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

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VII. Service/Maintenance GENERAL GUIDELINES 1. A thorough and complete boiler inspection and check must be conducted a minimum of one (1) time per year. 2. Follow any checks and/or inspections that may be required as specified in the component manufacturer's instruction manuals. 3. Repair or replace any defective compontents immediately. 4. The following service procedures are required for proper and safe boiler operation. 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. 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. 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. CAUTION USE caution when servicing components behind upper front jacket panel. Filter/mounting bracket may cause head injury. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. 48
A. SAFETY AND OPERATING CONTROLS. OPERATION AND SHUT DOWN Component Circuit Board Fuse Power Switch Operating Aquastat Manual Reset High Limit Aquastat Flow Switch Pressure (Safety) Relief Valve Mixer Fuseable Link Vestibule Fuseable Link High and Low Gas Pressure Switches Combustion Air Flow Switch Flame Safeguard Control Variable Frequency Drive (VFD) Function If the power draw of the control circuit exceeds approximately 5 amps, the circuit board fuse trips and prevents the boiler from operating until the fuse is replaced. If this switch is in the off position, power is interrupted to the control circuit of the boiler, which prevents the boiler from operating. If the switch is in the on position, power is supplied to the control circuit. If the boiler water temperature exceeds the adjustable set point, power is interrupted to the control circuit of the boiler, which prevents the boiler from operating. When the boiler water temperature drops below the set point minus the adjustable differential setting, power is again supplied to the control circuit. If the boiler water temperature exceeds the adjustable set point, power is interrupted to the control circuit of the boiler, which prevents the boiler from operating. Power is interrupted until the control is manually reset by pressing the control’s reset button. When the button is depressed, power will again be supplied to the control circuit. If the water flow through the boiler drops below the fixed flow rate required to move the control’s paddle enough to close the controls contacts, power is interrupted to the control circuit, which prevents the boiler from operating. When the water flow rate is increased, the paddle closes the control’s contacts and power is supplied to the control circuit. If the pressure inside the appliance exceeds the fixed set point, the valve opens mechanically and discharges water. The valve remains open until the pressure inside the appliance drops below the set point. 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. If the temperature in the interior of the vestibule enclosure 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. If the gas pressure reaches a point below the adjustable set point, or above the adjustable 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 gas pressure is between the high and low set points and the control is manually reset by moving the switch to the reset position. The switches will not reset until the gas pressure is within the set point parameters. If the differential air pressure drops below 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 air flow increases so that the contacts close. Refer to the manual supplied with the boiler. The variable frequency drive’s primary function is to vary the rotational speed of the blower fan based on the air requirements of the boiler combustion process. The VFD responds to a 0-10 VDC signal from the TSBC. Thermal Solutions Boiler Control (TSBC) The Thermal Solutions Boiler Control (TSBC) is a complete boiler and automation system. It provides advanced boiler modulation control, operating control, diagnostics, multiple boiler lead lag and auxiliary device control. Refer to the TSBC manual shipped with the boiler to learn more about these features and functions. 49
Page 1 and 2: INSTALLATION, OPERATING AND SERVICE
Page 3 and 4: WARNING This boiler requires regula
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: Product Features Boiler Sequence (C
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 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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