Thermal Solutions SOLARIS Installation, Operating And Service Instructions
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Thermal Solutions SOLARIS Installation, Operating And Service Instructions

Gas-fired boiler
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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
Gas-Fired Boiler
For service or repairs to boiler, call your heating contractor. When seeking information on boiler,
provide Boiler Model Number and Serial Number as show on Rating Label.
Boiler Model Number
SOL __ __ __ __ - __ __ __
Heating Contractor
Address
84SOL000-8/09
SOLARIS
Boiler Serial Number
6 __ __ __ __ __ __ __
Installation Date
Phone Number
Price - $5.00


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  • Page 1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR SOLARIS Gas-Fired Boiler For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as show on Rating Label. Boiler Model Number Boiler Serial Number...
  • 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 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 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

    Table of Contents Pre-Installation ..........6 VIII. System Start-up ........... 39 II. Unpack Boiler ........... 7 IX. Service and Maintenance ....... 46 III. Venting/Air Intake Piping ........ 8 A. Periodic Maintenance ......46 A. Vent Guidelines Due to Removal of an B.

  • Page 6: Pre-Installation

    (through open- boiler cycling and accelerated component ings not furnished with doors) are considered part of failure. Thermal Solutions DOES NOT space. warrant failures caused by mis-sized boiler Volume [ft³] = Length [ft] x Width [ft] x Height [ft] applications.

  • Page 7: Unpack Boiler

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

  • Page 8: Venting/Air Intake Piping

    III. Venting / Air Intake Piping WARNING Do not use this boiler with galvanized, non metallic or any other venting material that is not de- signed for condensing flue gas applications. Do not use a drafthood with this appliance. Do not use vent dampers with this boiler. 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 1. Vent system installation must be in accordance with pipe plus equivalent length of fittings). Maximum Part 7, Venting of Equipment of the National Fuel vent/air lengths are listed in Table 1.

  • Page 10: Supplemental Vent Terminal Location Instructions

    C. Supplemental Vent Terminal Location In- e. Minimum of four (4) feet horizontally from, and in no case above or below, unless a 4 foot hori- structions (Massachusetts Code Only) zontal distance is maintained from electric me- The Commonwealth of Massachusetts requires compli- ters, gas meters, regulators and relief equipment.

  • Page 11: Separate Horizontal Venting System

    the inspector observes carbon monoxide detectors and (e) A copy of all installation instructions for all Product signage installed in accordance with the provisions of Approved side wall horizontally vented gas fueled 248 CMR 5.08(2)(a)1 through 4. equipment, all venting instructions, all parts lists for (b) EXEMPTIONS: The following equipment is exempt venting instructions, and/or all venting design instruc- from 248 CMR 5.08(2)(a)1 through 4:...
  • Page 13 Figure 5: Side Vent...

  • Page 14: Optional 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 1. 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 a. The minimum chimney height is 15 feet. 2. Do not exceed maximum air intake length. See Table 1. b. The chimney must be protected from down 3. Use single wall metal pipe and fittings or thin wall PVC drafts, rain and debris by using a chimney cap or available at most heating distributors.

  • Page 17: Separate Vertical Venting System

    H. Separate Vertical Venting System - See Figures 9, 10, and 11. with straps or supports no less than five (5) feet Vertical Venting – apart on horizontal runs. The complete air intake 1. Do not exceed maximum vent lengths. Refer to piping system must be rigid and able to withstand Table 1.
  • Page 18 Figure 9: Vertical Vent Installation...
  • Page 19 Figure 0: Attic Offset Figure : Indoor Air - Horizontal / Vertical Vent Terminal Installation Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve () inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation.

  • Page 20: Water Piping And Trim

    Piping Guides. Maintain ½” minimum distance between water piping and combustible material. a. There are many possible causes of oxygen con- Consult Thermal Solutions for unusual system tamination such as: requirements. 4. A pressure relief valve is supplied with each appli- Addition of excessive make-up water as a ance.
  • Page 21 Table 2. Boiler tube erosion and pitting will boiler when any connected heat distributor (radia- tion) is installed below the top of the hot water occur. Thermal Solutions Standard War- boiler (i.e. baseboard on the same floor level as the ranty does not cover problems caused by boiler).
  • Page 22 Table 2 - Solaris Boiler Flow and Pressure Drop 20° ΔT (max) 40° ΔT (min) Boiler Flow Flow Supply/Return Model Δ P (ft) (GPM) Δ P (ft) (GPM) Pipe (in. dia.) SOL-300 SOL-500 SOL-750 SOL-1000 16.1 SOL-1250 23.5 SOL-1500 29.1 10.6...
  • Page 23 Figure : Safety & Drain Valve Installation Figure  A: Recommended Piping for Combination Heating & Cooling (Refrigeration) System...

  • Page 24: 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 boiler For specific gravity greater than 0.70, apply gravity may result in improper operation and dam- factor from Table 4.
  • Page 25 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 *  CFH of Natural Gas is approximately equal to  MBH.

  • Page 26: Electrical

    VI. Electrical DANGER Positively assure all electrical connections are unpowered before attempting installation or ser- vice of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm. Electrical power may be from more than one source.
  • Page 27 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 28 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 boiler jacket, junction boxes and/or control boxes. 3.

  • Page 29: Modular Installations

    Refer to National Fuel Gas Code to determine required chimney diameter and common vent- Thermal Solutions recommends sizing each boiler in a ing diameter. Note that combined input, lateral modular system to provide 20 % of the combined heat- length and chimney height affect vent diameter.
  • Page 30 Water Piping 1. Refer to Figures 20 through 25 for typical water pip- ing installation details for modular boilers. 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 boiler.
  • Page 31 Figure : Modular Boiler Conventional Venting Figure 8: Modular Boiler Horizontal Air Intake Piping...
  • Page 32 LISTED IN TABLE 1. Figure 9: Modular Boiler Vertical Air Intake Piping...

  • Page 39: 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 met the full port ball valve in the system supply piping. with gas manifold and control assembly provided on (Note - Terminate hose in five gallon bucket at a boiler when boiler underwent tests specified in Ameri- suitable floor drain or outdoor area).
  • Page 40 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 boiler. 9. Check that boiler gas piping, valves, and all other components are leak free using a soap solution or a similar non-combustible solution, electronic leak Figure : Pilot Burner/Main Burner Flame...

  • Page 41: 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. Do not try to light the pilot by ment. hand.
  • Page 42 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 5 Type plate...
  • Page 43 Figure 9: Sequence of Operation...
  • Page 44 If the boiler is still over fired, contact the low water cutoff probe. Verify limit, thermostat your Thermal Solutions representative. or other controls have not shut off the boiler. b. If the measured value is less than 98% of the 4.
  • Page 45 with the values given on the factory fire test report supplied with the boiler. 7. Return gas fired appliances to previous conditions of use. S. Review user’s information manual and system Op- eration with owner or operator. Table 7: Gas Flow Rate in Cubic Feet Per Hour Size of Gas Meter Dial Seconds One-Half...

  • Page 46: Service And Maintenance

    IX. Service and Maintenance DANGER This boiler 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 tempera- ture is cool before attempting any disassembly or service. Do not attempt any service work if gas is present in the air in the vicinity of the boiler.
  • Page 47 pipe, fittings, and joints. 1/2 inch of sensing probe. If flame is yellow and lazy, follow instructions TO TURN OFF GAS a. Clean terminal screens. Terminals must be free TO APPLIANCE (see Figure 27), and contact of obstruction, undamaged, with screens securely qualified agency.
  • Page 48 sor wire, ground wire and gas valve wiring. 14. Install air box cover and attachment hard- ware. 15. Install front door. 6. Check Operation . Follow steps from Section VIII for system start-up. WIRE BRUSH SOFT BRISTLE BRUSH Figure 0: Cleaning Boiler Flue Passages...

  • Page 49: Safety & Operating Controls

    0-10 VDC or 4-20 ma signal from the Digital Temperature Control- ler. The Thermal Solutions Sage Boiler Control™ (SBC™) is a complete boiler and automa- Thermal Solutions tion system. It provides advanced boiler modulation control, operating control, diagnostics, Sage Boiler Control™...

  • Page 50: Trouble Shooting

    C. Trouble Shooting Guide Alarm Messages are shown one at a time in priority order. The message closes 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...
  • Page 51 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 52: Sage Boiler Control

    X. Sage Boiler Control (SBC A. INTRODUCTION: The intent of this section is to briefly perature sensor failure, the SBC will automatically summarize the controllers capabilities, familiarize the user switch to boiler outlet temperature sensor based with its basic features and to list factory supplied default control.

  • Page 53: Front Panel Display

    A factory configured RS485 Modbus interface is available for Energy Management System (EMS) or SCADA system monitoring and control. B. FRONT PANEL DISPLAY POWER LED (Steady On Green LED) indicates power is available down stream of the Electronic Control Module’s on board fuse. (Flashing On Green LED) indicates manual mode operation for boiler modulation, Call For Heat, and/or mixing valve modula tion.

  • Page 54: Setup Menu

    C. SETUP MENU Factory Description Display Range/Choices Settings WWSD Specifies Warm Weather Shut-Down (WWSD) control of boiler and/or system pump: Ignores Warm Weather setpoint WWSD of Boiler When Outside Air Temperature (OAT) is higher than the WWSD setpoint, inhibits boiler start WWSD of Sys When OAT is higher than the WWSD setpoint de-energize System Pump output (SO) WWSD...
  • Page 55 C. Setup Menu (Continued) Factory Display Range/Choices Description Settings Local PID I Local Integral Gain value for boiler outlet temperature sensor control Modes. A smaller value makes the 0 to 10000 PID I Integral ramp in less time (i.e.., faster). Integral is a secondary PID modulation rate tuning adjustment that ramps the output over time (typically minutes).

  • Page 56: Boiler Configuration Menu

    D. Boiler Configuration Menu Factory Display Range/Choices Description Setting Display °F Display Units °F Units °C Selects how temperature parameter values are displayed. Boiler Pump None No Boiler Pump. Always On Pump Runs Continuously. Boiler None Purge Pump Runs during pump pre/post purge operations and during call for heat and then turns off. Pump Lead boiler’s pump runs continuously when the boiler is the lead boiler and revers to “Purge”...

  • Page 57: System Configuration Menu

    E. 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. Boiler that received the input (DP) drops off the Peer-To-Peer network and its temperature setpoint Isolated is adjusted above the DHWP setpoint.

  • Page 58: Setpoints Menu

    F. 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 boiler starts when the water temperature drops “On Point”...

  • Page 59: Communication Menu

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

  • Page 60: Security Menu

    I. Security Menu Passwords There are three Access Levels in the system: Basic, Supervisor, and Factory. • At the BASIC Access Level, the user can view many parameters, but is only allowed to edit a small sub-set of the parameters that are visible. •...

  • Page 61: 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 62 Figure : Burner Tray No. Description Part Number 1. Burner Tray 1 3 Burner Assembly 102017-01 2 Ignitor Assembly 812SOL0010 3 Gasket, Burner Mounting Plate 820SOL0004 4 Gasket, Ignitor Assembly 820SOL0005...
  • Page 63 Figure : Gas Train (SOL-00) (Reference Table 8)
  • Page 64 SIDE VIEW OF GAS VALVE Figure 4: Gas Trains (SOL-500 through SOL-500) (Reference Table 8)

  • Page 66: Model

    Manifold Orifice Assembly Boiler Model Description SOL-300 SOL-500 SOL-750 SOL-1000 SOL-1250 SOL-1500 1 Manifold Orifice Assembly 812SOL0200 812SOL0500 812SOL0700 812SOL1000 812SOL1200 812SOL1500 2a Natural Gas Prejet 812SOL0034 2b Liquid Propane (LP) Gas Prejet 812SOL0001 Figure 35: Manifold Orifice Assembly...
  • Page 67 Heat Exchanger Assembly (SOL-300 & 500) Part Number Key No. Description Quantity SOL-300 SOL-500 Heat Exchanger 603SOL0210 603SOL0510 Immersion Well 80160456 Inlet/Outlet Temp. Sensor 801SOL0010 Temp/Pressure Gauge 0-100PSI 8056248 Temp/Pressure Gauge 0-200PSI 8056249 Temp/Pressure Gauge 0-240PSI 8056250 Water Flow Switch 80160175 Tube Baffles 718SOL0219 718SOL0519...
  • Page 68 Part Number Key No. Description SOL-750 SOL-1000 SOL-1250 SOL-1500 Heat Exchanger 102499-01 102499-02 102499-03 102499-04 Tube Baffle 718SOL0719 718SOL1019 718SOL1219 718SOL1519 Inlet/Outlet Temp Sensor 801SOL0010 Hose Banding 924660281 Hose Clamp 80860491 Fiberglass Tape Gasket 9206032 Figure 37: Heat Exchanger Assembly (SOL-750 through 1500)
  • Page 69 Key No. Description Quantity Part Number 1. Electrical Panel 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 71: Service Record

    SERVICE RECORD Date Service Performed...
  • Page 72 SERVICE RECORD Date Service Performed...
  • Page 73 SERVICE RECORD Date Service Performed...

  • Page 74: 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.

  • Page 75: 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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