Thermal Solutions EVO-1000, Installation, Operating And Service Instructions

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D. Inspection and Cleaning Procedures
Air Filter:
A. Perform a visual inspection of air filter and
replace as necessary.
1. Remove upper front panel.
2. Remove red tube from nipple on filter assembly.
3. Remove wing nut.
4. Remove filter assembly from boiler. Remove the
blower filter front plate, if necessary.
5. Remove foam pre-filter and wash with soap and
water.
6. Replace primary filter as necessary.
Pilot Flame:
A. Perform a visual inspection of pilot burner
flame.
1. Refer to the flame safeguard instruction manual
and conduct a pilot turndown test.
2. Observe pilot operation and record pilot signal.
Flame should be steady medium hard blue
clearly visible through sight glass.
B. Pilot Cleaning and Maintenance
1. Shut off gas supply and disconnect electrical
service.
2. Disconnect scanner, ignition electrode, loosen
and remove pilot gas line and combustion air line
from fan.
3. Remove mounting fasteners and pull pilot
assembly from heat exchanger.
4. Examine pilot electrode and set gap to 1/8” if
needed. Clean as required.
5. Reassemble in reverse order using a new gasket
available from Thermal Solutions.
Burner Flame:
A. Perform a visual inspection of main burner flame.
1. Observe main flame and record flame signal.
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 operated the burner
does not require servicing.
CAUTION
Do not attempt to remove or service burner.
Damage to the burner may result. Consult boiler
manufacturer.
B. When the air filter is not properly maintained, the
burner is susceptible of clogging. Check manifold
pressure during the purge cycle to test for clogging.
1. Install a pressure fitting in the tapping on the gas
manifold valve inside the boiler.
2. Attach a pressure monitoring device to the
pressure fitting.
3. Check the pressure while the boiler is in the
purge sequence.
4. If the measured pressure is considerably higher
than expected, consult factory.
Check Combustion and Safety Controls:
A. Check flame failure detection system with system
operating.
1. Pilot
a. Refer to the flame safeguard instruction
manual.
b. Manually close pilot fuel supply and
verify lock out of primary control.
2. Main Flame
a. Refer to the flame safeguard instruction.
b. Close manual main fuel shut off valve
and verify lockout of primary control.
Check Heat Exchanger:
A. Remove lower front jacket panel and check for any
signs of corrosion and leaks.
B. Remove pipe plugs in header and inspect inside of
copper tubes and header.
C. Flush boiler and mechanically remove any scale.