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CONTROLS (Modulation)

Key

No.

Description

(Quantity) Part Number

EVO-

500

EVO-

750

EVO-

1000

EVO-

1500

EVO-

2000

5. Controls and Components

RM7896D1027 Flame Safeguard Con-

trol for UL/FM/CSD-1/DB&B

(1) 80160212

RM7840L1075 Flame Safeguard Con-

trol for DB&B w/POC & LFP

(1) 801602303

Modbus Module for 5A (optional - not

shown)

(1) 80160909

Display Module for 5A (optional - not

shown)

(1) 80160640

Amplifier Card (not shown)

R7849A1023

(1) 80160243

Purge Card (not shown) ST7800A1039

(UL/FM, CSD-1)

(1) 8136362

Purge Card (not shown) ST7800A1005

(DB&B w/POC)

(1) 81363621

Power Switch with Filter Light (not

shown)

(1) 8136363

Operating Limit, Digital RWF40

(1) 80160905

Operating Limit, Digital Modbus,

RWF40 (optional)

(1) 80160908

High Limit L4008E1305 (Manual Reset

- max 240F)

(1) 80160667

High Limit L4008E1313 (Manual Rest -

max 200F) (optional)

(1) 80160660

Water Flow Switch FS8-W (not shown)

(1) 80160175

Vestibule Fuse Switch (not shown)

(1) 80160209

Terminal Block/Circuit Breaker

Assembly

(1) 8136498

Blocked Filter Switch

(1) 80160295

Combustion Air Flow Switch

(1) 102382-02

Ignition Transformer

(1) 80160018

Variable Frequency Drive 115 volt input

(1) 80160933

Variable Frequency Drive 208/230 volt

input

(1) 80160940

Variable Frequency Drive 460 volt input

(1) 80160941

Control Transformer (High Voltage

Option)

(1) 80160820

Fuses and Fuse Block (High Voltage

Option)

(2) 8136426 & (2) 8136427

Delay Timer (No Timer for EVO500-

2000 UL/FM,CSD-1)

(1) 80160675

Resistor 1k 25watt (LFP option only)

(not shown)

(1) 103577-01

Содержание EVO-1000

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

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

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

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

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 48: ...48 Troubleshooting Guide B Troubleshooting Guide...

Страница 49: ...49 Troubleshooting Guide...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 72: ...72 NOTES...

Страница 73: ...73 NOTES...

Страница 74: ...74 NOTES...

Страница 75: ...75 NOTES...

Страница 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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