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Thermal Solutions SOLARIS Service Instructions Manual

Gas-fired water heater
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Download this manual See also: Installation, Operating and Service Instructions
INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
Gas-Fired Water Heater
A
S
M
E
H
For service or repairs to water heater, call your heating contractor. When seeking information on
water heater, provide Water Heater Model Number and Serial Number as show on Rating Label.
Water Heater Model Number
SOL __ __ __ __ - __ __ __
Heating Contractor
Address
104494-01R1-1/13
SOLARIS
Water Heater Serial Number
6 __ __ __ __ __ __ __
Installation Date
Phone Number
Price - $5.00
1

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Summary of Contents for Thermal Solutions SOLARIS

  • Page 1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR SOLARIS Gas-Fired Water Heater For service or repairs to water heater, call your heating contractor. When seeking information on water heater, provide Water Heater Model Number and Serial Number as show on Rating Label.
  • Page 2 Immediately, call the gas supplier from a remotely lo- cated phone, Follow the gas supplier’s instructions or if the supplier is unavailable, contact the fire department. Manufacturer’s Contact Information: Thermal Solutions 1175 Manheim Pike Lancaster, PA 17601 717-239-7642...
  • Page 3 WARNING This water heater requires regular maintenance and service to operate safely. Follow the instruc- tions 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.

  • Page 4: Table Of Contents

    A. Vent Guidelines Due to Removal of an B. Safety & Operating Controls .......45 Existing Water heater ..........8 C. Trouble Shooting Guide ........46 B. General Guidelines ..........9 Thermal Solutions Boiler Control (TSBC ) ..48 C. Supplemental Vent Terminal Location A. Introduction ............48 Instructions ............10...
  • Page 5 CAPACITIES RATED RATED Water MOTOR BLOWER heater GROSS WATER HORSE ELECTRICAL Model INPUT OUTPUT VOLUME WEIGHT WEIGHT POWER DRAW SUPPLY Number (MBH) (MBH) (Gallons) (lbs.) (lbs.) (HP) (Amps) (Voltz/Hertz/Phase) SOL-500 316.0 326.8 120/60/1 1. See notes concerning Net AHRI Ratings on page 4. (TYP.) (TYP.) G INLET GAS...

  • Page 6: Pre-Installation

    I. Pre-Installation Protect gas ignition system components from water WARNING (dripping, spraying, rain, etc.) during water heater op- eration and service (circulator replacement, condensate trap, control replacement, etc.). If you do not follow these instructions ex- actly, a fire or explosion may result causing Provide combustion and ventilation air in accordance property damage or personal injury.

  • Page 7: Unpack Water Heater

    5. For water heater located in an unconfined space Alternate method for water heater located within in a building of other than unusually tight con- confined space: Use indoor air if two permanent struction, adequate combustion and ventilation openings communicate directly with additional air is normally provided by fresh air infiltration space(s) of sufficient volume such that combined through cracks around windows and doors. volume of all spaces meet criteria for unconfined space.

  • Page 8: Venting/Air Intake Piping

    III. Venting / Air Intake Piping WARNING Do not use this water heater with galvanized, non metallic or any other venting material that is not designed for condensing flue gas applications. Do not use a drafthood with this appliance. Do not use vent dampers with this water heater. Moisture and ice may form on surfaces around termination.

  • Page 9: General Guidelines

    B. General Guidelines 7. Vent length restrictions are based on equivalent length of vent/air pipe (total length of straight pipe 1. Vent system installation must be in accordance with plus equivalent length of fittings). Maximum vent/ Part 7, Venting of Equipment of the National Fuel air lengths are listed in Table 0. Do not exceed Gas Code, ANSI Z223.1/NFPA 54, or Section 7, maximum vent/air intake lengths.
  • Page 10 C. Supplemental Instructions (Massachusetts e. Minimum of four (4) feet horizontally from, and in no case above or below, unless a 4 foot hori- Code Only) zontal distance is maintained from electric me- The Commonwealth of Massachusetts requires compli- ters, gas meters, regulators and relief equipment. ance with regulation 248 CMR 4.00 and 5.00 for instal- This distance may be reduced if equipment is lation of side-wall vented gas appliances as follows:...

  • Page 11: Instructions

    b. EXEMPTIONS: The following equipment is exempt- A copy of all installation instructions for all Product Ap- from 248 CMR 5.08(2)(a)1 through 4: proved side wall horizontally vented gas fueled equip- 1. The equipment listed in Chapter 10 entitled “Equip- ment, all venting instructions, all parts lists for venting ment Not Required To Be Vented”...
  • Page 13 Figure 5: Side Vent...

  • Page 14: Optional Separate Horizontal Vent Terminal Mounting

    E. Optional Separate Horizontal Vent Terminal Mounting – See Figure 6 1. Do not exceed maximum vent/air intake lengths. e. Install 45° elbow to upper 90° elbow so that leg Refer to Table 0. of 45° is in down direction (see Figure 6). If not using indoor air, proceed to Step f.

  • Page 15: Conventional Venting

    F. Conventional Venting (Negative Draft) – See Figure 7 1. The minimum chimney height is 15 feet. 2. Do not exceed maximum air intake length. See Table 0. 2. The chimney must be protected from down drafts, rain and debris by using a chimney cap or star. 3. Use single wall metal pipe and fittings or thin 3.

  • Page 17: Separate Vertical Venting System

    H. Separate Vertical Venting System - See Figures 9, 10, and 11. 7. The air intake pipe must be adequately supported Vertical Venting – with straps or supports no less than five (5) feet 1. Do not exceed maximum vent lengths. Refer to apart on horizontal runs. The complete air intake Table 0.
  • Page 18 Figure 9: Vertical Vent Installation...
  • Page 19 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.

  • Page 20: Water Treatment, Piping And Trim

    Thermal Solutions Standard Warranty Table 1: Chemical Agents and Effects does not cover problems caused by oxygen Compound Effect contamination of system water.
  • Page 21 In addition, some jurisdictions terial. Consult Thermal Solutions for unusual system require the use of a LWCO with a hot water water requirements. heater. If a low water cutoff is required, it must be mounted in the system piping above the water heater.
  • Page 22 Do not operate water heater with flow rates in excess of the maximum flow rates listed in Table 2. Water heater tube erosion and pitting will occur. Thermal Solutions Stan- dard Warranty does not cover problems caused by excessive water flow rates.
  • Page 23 Table 2 - Solaris Water heater Flow and Pressure Drop 20° ΔT (max) 40° ΔT (min) Water Heater Flow Flow Supply/Return Model Δ P (ft) (GPM) Δ P (ft) (GPM) Pipe (in. dia.) SOL-500 Figure 12: Water Piping (Single Water heater)
  • Page 24 Figure 13: Safety & Drain Valve Installation...

  • Page 25: Gas Piping

    V. Gas Piping 4. Specific gravity of gas. Gas piping systems for WARNING gas with a specific gravity of 0.70 or less can be sized directly from Table 5, unless authority having jurisdiction specifies a gravity factor be applied. Failure to properly pipe gas supply to water For specific gravity greater than 0.70, apply gravity heater may result in improper operation and factor from Table 4. If exact specific gravity is not damage to the water heater or structure. Al- shown choose next higher value.
  • Page 26 Table 5: Maximum Capacity of Schedule 40 Pipe in CFH* for Gas Pressures of 0.5 psig or Less 0.3 inch w.c. Pressure Drop 0.5 inch w.c. Pressure Drop Length (Feet) 1-1/4 1-1/2 1-1/4 1-1/2 1060 1580 1390 2090 1090 1430 1150 * 1 CFH of Natural Gas is approximately equal to 1 MBH.

  • Page 27: Electrical

    VI. Electrical DANGER Positively assure all electrical connections are unpowered before attempting installation or ser- vice of electrical components or connections of the water heater or building. Lock out all electri- cal boxes with padlock once power is turned off. WARNING Failure to properly wire electrical connections to the water heater may result in serious physical harm.
  • Page 28 FUSE MUST BE WIRED FROM TERMINAL TO THE THERMAL FUSE. IF THE HIGH AND LOW GAS PRESSURE SWITCHES ARE NOT USED, A Solaris WIRE MUST BE INSTALLED BETWEEN TERMINAL Ladder Diagram FACTORY WIRING, LOW VOLTAGE IS 24VAC UNLESS OTHERWISE INDICATED.
  • Page 29 System Controls and Wiring 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 water heater jacket, junction boxes and/or control boxes. 3.

  • Page 30: Modular Installation

    Module Sizing b. Refer to National Fuel Gas Code to determine required chimney diameter and common vent- Thermal Solutions recommends sizing each water ing diameter. Note that combined input, lateral heater in a modular system to provide 20 % of the length and chimney height affect vent diameter.
  • Page 31 Water Piping 1. Refer to Figure 12 for typical water piping installa- tion details for modular water heaters. 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 flow require- ments for each water heater. 4.
  • Page 32 Figure 17: Modular Water heater Conventional Venting Figure 18: Modular Water heater Horizontal Air Intake Piping...
  • Page 33 LISTED IN TABLE 0. Figure 19: Modular Water heater Vertical Air Intake Piping...

  • Page 34: System Start-Up

    VIII. System Start-up 3. Attach a hose to the vertical hose bib located prior to Safe operation and other performance criteria were the full port ball valve in the system supply piping. met with gas manifold and control assembly provided (Note - Terminate hose in five gallon bucket at a on water heater when water heater underwent tests suitable floor drain or outdoor area).
  • Page 35 DANGER Do not use matches, candles, open flames or other ignition source to check for leaks. 8. Open the field installed manual gas shut-off valve located upstream of the gas valve on the water heater. 9. Check that water heater gas piping, valves, and all other components are leak free using a soap solution Figure 20: Pilot Burner/Main Burner Flame or a similar non-combustible solution, electronic leak detector or other approved method.

  • Page 36: For Your Safety Read Before Operating

    FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result WARNING: causing property damage, personal injury, or loss of life. This appliance is equipped with an ignition device, which • If you cannot reach your gas supplier, call the fire depart- automatically lights the pilot.
  • Page 37 O. Check the pilot and main burner flames. Allow the pressure at high fire. Turn the screw setting water heater to complete pre-purge, PTFI, and MTFI. clockwise to increase and counterclockwise to Look through the water heater sight glass and check the decrease the manifold pressure. pilot and main burner flames. For the pilot and main c.
  • Page 38 Figure 22: SOL500-1500 Pilot Valve 1 Electrical connection for valves (DIN EN 175 301-803) 10 Setting screw Ratio V 2 Input flange 11 Vent nozzle G 1/8 3 Pressure connection G 1/8 upstream of filter 12 G 1/8 pressure connection Burner pressure p 4 Filter 13 Output flange Test point connection G 1/8 upstream of V1, possible...
  • Page 39 This page intentionally left blank...
  • Page 40 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 41: Service And Maintenance

    IX. Service and Maintenance DANGER This water heater uses flammable 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. More than one gas valve is used on the water heater.

  • Page 42: Periodic Maintenance

    A. General Guidelines 7. Terminal Wall thimbles (if used) must be weathertight 1. A thorough and complete water heater inspection and check must be conducted a minimum of one 8. Horizontal vent tee drain or vertical vent tee (1) time per year. drain (if used) must have minimum 6 inch trap and allow condensate to flow freely.
  • Page 43 To clean: 5. Reassemble in reverse order using a new i) Disconnect drain tube from drain fitting. gasket available from Thermal Solutions. ii) Flush drain tube with water. Fill trap with C. Perform a visual inspection of main burner water.
  • 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.

  • Page 45: Safety & Operating Controls

    Flame Safeguard Refer to the manual supplied with the water heater. Control The Thermal Solutions Water heater Control™ (TSBC™) is a complete water heater Thermal Solutions monitoring and automation system. It provides advanced water heater modulation control, Water heater Con- operating control, diagnostics, multiple water heater lead lag and auxiliary device control.

  • Page 46: Trouble Shooting Guide

    C. Trouble Shooting Guide 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 show until the higher priority message has cleared. All alarm messages are also stored in the fault history. LCD Display Recommended Explanation Alarm Message Action Low Water Cutoff Switch When this option is configured and an instrument is installed, the manual reset Manually Reset the Low Low Water Level low water safety relay is preventing the water heater from starting.
  • Page 47 Trouble Shooting Guide (continued) LCD Display Recommended Explanation Alarm Message Action Remote Control Input Fail The Remote Control Input is configured and is not connected or is above or be- low a valid range. When the remote control input fails the following control mode changes are taken automatically: Check Wiring and Remote Input Fail...

  • Page 48: Introduction

    TSBC to learn more about the controllers features and capabilities. 1. Thermal Solutions Water heater Control™ Overview The Thermal Solutions Water heater Control™ (TSBC™) is a complete water heater monitoring and automation system. The TSBC™ provides advanced water heater modulation, operating control, diagnostics, multiple water heater lead-lag and auxiliary device control.

  • Page 49: Front Panel Display

    B. Thermal Solutions Water heater Control (TSBC ) Wiring When wiring to the Thermal Solutions Water heater Control (TSBC™) terminals, see the terminal layout drawing on the following page or the terminal markings on the control . The TSBC™ terminals are removable for easier field wiring connection.

  • Page 51: Security Menu

    All relevant internal parameters in the system will be visible and programmable. Factory Please consult Thermal Solutions for the factory access level password. Consult Thermal Solutions Water heater Control (TSBC) Instruction manual for operation guidance and a detailed list of parameters and their associated access levels.

  • Page 52: Setup Menu

    D. SETUP MENU Factory Description Display Range/Choices Settings WWSD Specifies Warm Weather Shut-Down (WWSD) control of water heater and/or system pump: Ignores Warm Weather setpoint WWSD of Water When Outside Air Temperature (OAT) is higher than the WWSD setpoint, inhibits water heater start heater WWSD WWSD of Sys...
  • Page 53 D. Setup Menu (Continued) Factory Display Range/Choices Description Settings Local PID I Local Integral Gain value for water heater outlet temperature sensor control Modes. A smaller value makes 0 to 10000 PID I the Integral ramp in less time (i.e.., faster). Integral is a secondary PID modulation rate tuning adjust- ment that ramps the output over time (typically minutes).

  • Page 54: Boiler Configuration Menu

    E. Boiler Configuration Menu Factory Range/ Display Description Setting Choices Display °F Display Units °F Units °C Selects how temperature parameter values are displayed. Water heater Pump None No Water heater Pump. Always On Pump Runs Continuously. Water heater None Purge Pump Runs during pump pre/post purge operations and during call for heat and then turns off.

  • Page 55: System Configuration Menu

    F. System Configuration Menu Factory Display Range/Choices Description Setting DHWP Enables Domestic Hot Water Priority (DHWP) control feature. When input (DP) is energized DHWP becomes active as selected: No DHWP. Water heater that received the input (DP) drops off the Peer-To-Peer network and its temperature Isolated setpoint is adjusted above the DHWP setpoint.

  • Page 56: Setpoints Menu

    G. Setpoints Menu Factory Display Range/Choices Description Setting Operational SP Opera- 180°F 60°F to 230°F Setpoint used in Local Setpoint Mode when not servicing a Domestic Hot Water Priority (DHWP) tional SP request. On Point On Point -5°F 0°F to -99°F The water heater starts when the water temperature drops “On Point”...

  • Page 57: Communication Menu

    H. Communication Menu Factory Display Range/Choices Description Setting Protocol Peer-To- Peer-To-Peer Protocol Selects between Peer-To-Peer (Multiple water heater lead/lag control network) and a Modbus slave Peer Modbus communication. Modbus Address Modbus 1 - 247 Each water heater must be given a unique address. Address Only visible when Protocol equals Modbus.

  • Page 58: Repair Parts

    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 (717) 239-7642 or Fax (877) 501-5212.
  • Page 59 Figure 26: Burner Tray Quantity Description Part Number Per Model SOL-500 1. Burner Tray 3 Burner Assembly 102017-01 Ignitor Assembly 812SOL0010 Gasket, Burner Mounting Plate 820SOL0004 Gasket, Ignitor Assembly 820SOL0005...
  • Page 60 SIDE VIEW OF GAS VALVE Figure 27: Gas Train (SOL-500 ) (Reference Table 8)
  • Page 61 Gas Trains: Reference Figure 27 (Quantity) No. Description Part Number SOL-500 1 Main Gas Valve Body (1)816SOL0510 Main Gas Valve Flange(s) 3/4” NPT — Main Gas Valve Flange(s) 1” NPT (2) 816SOL0503 Main Gas Valve Flange(s) 1-1/4” NPT — Main Gas Valve Flange(s) 1-1/2” NPT —...
  • Page 62 Manifold Orifice Assembly Water Heater Model Description SOL-500 1 Manifold Orifice Assembly 812SOL0500 2a Natural Gas Prejet 812SOL0034 2b Liquid Propane (LP) Gas Prejet 812SOL0001 Figure 28: Manifold Orifice Assembly...
  • Page 63 Heat Exchanger Assembly (SOL-500) Part Number Key No. Description Quantity SOL-500 Heat Exchanger 603SOL0510 Immersion Well 80160456 Inlet/Outlet Temp. Sensor 801SOL0010 Temp/Pressure Gauge 0-100PSI 103470-01 Temp/Pressure Gauge 0-200PSI 103470-02 Temp/Pressure Gauge 0-250PSI 103470-03 Water Flow Switch 80160175 Center Tube Baffles 718SOL0519 Front Tube Baffle 102269-02...
  • Page 64 Key No. Description Quantity Part Number 1. Electrical Panel SOL-500 Q7800H1009 Electrical Side Panel 704SOL0006 Q7800H1009 Honeywell Relay Module Circuit Board 101182-01 Relay Module Honeywell RM7897A1002 801602121 Flame Rectification Amplifier 80160207 Purge Card 8136362 Keyboard Display Module 80160640 Transformer, 120V Primary, 24V Secondary 801600502 Combustion Airflow Switch 102382-03...
  • Page 65 Part Number Description SOL-500 Base Panel Assembly 604SOL0511 Jacket, Rear Panel Assembly 604SOL0503 Exhaust CV Assembly 618SOL0001 Jacket, Right Side Panel Assembly 604SOL0504 Jacket, Left Side Panel Assembly 604SOL0505 Jacket, Top Panel Assembly 604SOL0506 Jacket Front Panel 704SOL0502 Insulation Box 820SOL0032 Intake Corner Vent Assembly 604SOL0508...

  • Page 66: Service Record

    SERVICE RECORD Date Service Performed...

  • Page 67: Refractory Ceramic Fiber

    Important Product Safety Information Refractory Ceramic Fiber Product Warning: This product contains refractory ceramic fibers (RCF). RCF has been classified as a pos- sible human carcinogen. After this product is fired, 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 hazard- ous to your health. AVOID Breathing Fiber Particulates and Dust Precautionary Measures: Do not remove or replace previously fired RCF (combustion chamber insulation, tar-...

  • Page 68: Limited Warranty

    Thermal Solutions, Seller warrants to the original owner G. Equipment furnished by the owner, either mounted or at the original installation site that products manufactured by unmounted, or when contracted for by the owner to be Seller (“Products”) comply, at the time of manufacture, the...

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