Water Heater Installation and Safety Guidelines, Study Guides, Projects, Research of Human Physiology

Download Water Heater Installation and Safety Guidelines and more Study Guides, Projects, Research Human Physiology in PDF only on Docsity! 1 Price - $3.00 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS EVSW™ SERIES MODULATING WATER HEATER 104491-01-1/13 Your Local Thermal Solutions Representative: File Number MH47005 For Service and repairs to the heating plant, call your heating contractor. When seeking information on the water heater from the manufacturer, provide water heater model and serial number as shown on rating label. Water Heater Model Serial Number Type System Heating Contractor EVS - Phone NumberAddress Installation Date AS M E H 2 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. 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 Water Heaters installed in the USA shall be in accordance with the National Electrical Code and/or local regulations. All wiring on Water Heaters installed in Canada shall be in accordance with the Canadian Electrical Code and/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 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. AVERTISSEMENT. Assurez-vous de bien suivre les instructions données dans cette notice pour réduire au minimum le risque d'incendie ou d'explosion ou pour éviter tout dommage matériel, toute blessure ou la mort. - Ne pas entreposer ni utiliser d'essence ou ni d'autres vapeurs ou liquides inflammables à proximité de cet appareil ou de tout autre appareil. - QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ: • Ne pas tenter d'allumer d'appareil. • Ne touchez à aucun interrupteur; ne pas vous servir des téléphones se trouvant dans le bâtiment. • Appelez immédiatement votre fournisseur de gaz depuis un voisin. Suivez les instructions du fournisseur. • Si vous ne pouvez rejoindre le fournisseur, appelez le service des incendies. - L'installation et l'entretien doivent être assurés par un installateur ou un service d'entretien qualifié ou par le fournisseur de gaz. WARNING: If the information in theses instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. - Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. - WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor's phone. Follow the gas suppliers instructions. • If you cannot reach your gas supplier, call the fire department. - Installation and service must be performed by a qualified installer, service agency or the gas supplier. 5 28.3 [717.6] 30.3 [768.4] 71 .2 [1 80 8. 2] 16 .0 [4 06 .4 ]REQUIREMENT FOR BURNER REMOVAL 11.3 [285.8] 41 .1 [1 04 4. 6] 17 .1 [4 35 .0 ] 13.3 [336.6] 6. 1 [1 55 .6 ] 14.1 [358.8] 2. 4 [6 1. 9]BOILER DRAIN 1" NPT PIPE CONDENSATE DRAIN 5 8" TUBE FLUE OUTLET 4" SAF-T-VENT 23 .6 [6 00 .1 ] 21 .8 [5 52 .5 ] 6.3 [158.8] 3.5 [88.9] WATER RETURN FROM SYSTEM 2" NPT 8.1 [206.4] 9.3 [235.0] 14 .4 [3 66 .7 ] 5.5 [139.7] 31.0 [787.4] P&T GAUGE WATER FLOW SWITCH RELIEF VALVE 10.8 [274.3] 10.0 [254.0] WATER SUPPLY TO SYSTEM 2" NPT GAS SUPPLY 1" NPT GAS PILOT 1 4" TUBEGAS VENT 3 4" NPT PIPE 30 .6 [7 77 .9 ] 13.9 [352.4] 7. 0 [1 77 .8 ] 9.6 [242.9] 2. 3 [5 7. 2] 19.0 [482.6] 6.3 [158.8] 3.5 [88.9] 4.4 [111.1] REQUIREMENT FOR BURNER REMOVAL 16 .0 [4 06 .4 ] 17 .9 [4 54 .0 ] 21 .8 [5 52 .5 ] 23 .6 [6 00 .1 ] 60 .9 [1 54 7. 8] 28.3 [717.6] 30.3 [768.4] 9.3 [235.0] 15 .4 [3 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 Water Heater Model Number CAPACITIES INPUT (MBH) GROSS OUTPUT (MBH) WATER VOLUME (gallons) DRY WEIGHT (lbs.) WET WEIGHT (lbs.) EVS-500 500 410 6.1 817 868 EVS-750 750 615 15.9 1,172 1,305 Water Heater MODEL RANGE ELECTRICAL SUPPLY (volts/Hz/phase) Blower Motor (hp) Nominal power draw (amps) EVS-500 120/60/1 1/2 4.5 208/60/1 3.5 230/60/1 3.4 208/60/3 3.0 230/60/3 2.9 460/60/3 1.5 EVS-750 120/60/1 1-1/2 7.5 208/60/1 6.6 230/60/1 6.4 208/60/3 6.0 230/60/3 6.0 460/60/3 3.0 Figure 1a: Dimensions and capacities EVS 500 & 750 EVS-500 EVS-750 Notes: 1. Piping removed for visual clarity (rear view). 2. See notes concerning Net AHRI Ratings on page 4. 6 Water Heater MODEL RANGE ELECTRICAL SUPPLY (volts/Hz/phase) Blower Motor (hp) Nominal power draw (amps) EVS-1000/1500 120/60/1 1-1/2 7.5 208/60/1 6.6 230/60/1 6.4 208/60/3 6.0 230/60/3 6.0 460/60/3 3.0 Figure 1b: Dimensions and capacities EVS 1000 & 1500 4.4 [111.1] 19.0 [482.6] 2. 3 [5 7. 2] 9.6 [242.9] 7. 3 [1 84 .2 ] 13.9 [352.4] 36 .9 [9 38 .2 ] 17 .6 [4 47 .7 ] 3.5 [88.9] 6.3 [158.8] 16 .0 [4 06 .4 ]REQUIREMENT FOR BURNER REMOVAL 23 .6 [6 00 .1 ] 21 .8 [5 52 .5 ] 67 .3 [1 07 9. 8] 28.3 [717.6] 30.3 [768.4] 9.3 [235.0] 15 .4 [3 92 .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 FROM SYSTEM 3" NPT WATER SUPPLY TO SYSTEM 3" NPT GAS PILOT 1 4" TUBEGAS VENT 3 4" NPT PIPE 4.4 [111.1] 19.0 [482.6] 49 .0 [1 24 4. 6] 2. 3 [5 7. 2] 9.6 [242.9] 7. 0 [1 77 .8 ] 13.9 [352.4] 17 .9 [4 54 .0 ] 19 .0 [4 82 .6 ] 3.5 [88.9] 6.3 [158.8] 23 .6 [6 00 .1 ] 21 .8 [5 52 .5 ] REQUIREMENT FOR BURNER REMOVAL 79 .4 [2 01 7. 7] 28.3 [717.6] 30.3 [768.4] 9.3 [235.0] 27 .4 [6 96 .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 5 8" TUBE FLUE OUTLET 6" 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 EVS-1000 EVS-1500 Water Heater Model Number CAPACITIES INPUT (MBH) GROSS OUTPUT (MBH) WATER VOLUME (gallons) DRY WEIGHT (lbs.) WET WEIGHT (lbs.) EVS-1000 1,000 820 16.4 1,260 1,397 EVS-1500 1,500 1,230 17.4 1,402 1,547 Notes: 1. Piping removed for visual clarity (rear view). 2. See notes concerning Net AHRI Ratings on page 4. 7 Water Heater MODEL RANGE ELECTRICAL SUPPLY (volts/Hz/phase) Blower Motor (hp) Nominal power draw (amps) EVS-2000 120/60/1 1-1/2 7.5 208/60/1 6.6 230/60/1 6.4 208/60/3 6.0 230/60/3 6.0 460/60/3 3.0 Figure 1c: Dimensions and capacities EVSW 2000 61 .4 [1 55 8. 9] 13.9 [352.4] 7. 0 [1 77 .8 ] 9.6 [242.9] 2. 3 [5 7. 2] 19.0 [482.6] 4.4 [111.1] 17 .9 [4 54 .0 ] 31 .0 [7 87 .4 ] 3.5 [88.9] 6.3 [158.8] 23 .6 [6 00 .1 ] 21 .8 [5 52 .5 ] REQUIREMENT FOR BURNER REMOVAL 91 .8 [2 33 2. 0] 28.3 [717.6] 30.3 [768.4] 9.3 [235.0] 27 .4 [6 96 .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] CONDENSATE DRAIN 5 8" TUBE FLUE OUTLET 6" SAF-T-VENT WATER RETURN FROM SYSTEM 3" NPT WATER SUPPLY TO SYSTEM 3" NPT GAS PILOT 1 4" TUBEGAS VENT 3 4" NPT PIPE EVS-2000 Water Heater Model Number CAPACITIES INPUT (MBH) GROSS OUTPUT (MBH) WATER VOLUME (gallons) DRY WEIGHT (lbs.) WET WEIGHT (lbs.) EVS-2000 2,000 1,640 18.5 1,536 1,690 Notes: 1. Piping removed for visual clarity (rear view). 2. See notes concerning Net AHRI Ratings on page 4. 10 III. Installation A. VENT GUIDELINES DUE TO REMOVAL OF AN EXISTING WATER HEATER For installations not involving the replacment of an existing water heater, proceed to step B. When an existing water heater is removed from a common venting system, the common venting system is likely to be too large proper venting of the remaining appliances. At the time of removal of an existing water heater, the following steps shall be followed with each appliance remaining connected to the common venting sytem placed in operation, while the other appliances remaining connected to the common venting system are not in operation: 1. Seal any unused openings in the common venting system. 2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, and other deficiencies which could cause an unsafe condition. 3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common ventings system. Turn on any exhaust fans, such as range-hoods and bathroom exhausts, so they will operate at maximum speed. do not operate a summer exhaust fan. Close fireplace dampers. 4. Place in operation the appliance being inspected. Follow the Lighting (or Operating) Instructions. Adjust thermostat so appliance will operate continuously. 5. Test for Spillage at the draft hood relief opening after five (5) minutes of main burner operation. Use the flmae of a match or candle, or smoke from a cigarette, cigar, or pipe. 6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fants, fire place dampers and any other gas burning appliance to their previous conditions of use. 7. Any improper operation of the common venting system should be corrected so teh installation conforms with the National Fuel Gas Code, NFPA 54/ANSI Z223.1. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part II in the National Fuel Gas Code, NFPA 54/ANSI Z223.1. B. VENTING 1. General Venting Requirements In order to properly vent this Water Heater, the installer must select and install a vent system that meets all requirements specified in this section (VENTING) as well as following the instructions provided by the vent system manufacturer. a. The vent system shall be designed and constructed in accordance with the National Fuel Gas Code/NFPA 54 ANSI Z223.1 and applicable local building codes to develop a positive flow adequate to convey flue or vent gasses to the outdoors. b. If this Water Heater is being installed in Massachusetts, follow the Massachusetts Code instructions printed later in this section. c. Consult the vent pipe manufacturer’s instructions for vent system assembly and system specific installation requirements. WARNING Vent pipe system must be made of materials approved for use with condensing flue gasses. d. Vent pipe system shall be acceptable for use with Water Heater fuel type. e. Vent pipe system shall be compatible either by directly connecting, or by use of an adapter, to the Water Heater vent connection. i. This Water Heater is shipped with an AL 29- 4C® Heat-Fab Saf-T-Vent connection. ii. Alteration of the Water Heater vent connection is prohibited. f. Do not reduce the diameter of the vent pipe. The vent pipe must not be smaller than the vent connector on the Water Heater. g. Vent pipe system must be adequately supported at intervals no less than five (5) feet apart. The completed vent system must be rigid and able to withstand impacts without collapse. h. If any point of the vent pipe system is higher than WARNING Improper venting may result in property damage and the release of flue gasses which contain deadly carbon monoxide (CO) into the building, which can cause severe personal injury and/or death. 11 the Water Heater flue collar, the vent system must have adequate condensate drain loop(s) to prevent condensate from running back into the Water Heater. i. It is permissible to run vent pipe through a vertical or horizontal chase provided minimum clearances to combustible materials are maintained. j. The minimum clearance to combustible material is six (6) inches, unless otherwise specified by the vent system manufacturer. k. Horizontal vent pipe must slope no less than one (1) inch in four (4) feet of run. l. The vent termination location is restricted as follows: i. Minimum twelve (12) inches above grade plus normally expected snow accumulation or seven (7) feet above grade if located adjacent to public walkways. DO NOT INSTALL over public walkway where local experience indicates condensation or vapor from the Water Heater creates a nuisance or hazard. ii. Minimum three (3) feet above any forced air inlet located within ten (10) feet of the vent termination. iii. Minimum four (4) feet below, four (4) feet horizontally or one (1) foot above any door, window or gravity air inlet. iv. Minimum four (4) feet horizontally from electric meters, gas meters, regulators and relief valves. This distance may be reduced if equipment is protected from damage due to condensation or vapor by enclosure, overhangs, etc. v. Minimum twelve (12) inches from corners of building. m. Use appropriately designed thimbles when passing through combustible walls or roofs. n. Install fire-stops where vent passes through floors, ceilings or framed walls. The fire-stop must close the opening between the vent pipe and the structure. o. Enclose vent passing through occupied or unoccupied spaces above the Water Heater with materials having a fire resistance rating at least equal to the rating of the adjoining floor or ceiling. Maintain minimum clearance to combustible materials. p. Locate vent terminal above combustion air intake terminal (if used) and no closer than one (1) foot horizontally. q. Vertical venting requires flashing and a storm collar to prevent moisture from entering the structure. r. Vertical vent termination must be at least two (2) feet plus the expected snow accumulation above roof penetration height. s. This Water Heater’s venting may be Category IV (positive vent pressure, flue condensing) or Category II (non-positive vent pressure, flue condensing), with regards to National Fuel Gas Code/NFPA 54 ANSI Z223.1. 2. Positive Pressure Venting Requirements a. Vent pipe system must be fully sealed. WARNING Do not use vent dampers or barometric dampers with positive pressure vent systems. b. Direct vent applications: For direct vent (ducted combustion air) installations, the maximum vent length is 50 equivalent feet. The vent length is equal to the total length of straight pipe plus the equivalent length of vent fittings. c. Non-direct vent applications: For non-direct vent installations (those without ducted combustion air), design the vent system so that the pressure measured at the outlet of the Water Heater is between 0”w.c. and 0.3”w.c. at high fire. d. For sidewall venting, slope pipe toward vent termination, if possible. e. See Figures 2, 3 and 4 for examples of positive pressure venting arrangements. 3. Negative Pressure (Conventional) Venting Requirements This section outlines requirements for conventional venting installations, where a negative pressure at the Water Heater flue outlet is achieved by means of natural convection through a vertical length of vent pipe or lined chimney. a. Refer to Figure 5 for an example of a typical conventional venting arrangement. b. A lined chimney or vertical length of vent 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 to provide a minimum - 0.04 inch w.c. pressure (draft) at the Water Heater flue outlet. g. The chimney must be protected from down drafts, rain and debris by using a chimney cap or star. 12 Figure 3: Sidewall Positive Pressure Venting (Optional) Figure 2: Sidewall Positive Pressure Venting 15 Figure 5: Typical Negative Pressure (Conventional) Venting d. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer: 1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and 2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions. e. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation. 16 C. COMBUSTION AIR - See Figures 6 and 7. 1. The Water Heater may be operated with inside or outside air. 2. Refer to air intake piping drawings in this section for proper outside air installation details. 3. Combustion air conduit can be galvanized smoke pipe, PVC, CPVC, or flexible aluminum conduit. 4. The maximum air intake pipe length is fifty (50) equivalent feet. Air intake pipe length is equal to the total length of straight pipe plus the equivalent length of fittings. Consult intake pipe manufacturer for equivalent length of fittings and pipe. 5. Consult air intake pipe manufacturer's instructions for proper method of sealing intake pipe sections and fittings. Do not use other adhesives or sealants except as expressly permitted by the intake pipe manufacturer's instructions. WARNING Do not reduce size of air intake pipe. Read, understand and follow combustion air instruction restrictions contained in the Pre- Installation instructions of this manual. 6. Air intake termination must be located at least twelve (12) inches above grade plus the expected snow accumulation. Figure 6: Horizontal Air Intake Piping 7. Water Heater 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 and able to withstand impacts without collapse. CAUTION Dirty, contaminated or dusty air used for combustion will decrease the useful life of the Water Heater air filter. Use outside air if inside air quality is questionable. Use outside air if the Water Heater is installed in manufacturing plants, laundries, dry cleaners or other locations with heavy particulates in the air. WARNING Do not locate air intake where petroleum distillates, CFCs, detergents, volatile vapors or any other chemicals are present. Severe Water Heater corrosion and failure will result. Thermal Solutions does not warrant failures caused by contaminated air. Do not locate air intake termination where natural convection or wind conditions may cause the Water Heater exhaust gases to be drawn into the air intake. PLUS EXPECTED 2’ MINIMUM CLEARANCE “| SNOW ACCUMULATION FROM VERTICAL VENT LOCATE 1’ MINIMUM J TERMINATION m7 ELBOW WITH SCREEN FLASHING AND STORM COLLAR INSULATION FIRESTO. TaN Cy Ul 3/4” PIPE STRAP CLOSE TO ELBOW ALL EXPOSED AIR INTAKE -(\ -\ PIPING MUST BE CONSTRUCTED OF CORROSION RESISTANT MATERIAL SUCH AS ALUMINUM, STAINLESS STEEL OR PVC XN FIRESTOP / SUPPORT \ supe ANY OFFSET TOWARD APPLIANCE 1” IN 4’ MINIMUM AIR INTAKE PIPE SAME DIAMETER AS VENT CONNECTOR AIR INTAKE CONNECTOR Figure 7: Vertical Air Intake Piping 17 20 TABLE 2 - EVS WATER HEATER FLOW AND PRESSURE DROP Water Heater MODEL 20°DT (at 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) EVS-500 2.93 41 0.74 21 21 41 2 EVS-750 1.81 62 0.46 31 31 62 3 EVS-1000 3.24 82 0.81 41 41 82 3 EVS-1500 7.37 123 1.85 62 62 123 3 EVS-2000 13.27 164 3.32 82 82 164 3 Figure 8: Water Piping 21 . WARNING Failure to operate the unit with the proper water flow rate can lead to appliance failure. Always verify proper water flow switch operation so that the unit stops operating if improper water flow is present. Safety relief valve discharge piping must be piped such that the potential of severe burns is eliminated. DO NOT pipe in any area where freezing could occur. DO NOT install any shut- off valves, plugs or caps. Consult Local Codes for proper discharge piping arrangement. If a high head system pump is installed, ensure that the Water Heater relief valve and system piping are capable of operating properly at the combined pressure of the system fill pressure plus the pump static head pressure. Do not install valves, plugs or caps in safety relief valve piping. Safety relief valve piping must be terminated such that in the event the safety relief valve opens, the discharge will not cause personal injury or damage. 9. If the Water Heater 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 10. A pressure relief valve is supplied with each Water Heater. No valve is to be placed between the relief valve and appliance. a. Pipe the safety relief discharge to a suitable place for disposal when relief occurs. b. Do not install reducing couplings or other restrictive devices in the safety relief discharge line. c. The safety relief discharge line must allow for complete drainage of both the valve and line. 11. If the relief valve discharges periodically, this may be due to thermal expansion 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. 12. The seperate hot water storage container must have a temperature and pressure relief valve installed. a. This relief valve shall comply with the standard for relief valves for hot water sup- ply systems ANSI 221.22-CSA4.4. b. No reducing coupling or other restriction shall be installed in the discharge line. c. No valve shall be placed between the relief valve and tank. 13. The discharge from temperature and pressure valve(s) shall be conducted to a suitable place for disposal when relief occurs. 14. If the appliance is used in an application other than that of a circulating type, a temperature and pressure relief valve must be installed near the hot water outlet. 15. All relief valves shall be installed in a manner such that they are accessible for servicing or replacement. F. GAS PIPING WARNING Failure to properly pipe gas supply to Water Heater may result in improper operation and damage to the Water Heater or structure. Always assure gas piping is absolutely leak free and of the proper size and type for the connected load. An Additional gas pressure regulator may be needed. Consult gas supplier. 1. Size gas piping. Design system to provide adequate gas supply to Water Heater. Consider these factors. a. Allowable pressure drop from point of delivery to Water Heater. Refer to Table 3 for minimum and maximum Water Heater gas train inlet pressure at steady state. If gas supply pressure is higher than maximum as listed in Table 3, an additional field supplied pressure regulator will be required. b. If a lower minimum gas pressure is needed, the low gas pressure build can be used. The minimum gas pressure on all the low gas pressure builds is 4.0 in. w.c. Consult factory if this option is desired. This option is not available on the EVS-500, 2000S, 2500 or 3000. c. Maximum gas demand. Table 7 lists Water Heater input rate. Also consider existing and expected future gas utilization equipment (i.e., water heater, cooking equipment). d. Length of piping and number of fittings. Refer to Table 4 for maximum capacity of schedule 40 pipe. Table 6 lists equivalent pipe length for standard fittings. i. Specific gravity of gas correction factor, to be applied to the value found in Table 4, 22 can be found in Table 5. ii. For gas piping material other than schedule 40 pipe, refer to the National fuel gas code, NFPA 54/ANSI Z223.1 and/or CAN/GCA B149 Installation codes. 2. If step down regulator is required, it must be used in conjunction with the factory supplied regulator and be located as far away from the Water Heater as possible to prevent nuisance shutdowns. The minimum and maximum inlet gas pressure must not exceed the value specified in Table 3. 3. Install field supplied sediment trap, ground-joint union and manual non-displacable shut-off valve upstream of factory supplied shut-off valve outside the Water Heater jacket. Use methods and materials in accordance with Local Codes and requirements of gas supplier. In absence of such requirements, follow National Fuel Gas Code, NFPA 54/ANSI Z223.1 and/or CAN/CSA B149 Installation Codes. 4. Use thread joint compound resistant to the action of liquefied petroleum gas. WARNING Failure to use proper thread compounds on all gas connectors may result in leaks of flammable gas. 5. All above ground gas piping upstream from field supplied manual gas valve must be electrically continuous and bonded to a grounding electrode. Do not use gas piping as grounding electrode. Refer to National Electrical Code, ANSI/NFPA 70 and /or CSA C22.1 Electrical Codes. TABLE 3 - Water Heater GAS TRAIN INLET PRESSURE Water Heater Model MIN. ("w.c.) MAX. EVS-500 5.0 5 psi-NG 2 psi-LP EVS-750* 7.0 EVS-1000* 7.0 EVS-1500* 7.0 EVS-2000* 9.0 * Available with optional gas train with min 4" w.c. inlet gas pressure. WARNING Gas supply to Water Heater and system must be absolutely shut off prior to installing or servicing Water Heater gas piping. WARNING Use an additional gas pressure regulator where the gas pressure is greater than 5 psig. Using one additional regulator for multiple Water Heaters may result in unsafe Water Heater operation. The additional regulator must be able to properly regulate gas pressure flow at the lowest input of a single Water Heater. 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 Water Heater and its gas connection must be leak tested before placing Water Heater in operation. a. Protect Water Heater gas control valve. For all testing over ½ psig, Water Heater and its individual shutoff valve must be disconnected from gas supply piping. For testing at ½ psig or less, isolate Water Heater from gas supply piping by closing the Water Heater's individual manual shutoff valve. b. The appliance and its gas connection must be leak tested before placin into operation. Locate leaks using approved combustible gas detector, soap and water, or similar nonflammable solution. DANGER Do not use matches, candles, open flames or other ignition source to check for leaks. 25 G. ELECTRICAL 1. General. Install wiring and ground Water Heater in accordance with authority having jurisdiction or in absence of such requirements National Electrical Code, ANSI/NFPA 70 and/or CSA C22.1 Electrical Code. 2. The appliance, when installed, must be electrically grounded in accordance with local codes or, in the abscence of local codes, with the National Electric Code, ANSI/FPA 70 and/or the CSA C22.21, Canadian Electric Code 3. A separate electrical circuit must be run from the main electrical service with an over-current device/disconnect in the circuit. A service switch is recommended and may be required by some local jurisdictions. Locate the service switch such that the appliance can be shut off without exposing personnel to danger in the event of an emergency. DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the Water Heater or building. Lock out all electrical boxes with padlock once power is turned off. 4. Connect the main power supply and ground from fused disconnect to proper Water Heater electrical leads located in the junction box at the rear of the Water Heater. Refer to electrical consumption plate on Water Heater jacket. 5. Connect field supplied safety limits or devlices 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. 6 The following pages have sample wiring diagrams. Contact Thermal Solutions Representative or visit website (www. thermalsolutions.com) for current wiring options. CAUTION Each Water Heater must be protected with a dedicated properly sized fused disconnect. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper operation. Verify proper operation after servicing. WARNING Electrical power may be supplied from more than one service. Make sure all power is off before attempting any electrical work. The wiring diagrams contained in this manual are for reference purposes only. Each Water Heater may be wired differently according to the specifications given to Thermal Solutions at the time the Water Heater was purchased. Always use the wiring diagram provided with the Water Heater. If the wiring diagram provided with the Water Heater is unavailable, STOP all wiring work and contact Thermal Solutions for a replacement diagram. Do not directly connect low voltage (24 volt, milliamp, etc.) controls to this Water Heater. If low voltage controls are desired, isolating relays must be used. Never jump out or bypass any safety controls. Never jump out or make inoperative any safety or operating controls. Each Water Heater must be protected with a properly sized over-circuit device. 7. An as-built wiring diagram is included with every Water Heater when it is shipped from the factory. 8. Install water heater circulator with a separate fused disconnect switch. Refer to as-built wiring diagram & manufacturer's data for electrical requirements. 9. Field Wiring to be performed at the time of water heater installation. WARNING Failure to properly wire electrical connections to the water heater may result in serious physical harm. DO NOT ATTACH ADDITIONAL J-Box to back or top of water heater jacket. 26 Figure 9a: 208/230/460V-1/3 ph-60 Hz Supply Power Wiring Schematic SUNCTION BOX TO DISCONNECT, (By OTHERS) GROUND UNIT 70 TECHNICAL EARTH GND. 120V-1PH-BOHZ cno— 7 VARIABLE GND To SPEED DRIVE CHASSIS Ae TECH SCF SEE NOTE 1 BLOWER to Pu ca SEE FIGURE 9C—9F FOR CONTROL CIRCUIT To Pr-ig WE GND TO CHASSIS. NOTES: 1, USE SPRING CAGE CONNECTORS (PN 81:568915) FOR WIRE JUNCTIONS, XX Figure 9b: 120V-1ph-60Hz Supply Power Wiring Schematic 27 30 Figure 10: Modular System: Conventional Venting (Negative Pressure) H. MODULAR SYSTEMS 1. General Guidelines a. Read and follow all venting, combustion air, water piping, gas piping and electrical instructions contained in this manual unless otherwise instructed in this section. b. Design and installation of modular systems should only be undertaken by skilled and knowledgeable engineers and contractors. c. Consult Local Building Codes, National Fuel Gas Code, or NFPA 54/ANSI Z223.1 for restrictions and instructions for modular Water Heaters. d. Refer to the Pre-Installation section for further warnings, cautions, notices and instructions. e. Modular systems are complex. Design and installation of modular systems should only be undertaken by skilled and knowledgable engineers and contractors. 2. Module Sizing Consult factory for recommended number and size of Water Heaters for a given input. 3. Venting This section outlines venting requirements for multiple Water Heater installations and should be used in addition to the “VENTING” 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 chase so that a single roof penetration can be made. Each vent termination must be one (1) foot from all other terminations. WARNING DO NOT manifold vent components of multiple Water Heaters without converting to a negative pressure venting arrangement. b. Negative Pressure (Conventional) Venting i. Refer to Figure 10 for an example of a typical conventional venting arrangement for modular Water Heaters. ii. Refer to National Fuel Gas Code to determine required chimney diameter and common venting diameter. Note that combined input, lateral length and chimney height affect vent diameter. 31 iii. Install a double acting barometric damper with integral flue spillage interlock (as shown in Figure 10). iv. Locate Water Heater(s) with lowest input closest to chimney/vertical common vent. v. Chimney lining must be acceptable for use with condensing flue gases. vi. Install a condensate drain to collect any condensate that may form in the lined chimney or vertical common vent (refer to figure 10). CAUTION Installing multiple vent terminations close together promotes frost build up on buildings. To minimize this possibility, extend the distance from the building to the end of the vent termination and increase the horizontal distance between vent terminations. 4. Air Intake Piping a. Consult intake pipe manufacturer for common air intake pipe sizing. b. Refer to Figures 11 and 12 for common air intake guidelines for modular Water Heaters. c. Individual air intake pipes may be used in lieu of common air intake piping. d. The maximum air intake length is (50) equivalent feet. Common air intake straight lengths and fittings should be assumed to have the equivalent length the same as an individual air intake pipe, used for a given Water Heater 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. Refer to the Combustion Air section for further warnings, cautions, notices and instructions. 5. Water Piping a. Refer to Figure 8 for typical piping for the water heater. b. Installing a low water cut-off in the system piping is highly recommended and may be required by Code, if not factory mounted on Water Heater. c. Refer to Table 1 for pressure drop and flow requirements for each Water Heater. d. Consult I=B=R Installation and Piping Guide. e. Maintain ½" minimum distance between water piping and combustible material. f. Refer to Water Piping and Trim section for further warnings, cautions, notices and instructions. 6. Gas Piping a. Refer to National Fuel Gas Code, Local Codes and Tables 2 through 7 for gas pipe sizing. b. Refer to Gas Piping section for further warnings, cautions, notices and instructions. WARNING If gas pressure in the building is above 1/2 psig, for ON/OFF water heaters, an additional gas pressure regulator is required. Use an additional gas pressure regulator for modulating water heat- ers, where the gas pressure is greater than 5 psig. Using one additional regulator for multiple water heaters may result in unsafe water heater opera- tion. The additional regulator must be able to properly regulate gas pressure flow at the lowest input of a single water heater. If the regulator cannot do this, two or or more additional regulators are required. Consult regulator manufacturer's instructions for minimum gas flow rate. 32 Fi gu re 1 1: M od ul ar S ys te m H or iz on ta l A ir In ta ke P ip in g 35 IV. System Start-up CAUTION Failure to properly pipe Water Heater may result in improper operation and damage to Water Heater or structure. Oxygen contamination of Water Heater water will cause corrosion of iron and steel Water Heater components, and can lead to Water Heater failure. Thermal Solutions Standard Warranty does not cover problems caused by oxygen contamination of Water Heater water. Proper water treatment is required to avoid scale build-up on the inside of the Water Heater. Thermal Solutions standard warranty does not cover problems caused by scale build-up. All piping either new or existing must be cleaned with a tri sodium phosphate (TSP) solution to remove mill scale and oils from the system. Failure to do so could result in premature failure of the heat exchanger (not covered by Thermal Solutions warranty). On an existing or retrofit system, a filter or strainer must be installed on the system return prior to the Water Heaters. A. System Check 1. Verify that the venting, water piping, gas piping and electrical system are installed properly. Refer to installation instructions contained in this manual. WARNING Completely read, understand and follow all instructions in this manual, Honeywell flame safeguard, and all other component manuals supplied with this Water Heater before attempting start up. 2. Confirm all electrical, water and gas supplies are turned off at the source and that chimney/vent is clear of obstructions. If Water Heater is controlled by an external control system, this system must be temporarily disconnected. The local Water Heater controls should be allowed to operate the Water Heater. 3. Remove the upper front jacket panel. 4. Confirm that all manual shut-off gas valves between the Water Heater and gas supply are closed. CAUTION This Water Heater 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 Series Loop or multi-zoned system installed to remove air from the system while filling. 1. Close full port ball valve in Water Heater 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 system piping and terminate hose in a five gallon bucket at a suitable floor drain or outside area. 4. Starting with one circuit at a time, open zone valve or shut-off valve in system supply and return piping. a. Open hose bib. b. Open fill valve (Make-up water line should be located directly after full port ball valve in system supply piping between air scoop and expansion tank). c. Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds. d. Close the opened zone valve or shut-off valve for the zone being purged of air, then open the zone valve or shut-off valve for the next zone to be purged. Repeat this step until all zones have been purged. At completion, open all zone valves or shut-off valves. 5. Close hose bib, continue filling the system until the pressure gauge indicates required system operating pressure. Close fill valve. (Note - if make-up water line is equipped with pressure reducing valve, system will automatically fill to set pressure. Follow fill valve manufacturer's instructions). 6. Open isolation valve in Water Heater supply piping. 7. Remove hose from hose bib. 8. Confirm that the Water Heater and system have no water leaks. 36 WARNING The maximum operating pressure of this Water Heater is 160 psig. Never exceed this pressure. This Water Heater was supplied with a safety relief valve with a pressure relief setting specified at the time of purchase. The relief valve setting must be above the maximum operating pressure of the system. Consult Thermal Solutions if the desired system operating pressure is above the safety relief valve pressure setting. Do not plug or change safety relief valve. C. Power the Water Heater - Turn on electrical supply to the Water Heater and circulation system at fused disconnect switches. Note that there is electrical power at certain components even with the power switch off. See wiring diagrams in Figures 9a-9d. D. Power the Circulators - Turn system circulators on and purge air from the Water Heater and system piping. 1. Confirm motor rotation on Water Heater and system circulators. 2. Confirm that water flow switch is operating properly. E. Pressurize the Fuel System - Turn on gas supply to the Water Heater gas piping. 1. Confirm that the supply pressure to the gas regulator supplied with the Water Heater conforms to Table 3 for maximum and minimum supply pressures. 2. Open the manual gas shut-off valves located upstream of the gas regulator supplied with the Water Heater. Do not open manual gas valve inside of Water Heater jacket. DANGER Do not use matches, candles, open flames or other ignition source to check for leaks. 3. Using soap solution, or similar non-combustible solution, electronic leak detector or other approved method, check that Water Heater gas piping valves, regulators and all other components are leak free. Eliminate any leaks. 4. Purge gas line of air. 5. Reset low gas pressure safety switch. F. Select Operational Mode - Refer to the Thermal Solutions Water Heater ControlTM (TSBCTM) Instruction Manual to select the desired control features. G. Check Blower Rotation - Remove air filter to expose the fan blades. 1. Allow Water Heater 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 Water Heater off and position the flame control back to run. Reinstall air filter. H. Flame Safeguard Operation Check - Turn Water Heater operating switch to the on position. 1. Allow Water Heater 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 Water Heater sight glass and confirm that pilot flame is blue and steady and that the flame signal is steady and between 1.5 and 5.0 volts DC. On some Water Heater sizes, the pilot flame may not be visible. In these cases, confirm proper flame signal (as indicated above.) 3. Adjust pilot gas regulator until proper pilot manifold gas pressure is achieved per firetest report label. Pilot flame should be blue with very little yellow. 4. Turn the Water Heater off, place flame control switch in "run" position, and repeat Steps H.1 and H.2 at least five times until reliable pilot ignition and signal is achieved and confirmed. 5. With the pilot operating properly, allow Water Heater to continue to trial for main flame. Confirm that the flame control locks out on main flame failure. 6. Open the manual main gas shut-off valve located inside the Water Heater jacket. Using the procedure detailed in Step E.3, leak test gas piping and valves inside of jacket. Eliminate any leaks. 7. Reset flame safeguard and allow Water Heater to run through prepurge, trial for pilot and trial for main flame. 8. Confirm that main flame ignites smoothly. 9. Observe main flame and confirm that burner element is evenly orange without flickering. 10. Observe flame signal and confirm signal is steady and between 1.5 and 5.0 volts DC. 11. Using the procedure detailed in step E.3, leak test gas piping and valves inside of jacket. Eliminate any leaks. 12. Turn Water Heater off and repeat Steps H.7-H.10 at least five times to confirm proper main burner operation. I. Begin Commissioning the Water Heater - With main flame on, at high fire, measure gas pressure upstream and downstream of the main gas valves 37 1. Adjust the manifold pressure to match the pressure indicated on the factory firetest label. 2. Reassure that the inlet gas pressure is within the acceptable range found in Table 2. Adjust if necessary. WARNING Failure to properly adjust gas input rate will result in over firing or under firing of the appliance. Improper and unsafe Water Heater operation may result. 3. Confirm that high and low gas pressure switches are functioning and are adjusted to prevent over firing or under firing of the Water Heater. 4. Adjust setting of air filter flow switch by rotating knob on switch counter clockwise until change filter light switch is illuminated. Turn switch knob clockwise ¼ turn past the point where the change filter light goes out. Replace upper front jacket panel. 5. With Water Heater running and all panels attached, measure oxygen (O2) and carbon monoxide (CO) concentrations in the flue gas and flue gas temperature. Compare results with values given on factory firetest report supplied with the Water Heater. DANGER Failure to properly adjust excess air will result in unsafe levels of carbon monoxide. Variations in venting or combustion air pressure and temperature will change excess air. Adjust excess air levels so that variation in venting or combustion air pressures and temperatures caused by change of seasons, wind conditions, opening or closing of Water Heater room doors or windows do not cause the Water Heater 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 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 Water Heater. J. Finish Commissioning at the Water Heater - Reconnect any wires from the external control system, if applicable. 1. Test function of external control system. 2. Place system control back in normal operation, if necessary. K. Water Treatment - Contact reputable chemical treatment company for recommendations on proper water treatment for the installation. Each installation is different and must be analyzed based on local water conditions and Water Heater operating schedule. The treatment chemicals must be compatible with copper, bronze, steel and cast iron materials of construction. L. Replace access panels and turn water heater off. Allow system and appliance water to cool. M. After water heater and system water has cooled to less than 80°F, turn water heater on and observe the return water temperature from the system. If the return water temperature rises to above 120°F in less than five (5) minutes, leave the bypass balancing valve fully closed. If return water temperature is not above 120°F or it takes a longer period than five (5) minutes to rise above 120°F, slowly open bypass balancing valve. Continue to open bypass balancing valve so that return water temperature to the water heater is above 140°F. Note that if the temperature does not rise above 140°F with the bypass valve fully open, slowly begin to close balancing valve in the system and return piping until appliance return water temperature is above 140°F. Turn water heater off and allow water heater and system water to cool to less than 80°F. Turn water heater on and note return water temperature to the water heater. Confirm that water temperature rises above 120°F in less than five (5) minutes. If not, continue to open bypass balancing valve. N. When water adjustment is complete, allow water heater to operate and confirm proper operation. Place system control back in normal operation. There is a hot water scald potential if the thermostat is set too high. Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance. Do not operate water heater without air filter in place and securely fastened and sealed. Replacement air filters must be purchased from authorized Thermal Solutions representatives. Part numbers are listed in Figure 20. Do not readjust gas regulator, bypass water valve, system return water valve, system supply water valve, pressure switch or water flow switch from setting determined during system start-up. Do not tamper with any other water heater components. WARNING 40 1. ARRÊTEZ ! Lisez les instructions de sécurité sur la portion supérieure (à gauche) de cette étiquette. 2. Coupez l’alimentation êlectrique de l’appareil. 3. Réglez le thermostat à la température la plus basse. 4. This water heater 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. This appliance is equipped with an ignition device, which automatically lights the pilot. Do not try to light the pilot by hand. 6. Remove front door panel. 7. Locate the gas pilot valve at the rear of the water heater. 8. Locate the gas main vavles at the rear of the water heater and at the end of the gas supply pipe inside the water heater. 9. Rotate gas shutoff valves clockwise from "ON" possition to "OFF". Make sure handle rests against stop.p. 10. Attendre cinq (5) minutes** pour laisser échapper tout le gaz. Reniflez tout autour de l’appareil, y compris près du plancher, pour déceler une odeur de gaz. Si vous sentez une odeur de gaz, ARRETEZ ! Passez à l’ étape B des instructions de sécurité sur la portion supérieure (à gauche) de cette étiquette. S’il n’y a pas d’ odeur de gaz, passez à l’étape suivante. 11. Rotate gas shutoff valves counterclockwise from "OFF" to "ON". Make sure handle rests against stop. Do not force. 12. Mettez l’appareil sous tension. 13. Réglez le thermostat à la température désirée. 14. If the appliance will not operate, follow the instructions " TO TURN OFF GAS TO APPLIANCE" and call your service technician or gas supplier. 15. Move the switch to the "ON" possition. 16. Set system control so that there is a call for heat from the system. 17. Observe prepurge, pilot ignition and main flame ignition. 18. If pilot or main flame ignition does not occur during initial attempt, remove the upper front jacket panel of the water heater. If the water heater pilot and main flame light, go to step 19. 19. Reset the burner control by pressing the reset button located on the burner control. If you do not know where the control reset button is, do not touch any part of the control system or wiring. Turn all gas and electrical power off to the water heater and call a qualified service technician. 20. Replace the upper front jacket panel. INSTRUCTIONS DE MISE EN MARCHE POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE EN MARCHE AVERTISSEMENT: Quiconque ne respecte pas à la lettre les instructions dans la présente notice risque de déclencher un incendie ou une explosion entraînant des dommages, des • Appelez immédiatement votre fournisseur de gaz depuis un voisin. Suivez les instructions du fournisseur. • Si vous ne pouvez rejoindre le fournisseur, appelez le service des incendies. C. N’utilisez pas cet appareil s’il a été plongé dans l’eau, même partiellement. Faites inspecter l’appareil par un technicien qualifié et remplacez toute partie du système de contrôle et toute commande qui ont été plongés dans l’eau. A. Cet appareil est muni d’un dispositif d’allumage qui allume automatiquement la veilleuse. Ne tentez pas d’allumer la veilleuse manuellement. B. AVANT DE FAIRE FONCTIONNER, reniflez tout autour de l’appareil pour déceler une odeur de gaz. Reniflez près du plancher, car certains gaz sont plus lourds que l’air et peuvent s’accumuler au niveau du sol. . QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ: • Ne pas tenter d’allumer d’appareil. • Ne touchez à aucun interrupteur ; ne pas vous servir des téléphones se trouvant dans lé bâtiment.. 41 Comment couper l’admission de gaz de l’appareil 1. Réglez le thermostat à la tempé la température la plus basse. 2. Coupez l’alimentation électrique de l’appareil s’il faut procéder à l’entretien. 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. INSTRUCTIONS DE MISE EN MARCHE 21. Observe several on and off cycles of the water heater. If any light offs are excessively noisy or rough, or any questionable water heater operation is noticed, immediately turn off all gas and electrical power and call qualified service technician. 22. Should overheating occur or the gas supply fail to shut off, turn off the manual gas control to the appliance. 42 VI. Water Heater Operational Sequence Sage Boiler Control Instruction Manual Page 6 of 52 Product Features Boiler Sequence SI CS SI CH AL DP O+,O- VI BP - - 2,30 SP 25,30 70,71, 72 Outdoor Air Temp > Warm Weather Shutdown Setpoint - R el ay O ut pu ts In te rlo ck In pu ts Te rm in al N um be r Pa ra m et er /N ot e Low Fire Hold Spare Output Boiler Pump System Pump M od ul at io n O ut pu ts Call For Heat Relay Domestic Hot Water Priority Flame Safeguard Alarm Parameter / Notes 20,74 Li m its In pu ts 9 Call For Heat Lockout Indicator (Manual Reset Required) LO - 44,30, 75 Fuel Valve Energized Recycling Limits (LC, OO, WF , GP and HL inputs) Pu m p P ur ge M ai n Ig ni tio n Lo w F ire H ol d Pu rg e / P ilo t I gn iti on Lo w F ire / Ig ni tio n Pu m p Co ol do w n B oi le r R un ni ng BOILER STATE LCD Display System Pump Feedback 9 - 8,27, 28 -Non-Recycling Limits (Combustion Air Flow (CA Input)) Blower High Speed Purge % Modulation Low Fire % Blower 0 Volts V+,V-, P+,P- 49 52 - 9,51/f 50 R+,R- OR BO,BC SO 10System Pump Backup Pump SO 10,27/ eCombustion Air Damper SO 10System Alarm LC, OO ,WF, GP,HL CA Mixing Valve Output MS,MR 6,79, 80 Fi rin g R at e B oi le r D is ab le ROBoiler 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 - W ar m W ea th er Sh ut do w n St an db y Lo ck ou t Li m it H ol d Combustion Air Damper Open V+,V-, P+,P- V+,V-, P+,P- V+,V-, P+,P- V+,V-, P+,P- b &ca aa Fa n Po st P ur ge 54/d Boiler Pump On Domestic Hot Water Demand Monitored System Pump On System Pump Feedback Monitored Starts in response to System Pump Feedback Input SI Alarm Status is Monitored Modulate Boiler Enable/Disable On Start/Stop Sequence StatesPre-Sequence States Notes a. Boiler Pump is “On” when the Boiler Pump is set to “On Always” or the boiler is lead boiler and Boiler Pump is set to “On Lead”. b. Boiler Pump is "On" when the Boiler Pump is set to "On Always" and WWSD is set to "WWSD of System Pump" or “Off”. c. System Pump is "On" when the System Pump is set to “yes” and WWSD is set to either "WWSD of Boiler" or "Off". d. Boiler pump is "On" during Prepurge and Post Purge when Boiler Pump is set to "Purge" or boiler is lead & Boiler Pump is set to “On Lead”. e. Combustion Air Damper Spare Output is maintained “On” for 2 minutes after the Call For Heat is removed. f. Modulation rate is held at purge % when low fire input is not provided. 45 A. SAFETY AND OPERATING CONTROLS. OPERATION AND SHUT DOWN Component Function Circuit Board Fuse If the power draw of the control circuit exceeds approximately 5 amps, the circuit board fuse trips and prevents the Water Heater from operating until the fuse is replaced. Power Switch If this switch is in the off position, power is interrupted to the control circuit of the Water Heater, which prevents the Water Heater from operating. If the switch is in the on position, power is supplied to the control circuit. Operating Aquastat If the Water Heater water temperature exceeds the adjustable set point, power is interrupted to the control circuit of the Water Heater, which prevents the Water Heater from operating. When the Water Heater water temperature drops below the set point minus the adjustable differential setting, power is again supplied to the control circuit. Manual Reset High Limit Aquastat If the Water Heater water temperature exceeds the adjustable set point, power is interrupted to the control circuit of the Water Heater, which prevents the Water Heater 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. Flow Switch If the water flow through the Water Heater 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 Water Heater from operating. When the water flow rate is increased, the paddle closes the control’s contacts and power is supplied to the control circuit. Pressure (Safety) Relief Valve 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. Mixer 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 Water Heater 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 switch open and power is interrupted to the control circuit, which prevents the Water Heater from operating. Power is interrupted until the switch is replaced. High and Low Gas Pressure Switches 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 Water Heater 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. Combustion Air Flow Switch 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 Water Heater from operating. Power is interrupted until air flow increases so that the contacts close. Flame Safeguard Control Refer to the manual supplied with the Water Heater. Variable Frequency Drive (VFD) The variable frequency drive’s primary function is to vary the rotational speed of the blower fan based on the air requirements of the Water Heater combustion process. The VFD responds to a 0-10 VDC signal from the TSBC. 46 B. TROUBLESHOOTING GUIDE Alarm Messages Alarm Messages are shown one at a time in priority order. The message closest to the top of this list is displayed first. Following messages are not shown until the higher priority message has cleared. All alarm messages are also stored in the Fault History. LCD Display Alarm Message Recommended Action Explanation Low Water Level Manually Reset the Low Water Cutoff Low Water Cutoff Switch When this option is configured and an instrument is installed, the manual reset low water safety relay is preventing the Water Heater from starting. If terminal (LC) does not receive power and the Call For Heat output (CH) is powered, the “Low Water Level” Message is displayed. Off Switch Turn Burner Switch On Burner Switch is Off Control switch is in the OFF position and is preventing the Water Heater from starting. If terminal (OO) does not receive power and the Call For Heat output (CH) is powered the “OFF Switch” Message is displayed. Low Water Flow Ensure Water Heater Pump is Running and Water Heater Water Flow is Unobstructed Low Water Flow Switch Low water flow is preventing the Water Heater from starting. If terminal (WF) does not receive power and the Call For Heat output (CH) is powered, the “Low Water Flow” Message is displayed. Fuel Limit Manually Reset the Fuel Pressure Switch Low or High Gas Pressure Switch The low or high gas pressure switch is preventing the Water Heater from starting. If terminal (GP) does not receive power and the Call For Heat output (CH) is powered the “Fuel Limit” Message is displayed. High Temp Limit Manually Reset the High Temperature Aquastat High Limit Temperature The high temperature limit (HL) (and operational temperature limit when provided) aquastat is preventing a Water Heater start. If terminal (HL) does not receive 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 Water Heater start. If terminal (CA) does not receive power and the Call For Heat out- put (CH) is powered, the “Low Air Flow” Message is displayed. FSG Fault Manually Reset Required, Refer to Flame Safeguard Manual Corrective Actions Flame Safeguard Fault The Flame Safeguard is preventing a Water Heater start. If terminal (AL) re- ceives power at any time, the “Flame Failure” Message is displayed. Outlet Temp Fail Check Wiring and Sensor Water Heater Outlet Temperature Sensor Fail The Water Heater outlet temperature sensor is not connected or is reading above or below a valid range. When the Water Heater outlet sensor fails and the Outlet Sensor mode was selected, the control will transfer to Lost Sensor Blind Mode. Inlet Temp Fail Check Wiring and Sensor Water Heater Inlet Temperature Sensor Fail The Water Heater inlet temperature sensor is not connected or is reading above or below a valid range. When the Water Heater inlet sensor fails, the mixing valve output will drive to 0% and low temperature alarm and maximum water differential (Water Heater outlet minus Water Heater inlet) temperature hold are disabled. OA Temp Fail Check Wiring and Sensor Outside Air Temperature Sensor Fail The outside air sensor is configured and is not connected or is reading above or below a valid range. When the outside air sensor fails, the warm weather shut- down (WWSD) and outside air reset control logics are disabled. 47 LCD Display Alarm Message Recommended Action Explanation Remote Input Fail Check Wiring and Remote System Remote Control Input Fail The Remote Control Input is configured and is not connected or is above or be- low a valid range. When the remote control input fails, the following control mode changes are taken automatically: Selected Modes Resulting Control Mode Remote Mod Outlet Sensor and Local Setpoint Remote Mod & Remote Sensor Remote Sensor and Local Setpoint Remote SP Outlet Sensor and Local Setpoint Remote SP & Remote Sensor Remote Sensor and Local Setpoint Comm Failure Confirm each Water Heater has a unique address Check Wiring and Remote System Communication Failure The Modbus or Peer-To-Peer network has failed. When the Modbus network fails the following control mode changes are taken automatically: Selected Modes Resulting Control Mode Modbus Mod Outlet Sensor and Local Setpoint Modbus Mod & Remote Sensor Remote Sensor and Local Setpoint Modbus SP Outlet Sensor and Local Setpoint Modbus SP & Remote Sensor Remote Sensor and Local Setpoint After a Modus communication failure, the ‘Comm Failure’ alarm is not cleared until communication is restored and successfully writes 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 Water Heaters begin operation as stand alone Water Heaters using the selected parameters. After a Peer-To-Peer communication failure the ‘Comm Failure’ alarm is not cleared until communication is restored and the Water Heater rejoins a network with at least one other Water Heater, power is cycled or the protocol parameter is changed to Modbus and then back to Peer-To-Peer. Low Inlet Temp Check return water temperature. Consider system or operational changes to avoid low temperature events Check wiring and sensor Low Water Heater Inlet Temperature If the Water Heater inlet temperature is below the low Water Heater inlet tempera- ture setpoint, the “Low Inlet Temp” Message is displayed and the Water Heater inlet temperature history is stored. Memory Failure Call Factory Reset all memories in System menu: Clr BIT History Clr Alarm Hist Clr Run Time Cnt Clr Cycle Cnt Factory Defaults (Factory Level Password is required) Memory Failure New software has been installed in the Thermal Solutions Water Heater Control (TSBC) or a power interruption has caused a memory failure. The Call For Heat will be prevented until the condition is cleared. Alarm Messages (continued) B. TROUBLESHOOTING GUIDE 50 VIII. Repair Parts EVS™ Series repair parts can be ordered through your nearest Thermal Solutions Representative for delivery from Lancaster, PA. The Representatives can also advise as to the availability of product and repair parts from local sources. Contact Thermal 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 Water Heater. Different contents and components may have been supplied due to the request of the equipment and user. Consult Thermal Solutions for repair parts on non-standard controls and components. 51 Figure 19: Combustion Chamber Assembly 52 COMBUSTION CHAMBER ASSEMBLY Key No. Description (Quantity) Part Number EVS-500 EVS-750 EVS-1000 EVS-1500 EVS-2000 1. COMBUSTION CHAMBER ASSEMBLY 1A Heat Exchanger (1) 103530-01 (1) 6035630031 (1) 6035630041 (1) 6035630051 (1) 6035630061 1B Base (1) 61556042 (1) 61556024 1F Tube Baffle (1) 70356116 (31) 70356215 (31) 70356216 (31) 70356217 (31) 70356218 1G Sight Tube Baffle (1) 70356122 (1) 70356223 (1) 70356224 (1) 70356225 (1) 70356226 1H Combustion 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) 70356236 (1) 70356237 (1) 70356238 (1) 70356239 1K Condensate Drain Tube (1) 8065603 (1) 8065601 1L 1" Fiber Gasket (9 LF) 9206032 (14 LF) 9206032 1M Sight Glass Lens Retainer (1) 7186019 (1) 7186019 1N Sight Glass Gaskets (2) 8206039 (2) 8206039 1O Sight Glass Lens (1) 8026082 (1) 8026082 1P Vent Connector Gasket (1) 8205623 (1) 8205624 1Q Vent Connector (1) 81156027 (1) 81156016 (1) 81156017 1R Wrapper Banding (12 LF) 92466028 (24 LF) 92466028 1S Banding Buckle (3) 80860946 (4) 80860946 1T Temperature Probe (not shown) (2) 101935-01 kow? ea ROY ~& VIEW TOP © \ © UO Z FRONT SIDE VIEW Figure 21: UL/FM/CSD-1 Main Gas Train Assembly 55 56 UL/FM/CSD-1 GAS TRAIN - MAIN AND PILOT Key No. Description (Quantity) Part Number EVS- 500 EVS- 750 EVS- 1000 EVS- 1500 EVS- 2000 3. Main and Pilot Gas Train (UL/FM/CSD-1) 3A Main Gas Valve Body 1" NPT (1) 816634041 -- -- -- Main Gas Valve Body, 1-1/2" NPT -- -- (1) 81663404 Main Gas Valve Body, 2" NPT -- -- -- -- -- 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 -- -- -- -- -- 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" -- -- -- -- -- 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 57 Figure 22a: DB&B Gas Train (500-750) DB&B – MAIN AND PILOT Key No. Description (Quantity) Part Number EVSW-500 EVSW-750 3. MAIN AND PILOT GAS TRAIN 3A Main Gas Valve Body 1" NPT (1) 816634041 Main Gas Valve Body, DBL, 1-1/2" NPT — 3B Manual Gas Valve with Pilot Tapping, 1" NPT (1) 806603055 Manual Gas Valve with Pilot Tapping, 1-1/2" NPT (1) 806603053 3C DB&B Actuator/Regulator Ratio Valve, Siemens SKP75 (max 5 PSI) (1) 81663408 3D DB&B Solenoid Valve (1) 81660207 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 60 Fi gu re 2 3: J ac ke t P an el s 61 JACKET Key No. Description (Quantity) Part Number EVS-500 EVS-750 EVS-1000 EVS-1500 EVS-2000 4. Jacket Assembly 4A Jacket Lower Front Panel (Modulation) (1) 103524-01 (1) 60456342 (1) 60456343 (1) 60456344 (1) 60456345 4B Jacket Lower Rear Panel (1) 604563041 (1) 604563051 (1) 604563061 (1) 604563071 (1) 604563081 4C Jacket Upper Rear Panel (1) 70456279 4D Jacket Center Rear Panel (1) 704562471 4E Jacket Panel Left Side (1) 604563281 (1) 604563291 (1) 604563301 (1) 604563311 (1) 604563321 4F Jacket Top Panel (1) 704562541 4G Jacket Vestibule Panel (1) 604563011 (1) 604563021 4H Jacket Upper Front Panel (1) 70456280 4I Jacket Panel Right Side (1) 604563221 (1) 604563231 (1) 604563241 (1) 604563251 (1) 604563261 4J Handle (2) 8056256 4K View Port Cover for Flame Safeguard (1) 81356007 4L Observation Port Gasket (1) 8026082 4M Observation Port Gasket (2) 8206039 4N Observation Port Lens Retainer (1) 7186019 4P Latch (2) 80861722 4Q Power Switch w/Filter Light (1) 81363631 62 Figure 24: Control Panel Assembly OMRON MY2 12VDC idec RJ1S-CD -D12 IDEC RH1B-U DC12V IDEC RH1B-U DC12V IDEC RH1B-U DC12V OMRON MY2 12VDC 65 PILOT ASSEMBLY (Bishop Design) Key No. Description (Quantity) Part Number EVS- 500 EVS- 750 EVS- 1000 EVS- 1500 EVS- 2000 EVS- 2000S EVS- 2500 EVS- 3000 7. Pilot Assembly, Bishop --- Pilot Assembly, Natural Gas, ULX2 (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 66 IX. Thermal Solutions Water Heater Control™ (TSBC™) A. INTRODUCTION - The intent of this section is to briefly summarize the controllers capabilities, familiarize the user with its basic features and to list the factory supplied default settings. Read the additionally supplied Factory Instruction Manual for the TSBC to learn more about the controllers features and capabilities. 1. Thermal Solutions Water Heater Control™ Overview The Thermal Solutions Water Heater Control™ (TSBC™) is a complete Water Heater monitoring and automation system. The TSBC™ provides advanced Water Heater modulation, operating control, diagnostics, multiple Water Heater lead-lag and auxiliary device control. The TSBC™ provides advanced control features in an easy to use package. 2. Flexible, Field Selectable Control Control modes, water system, Water Heater auxiliary and modulating lead/lag control features are menu selectable without the need for external programmers, lap tops or down loads. Every Water Heater is shipped with factory defaults that make field menu selections unnecessary unless you are applying additional control features. 3. Water Heater Monitoring and Diagnostic Displays The TSBC™'s two line by sixteen character LCD display may be used for monitoring Water Heater inlet and outlet, remote system and outside air temperatures, modulation rate setpoint and modulating percent and mixing valve demand percent. Additionally, the display automatically presents Water Heater sequence messages, alarms, hold and lockout messages. A diagnostic menu is included that provides the last 10 alarm messages and Water Heater inlet temperature alarm history. Water Heater inlet temperature alarm history includes time and date, the lowest inlet temperature reached and the amount of time the water temperature dropped below the alarm setpoint. 4. Modulation Rate and On/Off Modes The TSBC™ may simply control Water Heater modulation and on/off output based on the Water Heater water outlet temperature and an operator adjusted setpoint. However, using parameter selections, the TSBC™ allows the Water Heater modulation and on/off output to respond to remote system water and outside air temperatures, Domestic Hot Water Priority (DHWP) input or Energy Domestic Hot Water Priority (EMS) modulation rate demand, remote setpoint or remote start/stop commands. 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 Water Heater. For example, in the event of a remote system temperature sensor failure, the TSBC™ will automatically switch to Water Heater outlet temperature sensor based control. 6. Outdoor Air Reset When selected the modulation rate setpoint is automatically adjusted based on outside air temperature. Outdoor air "reset" setpoint saves fuel by adjusting the water temperature of a heating Water Heater lower as the outside air temperature increases. 7. Warm Weather Shutdown (WWSD) Some Water Heaters are used primarily for heating buildings, and the Water Heaters can be automatically shutdown when the outdoor air temperature is warm. When outside air temperature is above the WWSD setpoint, this function will prevent the Water Heater, Water Heater pump and/or the system pump from starting. 8. Domestic Hot Water Priority (DHWP) Some Water Heaters are used primarily for building space heating, but also provide heat for the domestic hot water users. When the outdoor temperature is warm, the outdoor reset setpoint may drop lower than a desirable domestic hot water temperature. When enabled and a DHWP contact input is detected, the hot water setpoint is adjusted to be greater than a field adjustable DHWP Setpoint. 9. Water Side Control Outputs In order to maximize the life and availability of a hot water systems it may be desirable to automate mixing valves, Water Heater pumps, system pumps, and standby system pumps. The TSBC™ makes this type of automation totally integrated and cost effective. The control of these devices is field selectable through simple yes/no menu selections. 10. Combustion Air Side Control Outputs Water Heater room Combustion air dampers (fresh air dampers) and Vent Inducer control outputs are field selectable options. 11. Peer-To-Peer Network The TSBC™ includes state-of-the-art modulating lead-lag sequencer for up to eight (8) Water Heaters capable of auto rotation, outdoor reset and peer-to- 67 modulation rate. For example, the lead Water Heater can be configured to start a lag Water Heater after operating above 90% modulation rate for longer than an adjustable time. The Water Heaters are modulated in "unison" (parallel) modulation rate to ensure even heat distribution. 12. Modbus Communication Interface 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 Water Heater ControlTM (TSBCTM) Wiring When wiring to the Thermal Solutions Water Heater Control (TSBC™) terminals, see the terminal layout drawing on the following page or the terminal jacket label, located on the inside surface of the Water Heater jacket upper front panel. The TSBC™ terminals are removable for easier field wiring connection. NOTE: Although some TSBC menus show as "Boiler" cotrols, the TSBC is equally capable of being configured for water heater control using the same paramaters with sometimes differing settings. 70 D. SETUP MENU EVS Fire Test Procedures and Specifications Page 14 of 22 APPENDIX D (Cont…) - TSBCTM SETUP Menu Display Factory Settings Range/Choices Description WWSD Off Off WWSD of Boiler WWSD of Sys Pump Both Specifies Warm Weather Shut-Down (WWSD) control of boiler and/or system pump. Off: Ignores Warm Weather setpoint WWSD of boiler: When Outside Air Temperature (OAT) is higher than the WWSD setpoint, inhibits boiler start WWSD of Sys Pump: When OAT is higher than the WWSD setpoint de-energize System Pump output (SO) Both: When OAT is higher than the WWSD setpoint, inhibit Call for Heat and de-energized system pump output (SO) LL Start Trigger 90 50 to 100 % Specifies the percent of maximum modulation rate the running boiler(s) must reach before calling upon additional boilers for help. LL Stop Trigger 25 0 to 50 % Specifies the percent of modulation rate that the running boiler(s) must be below before shutting down a lag boiler Boiler On Delay 120 0 to 900 (s) Time Delay after On Point setpoint has been reached before starting the next boiler. Short time delay to prevent nuisance starts due to momentary temperature and modulation rate swings. Boiler Off Delay 30 0 to 900 (s) Time Delay after the Off Point setpoint before stopping the next boiler. Short time delay to prevent nuisance stops due to momentary temperature and modulation rate swings. %FR On Delay 1 1 to 30 (m) Time Delay after the modulation rate is above the LL Start Trigger before starting the next boiler. Shorten time delay to avoid temperature going below setpoint as a result of a slow process change. %FR Off Delay 1 1 to 30 (m) Time Delay after the modulation rate is below the LL Stop Trigger before stopping the next boiler. Shorten time delay to avoid temperature going above setpoint as a result of a slow process change. High Fire Limit 100 40 – 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 boiler is not started. Also, if the temperature is decreasing faster than this rate of change, the next boiler is stopped. Cutback Setpoint Boiler 220 100 to 240 F Boiler outlet temperature above the Cutback Setpoint causes the modulation rate to be reduced proportionally to help avoid a high temperature limit lockout. This parameter is significant while the modulation rate of the boiler is controlled according to the remote system temperature sensor, remote input (C+, C-) or Modbus (40006). Water Heater 195 Net Start Dwell 120 16 to 420 (s) The Net Start Dwell Time Delay specifies the length of time the peer-to-peer network will wait for the Main Fuel Valve Energized input (CS) to be energized after a boiler call for heat. If the Net Start Dwell time is exceeded before the main fuel valve is open, the next boiler Call for Heat is immediately initiated. Limit Fault Time 5 3 to 120 (s) The Limit Fault time Delay specifies the length of time the peer-to-peer network will wait for the boiler limits input (CA) to be energized after a boiler Call for Heat. If the Limit Fault time is exceeded before the limits are energized, the next boiler Call for Heat is immediately initiated. Rotation Disable Disable Enable Specifies number of hours (cumulative) a lead boiler runs before passing the lead to another boiler. Lead role will be surrendered earlier if the lead boiler is placed into manual mode, is run remotely (mode 6), fails to start, is “blind” (all input sensors failed), or is satisfying a DHWP request Rotation After 168 8-720 (hr) Specifies number of hours (cumulative) a lead boiler runs before passing the lead to another boiler. 71 D. SETUP MENU (continued) EVS Fire Test Procedures and Specifications Page 15 of 22 APPENDIX D (Cont…) - TSBCTM SETUP Menu Display Factory Settings Range/Choices Description Outdoor Sensor No No Display Only Outdoor Reset Enables the Outside Air Temperature sensor display and control logic. No: Outside Air Input (O+O-) is ignored. Display Only: Do Not Calculate setpoint based on outdoor temperature, Display Outside Air Temperature Outdoor Reset: Calculate the temperature setpoint based on outdoor temperature using a reset curve defined by Outdoor Set Up, Boiler Set Up, Outdoor Design and boiler Design parameters Outdoor Set Up 55 40 F to 100 F The Outdoor Set Up temperature is the outdoor temperature at which the Boiler Set Up temperature is supplied. Only visible when Outdoor Sensor is set to Outdoor Reset Boiler Set Up 140 80F to 180 F The Boiler Set Up Temperature is the starting boiler water temperature of the reset ratio. If the building feels cool during mild outdoor conditions, the Boiler Set Up setting should be increased. Only visible when Outdoor Sensor is set to Outdoor 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 during cold outside conditions, the Boiler Design setting should be increased. Only visible when Outdoor Sensor is set to Outdoor Reset Blower SPD High 100 0 to 100 % Percent of (0 - 10 vdc output (V+, V-) output that represents a 100% modulation rate. This scaling factor allows the controller to display 100% when the blower is at rated boiler output. Blower SPD Low 0 0 to 100 % Percent of (0 - 10 vdc output (V+, V-) output that represents a 0% modulation rate. This scaling factor allows the controller to display 0% when the blower is at minimum boiler output. Low Fire Spd 50 0 to 100 % Modulation % used for Low Fire Hold and Low Fire Start conditions Fan Purge Spd See Description 0 to 100 % Percent of blower operating range that the blower should be run during Fan Purge (at ignition) Build Boiler model 500 750 1000 1500 2000 2000S 2500 3000 Standard 100 100 100 100 100 47 84 55 Low fire proving 25 25 24 19 26 47 84 55 Venturi NA 100 100 23 26 NA NA NA 72 EVCA Modulating Fire Test Procedures and Specifications APPENDIX D (Cont…) - TSBCTM SETUP Menu Display Factory Settings Range Description Low Fire Hold 20 10 to 1200 (s) Time modulation rate is held at present value (Low Fire Spd or Fan Purge Spd depending on the state and configuration of spare input) after the Fuel Valve Energized Input (CS) is energized. Post Purge Time 30 0 to 600 (s) Time modulation rate is held at Fan Purge Spd after the Fuel Valve Energize Input (CS) is de-energized. Local Pid P 20 0 to 10000 Proportional Gain value for boiler outlet temperature sensor control Modes. A larger gain value results in tighter, more active, PID control. Gain is the primary PID modulation rate tuning adjustment and provides the immediate modulation rate response. Local PID I 30 0 to 10000 Integral gain value for boiler outlet temperature sensor control Modes. A smaller value makes the Integral ramp in less time (i.e., faster). Integral is a secondary PID modulation rate tuning adjustment that ramps the output over time (typically minutes). Local PID D 0 0 to 10000 The Derivative gain value for boiler outlet temperature sensor control Modes. A larger Derivative gain value produces a larger PID output contribution proportional to the rate of change of the error (Setpoint – Boiler Outlet Temperature). When set equal to zero it has no effect on the output. Remote PID P 20 0 to 10000 Proportional Gain value for Remote System Temperature sensor control Modes. Refer to Local PID P for explanation. Remote PID I 30 0 to 10000 Integral Gain Term for Remote System Temperature sensor control Modes. Refer to Local 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 immediate mixing valve modulation response. Only visible when mixing valve = yes. Mixing Valve I 60 0 to 10000 Integral gain value for boiler inlet temperature sensor control mode. A smaller value makes the Integral ramp in less time (i.e., faster). Integral is a secondary PID modulation rate tuning adjustment that ramps the output over time (typically minutes). Only visible when mixing valve = yes. Mixing Valve D 0 0 to 10000 The Derivative gain value for boiler inlet temperature sensor control mode. A larger Derivative gain value produces a larger PID output contribution proportional to the rate of change of the error (Setpoint – Boiler Inlet Temperature). When set equal to zero it has no effect on the output. Only visible when mixing valve = yes. Max Delta T P 10 0 to 10000 Proportional Gain value for boiler differential (boiler outlet minus inlet temperature sensor) temperature control mode. Refer to Local PID P for explanation. Only visible when mixing valve = yes. Max Delta T I 60 0 to 10000 Integral Gain value for boiler differential (boiler outlet minus inlet temperature sensor) temperature control mode. Refer to Local PID I for explanation. Only visible when mixing valve = yes. Max Delta T D 0 0 to 10000 Derivative Gain Term for boiler differential (boiler outlet minus inlet temperature sensor) temperature control mode. Refer to Local PID D for explanation. Only visible when mixing valve = yes. Page 16 of 22 D. SETUP MENU (continued) 75 G. SETPOINTS MENU EVCA Modulating Fire Test Procedures and Specifications APPENDIX D (Cont…) - TSBCTM SETPOINTS Menu Display Factory Settings Range/Choices Description Operational SP 180 60 to 230 F Setpoint used in Local Setpoint Mode when not servicing a Domestic Hot Water Priority (DHWP) request. On Point -5 0 to 99 F The boiler starts when the water temperature drops ‘On Point’ degrees below the setpoint. Off Point 15 0 to 99 F The boiler stops when the water temperature rises ‘Off Point’ degrees above the setpoint. High Temp Stop Boilers 230 60 to 230 F The boiler stops when water temperature is above the High Temperature Stop setpoint. This setpoint is active in every control mode. DHWP Setpoint 180 140 to 230 F The Domestic Hot Water Priority (DHWP) Setpoint is active when DHW Input (DP) closes and “DHWP” parameter is set to “yes” and Local SP Mode is selected. When the contact is closed, the boiler outlet 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 possible Local and Remote modes. Min SP 70 60 to 230 F The Minimum Operational Setpoint is the lower limit for all Local and Remote modes. Min BIT 120 60 to 235 F Low Boiler Inlet Temperature alarm and event setpoint. Min In H2O Temp 130 110 to 180 F Minimum Inlet Water Temperature setpoint used as the Mixing Valve inlet temperature setpoint. Only visible when Mixing Valve equals Yes. Max H2O Delta T 50 20 to 50 F Maximum Water Differential (Boiler Outlet minus Boiler Inlet) Temperature setpoint used as the Mixing Valve differential temperature setpoint. Only visible when Mixing Valve equals Yes. Max Delta T Hold 50 20 to 50 F Maximum Water Differential (Boiler Outlet minus Boiler Inlet) Temperature used to hold modulation rate at low fire. Page 17 of 22 Water Heaters 230 Water Heaters Water Heaters 230 Water Heaters 14 76 H. COMMUNICATION MENU EVCA Modulating Fire Test Procedures and Specifications APPENDIX D (Cont…) – TSBCTM COMMUNICATIONS Menu Display Factory Settings Range/Choices Description Protocol Peer to Peer Peer to Peer Modbus Selects between Peer-To-Peer (multiple boiler Lead/Lag control network) and a Modbus slave communication. Modbus Address 1 1 to 247 Each boiler must be given a unique address. Only visible when Protocol equals Modbus. Baud Rate 19.2 9.6 19.2 38.4 Units are 1000 Bits Per Second (KBPS). Only visible when Protocol equals Modbus. Parity Odd Odd Even None Only visible when Protocol equals Modbus. Timeout 30 1 to 120 Only visible 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 boiler sequencing order. A value of 0 disables the network communications. Only visible when Protocol equals Peer to Peer. Online Status xxxxxxxx Each space can be either the boiler address or a ‘ - ‘ depending on whether there is a boiler of that address on-line. Example: - - 6 - - - 321 indicates that boilers 6,3,2 and 1 are online Only visible when Protocol equals Peer to Peer. Page 18 of 22 . 77 I. MANUAL MODE MENU EVCA Modulating Fire Test Procedures and Specifications APPENDIX D (Cont…) - TSBCTM MANUAL MODE Menu Display Factory Settings Range/Choices Description Boiler Man/Auto Auto Man Auto Man: Remain in Manual Mode. Auto: Return to Boiler Mode specified by parameter/boiler conditions. Activated only when in Supervisor Mode. Modulation Rate Varies 0 to 100 Sets the modulation rate to be used for boiler when in Manual Mode. Activated 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 parameter/boiler conditions. Activated only when in Supervisor Mode. Mixing Valve Varies 0 to 100 Sets the Mixing Valve % Open to be used for valve when in Manual Mode. Activated only when in Supervisor Mode and Mixing Valve M/A equals Man. Page 19 of 22