45
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 temperature is cool
before attempting any disassembly or service.
More than one gas shut-off valve and electrical disconnect switch are used on the boiler. Assure that all
gas valves and electrical disconnect switches are off 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.
Never modify, remove or tamper with any control device.
WARNING
This boiler must only be serviced and repaired by skilled and experienced service technicians.
If any controls are replaced, they must be replaced with identical models.
Read, understand and follow all the instructions and warnings contained in all the sections of this
manual.
If any electrical wires are disconnected during service, clearly label the wires and ensure that the wires
are reconnected 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, understand and follow all the instructions and warnings contained in ALL of the component
instruction manuals.
Assure that all safety and operating controls and components are operating properly before placing the
boiler back in service.
CAUTION
USE caution when servicing components behind upper front jacket panel. Filter/mounting bracket may
cause head injury.
WARNING
The service instructions contained in this manual are in addition to the instructions provided by the
manufacturer of the boiler components. Follow component manufacturer’s instructions. Component
manufacturer’s instructions were provided with the boiler. Contact component manufacturer for
replacement if instructions are missing. 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.
VII. Service
Summary of Contents for EVO-1000
Page 13: ...13 Figure 4 Vertical Pressurized Venting...
Page 15: ...15 Figure 5 Typical Negative Pressure Conventional Venting...
Page 17: ...17 Figure 7 Vertical Air Intake Piping...
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 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 47: ...47 This Page Intentionally Left Blank...
Page 48: ...48 Troubleshooting Guide B Troubleshooting Guide...
Page 49: ...49 Troubleshooting Guide...
Page 53: ...53 This Page Intentionally Left Blank...
Page 54: ...54 Figure 19 Combustion Chamber Assembly...
Page 56: ...56 Figure 20 Burner Assembly FRONT VIEW TOP VIEW...
Page 58: ...58 Figure 21 UL FM CSD 1 Main Gas Train Assembly...
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 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 64: ...64 Figure 24a Control Panel Assembly On Off...
Page 66: ...66 Figure 24b Control Panel Assembly Modulation...
Page 68: ...68 Figure 25 Bishop Pilot Assembly...
Page 72: ...72 NOTES...
Page 73: ...73 NOTES...
Page 74: ...74 NOTES...
Page 75: ...75 NOTES...