Thermal Solutions EVCA SERIES, Installation, Operating And Service Instructions

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CAUTION
Failure to properly pipe boiler may result in
improper operation and damage to boiler or
structure.
Oxygen contamination of boiler water will cause
corrosion of iron and steel boiler components,
and can lead to boiler failure. Thermal Solutions
Standard Warranty does not cover problems
caused by oxygen contamination of boiler water.
Proper water treatment is required to avoid scale
build-up on the inside of the boiler. Thermal
Solutions standard warranty does not cover
problems caused by scale build-up.
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 warranty).
On an existing or retrofit system, a filter or
strainer must be installed on the system return
prior to the boilers.
When using Glycol products, all Glycol manu-
factures' requirements, including rust inhibitors,
must be adhered. Max 50% Glycol.
A.
System Check
1. Verify that the venting, water piping, gas piping and
electrical system are installed properly. Refer to
installation instructions contained in this manual.
WARNING
Completely read, understand and follow all
instructions in this manual, Honeywell flame
safeguard, and all other component manuals
supplied with this boiler before attempting start
up.
2
. Confirm all electrical, water and gas supplies are
turned off at the source and that chimney/vent
is clear of obstructions. If boiler is controlled by
an external control system, this system must be
temporarily disconnected. The local boiler controls
should be allowed to operate the boiler.
3
. Remove the upper front jacket panel.
4
. Confirm that all manual shut-off gas valves between
the boiler and gas supply are closed.
B
. Pressurize the Hydronic System - fill entire heating
system with water and vent air from system. Use the
following procedure on a Series Loop or multi-zoned
system installed to remove air from the system while
filling.
1. Close full port ball valve in boiler supply piping.
2. Isolate all zones by closing zone valves or shut-off
valves in supply and return of each zone(s).
3. Attach a hose to the hose bib in system piping and
terminate hose in a five gallon bucket at a suitable
floor drain or outside area.
4. Starting with one circuit at a time, open zone valve
or shut-off valve in system supply and return piping.
a. Open hose bib.
b. Open fill valve (Make-up water line should be
located directly after full port ball valve in system
supply piping between air scoop and expansion
tank).
c. Allow water to overflow from bucket until
discharge from hose is bubble free for 30 seconds.
d. Close the opened zone valve or shut-off valve for
the zone being purged of air, then open the zone
valve or shut-off valve for the next zone to be
purged. Repeat this step until all zones have been
purged. At completion, open all zone valves or
shut-off valves.
5. Close hose bib, continue filling the system until the
pressure gauge indicates required system operating
pressure. Close fill valve.
(Note - if make-up water line is equipped with
pressure reducing valve, system will automatically
fill to set pressure. Follow fill valve manufacturer's
instructions).
6. Open isolation valve in boiler supply piping.
7. Remove hose from hose bib.
8. Confirm that the boiler and system have no water leaks.
CAUTION
For the EVCA-3000, do not open or adjust mixing
valve actuator rotating knob at the top of the
actuator. This will affect proper boiler operation.
IV. System Start-up
WARNING
Prior to pressurizing the boiler water supply
system, be sure the boiler piping air vent is
properly installed. Refer to water piping section
of this manual.
CAUTION
This boiler contains a manual gas shut-off valve
inside of the upper front jacket panel