's liquefied petroleum gas. individual manual shutoff valve. b. Locate leaks using approved combustible WARNING WARNING gas detector, soap and water, or similar nonflammable solution.
  • Page 28 TABLE 4: MAXIMUM GAS CAPACITY OF SCHEDULE 40 PIPE. (Based on Gas Pressure less than 2 psi, pressure drop of 0.3 in w.c. and 0.6 specific gravity.) Pipe Size (in.) Pipe Length in 1-1/4 1-1/2 2-1/2 Equivalent Feet Capacity in Cubic Feet of Gas Per Hour 1060 1580 3050...
  • Page 29 TABLE 6 - EQUIVALENT OF STANDARD PIPE FITTING & VALVES Valves Fully Open (Screwed, Schedule 40, Screwed Fittings Flanged, Welded) Pipe I.D. 90° 45° 90° Tee, Flow Size Inches Swing Gate Globe Angle Elbow Elbow through Branch Check (threaded) (threaded) (threaded) 1/2"...
  • Page 30 DO NOT ATTACH ADDITIONAL J-Box to back or for reference purposes only. Each boiler may be top of boiler jacket. wired differently according to the specifications given to Thermal Solutions at the time the boiler was purchased. Always use the wiring diagram DANGER DANGER provided with the boiler.
  • Page 31 à titre de référence. chaudière. Chaque chaudière peut être câblée de façon dif- férente selon les spécifications données à Thermal Solutions au moment de l’achat DANGER DANGER de la chaudière. Utiliser toujours le diagramme de câblage fourni avec la chaudière. Si le diagramme S’assurer absolument que toutes les connex-...
  • Page 32 Figure 9b: Standard UL/FM/CSD-1 Wiring Diagram (Modulation) EVA 500-2000 EVA/EVO boiler manual, 9/24 rev 13...
  • Page 33 Figure 9c: Standard UL/FM/CSD-1 Wiring Diagram (Modulation) EVA 2000S-3000 EVA/EVO boiler manual, 9/24 rev 13...

  • Page 34: Modular Systems

    Figure 10: Modular System: Conventional Venting (Negative Pressure) ii. Positive pressure systems can be piped . MODULAR SYSTEMS individually through a common vertical 1. General Guidelines or horizontal chase provided minimum a. Read and follow all venting, combustion clearances to combustible materials are air, water piping, gas piping and electrical maintained.
  • Page 35 shown in Figure 10). iv. Locate boiler(s) with lowest input closest to 6. Gas Piping chimney/vertical common vent. a. Refer to National Fuel Gas Code, Local Codes Chimney lining must be acceptable for use and Tables 2 through 7 for gas pipe sizing. with condensing flue gases.
  • Page 36 EVA/EVO boiler manual, 9/24 rev 13...
  • Page 37 EVA/EVO boiler manual, 9/24 rev 13...
  • Page 38 EVA/EVO boiler manual, 9/24 rev 13...
  • Page 39 EVA/EVO boiler manual, 9/24 rev 13...
  • Page 40 EVA/EVO boiler manual, 9/24 rev 13...

  • Page 41: Condensate Drains

    (calcium carbonate) bed. The condensate will be slightly acidic and range between c. Refer to Figure 1 for electrical data for each size 3-5 on the pH scale. Consult Thermal Solutions or a boiler. chemical treatment company for buffering systems.

  • Page 42: System Start-Up

    Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, 1. fill entire heating system with water and vent air and can lead to boiler failure. Thermal Solutions from system. Use the following procedure on a Standard Warranty does not cover problems Series Loop or multi-zoned system installed to caused by oxygen contamination of boiler water.
  • Page 43 4. Confirm proper blower motor rotation. Consult Thermal Solutions if the desired system operating pressure is above the safety relief 5. Shut boiler off and position the flame control back valve pressure setting.
  • Page 44 DANGER DANGER I. Begin Commissioning the boiler Failure to properly adjust excess air will result 1. With main flame on, at high fire, measure gas in unsafe levels of carbon monoxide. Variations pressure upstream and downstream of the main gas in venting or combustion air pressure and valves.
  • Page 45 à l’intérieur de la chaudière. La DANGER DANGER garantie standard de Thermal Solutions ne couvre pas les problèmes causés par le dépôt de calcaire. Ne pas utiliser d’allumettes, bougies, flamme nue ou Toute tuyauterie soit neuve, soit existante doit être autre source d’allumage pour rechercher des fuites.
  • Page 46 EVA/EVO boiler manual, 9/24 rev 13...

  • Page 47: Boiler Operational Sequence

    VI. Boiler Operational Sequence NORMAL SEQUENCE OF OPERATION Limits and operating controls such as safety and operating temperature limits, Boiler in Standby water flow switch, thermal fuse switches and high/low gas pressure switch contacts must be closed to initiate and continue burner sequence. Flame signal must not be present.

  • Page 48: Service/Maintenance

    Do not allow the boiler to operate with altered, disconnected or jumpered components. Only use replacement components identical to those originally supplied by Thermal Solutions. EVA/EVO boiler manual, 9/24 rev 13...
  • Page 49 Ne pas autoriser le fonctionnement de la chaudière avec des composants dé- gradés, déconnectés ou court-circuités. Utiliser seulement des composants de rechange identiques à ceux fournis à l’origine par Thermal Solutions. EVA/EVO boiler manual, 9/24 rev 13...
  • Page 50 Safety and Operating Controls. Operation and Shut Down Component Function If the power draw of the control circuit exceeds approximately 5 amps, the circuit breaker Control Circuit Breaker trips and prevents the boiler from powering until circuit breaker is reset. If this switch is in the off position, power is interrupted to the control circuit of the boiler Power Switch which prevents the boiler from operating.
  • Page 51 Troubleshooting Guide Troubleshooting Guide EVA/EVO boiler manual, 9/24 rev 13...
  • Page 52 Troubleshooting Guide EVA/EVO boiler manual, 9/24 rev 13...
  • Page 53 C. PERIODIC MAINTENANCE RECOMMENDED CHECK LIST Frequency Component/Item Recommended Test Inspect the area to assure proper clearance to combustible materials, Boiler surroundings gasoline, and other flammable vapors and liquids. Gauges, monitors, and indicators Make visual inspection and record readings. Daily Combustion Properties Check combustion properties as specified in section VII, part D.
  • Page 54 4. Examine pilot electrode and set gap to 1/8” if C. Flush boiler and mechanically remove any scale. needed. Clean as required. 5. Reassemble in reverse order using a new gasket available from Thermal Solutions. Burner Flame: A. Perform a visual inspection of main burner flame. ATTENTION ATTENTION 1.

  • Page 55: Repair Parts

    VIII. Repair Parts EVA Series repair parts can be ordered through your nearest Thermal Solutions Representative for delivery from Lancaster, PA. The Representatives can also advise as to the availability of product and repair parts from local sources. Contact Thermal Solutions for your Representative at:...
  • Page 56 Figure 19: Combustion Chamber Assembly EVA/EVO boiler manual, 9/24 rev 13...
  • Page 57 EVA/EVO boiler manual, 9/24 rev 13...
  • Page 58 Figure 20: Burner Assembly EVA/EVO boiler manual, 9/24 rev 13...
  • Page 59 EVA/EVO boiler manual, 9/24 rev 13...
  • Page 60 Figure 21: UL/FM/CSD-1 Main Gas Train Assembly EVA/EVO boiler manual, 9/24 rev 13...
  • Page 61 EVA Modulating, UL/FM/CSD-1 (Quantity) Part Number Description EVA-1000 to EVA-2500 to EVA-500 EVA-750 EVA-2000S 2000 3000 Main Valve Body (1) 816634041 (1) 81663404 (1) 816634043 Manual Gas Valve (2) 806603055 (2) 806603053 (2) 806604691 Actuator (1) 81663408 Solenoid Gas Valve (1) 81660207 (1) 81660205 (1) 816602051...
  • Page 62 Figure 22c: DB&B Gas Train (500-750) Figure 22d: DB&B Gas Train (1000-2000) EVA/EVO boiler manual, 9/24 rev 13...
  • Page 63 DB&B – MAIN AND PILOT (Quantity) Part Number Description EVA-500 EVA-750 EVA-1000 EVA-1500 EVA-2000 3. MAIN AND PILOT GAS TRAIN Main Gas Valve Body 1" — — — 816634041 Main Gas Valve Body, — DBL, 1-1/2" NPT 81663404 Manual Gas Valve with —...
  • Page 64 Figure 22c: DB&B w/POC Gas Train (500-750) Figure 22d: DB&B w/POC Gas Train (1000-2000) EVA/EVO boiler manual, 9/24 rev 13...
  • Page 65 DB&B W/POC - MAIN AND PILOT (Quantity) Part Number Description 500-750 Main and Pilot Gas Train Main Gas Valve Body 1" NPT (2) 816634041 Manual Gas Valve with Pilot (2) 806603055 Tapping, 1" NPT Actuator/Regulator Ratio Valve, Siemens SKP75, (max (1) 81663409 5psi), DB&B w/POC Actuator, Siemens SKP15,...
  • Page 66 Figure 22e: DB&B Gas Train (2000S-3000) DB&B AND DB&B W/POC - MAIN AND PILOT (Quantity) Part Number Description EVA-2000S EVA-2500 EVA-3000 3. MAIN AND PILOT GAS TRAIN Main Gas Valve Body, DB&B, 2" NPT (1) 816634043 Main Gas Valve Body, DB&B w/POC, 2" NPT (1) 816634051 Manual Gas Valve with Pilot Tapping (2) 80660491...
  • Page 67 Figure 23: Jacket Panels EVA/EVO boiler manual, 9/24 rev 13...
  • Page 68 EVA/EVO boiler manual, 9/24 rev 13...
  • Page 69 JACKET (outdoor models) Description EVO-750 EVO-1000 EVO-1500 EVO-2000 Jacket Lower Front Panel (1) 60456311 (1) 60456312 (1) 60456313 (1) 60456314 (Modulation) Jacket Lower Rear Panel (1) 60456305 (1) 60456306 (1) 60456307 (1) 60456308 Jacket Upper Rear Panel (1) 70456251 Jacket Center Rear Panel (1) 70456250 Jacket Panel Left Side (1) 60456329...
  • Page 70 Figure 24a: Control Panel Assembly (Modulation) EVA/EVO boiler manual, 9/24 rev 13...
  • Page 71 CONTROLS (Modulation) (Quantity) Part Number Description EVA- EVA- EVA- EVA- EVA- EVA- EVA- EVA- 1000 1500 2000 2000S 2500 3000 5. Controls and Components RM7896D1027 Flame Safeguard Con- (1) 80160212 trol for UL/FM/CSD-1/DB&B RM7840L1075 Flame Safeguard Con- (1) 801602303 trol for DB&B w/POC & LFP Modbus Module for 5A (optional - not (1) 80160909 shown)
  • Page 72 Figure 25: "Bishop" Pilot Assembly EVA/EVO boiler manual, 9/24 rev 13...
  • Page 73 PILOT ASSEMBLY (Bishop Design) (Quantity) Part Number Description EVA- EVA- EVA- EVA- EVA- EVA- EVA- EVA- 1000 1500 2000 2000S 2500 3000 7. Pilot Assembly, Bishop Pilot Assembly Natural Gas, ULZ2 (1) 62356110 — Pilot Assembly Propane, LUX2 (1) 62356210 Ultraviolet Sensor (1) 8026145 Pilot Orifice Natural Gas...

  • Page 74: Temperature Controller Operation For Modulating Boilers

    IX. Temperature Controller Operation for Modulating Boilers A. Description The microprocessor based temperature controller is utilized for all modulating Thermal Solutions water boilers. The basic function of the controller is to modulate the firing rate of the burner in response to the boiler heat load.
  • Page 75 Actual Value (red display) Communication via interface Setpoint Value (green display) Burner On Increase Value Decrease Value Enter Button Escape Button To alter any of these process parameters follow the following steps: • To obtain access into the programming mode of the controller, briefly press the button “Enter”, so OPr is displayed on the second line in green LEDs.
  • Page 76 EVA/EVO boiler manual, 9/24 rev 13...
  • Page 77 NOTES EVA/EVO boiler manual, 9/24 rev 13...
  • Page 78 "Warranty" Period). c. contrary to the written instructions furnished with the unit For products or parts not manufactured by Thermal Solutions, the warranty obligations of Thermal Solutions shall, in all 2. Adverse local conditions in general and, specifically, respects, be limited to one year.

This manual is also suitable for:

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