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Thermal Solutions EVS SERIES, Installation, Operating And Service Instructions

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Thermal Solutions EVS SERIES Installation, Operating And Service Instructions Download Page 51

51

VII. Service

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.

Summary of Contents for EVS SERIES

Page 1: ...esentative File Number MH25585 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 EVS Phone Number Address Installation Date A S M E H ...

Page 2: ...d or local regulations DANGER Indicates 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 result in moderate or minor injury or property damage WARNING Indicates a potentially hazardous situation which if not avoided could result in death serious inju...

Page 3: ...ct 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 prevent scald injuries Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler This boiler contains components which become very hot when the boiler...

Page 4: ...its are mounted side by side front service clearance increases by 12 and the rear service clearance increases by 24 NOTE Verify clearance with local codes H Condensate Drains 43 IV System Start up 44 V Lighting Instructions 47 VI Boiler Operational Sequence 49 VII Service 51 VIII Repair Parts 57 IX Thermal Solutions Boiler Control TSBC 72 Warranty Back Cover Net AHRI Ratings 1 The Net AHRI Water R...

Page 5: ...92 1 6 1 155 6 31 0 787 4 P T GAUGE 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 3 NPT GAS PILOT 1 4 TUBE GAS VENT 3 4 NPT PIPE Boiler Model Number CAPACITIES INPUT MBH GROSS OUTPUT MBH NET AHRI RATING MBH 2 WATER VOLUME gallons DRY WEIGHT lbs WET...

Page 6: ...SYSTEM 3 NPT GAS PILOT 1 4 TUBE GAS VENT 3 4 NPT PIPE 4 4 111 1 19 0 482 6 49 0 1244 6 2 3 57 2 9 6 242 9 7 0 177 8 13 9 352 4 17 9 454 0 19 0 482 6 3 5 88 9 6 3 158 8 23 6 600 1 21 8 552 5 REQUIREMENT FOR BURNER REMOVAL 79 4 2017 7 28 3 717 6 30 3 768 4 9 3 235 0 27 4 696 9 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...

Page 7: ...GAS VENT 3 4 NPT PIPE 70 5 1790 7 38 1 968 2 40 1 1019 0 19 6 496 8 4 0 102 4 5 0 126 2 8 5 215 1 5 9 149 2 26 2 666 7 7 0 178 6 14 4 365 9 19 0 481 8 2 2 55 5 6 9 174 6 18 6 471 4 20 9 531 8 22 4 569 9 23 4 595 3 REQUIREMENT FOR BURNER REMOVAL 13 0 330 2 39 6 1004 8 40 8 1036 3 P T GAUGE WATER FLOW SWITCH RELIEF VALVE 13 3 337 8 10 5 266 7 BOILER DRAIN 1 NPT PIPE FLUE OUTLET 6 SAF T VENT WATER RE...

Page 8: ...ER SUPPLY TO SYSTEM 4 NPT GAS SUPPLY 2 NPT GAS PILOT 1 4 TUBE GAS VENT 1 NPT PIPE 84 5 2146 3 38 1 968 2 40 1 1019 0 19 6 496 8 4 0 102 4 5 0 126 2 8 5 215 1 5 9 149 2 26 2 666 7 7 0 178 6 14 4 365 9 19 0 481 8 2 2 55 5 6 9 174 6 18 6 471 4 20 9 531 8 22 4 569 9 23 4 595 3 REQUIREMENT FOR BURNER REMOVAL 26 5 673 1 53 6 1360 4 40 8 1036 3 P T GAUGE WATER FLOW SWITCH RELIEF VALVE 13 3 337 8 11 5 292...

Page 9: ...ning within 12 inches 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 before installing boiler Failure to follow all instructions in proper order can cause personal injury or death A Installation must conform to the requirements of the authority havi...

Page 10: ...ut not less than 100 square 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 must be fixed in open position or interlocked with equipment to open automatically before burner operation Screens must not be smaller than inch mesh Consider the blocking effect...

Page 11: ... must be rigid and able to withstand impacts without collapse h If any point of the vent pipe system is higher than the boiler 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 chase provided minimum clearances to combustible materials are maintained j ...

Page 12: ... pipe may be used Chimney lining must be 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 vent e Install a double acting barometric damper with integral flue spillage interlock f The chimney vertical vent and flue connector must be sized and configured...

Page 13: ...13 Figure 3 Sidewall Positive Pressure Venting Optional Figure 2 Sidewall Positive Pressure Venting ...

Page 14: ...14 Figure 4 Vertical Pressurized Venting ...

Page 15: ... 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 licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with a...

Page 16: ...16 Figure 5 Typical Negative Pressure Conventional Venting ...

Page 17: ...take 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 sidewall intake air or visa versa 8 The horizontal air intake pipe must be adequately supported with straps or supports no less than five 5 feet apart The completed air intake pipe system must be rigid a...

Page 18: ...18 Figure 7 Vertical Air Intake Piping ...

Page 19: ... 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 professional for establishing a treatment plan In addition a periodic testing sampling plan should be developed The intent of the plan should be to 1 ensure the protection of the boiler and system equipment 2...

Page 20: ...s which allow oxygen absorption iii Using of non permeable materials in the distribution system iv Isolating the boiler from the system water by installing a heat exchanger v Using properly designed and operating air elimination devices in water piping 2 Connect system supply and return piping to boiler a Refer to Figure 8 b Consult I B R Installation and Piping Guides c Maintain minimum distance ...

Page 21: ...aximum Flow Rate gpm Supply Return Pipe inch dia DP Ft Flow GPM DP Ft Flow GPM EVS 500 2 93 43 0 74 22 22 43 2 EVS 750 1 81 62 0 46 31 31 62 3 EVS 1000 3 24 82 0 81 41 44 82 3 EVS 1500 7 37 125 1 85 63 63 125 3 EVS 2000 13 27 170 3 32 85 85 170 3 EVS 2000S 4 27 173 1 36 87 87 173 4 EVS 2500 4 34 217 1 43 109 109 217 4 EVS 3000 4 41 261 1 73 131 131 261 4 ...

Page 22: ...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 gas supply to boiler may result in improper operation and damage to the boiler or structure Always assure gas piping is absolutely leak free and of the proper size and type for the connected load An Additional ...

Page 23: ...s 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 for minimum gas flow rate 6 Pressure test The boiler and its gas connection must be leak tested before placing boiler in operation a Protect boiler gas control valve For all testing over psig boiler and its individual sh...

Page 24: ...0 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 70 131 269 403 777 1240 2190 4460 150 63 119 244 366 704 1120 1980 4050 175 58 109 224 336 648 1030 1820 3720 200 54 102 209 313 602 960 1700 3460 TABLE 5 SPECIFIC GRAVITY CORRECTION FACTORS Specific Gravi...

Page 25: ...Screwed Flanged Welded Schedule 40 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 65 11 4 14 6 19 1 4 32 5 72 7 27 9 58 1 55 2 06 2 62 3 45 0 73 0 96 1 22 1 61 3 10 4 12 5 24 6 90 1 1 2 2 2 1 2 3 1 610 2 067 2 469 3 068 0 94 1 21 1 44 1 79 44 7 57...

Page 26: ...er terminals provided in boiler electrical cabinet Refer to wiring diagram supplied with boiler for wiring information Refer to Figures 9a 9f for typical wiring diagrams Refer to Figure 1 for electrical requirements for boiler CAUTION Each boiler must be protected with a dedicated properly sized fused disconnect WARNING Electrical power may be supplied from more than one service Make sure all powe...

Page 27: ...27 Figure 9a 208 230 460V 1 3 ph 60 Hz Supply Power Wiring Schematic ...

Page 28: ...28 Figure 9b 120V 1ph 60Hz Supply Power Wiring Schematic ...

Page 29: ...29 Figure 9c Standard UL FM CSD 1 Wiring Diagram EVS 500 2000 ...

Page 30: ...PTIONS C C MR MS 24VAC 24VAC 2 12 7 5 4 6 8 9 1 11 10 3 K1 CS AL PR C LC CH FUSE 24VAC 24VAC 2 3 7 5 4 6 8 9 1 10 Pin 6 Pin 1 Pin 7 Pin 1 BO BC BI COMBUSTION BLOWER SPEED CONTROL CIRCUIT 115V TO 24V TRANSFORMER C C O O R R RJ11 21 2 5 VARIABLE SPEED DRIVE AC Tech SCF GND TO CHASSIS G IGNITION PILOT IGNITION XFMR INTERRUPTED IGNITION PILOT GAS VALVE NC NC BURNER THERMAL FUSE VESTIBULE THERMAL FUSE ...

Page 31: ...31 Figure 9e Standard UL FM CSD 1 EVS 2000S 3000 ...

Page 32: ...6 8 9 1 10 Pin 6 Pin 1 Pin 7 Pin 1 COMBUSTION BLOWER SPEED CONTROL CIRCUIT 115V TO 24V TRANSFORMER C C O O R R RJ11 21 2 5 VARIABLE SPEED DRIVE AC Tech SCF GND TO CHASSIS G IGNITION PILOT IGNITION XFMR INTERRUPTED IGNITION PILOT GAS VALVE NC NC VESTIBULE THERMAL FUSE UV SCANNER BLOCKED AIR FILTER SWITCH AND LIGHT LT NO C LINE VOLTAGE ALARM BLOWER MOTOR AUXILIARY RELAY MAIN FUEL VALVE S HIGH LIMIT ...

Page 33: ... 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 through a common vertical or horizontal chase provided minimum clearances to combustible materials are maintained iii Positive pressure systems can be piped individually through a common vertical chas...

Page 34: ...ermination 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 section for further warnings cautions notices and instructions 5 Water Piping a Refer to Figures 13 thru 18 for typical water piping for modular boilers b Installing a low water cut off in the system...

Page 35: ...35 Figure 11 Modular System Horizontal Air Intake Piping ...

Page 36: ...36 Figure 12 Modular System Vertical Air Intake Piping ...

Page 37: ...37 Figure 13 Modular System Typical One Pipe Water Piping ...

Page 38: ...38 Figure 14 Modular System Typical Primary Secondary Water Piping ...

Page 39: ...39 Figure 15 Modular System Typical Primary Secondary without System Pump ...

Page 40: ...40 Figure 16 Modular System Typical Reverse Return Water Piping ...

Page 41: ...41 Figure 17 Modular System Reverse Return with System Pump Only ...

Page 42: ...42 Figure 18 Modular System Typical Primary Secondary with Reverse Return ...

Page 43: ... 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 lines or reduce drain line inner diameter size Each condensate drain must contain a siphon pigtail or trap to prevent flue gas flow through the condensate piping The height of the top of the syphon pigta...

Page 44: ...trols 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 CAUTION This boiler contains a manual gas shut off valve inside of the upper front jacket panel B Pressurize the Hydronic System fill entire heating system with water and vent air from system Use the following procedure on a ...

Page 45: ... desired control features G 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 blower motor rotation 4 Shut boiler off and position the flame control back to run Reinstall air filter H Flame Safeguard Operation Check Turn boiler operating switch to t...

Page 46: ...indows 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 controls and limits include combustion air switch water temperature operating control manual reset water temperature safety limit vestibule fuseable link mixer fuseable link high and low gas pressure ...

Page 47: ...or heat to the appliance 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 pilot valve at the rear of the appliance 7 Locate the gas main valves at the rear of the appliance and at the end of the gas supply pipe inside the appliance 8 Rotate gas shu...

Page 48: ...ice 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 the rear of the unit rotate the pilot and main gas valves clockwise from ON position to OFF Make sure handle rests against stop 21 Observe several on and off cycles of the water heater If any light o...

Page 49: ... 80 Firing Rate Boiler Disable RO Boiler Disable or Remote On Off 3 d 53 4 d Spare Output On Call For Heat Relay On Recycling Limits Made Call For Heat Non Recycling Limits Made Warm Weather Shutdown Standby Lockout Limit Hold Combustion Air Damper Open V V P P V V P P V V P P V V P P b c a a a Fan Post Purge 54 d Boiler Pump On Domestic Hot Water Demand Monitored System Pump On System Pump Feedba...

Page 50: ...y CONTROL MODE LCD Display Description Pump Purge Any Mode Except Manual Mode Once a Call For Heat is initiated and Boiler Pump Purge is selected the pump output is energized until the Pump Prepurge Time is complete If the Call For Heat condition still exists at the end of the Prepurge Time the temperature of the water at the sensor may rise with boiler water flowing passed it the pump will contin...

Page 51: ...re 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 b...

Page 52: ...xer Fuseable Link If the temperature in the interior of the burner exceeds the fixed set point The contacts of the switch open and power 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 vestibule enclosure exceeds the fixed set point the contacts of the ...

Page 53: ...eceive power and the Call For Heat output CH is powered the High Temp Limit Message is displayed Low Air Flow Check Combustion Air Blower and Air Pressure Switch Settings and Wiring Low Air Flow or Blocked Vent Switch Not Made The air flow and blocked vent switch when installed is preventing a boiler start If terminal CA does not receive power and the Call For Heat output CH is powered the Low Air...

Page 54: ... both the Remote On Off Modbus Command 00004 and Remote Firing Rate or Remote Setpoint 40006 points have been completed power is cycled or the protocol parameter is changed to Peer To Peer and then back to Modbus When a Peer To Peer network has failed the boilers begin operation as stand alone boilers using the selected parameters After a Peer To Peer communication failure the Comm Failure alarm i...

Page 55: ...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 all indicating and recording gauges Flame failure detection system Check components Condensate drain tubes Check drain tubes have liquid in trap and condensate is properly directed Air filter Check air...

Page 56: ...ame 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 ...

Page 57: ...rmal Solutions for 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 noted in this section are for a standard EVS Series Boiler Different contents and components may have been supplied due to the request of the equipment and user Consult Thermal Sol...

Page 58: ...58 Figure 19 Combustion Chamber Assembly ...

Page 59: ...1 4 603562061 4 603562071 6 60356208 6 60356209 6 60356210 1I Heat Exchanger Wrapper 1 70356119 1 70356219 1 70356220 1 70356221 1 70356222 1 70356246 1 70356247 1 70356248 1J Heat Exchange Baffle 1 70356235 1 70356236 1 70356237 1 70356238 1 70356239 1 70356240 1 70356241 1 70356242 1K Condensate Drain Tube 1 8065603 1 8065601 1L 1 Fiber Gasket 9 LF 9206032 14 LF 9206032 19 5 LF 9206032 1M Sight ...

Page 60: ...60 Figure 20 Burner Assembly FRONT VIEW TOP VIEW ...

Page 61: ...6300 Mixer Assembly LP 1 602561061 1 60256213 1 60256214 1 60256215 1 60256216 1 62156300 2E Burner Element 1 TS500CF 1 TS750CF 1 TS1000CF 1 TS1500CF 1 TS2000CF 1 TS2000SCF 1 TS2500CF 1 TS3000CF 2F Air Orifice Gasket 2 82056061 2 8205603 2 8205603 2 8205666 2G Air Orifice 1 802561041 1 80256235 1 80256253 1 80256236 1 80256237 1 80256237 1 82156307 N A 2H Pilot Gasket 1 8205608 2I Gas Mixing Orifi...

Page 62: ...62 Figure 21 UL FM CSD 1 Main Gas Train Assembly ...

Page 63: ...816634043 3B Manual Gas Valve with Pilot Tapping 1 NPT 2 806603055 Manual Gas Valve with Pilot Tapping 1 1 2 NPT 2 806603053 Manual Gas Valve with Pilot Tapping 2 NPT 2 806604691 3C Air Gas Ratio Controller Siemens SKP75 1 81663408 3D Solenoid Valve V4295A1031 1 NPT 1 81660207 Solenoid Valve V4295A1056 1 1 2 1 81660205 Solenoid Valve V4295A1064 2 1 816602051 3E Manual Gas Cock 1 4 3 822758 3F Pilo...

Page 64: ...NPT 2 816634041 3B Manual Gas Valve with Pilot Tapping 1 NPT 2 806603055 3C Actuator Regulator Ratio Valve Siemens SKP75 max 5psi DB B w POC 1 81663409 3D Actuator Siemens SKP15 DB B w POC 1 81663407 3E Manual Gas Cock 1 4 3 822758 3F Pilot Gas Regulator 1 822702 3G High Gas Pressure Switch 1 80160333 3H Low Gas Pressure Switch 1 80160332 3I Normally Open Vent Valve 1 81660262 ...

Page 65: ...65 Figure 22b DB B Gas Train 500 750 Figure 22c DB B Gas Train 1000 2000 ...

Page 66: ... NPT 1 81663404 3B Manual Gas Valve with Pilot Tapping 1 NPT 1 806603055 Manual Gas Valve with Pilot Tapping 1 1 2 NPT 1 806603053 2 806603053 3C DB B Actuator Regulator Ratio Valve Siemens SKP75 max 5 PSI 1 81663408 3D DB B Solenoid Valve 1 81660207 1 81660205 3E Manual Gas Cock 1 4 3 822758 3F Pilot Gas Regulator 1 822702 3G High Gas Pressure Switch 1 80160333 3H Low Gas Pressure Switch 1 801603...

Page 67: ...1663404 1 816634043 3B Manual Gas Valve 2 806603053 2 806604691 3C Ratio Valve 1 81663408 3D Actuator 1 81660205 1 8016602051 3E Gas Cock 3 822758 3F Pilot Regulator 1 822702 3G High Pres Switch 1 80130333 3H Low Pres Switch 1 80160332 3I Vent Valve N O 1 81660748 1 816607501 Figure 22d DB B Gas Train 2000S 3000 ...

Page 68: ...T 1 81663404 3B Manual Gas Valve with Pilot Tapping 1 1 2 NPT 2 806603053 3C DB B w POC Actuator Regulator Ratio Valve Siemens SKP75 max 5 PSI 1 81663409 3D DB B w POC Actuator Siemens SKP15 1 81663407 3E Manual Gas Cock 1 4 3 822758 3F Pilot Gas Regulator 1 822702 3G High Gas Pressure Switch 1 80160333 3H Low Gas Pressure Switch 1 80160332 3I Normally Open Vent Valve 1 81660748 ...

Page 69: ... Valve Body 1 81663405 1 816634051 3B Manual Gas Valve 2 806603053 2 806604691 3C Ratio Valve 1 81663409 3D Actuator 1 81663407 3E Gas Cock 3 822758 3F Pilot Regulator 1 822702 3G High Pres Switch 1 80160333 3H Low Pres Switch 1 80160332 3I Vent Valve N O 1 81660748 1 816607501 Figure 22f DB B w POC Gas Train 2000S 3000 ...

Page 70: ...70 Figure 23 Jacket Panels ...

Page 71: ...04562471 1 704563004 4E Jacket Panel Left Side 1 604563281 1 604563291 1 604563301 1 604563311 1 604563321 1 6045612010 1 6045602510 1 6045603010 4F Jacket Top Panel 1 704562541 1 704563000 4G Jacket Vestibule Panel 1 604563011 1 604563021 1 604563000 4H Jacket Upper Front Panel 1 70456280 1 104023 01 4I Jacket Panel Right Side 1 604563221 1 604563231 1 604563241 1 604563251 1 604563261 1 60456120...

Page 72: ...72 Figure 24 Control Panel Assembly O M RO N M Y2 1 2VD C idec RJ1 S CD D 1 2 I D EC RH1 B U D C1 2V I D EC RH1 B U D C1 2V I D EC RH1 B U D C1 2V O M RO N M Y2 1 2VD C ...

Page 73: ... shown 1 8136363 5E Operating Limit L4008A1015 Auto Reset 1 80160626 5F High Limit L4008E 1313 Manual Reset Max 240F 1 80160667 5G Water Flow Switch FS4 3 not shown 1 80160175 5H Vestibule Fuse Switch not shown 1 80160209 5J Blocked Filter Switch 1 80160295 5K Combustion Air Flow Switch 1 102382 02 5L Ignition Transformer 1 80160018 5M Variable Frequency Drive 208 230 volt input 1 80160940 Variabl...

Page 74: ...74 Figure 25 Pilot Assembly Bishop Design ...

Page 75: ...X2 1 62356110 Pilot Assembly Propane ULX2 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 Ignitor Assembly ULX2 1 82356009 7F Nipple 1 2 NPT x Close 1 806600040 7G Pilot Ignition Cable not shown 1 103827 01 7H Pilot Solenoid Valve V4046C1047 1 81660204 7I O Ring 1 8206054 ...

Page 76: ...rameter selections of remote system water temperature and remote mode determine the choice of one of six different control modes 5 Advanced Availability The above control modes are menu selectable options However if a selected sensor fails the TSBC automatically changes to a control mode that will allow continued automatic operation of the boiler For example in the event of a remote system tempera...

Page 77: ...ce A factory configured RS485 Modbus interface is available for Energy Management System EMS or SCADA system monitoring and control FRONT PANEL DISPLAY B Thermal Solutions Boiler ControlTM TSBCTM Wiring When wiring to the Thermal Solutions Boiler Control TSBC terminals see the terminal layout drawing on the following page or the terminal jacket label located on the inside surface of the boiler jac...

Page 78: ...r Peer To Peer Communication Network V V P P GP WF HL Power Common 24 Vac Power Supply 24 Vac Flame Safeguard Alarm 24 Vac Fuel Valve Energized 24 Vac P P Firing Rate Demand 0 10 Vdc PWM V V Firing Rate Demand 0 10 Vdc OO Burner On Off Switch WF Low Water Flow Switch GP Gas Pressure Switch HL Operating or High Limit CA Low Combustion Air Flow Thermal Solutions Boiler Control TSBC TERMINAL LAYOUT G...

Page 79: ... Basic 0 NONE This is the default access level The user can view many parameters but is only allowed to edit a small sub set of the parameters that are visible Supervisor 15 This password is set at the factory but can be changed in the field The user can view and edit most parameters that are visible Note Not all parameters will be vis ible at the Supervisor Access Level Factory All relevant inter...

Page 80: ... 100 High modulation rate limit for all boilers on the peer to peer network as long as at least one boiler is still not running After the last boiler has started the modulation rate is released up to 100 Deg Min Hold Off 1 1 10 F Specifies a temperature rate of change that inhibits the next boiler being started or stopped If the temperature is increasing faster than this rate of change the next bo...

Page 81: ...30 20 F to 50 F The Outdoor Design Temperature is the outdoor temperature at which the Boiler Design temperature is supplied Only visible when Outdoor Sensor is set to Outdoor Reset Boiler Design 180 80F to 220 F The Boiler Design setting is the water temperature required to satisfy the building heat loss during the Outdoor Design temperature If the building feels cool during cold outside conditio...

Page 82: ...explanation Remote PID D 0 0 to 10000 Derivative Gain Term for Remote System Temperature sensor control Modes Refer to Local PID D for explanation Mixing Valve P 10 0 to 10000 Proportional Gain value for boiler Inlet temperature sensor control mode A larger gain value results in tighter more active PID control Gain is the primary PID modulation rate tuning adjustment and provides the immediate mix...

Page 83: ...me and date of the boiler s real time clock This item also displays the time and date Spare Input Off Off Sys Pump FB Low Fire Sets the function of the Spare Input Terminal SI Off Ignore Sys Pump Feedback Input SI should be wired to a flow switch inserted in the flow path of the primary system pump Input SI indicates the primary system pump is operating If output SO is set to System Backup Pump sy...

Page 84: ...Remote Mod Remote Input C C is used as the modulation rate Modbus Mod RS485 Modbus 40006 is used as the modulation rate Remote 1 0 volt 140 60 F to 170 F Sets the temperature corresponding to input C C 1V Voltage below 1V is considered invalid failed or miss wired sensor Only visible when Remote Control equals Remote SP Remote 9 0 volt 220 150 F to 220 F Sets the temperature corresponding to input...

Page 85: ... when DHWP equals Yes WWSD Setpoint 70 40 to 90 F The Warm Weather Shutdown WWSD Setpoint used to disable boiler and or system pump operation when enabled by setting the WWSD parameter to WWSD of Boiler WWSD of Sys Pump or Both Only visible when WWSD does not equal Off Max SP Boilers 230 140 to 230 F The Maximum Operational Setpoint for all possible Local and Remote modes Min SP 70 60 to 230 F The...

Page 86: ...sible when Protocol equals Modbus Messages Rcvd Diagnostic tool used to confirm wiring and Modbus master configuration Only visible when Protocol equals Modbus Messages Sent Diagnostic tool used to confirm wiring and Modbus master configuration Only visible when Protocol equals Modbus Boiler Address 1 1 to 8 Each boiler must be given a unique address The boiler address assignment determines the bo...

Page 87: ... only when in Supervisor Mode and Boiler Man Auto Man Boiler On Off Varies On Off Sets the boiler start stop status when in Manual Mode No Turn off boiler if running otherwise remain off Yes Turn on boiler if off otherwise remain on Activated only when in Supervisor Mode and Boiler Man Auto Man Mixing Valve M A Auto Man Auto Man Remain in Manual Mode Auto Return to Control Mode specified by parame...

Page 88: ...88 NOTES ...

Page 89: ...89 NOTES ...

Page 90: ...90 NOTES ...

Page 91: ...91 NOTES ...

Page 92: ...ures 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 any Product for any particular application F Any failure resulting from misuse modification not authorized by Seller in writing improper installation or lack of or improper maintenance G Equipment furnish...

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