Water Piping And Trim - Thermal Solutions EVS SERIES Installation, Operating And Service Instructions

D.

WATER PIPING AND TRIM

CAUTION
Failure to properly pipe boiler may result in
improper operation and damage to boiler or
structure.
All piping either new or existing must be cleaned
with a tri sodium phosphate (TSP) solution to
remove mill scale and oils from the system.
Failure to do so could result in premature failure
of the heat exchanger (not covered by Thermal
Solutions Standard Warranty).
On an existing or retrofit system, a filter or
strainer must be installed on the system return
prior to the boilers.
Return water temperature below 120°F will cause
flue gas condensation inside the boiler. Flue gas
condensate can lead to boiler failure. Thermal
Solutions Standard Warranty does not cover
problems caused by flue gas condensation.
Supply and return water temperature differences
greater than 40'F at high fire can lead to boiler
failure. Thermal Solutions Standard Warranty
does not cover problems caused by temperature
differences greater than 40°F at high fire.
1. Design and install boiler and system piping to
prevent oxygen contamination of boiler water and
frequent water additions.
a. There are many possible causes of oxygen
contamination such as:
i. Addition of excessive make-up water
as a result of system leaks.
ii. Absorption through open tanks and fittings.
iii. Oxygen permeable materials in the
distribution system.
b. In order to insure long product life, oxygen
sources must be eliminated. This can be
accomplished by taking the following measures:
i. Repairing system leaks to eliminate the need
for addition of make-up water.
ii. Eliminating and/or repairing fittings which
allow oxygen absorption.
iii. Using of non-permeable materials in the
distribution system.
iv. Isolating the boiler from the system water by
installing a heat exchanger.
v.
Using properly designed and operating air
elimination devices in water piping.
2. Connect system supply and return piping to boiler.
a. Refer to Figure 8.
b. Consult I=B=R Installation and Piping Guides.
c. Maintain ½" minimum distance between water
piping and combustible material.
d. Consult Thermal Solutions for unusual system
requirements.
Support weight of system piping adequately.
e. Design and install system piping to prevent
return water temperatures below 120°F. Refer
to Table 2 for boiler flow and pressure drop
requirements.
3. Remove protective cap from boiler drain line
located in the rear of the boiler .
4. Install drain valve in the boiler drain line at bottom
rear of the boiler.
5. If this boiler is used in connection with refrigeration
systems, the boiler must be installed so that the
chilled medium is piped in parallel with the boiler
using appropriate valves to prevent the chilled
medium from entering the boiler. Also consult
I=B=R Installation and Piping Guides. If this boiler
is connected to heating coils located in air handling
units where they may be exposed to refrigerated air,
the boiler piping must be equipped with flow control
valves to prevent gravity circulation of boiler water
during operation of the cooling system.
6. Install optional low water cut-off in system piping
above the boiler, if not shipped with boiler. On
EVS-500 through -2000 boilers, a low water cut-
off may be installed on the boiler at the factory as
an option. A factory-mounted low water cut-off is
standard on all EVS-2000S, 2500 & 3000 boilers.
7. Install an air eliminating device to remove air from
the system.
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CAUTION