Commercial, condensing, high efficiency, direct vent, gas-fired, water boiler (160 pages)
Summary of Contents for Thermal Solutions EVCA SERIES
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Price - $3.00 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS EVCA SERIES CONDENSING BOILER 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.
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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.
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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.
A. Venting ..........10 B. Combustion Air ......... 15 VIII. Repair Parts ..........56 C. Water Treatment ........ 17 Thermal Solutions Boiler Control™ D. Water Piping and Trim ...... 18 (TSBC™) ........... 85 E. Gas Piping ........... 21 A. Introduction ........85 F.
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Notes: 1. Piping removed for visual clarity. 12.0 [304.8] REQUIREMENT 2. See notes concerning Net AHRI Ratings on page 4. FOR BURNER REMOVAL MANUAL MOUNTED LOW SHUT-OFF VALVE [76.2] 31.0 WATER CUT-OFF [787.4] GAS PILOT Ø.25 TUBE GAS SUPPLY GAS VENT .75 NPT PIPE 1 NPT 14.5...
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12.0 [304.8] REQUIREMENT MANUAL SHUT-OFF FOR BURNER VALVE MOUNTED LOW REMOVAL WATER CUT-OFF 31.0 [787.4] [76.2] GAS PILOT Ø.25 TUBE GAS VENT .75 NPT GAS SUPPLY PIPE 1.5 NPT 14.5 [368.7] SUPPLY TO SYSTEM, 2" VICTAULIC CONDENSATE DRAINS TO BE PIPED TO AN EXTERNAL TRAP FLUE OUTLET Ø6 SAF-T-VENT...
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REQUIREMENT FOR BURNER REMOVAL MANUAL SHUT-OFF VALVE MOUNTED LOW 40.8 WATER CUT-OFF [1036.3] GAS SUPPLY 2 NPT SUPPLY TO SYSTEM, 4 Victaulic FLUE OUTLET Ø8 SAF-T-VENT WATER INLET 4 NPT INLET AIR Ø8 GALVANIZED DUCT BOILER DRAIN 1 NPT PIPE 38.1 26.0 [968.2]...
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 Volume [ft³] = Length [ft] x Width [ft] x Height [ft] order can cause personal injury or death.
Thermal Solutions DOES NOT warrant and rodents. Louvers and grilles must be fixed in failures caused by incorrectly sized boiler open position or interlocked with equipment to applications.
III. Installation Vent pipe system must be adequately supported at A. VENTING intervals no less than five (5) feet apart. The completed vent system must be rigid and able to withstand impacts WARNING without collapse. Improper venting may result in property damage h.
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3. IMPORTANT ii. Minimum three (3) feet above any forced air inlet located within ten (10) feet of the vent termination. The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for iii. Minimum four (4) feet below, four (4) feet installation of side-wall vented gas appliances as follows: horizontally or one (1) foot above any door, window or gravity air inlet.
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INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4. B.
Thermal Solutions does not warrant failures 3. Combustion air conduit can be galvanized smoke caused by contaminated air. pipe, PVC, CPVC, or flexible aluminum conduit.
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Figure 5: Horizontal Air Intake Piping Figure 6: Vertical Air Intake Piping...
Table 1A 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 1A: Chemical Agents and Effects caused by oxygen contamination of boiler water.
Maintain ½" minimum distance between water CAUTION piping and combustible material. Failure to properly pipe boiler may result in d. Consult Thermal Solutions for unusual system improper operation and damage to boiler or requirements. structure. 3. Remove protective cap from boiler drain line located...
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supplier or local plumbing inspector on how best to WARNING control this situation. 12. A pressure relief valve is supplied with each boiler. No valve is to be placed between the relief valve and Failure to operate the unit with the proper water appliance.
be located as far away from the boiler as possible to GAS PIPING prevent nuisance shutdowns. WARNING a. The minimum and maximum inlet gas pressure must not exceed the value specified in Table 2. Failure to properly pipe gas supply to boiler may 3.
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6. Pressure test. The boiler and its gas connection must DANGER be leak tested before placing boiler in operation. a. Protect boiler gas control valve. For all testing Do not use matches, candles, open flames or over ½ psig, boiler and its individual shutoff other ignition source to check for leaks.
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TABLE 5 - 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"...
Each boiler may be 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.
f. Vertical air intake pipe must terminate at least MODULAR SYSTEMS two (2) feet above the closest portion of the roof. 1. General Guidelines g. IMPORTANT: Refer to the Combustion Air a. Read and follow all venting, combustion section for further warnings, cautions, notices air, water piping, gas piping and electrical and instructions.
3 - 5 on the pH with flue gas condensate for condensate piping. scale. Consult Thermal Solutions or a chemical treatment company for buffering systems. CAUTION Do not use material that is not approved for use with flue gas condensate for condensate piping.
Oxygen contamination of boiler water will cause CAUTION corrosion of iron and steel boiler components, and can lead to boiler failure. Thermal Solutions This boiler contains a manual gas shut-off valve Standard Warranty does not cover problems inside of the upper front jacket panel caused by oxygen contamination of boiler water.
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The relief valve setting must be above the maximum operating pressure of the system. 1. Allow boiler to complete prepurge and trial for Consult Thermal Solutions if the desired system ignition period. Once pilot flame is recognized by operating pressure is above the safety relief controller, position flame control switch to TEST valve pressure setting.
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temperature operating control, manual reset water WARNING temperature safety limit, vestibule fuseable link, mixer fuseable link, high and low gas pressure Failure to properly adjust gas input rate will switches. Refer to manuals for these components for result in over firing or under firing of the proper start-up and operating 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 .
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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, or any located on the burner control. If you do not know questionable boiler operation is noticed, immediately where the control reset button is, do not touch any turn off all gas and electrical power and call qualified...
VI. Boiler Operational Sequence Product Features Boiler Sequence Pre-Sequence States Start/Stop Sequence States BOILER STATE LCD Display Parameter / Notes b &c 54/d Boiler Disable or Remote On/Off Boiler Enable/Disable On Outdoor Air Temp > 44,30, O+,O- Warm Weather Shutdown Setpoint Domestic Hot Water Priority Domestic Hot Water Demand Monitored 20,74...
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Product Features Boiler Sequence (Continued) Pre-Sequence States BOILER CONTROL MODE STATE Description LCD Display LCD Display Any Mode Boiler Boiler is prevented from starting, Remote On/Off (Enable) (Terminal RO) Input is not (Except for Disabled energized. Remote Control) Warm Any Mode Boiler is prevented from starting, Warm Weather Shutdown (WWSD) is enabled and Weather (Except for...
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. CAUTION USE caution when servicing components behind upper front jacket panel. Filter/mounting bracket may cause head injury.
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™...
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.
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Call Factory Reset Memory Failure 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.
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.
D. INSPECTION AND CLEANING PROCEDURES the sediment chamber so the device will be free to function properly. Daily Boiler Inspection & Check 8. Inspect and replace air filter as needed. 1. Inspect the area to assure proper clearance from 9. Check high and low gas pressure switch interlocks. combustible materials, gasoline, and other flammable 10.
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Clean as required. valve body. 5. Reassemble in reverse order using a new gasket available from Thermal Solutions. C. Perform a visual inspection of main burner flame 1. Observe main flame and record flame signal. Flame color should be steady deep orange in color...
VIII. Repair Parts EVCA 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:...
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VIEW FRONT VIEW Figure 20: Burner Assembly...
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BURNER ASSEMBLIES (Quantity) Part Number Description EVCA-750 EVCA-1000 EVCA-1500 EVCA-2000 EVCA-3000 2. BURNER/ FAN ASSEMBLY Fan (three phase) 81156018 81156300 Air Filter 81156011 81156012 81156101 Pilot Assembly - Natural See Figure 27 -OR- Pilot Assembly -LP Mixer Assembly - Natural 60256209 60256210 60256211...
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Figure 21a: UL/FM/CSD-1 Main Gas Train Assembly (EVCA-750/2000)
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UL/FM/CSD-1 GAS TRAIN - MAIN AND PILOT (Quantity) Part Number Description EVCA-750 EVCA-1000 EVCA-1500 EVCA-2000 3. MAIN AND PILOT GAS TRAIN (UL/FM/CSD-1) Main Gas Valve Body, 1" 816634041 Main Gas Valve Body, 1½" 81663404 Manual Gas Valve with Pilot Tapping, 1" NPT 806603055 Manual Gas Valve with Pilot Tapping, 1½"...
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Figure 21b: UL/FM/CSD-1 Main Gas Train Assembly (EVCA-3000)
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UL/FM/CSD-1 Gas Train - Main and Pilot (Quantity) Key No. Description Part Number EVCA-3000 Main and Pilot Gas Train (UL/FM/CSD-1) Main Gas Valve Body, 2" NPT 816634043 Manual Gas Valve Body with Pilot Tapping, 2" NPT 806604691 Air/Gas Ratio Controller, Siemens SKP75 81663408 Solenoid Valve V4295A1064, 2"...
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Figure 22a: DB&B Gas Train (750) Figure 22b: DB&B Gas Train (1000-2000)
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DB&B – MAIN AND PILOT (Quantity) Part Number Description EVCA-750 EVCA-1000 EVCA-1500 EVCA-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 —...
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Figure 22c: DB&B w/POC Gas Train (750) Figure 22d: DB&B w/POC Gas Train (1000-2000)
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DB&B W/POC – MAIN AND PILOT (Quantity) Part Number Description EVCA-750 EVCA-1000 EVCA-1500 EVCA-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 —...
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Figure 22e: DB&B Gas Train (EVCA-3000) Figure 22f: DB&B w/POC Gas Train (EVCA-3000)
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DB&B AND DB&B W/POC - MAIN AND PILOT (Quantity) Part Number Description EVCA-3000 3. MAIN AND PILOT GAS TRAIN Main Gas Valve Body, DB&B, 2" NPT 816634043 Main Gas Valve Body, DB&B w/POC, 2" NPT 816634051 Manual Gas Valve with Pilot Tapping 80660491 DB&B Actuator/Regulator...
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PILOT ASSEMBLY (Quantity) Part Number Description EVCA-750 EVCA-1000 EVCA-1500 EVCA-2000 EVCA-3000 6. Pilot Assembly Pilot Assembly Natural Gas, ULX2 62356110 Pilot Assembly Propane, ULX2 62356210 7A Ultraviolet Sensor 8026145 Pilot Orifice Natural Gas 722606 Pilot Orifice Propane 722605 7C Pilot Air Orifice 722607 7D Cast-Iron Body 82361581...
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EVCA LOOP PIPING - MAJOR COMPONENTS (Quantity) Part Number Description EVCA-750 EVCA-1000 EVCA-1500 EVCA-2000 EVCA-3000 8. EVCA Loop Piping 1-Phase 120/208/230V — — ¼ HP Pump 805622005 3-Phase 208/230/460V — — ¼ HP Pump 805622006 1-Phase 120/208/230V — — ¾ HP Pump 805622007 3-Phase 208/230/460V —...
TSBC to learn more about the controllers features and capabilities. 1. Thermal Solutions Boiler Control™ Overview 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.
) 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...
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 Boiler Control (TSBC) Instruction manual for operation guidance and a detailed list of parameters and their associated access levels.
APPENDIX D (Cont…) - TSBC SETUP Menu SETUP MENU Factory Display Range/Choices Description Settings Specifies Warm Weather Shut-Down (WWSD) control of boiler and/or system pump. Off: Ignores Warm Weather setpoint WWSD of boiler: When Outside Air Temperature (OAT) is higher than the WWSD of Boiler WWSD setpoint, inhibits boiler start WWSD...
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EVCA Modulating Fire Test Procedures and Specifications APPENDIX D (Cont…) - TSBC SETUP Menu (continued) SETUP MENU Factory Display Range/Choices Description Settings Enables the Outside Air Temperature sensor display and control logic. Outside Air Input (O+O-) is ignored. Display Only: Do Not Calculate setpoint based on outdoor temperature, Outdoor Display Outside Air Temperature.
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EVCA Modulating Fire Test Procedures and Specifications (continued) SETUP MENU APPENDIX D (Cont…) - TSBC SETUP Menu Factory Display Range Description Settings Time modulation rate is held at present value (Low Fire Spd or Fan Purge Spd Fire 10 to 1200 (s) depending on the state and configuration of spare input) after the Fuel Valve Hold Energized Input (CS) is energized.
EVCA Modulating Fire Test Procedures and Specifications APPENDIX D (Cont…) - TSBC BOILER CONFIG Menu BOILER CONFIGURATION MENU Factory Range/ Display Description Setting Choices Deg F Display Deg F Selects how temperature parameter values are displayed. Deg C Units None: No Boiler Pump.
APPENDIX D (Cont…) – TSBC SYSTEM CONFIG Menu SYSTEM CONFIGURATION MENU Factory Description Display Range Settings Enables Domestic Hot Water Priority (DHWP) control feature. When input (DP) is energized DHWP becomes active as selected. Off: No DHWP. Isolated Demand: Boiler that receives the input (DP) drops off the Peer-To-Peer Isolated network and it’s temperature setpoint is adjusted above the DHWP Demand...
EVCA Modulating Fire Test Procedures and Specifications APPENDIX D (Cont…) - TSBC SETPOINTS Menu 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’...
APPENDIX D (Cont…) – TSBC COMMUNICATIONS Menu COMMUNICATION MENU Factory Description Display Range/Choices Settings Peer to Peer to Peer Selects between Peer-To-Peer (multiple boiler Lead/Lag control network) and a Protocol Peer Modbus Modbus slave communication. Each boiler must be given a unique address. Modbus 1 to 247 Address...
EVCA Modulating Fire Test Procedures and Specifications APPENDIX D (Cont…) - TSBC MANUAL MODE Menu MANUAL MODE MENU Factory Display Range/Choices Description Settings Man: Remain in Manual Mode. Boiler Auto: Return to Boiler Mode specified by parameter/boiler conditions. Auto Man/Auto Auto Activated only when in Supervisor Mode.
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...