Thermal Solutions EVO-1000 Installation, Operating And Service Instructions Download Page 1

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INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS

EVO SERIES BOILER

104492-01R1-4/13

Your Local Thermal Solutions Representative:

File Number MH25585

ON/OFF AND MODULATION, OUTDOOR

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

Serial Number

Type System

Heating Contractor

EVO -

Phone Number

Address

Installation Date

Summary of Contents for EVO-1000

Page 1: ...r MH25585 ON OFF AND MODULATION OUTDOOR A S M E H For Service and repairs to the heating plant call your heating contractor When seeking information on the boiler from the manufacturer provide boiler...

Page 2: ...s an imminently hazardous situation which if not avoided will result in death serious injury or substantial property damage CAUTION Indicates a potentially hazardous situation which if not avoided may...

Page 3: ...t any components of this boiler without positively assuring the water is cool and has no pressure Always wear protective clothing and equipment when installing starting up or servicing this boiler to...

Page 4: ...creases by 12 and the rear service clearance increases by 24 NOTE Verify clearance with local codes H Condensate Drains 38 IV System Start up 39 V Lighting Instructions 42 VI Boiler Operational Sequen...

Page 5: ...GE WATER FLOW SWITCH RELIEF VALVE 11 8 298 5 8 8 222 3 GAS SUPPLY 1 NPT BOILER DRAIN 1 NPT PIPE CONDENSATE DRAIN 5 8 TUBE FLUE OUTLET 4 SAF T VENT WATER RETURN FROM SYSTEM 3 NPT WATER SUPPLY TO SYSTEM...

Page 6: ...768 4 9 3 235 0 15 4 392 1 6 1 155 6 31 0 787 4 P T GAUGE WATER FLOW SWITCH RELIEF VALVE 11 8 298 5 10 0 254 0 BOILER DRAIN 1 NPT PIPE CONDENSATE DRAIN 5 8 TUBE FLUE OUTLET 6 SAF T VENT WATER RETURN F...

Page 7: ...1c Dimensions and capacities EVO 2000 61 4 1558 9 13 9 352 4 7 0 177 8 9 6 242 9 2 3 57 2 19 0 482 6 4 4 111 1 17 9 454 0 31 0 787 4 3 5 88 9 6 3 158 8 23 6 600 1 21 8 552 5 REQUIREMENT FOR BURNER REM...

Page 8: ...s of top of space Locate remaining opening within 12 inches of bottom of space Minimum dimension of air opening is 3 inches Size each opening per the following WARNING Carefully read all instructions...

Page 9: ...are inches 7 Ventilation Duct Louvers and Grilles Equip outside openings with louvers to prevent entrance of rain and snow and screens to prevent entrance of insects and rodents Louvers and grilles mu...

Page 10: ...ler flue collar the vent system must have adequate condensate drain loop s to prevent condensate from running back into the boiler i It is permissible to run vent pipe through a vertical or horizontal...

Page 11: ...acceptable for use with condensing flue gas c The minimum chimney vertical vent height is 15 feet d Install a condensate drain to collect any condensate that may form in the lined chimney vertical ve...

Page 12: ...12 Figure 3 Sidewall Positive Pressure Venting Optional Figure 2 Sidewall Positive Pressure Venting...

Page 13: ...13 Figure 4 Vertical Pressurized Venting...

Page 14: ...onal level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified...

Page 15: ...15 Figure 5 Typical Negative Pressure Conventional Venting...

Page 16: ...e termination must be located at least twelve 12 inches above grade plus the expected snow accumulation Figure 6 Horizontal Air Intake Piping 7 Boiler may be installed with vertical venting and sidewa...

Page 17: ...17 Figure 7 Vertical Air Intake Piping...

Page 18: ...the water Once all the impurities are identified the proper treatment plan can be established Therefore it will be essential to obtain the expertise of a qualified industrial water treatment professio...

Page 19: ...eaks 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 Isola...

Page 20: ...t high fire 40 DT at high fire Minimum Flow Rate gpm Maximum Flow Rate gpm Supply Return Pipe inch dia DP Ft Flow GPM DP Ft Flow GPM EVO 500 2 93 43 0 74 22 22 43 2 EVO 750 1 81 62 0 46 31 31 62 3 EVO...

Page 21: ...on in a closed water supply system Contact the water supplier or local plumbing inspector on how to correct this situation DO NOT PLUG THE RELIEF VALVE E GAS PIPING WARNING Failure to properly pipe ga...

Page 22: ...roperly regulate gas pressure flow at the lowest input of a single boiler If the regulator cannot do this two or more additional regulators are required Consult regulator manufacturer s instructions f...

Page 23: ...60 104 195 400 600 1160 1840 3260 6640 70 95 179 368 552 1060 1690 3000 6110 80 89 167 343 514 989 1580 2790 5680 90 83 157 322 482 928 1480 2610 5330 100 79 148 304 455 877 1400 2470 5040 125 70 131...

Page 24: ...Screwed Fittings Gate Globe Angle Swing Check 90 Elbow threaded 45 Elbow threaded 90 Tee Flow through Branch threaded 1 2 3 4 1 1 1 4 0 622 0 824 1 049 1 380 0 36 0 48 0 61 0 81 17 3 22 9 29 1 38 3 8...

Page 25: ...limits or devices using proper terminals provided in boiler electrical cabinet Refer to wiring diagram supplied with boiler for wiring information Refer to Figures 9a 9c for typical wiring diagrams R...

Page 26: ...26 Figure 9a Standard UL FM CSD 1 Wiring Diagram on off EVO 500 2000...

Page 27: ...27 Figure 9b Standard UL FM CSD 1 Wiring Diagram Modulation EVO 500 2000...

Page 28: ...section earlier in this manual a Positive Pressure Sidewall and Vertical Venting i Positive pressure vent systems cannot be manifolded together ii Positive pressure systems can be piped individually t...

Page 29: ...rmination center line below horizontal vent termination s center line f Vertical air intake pipe must terminate at least two 2 feet above the closest portion of the roof g Refer to the Combustion Air...

Page 30: ...30 Figure 11 Modular System Horizontal Air Intake Piping...

Page 31: ...31 Figure 12 Modular System Vertical Air Intake Piping...

Page 32: ...32 Figure 13 Modular System Typical One Pipe Water Piping...

Page 33: ...33 Figure 14 Modular System Typical Primary Secondary Water Piping...

Page 34: ...34 Figure 15 Modular System Typical Primary Secondary without System Pump...

Page 35: ...35 Figure 16 Modular System Typical Reverse Return Water Piping...

Page 36: ...36 Figure 17 Modular System Reverse Return with System Pump Only...

Page 37: ...37 Figure 18 Modular System Typical Primary Secondary with Reverse Return...

Page 38: ...condensate system will greatly reduce boiler life Do not install plugs caps or valves on condensate piping Do not manifold boiler condensate drains or vent drains together Do not crimp condensate line...

Page 39: ...wed 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 CAUTION This boiler contains a manual gas shu...

Page 40: ...Check Blower Rotation Remove air filter to expose the fan blades 1 Allow boiler to enter the sequence of operation 2 While in Pre Purge position the flame control to the test position 3 Confirm proper...

Page 41: ...dows do not cause the boiler to operate with carbon monoxide concentrations above 400 parts per million 6 Verify that all safety and operating limits and flame controls are operating properly These co...

Page 42: ...4 This appliance is equipped with an ignition device which automatically lights the pilot and main burner Do not try to light the pilot or main flame by hand 5 Remove front door panel 6 Locate the gas...

Page 43: ...ce is to be performed 3 Remove front door 4 Rotate gas main shutoff valves located inside the appliance clockwise from ON position to OFF Make sure handle rests against stop 5 Replace front door 6 At...

Page 44: ...by pilot flame Pilot and main flames are detected by ultraviolet scanner Flame signal continues to maintain 1 5 to 5 0 volts DC After 5 seconds pilot gas valve s is de energized Gas flow to pilot stop...

Page 45: ...d properly Never jump out or bypass any safety or operating control or component of this boiler Do not attempt to remove and or service the burner This may result in damage to the burner Read understa...

Page 46: ...wer is interrupted to the control circuit which prevents the boiler from operating Power is interrupted until the switch is replaced Vestibule Fuseable Link If the temperature in the interior of the v...

Page 47: ...47 This Page Intentionally Left Blank...

Page 48: ...48 Troubleshooting Guide B Troubleshooting Guide...

Page 49: ...49 Troubleshooting Guide...

Page 50: ...s pressure interlocks Test high and low gas pressure interlocks Water condition Test condition of water correct condition as needed Semi Annual Maintenance Gauges monitors and indicators Recalibrate a...

Page 51: ...gnal Flame should be steady deep orange in color with dark blue checkerboard pattern throughout 2 Main burner requires no cleaning or annual maintenance Main Burner A When properly maintained and oper...

Page 52: ...your Representative at Thermal Solutions Products LLC 1175 Manheim Pike Lancaster Pennsylvania 17601 Telephone 717 239 7642 Fax 877 501 5212 toll free www thermalsolutions com WARNING The repair parts...

Page 53: ...53 This Page Intentionally Left Blank...

Page 54: ...54 Figure 19 Combustion Chamber Assembly...

Page 55: ...stion Pan Support 4 603561061 4 603562041 4 603562051 4 603562061 4 603562071 1I Heat Exchanger Wrapper 1 70356119 1 70356219 1 70356220 1 70356221 1 70356222 1J Heat Exchange Baffle 1 70356235 1 7035...

Page 56: ...56 Figure 20 Burner Assembly FRONT VIEW TOP VIEW...

Page 57: ...1 60256210 1 60256211 1 60256212 Mixer Assembly LP 1 602561061 1 60256213 1 60256214 1 60256215 1 60256216 2E Burner Element 1 TS500CF GBNR 1 TS750CF GBNR 1 TS1000CF GBNR 1 TS1500CF GBNR 1 TS2000CF G...

Page 58: ...58 Figure 21 UL FM CSD 1 Main Gas Train Assembly...

Page 59: ...22758 3F Pilot Regulator 1 822702 3G High Pressure Switch 1 80160333 3H Low Pressure Switch 1 80160332 EVO Modulating UL FM CSD 1 Key No Description Quantity Part Number EVO 500 EVO 750 EVO 1000 to 20...

Page 60: ...60 Figure 22a DB B DB B w POC Gas Train 500 750 Figure 22b DB B DB B w POC Gas Train 1000 2000...

Page 61: ...3G High Pres Switch 1 80130333 3H Low Pres Switch 1 80160332 3I Vent Valve N O 1 81660748 EVO Modulating DB B w POC Proof of Closure Key No Description Quantity Part Number EVO 500 to 750 EVO 1000 to...

Page 62: ...62 Figure 23 Jacket Panels 4D 4J 4C 4B 4F 4I 4G 4E 4R 4K 4H 4J 4N 4M 4L 4Q 4A 4P 4P...

Page 63: ...456328 1 60456329 1 60456330 1 60456331 1 60456332 4F Jacket Top Panel 1 7056254 4G Jacket Vestibule Panel 1 60456301 1 60456302 4H Jacket Upper Front Panel 1 70456252 4I Jacket Panel Right Side 1 604...

Page 64: ...64 Figure 24a Control Panel Assembly On Off...

Page 65: ...ng Limit L4008A1015 Auto Re set max 240F 1 80160626 Operating Limit L4008A1242 Auto Re set max 200F optional 1 80160659 5F High Limit L4008E1313 Manual Reset max 240F 1 80160667 High Limit L4008E1313...

Page 66: ...66 Figure 24b Control Panel Assembly Modulation...

Page 67: ...perating Limit Digital Modbus RWF40 optional 1 80160908 5F High Limit L4008E1305 Manual Reset max 240F 1 80160667 High Limit L4008E1313 Manual Rest max 200F optional 1 80160660 5G Water Flow Switch FS...

Page 68: ...68 Figure 25 Bishop Pilot Assembly...

Page 69: ...Assembly Propane LUX2 1 62356210 7A Ultraviolet Sensor 1 8026145 7B Pilot Orifice Natural Gas 1 722606 Pilot Orifice Propane 1 722605 7C Pilot Air Orifice 1 722607 7D Cast Iron Body 1 82361581 7E Igni...

Page 70: ...to an alternate set point through an external signal for low load conditions i e weekend use night setback Outdoor reset is another standard feature allowing the boiler operating temperature to vary b...

Page 71: ...light above manual operation hand symbol illuminates Press button to raise firing rate Press button to lower firing rate 0 50 of Maximum firing rate and 100 100 of Maximum firing rate Press EXIT butto...

Page 72: ...72 NOTES...

Page 73: ...73 NOTES...

Page 74: ...74 NOTES...

Page 75: ...75 NOTES...

Page 76: ...eratures or the influence of foreign matter or energy D The design or operation of owner s plant or equipment or of any facility or system of which any Product may be made a part E The suitability of...

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