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Thermal Solutions EVO-500 Installation, Operating And Service Instructions

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INSTALLATION, OPERATING AND
ON/OFF AND MODULATION, OUTDOOR
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
EVO -
Heating Contractor
Address
Your Local Thermal Solutions Representative:
104492-01R1-4/13

SERVICE INSTRUCTIONS

EVO SERIES BOILER
Serial Number
1
Price - $3.00
A
S
Type System
Phone Number
M
E
H

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Summary of Contents for Thermal Solutions EVO-500

  • Page 1: Service Instructions

    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 Serial Number Type System Installation Date EVO - Heating Contractor Address Phone Number Your Local Thermal Solutions Representative: 104492-01R1-4/13...
  • 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 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: Table Of Contents

    Table of Contents Pre-Installation ........8 H. Condensate Drains ......38 Unpacking the Boiler ......9 System Start-up ........39 III. Installation ..........10 Lighting Instructions ......42 A. Venting ..........10 Boiler Operational Sequence....44 B. Combustion Air .......16 VII. Service ..........45 C. Water Treatment ......18 VIII.
  • Page 5 VALVE for visual clarity WATER RETURN FROM SYSTEM 2" NPT WATER FLOW (rear view). WATER SUPPLY SWITCH 11.3 TO SYSTEM EVO-500 P&T GAUGE [285.8] 2" NPT 2. See notes FLUE OUTLET [206.4] 4" SAF-T-VENT concerning Net AHRI Ratings on 14.1 [358.8]...
  • Page 6 [158.8] REQUIREMENT 10.0 FOR BURNER 31.0 [254.0] [235.0] [88.9] REMOVAL [787.4] Notes: GAS PILOT GAS VENT " TUBE 1. Piping removed " NPT PIPE for visual clarity RELIEF VALVE WATER RETURN (rear view). FROM SYSTEM 3" NPT WATER FLOW EVO-1000 WATER SUPPLY SWITCH 19.0...
  • Page 7 [158.8] REQUIREMENT 10.0 FOR BURNER 31.0 [254.0] [235.0] [88.9] REMOVAL [787.4] Notes: GAS PILOT GAS VENT " TUBE " NPT PIPE 1. Piping removed RELIEF VALVE WATER RETURN for visual clarity FROM SYSTEM 3" NPT WATER FLOW WATER SUPPLY SWITCH (rear view).

  • Page 8: Pre-Installation

    I. Pre-Installation 1. Determine volume of space (boiler room). Rooms WARNING communicating directly with space (through openings not furnished with doors) are considered Carefully read all instructions before installing part of space. boiler. Failure to follow all instructions in proper order can cause personal injury or death.

  • Page 9: Unpacking The Boiler

    a. Direct communication with outdoors. Minimum Consider the blocking effect of louvers, grilles and free area of 1 square inch per 4,000 Btu per hour screens when calculating the opening size to provide input of all equipment in space. the required free area. If free area of louver or grille is not known, assume wood louvers have 20-25 b.

  • Page 10: Installation

    Do not reduce the diameter of the vent pipe. The vent Although details for indoor installation may be pipe must not be smaller than the vent connector on the rarely applicable, Thermal Solutions recognizes boiler. that instances may exist where such details are...
  • Page 11 The minimum chimney/vertical vent height is 15 feet. Locate vent terminal above combustion air intake d. Install a condensate drain to collect any condensate that terminal (if used) and no closer than one (1) foot may form in the lined chimney/vertical vent. horizontally.
  • Page 12 Figure 2: Sidewall Positive Pressure Venting Figure 3: Sidewall Positive Pressure Venting (Optional)
  • Page 13 Figure 4: Vertical Pressurized Venting...
  • Page 14 a hard wired carbon monoxide detector with an alarm separate from the dwelling, building or structure and battery back-up is installed on the floor level used in whole or in part for residential purposes. where the gas equipment is to be installed. In addition, c.
  • Page 15 Figure 5: Typical Negative Pressure (Conventional) Venting...

  • Page 16: 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 17 Figure 7: Vertical Air Intake Piping...

  • Page 18: 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 19: Water Piping And Trim

    Maintain ½" minimum distance between water WATER PIPING AND TRIM piping and combustible material. d. Consult Thermal Solutions for unusual system CAUTION requirements. Failure to properly pipe boiler may result in CAUTION improper operation and damage to boiler or structure.
  • Page 20 (at high fire) BOILER Minimum Flow Maximum Flow Pipe MODEL Rate (gpm) Rate (gpm) Flow Flow (inch dia.) (Ft.) (GPM) (Ft.) (GPM) EVO-500 2.93 0.74 EVO-750 1.81 0.46 EVO-1000 3.24 0.81 EVO-1500 7.37 1.85 EVO-2000 13.27 3.32 Figure 8: Water Piping (Single Boiler)

  • Page 21: Gas Piping

    This option is not available Do not operate the boiler with flow rates in on the EVO-500. excess of the maximum flow rates listed in Table c. Maximum gas demand. Table 7 lists boiler input 2.
  • Page 22 ½ psig, boiler and its individual shutoff valve must be disconnected from gas supply piping. For testing at ½ psig or less, isolate TABLE 3 - BOILER GAS TRAIN INLET PRESSURE Boiler Model MIN. ("w.c.) MAX. EVO-500 EVO-750* 5 psi-NG EVO-1000* 2 psi-LP EVO-1500* EVO-2000*...
  • Page 23 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 24 Table 7 lists gas inputs at sea level to 2000 feet altitude. Reduce gas input four percent (4%) for each additional 1000 feet above sea level. TABLE 7 - RATED INPUT Rated Capacity (CFH) Boiler Model Gas Connection Size (inch dia.) Natural LP/Propane EVO-500 1-1/4 EVO-750 1-1/2 EVO-1000 1000 1-1/2 EVO-1500...

  • Page 25: Electrical

    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 provided with the boiler. If the wiring diagram...
  • Page 26 Figure 9a: Standard UL/FM/CSD-1 Wiring Diagram(on/off) EVO 500-2000...
  • Page 27 Figure 9b: Standard UL/FM/CSD-1 Wiring Diagram (Modulation) EVO 500-2000...

  • Page 28: 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 29 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 38: Condensate Drains

    2. Use continuous Teflon, high temperature resistant 3-5 on the pH scale. Consult Thermal Solutions or a silicone tubing, or other tubing material compatible chemical treatment company for buffering systems. with flue gas condensate, for condensate piping. Do not install valves on condensate drain lines.

  • Page 39: System Start-Up

    Use the corrosion of iron and steel boiler components, following procedure on a Series Loop or multi-zoned and can lead to boiler failure. Thermal Solutions system installed to remove air from the system while Standard Warranty does not cover problems filling.
  • Page 40 The relief valve setting must be above 3. Confirm proper blower motor rotation. the maximum operating pressure of the system. Consult Thermal Solutions if the desired system 4. Shut boiler off and position the flame control back operating pressure is above the safety relief to run.
  • Page 41 12. Turn boiler off and repeat Steps H.7-H.10 at least DANGER five times to confirm proper main burner operation. Failure to properly adjust excess air will result Begin Commissioning the boiler - With main flame in unsafe levels of carbon monoxide. Variations on, at high fire, measure gas pressure upstream and in venting or combustion air pressure and downstream of the main gas valves...

  • Page 42: Lighting Instructions

    V. Lighting Instructions FOR YOUR SAFETY, READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. • If you cannot reach your gas supplier, call the fire .
  • Page 43 OPERATING INSTRUCTIONS CONTINUED 21. Observe several on and off cycles of the water heater. 19. Reset the burner control by pressing the reset button If any light offs are excessively noisy or rough, located on the burner control. If you do not know or any questionable boiler operation is noticed, where the control reset button is, do not touch any immediately turn off all gas and electrical power and...

  • Page 44: 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 45: Service

    Do not install, start up, operate, maintain or service this boiler without reading and understanding all of the component instructions. Do not allow the boiler to operate with altered, disconnected or jumpered components. Only use replacement components identical to those originally supplied by Thermal Solutions.

  • Page 46: Component Function

    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 47 This Page Intentionally Left Blank...
  • Page 48 Troubleshooting Guide Troubleshooting Guide...
  • Page 49 Troubleshooting Guide...
  • Page 50 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 51: Main Burner

    Clean as required. C. Flush boiler and mechanically remove any scale. 5. Reassemble in reverse order using a new gasket available from Thermal Solutions. Burner Flame: A. Perform a visual inspection of main burner flame. 1. Observe main flame and record flame signal.

  • Page 52: Repair Parts

    VIII. Repair Parts EVO 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 53 This Page Intentionally Left Blank...
  • Page 54 Figure 19: Combustion Chamber Assembly...
  • Page 55 COMBUSTION CHAMBER ASSEMBLY (Quantity) Part Number Description EVO-500 EVO-750 EVO-1000 EVO-1500 EVO-2000 1. COMBUSTION CHAMBER ASSEMBLY 1A Heat Exchanger (1) 603563002 6035630031 6035630041 6035630051 6035630061 Base (1) 61556042 (1) 61556024 Tube Baffle (17) 70356116 (31) 70356215 (31) 70356216 (31) 70356217 (31) 70356218...
  • Page 56 VIEW FRONT VIEW Figure 20: Burner Assembly...
  • Page 57 BURNER ASSEMBLY (Quantity) Part Number Description EVO-500 EVO-750 EVO-1000 EVO-1500 EVO-2000 2. BURNER/FAN ASSEMBLIES Fan (120V / 1 ph) (1) 81156001 811560022 Fan (3 phase) (1) 81156018 811560021 Air Filter (1) 81156009 (1) 81156011 (1) 81156012 Pilot Assembly - NG...
  • Page 58 Figure 21: UL/FM/CSD-1 Main Gas Train Assembly...
  • Page 59 Pilot Regulator (1) 822702 High Pressure Switch (1) 80160333 Low Pressure Switch (1) 80160332 EVO Modulating, UL/FM/CSD-1 (Quantity) Part Number Description EVO-1000 to EVO-500 EVO-750 2000 Main Valve Body (1) 816634041 (1) 81663404 Manual Gas Valve (2) 806603055 (2) 806603053 Actuator...
  • Page 60 Figure 22a: DB&B & DB&B w/POC Gas Train (500-750) Figure 22b: DB&B & DB&B w/POC Gas Train (1000-2000)
  • Page 61 EVO Modulation DB&B (Quantity) Part Number Key No. Description EVO-1000 to EVO-500 to 750 2000 Main Valve Body (1) 806634041 (1) 81663404 Manual Gas (2) 806603055 (2) 806603053 Valve Ratio Valve (1) 81663408 Actuator (1) 81660207 (1) 81660205 Gas Cock...
  • Page 62 Figure 23: Jacket Panels...
  • Page 63 JACKET Description EVO-500 EVO-750 EVO-1000 EVO-1500 EVO-2000 4. Jacket Assembly Jacket Lower Front Panel (1) 60456310 (1) 60456311 (1) 60456312 (1) 60456313 (1) 60456314 (Modulation) Jacket Lower Rear Panel (1) 60456304 (1) 60456305 (1) 60456306 (1) 60456307 (1) 60456308 Jacket Upper Rear Panel...
  • Page 64 Figure 24a: Control Panel Assembly (On/Off)
  • Page 65 CONTROLS ON/OFF (Quantity) Part Number Description EVO-500 EVO-750 EVO-1000 EVO-1500 EVO-2000 5. Controls and Components RM7896D1027 Flame Safeguard Control for (1) 80160212 UL/FM/CSD-1/DB&B RM7800M1011 Flame Safeguard Control for (1) 80160230 Modbus Module for 5A (1) 80160909 (optional - not shown)
  • Page 66 Figure 24b: Control Panel Assembly (Modulation)
  • Page 67 CONTROLS (Modulation) (Quantity) Part Number Description EVO- EVO- EVO- EVO- EVO- 1000 1500 2000 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) Display Module for 5A (optional - not...
  • Page 68 Figure 25: "Bishop" Pilot Assembly...
  • Page 69 PILOT ASSEMBLY (Bishop Design) (Quantity) Part Number Description EVO- EVO- EVO- EVO- EVO- 1000 1500 2000 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 (1) 722606 Pilot Orifice Propane (1) 722605...

  • Page 70: 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. The controller monitors the boiler water temperature through the use of a sensor located in the boiler pressure vessel.
  • Page 71 Actual Value (red display) Setpoint Value (green display) Indicates Manual Operation Burner On Limit Comparator Increase Value Decrease Value Programming Key EXIT Key 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 “PGM”. •...
  • Page 72 NOTES...
  • Page 73 NOTES...
  • Page 74 NOTES...
  • Page 75 NOTES...

  • Page 76: Limited Warranty

    "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:

Evo-1500Evo-750Evo-2000Evo-1000

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