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Thermal Solutions EVAW Series Installation, Operating And Service Instructions

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INSTALLATION, OPERATING AND
EVAW SERIES WATER HEATER
File Number
MH47005
For Service and repairs to the heating plant, call your heating contractor. When seeking information on the water
heater from the manufacturer, provide water heater model and serial number as shown on rating label.
Water Heater Model
EVAW-
Heating Contractor
Address
Your Local Thermal Solutions Representative:
102462-01-12/12

SERVICE INSTRUCTIONS

ON/OFF, MODULATION
Serial Number
Installation Date
1
Price - $3.00
A
S
Type System
Phone Number
M
E
H

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Summary of Contents for Thermal Solutions EVAW Series

  • Page 1: Service Instructions

    Price - $3.00 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS EVAW SERIES WATER HEATER ON/OFF, MODULATION File Number MH47005 For Service and repairs to the heating plant, call your heating contractor. When seeking information on the water heater from the manufacturer, provide water heater model and serial number as shown on rating label.
  • 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 water heater 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 ......... 6 H. Modular Systems ...... 29 I. Condensate Drains ....34 Unpacking the Water Heater ..8 System Start-up ......36 III. Installation........9 Operation ........39 A. Vent Guidelines Due to Removal of an Existing Water Heater..9 Service/Maintenance .....

  • Page 6: Pre-Installation

    I. Pre-Installation WARNING WARNING Adequate combustion and ventilation air must be Carefully read all instructions before installing provided to assure proper combustion. water heater. Failure to follow all instructions in proper order can cause personal injury or death. installed under the appliance; however, the pan must not restrict combustion air flow.
  • Page 7 Vertical ducts. Minimum free area of 1 excessive cycling and accelerated component square inch per 4,000 Btu per hour input of failure. Thermal Solutions DOES NOT warrant all equipment in space. Duct cross-sectional failures caused by incorrectly sized water heater area shall be same as opening free area.

  • Page 8: Unpacking The Water Heater

    II. Unpacking the Water Heater NOTICE WARNING Installation of this water heater should be under- Water heater crate is equipped with a tip & tell taken only by trained and skilled personnel from label. If label indicates water heater has been a qualified service agency.

  • Page 9: Installation

    III. Installation B. VENTING VENT GUIDELINES DUE TO REMOVAL OF AN EXISTING WATER HEATER WARNING For installations not involving the replacment of an existing water heater, proceed to step B. Improper venting may result in property damage When an existing water heater is removed from and the release of flue gasses which contain a common venting system, the common venting deadly carbon monoxide (CO) into the building,...
  • Page 10 g. Vent pipe system must be adequately supported p. Locate vent terminal above combustion air intake at intervals no less than five (5) feet apart. The terminal (if used) and no closer than one (1) foot completed vent system must be rigid and able to horizontally. withstand impacts without collapse. q. Vertical venting requires flashing and a storm h.
  • Page 11 c. The minimum chimney/vertical vent height is 15 (a) For all side wall horizontally vented gas feet. fueled equipment installed in every dwelling, building or structure used in whole or in part for d. Install a condensate drain to collect any residential purposes, including those owned or condensate that may form in the lined chimney/ operated by the Commonwealth and where the...
  • Page 12 2. Product Approved side wall horizontally venting system design or the venting system vented gas fueled equipment installed in a room components; and or structure separate from the dwelling, building 2. A complete parts list for the venting system or structure design or venting system.
  • Page 13 Figure 2: Sidewall Pressurized Venting Figure 3: Sidewall Pressurized Venting (Optional)
  • Page 14 Figure 4: Vertical Pressurized Venting...

  • Page 15: Combustion Air

    7. Water heater may be installed with vertical . COMBUSTION AIR - See Figures 6 and 7. venting and sidewall combustion air inlet or 1. The water heater may be operated with inside visa versa. or outside air. 2. Refer to combustion air piping drawings in this 8.
  • Page 16 Figure 7: Vertical Air Intake Piping...

  • Page 17: Water Treatment

    D. WATER TREATMENT CAUTION The quality of water used in the system is essential for The system water shall have a maximum water the successful operation and longevity of the system hardness of 8.5 grains or 150 ppm. However, components. A successful water treatment plan will other aspects of water quality can affect system help to maintain efficiency, reduce the regularity of operation and longevity.

  • Page 18: Water Piping And Trim

    Failure to do so could result in fittings. premature failure of the heat exchanger (not cov- iii. Oxygen permeable materials in the ered by Thermal Solutions Standard Warranty). distribution system. b. In order to insure long product life, oxygen sources must be eliminated. This can...
  • Page 19 TABLE 1 – EVA WATER HEATER FLOW AND PRESSURE DROP 20°ΔT 40°ΔT WATER Minimum Maximum Supply/Return (at high fire) (at high fire) HEATER Flow Rate Flow Rate Pipe ΔP Flow ΔP Flow MODEL (GPM) (GPM) (inch dia.) (ft.) (GPM) (ft.) (GPM) EVA-500 2.93...
  • Page 20 b. No reducing coupling or other restriction shall be installed in the discharge line. c. No valve shall be placed between the relief valve and tank. 11. The discharge from temperature and pressure valve(s) shall be conducted to a suitable place for disposal when relief occurs.

  • Page 21: Gas Piping

    . GAS PIPING WARNING f. Specific Gravity of Gas. Refer to Table 5 unless an authority having juristiction specifies a specific gravity factor to be Failure to properly pipe gas supply to water applied. If the exact specific gravity is not heater may result in improper operation and shown, choose next highest value. For damage to the appliance or structure. Always gas piping material other than schedule assure gas piping is absolutely leak free and of 40 pipe, refer to National Fuel Gas Code,...
  • Page 22 5. All above ground gas piping upstream from field supplied manual gas valve must be electrically continuous and bonded to a grounding electrode. Do not use gas piping as grounding electrode. Refer to National Electrical Code, ANSI/NFPA 70 and /or CSA C22.1 Electrical Codes. WARNING Gas supply to water heater and system must be absolutely shut off prior to installing or servicing appliance gas piping.
  • Page 23 TABLE 3: MAXIMUM GAS CAPACITY OF SCHEDULE 40 PIPE. TABLE 3: MAXIMUM GAS CAPACITY OF SCHEDULE 40 PIPE (Based on pressure drop of 0.3in. W.c. and 0.6 specific gravity) (Based on pressure drop of 0.3 in w.c. and 0.6 specific gravity) Nominal schedule 40 pipe size inch.
  • Page 24 TABLE 6 - EQUIVALENT OF STANDARD PIPE FITTING & VALVES VALVES FULLY OPEN 90° Tee, Flow Pipe I.D. Sing 90° 45° 90° Tee, Flow Gate Globe Angle Through Size Inches Check Elbow Elbow Through Run Branch 1/2" 0.622 0.35 18.6 0.78 3/4"...

  • Page 25: Electrical

    Each water heater may be wired differently according to 2. The appliance, when installed, must be the specifications given to Thermal Solutions at electrically grounded in accordance with local the time the water heater was purchased. Always...
  • Page 26 Figure 9a: Standard UL/FM/CSD-1 Wiring Diagram (On/Off)
  • Page 27 Figure 9b: Standard UL/FM/CSD-1 Wiring Diagram (Modulation)

  • Page 28: Modular Systems

    Refer to National Fuel Gas Code to . MODULAR SYSTEMS determine required chimney diameter 1. General Guidelines and common venting diameter. Note a. Read and follow all venting, combustion that combined input, lateral length and air, water piping, gas piping and electrical chimney height affect vent diameter.
  • Page 29 4. Air Intake Piping e. Position horizontal air intake termination center line below horizontal vent a. Consult factory for common air intake pipe termination's center line. sizing f. Vertical air intake pipe must terminate at b. Refer to Figures 11 and 12 for common least two (2) feet above the closest portion of air intake guidelines for modular water the roof.

  • Page 32: Condensate Drains

    5. Water Piping 7. Electrical a. Refer to Figure 8 for typical water piping for a. Each water heater must be provided with a water heaters. dedicated fused disconnect. b. Installing a low water cut-off in the system b. Install wiring and ground water heater in piping is highly recommended and may be accordance with requirements of authority required by Code.
  • Page 33 3. Each condensate drain must contain a siphon/ pigtail to prevent flue gas flow through the condensate piping. 4. A common condensate pump/sump may be used. Run separate piping from each condensate drain to the sump. A common drain may be used to discharge condensate from the sump. Consult pump/sump manufacturer for compatibility of pump/sump materials of construction.

  • Page 34: System Start-Up

    The relief valve setting CAUTION must be above the maximum operating pressure of the system. Consult Thermal Solutions if the On an existing or retrofit system, a filter or desired system operating pressure is above the strainer must be installed on the system return safety relief valve pressure setting.
  • Page 35 . Turn water heater off and repeat Steps X and Y DANGER at least five times to confirm proper main burner operation. Do not use matches, candles, open flames or other ignition source to check for leaks. . With main flame on, at high fire and low fire, measure gas pressure downstream of the main gas valves and adjust to the manifold pressure .
  • Page 36 Do not operate water heater without air filter in place and securely fastened and sealed. Replacement air filters must be purchased from authorized Thermal Solutions representatives. Part numbers are listed in Figure 20. Do not readjust gas regulator, bypass water valve, system return water valve, system supply water valve, pressure switch or water flow switch from setting determined during system start-up.

  • Page 37: Operation

    V. Operation 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 38 OPERATING INSTRUCTIONS CONTINUED 21. Observe several on and off cycles of the water 19. Reset the burner control by pressing the reset button heater. If any light offs are excessively noisy or located on the burner control. If you do not know rough, or any questionable water heater operation is where the control reset button is, do not touch any noticed, immediately turn off all gas and electrical...
  • Page 39 POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE EN MARCHE AVERTISSEMENT: Quiconque ne respecte pas à la lettre les instructions dans la présente notice risque de déclencher un incendie ou une explosion entraînant des dommages, des • Appelez immédiatement votre fournisseur de .
  • Page 40 INSTRUCTIONS DE MISE EN MARCHE 22. Should overheating occur or the gas supply fail 21. Observe several on and off cycles of the water to shut off, turn off the manual gas control to the heater. If any light offs are excessively noisy or appliance.

  • Page 41: Service/Maintenance

    Do not allow the appliance to operate with altered, disconnected or jumpered components. Only use replacement components identical to those originally supplied by Thermal Solutions. DANGER This water heater uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure.
  • Page 42 B. Daily Water Heater Inspection & Check 6. Repair or replace any inoperative or damaged components. 1.Inspect the area to assure proper clearance from combustible materials, gasoline, and other 7. Low water cutoff, float type (If so equiped). flammable vapors, and liquids. a) Monthly Blowoff. During the heating 2.Observe burner color. See Item H. season, if an external float type low water cutoff is above the water heater, the blow 3. Check flame control for proper operation and...
  • Page 43 Inspect connecting lines to water heater 5. Reassemble in reverse order using a new for accumulation of mud, scale, etc., and gasket available from Thermal Solutions. clean as required. C. Perform a visual inspection of main burner ii) Examine all visible wiring for brittle or flame.
  • Page 44 I. Check Combustion and Safety Controls: A. Check flame failure detection system with system operating. 1. Pilot a. Refer to the flame safeguard instruction manual. b. Manually close pilot fuel supply and verify lock out of primary control. 2. Main Flame a. Refer to the flame safeguard instruction. b. Close manual main fuel shut off valve and verify lockout of primary control. J.
  • Page 45 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 trips and Control Circuit Breaker prevents the water heater from operating until the circuit breaker is reset. If this switch is in the "off"...
  • Page 46 This Page is Deliberately Left Blank...
  • Page 47 Troubleshooting Guide...
  • Page 48 Troubleshooting Guide...

  • Page 49: Normal Sequence Of Operation

    NORMAL SEQUENCE OF OPERATION Limits and operating controls such as safety and operating temperature limits, Water Heater 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. Airflow switch must be open. Control terminal 5 is energized and all safety and operating control contacts Call for Heat are closed.

  • Page 50: Repair Parts

    WARNING The repair parts noted in this section are for the standard EVAW Series water heater. Different contents and componnets may have been supplied due to the request of the equipment end user. Consult Thermal Solu- tions for repair parts on non-standard controls and components.
  • Page 51 Figure 19: Combustion Chamber Assembly...
  • Page 52 WATER HEATER COMBUSTION CHAMBER (Quantity) Part Number Key No. Description EVA-500 EVA-750 EVA-1000 EVA-1500 EVA-2000 1. COMBUSTION CHAMBER ASSEMBLY Heat Exchanger 603563008 603563009 603563010 603563011 603563012 Base 61556043 61556025 (17) (31) (31) (31) (31) Tube Baffle 70356116 70356215 70356216 70356217 70356218 Sight Tube Baffle 70356122 70356123...
  • Page 53 VIEW FRONT VIEW Figure 20: Burner Assembly...
  • Page 54 BURNER ASSEMBLIES (Quantity) Part Number Key No. Description EVA-500 EVA-750 EVA-1000 EVA-1500 EVA-2000 2. BURNER FAN ASSEMBLIES Fan (120v/1ph) 811560022 81156001 Fan (three phase) 811560021 81156018 Air Filter 81156009 81156011 81156012 Pilot Assembly - Natural -OR- See Page 68 Pilot Assembly - LP Mixer Assembly - Natural 602561031 60256209...
  • Page 55 Figure 21c: UL/FM/CSD-1 Main Gas Train Assembly (On/Off & Modulation)
  • Page 56 UL/FM/CSD-1 GAS TRAIN (On/Off and Modulation) – MAIN AND PILOT (Quantity) Part Number Key No. Description EVA-500 EVA-750 EVA-1000 EVA-1500 EVA-2000 3. Main and Pilot Gas Train Main Gas Valve — Body, 1" NPT 816634041 Main Gas Valve — Body, 1-1/2" NPT 81663404 Manual Gas Valve with Pilot Tapping,...
  • Page 57 Figure 22a: DB&B w/POC Gas Train (On-Off, 500-750) Figure 22b: DB&B w/POC Gas Train (On-Off, 1000-2000)
  • Page 58 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" NPT — — — 816634041 Main Gas Valve Body, DBL, — 1-1/2" NPT 81663404 Manual Gas Valve with Pilot —...
  • Page 59 Figure 24a: DB&B w/POC Gas Train (Modulation, 500-750) Figure 24b: DB&B w/POC Gas Train (Modulation, 1000-2000)
  • Page 60 DB&B W/POC (Modulation) – 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 81663405 Manual Gas Valve with Pilot —...
  • Page 61 Figure 25: Jacket Panels Indoor Units...
  • Page 62 JACKET - INDOOR (Quantity) Part Number Description EVA-500 EVA-750 EVA-1000 EVA-1500 EVA-2000 4. Jacket Assembly Jacket Lower Front Panel (on/off) 604563161 604563171 604563181 604563191 604563201 Jacket Lower Front Panel Modulation 60456316 60456317 60456318 60456319 60456320 Jacket Lower Rear Panel 604563041 604563051 604563061 604563071...
  • Page 63 Figure 26a: Control Panel Assembly (On/Off)
  • Page 64 CONTROLS (ON/OFF) (Quantity) Part Number Description EVA-500 EVA-750 EVA-1000 EVA-1500 EVA-2000 5. Controls and Components RM7896D1027 Flame Safeguard Control for UL/ 80160212 FM/CSD-1/DB&B RM7896D1027 Flame Safeguard Control for 80160230 Modbus Module for 5A (optional - not shown) 80160909 Display Module for 5A (optional - not shown) 80160640 Amplifier Card (not...
  • Page 65 Figure 26b: Control Panel Assembly (Modulation)
  • Page 66 CONTROLS (Modulation) (Quantity) Part Number Description EVA-500 EVA-750 EVA-1000 EVA-1500 EVA-2000 5. Controls and Components RM7896D1027 Flame Safe- guard Control For UL/FM/ 80160212 CSD-1/DB&B RM7896D1027 Flame Safe- guard Control For POC 80160230 Modbus Module for 5A (optioinal-not shown) 80160909 Display Module for 5A (optional-not shown) 80160640 Amplifier Card (not shown)
  • Page 67 Figure 27: "Bishop" Pilot Assembly...
  • Page 68 Pilot Assembly (Bishop Design) (Quantity) Part Number Description EVA-500 EVA-750 EVA-1000 EVA-1500 EVA-2000 7. Pilot Assembly, Bishop Pilot Assembly Natural Gas, ULX2 62356110 — Pilot Assembly Pro- pane, ULX2 62356110 Ultraviolet Sensor 8026145 Pilot Orifice, Natural 722606 Pilot Orifice, Propane 722605 Pilot Air Orifice 722607 Cast Iron Body 82361581 Ignitor Assembly, ULX2...

  • Page 69: Appendix A. Temperature Controller Operation For Modulating Water Heaters

    A. Description The microprocessor based temperature controller is utilized for all modulating Thermal Solutions water heaters. The basic function of the controller is to modulate the firing rate of the burner in response to the water heater heat load. The controller monitors the water heater temperature through the use of a sensor located in the boiler pressure vessel.
  • Page 70 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 71 NOTES...
  • Page 72 NOTES...
  • Page 73 NOTES...

  • Page 74: 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...

This manual is also suitable for:

Eva-500Eva-750Eva-1000Eva-1500Eva-2000

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