I&O Manual - EVCA - Categories On Thermal Solutions Products LLC

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IMPORTANT INFORMATION - READ CAREFULLY NOTE: Post these instructions and maintain in legible condition. NOTE: The equipment shall be installed in accordance with those installation regulations required in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. All wiring on boilers installed in the USA shall be in accordance with the National Electrical Code and/or local regulations. All wiring on boilers installed in Canada shall be in accordance with the Canadian Electrical Code and/or local regulations. The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. 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 injury or substantial property damage. NOTICE Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards. DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the gas supplier’s instructions or if the supplier is unavailable, contact the fire department. 2
WARNING This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. Improper installation, adjustment, alteration, service, or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start-up, operation, or service. Installation and service must be performed only by an experienced, skilled installer or service agency. This boiler must be properly vented. This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air. The interior of the venting and air intake systems must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions. Clean and unobstructed venting and air intake systems are necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler’s efficiency. This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start without service - If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative. This boiler contains very hot water under high pressure. Do not unscrew any pipe fittings nor attempt to disconnect 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 is operating. Do not touch any components unless they are cool. Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing or working nearby the appliance. Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions, including all those contained in component manufacturers manuals which are provided with the boiler before installing, starting up, operating, maintaining or servicing. Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors or liquids. All cover plates, enclosures and guards must be in place at all times. This product must be installed by a licensed plumber or gas fitter when installed within the Commonwealth of Massachusetts. NOTICE This boiler has a limited warranty, a copy of which is printed on the back of this manual. It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete. 3
Page 1: INSTALLATION, OPERATING AND SERVICE
Page 5 and 6: Notes: 1. Piping removed for visual
Page 7 and 8: 40.8 [1036.3] MOUNTED LOW WATER CUT
Page 9 and 10: a. Direct communication with outdoo
Page 11 and 12: ii. Minimum three (3) feet above an
Page 13 and 14: Figure 2: Typical Sidewall Pressuri
Page 15 and 16: B. COMBUSTION AIR - See Figures 5 a
Page 17 and 18: C. WATER TREATMENT The quality of w
Page 19 and 20: Figure 8: Schematic Boiler Piping 1
Page 21 and 22: E. GAS PIPING WARNING Failure to pr
Page 23 and 24: Pipe Size 1/2" 3/4" 1" 1-1/4" 1-1/2
Page 25 and 26: Figure 9a: 208/230/480V - 1PH/3PH -
Page 27 and 28: 27 Figure 9c: Control Wiring Schema
Page 29 and 30: 29 Figure 9e: Control Wiring Schema
Page 31 and 32: G. MODULAR SYSTEMS 1. General Guide
Page 33 and 34: 33 Figure 11: Modular System Vertic
Page 35 and 36: 35 Figure 13: Modular System: Typic
Page 41 and 42: IV. System Start-up CAUTION Failure
Page 43 and 44: WARNING Failure to properly adjust
Page 45 and 46: 19. Reset the burner control by pre
Page 47 and 48: Product Features Boiler Sequence (C
Page 49 and 50: A. SAFETY AND OPERATING CONTROLS. O
Page 51 and 52: TROUBLESHOOTING GUIDE (CONTINUED) L
Page 53 and 54:
D. INSPECTION AND CLEANING PROCEDUR
Page 55 and 56:
2 1 Figure 18: Cleaning Secondary H
Page 57 and 58:
VIII. Repair Parts EVCA Series repa
Page 59 and 60:
Key No. Description 1. COMBUSTION C
Page 61 and 62:
Key No. Description 2. BURNER/ FAN
Page 63 and 64:
Key No. Description 3. MAIN AND PIL
Page 65 and 66:
Key No. Description UL/FM/CSD-1 Gas
Page 67 and 68:
Page 69 and 70:
Page 71 and 72:
Key No. DB&B AND DB&B W/POC - MAIN
Page 73 and 74:
Key No. Description 4. JACKET ASSEM
Page 75 and 76:
EVCA-750/1500 SECONDARY HEAT EXCHAN
Page 77 and 78:
Key Number EVCA-2000 SECONDARY HEAT
Page 79 and 80:
Key No. EVCA-3000 SECONDARY HEAT EX
Page 81 and 82:
Controls Key No. 5. Controls and Co
Page 83 and 84:
Key No. Description PILOT ASSEMBLY
Page 85 and 86:
IX. Thermal Solutions Boiler Contro
Page 87 and 88:
Label 101175-04 RJ-11 (6 pin) Boile
Page 89 and 90:
D. SETUP MENU APPENDIX D (Cont…)
Page 91 and 92:
EVCA Modulating Fire Test Procedure
Page 93 and 94:
APPENDIX D (Cont…) - TSBC TM SYST
Page 95 and 96:
APPENDIX D (Cont…) - TSBC TM COMM
Page 97 and 98:
NOTES 97
Page 99 and 100:
NOTES 99
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I&O Manual - EVCA - Categories On Thermal Solutions Products LLC

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