Thermal Solutions EVCA SERIES, Installation, Operating And Service Instructions

Page 1: ...presentative 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 Installation Date Serial Number Type System Heating Contractor EVCA Phone Number Address A S M E H ...

Page 2: ...RMATION READ CAREFULLY 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: ...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 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: ... 12 and the rear service clearance increases by 24 2 Verify clearances with local codes Table of Contents A Safety and Operating Controls 49 B Troubleshooting 50 C Periodic Maintenance 52 D Inspection Cleaning Procedure 53 VIII Repair Parts 56 IX Thermal Solutions Boiler Control TSBC 85 A Introduction 85 B Front Panel Display 86 C Security Menu 88 D Setup Menu 89 E Boiler Configuration Menu 92 F S...

Page 5: ...5 63 5 5 1 128 4 MOUNTED LOW WATER CUT OFF 29 6 751 1 14 5 368 7 63 9 1623 1 REQUIREMENT FOR BURNER REMOVAL 16 0 406 4 65 2 1655 8 12 0 304 8 28 3 717 6 19 5 495 3 46 0 1169 5 56 5 1435 1 21 8 552 9 3 0 76 2 31 0 787 4 9 4 239 7 14 2 360 0 4 6 116 7 16 0 406 3 18 6 472 7 13 0 330 9 2 5 63 5 5 1 128 4 MANUAL SHUT OFF VALVE MOUNTED LOW WATER CUT OFF GAS PILOT Ø 25 TUBE GAS VENT 75 NPT PIPE FLUE OUTL...

Page 6: ...NAL TRAP SUPPLY TO SYSTEM 2 VICTAULIC 51 9 1318 5 15 1 384 0 92 8 2357 1 REQUIREMENT FOR BURNER REMOVAL 19 0 482 6 79 1 2009 1 12 0 304 8 28 3 717 6 19 5 495 3 46 0 1169 5 56 5 1435 1 21 8 552 9 3 0 76 2 31 0 787 4 9 4 239 7 14 2 360 0 4 6 116 7 26 5 672 8 16 5 418 8 6 2 157 2 2 5 63 5 21 8 552 5 MANUAL SHUT OFF VALVE MOUNTED LOW WATER CUT OFF GAS PILOT Ø 25 TUBE GAS VENT 75 NPT PIPE FLUE OUTLET Ø...

Page 7: ... 9 47 3 60 2 1528 3 MANUAL SHUT OFF VALVE MOUNTED LOW WATER CUT OFF SUPPLY TO SYSTEM 4 Victaulic FLUE OUTLET Ø8 SAF T VENT WATER INLET 4 NPT INLET AIR Ø8 GALVANIZED DUCT BOILER DRAIN 1 NPT PIPE GAS SUPPLY 2 NPT CONDENSATE DRAINS TO BE PIPED TO AN EXTERNAL TRAP 20 9 531 8 86 1 2188 1 Notes 1 Piping removed for visual clarity 2 See notes concerning Net AHRI Ratings on page 4 BOILER MODEL NUMBER CAPA...

Page 8: ...es 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 having jurisdiction In ...

Page 9: ...nings 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 of louvers grilles and screens when calculating the opening size to provide the required f...

Page 10: ...ollapse h This boiler s venting is Category IV positive vent pressure flue condensing with regards to National Fuel Gas Code NFPA 54 ANSI Z223 1 i Vent pipe system must be fully sealed j Atmospheric venting is prohibited k For multiple boiler installations each boiler must have its own independent vent system Common venting with additional or any other appliances is prohibited WARNING Do not use v...

Page 11: ...ally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfi...

Page 12: ...manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system D MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizonta...

Page 13: ...13 Figure 3 Typical Sidewall Pressurized Venting Optional Figure 2 Typical Sidewall Pressurized Venting ...

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

Page 15: ...s manual 6 Air intake termination must be located at least twelve 12 inches above grade plus the expected snow accumulation 7 Boiler may be installed with vertical venting and sidewall combustion air inlet or visa versa 8 The 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 and able to withstand i...

Page 16: ...16 Figure 6 Vertical Air Intake Piping Figure 5 Horizontal Air Intake Piping ...

Page 17: ...n 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 ...

Page 18: ...ler must be installed so that the chilled medium is piped in parallel with the boiler using appropriate valves to prevent the chilled medium from entering the boiler Also consult I B R Installation and Piping Guides If this boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air the boiler piping must be equipped with flow control valves to ...

Page 19: ...19 Figure 8 Schematic Boiler Piping ...

Page 20: ...or or the system supply circulator It provides a constant flow to the primary heat exchanger 11 If the boiler is installed in a closed water supply system such as one having a back flow preventer in the cold water supply line means shall be provided to control thermal expansion Contact the water supplier or local plumbing inspector on how best to control this situation 12 A pressure relief valve i...

Page 21: ...tep down regulator is required it must be used in conjunction with the factory supplied regulator and be located as far away from the boiler as possible to prevent nuisance shutdowns a The minimum and maximum inlet gas pressure must not exceed the value specified in Table 2 3 Install field supplied sediment trap ground joint union and manual non displaceable shut off valve upstream of factory supp...

Page 22: ...et Pipe Size in 3 4 1 1 1 4 1 1 2 2 2 1 2 3 4 Capacity in Cubic Feet of Gas Per Hour 10 273 514 1060 1580 3050 4860 8580 17500 20 188 353 726 1090 2090 3340 5900 12000 30 151 284 583 873 1680 2680 4740 9660 40 129 243 499 747 1440 2290 4050 8270 50 114 215 442 662 1280 2030 3590 7330 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 9...

Page 23: ...9 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 4 68 5 85 2 22 4 28 7 34 3 42 6 11 2 14 4 17 1 21 3 4 02 5 17 6 16 7 67 1 88 2 41 2 88 3 58 8 04 10 3 12 3 15 3 4 6 4 026 6 065 2 35 3 54 112 168 56 84 1 28 0 42 1 10 1 15 2 4 70 7 07 20 2 30 4 Equivalent lengths are for standard screwed fittings a...

Page 24: ...irculator installed i e boiler and system circulators 5 Connect field supplied safety 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 9f for typical wiring diagrams Refer to Figure 1 for electrical requirements for boiler CAUTION Each boiler must be protected with a dedicated prop...

Page 25: ...25 Figure 9a 208 230 480V 1PH 3PH 60HZ Supply Power Wiring Schematic ...

Page 26: ...26 Figure 9b 120V 1PH 60HZ Supply Power Wiring Schematic ...

Page 27: ...27 Figure 9c Control Wiring Schematic EVCA 750 2000 ...

Page 28: ...ION BLOWER SPEED CONTROL CIRCUIT 115V TO 24V TRANSFORMER C C O O R R RJ11 21 2 5 VARIABLE SPEED DRIVE AC Tech SCF 1 2 3 GND TO CHASSIS G IGNITION PILOT IGNITION XFMR INTERRUPTED IGNITION PILOT GAS VALVE NC NC BURNER THERMAL FUSE 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 OPERATING LIMIT ...

Page 29: ...29 Figure 9e Control Wiring Schematic EVCA 3000 ...

Page 30: ...CIRCUIT 115V TO 24V TRANSFORMER C C O O R R RJ11 21 2 5 VARIABLE SPEED DRIVE AC Tech SCF G G0 Y 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 OPERATING LIMIT HIGH LOW GND TO CHASSIS GAS VALVE GAS RATIO ...

Page 31: ...tings should be assumed to have the equivalent length the same as an individual air intake pipe used for a given boiler intake pipe diameter e Position horizontal air intake termination 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 IMPORTANT Refer to the Combustion Air section for fu...

Page 32: ...32 Figure 10 Modular System Horizontal Air Intake Piping ...

Page 33: ...33 Figure 11 Modular System Vertical Air Intake Piping ...

Page 34: ...34 Figure 12 Modular System Typical One Pipe Water Piping ...

Page 35: ...35 Figure 13 Modular System Typical Primary Secondary Water Piping ...

Page 36: ...36 Figure 14 Modular System Typical Primary Secondary without System Pump ...

Page 37: ...37 Figure 15 Modular System Typical Reverse Return Water Piping ...

Page 38: ...38 Figure 16 Modular System Reverse Return with System Pump Only ...

Page 39: ...39 Figure 17 Modular System Typical Primary Secondary with Reverse Return ...

Page 40: ... 3 4 EVCA 1000 4 5 EVCA 1500 6 8 EVCA 2000 9 1 EVCA 3000 18 6 CAUTION Failure to properly pipe 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...

Page 41: ...Pressurize the Hydronic System fill entire heating system with water and vent air from system Use the following procedure on a Series Loop or multi zoned system installed to remove air from the system while filling 1 Close full port ball valve in boiler supply piping 2 Isolate all zones by closing zone valves or shut off valves in supply and return of each zone s 3 Attach a hose to the hose bib in...

Page 42: ...rm 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 the ON position 1 Allow boiler to complete prepurge and trial for ignition period Once pilot flame is recognized by controller position flame control switch to TEST position 2 Look through the boiler sight glass and conf...

Page 43: ...s 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 switches Refer to manuals for these components for proper start up and operating instructions Follow all instructions contained in these manuals This manual was provided with the boiler J Finish Commissioning at the Bo...

Page 44: ...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 45: ...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 46: ... 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 47: ...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 48: ...als Assure that all safety and operating controls and components are operating properly before placing the boiler back in service 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...

Page 49: ...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 50: ...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 51: ...rites to 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...

Page 52: ...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 filter as specified in section VII Part D Interlocks and valves Check...

Page 53: ... so the device will be free to function properly 8 Inspect and replace air filter as needed 9 Check high and low gas pressure switch interlocks 10 Log service procedure in appliance log Semi Annual Tune Up 1 Inspect condensate drain tubes for deterioration cracking etc 2 Inspect air intake and exhaust pipes for leaks deterioration scale etc 3 Measure fuel input oxygen and carbon monoxide in flue p...

Page 54: ...mbly from heat exchanger 4 Examine pilot electrode and set gaps to 1 8 if needed Clean as required 5 Reassemble in reverse order using a new gasket available from Thermal Solutions C Perform a visual inspection of main burner flame 1 Observe main flame and record flame signal Flame color should be steady deep orange in color with dark blue checkerboard pattern throughout 2 Main burner requires no ...

Page 55: ...55 Figure 18 Cleaning Secondary Heat Exchanger 1 2 ...

Page 56: ...56 This page intentionally left blank ...

Page 57: ... 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 VIII Repair Parts WARNING The repair parts noted in this section are for a standard EVCA Series boiler Different contents and components may have been supplied due to the request of the equipment end user Consult Thermal So...

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

Page 59: ...1 70356226 1 70356320 1H Combustion Pan Sup port 4 603562041 4 603562051 4 603562061 4 603562071 6 60356210 1I Heat Exchanger Wrap per 1 804EVC2003 1 804EVC2004 1 804EVC2005 1 804EVC2006 1 103081 02 1J Heat Exchanger Baffle 1 70356236 1 70356237 1 70356238 1 70356239 1 70356242 1K Condensate Drain Tube 1 806EVC01 1 8065601 1L 1 Fiber Gasket 14 LF 9206032 19 5 9206032 1M Sight Glass Lens Re tainer ...

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

Page 61: ...mbly Natural 1 60256209 1 60256210 1 60256211 1 60256212 1 62156300 Mixer Assembly LP 1 60256213 1 60256214 1 60256215 1 60256216 1 62156300 2E Burner Element 1 TS750CF GBNR 1 TS1000CF GBNR 1 TS1500CF GBNR 1 TS2000CF GBNR 1 TS3000CF GBNR 2F Air Orifice Gasket 2 8205603 2 8205666 2G Air Orifice 1 80256235 1 80256236 1 80256237 N A 2H Pilot Gasket 1 8205608 2J Burner Gasket 1 82056041 1 82056501 2K ...

Page 62: ...62 Figure 21a UL FM CSD 1 Main Gas Train Assembly EVCA 750 2000 ...

Page 63: ... 1 NPT 1 81663404 3B Manual Gas Valve with Pilot Tapping 1 NPT 1 806603055 Manual Gas Valve with Pilot Tapping 1 NPT 1 806603053 2 806603053 3C Air Gas Ratio Controller Siemen s SKP75 1 81663408 3D Solenoid Valve V4295A1031 1 NPT 1 81660207 Solenoid Valve V4295A1056 1 NPT 1 81660205 3E Manual Gas Cock 3 822758 3F Pilot Gas Regulator 1 822702 3G High Gas Pressure Switch 1 80160333 3H Low Gas Pressu...

Page 64: ...64 Figure 21b UL FM CSD 1 Main Gas Train Assembly EVCA 3000 ...

Page 65: ... Gas Valve Body 2 NPT 1 816634043 3B Manual Gas Valve Body with Pilot Tapping 2 NPT 2 806604691 3C Air Gas Ratio Controller Siemens SKP75 1 81663408 3D Solenoid Valve V4295A1064 2 NPT 1 816602051 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 80160322 ...

Page 66: ...66 Figure 22a DB B Gas Train 750 Figure 22b DB B Gas Train 1000 2000 ...

Page 67: ...anual 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 80160332 3I Normally Open ...

Page 68: ...68 Figure 22c DB B w POC Gas Train 750 Figure 22d DB B w POC Gas Train 1000 2000 ...

Page 69: ...ual 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 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 Normall...

Page 70: ...70 Figure 22e DB B Gas Train EVCA 3000 Figure 22f DB B w POC Gas Train EVCA 3000 ...

Page 71: ...Tapping 2 80660491 3C DB B Actuator Regulator Ratio Valve Siemens SKP75 max 5 psi 1 81663408 DB B w POC Actuator Regu lator Ratio Valve Siemens SKP75 max 5 psi 1 81663409 3D DB B Solenoid Gas Valve Honeywell 1 8016602051 DB B w POC Actuator Sie mens SKP15 1 81663407 3E Manual Gas Cock 3 822758 3F Pilot Gas Regulator 1 822702 3G High Gas Pressure Switch 1 80160333 3H Low Gas Pressure Switch 1 80160...

Page 72: ...72 Figure 23 Jacket ...

Page 73: ...ket Panel Left Side 1 604563291 1 604563301 1 604563311 1 604563321 1 6045603010 4E Jacket Top Panel 1 704562541 1 704563000 4F Jacket Vestibule Panel 1 604563021 1 604563000 4G Jacket Upper Front Panel 1 70456280 1 104023 01 4H Jacket Panel Right Side 1 604563231 1 604563241 1 604563251 1 604563261 1 6045603020 4I Handle 2 8056256 4K Observation Port Lens 1 8026082 4L Observation Port Gasket 2 82...

Page 74: ...74 Figure 24 EVCA 750 1000 and 1500 Secondary Heat Exchanger and Housing ...

Page 75: ...21 1 70446129 4L Secondary Heat Exchanger Jacket Bottom Panel 1 604EVC220401 4M Secondary Heat Exchanger Jacket Side Panel 2 604EVC22010 2 604EVC22011 2 604EVC22012 4N Secondary Heat Exchanger Jacket Back Panel 1 604EVC22020 1 604EVC22021 1 604EVC22022 4O Secondary Heat Exchanger Jacket Top Panel 1 604EVC220301 4P Stack Trim Ring Gasket 1 820EVC01 1 820EVC02 4Q 1 2 Condensate Trim Ring 1 704EVC002...

Page 76: ...76 Figure 25a EVCA 2000 Secondary Heat Exchanger and Housing 4A 4S 4T 4O 4D 4C 4B 4L 4Q 4R 4M 4M 4N 4J 4K 4G 4H 4F 4G 4H 4G 4P 4E 4X 4U 4Z 4Y 4W ...

Page 77: ...g 3 704EVC001 4J Stack Adapter Gasket 1 8205642 4K Stack Adapter Trim Ring 1 70456129 4L Secondary Heat Exchanger Jacket Bottom Panel 1 604EVC22040 4M Secondary Heat Exchanger Jacket Side Panel 2 604EVC22013 4N Secondary Heat Exchanger Jacket Rear Panel 1 604EVC22023 4O Secondary Heat Exchanger Jacket Top Panel 1 604EVC22030 4P Stack Adapter Gasket 1 820EVC02 4Q Condensate Drain Trim Ring 1 2 1 70...

Page 78: ...78 Figure 25b EVCA 3000 Secondary Heat Exchanger and Housing ...

Page 79: ...4004 01 4N1 Secondary Heat Exchanger Jacket Rear Panel Water Side 1 103099 01 4N2 Secondary Heat Exchanger Jacket Rear Panel Intake Side 1 103098 01 4O Secondary Heat Exchanger Jacket Top Panel 1 104005 01 4P Stack Trim Ring Gasket 1 820EVC03 4Q Secondary Heat Exchanger Pan Support Brace 2 103079 01 4R Condensate Line Brace 1 104022 01 4S 4 Trim Ring 2 70456131 4T 4 Trim Ring Gasket 2 8205661 4U J...

Page 80: ...80 Figure 26 Control Panel Assembly ...

Page 81: ... Variable Frequency Drive 460 volt input 1 80160941 Variable Frequency Drive 115 120 volt input 1 80160933 5N Control Transformer 1 80160820 5P Fuses and Fuse Block for 208 230 460V Application 2 8136426 2 8136427 5Q Overload Relay See Table Below 5R Transformer AT140B1206 2 801600502 5S Contactor 3PH 120 Volt Coil see table below for permutations See Table Below 5T Q7800H1109 Board for Thermal So...

Page 82: ...82 Figure 27 Bishop Pilot Assembly ...

Page 83: ...y 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 V4048C1047 not shown 1 81660204 7I O Ring 1 8206054 ...

Page 84: ... Phase 120 208 230V HP Pump 1 805622005 3 Phase 208 230 460V HP Pump 1 805622006 1 Phase 120 208 230V HP Pump 1 805622007 3 Phase 208 230 460V HP Pump 1 805622008 3 Phase 208 230 460V 2 HP Pump 1 104033 02 8B Temperature Probe 1 101935 01 8C 3 Way Valve 1 102653 01 8D 3 Way Valve Actuator 1 101894 01 8E 3 Way Valve and Actuator Assembly 1 104032 01 ...

Page 85: ... Parameter 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 temp...

Page 86: ...s Communication Interface A factory configured RS485 Modbus interface is available for Energy Management System EMS or SCADA system monitoring and control B 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 ...

Page 87: ...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 88: ...tion 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 i...

Page 89: ...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 boi...

Page 90: ...tdoor Reset Outdoor Design 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 d...

Page 91: ...cal PID I for 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...

Page 92: ...y year Sets the time 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 SP is set to Sys...

Page 93: ...rature setpoint 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 corres...

Page 94: ...et is maintained at or above the DHW Setpoint Only visible 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...

Page 95: ...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 96: ... 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 97: ...97 NOTES ...

Page 98: ...98 NOTES ...

Page 99: ...99 NOTES ...

Page 100: ...terioration abnormal temperatures 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 ma...