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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:
102667-01-10/13
SERVICE INSTRUCTIONS
Serial Number
File Number MH25585
1
Price - $3.00
A
S
Type System
Phone Number
M
E
H
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Table of Contents
Related Manuals for Thermal Solutions EVS SERIES
Summary of Contents for Thermal Solutions EVS SERIES
- Page 1 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 Serial Number Type System EVS - Heating Contractor Address Phone Number Your Local Thermal Solutions Representative: 102667-01-10/13...
- 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.
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Page 4: Table Of Contents
C. Water Treatment ......19 VIII. Repair Parts ......... 57 D. Water Piping and Trim ....20 E. Gas Piping ........22 Thermal Solutions Boiler Control™ ..(TSBC™) ..........72 F. Electrical ......... 26 Warranty ........ Back Cover G. Modular Systems ......33... -
Page 5: Boiler Model
[158.8] REQUIREMENT 10.0 FOR BURNER [254.0] 31.0 [235.0] [88.9] REMOVAL [787.4] Notes: GAS SUPPLY 1" NPT GAS PILOT 1. Piping removed GAS VENT " TUBE " NPT PIPE for visual clarity RELIEF VALVE WATER RETURN (rear view). FROM SYSTEM 2" NPT WATER FLOW EVS-500 WATER SUPPLY... - Page 6 [158.8] REQUIREMENT 10.0 FOR BURNER [254.0] 31.0 [235.0] [88.9] REMOVAL [787.4] GAS PILOT GAS VENT Notes: " TUBE " NPT PIPE 1. Piping removed RELIEF VALVE WATER RETURN for visual clarity EVS-1000 FROM SYSTEM 3" NPT WATER FLOW (rear view). 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 for visual clarity WATER RETURN FROM SYSTEM 3" NPT WATER FLOW EVS-2000 WATER SUPPLY (rear view).
- Page 8 REQUIREMENT FOR BURNER REMOVAL [215.1] 11.5 40.8 [292.1] [126.2] [1036.3] [102.4] Notes: GAS PILOT GAS SUPPLY 2" NPT " TUBE 1. Piping removed GAS VENT 1" NPT PIPE for visual clarity RELIEF VALVE WATER RETURN WATER FLOW (rear view). EVS-2500 26.3 FROM SYSTEM 4"...
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Page 9: 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 10: 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 11: Installation
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 If any point of the vent pipe system is higher than the and the release of flue gasses which contain boiler flue collar, the vent system must have adequate... - Page 12 adjoining floor or ceiling. Maintain minimum clearance used. Chimney lining must be acceptable for use with to combustible materials. condensing flue gas. p. Locate vent terminal above combustion air intake The minimum chimney/vertical vent height is 15 feet. terminal (if used) and no closer than one (1) foot d.
- Page 13 Figure 2: Sidewall Positive Pressure Venting Figure 3: Sidewall Positive Pressure Venting (Optional)
- Page 14 Figure 4: Vertical Pressurized Venting...
- Page 15 a hard wired carbon monoxide detector with an used in whole or in part for residential purposes. alarm and battery back-up is installed on the floor c. MANUFACTURER REQUIREMENTS - GAS level where the gas equipment is to be installed. In EQUIPMENT VENTING SYSTEM PROVIDED.
- Page 16 Figure 5: Typical Negative Pressure (Conventional) Venting...
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Page 17: 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 18 Figure 7: Vertical Air Intake Piping...
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Page 19: 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 20: 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 21 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...
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Page 22: Gas Piping
. GAS PIPING WARNING WARNING Failure to operate the unit with the proper water flow rate can lead to appliance failure. Always Failure to properly pipe gas supply to boiler may verify proper water flow switch operation so that result in improper operation and damage to the the unit stops operating if improper water flow is boiler or structure. - Page 23 4. Use thread joint compound resistant to the action of boiler from gas supply piping by closing the liquefied petroleum gas. boiler's individual manual shutoff valve. b. Locate leaks using approved combustible WARNING gas detector, soap and water, or similar nonflammable solution.
- Page 24 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 25 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"...
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Page 26: 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 27 Figure 9a: 208/230/460V-1/3 ph-60 Hz Supply Power Wiring Schematic...
- Page 28 Figure 9b: 120V-1ph-60Hz Supply Power Wiring Schematic...
- Page 29 Figure 9c: Standard UL/FM/CSD-1 Wiring Diagram (EVS 500-2000)
- Page 30 GND TO Q7800H1009 INTERNAL WIRING CHASSIS 120V-1PH-60HZ FUSE SEE FIG. 9A-9B FOR SUPPLY POWER WIRING MM 750- MT-120 BURNER LOW WATER SENSE VESTIBULE THERMAL FUSE CUTOFF ALARM RELAY K2 THERMAL FUSE OPTIONAL OPTION SENSE (SEE NOTE 1) LOW WATER CUTOFF ALARM SILENCE PUSH BUTTON BURNER ON/OFF SWITCH...
- Page 32 FLAME SAFEGUARD SUBBASE HEAT PROGRAMMER CONTROL RM7896D 1027 Pin 7 Pin 1 24VAC - 24VAC + 115V TO 24V TRANSFORMER GND TO THERMAL SOLUTIONS CHASSIS BOILER CONTROL (TSBC) 24VAC - FUSE 24VAC + OUTLET SENSOR COMBUSTION BLOWER SPEED CONTROL INLET...
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Page 33: 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 34 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.
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Page 43: 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 44: 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 45 The relief valve setting must be above test position. the maximum operating pressure of the system. Consult Thermal Solutions if the desired system 3. Confirm proper blower motor rotation. operating pressure is above the safety relief valve pressure setting. Do not plug or change 4.
- Page 46 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...
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Page 47: 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 48 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...
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Page 49: Boiler Operational Sequence
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... - Page 50 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...
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Page 51: 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 52: Component Function
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 53 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 54 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.
- Page 55 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.
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Page 56: Main Burner
Clean as required. Remove pipe plugs in header and inspect inside 5. Reassemble in reverse order using a new gasket of copper tubes and header. available from Thermal Solutions. Flush boiler and mechanically remove any Burner Flame: scale. A. Perform a visual inspection of main burner flame. -
Page 57: Repair Parts
VIII. Repair Parts 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 58 Figure 19: Combustion Chamber Assembly...
- Page 60 VIEW FRONT VIEW Figure 20: Burner Assembly...
- Page 62 Figure 21: UL/FM/CSD-1 Main Gas Train Assembly...
- Page 63 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 64 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 65 Figure 22b: DB&B Gas Train (500-750) Figure 22c: DB&B Gas Train (1000-2000)
- Page 66 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 67 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 68 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 69 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...
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Page 72: (Tsbc™)
idec RH1 B-U RH1 B-U RH1 B-U RJ 1 S-CD O M RO N O M RO N D C1 2V D C1 2V D C1 2V -D 1 2 M Y2 M Y2 1 2VD C 1 2VD C I D EC I D EC I D EC... - Page 73 Control Transformer (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)
- Page 74 Figure 25: Pilot Assembly (Bishop Design)
- Page 75 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 76 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.
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Page 77: Thermal Solutions Boiler 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... - Page 79 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.
- Page 80 EVS Fire Test Procedures and Specifications 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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Page 81: Setup Menu
EVS 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 Only Display Outside Air Temperature... - Page 82 EVCA Modulating Fire Test Procedures and Specifications APPENDIX D (Cont…) - TSBC SETUP Menu (continued) 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.
- Page 83 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.
- Page 84 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...
- Page 85 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’...
- Page 86 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...
- Page 87 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.
- Page 88 NOTES...
- Page 89 NOTES...
- Page 90 NOTES...
- Page 91 NOTES...
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Page 92: 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...