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Thermal Solutions EVS Series Installation, Operating And Service Instructions

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INSTALLATION, OPERATING, AND
EVS™ SERIES MODULATING BOILER
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
EVS___________
Heating Contractor
Address
Your Local Thermal Solutions Representative:
102667-02 EVS Boiler manual S2, 9/24 rev 1
SERVICE INSTRUCTIONS
File Number MH25585
Serial Number
Type System
Phone Number
1

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Summary of Contents for Thermal Solutions EVS Series

  • Page 1 Boiler Model Type System Installation Date Serial Number EVS___________ Heating Contractor Address Phone Number Your Local Thermal Solutions Representative: 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • 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, personal 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

    Recommended Maintenance Check List General Guidelines Inspection and Cleaning Procedures IMPORTANT Combustion Air Water Treatment VIII. RepairParts Introduction Water Piping and Trim IX. ThermalSolutionsBoilerControl™(TSBC™) Thermal Solutions Boiler Control (TSBC Gas Piping Wiring Electrical Security Menu Modular Systems Setup Menu Condensate Drains Setup Menu (continued)
  • Page 6 Notes: 1. Piping removed for visual clarity (rear view). EVS-500 2. See notes concerning Net AHRI Ratings on page 4. CAPACITIES Boiler Model GROSS NET AHRI WATER Number INPUT DRY WEIGHT WET WEIGHT OUTPUT RATING VOLUME (MBH) (lbs.) (lbs.) (MBH) (MBH)2 (gallons) EVS-500...
  • Page 7 Notes: 1. Piping removed for visual clarity EVS-1000 (rear view). 2. See notes concerning Net AHRI Ratings on page 4. CAPACITIES Boiler Model GROSS NET AHRI WATER Number INPUT DRY WEIGHT WET WEIGHT OUTPUT RATING VOLUME (MBH) (lbs.) (lbs.) (MBH) (MBH)2 (gallons) EVS-1000...
  • Page 8 Notes: 1. Piping removed for visual clarity EVS-2000 (rear view). 2. See notes concerning Net AHRI Ratings on page 4. CAPACITIES Boiler Model GROSS NET AHRI WATER Number INPUT DRY WEIGHT WET WEIGHT OUTPUT RATING VOLUME (MBH) (lbs.) (lbs.) (MBH) (MBH) (gallons) EVS-2000...
  • Page 9 Notes: 1. Piping removed for visual clarity (rear view). EVS-2500 2. See notes concerning Net AHRI Ratings on page 4. CAPACITIES Boiler Model GROSS NET AHRI WATER Number INPUT DRY WEIGHT WET WEIGHT OUTPUT RATING VOLUME (MBH) (lbs.) (lbs.) (MBH) (MBH) (gallons) EVS-2500...

  • Page 10: General

    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. Une combustion et une ventilation d’air adéquates Lire avec attention toutes les instructions avant doivent être fournies pour assurer une combustion...
  • Page 11 Duct cross-sectional area shall be same en des cycles excessifs de la chaudière et accélérer as opening free area. la défaillance des composants. Thermal Solutions c. Horizontal ducts. Minimum free area of 1 square NE garantit PAS les défaillances dues à des applica- inch per 2,000 Btu per hour input of all equipment tions incorrectement dimensionnées de la chaudière.

  • Page 12: Packaging 12

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

  • Page 13: General Venting Requirements

    III. Installation 9. If any point of the vent pipe system is higher than WARNING WARNING the boiler flue collar, the vent system must have adequate condensate drain loop(s) to prevent Improper venting may result in property damage condensate from running back into the boiler. and the release of flue gasses which contain 10.
  • 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: Negative Pressure (Conventional) Venting

    19. Vertical vent termination must be at least two (2) D. General Guidelines feet plus the expected snow accumulation above 1. This boiler has been certified with AL29-4C® roof penetration height. venting. Select a vent material that is approved for 20.
  • Page 16 Figure 2: Sidewall Positive Pressure Venting Figure 3: Sidewall Positive Pressure Venting (Optional) 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 17 Figure 4: Vertical Pressurized Venting 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 18: Approved Carbon Monoxide Detectors

    b. In the event that the requirements of this 9. MANUFACTURER REQUIREMENTS - GAS subdivision can not be met at the time of EQUIPMENT VENTING SYSTEM NOT PROVIDED. completion of installation, the owner shall have When the manufacturer of a Product Approved side a period of thirty (30) days to comply with the wall horizontally vented gas fueled equipment does above requirements;...
  • Page 19 Figure 5: Typical Negative Pressure (Conventional) Venting 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 20: Combustion Air

    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 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 22: Water Treatment

    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

    Consult I=B=R Installation and Piping Guides. c. Maintain ½" minimum distance between water CAUTION CAUTION piping and combustible material. d. Consult Thermal Solutions for unusual system Failure to properly pipe boiler may result in requirements. improper operation and damage to boiler or structure.
  • Page 24 TABLE 2 - EVS 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) EVS-500 2.93 0.74 EVS-750 1.81 0.46...
  • Page 25 Le condensat de fumées de combustion peut con- damage. duire à une défaillance de la chaudière. La garantie 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

    La garantie standard d. Length of piping and number of fittings. Refer de Thermal Solutions ne couvre pas les problèmes to Table 4 for maximum capacity of schedule causés par des taux excessifs de débit d’eau.
  • Page 27 3. Install field supplied sediment trap, ground-joint Pressure test. The boiler and its gas connection union and manual non-displacable shut-off valve must be leak tested before placing boiler in upstream of factory supplied shut-off valve outside operation. the boiler jacket. Use methods and materials in a.
  • 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: Electrical

    Each boiler may be WARNING WARNING wired differently according to the specifications given to Thermal Solutions at the time the boiler Failure to properly wire electrical connections to was purchased. Always use the wiring diagram the boiler may result in serious physical harm.
  • 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 9a: 208/230/460V-1/3 ph-60 Hz Supply Power Wiring Schematic 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 33 Figure 9b: 120V-1ph-60Hz Supply Power Wiring Schematic 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 34 Figure 9c: Standard UL/FM/CSD-1 Wiring Diagram (EVS 500-2000) 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 35 Figure 9d: Standard UL/FM/CSD-1 Wiring Diagram (EVS500-2000) 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 36 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 37 Figure 9f: Standard UL/FM/CSD-1 Wiring Diagram (EVS 2000S-3000) 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 38: Modular Systems

    Figure 10: Modular System: Conventional Venting (Negative Pressure) K. Modular Systems ii. Positive pressure systems can be piped individually through a common vertical or 1. General Guidelines horizontal chase provided minimum clearances to combustible materials are maintained. a. Read and follow all venting, combustion air, water piping, gas piping and electrical instructions iii.
  • Page 39 iv. Locate boiler(s) with lowest input closest to NOTICE NOTICE chimney/vertical common vent. Chimney lining must be acceptable for use with The pressure drop given in Table 1 is for the condensing flue gases. boiler only. The pressure drop of each system fitting and component must be added to the vi.
  • Page 40 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 41 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 42 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 43 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 44 Figure 15: Multiple Boiler Water Piping with Common Header 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 45 This Page Left Intentionally Blank 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 46: Condensate Drains

    7. Electrical 3. A common condensate pump/sump may be used. Run separate piping from each condensate drain a. Each boiler must be provided with a dedicated to the sump. A common drain may be used to fused disconnect. discharge condensate from the sump. Consult b.

  • Page 47: System Check

    Thermal Solutions system. Use the following procedure on a Series Loop Standard Warranty does not cover problems or multi-zoned system installed to remove air from the caused by oxygen contamination of boiler water.

  • Page 48: Power The Boiler

    F. Select Operational Mode WARNING WARNING 1. Refer to the Thermal Solutions Boiler Control The maximum operating pressure of this boiler (TSBC ) Instruction Manual to select the desired is 160 psig. Never exceed this pressure. This control features. boiler was supplied with a safety relief valve with G.

  • Page 49: Begin Commissioning The Boiler

    13. Turn boiler off and repeat Steps H.7-H.10 at least DANGER DANGER five times to confirm proper main burner operation. I. Begin Commissioning the boiler Failure to properly adjust excess air will result in unsafe levels of carbon monoxide. Variations 1.
  • Page 50 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 51: LightingInstructions

    V. LightingInstructions 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 52: BoilerOperationalSequence

    VI. BoilerOperationalSequence 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 53 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 54: Service

    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. 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 55 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. 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 56: Safety And Operating Controls

    The VFD responds to Drive (VFD) a 0-10 VDC signal from the TSBC. The Thermal Solutions Boiler Control™ (TSBC™) is a complete boiler and automation Thermal Solutions system. It provides advanced boiler modulation control, operating control, diagnostics, Boiler Control™...

  • Page 57: Troubleshooting Guide

    B. Troubleshooting Guide Alarm Messages Alarm Messages are shown one at a time in priority order. The message closest to the top of this list is displayed first. Following messages are not shown until the higher priority message has cleared. All alarm messages are also stored in the Fault History.

  • Page 58: Troubleshooting Guide (Continued)

    Memory Failure Call Factory Reset all memories in New software has been installed in the Thermal Solutions Boiler Control (TSBC) System menu: or a power interruption has caused a memory failure. The Call For Heat will be Clr BIT History prevented until the condition is cleared.

  • Page 59: Recommended Maintenance Check List

    D. Recommended Maintenance 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 60: Inspection And Cleaning Procedures

    Examine pilot electrode and set gap to 1/8” if needed. Clean as required. e. Reassemble in reverse order using a new gasket available from Thermal Solutions. Burner Flame: 4. Perform a visual inspection of main burner flame. a. Observe main flame and record flame signal.

  • Page 61: RepairParts

    VIII. RepairParts EVS™ Series repair parts can be ordered through your nearest Thermal Solutions Representative for delivery from Lancaster, PA. The Representatives can also advise as to the availability of product and repair parts from local sources. Contact Thermal Solutions for your Representative at:...
  • Page 62 Figure 19: Combustion Chamber Assembly 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 63 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 64 Figure 20: Burner Assembly 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 65 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 66 Figure 21: UL/FM/CSD-1 Main Gas Train Assembly 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 67 UL/FM/CSD-1 GAS TRAIN - MAIN AND PILOT (Quantity) Part Number Description EVS- EVS- EVS- EVS- EVS- EVS- EVS- EVS- 1000 1500 2000 2000S 2500 3000 3. Main and Pilot Gas Train (UL/FM/CSD-1) Main Gas Valve (1) 816634041 Body 1" NPT Main Gas Valve (1) 81663404 Body, 1-1/2"...
  • Page 68 Figure 22a: DB&B w/POC Gas Train (500-750) DB&B W/POC - MAIN AND PILOT (Quantity) Part Number Description EVS-500 EVS-750 3. Main and Pilot Gas Train Main Gas Valve Body 1" NPT (2) 816634041 Manual Gas Valve with Pilot (2) 806603055 Tapping, 1"...
  • Page 69 Figure 22b: DB&B Gas Train (500-750) Figure 22c: DB&B Gas Train (1000-2000) 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 70 Figure 22c: DB&B Gas Train (1000-2000) DB&B – MAIN AND PILOT (Quantity) Part Number Description EVS-500 EVS-750 EVS-1000 EVS-1500 EVS-2000 3. MAIN AND PILOT GAS TRAIN Main Gas Valve Body 1" NPT — — — 816634041 Main Gas Valve Body, DBL, —...
  • Page 71 Figure 22d: DB&B Gas Train (2000S-3000) EVS Modulation DB&B (Quantity) Part Number Key No. Description EVS-2500 to EVS-2000S 3000 Main Valve Body (1) 81663404 (1) 816634043 Manual Gas (2) 806603053 (2) 806604691 Valve Ratio Valve (1) 81663408 Actuator (1) 81660205 (1) 8016602051 Gas Cock (3) 822758...
  • Page 72 Figure 22e: DB&B w/POC Gas Train (1000-2000) DB&B W/POC – MAIN AND PILOT Description EVS-1000 EVS-1500 EVS-2000 3. MAIN AND PILOT GAS TRAIN Main Gas Valve Body, DBL, 1-1/2" NPT 81663404 Manual Gas Valve with Pilot Tapping, 1-1/2" NPT 806603053 DB&B w/POC Actuator/ Regulator Ratio Valve, 81663409...
  • Page 73 Figure 22f: DB&B w/POC Gas Train (2000S-3000) EVS Modulating DB&B w/POC (Proof of Closure) (Quantity) Part Number Description EVS-2500 to EVS-2000S 3000 Main Valve Body (1) 81663405 (1) 816634051 Manual Gas Valve (2) 806603053 (2) 806604691 Ratio Valve (1) 81663409 Actuator (1) 81663407 Gas Cock...
  • Page 74 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 75 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 76 Figure 24: Control Panel Assembly 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 77 (1) 80160820 Fuses and Fuse Block, for 208/230/460V (2) 8136426, (2) 8136427 Application Transformer AT140B1206 (2) 801600502 Q7800H1109 Board for Thermal Solutions (1) 101182-01 Boiler Control (TSBC Thermal Solutions Boiler Control (TSBC) (1) 101171-03 Assembly (not shown) PCB-01 Line Connections...
  • Page 78 Figure 25: Pilot Assembly (Bishop Design) 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 79 PILOT ASSEMBLY (Bishop Design) (Quantity) Part Number Description EVS- EVS- EVS- EVS- EVS- EVS- EVS- EVS- 1000 1500 2000 2000S 2500 3000 7. Pilot Assembly, Bishop Pilot Assembly, Natural Gas, ULX2 (1) 62356110 Pilot Assembly, Propane, ULX2 (1) 62356210 Ultraviolet Sensor (1) 8026145 Pilot Orifice, Natural Gas (1) 722606...

  • Page 80: Introduction

    Read the additionally supplied Factory Instruction Manual for the TSBC to learn more about the controllers features and capabilities. 1. The Thermal Solutions Boiler Control™ (TSBC™) is a complete boiler monitoring and automation system. The TSBC™ provides advanced boiler modulation, operating control, diagnostics, multiple boiler lead-lag and auxiliary device control.

  • Page 81: Front Panel Display

    ) Wiring When wiring to the Thermal Solutions Boiler Control (TSBC™) terminals, see the terminal layout drawing on the following page or the terminal jacket label, located on the inside surface of the boiler jacket upper front panel. The TSBC™ terminals are removable for easier field wiring connection.
  • Page 82 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 83: Security Menu

    Please consult Thermal Solutions for the factory access level password. Consult Thermal Solutions Boiler Control (TSBC) Instruction manual for operation guidance and a detailed list of parameters and their associated access levels. 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 84: Setup Menu

    D. Setup Menu 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 85: Setup Menu (Continued)

    E. Setup Menu (continued) 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 86: Setup Menu (Continued)

    F. Setup Menu (continued) 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 87: Boiler Configuration Menu

    G. Boiler Configuration Menu None 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 88: System Configuration Menu

    H. System Configuration Menu 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 89: Setpoints Menu

    I. Setpoints Menu Factory Display Range/Choices Description Settings Operational Setpoint used in Local Setpoint Mode when not servicing a Domestic Hot Water 60 to 230 F Priority (DHWP) request The boiler starts when the water temperature drops "On Point" degrees below On Point 0 to 99 F the setpoint...

  • Page 90: Communication Menu

    J. Communication Menu 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 91: Manual Mode Menu

    K. Manual Mode Menu 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 92 NOTES 102667-02 EVS Boiler manual S2, 9/24 rev 1...
  • Page 93 102667-02 EVS Boiler manual S2, 9/24 rev 1...

  • Page 94: Limited Warranty

    H. Leakage or other malfunction caused by: manufactured by Thermal Solutions, Seller warrants to the original owner at the original installation site that products 1. Defective installations in general and specifically, any manufactured by Seller (“Products”) comply, at the time of...

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