Solaris Manual 8-091.pdf - Categories On Thermal Solutions ...

WARNINGThis boiler requires regular maintenance and service to operate safely. Follow the instructionscontained in this manual.Improper installation, adjustment, alteration, service or maintenance can cause property damage,personal injury or loss of life. Read and understand the entire manual before attemptinginstallation, start-up operation, or service. Installation and service must be performed only by anexperienced, skilled, and knowledgeable installer or service agency.This boiler must be properly vented.This boiler needs fresh air for safe operation and must be installed so there are provisions foradequate combustion and ventilation air.The interior of the venting system must be inspected and cleaned before the start of the heatingseason and should be inspected periodically throughout the heating season for any obstructions.A clean and unobstructed venting system is necessary to allow noxious fumes that could causeinjury or loss of life to vent safely and will contribute toward maintaining the boiler’s efficiency.Installation is not complete unless a pressure relief valve is installed into the tapping located ontop of appliance. - See the Water Piping and Trim Section of this manual for details.This boiler is supplied with safety devices which may cause the boiler to shut down and not restartwithout service. If damage due to frozen pipes is a possibility, the heating system shouldnot be left unattended in cold weather; or appropriate safeguards and alarms should be installedon the heating system to prevent damage if the boiler is inoperative.This boiler contains very hot water under high pressure. Do not unscrew any pipe fittings norattempt to disconnect any components of this boiler without positively assuring the water is cooland has no pressure. Always wear protective clothing and equipment when installing, startingup or servicing this boiler to prevent scald injuries. Do not rely on the pressure and temperaturegauges to determine the temperature and pressure of the boiler. This boiler contains componentswhich become very hot when the boiler is operating. Do not touch any components unlessthey are cool.Boiler materials of construction, products of combustion and the fuel contain alumina, silica,heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substanceswhich can cause death or serious injury and which are known to the state of Californiato cause cancer, birth defects and other reproductive harm. Always use proper safety clothing,respirators and equipment when servicing or working nearby the appliance.Failure to follow all instructions in the proper order can cause personal injury or death. Read allinstructions, including all those contained in component manufacturers manuals which are providedwith the boiler before installing, starting up, operating, maintaining or servicing.Keep boiler area clear and free from combustible materials, gasoline and other flammable vaporsor liquids.All cover plates, enclosures and guards must be in place at all times.This product must be installed by a licensed plumber or gas fitter when installed within the Commonwealthof Massachusetts.NOTICEThis boiler has a limited warranty, a copy of which is printed on the back of this manual. It is theresponsibility of the installing contractor to see that all controls are correctly installed and areoperating properly when the installation is complete.

Table of ContentsI. Pre-Installation..................................................6II. Unpack Boiler....................................................7III. Venting/Air Intake Piping................................8A. Vent Guidelines Due to Removal of anExisting Boiler..............................................8B. General Guidelines......................................9C. Supplemental Vent Terminal LocationInstructions.................................................10D. Separate Horizontal VentingSystem......................................................... 11E. Optional Horizontal Vent TerminalMounting....................................................14F. Conventional Venting.................................15G. Air Intake Piping.......................................15H. Separate Vertical Venting System............17IV. Water Piping and Trim...................................20V. Gas Piping........................................................24VI. Electrical .........................................................26VII. Modular Installations.....................................29VIII. System Start-up...........................................39IX. Service and Maintenance................................46A. Periodic Maintenance ...............................46B. Safety & Operating Controls.....................49C. Trouble Shooting........................................50X. Sage Boiler Control TM (SBC TM )......................52A. Introduction................................................52B. Front Panel Display...................................53C. Setup Menu................................................54D. Boiler Configuration Menu.......................56E. System Configuration Menu.....................57F. Setpoints Menu..........................................58G. Communication Menu...............................59H. Manual Mode Menu..................................59I. Security Menu............................................60XI. Repair Parts.....................................................61XII. Service Record...............................................71XIII. Refractory Ceramic Fiber...........................74XIV. Warranty........................................................75Minimum Clearance to Combustible MaterialsLeft Side Right Side Front Rear Top Flue Connector1” 1” 24” 3” 1” 6”Recommended Clearance for ServiceModelLeft Side or Right Front Rear TopSideSOL-300 24” 24” 24” 16”SOL-750 24” 24” 24” 16”SOL-1000 24” 24” 24” 19”SOL-1250 24” 24” 24” 31”SOL-1500 24”Note: Verify clearance with jurisdiction having authority and local codes.

BoilerModelBTU Input(MBH)General Ratings and CapacitiesBTUOutput(MBH)WaterVolume(Gallons)DryWeight(lbs.)WetWeight(lbs.)Electrical Supply(Voltz/Hertz/Phase)Rated MotorHorse Power(HP)Rated BlowerAmp Draw(Amps)SOL-300 300 252 1.1 288.5 297.7 3/4 8.5SOL-500 500 420 1.3 316.0 326.8 3/4 8.5SOL-750 750 637.5 2.4 508.5 528.5 120/60/1 3/4 8.0SOL-1000 1000 850 2.6 548.5 570.2 3/4 8.0SOL-1250 1250 1062.5 2.9 620.0 644.2 1-1/8 12SOL-1500 1500 1275 3.3 713.0 740.5 1-1/8 12L(TYP.)L(TYP.)KAG INLET GASCBDF OULETWATERJEF INLETWATER13.00M VENTOUTLET2.71TOP VIEW REAR VIEWSIDE VIEWM VENTINLETHBoilerModelDimensions‘A’ ‘B’ ‘C’ ‘D’ ‘E’ ‘F’ ‘G’ ‘H’ ‘J’ ‘K’ ‘L’ ‘M’SOL-300 27.8 32.6 28.1 25.9 15.0 2.0 1.00 4.1 29.3 17.0 4.1 4.0SOL-500 42.6 32.6 28.1 28.0 15.0 2.0 1.00 7.2 27.8 17.0 4.1 6.0SOL-750 41.4 36.9 31.8 32.4 13.0 3.0 1.00 3.5 32.1 23.6 6.2 8.0SOL-1000 49.4 36.9 31.8 32.4 13.0 3.0 1.25 3.5 32.1 21.6 6.2 8.0SOL-1250 61.6 36.9 31.8 32.4 13.0 3.0 1.25 3.5 32.1 26.5 6.2 10.0SOL-1500 73.9 36.9 31.8 32.4 13.0 3.0 1.50 3.5 32.1 25.6 6.2 10.0Figure 1: Dimensions

I. Pre-InstallationWARNINGIf you do not follow these instructions exactly,a fire or explosion may result causingproperty damage or personal injury.DANGERDo not install boiler where gasoline or otherflammable vapors or liquids, or sourcesof hydrocarbons (i.e. bleaches, cleaners,chemicals, sprays, paint removers, fabricsofteners, etc.) are used or stored.NOTICEDue to the low water content of the boiler,mis-sizing of the boiler with regard to theheating system load will result in excessiveboiler cycling and accelerated componentfailure. Thermal Solutions DOES NOTwarrant failures caused by mis-sized boilerapplications. DO NOT oversize the boilerto the system. Modular boiler installationsgreatly reduce the likelihood of boiler oversizing.A. Installation must conform to the requirements of theauthority having jurisdiction. In the absence of suchrequirements, installation must conform to the NationalFuel Gas Code, NFPA 54/ANSI Z223.1, and/orCAN/CGA B149 Installation Codes. Where requiredthe installation must conform to the standard for controlsand safety devices for automatically fired boilers,ANSI/ASME CSD-1.B. Appliance is design certified for installation on combustibleflooring. Do not install boiler on carpeting.C. Provide clearance between boiler jacket and combustiblematerial in accordance with local fire ordinance.Refer to Figure 1 for minimum listed clearance fromcombustible material. Recommended service clearanceis 24 inches from left side, right side and front. Recommendedservice clearance is 36” at rear of unit. Serviceclearances may be reduced to minimum clearancesto combustible materials.E. Protect gas ignition system components from water(dripping, spraying, rain, etc.) during boiler operationand service (circulator replacement, condensate trap,control replacement, etc.).F. Provide combustion and ventilation air in accordancewith sections 5.3 of the National Fuel Gas code,ANSIZ223.1/NFPA 54, or sections 7.2, 7.3, or 7.4 ofCAN/CSA B149.1, Natural Gas and Propane Installationcode, or applicable provisions of the local buildingcodes.WARNINGAdequate combustion and ventilation airmust be provided to assure proper combustion.The following guideline is based on the National Fuel GasCode, NFPA 54/ANSI Z223.1.1. Determine volume of space (boiler room). Roomscommunicating directly with space (through openingsnot furnished with doors) are considered part ofspace.Volume [ft³] = Length [ft] x Width [ft] x Height [ft]2. Determine Total Input of all appliances in space.Round result to nearest 1,000 Btu per hour (Btuh).3. Determine type of space. Divide Volume by TotalInput.a. If result is greater than or equal to 50 ft³ per1,000 Btuh, space is considered an unconfinedspace.b. If result is less than 50 ft³ per 1,000 Btuh, spaceis considered a confined space.4. Determine building type. A building of unusuallytight construction has the following characteristics:a. Walls and ceiling exposed to outside atmospherehave a continuous water vapor retarder with arating of 1 perm or less with openings gasketedand sealed, and;b. Weather-stripping has been added on openablewindows and doors, and;c. Caulking or sealants applied in joints aroundwindow and door frames, between sill plates andfloors, between wall-ceiling joints, between wallpanels, at plumbing and electrical penetrations,and at other openings.D. Install on level floor. Floor must be able to supportweight of boiler, water and all additional system components.

5. For boiler located in an unconfined space in abuilding of other than unusually tight construction,adequate combustion and ventilation airis normally provided by fresh air infiltrationthrough cracks around windows and doors.6. For boiler located within unconfined space inbuilding of unusually tight construction, orwithin equate confined space, provide outdoorair through two permanent openings whichcommunicate directly or by duct with theoutdoors or spaces (crawl or attic) freely communicatingwith the outdoors. Locate one openingwithin twelve (12) inches of top of space. Locateremaining opening within twelve (12) inches ofbottom of space. Minimum dimension of airopening is three (3) inches. Size each openingper following:a. Direct communication with outdoors. Minimumfree area of one (1) square inch per 4,000 Btu perhour input of all equipment in space.b. Vertical ducts. Minimum free area of one (1)square inch per 4,000 Btu per hour input of allequipment in space. Duct cross-sectional areashall be same as opening free area.c. Horizontal ducts. Minimum free area of one (1)square inch per 2,000 Btu per hour input of allequipment in space. Duct cross-sectional areashall be same as opening free area.Alternate method for boiler located withinconfined space. Use indoor air if two permanentopenings communicate directly with additionalspace(s) of sufficient volume such that combinedvolume of all spaces meet criteria for unconfinedspace. Size each opening for minimum free areaof one (1) square inch per 1,000 Btu per hourinput of all equipment in spaces, but not less than100 square inches.7. Combustion Air/Ventilation Duct Louvers andGrilles. Equip outside openings with louvers toprevent entrance of rain and snow, and screens toprevent entrance of insects and rodents. Louvers andgrilles must be fixed in open position or interlockedwith equipment to open automatically before burneroperation. Screens must not be smaller than ¼ inchmesh.Consider the blocking effect of louvers, grilles andscreens when calculating the opening size to providethe required free area. If free area of louver or grilleis not known, assume wood louvers have 20-25percent free area and metal louvers and grilles have60-75 percent free area.II. Unpack BoilerCAUTIONAvoid operating this boiler in an environment where saw dust, loose insulation fibers, dry walldust, etc. are present. If boiler is operated under these conditions, the burner interior and portsmust be cleaned and inspected daily to insure proper operation.CAUTIONDo not drop boiler. Do not bump boilerjacket against the floor.A. Move boiler to approximate installed position.B. Remove all crate fasteners.C. Lift and remove outside container. Save two of thewooden slats from the container sleeve for use in StepsE and F.D. Remove all boiler hold-down fasteners.WARNINGInstallation of this boiler should be undertakenonly by trained and skilled personnelfrom a qualified service agency.E. Tilt the boiler to its front side or back side and slide awooden slat under the raised feet.F. Tilt the boiler in the opposite direction and slide anotherwooden slat under the raised feet.G. Slide the boiler left or right off the skid using the twowooden slats as runners.H. Move boiler to its permanent location.

III. Venting / Air Intake PipingWARNINGDo not use this boiler with galvanized, non metallic or any other venting material that is not designedfor condensing flue gas applications.Do not use a drafthood with this appliance.Do not use vent dampers with this boiler.Moisture and ice may form on surfaces around termination. To prevent deterioration, surfacesshould be in good repair (sealed, painted, etc.).This appliance needs fresh air for safe operation and must be installed so there are provisionsfor adequate combustion and ventilation air.Do not reduce size of air intake pipe.Read, understand and follow combustion air instruction restrictions contained in the Pre-Installationinstructions of this manual.Do not operate appliance where gasoline or other flammable vapors or liquids, or sources ofhydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.)are used, stored and/or present in the air.When installing vent pipe through chimney, no other appliance can be vented into the chimney.Do not exceed maximum vent/air intake lengths. Refer to Table 1.A. Vent Guidelines Due to Removal of an ExistingBoilerFor installations not involving the replacement of anexisting boiler, proceed to Step B.When an existing boiler is removed from a commonventing system, the common venting system is likely tobe too large for proper venting of the remaining appliances.At the time of removal of an existing boiler, thefollowing steps shall be followed with each applianceremaining connected to the common venting systemplaced in operation, while the other appliances remainingconnected to the common venting system are not inoperation:1. Seal any unused openings in the common ventingsystem.2. Visually inspect the venting system for proper sizeand horizontal pitch and determine there is noblockage or restriction, leakage, corrosion, andother deficiencies which could cause an unsafecondition.3. Insofar as is practical, close all building doors andwindows and all doors between the space in whichthe appliances remaining connected to the commonventing system are located and other spaces of thebuilding. Turn on clothes dryers and any appliancenot connected to the common venting system.Turn on any exhaust fans, such as range-hoodsand bathroom exhausts, so they will operate atmaximum speed. Do not operate a summer exhaustfan. Close fireplace dampers.4. Place in operation the appliance being inspected.Follow the Lighting (or Operating) Instructions.Adjust thermostat so appliance will operatecontinuously.5. Test for spillage at the draft hood relief openingafter five (5) minutes of main burner operation. Usethe flame of a match or candle, or smoke from acigarette, cigar or pipe.6. After it has been determined that each applianceremaining connected to the common ventingsystem properly vents when tested as outlinedabove, return doors, windows, exhaust fans, fireplace dampers and any other gas burning applianceto their previous conditions of use.7. Any improper operation of the common ventingsystem should be corrected so the installationconforms with the National Fuel Gas Code, NFPA54/ANSI Z223.1 and/or CAN/CSA B149.1 NaturalGas and Propane Installation Code. When resizingany portion of the common venting system, thecommon venting system should be resized to approachthe minimum size as determined using theappropriate tables in Part 11 of the National FuelGas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSAB149.1 Natural Gas and Propane Installation Code.

B. General Guidelines1. Vent system installation must be in accordance withPart 7, Venting of Equipment of the National FuelGas Code, ANSI Z223.1/NFPA 54, or Section 7,Venting Systems and Air Supply for Appliances ofthe CAN/CSA B149.1, Natural Gas and Propane InstallationCode, or applicable provisions of the localbuilding codes.2. Contact local building or fire officials about restrictionsand installation inspection in your area.3. Refer to the appropriate drawings in this section ofthis manual to determine the proper configuration ofventing system. Figures 2 thru 11. The vent systemshall be installed in accordance with the instructionslisted in this manual.4. This appliance requires a Special Gas Vent. Theproduct is designed to use AL 29-4C ® StainlessSteel or other Stainless Steel material approved forcondensing flue gas applications. The boilers areshipped with AL 29-4C ® vent adapter to directlyconnect to Heat Fab Saf-T-Vent. The use of alternatemanufacturer’s venting systems will requireadapters and vent terminal. These adapters are notsupplied with this unit and should be obtained fromthe supplier of alternate venting system.5. The venting system must be installed so as toprevent accumulation of condensate. Horizontalvent pipe must maintain a minimum ¼ inch per footslope down towards boiler.a. Do not manifold condensate drains.b. A common condensate pump/sump may be used.Run separate condensate piping from each ventdrain to the sump. A common drain may be usedto discharge condensate from the sump.Consult pump/sump manufacturer for compatibilityof materials of construction with flue gascondensate. If a common pump/sump is used,individual vent drain lines must be connectedsuch that one drain pipe cannot back feed intoanother vent drain.c. Consult local authorities regarding disposal offlue gas condensate into public waste water system.Some jurisdictions require that the condensatebe buffered before discharge. this bufferingis commonly achieved by draining the condensatethrough a limestone bed. Consult chemicaltreatment company for buffering systems.6. Use noncombustible ¾ inch pipe strap to supporthorizontal runs and maintain vent location andslope while preventing sags in pipe. Do not restrictthermal expansion or movement of vent system.Maximum support spacing is five (5) feet. Do notpenetrate any part of the vent system with fasteners.7. Vent length restrictions are based on equivalentlength of vent/air pipe (total length of straightpipe plus equivalent length of fittings). Maximumvent/air lengths are listed in Table 1. Do not exceedTable 1: Vent & Air Intake LengthBoiler ModelVent/Air IntakeMinMaxPipe Dia.ft. ft. In.SOL-300 5 50 4SOL-500 5 78 6SOL-750 5 50 8SOL-1000 5 50 8SOL-1250 5 50 10SOL-1500 5 50 10maximum vent/air intake lengths. Refer to ventmanufacturer’s recommendations for the equivalentlength of fittings.8. Provide and maintain vent pipe minimum clearancesto combustible materials. Vent pipe minimum clearanceto combustible material is four (4) inches whenvent is installed in a fully enclosed (chase) applicationor three (3) inches when vent is installed withat least one side open, similar to a joist bay application.Use double wall thimble when penetrating acombustible wall. Some examples of Wall thimblemanufactures are American Metal Products, Hart &Cooley, and Metal Fab.9. Do not install venting system components on the exteriorof the building except as specifically requiredby these instructions. The vent termination locationis restricted as follows:a. The minimum distance from adjacent publicwalkways, adjacent buildings, openable windows and building openings shall not be lessthan those values specified in the National FuelGas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.b. Minimum twelve (12) inches above grade plusnormally expected snow accumulation level, orseven (7) feet above grade if located adjacent topublic walkway. Do not install over public walkwaywhere local experience indicates applianceflue gas vapor or condensate creates a nuisanceor hazard.c. Minimum three (3) feet above any forced airinlet located within ten (10) feet.d. Power Vent - Minimum four (4) feet below, four(4) feet horizontally from, or four (4) feet aboveany door, window, or gravity air inlet.

e. Minimum of four (4) feet horizontally from, andin no case above or below, unless a 4 foot horizontaldistance is maintained from electric meters,gas meters, regulators and relief equipment.This distance may be reduced if equipment isprotected from damage due to condensation orvapor by enclosure, overhangs, etc.f. Minimum twelve (12) inches from overhang orcorner of building.g. The vent termination shall be located such thatno damage to building materials will occur fromFigure 2: Vent Therminal LocationNOTICECut must be square with pipe and filed orsanded smooth before joining. Carefullyensure roundness of cut pipe by hand withgloves before installing. Seal joint with RTVspecified in this manual.flue gasses degradation.10. Enclose vent passing through occupied or unoccupied spaces above the boiler with material having afire resistance rating of at least equal to the ratingof the adjoining floor or ceiling. Maintain minimumclearances to combustible materials. See page 4.11. Plan venting system to avoid possible contact withplumbing or electrical wires. Start at vent connectoron top of boiler and work towards vent terminal.12. Once a vent pipe manufacturer and system is chosennever mix and match vent systems.13. Field Supplied Vent Terminations (One per boiler)a. Horizontal - Use Saf-T Vent mitered terminationwith screen or equivalentb. Vertical - Use Saf-T Vent rain cap or equivalentC. Supplemental Vent Terminal Location Instructions(Massachusetts Code Only)The Commonwealth of Massachusetts requires compliancewith regulation 248 CMR 4.00 and 5.00 for installationof side-wall vented gas appliances as follows:(a) For all side wall horizontally vented gas fueled equipmentinstalled in every dwelling, building or structureused in whole or in part for residential purposes, includingthose owned or operated by the Commonwealth andwhere the side wall exhaust vent termination is less thanseven (7) feet above finished grade in the area of theventing, including but not limited to decks and porches,the following requirements shall be satisfied:1. INSTALLATION OF CARBON MONOXIDE DETEC-TORS. At the time of installation of the side wallhorizontal vented gas fueled equipment, the installingplumber or gasfitter shall observe that a hard wiredcarbon monoxide detector with an alarm and batteryback-up is installed on the floor level where the gasequipment is to be installed. In addition, the installingplumber or gasfitter shall observe that a batteryoperated or hard wired carbon monoxide detector withan alarm is installed on each additional level of thedwelling, building, or structure served by the side wallhorizontal vented gas fueled equipment. It shall be theresponsibility of the property owner to secure the servicesof qualified licensed professionals for the installationof hard wired carbon monoxide detectors.a. In the even that the side wall horizontally ventedgas fueled equipment is installed in a crawl space oran attic, the hard wired carbon monoxide detector withalarm and battery back-up may be installed on the nextadjacent floor level.b. In the event that the requirements of this subdivisioncan not be met at the time of completion of installation,the owner shall have a period of thirty (30) daysto comply with the above requirements; provided, however,that during said thirty (30) day period, a batteryoperated carbon monoxide detector with an alarm shallbe installed.2. APPROVED CARBON MONOXIDE DETECTORS.Each carbon monoxide detector as required in accordancewith the above provisions shall comply withNFPA 720 and be ANSI/UL 2034 listed and IAS certified.3. SIGNAGE. A metal or plastic identification plate shall bepermanently mounted to the exterior of the building ata minimum height of eight (8) feet above grade directlyin line with the exhaust vent terminal for the horizontallyvented gas fueled heating appliance or equipment.The sign shall read, in print size no less than one-half(1/2) inch in size, “GAS VENT DIRECTLY BELOW,KEEP CLEAR OF ALL OBSTRUCTIONS”.4. INSPECTION. The state or local gas inspector of the sidewall horizontally vented gas fueled equipment shallnot approve the installation unless, upon inspection,10

the inspector observes carbon monoxide detectors andsignage installed in accordance with the provisions of248 CMR 5.08(2)(a)1 through 4.(b) EXEMPTIONS: The following equipment is exemptfrom 248 CMR 5.08(2)(a)1 through 4:1. The equipment listed in Chapter 10 entitled “EquipmentNot Required To Be Vented” in the most currentedition of NFPA 54 as adopted by the board; and2. Product Approved side wall horizontally ventedgas fueled equipment installed in a room or structureseparate from the dwelling, building or structure used inwhole or in part for residential purposes.(c) MANUFACTURER REQUIREMENTS - GASEQUIPMENT VENTING SYSTEM PROVIDED.When the manufacturer of Product Approved side wallhorizontally vented gas equipment provides a ventingsystem design or venting system components with theequipment, the instructions provided by the manufacturerfor installation of the equipment and the ventingsystem shall include:1. Detailed instructions for the installation of the ventingsystem design or the venting system components;and2. A complete parts list for the venting system design orventing system.(d) MANUFACTURER REQUIREMENTS - GASEQUIPMENT VENTING SYSTEM NOT PROVIDED.When the manufacturer of a Product Approved sidewall horizontally vented gas fueled equipment does notprovide the parts for venting the flue gasses, but identifies“special venting systems”, the following requirementsshall be satisfied by the manufacturer:1. The referenced “special venting system” instructionsshall be included with the appliance or equipmentinstallation instructions; and2. The “special venting systems” shall be ProductApproved by the Board, and the instructions for thatsystem shall include a parts list and detailed installationinstructions.(e) A copy of all installation instructions for all ProductApproved side wall horizontally vented gas fueledequipment, all venting instructions, all parts lists forventing instructions, and/or all venting design instructionsshall remain with the appliance or equipment atthe completion of the installation.D. Separate Horizontal Venting System. SeeFigures 3, 4 and 5.1. Vent Piping –a. Do not exceed maximum vent/air intakelengths. Refer to Table 1.b. Recommended horizontal installation consistsof vent being sloped down ¼ inch per foottoward boiler.c. Use appropriate designed thimbles whenpassing through combustible walls (thimbleuse optional for noncombustible walls). Insertthimble through wall from outside. Secureoutside flange to wall with nails or screws, andseal ID, OD and vent holes with sealantmaterial. Install inside flange to inside wall,secure with nails or screws, and seal withsealant material.d. For noncombustible wall application whenthimble is not used, size opening such that bellwith locking band attached cannot passthrough.e. Join vent terminal to vent pipe. Locate ventpipe such that vent terminal is between six (6)inches and twenty-four (24) inches from wallwhen joined to inside vent piping. See Figure3 or 4.f. Insert vent pipe through thimble/opening fromoutside and join to vent system. Apply sealantbetween vent pipe and opening/thimble toprovide weathertight seal.2. Side Vent Installation. See figure 5.a. Horizontal vent/air intake runs with novertical rise in piping allowed.b. Do not exceed maximum vent/air intakelengths. Refer to Table 1.c. Recommended Horizontal Installation onlyconsists of vent/air intake sloped down 1/4inch per foot toward termination.d. Thimbles, same as “C” above in section D.1e. same as “D” above in section D.1f. same as “E” above in section D.1g. same as “F” above in section D.1Figure 3: Side Top Vent11

12Figure 4: Recommended Separate Horizontal - Vent/Air Intake Installation

Figure 5: Side Vent13

E. Optional Separate Horizontal Vent Terminal Mounting – See Figure 61. Do not exceed maximum vent/air intake lengths.Refer to Table 1.2. This installation will allow a maximum of five (5)feet vertical exterior run of the vent/air intake pipingto be installed on separate horizontal venting andindoor air horizontal venting.Note: Exterior run to be included in equivalent vent/air intake lengths.3. Install vent piping.a. Install vent piping for desired venting system.Refer to specific section for details for vent pipeinstallation.b. After penetrating wall/thimble, install a 90°elbow so that elbow leg is in the up direction.c. Install maximum of five (5) feet of vent pipe.Refer to Sections C through E for proper proceduresfor joining vent pipe and fittings.d. At top of vent pipe length install a 90° elbow sothat elbow leg is opposite the building’s exteriorsurface.e. Install 45° elbow to upper 90° elbow so that legof 45° is in down direction (see Figure 6). If notusing indoor air, proceed to Step f.f. Install horizontal vent terminal.g. Brace piping if required.4. Air Intake Piping (not required for indoor air).a. Install air intake piping for desired venting system.Refer to specific section for details for airintake installation.b. After penetrating wall, install a corrosion resistant90 o elbow so that elbow leg is in the updirection.c. Install maximum of five (5) feet of corrosionresistant air intake pipe.d. At top of air intake pipe install air intake terminal(provided with boiler).e. Brace piping if required.14Figure 6: Optional Indoor Air – Vent Terminal Installation

F. Conventional Venting (Negative Draft) – See Figure 7a. The minimum chimney height is 15 feet.b. The chimney must be protected from downdrafts, rain and debris by using a chimney cap orstar.c. Start installing vent at vent cap and continueinstallation toward the boiler.d. The flue connector and chimney flue diametermay need to be increased or decreased depending on the dimensions of the boiler. Consult theNational Fuel Gas Code or Local Codes for sizing.Boiler input, flue connector lateral distanceand chimney height affect the flue connector orchimney flue diameters.e. A double acting barometric damper with integralflue spillage interlock switch must be used whenthe boiler is vented conventionally.f. The chimney and flue connector must be sizedand configured to provide a minimum - 0.04 inchw.c. draft at the vent outlet of the boiler.g. Maintain a minimum vertical pitch of one (1)inch in four (4) feet of vent connector run.G. Air Intake Piping - See Figure 4 & 81. Locate air intake termination on the same wall as thevent termination if possible, to prevent nuisance boilershutdowns. However, boiler may be installed with verticalventing and sidewall combustion air inlet or viceversa, if installation conditions do not allow alternatearrangement.2. Do not exceed maximum air intake length. See Table 1.3. Use single wall metal pipe and fittings or thin wall PVCavailable at most heating distributors.4. Air intake termination must be located: Horizontal - Atleast twelve (12) inches above grade plus the expectedsnow accumulation.5. Start at collar on burner enclosure (inside boiler jacket)and work towards the air intake terminal.6. Maintain minimum of 1/4 inch per foot slope onhorizontal runs. Slope towards air inlet terminal whenpossible. If not, slope towards boiler.7. The air intake pipe must be adequately supported withstraps or supports no less than five (5) feet apart onhorizontal runs. The complete air intake piping systemmust be rigid and able to withstand minor impacts withoutcollapse.8. Inlet air pipe penetration: Horizontal - Size wall penetrationto allow easy insertion of air inlet piping. Sealaround pipe with sealant to form weathertight exteriorjoint.9. Seal all joints airtight, using silicone caulk or self-adhesivealuminum tape.10. Install Air Intake Terminal.Figure 7: Conventional Venting (Negative Draft)15

SEE TABLE 1.Figure 8: Separate Horizontal – Vent/Air Intake Terminal Configuration16

H. Separate Vertical Venting System - See Figures 9, 10, and 11.Vertical Venting –1. Do not exceed maximum vent lengths. Refer toTable 1.2. Slope horizontal runs minimum ¼ inch per footdown towards boiler.3. Install fire stops where vent passes through floors,ceilings or framed walls. The fire stop must closethe opening between the vent pipe and the structure.Fire stop manufacturers are Air-Jet, American MetalProducts, Metal-Fab, and Simpson Dura-Vent.4. Whenever possible, install vent straight through theroof. Refer to Figure 9 if offset is necessary. Maintainminimum clearance to combustiblematerials.5. Install Vent Terminal.a. Size roof opening to maintain minimum clearancefrom combustible materials.b. Extend vent pipe to maintain minimum verticaland horizontal distance of twelve (12) inchesfrom roof surface. Allow additional vertical distancefor expected snow accumulation. Providebrace as required. Refer to Figure 11.c. Vertical venting requires use of the roof flashingand storm collar to prevent moisture from enteringthe structure.d. Install storm collar on vent pipe immediatelyabove flashing. Apply Dow Corning Silastic 732RTV Sealant between vent pipe and storm collarto provide weathertight seal.e. Attach vent terminal.Vertical Air Intake Piping –1. Do not exceed maximum air intake length. Refer toTable 1.2. Locate air intake termination on the same roof locationas the vent termination if possible, to preventnuisance boiler shutdowns. However, boiler may beinstalled with vertical venting and sidewall combustionair inlet or vica versa, if installation conditionsdo not allow alternate arrangement.3 Use single wall metal pipe and fittings or thin wallPVC available at most heating distributors.4. Air intake termination must be located:Vertical - At least twelve (12) inches above the roofsurface plus the expected snow accumulation.5. Start at collar on burner enclosure (inside boilerjacket) and work towards the air intake terminal.6. Maintain minimum of 1/4 inch per foot slope onhorizontal runs. Slope down towards boiler.with straps or supports no less than five (5) feetapart on horizontal runs. The complete air intakepiping system must be rigid and able to withstandminor impacts without collapse.8. Inlet air pipe penetration:Vertical - Size roof opening to allow easy insertionof inlet piping and allow proper installation of flashingand storm collar.a. Use appropriately designed vent flashing whenpassing through roofs. Follow flashing manufacturers’instructions for installation procedures.Flashing manufacturers are Air-Jet, AmericanMetal Products, Metal Fab, and Simpson Dura-Vent.b. Extend air intake pipe to maintain minimumvertical and horizontal distance of twelve (12)inches from roof surface. Allow additional verticaldistance for expected snow accumulation.Provide brace as required. Refer to Figure 11.c. Vertical air intake requires flashing and a stormcollar to prevent moisture from entering thestructure.d. Install storm collar on air intake pipe immediatelyabove flashing. Apply Dow Corning Silastic732 RTV Sealant between air intake pipe andstorm collar to provide weathertight seal.9. Seal all joints airtight, using silicone caulk or self -adhesive aluminum tape.10. Install Air Intake Terminal:Vertical - Insert intake piping into intake terminalcollar. Secure terminal to intake piping and sealjoint with silicone caulk.7. The air intake pipe must be adequately supported17

18Figure 9: Vertical Vent Installation

Figure 10: Attic OffsetFigure 11: Indoor Air - Horizontal / Vertical Vent Terminal InstallationExtend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve(12) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation.19

IV. Water Piping and Trim20CAUTIONFailure to properly pipe boiler may result inimproper operation and damage to boiler orstructure.1. Design and install boiler and system piping toprevent oxygen contamination of boiler water andfrequent water additions.CAUTIONOxygen contamination of boiler water willcause corrosion of iron and steel boilercomponents, and can lead to boiler failure.Thermal Solutions Standard Warrantydoes not cover problems caused by oxygencontamination of boiler water or scale(lime) build-up cause by frequent addition ofwater.CAUTIONAll piping either new or existing must becleaned with a tri sodium phosphate (TSP)solution to remove mill scale and oils fromthe system. Failure to do so could result inpremature failure of the heat exchanger (notcovered by Thermal Solutions warranty.)CAUTIONOn an existing or retrofit system, a filter orstrainer must be installed on the systemreturn prior to the boilers.CAUTIONWhen using Glycol products, all Glycolmanufacturers’ requirements, includingrust inhibitors, must be adhered. Max 50%Glycol.a. There are many possible causes of oxygen contaminationsuch as:i. Addition of excessive make-up water as aresult of system leaks.ii. Absorption through open tanks and fittings.iii. Oxygen permeable materials in the distributionsystem.b. In order to insure long product life, oxygensources must be eliminated. This can be accomplishedby taking the following measures:i. Repairing system leaks to eliminate the needfor addition of make-up water.ii. Eliminating and/or repairing fittings whichallow oxygen absorption.iii. Using non-permeable materials in the distributionsystem.iv. Isolating the boiler from the system water byinstalling a heat exchanger.vi. Using properly designed and operating airelimination devices in water piping.2. Design and install system piping to prevent returnwater temperatures below 130°F. Refer to Table 2for boiler flow and pressure drop requirements.3. Connect system supply and return piping to boiler.Refer to Figure 12. Also consult I=B=R InstallationCAUTIONReturn water temperature below 130°Fwill cause flue gas condensation inside theboiler. Flue gas condensate can lead toboiler failure. Thermal Solutions StandardWarranty does not cover problems causedby flue gas condensation.WARNINGSupply and return water temperature differencesgreater than 40°F can lead to boilerfailure. Thermal Solutions Standard Warrantydoes not cover problems caused bytemperature difference greater than 40°F.and Piping Guides. Maintain ½” minimum distancebetween water piping and combustible material.Consult Thermal Solutions for unusual systemrequirements.4. A pressure relief valve is supplied with each appliance.No valve is to be placed between the reliefvalve and appliance. No reducing coupling or otherrestriction shall be installed in the discharge line.

See Figure 13.a. Pipe the safety relief discharge to a suitable placefor disposal when relief occurs.b. Do not install reducing couplings for otherrestrictive devices in the safety relief dischargeline.c. The safety relief discharge line must allow forcomplete drainage of both the valve and line.5. If the relief valve discharges periodically, this maybe due to thermal expansion in a closed watersupply system. Contact the water supplier or localplumbing inspector on how to correct this situation.DO NOT PLUG THE RELIEF VALVE.6. Install the drain valve provided with the appliance atthe lowest elevation. See Figure 13.7. If this boiler is used in connection with refrigerationsystems, the boiler must be installed so that thechilled medium is piped in parallel with the boilerusing appropriate valves to prevent the chilledmedium from entering the boiler, see figure 13A.Also consult I=B=R Installation and Piping Guides.If this boiler is connected to heating coils locatedin air handling units where they may be exposed torefrigerated air circulation, the boiler piping must beequipped with flow control valves or other automaticmeans to prevent gravity circulation of boilerwater during operation of the cooling system.8. Install water flow switch. Water flow switch mustbe located such that water flow disruptions do notaffect switch operation. Maintain maximum practicalstraight piping before and after flow switch tominimize water disruptions. Refer to manufactures’instructions for proper paddle length.9. A low water cutoff is required to protect a hot waterboiler when any connected heat distributor (radiation)is installed below the top of the hot waterboiler (i.e. baseboard on the same floor level as theboiler). In addition, some jurisdictions require theuse of a LWCO with a hot water boiler. If a lowwater cutoff is required, it must be mounted in thesystem piping above the boiler. The minimum safewater level of a hot water boiler is just above thehighest water containing cavity of the boiler; that is,a hot water boiler must be full of water to operatesafely.10. Oil, grease, and other foreign materials whichaccumulate in new hot water boilers and a new orreworked system should be boiled out, and thenthoroughly flushed. A local qualified watertreatment chemical specialist is a suggested sourcefor recommendations regarding appropriatechemical compounds and concentrations which arecompatible with local environmental regulations.11. After the boiler and system have been cleaned andflushed, and before refilling the entire system addappropriate water treatment chemicals, if necessary,to bring the pH between 8.8 and 9.2.12. If it is required to perform a long term pressuretest of the hydronic system, the boiler should firstbe isolated to avoid a pressure loss due to theescape of air trapped in the boiler.To perform a long term pressure test including theboiler, ALL trapped air must first be removed fromthe boiler.A loss of pressure during such a test, with novisible water leakage, is an indication that theboiler contained trapped air.WARNINGFailure to operate the unit with the properwater flow rate can lead to appliance failure.Always install water flow switch so that theunit stops operating if improper water flowis present.Safety relief valve discharge piping mustbe piped such that the potential of severeburns is eliminated. DO NOT pipe in anyarea where freezing could occur. DO NOTinstall any shut-off valves, plugs or caps.Consult Local Codes for proper dischargepiping arrangement.Do not operate boiler with flow rates inexcess of the maximum flow rates listed inTable 2. Boiler tube erosion and pitting willoccur. Thermal Solutions Standard Warrantydoes not cover problems caused byexcessive water flow rates.If a high head system pump is installed, assurethat the boiler relief valve and systempiping are capable of operating properlyat the combined pressure of the system fillpressure plus the pump static head pressure.21

Table 2 - Solaris Boiler Flow and Pressure DropBoilerModel20° ΔT (max) 40° ΔT (min)Δ P (ft)Flow(GPM)Δ P (ft)Flow(GPM)Supply/ReturnPipe (in. dia.)SOL-300 0.8 24 0.5 12 2SOL-500 6.9 41 1.4 20 2SOL-750 6.5 64 1.5 32 3SOL-1000 16.1 85 3.7 43 3SOL-1250 23.5 106 6.9 53 3SOL-1500 29.1 128 10.6 64 322Figure 12: Water Piping (Single Boiler)

Figure 13: Safety & Drain Valve InstallationFigure 13 A: Recommended Piping for CombinationHeating & Cooling (Refrigeration) System23

V. Gas PipingWARNINGFailure to properly pipe gas supply to boilermay result in improper operation and damageto the boiler or structure. Always assuregas piping is absolutely leak free and of theproper size and type for the connected load.An additional gas pressure regulator maybe needed. Consult gas supplier.A. Size gas piping. Design system to provide adequate gassupply to boiler. Consider these factors:1. Allowable pressure drop from point of delivery toboiler. Maximum allowable system pressure is ½psig. Actual point of delivery pressure may be less;contact gas supplier for additional information. Theminimum and maximum gas valve inlet pressure isstamped on the rating label and can be found in table3.2. Maximum gas demand. Refer to the boiler’s inputfound in Figure 1 or as printed on it’s rating label.Also consider existing and expected future gasutilization equipment (i.e. water heater, cookingequipment).3. Length of piping and number of fittings. Refer toTable 5 for maximum capacity of Schedule 40 pipe.Table 6 lists equivalent pipe length for standard fittings.Table 3: Gas RatingsBoilerModelMaximumGas Pressure(in. w.c.)MinimumGas Pressure(in. w.c.)ManifoldPressure(in. w.c.)SOL-300 14 4.5 3.5SOL-500 14 4.5 1.3SOL-750 14 4.5 2.3SOL-1000 14 4.5 1.9SOL-1250 14 4.5 1.5SOL-1500 14 4.5 1.34. Specific gravity of gas. Gas piping systems forgas with a specific gravity of 0.70 or less can besized directly from Table 5, unless authority havingjurisdiction specifies a gravity factor be applied.For specific gravity greater than 0.70, apply gravityfactor from Table 4. If exact specific gravity is notshown choose next higher value.Table 4: Specific Gravity Correction FactorsSpecificGravityCorrectionFactorSpecificGravityCorrectionFactor0.50 1.10 1.10 0.740.55 1.04 1.20 0.710.60 1.00 1.30 0.680.65 0.96 1.40 0.660.70 0.93 1.50 0.630.75 0.90 1.60 0.610.80 0.87 1.70 0.590.85 0.84 1.80 0.580.90 0.82 1.90 0.561.00 0.78 2.00 0.55For materials or conditions other than those listed above, referto National Fuel Gas Code, NFPA54/ANSI Z223.1,or size system using standard engineering methodsacceptable to authority having jurisdiction.B. Connect boiler gas valve to gas supply system.1. Use methods and materials in accordance with localplumbing codes and requirements of gas supplier. Inabsence of such requirements, follow National FuelGas Code, NFPA 54/ANSI Z223.1.2. Use thread (joint) compounds (pipe dope) resistantto action of liquefied petroleum gas.3. Install sediment trap, ground-joint union and manualshut-off valve upstream of boiler gas control valveand outside jacket. See Figure 14.4. All above ground gas piping upstream from manualshut-off valve must be electrically continuous andbonded to a grounding electrode. Do not use gaspiping as grounding electrode. Refer to NationalElectrical Code, NFPA 70.C. Pressure test. The boiler and its gas connection must be24NOTICEUSA boilers built for installation at altitudes greater than 2,000 feet above sea level have beenspecifically orificed to reduce gas input rate 4 percent per 1,000 feet above sea level per theNational Fuel Gas Code, NFPA 54/ANSI Z223.1.

Table 5: Maximum Capacity of Schedule 40 Pipe in CFH* for Gas Pressures of 0.5 psig or Less0.3 inch w.c. Pressure Drop 0.5 inch w.c. Pressure DropLength (Feet) 3/4 1 1-1/4 1-1/2 3/4 1 1-1/4 1-1/210 273 514 1060 1580 360 678 1390 209020 188 353 726 1090 247 466 957 143030 151 284 583 873 199 374 768 115040 129 243 499 747 170 320 657 98550 114 215 442 662 151 284 583 87360 104 195 400 600 137 257 528 79170 95 179 368 552 126 237 486 72880 89 167 343 514 117 220 452 67790 83 157 322 482 110 207 424 635100 79 148 304 455 104 195 400 600* 1 CFH of Natural Gas is approximately equal to 1 MBH.leak tested before placing boiler in operation.1. Protect boiler gas control valve. For all testing over½ psig, boiler and its individual shutoff valve mustbe disconnected from gas supply piping. For testingat ½ psig or less, isolate boiler from gas supplypiping by closing boiler’s individual manual shutoffvalve.2. Locate leaks using approved combustible gas detector,soap and water, or similar nonflammable solution.DANGERDo not use matches, candles, open flamesor other ignition source to check for leaks.GROUND-JOINTUNIONMANUALSHUT-OFFVALVEWARNINGFailure to use proper thread compoundson all gas connectors may result in leaks offlammable gas.TEE3" MIN.CAPWARNINGGas supply to boiler and system must beabsolutely shut off prior to installing or servicingboiler gas piping.Figure 14: Recommended Gas PipingTable 6: Equivalent Lengths of Standard Pipe Fittings & ValvesVALVES FULLY OPENPipe Size I.D. Gate Globe Angle Swing 90° Elbow 45° Elbow 90° Tee, Flow 90° Tee, Flow1/2” 0.622 0.35 18.6 9.3 4.3 1.6 0.78 1.0 3.13/4” 0.824 0.44 23.1 11.5 5.3 2.1 0.97 1.4 4.11” 1.049 0.56 29.4 14.7 6.8 2.6 1.23 1.8 5.31-1/4” 1.380 0.74 38.6 19.3 8.9 3.5 1.60 2.3 6.925

VI. ElectricalDANGERPositively assure all electrical connections are unpowered before attempting installation or serviceof electrical components or connections of the boiler or building. Lock out all electrical boxeswith padlock once power is turned off.WARNINGFailure to properly wire electrical connections to the boiler may result in serious physical harm.Electrical power may be from more than one source. Make sure all power is off before attemptingany electrical work.Each boiler must be protected with a properly sized over-current device.Never jump out or make inoperative any safety or operating controls.The wiring diagrams contained in this manual are for reference purposes only. Each boiler isshipped with a wiring diagram attached to the front door. Refer to this diagram and the wiringdiagram of any controls used with the boiler. Read, understand and follow all wiring instructionssupplied with the controls.A. General. Install wiring and electrically ground boilerin accordance with authority having jurisdiction or, inthe absence of such requirements, follow the NationalElectrical Code, NFPA 70, and/or CSA C22.1 ElectricalCode.B. A separate electrical circuit must be run from the mainelectrical service with an over-current device/disconnectin the circuit. A service switch is recommendedand may be required by some local jurisdictions. Installthe service switch in the line voltage “Hot” leg of thepower supply. Locate the service switch such that theboiler can be shut-off without exposing personnel todanger in the event of an emergency. Connect the mainpower supply and ground to the three (3) boiler wires(black, white and green) located in the junction box atthe back of the boiler jacket.C. Refer to Figures 15 and 16 for details on the internalboiler wiring.D. When installed, the boiler must be electrically bondedto ground in accordance with the requirements of theauthority having jurisdiction or, in the absence of suchrequirements, with the National Electric Code, ANSI/NFPA70 and/or the Canadian Electrical Code Part 1,CSA C22.1, Electrical Code.NOTICEThis boiler is equipped with a high water temperature limit located inside the internal wiring of theboiler. This limit provides boiler shutdown in the event the boiler water temperature exceeds theset point of the limit control. Certain Local Codes require an additional water temperature limit. Inaddition, certain types of systems may operate at temperatures below the minimum set point ofthe limit contained in the boiler.If this occurs, install an additional water temperature limit (Honeywell L4006 Aquastat) located inthe system piping as shown in the Water Piping and Trim Section of this manual. Wire as indicatedin the Electrical Section of this manual.26

SolarisLadder DiagramNOTES:1. IF LOW WATER CUTOFF (LWCO) IS NOT USED, WIRE #P2 10/THERMALFUSE MUST BE WIRED FROM TERMINAL 10 TO THE THERMAL FUSE.SWITCHES ARE NOT USED, A2. IF THE HIGH AND LOW GAS PRESSUREWIRE MUST BE INSTALLED BETWEEN TERMINAL 16 AND 17 .FACTORY WIRING, LOW VOLTAGE IS 24VAC UNLESS OTHERWISE 3. INDICATED.TO DISCONNECT (BYOTHERS). GROUNDUNIT TO TECHNICALEARTH GROUND120V-1PH-60HZL2L1GND TOCHASSISGND TOCHASSISGL2L1FUSEK3G22GNRDGRP2MM 750-MT-1202931COMBUSTION BLOWER120 VAC CIRCUIT230313233K534 SENSEALARM RELAY K2K2LINE VOLTAGE ALARMK1 K1SENSELOW WATER CUTOFFSENSEBURNER ON/OFFSWITCH111010111213THERMAL FUSE35LOW WATERCUTOFFOPTION(SEE NOTE 1)BURNER ON/OFF SWITCH343536373839K5K34205K3BLOWER MOTORK5AUXILIARY RELAYSENSEWATER FLOW SWITCHSENSEGAS PRESS SWITCHESSENSEHIGH LIMIT987141516171819HIGHNC CHIGH LIMITNC CNO CLOWNO COPERATING LIMITNC CWATER FLOW SWITCHHIGH AND LOW GASPRESSURE SWITCHES(SEE NOTE 2)HIGH LIMIT AND OPERATINGTEMPERATURE SWITCHES4041K462021NCCBLOCKED VENT427K4AUXILIARY RELAYSENSECOMBUSTION AIRFLOW62223COMBUSTION AIR FLOWSWITCH4324NOC44K6SENSEMAIN FUEL VALVE525BOILERSTATUS4546K69MAIN FUEL VALVE(S)262213GND TOCHASSISMAINGAS VALVE3238272213GND TOCHASSISINTERMITTENTPILOTGAS VALVE23310 282GND TOCHASSISIGNITION XFMR4748K2FFlameRodIGN.LEADIGNITION PILOT4912(+)(-)250 200-10 VDCTO52135 OHM51121415HONEYWELL Q7800HFLAME SAFEGUARD SUBBASEANDPROGRAMMER CONTROLRM89A-00K1311CALL FORHEAT109Pin 7 87LC OO WF GP HL6CA CS AL CH C PR5GND TOCHASSISPin 1424VAC - 2115V TO 24VTRANSFORMER24VAC +1SAGECONTROLLERC24VAC -ALFUSEPR24VAC +CSOUTLETSENSORINLETSENSORCOLD AIR DAMPER,SYSTEM PUMP BACKUPOR ALARMCRA1BOBCBICCCSOPin 6CA HL GP WFOO V- V+ P- P+Pin 110987654321LCV+V-COMBUSTION BLOWERSPEED CONTROLCIRCUIT (0-10VDC)CHSYSTEM PUMPCRA2SPO+BOILER PUMPCRA3BP12 VDC0.5A MAX TOTALFOR SO, SP, BP,V1, & LOO+O-O-OUTSIDE AIRSENSOROUTSIDE AIRRESET OPTIONSPARELOCKOUT INDICATORCRA4CRA5VILOR+R+R-REMOTE SYSTEM SYSTEMSENSORTEMPERATURECONTROL OPTIONR-CONTROL RELAY OPTIONSDPDOMESTIC HOTWATER PRIORITYREMOTE CONTROLORREMOTE SETPOINT1-9 VDCMIXING VALVEACTUATORMSMRC-C+12 VDCLRROSICLOCAL/REMOTEREMOTE ON/OFF (ENABLE/DISABLE)(REMOVE JUMPER IF USED)SPARE INPUTCSAGE CONTROLLER PEER-TO-PEERCOMMUNICATIONRJ11GND TOCHASSISRJ45MULTIPLE BOILER OUTSIDE AIR ANDREMOTE SYSTEM TEMPERATURESENSOR SHARINGLINE TYPES:FACTORY WIRING, LINE VOLTAGEFACTORY WIRING, LOW VOLTAGE(SEE NOTE 3)FACTORY WIRING, SPECIAL IGNITERFIELD WIRING, LINE VOLTAGEFIELD WIRING, LOW VOLTAGEOPTIONAL WIRINGFigure 15: Internal Boiler Wiring Ladder Diagram27

E. System Controls and Wiring1. Refer to National Electric Code or Local Electric Codes for proper size and type of wire required. Follow Code.2. Use anti-short bushings on all wiring passing through boiler jacket, junction boxes and/or control boxes.3. Use armored cable (BX) over all exposed line voltage wiring.3 5BURNERON/OFF LOWSWITCH WATERLOW WATERFLOWCUTOFF (LWCO)SWITCHOPTIONNONCRESET HIGH LIMITNC C(SEE NOTE 2)GAS PRESSURE SWITCHNO C NC CYWNC CAUTOLOW YW HIGHMANUALGNDL2 L1 2 3 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 2 29P1 P2 P3W8 (REMOVE)120VAC POWERW9SUPPLY3024VCOIL31F132K1K53334250V T5ASIZE 3AG35P436HONEYWELL Q7800HF237PART NO. 101182-0138W139W2 (REMOVE)K3K440W3 (REMOVE)41W442W5 (REMOVE)43W6 (REMOVE)(REMOVE JUMPERS 11, 12, & 15)W7 HONEYWELLW15 W10 W1244PROGRAMMER CONTROL W14 W11 W1345E1RM789A-1002P5 4612K6L21314P6 471548YW1649K217501851195220P81021CAUTIONHAZARD OF ELECTRIC SHOCK.BEMORE THAN ONE DISCONNECT22SWITCH MAY BE REQUIRED TODE-ENERGIZE THE DEVICE12FOR SERVICING.BKWECOMBUSTIONAIR FLOWSWITCHOUTSIDEAIR SENSOROUTSIDE AIR RESET OPTIONSYSTEM TEMPERATURE CONTROL OPTIONDOMESTIC HOTWATER PRIORITYGND TOREMOTE ON/OFFCHASSIS(ENABLE/DISABLE)(SEE NOTE 3)SPARE INPUTIGNITIONTRANSFORMERINGITIONPILOTBELOADTRANSFORMERNECYWHL PRGPWFCHOO ALLC CSCABEYWYWYWYWYWYWYWYWYWYWFLAME ROD(INSTALL IGNITION TERMINAL,RAJAH MODEL AEBF)YWBN^BK^WETHERMAL SOLUTIONS SAGE CONTROLLER (SBC)PART NO. 801SOL0001RJ45(BACK VIEW)LCCHO+125V T5ASIZE 5MM X 20MMO+O-O-R+R+R-R-DPLRROSICSALPRGND TOCHASSISCA HL GP WF PIN 6OO V+ P+ PIN 1RJ11BCBOBISOSPBPVILOMRMSC-C+^WE^WE^BK^BKCOLD AIR DAMPER,SYSTEM PUMP BACKUPOR ALARM(CRA1)WEBNSYSTEM PUMP(CRA2)BNBNBNBOILER PUMPBN(CRA3)SPARE(CRA4)LOCKOUT INDICATOR(CRA5)AUXILIARY EQUIPMENTG3456789F2C271623232332CRCCCV-P-CCCCGNWEBKWEBKYWYWYWYWYWYWYWYWYWYWOEOEOEBNWEBNWEBNWEYW^WE^BKYWYWYWYWYWYWYWBEBEYWGND TOCHASSISBLOCKEDVENTSWITCHGND TOCHASSISP7GNGROUNDTO DISCONECT,(BY OTHERS)WEL2GROUND UNIT TOTECHINCAL EARTH GND.BK208/230/460V-3PH-60HZL1MAINGAS VALVELOCAL REMOTESWITCH OPTIONIGNITION PILOTGAS VALVEVARIABLE SPEEDGND TO^BKBLOWERCHASSIS^WEIGN LEADFUSE104 GNBKWEWIRE COLORS:BE = BLUEBK = BLACKBN = BROWNGN = GREENOE = ORANGEPK = PINKRD = REDVT = VIOLETWT = WHITEYW = YELLOWRELAY/SWITCH TERMINALS:C = COMMONNC = NORM. CLOSEDNO = NORM. OPENWIRE TYPES:(BLACK COLOR SHOWN, TYPICAL FOR ALL COLORS)*BKFACTORY WIRING, LINE VOLTAGE, 12 AWG, 105°CBKFACTORY WIRING, LINE VOLTAGE, 18 AWG, 105°CBKFACTORY WIRING, LOW VOLTAGE, 18 AWG, 105°C^BKFACTORY WIRING, LOW VOLTAGE, 18 AWG, SHIELDEDFACTORY WIRING, SPECIAL IGNITER, NOT IN HARNESSOPTIONAL WIRING, LINE VOLTAGE, NOT IN HARNESS, 18AWG, 105°COPTIONAL WIRING, LOW VOLTAGE, NOT IN HARNESSSTANDARD FACTORY WIRING, LINE VOLTAGE, NOT IN HARNESS, 18AWG, 105°CSTANDARD FACTORY WIRING, LOW VOLTAGE, NOT IN HARNESSSTANDARD FACTORY WIRING, NOT IN HARNESS, 16AWG, 200°C213213OEPIN 7PIN 1WEBKWE GN(SEE NOTE 1)THERMAL FUSEC NCNOGND TOCHASSISNOTES:1. IF THE LOW WATER CUTOFF(LWCO) IS USED, DISCONNECT WIRE LABELEDP2 10/THERMAL FUSE FROM THE THERMAL FUSE AND CONNECT IT TOLWCO TERMINAL 3. ALSO, CONNECT LWCO TERMINAL 5 TO THE THERMAL FUSE.2. IF GAS PRESSURE SWITCHS ARE USED, INSTALL WIRING BETWEEN P16 ANDP17 TO INCLUDE THE PRESSURE SWITCH(S) AS SHOWN. IF NO GAS PRESSURESWITCH IS REQUIRED, INSTALL A JUMPER BETWEEN TERMINALS P16 ANDP17 AS SHOWN.3. IF THE REMOTE ON/OFF FUNCTION IS DESIRED, REMOVE JUMPER WIRE BETWEENTERMINALS RO & C AND WIRE AS SHOWN. NOT TO BE DONE AT FACTORY.21PC28Figure 16: Schematic Diagram

VII. Modular InstallationA. General Guidelines1. Read and follow all venting, combustion air, waterpiping, gas piping and electrical instructions containedin this manual unless otherwise instructed inthis section.2. Consult Local Building Codes or National Fuel GasCode, NFPA 54/ANSI Z222.3 for restrictions andinstructions on modular boiler installations.3. Modular systems are complex. Design and installationof modular systems should only be undertakenby skilled and knowledgable engineers and contractors.4. Use stainless steel vent material approved for condensingflue gass applications.B. Module SizingThermal Solutions recommends sizing each boiler in amodular system to provide 20 % of the combined heatingload where ever possible. If the combined load exceedsthe output of five (5) boilers, install the minimumnumber of boilers to meet the load requirements.C. Venting1. Horizontal/Vertical Ventinga. Use Stainless Steel vent material approved forcondensing flue gas applications.WARNINGDo not manifold vent components of aboiler without correcting to negative draft.b. See Table 1 for the maximum vent length of eachsize boiler.c. Refer to Section III of this manual for guidelineson venting of modular boilers individually. Eachboiler requires an individual vent pipe.d. The minimum horizontal distance between ventterminations is one (1) foot. Additional horizontaldistance is desirable to avoid frost damage tothe building. Vent terminations must be at leasttwelve (12) inches above the ground plus theexpected snow accumulation.e. Multiple vertical vent pipes may be pipedthrough a common conduit or chase so that oneroof penetration may be made. Each vent terminationmust be one (1) foot from other terminations.A minimum of at least six (6) inches fromthe common conduit to combustible materialmust be maintained unless otherwise instructedby the conduit manufacturer.CAUTIONInstalling multiple vent terminations closetogether promotes frost buildup on buildings.To minimize this possibility, extend thedistance from the building to the end of thevent termination and increase the horizontaldistance between terminations.f. Refer to the cautions, notices, and warnings inSection III.2. Conventional Venting (Negative Draft)a. Refer to Figure 17 for conventional ventingguideline for modular boilers.b. Refer to National Fuel Gas Code to determinerequired chimney diameter and common ventingdiameter. Note that combined input, laterallength and chimney height affect vent diameter.c. A single double acting barometric damper canbe utilized on the common venting when ventingaccording to Figure 17.d. Slope common venting a minimum of one (1)inch in four feet of run towards boilers.e. Locate boiler(s) with lowest input closest tochimney.f. Refer to cautions, notices, and warnding in SectionIII.D. Air Intake Piping1. Locate air intake termination on the same wall asthe vent termination if possible, to prevent nuisanceboiler shutdowns. However, boiler may be installedwith vertical venting and sidewall combustion airinlet (or visa versa) if installation conditions do notallow alternate arrangement.2. Refer to Figures 18 and 19 for common air intakeguidelines for modular water heaters.3. Individual air intake pipes may be used in lieu ofcommon air intake piping. If so desired, refer toFigures 4 and 8.4. Refer to Table 1 for the maximum air intake length.Common air intake straight lengths and fittingsshould be assumed to have the equivalent lengththe same as an individual air intake pipe used for agiven boiler intake pipe diameter.5. Position horizontal air intake termination center linebelow horizontal vent termination’s center line.6. Vertical air intake pipe must terminate at least two(2) feet above teh closest portion of the roof.7. Refer to the cautions, notices, and warnings in theCombustion Air Section of this manual.29

E. Water Piping1. Refer to Figures 20 through 25 for typical water pipinginstallation details for modular boilers.2. Installing a low water cutoff in the system is highlyrecomended and may be required by code.3. Refer to Table 2 for pressure drop and flow requirementsfor each boiler.4. Refer to the instructions, cautions, notices, andwarnings in Section IV.F. Gas Piping1. Refer to National Fuel Gas Code, Local Codes andTables 5 and 6 for gas pipe sizing.2. Each boiler must be piped as shown in Figure 14.3. Refer to the instructions, catuions, notices, andwarnings in Section V.G. ElectricalWARNINGIf gas pressure in the building is above 1/2psig, an additional gas pressure regulator isrequired. Using one additional regulator formultiple boilers may result in unsafe boileroperation. The additional regulator must beable to properly regulate gas pressure atthe input of the smallest boiler. If the regulatorcannot do this, two or more additionalregulators are required. Consult regulatormanufacturer and/or local gas supplier forinstructions and equipment ratings.1. Each boiler must be provided with a fused disconnectand service switch.2. Install wiring in accordance with requirements ofauthority having jurisdiction. In the absence of suchrequirements, follow the National Electric Code,NFPA 70 and/or CSA C22.1 Electric Code.3. Refer to Figure 2 for electrical data for each boilersize.4. Refer to the instructions, cautions, notices, andwarnings found in Section VI.30

Figure 17: Modular Boiler Conventional VentingFigure 18: Modular Boiler Horizontal Air Intake Piping31

LISTED IN TABLE 1.Figure 19: Modular Boiler Vertical Air Intake Piping32

Figure 20: Modular System: Typical One Pipe Water Piping33

34Figure 21: Modular System: Typical Primary/Secondary Water Piping

Figure 22: Modular System: Typical Primary/Secondary without System Pump35

36Figure 23: Modular System: Typical Reverse - Return Water Piping

Figure 24: Modular System Reverse - Return with System Pump Only37

38Figure 25: Modular System: Typ Primary/Secondary with Reverse-Return

VIII. System Start-upA. Safe operation and other performance criteria were metwith gas manifold and control assembly provided onboiler when boiler underwent tests specified in AmericanNational Standard for Gas-Fired Low-PressureSteam and Hot Water Boilers, ANSI Z21.13.B. Verify that the venting, water piping, gas piping andelectrical system are installed properly. Refer to installationinstructions contained in this manual.C. Confirm all electrical, water and gas supplies are turnedoff at the source and that vent is clear of obstructions.D. Confirm that all manual shut-off gas valves between theboiler and gas source are closed.WARNINGCompletely read, understand and follow allinstructions in this manual before attemptingstart up.E. FILL ENTIRE HEATING SYSTEM WITH WATERand vent air from system. Use the following procedureon a Series Loop or multi-zoned system installed toremove air from the system while filling.WARNINGThe maximum operating pressure of thisboiler is 150 psig. Never exceed this pressure.Do not plug or change pressure reliefvalve.NOTICEIf it is required to perform a long term pressuretest of the hydronic system, the boilershould first be isolated to avoid a pressureloss due to the escape of air trapped in theboiler.To perform a long term pressure test includingthe boiler, ALL trapped air must first beremoved from the boiler.A loss of pressure during such a test, withno viable water leakage, is an indicationthat the boiler contained trapped air.1. Close full port ball valve in boiler supply piping.2. Isolate all zones by closing zone valves or shut-offvalves in supply and return of each zone(s).3. Attach a hose to the vertical hose bib located prior tothe full port ball valve in the system supply piping.(Note - Terminate hose in five gallon bucket at asuitable floor drain or outdoor area).4. Starting with one circuit at a time, open zone valveor shut-off valve in system supply and return piping.5. Open hose bib.6. Open fill valve (Make-up water line should be locateddirectly after full port ball valve in system supplypiping between air scoop and expansion tank).7. Allow water to overflow from bucket until dischargefrom hose is bubble free for 30 seconds.8. Close the opened zone valve or shut-off valve forthe zone being purged of air, then open the zonevalve or shut-off valve for the next zone to bepurged. Repeat this step until all zones have beenpurged. At completion, open all zone valves orshut-off valves.9. Close hose bib, continue filling the system until thepressure gauge indicates required system operatingpressure. Close fill valve.(Note - If make-up water line is equipped withpressure reducing valve, system will automaticallyfill to set pressure. Follow fill valve manufacturer’sinstructions).10. Open isolation valve in boiler supply piping.11. Remove hose from hose bib.F. Confirm that the water flow switch is operating properly.G. Turn on the electrical supply to the boiler and circulationsystem at the fused disconnect.H. Confirm that water flow switch is operating properly.I. Prepare to check operation.1. Obtain the gas heating value (in Btu per cubic feet)from the gas supplier.2. Connect a monometer to the pressure tapingupstream V1 on the main gas valve. Use the G 1/8test nipple provided. Reference item 7 on figure 28.3. Temporarily turn off all other gas-fired appliances.4. Turn on gas supply to the boiler gas piping.5. Purge the gas line of air.6. Reset the low gas pressure switch.7. Confirm that the supply pressure to the gas valve is14 in. w.c. or less. Refer to Table 3 for the minimumsupply pressure.39

DANGERDo not use matches, candles, open flamesor other ignition source to check for leaks.8. Open the field installed manual gas shut-off valvelocated upstream of the gas valve on the boiler.9. Check that boiler gas piping, valves, and all othercomponents are leak free using a soap solution ora similar non-combustible solution, electronic leakdetector or other approved method. Eliminate anyleaks.Figure 26: Pilot Burner/Main Burner FlameJ. Follow the operating instructions to place the boilerinto operation. Reference Figure 27.K. Sequence of operation. See Figure 29. If boiler fails tooperate properly, see Trouble shooting Guide in SectionIX.L. Select Desired Operating Mode. Refer to the SageBoiler Control (SBC ) instructional manual suppliedwith the boiler.M. Set operating limits. Refer to the (SBC ) instructionalmanual supplied with the boiler.N. Check Ignition control module shut-off.1. Rotate the manual gas shut-off valves clockwisefrom “ON” to “OFF” position.2. Turn on the boiler-operating switch located on theleft side of the unit.3. Allow boiler to complete prepurge and pilot trial forignition (PTIF) sequence. Confirm that the flamecontrol locks out on pilot flame failure.4. Rotate the manual shut off valve for the pilot to allowgas flow to the pilot valve.5. Allow the boiler to complete the pre-purge, PTIF,and main trial for ignition (MTFI). Confirm that theflame control locks out on main flame failure.6. Rotate the manual shut off valves for the main gasvalve to allow gas flow to the main gas valve. Confirmthat the flame control locks out on main flamefailure.7. Disconnect the pilot lead wires from the pilot gasvalve. If the burners do not shutdown, determine thecause of the malfunction. Replace necessary itemsand check operation.40

A.B.WARNING:FOR YOUR SAFETY READ BEFORE OPERATINGIf you do not follow these instructions exactly, a fire or explosion may resultcausing property damage, personal injury, or loss of life.This appliance is equipped with an ignition device, whichautomatically lights the pilot. Do not try to light the pilot byhand.BEFORE OPERATING smell all around the appliance areafor gas. Be sure to smell next to the floor because some gas isheavier than air and will settle on the floor.WHAT TO DO IF YOU SMELL GAS• Do not try to light any appliance.• Do not touch any electric switch; do not use any phone inyour building.• Immediately call your gas supplier from a neighbor’sphone. Follow the gas supplier’s instructions.C.D.OPERATING INSTRUCTIONS• If you cannot reach your gas supplier, call the fire department.Use only your hand to push in or turn the gas control knob.Never use tools. If the knob will not push in or turn by hand,don’t try to repair it, call a qualified service technician.Force or attempted repair may result in a fire or explosion.Do not use this appliance if any part has been under water.Immediately call a qualified service technician to inspect theappliance and to replace any part of the control system andany gas control which has been under water.1.2.3.4.5.6.STOP! Read the safety information above on this label.Set the thermostat to lowest setting.Turn off all electric power to the appliance.This appliance is equipped with an ignition device, whichautomatically lights the pilot. Do not try to light the pilotby hand.Inlet GasRemove front door.Locate the gas pilot & mainshutoff valves at the endof the gas supply pipeinside the boiler.7.8.Rotate gas shutoff valves clockwise from “ON” positionto “OFF”. Make sure handle rests against stop.Wait five (5) minutes to clear out any gas. Then smell forgas, including near the floor. If you smell gas, STOP! Follow“B” in the safety information above on this label. If you donot smell gas, go to the next step.9. Rotate gas shutoff valves counterclockwise from“OFF” to “ON”. Make sure handle rest against stop. Do notforce.10. Replace front door.11. Turn on all electric power to the appliance.12. Set thermostat to desired setting.Gas Shut Off Valves13.TO TURN OFF GAS TO APPLIANCEIf the appliance will not operate, follow the instructions “TOTURN OFF GAS TO APPLIANCE” and call your servicetechnician or gas supplier.1.2.Set the thermostat to lowest setting.Turn off all electric power to the appliance if service is to beperformed.4.5.Rotate gas shutoff valves clockwise from “ON” positionto “OFF”. Make sure handle rests against stop.Replace front door.3.Remove front door.814SOL0001Figure 27: Operating Instructions41

1 Electrical connection for valves (DIN EN 175 301-803) 10 Setting screw Ratio V2 Input flange 11 Vent nozzle G 1/83 Pressure connection G 1/8 upstream of filter 12 G 1/8 pressure connection Burner pressure p Br4 Filter 13 Output flange5 Type plate 14Test point connection G 1/8 upstream of V1, possibleboth sides6 Cover 15 G 1/8 pressure connection blower pressure p LTest point connection G 1/8 upstream of V1, possible7 on both sides16 G 1/8 pressure connection for p Ffurnace pressure8Test point connection G 1/8 downstream of V2possible on both sides17 Optional: Pulse line p Br9 Setting screw Zero point adjustment N * G 1/8: 1/8” Iso Parallel Threads42Figure 28: Main Gas Valve

Figure 29: Sequence of Operation43

O. Check the pilot and main burner flames. Allow theboiler to complete pre-purge, PTIF, and MTFI. Lookthrough the boiler sight glass and check the pilot andmain burner flames. Reference Figure 26 for flame appearance.The flames should have a clearly defined innercone with no yellow tipping. Orange-yellow streaksshould not be confused with true yellow tipping. If theflames do not meet the criteria in figure 26, adjust thegas valve settings as described in step R.P. Check low water cut-off (if so equipped).44WARNINGFailure to properly adjust gas input rate willresult in over firing or under firing of the appliance.Improper and unsafe boiler operationmay result.1. Adjust setpoint to highest setting.2. With boiler operating, open the drainvalve and slowly drain the boiler.3. Main burners and pilot burner will extinguish andblower will stop when the water level drops belowthe low water cutoff probe. Verify limit, thermostator other controls have not shut off the boiler.4. Adjust the setpoint to the desired value and refillthe boiler.Q. Verify that all safety and operating limits are operatingproperly. These controls and limits include differentialair switch, water temperature operating control,manual reset water temperature safety limit, and thehigh and low gas pressure switches (if provided). Referto the individual manuals, provided with the boiler, forthese components to obtain proper start-up and operatinginstructions. Follow all instructions contained inthese manuals. Refer to section IX to view a descriptionof the safety and operating controls.R. Adjust the gas input rate to the boiler.1. Administer a call for heat and allow the boiler tooperate.2. Check the manifold pressure at high fire and lowfire. See table 3 or the rating label located in theboiler’s vestibule compartment.a. Connect manometer to pressure tappingdownstream V1 on main gas valve. See item 8 onFigure 28.b. Use the V setting (Item 10 on Figure 28) onthe main gas valve to adjust the gas manifoldpressure at high fire. Turn the screw settingclockwise to increase and counterclockwise todecrease the manifold pressure.c. Use the N setting (Item 9 on Figure 28) on themain gas valve to adjust the gas manifold pressureat low fire. Turn the screw setting clockwiseto increase counterclockwise to decrease themanifold pressure.3. Clock the gas meter for at least 30 seconds. Usetable 7 to determine the gas flow rate in cubic feetper hour.4. Determine the input rate. Multiply the gas flow rateby the gas heating value.WARNINGFailure to properly adjust gas input willresult in over firing or under firing of theappliance. Improper and unsafe operationmay result.5. Compare the measured input rate to the input ratestated on the rating plate.a. The boiler must not be over fired. Reduce theinput rate by decreasing the manifold pressure asdescribed in step R. Do not reduce more than 0.3inch w.c. If the boiler is still over fired, contactyour Thermal Solutions representative.b. If the measured value is less than 98% of therating plate input, increase the input rate byincreasing the manifold gas pressure describedin step R. Do not increase the manifold pressuremore than 0.3 inch w.c. Contact your ThermalSolutions representative if the measured rate isstill less than 98% of the rated input.WARNINGFailure to properly adjust excess air willresult in unsafe levels of carbon monoxide.Variations in venting or combustion air pressureand temperature will change excessair. Adjust excess air levels so that variationin venting or combustion air pressures andtemperatures caused by change of seasons,wind conditions, opening or closing ofboiler room doors or windows do not causethe boiler to operate with carbon monoxideconcentrations above 400 parts per million.6. Measure the percent oxygen (%O2), the carbonmonoxide concentrations in the flue gas (CO ppm),and the flue gas temperature. Compare the results

with the values given on the factory fire test reportsupplied with the boiler.7. Return gas fired appliances to previous conditions ofuse.S. Review user’s information manual and system Operationwith owner or operator.Table 7: Gas Flow Rate in Cubic Feet Per HourSecondsfor OneOne-HalfCu. Ft.Size of Gas Meter DialOneCu. Ft. Two Cu. Ft.30 60 120 24032 56 113 22534 53 106 21236 50 100 20038 47 95 18940 45 90 18042 43 86 17244 41 82 16446 39 78 15748 37 75 15050 36 72 14452 35 69 13854 33 67 13356 32 64 12958 31 62 12460 30 60 12045

IX. Service and MaintenanceDANGERThis boiler uses flammable gas, high voltage electricity, moving parts, and very hot water underhigh pressure. Assure that all gas and electric power supplies are off and that the water temperatureis cool 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. Nevermodify, remove or tamper with any control device.WARNINGThis 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 thismanual.If any electrical wires are disconnected during service, clearly label the wires and assure that thewires 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 componentinstruction manuals.Assure that all safety and operating controls and components are operating properly before placingthe boiler back in service.CAUTIONLabel all wires prior to disconnection when servicing controls. Wiring errors can cause improperand dangerous operation.Verify proper operation after servicing.ATTENTIONAu moment de l’entretien des commandes, étiqueteztous les fils avant de les débrancher. Deserreurs de câblage peuvent entraîner un fonetionnement inadéquat et dangereux.S’assurer que l’appariel fonctionne adéquatement une fois l’entretien terminé.A. Periodic Maintenance. Inspection and service shouldbe conducted periodically. Turn off electrical power andgas supply while conducting service or maintenance.Follow instructions TO TURN OFF GAS TO APPLI-ANCE. See Figure 27.461. Generala. Keep the area around the boiler free from combustiblematerials, gasoline and other flammablevapors and liquids.b. Keep the area around the combustion air inletterminal free from contaminates.c. Keep the boiler room ventilation openings openand unobstructed.2. Low water cutoff (if so equipped).a. Probe Type (Annual Service). Probe typeLWCO should be removed once a year, examinedand cleaned of any dirt accumulations to assureproper operations. Do not attempt to repairmechanisms in the field. Complete replacementmechanisms, including necessary gaskets andinstallation instructions, are available from themanufacturer.3. Vent/Air Intake System. Inspect for obstructions,soot accumulation, proper support, deterioration of

pipe, fittings, and joints.a. Clean terminal screens. Terminals must be freeof obstruction, undamaged, with screens securelyin place.b. Inspect and clean the air filter as needed. Thefilter can be cleaned using water. See Figure 39,Item 11, for location.c. Terminal Wall thimbles (if used) must be weathertight.d. Pipe must be full round shape, and show no damagefrom impact or excessive temperature.e. Ensure that there is nothing obstructing the flowof combustion air and/or flue gas.f. Inspect and clean piping with soft bristle brushand vacuum to remove any lint, soot, or otherdirt.g. Replace immediately if any signs of deteriorationor corrosion are present.h. Pipe must be supported at minimum five (5) footintervals and must not sag.i. All vent joints must be secure and watertight.j. All air intake joints must be secure and airtight.k. Horizontal vent tee drain or vertical vent teedrain (if used) must have minimum 6 inch trapand allow condensate to flow freely. To Clean:i. Disconnect drain tube from drain fitting.ii. Flush drain tube with water. Fill trap withwater.iii. Securely fasten drain tube to drain fitting,providing gas-tight and watertight seal.l. If pipe must be disassembled for removal ofobstructions or resealing of joint, see Section III,Paragraph B.4. Inspect Condensate Drain Trap andDrain Line (Monthly)a. Inspect condensate trap water level. If low, addwater to bring level to trap discharge.b. Ensure condensate can flow freely to drain.5. Inspect Pilot and Main Burner Flames(Monthly).a. Remove jacket front panel.b. View flames through Flame Observation Port.c. Adjust thermostat to highest setting.d. Check pilot flame. See Figure 26. The pilot producesthree (3) flames. The center flame shouldbe steady, medium hard blue enveloping 3/8 to1/2 inch of sensing probe. If flame is yellow andlazy, follow instructions TO TURN OFF GASTO APPLIANCE (see Figure 27), and contactqualified agency.e. Check main burner flames. See Figure 26. Flameshould have clearly defined inner cone with noyellow tipping. Orange-yellow streaks causedby dust should not be confused with true yellowtipping. If yellow flames are observed, followinstructions TO TURN OFF GAS TO APPLI-ANCE (see Figure 27), and contact qualifiedservice agency.6. Combustion Chamber/Burners . Inspect forblockage or soot accumulation (annually).a. Remove Main Burners. See Figure 30.1. Remove front door.2. Remove air box cover.3. Disconnect ignition wire, sensor wire,ground wire and gas valve wiring.4. Disconnect manifold unions at pilot valveand main gas inlet on right side of air box.5. Remove attachment screws holding air boxto front of combustion chamber.6. Remove burner/fuel train assembly fromcombustion chamber.7. Inspect and clean burners with soft bristlebrush and vacuum to remove any dirt andlint.8. If burners show signs of deterioration or corrosion,replace immediately.9. Check gas orifices for dirt and lint. Clean asnecessary.10. Inspect heat exchanger and combustionchamber. Clean heat exchanger withstraight handle wire brush and vacuum heatexchanger and combustion chamber.1. Exercise care during vacuuming toavoid damaging base insulation.11. Inspect combustion chamber/burner assemblygaskets and replace if required.12. Install burner/fuel train assembly and securewith original fasteners.13. Connect manifold unions, ignition wire, sen-47

sor wire, ground wire and gas valve wiring.14. Install air box cover and attachment hardware.15. Install front door.6. Check Operation . Follow steps from Section VIIIfor system start-up.WIRE BRUSHSOFT BRISTLE BRUSH48Figure 30: Cleaning Boiler Flue Passages

B. Safety and Operating Controls. Operation and Shut DownComponentCircuit Board FusePower SwitchOperating AquastatManual Reset HighLimit AquastatFlow SwitchPressure (Safety)Relief ValveMixer Fuseable LinkVestibule FuseableLinkHigh and Low GasPressure SwitchesCombustion Air FlowSwitchFlame SafeguardControlVariable FrequencyDrive (VFD)Thermal SolutionsSage Boiler Control(SBC)FunctionIf the power draw of the control circuit exceeds approximately 5 amps, the circuit boardfuse 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 suppliedto the control circuit.If the boiler water temperature exceeds the adjustable set point, power is interrupted to thecontrol circuit of the boiler, which prevents the boiler from operating. When the boiler watertemperature drops below the set point minus the adjustable differential setting, power isagain supplied to the control circuit.If the boiler water temperature exceeds the adjustable set point, power is interrupted to thecontrol circuit of the boiler, which prevents the boiler from operating. Power is interrupteduntil the control is manually reset by pressing the control’s reset button. When the buttonis 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 thecontrol’s paddle enough to close the controls contacts, power is interrupted to the controlcircuit, 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 mechanicallyand discharges water. The valve remains open until the pressure inside the appliancedrops below the set point.If the temperature in the interior of the burner exceeds the fixed set point. The contacts ofthe switch open and power is interrupted to the control circuit, which prevents the boilerfrom operating. Power is interrupted until the switch is replaced.If the temperature in the interior of the vestibule enclosure exceeds the fixed set point, thecontacts of the switch open and power is interrupted to the control circuit, which preventsthe 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 adjustableset 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 betweenthe high and low set points and the control is manually reset by moving the switch tothe reset position. The switches will not reset until the gas pressure is within the set pointparameters.If the differential air pressure drops below the fixed set point, the contacts of the switchopen 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 blowerfan based on the air requirements of the boiler combustion process. The VFD on Modulatingboilers responds to a 0-10 VDC or 4-20 ma signal from the Digital Temperature Controller.The Thermal Solutions Sage Boiler Control (SBC) is a complete boiler and automationsystem. It provides advanced boiler modulation control, operating control, diagnostics,multiple boiler lead lag and auxiliary device control. Refer to the SBC manual shipped withthe boiler to learn more about these features and functions.49

C. Trouble Shooting GuideAlarm Messages are shown one at a time in priority order. The message closes to the top of this list is displayed first. Followingmessages are not show until the higher priority message has cleared. All alarm messages are also stored in the fault history.LCD DisplayAlarm MessageLow Water LevelOff SwitchLow Water FlowFuel LimitHigh Temp LimitLow Air FlowFSG FaultOutlet Temp FailInlet Temp FailOA Temp FailRemote Temp FailRecommendedActionManually Reset the LowWater CutoffTurn Burner Switch OnEnsure Boiler Pump isRunning and BoilerWater Flow isUnobstructedManually Reset the FuelPressure SwitchManually Reset theHigh TemperatureAquastatCheck Combustion AirBlower and AirPressure SwitchSettings and WiringManually ResetRequired, Refer toFlame SafeguardManualCorrective ActionsCheck Wiring andSensorCheck Wiring andSensorCheck Wiring andSensorCheck Wiring andSensorExplanationLow Water Cutoff SwitchWhen this option is configured and an instrument is installed, the manual resetlow water safety relay is preventing the boiler from starting. If terminal (LC) doesnot receive power and the Call For Heat output (CH) is powered the “Low WaterLevel” Message is displayed.Burner Switch is OffControl switch is in the OFF position and is preventing the boiler from starting. Ifterminal (OO) does not receive power and the Call For Heat output (CH) is poweredthe “OFF Switch” Message is displayed.Low Water Flow SwitchLow water flow is preventing the boiler from starting. If terminal (WF) does notreceive power and the Call For Heat output (CH) is powered the “Low WaterFlow” Message is displayed.Low or High Gas Pressure SwitchThe low or high gas pressure switch is preventing the boiler from starting. Ifterminal (GP) does not receive power and the Call For Heat output (CH) ispowered the “Fuel Limit” Message is displayed.High Limit TemperatureThe high temperature limit (HL) (and operational temperature limit whenprovided) aquastat is preventing a boiler start. If terminal (HL) does not receivepower and the Call For Heat output (CH) is powered the “High Temp Limit”Message is displayed.Low Air Flow or Blocked Vent Switch Not MadeThe air flow (and blocked vent switch when provided) is preventing a boiler start.If terminal (CA) does not receive power and the Call For Heat output (CH) ispowered the “Low Air Flow” Message is displayed.Flame Safeguard FaultThe Flame Safeguard is preventing a boiler start. If terminal (AL) receives powerat any time, the “Flame Failure” Message is displayed.Boiler Outlet Temperature Sensor FailThe boiler outlet temperature sensor is not connected or is reading above orbelow a valid range. When the boiler outlet sensor fails and the Outlet Sensormode was selected the control will transfer to Lost Sensor Blind Mode.Boiler Inlet Temperature Sensor FailThe boiler inlet temperature sensor is not connected or is reading above or belowa valid range. When the boiler inlet sensor fails the mixing valve output will driveto 0% and low temperature alarm and maximum water differential (boiler outletminus boiler inlet) temperature hold are disabled.Outside Air Temperature Sensor FailThe outside air sensor is configured and is not connected or is reading above orbelow a valid range. When the outside air sensor fails the warm weather shutdown(WWSD) and outside air reset control logics are disabled.Remote System Temperature Sensor FailThe remote system temperature sensor is configured and is not connected or isreading above or below a valid range. If Remote System Temperature Sensormode was selected the control will transfer to Boiler Outlet Sensor Mode.50

Trouble Shooting Guide (continued)LCD DisplayAlarm MessageRemote Input FailComm FailureLow Inlet TempMemory FailureRecommendedActionCheck Wiring andRemote SystemCheck Wiring andRemote SystemConfirm each boiler hasa unique addressCheck wiring andsensorCheck return watertemperature. Considersystem or operationalchanges to avoid lowtemperature eventsCall Factory Resetall memories inSystem menu:Clr BIT HistoryClr Alarm HistClr Run Time CntClr Cycle CntFactory Defaults(Factory LevelPassword is required)ExplanationRemote Control Input FailThe Remote Control Input is configured and is not connected or is above or belowa valid range. When the remote control input fails the following control modechanges are taken automatically:Selected ModesResulting Control ModeRemote ModOutlet Sensor and Local SetpointRemote Mod & Remote SensorRemote Sensor and Local SetpointRemote SPOutlet Sensor and Local SetpointRemote SP & Remote SensorRemote Sensor and Local SetpointCommunication FailureThe Modbus or Peer-To-Peer network has failed. When the Modbus network failsthe following control mode changes are taken automatically:Selected ModesResulting Control ModeModbus ModOutlet Sensor and Local SetpointModbus Mod & Remote SensorRemote Sensor and Local SetpointModbus SPOutlet Sensor and Local SetpointModbus SP & Remote SensorRemote Sensor and Local SetpointAfter a Modus communication failure, the ‘Comm Failure’ alarm is not cleareduntil 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 ischanged to Peer-To-Peer and then back to Modbus.When a Peer-To-Peer network has failed the boilers begin operation as standalone boilers using the selected parameters.After a Peer-To-Peer communication failure the ‘Comm Failure’ alarm is notcleared until communication is restored and the boiler rejoins a network with atleast one other boiler, power is cycled or the protocol parameter is changed toModbus and then back to Peer-To-Peer.Low Boiler Inlet TemperatureIf the boiler inlet temperature is below the low boiler inlet temperature setpoint,the “Low Inlet Temp” Message is displayed and the boiler inlet temperaturehistory is stored. See following page for additional information on low boiler inlettemperature history storage and retrieval.Memory FailureNew software has been installed in the SBC or a power interruption has causeda memory failure. The Call For Heat will be prevented until the condition iscleared.51

X. Sage Boiler Control TM (SBC TM )A. INTRODUCTION: The intent of this section is to brieflysummarize the controllers capabilities, familiarize the userwith its basic features and to list factory supplied defaultsettings. Read the additionally supplied Factory InstructionManual for the SBC to learn more about the controllersfeatures and capabilities.1. Sage Boiler Control OverviewThe Sage Boiler Control (SBC) is a complete boilermonitoring and automation system. The SBC providesadvanced boiler modulation, operating control,diagnostics, multiple boiler lead-lag and auxiliarydevice control. The SBC provides advanced controlfeatures in an easy to use package.522. Flexible, Field Selectable Control.Control modules, water system, boiler auxiliary andmodulating lead/lag control features are menu selectablewithout the need for external programmers,laptops or downloads. Every boiler is shipped withfactory defaults that make field menu selections unnecessaryunless you are applying additional controlfeatures.3. Boiler Monitoring and Diagnostic DisplaysThe SBC’s two line by sixteen character LCDdisplay may be used for monitoring boiler inlet andoutlet, remote system and outside air temperatures,modulation rate setpoint and modulating percent andmixing valve demand percent. Additionally, the displayautomatically presents boiler sequence messages,alarms, hold and lockout messages. A diagnosticmenu is included that provides the last 10 alarmmessages and boiler inlet temperature alarm history.Boiler inlet temperature alarm history includes timeand date, the lowest inlet temperature reached andthe amount of time the water temperature droppedbelow the alarm setpoint.4. Modulation Rate and On/Off ModesThe SBC may simply control boiler modulationand on/off output based on the boiler water outlettemperature and an operator adjusted setpoint.However, using parameter selections, the SBCallows the boiler modulation and on/off output torespond to remove system water and outside airtemperatures, Domestic Hot Water Priority (DHWP)input or Energy Domestic Hot Water Priority (EMS)modulation rate demand, remote setpoint or remotestart/stop commands. Parameter selections of remotesystem water temperature and remote mode determiningthe choice of one of six different controlmodes.5. Advanced AvailabilityThe above control modes are menu selectable options.However, if a selected sensor rails, the SBCautomatically changes to a control mode that willallow continued automatic operation of the boiler.For example, in the event of a remote system temperaturesensor failure, the SBC will automaticallyswitch to boiler outlet temperature sensor basedcontrol.6. Outdoor Air ResetWhen selected the modulation rate setpint is automaticallyadjusted based on outside air temperature.Outdoor air “reset” setpoint saves fuel by adjustingthe water temperature of a heating boiler lower asthe outside air temperature increases.7. Warm Weather Shutdown (WWSD)Some boilers are used primarily for heating buildings,and the boilers can be automatically shutdownwhen the outdoor air temperature is warm.When outside air temperature is above the WWSDsetpoint, this function will prevent the boiler, boilerpump and/or the system pump from starting.8. Domestic Hot Water Priority (DHWP)Some boilers are used primarily for building spaceheating, but also provide heat for the domestic hotwater users. When the outdoor temperature is warm,the outdoor reset setpoint may drop lower than adesirable domestic hot water temperature. Whenenabled and a DHWP contact input is detected, thehot water setpoint is adjusted to be greater than afield adjustable DHWP Setpoint.9. Water Side Control OutputsIn order to maximize the life and availability of ahot water system it may be desirable to automatemixing valves, boiler pumps, system pumps, andstandby system pumps. The SBC makes this type ofautomation totally integrated and cost effective. Thecontrol of these devices is field selectable throughsimple yes/no menu selections.10. Combustion Air Side Control OutputsBoiler room combustion air dampers (fresh airdampers) and vent inducer control outputs are fieldselectable options.11. Peer-To-Peer NetworkThe SBC includes state-of-the-art modulating leadlagsequencer for up to eight (8) boilers capable ofauto rotation, outdoor reset and peer-to-peer communication.The peer-to-peer network is truly “plugand play”. Communication is activated by simplyconnecting a RJ11 telephone line between boilers.The SBC provides precise boiler coordination bysequencing boilers based on both remote systemwater temperature and boiler modulation rate. Forexample, the lead boiler can be configured to starta lag boiler after operating above 90% modulationrate for longer than an adjustable time. The boilersare modulated in “unison” (parallel) modulation rateto ensure even heat distribution.12. Modbus Communication Interface

A factory configured RS485 Modbus interface isavailable for Energy Management System (EMS) orSCADA system monitoring and control.B. FRONT PANEL DISPLAYPOWER LEDALARM LEDSCREENENTERUP, DOWNMENU(Steady On Green LED) indicates power is available downstream of the Electronic Control Module’s on board fuse.(Flashing On Green LED) indicates manual mode operation forboiler modulation, Call For Heat, and/or mixing valve modulation.(Steady On Red LED) indicates an alarm is active. (FlashingOn Red LED) indicates a lockout alarm is active and a manualreset may be required.2 line by 16 character display provides operational, alarm,sequence status, configuration and diagnostic user interfaceThe ENTER key has no function in display mode. The ENTERkey is used to select menus, menu items and save edited parameters as follows:Select Mode (steady text): Press ENTER to change into EditMode or select a menu or menu itemEdit Mode (blinking text): Press ENTER to save the currentvalue. Press MENU to cancel the current editing operation.Select Mode (steady text): Press UP, DOWN to change theselected display and move up and down menu items.Edit Mode (blinking text): Press UP, DOWN to increase or decrease the value of the number being edited, or scrolls througha list of choices.Press and hold MENU to change to the Main Menu screen.When in a sub menu screen, press MENU to move to the nexthigher menu. When in Edit Mode (blinking text) Press MENU tocancel the current editing operation.53

C. SETUP MENUDisplayWWSDLL StartTriggerLL StopTriggerBoiler OnDelayBoiler OffDelayHigh FireLimitRotationRotationAfterOutdoorSensorOutdoorSet UpBoiler SetUpOutdoorDesignBoilerDesignLocalPID PFactorySettingsOffRange/ChoicesOffWWSD of BoilerWWSD of SysPumpBoth90 50 to 10025 0 to 50120 0 to 90030 0 to 900100 40 to 100DisableDisableEnable168 8 to 720NoNoDisplay OnlyOutdoor Reset55°F 40°F to 100°F140°F 80°F to 180°F30°F -20°F to 50°F180°F 80°F to 220°F20 0 to 10000DescriptionWWSDSpecifies Warm Weather Shut-Down (WWSD) control of boiler and/or system pump:Ignores Warm Weather setpointWhen Outside Air Temperature (OAT) is higher than the WWSD setpoint, inhibits boiler startWhen OAT is higher than the WWSD setpoint de-energize System Pump output (SO)When OAT is higher than the WWSD setpoint, inhibit Call for Heat and de-energized system pumpoutput (SO)LL Start TriggerSpecifies the percent of maximum modulation rate the running boiler(s) must reach before callingupon additional boilers for help.LL Stop TriggerSpecifies the percent of modulation rate that the running boiler(s) must be below before shuttingdown a lag boiler.Boiler On DelayTime Delay after the On Point setpoint before starting the next boiler. Short time delay to preventnuisance starts due to momentary temperature and modulation rate swings.Boiler Off DelayTime Delay after the Off Point setpoint before stopping the next boiler. Short time delay to preventnuisance stops due to momentary temperature and modulation rate swings.High Fire LimitHigh modulation rate limit for all boilers on the peer-to-peer network as long as at least one boiler isstill not running. After the last boiler has started the modulation rate is released up to 100%.RotationSpecifies number of hours (cumulative) a lead boiler runs before passing the lead to another boiler.Lead rote will be surrendered earlier if the lead boiler is placed into manual mode, is running remotely(mode 6), fails to start, is “blind” (all input sensors failed), or is satisfying a DHWP request.Rotate AfterSpecifies number of hours (cumulative) a lead boiler runs before passing the lead to another boiler.Outdoor SensorEnables the Outside Air Temperature sensor and display and control logic:Outside Air Input (O+O-) is ignored.Do Not Calculate setpoint based on outdoor temperature, Display Outside Air TemperatureCalculate the temperature setpoint based on outdoor temperature using a reset curve defined byOutdoor Set Up, Boiler Set Up, Outdoor Design and boiler Design parameters.Outdoor Set UpThe Outdoor Set Up temperature is the outdoor temperature at which the Boiler Set Up temperatureis supplied. Only visible when Outdoor Sensor is set to Outdoor Reset.Boiler Set UpThe Boiler Set Up temperature is the starting boiler water temperature of the reset ratio. If the buildingfeels cool during mild outdoor conditions, the Boiler Set Up setting should be increased. Onlyvisible when Outdoor Sensor is set to Outdoor Reset.Outdoor DesignThe Outdoor Design temperature is the outdoor temperature at which the Boiler Design temperatureis supplied.Only visible when Outdoor Sensor is set to Outdoor ResetBoiler DesignThe Boiler Design setting is the water temperature required to satisfy the building heat loss duringthe Outdoor Design temperature. If the building feels cool during cold outside conditions, the BoilerDesign setting should be increased.Only visible when Outdoor Sensor is set to Outdoor Reset.Local PID PPromotional gain value for boiler outlet temperature sensor control Modes. A larger gain value resultsin tighter, more active, PID control. Gain is the primary PID modulation rate tuning adjustment andprovides the immediate modulation rate response.54

C. Setup Menu (Continued)DisplayLocalPID ILocalPID DRemotePID PRemotePID IRemotePID DMixingValve PMixingValve IMixingValve DFactorySettingsRange/Choices30 0 to 100000 0 to 1000020 0 to 1000030 0 to 100000 0 to 1000010 0 to 1000060 0 to 100000 0 to 10000Max ΔT P 10 0 to 10000Max ΔT I 60 0 to 10000Max ΔT D 0 0 to 10000DescriptionLocal PID IIntegral Gain value for boiler outlet temperature sensor control Modes. A smaller value makes theIntegral ramp in less time (i.e.., faster). Integral is a secondary PID modulation rate tuning adjustmentthat ramps the output over time (typically minutes).Local PID DThe Derivative Gain value for boiler outlet temperature sensor control Modes. A larger Derivativegain 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 PProportional Gain value for Remote System Temperature sensor control Modes. Refer to Local PID Pfor explanation.Remote PID IIntegral Gain term for Remote System Temperature sensor control Modes. Refer to Local PID I forexplanation.Remote PID DDerivative Gain term for Remote System Temperature sensor control Modes. Refer to Local PID D forexplanationMixing Valve PProportional Gain value for boiler Inlet Temperature sensor control mode. A larger gain value resultsin tighter, more active, PID control. Gain is the primary PID modulation rate tuning adjustment andprovides the immediate mixing valve modulation response.Only visible when mixing valve = yes.Mixing Valve IIntegral Gain value for boiler inlet Temperature sensor control mode. A smaller value makes the Integralramp in less time (i.e., faster). Integral is a secondary PID modulation rate tuning adjustment thatramps the output over time (typically minuets).Mixing Valve DThe Derivative Gain value for boiler Inlet Temperature sensor control mode. A larger Derivative gainvalue 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.Max ΔT PPromotional Gain value for boiler differential (boiler outlet minus inlet temperature sensor) temperaturecontrol mode. Refer to Local PID P for explanation.Only Visible when mixing valve = yes.Max ΔT IIntegral Gain value for boiler differential (boiler outlet minus inlet temperature sensor) temperaturecontrol mode. Refer to Local PID I for explanation.Only visible when mixing valve = yes.Max ΔT DDerivative gain term for boiler differential (boiler outlet minus inlet temperature sensor) temperaturecontrol mode. Refer to Local PID D for explanation. Only visible when mixing valve = yes.55

D. Boiler Configuration MenuDisplayDisplayUnitsBoilerPumpPumpPrepurgePostpurgeΔTInlet SensorMixingValveSet Time/DateSpareInputSpareOutputFactorySetting°FNoneRange/Choices°F°CNoneAlways OnPurgeLead On15 0 to 6005 0 to 20YesNo____OffOffNoYesNoYeshour : minuteMonth / day /yearOffSys Pump FBLow FireOffCADSystem PumpBUSoft AlarmDescriptionDisplay UnitsSelects how temperature parameter values are displayed.Boiler PumpNo Boiler Pump.Pump Runs Continuously.Pump Runs during pump pre/post purge operations and during call for heat and then turns off.Lead boiler’s pump runs continuously when the boiler is the lead boiler and revers to “Purge” operationwhen it is a lag boiler.Pump PrepurgeSets length of time the boiler pump will be run prior to closing the “Call for Heat” relay (CH).Only visible when Boiler Pump does not equal None.Postpurge ΔTDefines the temperature above BIT that BOT must be at or below before turning off the boiler pumpduring pump post purge (Pump Cooldown State).Only visible when Boiler Pump does not equal None.Inlet SensorEnables the inlet temperature display and control logic.Mixing ValveEnables the mixing valve control output and user display.Set Time/DateSets the time and date of the boiler’s real time clock. This item also displays the time and date.Spare InputSet the function of the Spare Input Terminal (SL):IgnoreInput (SI) should be wired to a flow switch inserted in the flow of the of the primary system pump. Input(SI) indicates the primary system pump is operating. If output (SO) is set to System Backup Pump,system pump output (SO) is energized and System Pump Feedback is de-energized the SystemBackup Pump output (SO) is energized.When the Fuel Valve Energized input (SC) is not energized and input (SI) is energized the modulationrate is set to the “Low Fire Spd” setpoint. When input (SI) is not energized the modulation rate is set to“Fan Purge Spd” setpoint. When the fuel valve energized input (CS) is energized input (SI) is ignored.Spare OutputSets the function of the Spare Output Terminal (SO):Never close output (SO).Closes SO relay with a call for heat, Opens SO relay 2 minutes after call for heat has been deactivated.Closes when System Pump output is activated but the System Pump Feedback indicates the PrimarySystem Pump is not operating.Close when any alarm is active.56

E. System Configuration MenuDisplayDHWPRemoteControlRemote1.0 volt =Remote9.0 volt =RemoteSensorSystemPumpLWC orCADAlarmMessageFactorySettingOffNoRange/ChoicesOffIsolatedDemandShared DemandNo140°F 60°F to 170°F220°F 150°F to 220°FNoNoNo16 TextCharactersNoDisplay OnlyControlNoYesNoYes“Low WaterLevel”DescriptionDHWPEnables Domestic Hot Water Priority (DHWP) control feature. When input (DP) is energized DHWPbecomes active as selected:No DHWP.Boiler that received the input (DP) drops off the Peer-To-Peer network and its temperature setpointis adjusted above the DHWP setpoint. The PID output is based on boiler outlet temperature and setpoint.If Remote SP or Remote System temperature sensor were selected, control is switched to theBoiler Outlet Sensor.If the lead boiler receives the input (DP) the temperature setpoint for all boilers on the peer-to-peernetwork is adjusted above the DHWP setpoint.Remote ControlSets the remote (Energy Management System) control mode as follows:Local setpoint and modulation rate is used. Modbus and remote input (C+,C-) are ignored.Remote 1.0 Volt =Sets the temperature corresponding to the input (C+,C-) 1 Volt. Voltage below 1V is consideredinvalid, (failed or miswired sensor.)Remote 9.0 Volt =Sets the temperature corresponding to the input (C+,C-) 9 volts. Voltage above 9V is consideredinvalid (failed or miswired sensor.)Remote SensorEnables the Remote System Temperature sensor display and control logic:Remote Sensor Input (R+,R-) is ignored.Remote Sensor Input (R+,R-) is used for display only.Control Remote Sensor Input (R+,R-) is compared with the temperature setpoint to establish a modulationrate.System PumpEnables the System Pump Output (SO)LWC or CADSpecifies a Low Water Cut-off Switch or Combustion Air Damper (Fresh Air Damper). Open switchis connected to input (LC). Enables Limit Hold and alarm messages. Limit hold display message isdescribed by parameter 28.Alarm MessageLimit Hold and alarm message displayed corresponding to sensor connected to input (LC).The “ENTER” key and “up” and “Down” arrow keys are used to change the text message.Only visible when parameter 27 equals Yes.57

F. Setpoints MenuDisplayOperationalSPFactorySettingRange/Choices180°F 60°F to 230°FOn Point -5°F 0°F to -99°FOff Point 15°F 0°F to 99°FHighTempStopDHWPSetpointWWSDSetpoint200°F 60°F to 230°F180°F 140°F to 230°F70°F 40°F to 90°FMax SP 230°F 140°F to 230°FMin SP 140°F 60°F to 230°FMin InH 2OTempMax H 2ODelta TMaxDelta THold130°F 110°F to 180°F40°F 20°F to 50°F50°F 20°F to 50°FDescriptionOperational SPSetpoint used in Local Setpoint Mode when not servicing a Domestic Hot Water Priority (DHWP)request.On PointThe boiler starts when the water temperature drops “On Point” degrees below the setpoint.Off PointThe boiler stops when the water temperature rises “Off Point” degrees above the setpoint.High Temp StopThe boiler stops when water temperature is above the High Temperature Stop setpoint. This setpointis active in every control mode.DHWP SetpointThe Domestic How 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, theboiler outlet is maintained at, or above, the DHW Setpoint.WWSD SetpointThe Warm Weather Shutdown (WWSD) Setpoint used to disable boiler and/or system pump operationwhen enabled by setting the “WWSD” parameter to “WWSD of Boiler”, “WWSD of Sys Pump” or“Both”Max SPThe Maximum Operational Setpoint for all possible Local and Remote Modes.Min SPThe Minimum Operational Setpoint is the lower limit for all Local and Remote modes.Min In H 2O Temp.Minimum Inlet Water Temperature Setpoint used as the Mixing Valve inlet temperature setpoint.Only visible when Mixing Valve equals Yes.Max H 2O Delta TMaximum Water Differential (Boiler Outlet minus Boiler Inlet) temperature setpoint used as the MixingValve differential temperature setpoint.Only visible when Mixing Valve equals yes.Max Delta T HoldMaximum Water differential (Boiler Outlet minus Boiler Inlet) Temperature used to hold modulationrate at low fire.58

G. Communication MenuDisplayProtocolModbusAddressBaudRateParityFactorySettingPeer-To-PeerRange/ChoicesPeer-To-PeerModbus1 1 - 24719.2Odd9.619.238.4OddEvenNoneTimeout 30 1 - 120ProtocolSelects between Peer-To-Peer (Multiple boiler lead/lag control network) and a Modbus slave communication.MessagesRcvdMessagesSentBoilerAddressOnlineStatus1 1 to 8XXXXXXXXDescriptionModbus AddressEach boiler must be given a unique address.Only visible when Protocol equals Modbus.Baud RateUnits are 1000 Bits Per Second (KBPS).Only visible when Protocol Equals Modbus.ParityOnly visible when Protocol equals Modbus.TimeoutOnly visible when Protocol equals Modbus.Messages RcvdDiagnostic tool used to confirm wiring and Modbus master configuration.Only visible when Protocol equals Modbus.Messages SentDiagnostic tool used to confirm wiring and Modbus master configuration.Only visible when Protocol equals Modbus.Boiler AddressEach Boiler must be given a unique address. The boiler address assignment determines the boilersequencing order. A value of 0 disables the network communications.Only visible when Protocol equals Peer-To-Peer.Online StatusEach space can be either the boiler address or a “-” depending on whether there is a boiler of thataddress online.Example: _ _ 6 _ _ _ 321 indicates that boilers 6, 3,2, and 1 are online.Only visible when Protocol equals Peer-To-PeerH. Manual Mode MenuDisplayFactorySetting101 AutoRange/ChoicesManAuto102 Varies 0 to 100103 Varies104 AutoOnOffManAuto105 Varies 0 to 100DescriptionBoiler Man/AutoMan: Remain in Manual ModeAuto: Return to Boiler Mode specified by parameter/boiler conditions.Activated only when in Supervisor Mode.Modulation RateSets the modulation rate to be sued for boiler when in Manual Mode.Activated only when in Supervisor Mode and Boiler Man/Auto = Man.Boiler On/OffSets the boiler start/stop status when in Manual Mode.No: Turn of 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/AMan: Remain in Manual ModeAuto: Return to Control Mode specified by parameter/boiler conditionsActivated only when in Supervisor Mode.Mixing ValveSets 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.59

I. Security MenuPasswordsThere are three Access Levels in the system: Basic, Supervisor, and Factory.• At the BASIC Access Level, the user can view many parameters, but is only allowed to edit asmall sub-set of the parameters that are visible.• At the SUPERVISOR Access Level, the user can view and edit most parameters that are visible.Not all parameters will be visible at the Supervisor Access Level.• At the FACTORY Access Level, all relevant internal parameters in the system will be visibleand programmable.The Basic Access Level is the access level at power-up if the system password parameter is notequal to zero. The Supervisor Access Level is the access level at power-up if the system passwordparameter is equal to zero. If the system password is non-zero, the Supervisor Access Levelmay be reached by entering the correct password in the Enter Password parameter.The Factory Access Level can be reached by entering the factory password in the Enter Passwordparameter and holding the Enter key for at least two seconds when accepting the value entered.The display will jump to the Access Level parameter menu when the system has entered the FactoryAccess Level. Note that the Access Level parameters value will indicate “Supervisor”.To exit either of the privileged access levels (Factory or Supervisor), change the value of the AccessLevel parameter from “Supervisor” to “Basic”. Also, if no key is pressed for ~ 1 hour, the accesslevel will automatically revert to Basic.No.FactorySetting Range/Choices Parameter and DescriptionBasicSupervisor0 to 999915 0 to 9999Access LevelBasic: Select Basic Level Access to parameters/variablesSupervisor: Select Password Level Access to parameters/variables.Enter PasswordAllows user to enter password to gain access to both SupervisorAccess and Factory Access Levels.Set PasswordHolds the user-defined password for the boiler. A password= ) means no password protection. Access Level will defaultto Supervisor Level at power-up.60

XI. Repair PartsAll Solaris ® Series Repair Parts may be obtained through your local Thermal Solutionsrepresentative. Should you require assistance in locating a Thermal Solutions representative inyour area, or have questions regarding the availability of Thermal Solutions products or repair parts,please contact Thermal Solutions Customer Service at (717) 239-7642 or Fax (877) 501-5212.627910758431Figure 31: Combustion ChamberKeyNo. DescriptionPart Number1. Combustion Chamber SOL-300 SOL-500 SOL-750 SOL-1000 SOL-1250 SOL-15001 Base/Bottom Panel 618SOL0204 618SOL0504 618SOL0704 618SOL1004 618SOL1204 618SOL15042 Left Side Panel Assembly 618SOL0021 618SOL002113 Right Side Panel Assembly 618SOL0031 618SOL003114 Air Box Cover 718SOL0203 718SOL0503 718SOL0703 718SOL1003 718SOL1203 718SOL15035 Air Box Assembly 618SOL02051 618SOL05051 618SOL07051 618SOL10051 618SOL12051 618SOL150516 Canopy Assembly 618SOL0210 618SOL0510 618SOL0710 618SOL1010 618SOL1210 618SOL15107 Side Insulation 820SOL0020 820SOL00218 Front Insulation 820SOL0203 820SOL0503 820SOL0703 820SOL1003 820SOL1203 820SOL15039 Bottom Insulation 820SOL0200 820SOL0500 820SOL0700 820SOL1000 820SOL1200 820SOL150010 Back Insulation 820SOL0202 820SOL0502 102504-01 102504-02 102504-03 102504-0461

3142Figure 32: Burner TrayKeyNo. Description1. Burner TrayPart Number1 3 Burner Assembly 102017-012 Ignitor Assembly 812SOL00103 Gasket, Burner Mounting Plate 820SOL00044 Gasket, Ignitor Assembly 820SOL000562

36754213Figure 33: Gas Train (SOL-300)(Reference Table 8)63

63159847311SIDE VIEW OFGAS VALVE102 264Figure 34: Gas Trains (SOL-500 through SOL-1500)(Reference Table 8)

Gas Trains: Reference Figures 33 & 34Key Description (Quantity) Part NumberSOL-300 SOL-500 SOL-750 SOL-1000 SOL-1250 SOL-15001 Main Gas Valve Body (1)816SOL0006 (1)816SOL0510 (1) 816SOL0005Main Gas Valve Flange(s) 3/4” NPT (1) 102281-01 — — — — —23Main Gas Valve Flange(s) 1” NPT — (2) 816SOL0503 (2) 102281-02 — —Main Gas Valve Flange(s) 1-1/4” NPT — — — — (2) 102281-03 —Main Gas Valve Flange(s) 1-1/2” NPT — — — — — (2) 102281-04Manual Gas Valve 1” NPT (2) 816SOL0015 — —Manual Gas Valve 1-1/4” NPT — — — — (2) 816SOL0016 —Manual Gas Valve 1-1/2” NPT — — — — — (2) 816SOL00174 Pilot Gas Valve (1) 816SOL05015 Pilot Gas Valve Flange 1/2” NPT (1) 816SOL05026 Manual Gas Valve 1/2” NPT (1) 816SOL00107 Insulation Grommet (1) 820SOL00018 High Gas Pressure Switch (Optional) — (1) 816SOL00059 Low Gas Pressure Switch (Optional) — (1) 816SOL000610 G18 Test Nipple — (2) 816SOL000111 Hose Barb — (2) 816SOL0002Table 8: Gas Train Components65

12Manifold Orifice AssemblyKeyNo.66DescriptionBoiler ModelSOL-300 SOL-500 SOL-750 SOL-1000 SOL-1250 SOL-15001 Manifold Orifice Assembly 812SOL0200 812SOL0500 812SOL0700 812SOL1000 812SOL1200 812SOL15002a Natural Gas Prejet2b Liquid Propane (LP) Gas Prejet812SOL0034812SOL0001Figure 35: Manifold Orifice Assembly

6513234Heat Exchanger Assembly (SOL-300 & 500)Part NumberKey No. Description Quantity SOL-300 SOL-5001 Heat Exchanger 1 603SOL0210 603SOL05102 Immersion Well 2 801604563 Inlet/Outlet Temp. Sensor 2 801SOL00104A Temp/Pressure Gauge 0-100PSI 1 80562484B Temp/Pressure Gauge 0-200PSI 1 80562494C Temp/Pressure Gauge 0-240PSI 1 80562505 Water Flow Switch 1 801601756 Tube Baffles 10 718SOL0219 718SOL0519Figure 36: Heat Exchanger Assembly (SOL-300 & 500)67

Part NumberKey No. Description SOL-750 SOL-1000 SOL-1250 SOL-15001 Heat Exchanger 102499-01 102499-02 102499-03 102499-042 Tube Baffle 718SOL0719 718SOL1019 718SOL1219 718SOL15193 Inlet/Outlet Temp Sensor 801SOL00104 Hose Banding 9246602815 Hose Clamp 808604916 Fiberglass Tape Gasket 9206032Figure 37: Heat Exchanger Assembly (SOL-750 through 1500)68

6 59738412Key No. Description Quantity Part Number1. Electrical Panel1 Q7800H1009 Electrical Side Panel 1 704SOL00062Q7800H1009 Honeywell Relay Module Circuitboard 1 101182-013 Relay Module Honeywell RM7897A1002 1 8016021214 Flame Rectification Amplifier 1 801602075 Purge Card 1 81363626 Keyboard Display Module 1 801606407 Transformer, 120V Primary, 24V Secondary 1 8016005028 Combustion Airflow Switch 1 102382-03Figure 38: Electrical Panel69

611795341282101KeyNo. DescriptionPart NumberSOL-300 SOL-500 SOL-750 SOL-1000 SOL-1250 SOL-15001 Base Panel Assembly 604SOL0211 604SOL0511 604SOL0711 604SOL1011 604SOL1211 604SOL15112 Jacket, Rear Panel Assembly 604SOL0203 604SOL0503 604SOL0703 604SOL1003 604SOL1203 604SOL15033 Exhaust CV Assembly 618SOL0000 618SOL0001 618SOL0701 618SOL1001 618SOL1201 618SOL15014 Jacket, Right Side Panel Assembly 604SOL0204 604SOL0504 604SOL0704 604SOL1004 604SOL1204 604SOL15045 Jacket, Left Side Panel Assembly 604SOL0205 604SOL0505 604SOL0705 604SOL1005 608SOL1205 604SOL15056 Jacket, Top Panel Assembly 604SOL0206 604SOL0506 604SOL0706 604SOL1006 604SOL1206 604SOL15067A Jacket. Front Panel (Left Side SOL-1250 & 1500) 704SOL0202 704SOL0502 604SOL0702 604SOL1002 704SOL0090 704SOL00917B Jacket, Front Panel (Right Side SOL-1250 & 1500) — — — — 704SOL0092 704SOL00938 Insulation Box 820SOL0032 820SOL0032 820SOL0033 820SOL0033 820SOL0033 820SOL00339 Intake Corner Vent Assembly 604SOL0208 604SOL0508 604SOL0708 604SOL0708 604SOL1208 604SOL120810 Exhaust Corner Vent 704SOL0207 704SOL0507 704SOL0707 704SOL0707 704SOL1207 704SOL120711 Air Inlet Filter 811SOL0020 811SOL0020 811SOL0022 811SOL0022 811SOL0022 811SOL0022Figure 39: Boiler Jacket Assembly70

SERVICE RECORDDateService Performed71

SERVICE RECORDDateService Performed72

SERVICE RECORDDateService Performed73

Important Product Safety InformationRefractory Ceramic Fiber ProductWarning:This product contains refractory ceramic fibers (RCF). RCF has been classified as a possiblehuman carcinogen. After this product is fired, RCF may, when exposed to extremelyhigh temperature (>1800F), change into a known human carcinogen. When disturbedas a result of servicing or repair, RCF becomes airborne and, if inhaled, may be hazardousto your health.AVOID Breathing Fiber Particulates and DustPrecautionary Measures:Do not remove or replace previously fired RCF (combustion chamber insulation, targetwalls, canopy gasket, flue cover gasket, etc.) or attempt any service or repair workinvolving RCF without wearing the following protective gear:1. A National Institute for Occupational Safety and Health (NIOSH) approvedrespirator2. Long sleeved, loose fitting clothing3. Gloves4. Eye Protection• Take steps to assure adequate ventilation.• Wash all exposed body areas gently with soap and water after contact.• Wash work clothes separately from other laundry and rinse washing machineafter use to avoid contaminating other clothes.• Discard used RCF components by sealing in an air tight plastic bag.First Aid Procedures:• If contact with eyes: Flush with water for at least 15 minutes. Seek immediatemedical attention if irritation persists.• If contact with skin: Wash affected area gently with soap and water. Seekimmediate medical attention if irritation persists.• If breathing difficulty develops: Leave the area and move to a location withclean fresh air. Seek immediate medical attention if breathing difficultiespersist.74

LIMITED WARRANTYThermal Solutions(seller)LIMITED WARRANTYSubject to the terms and conditions herein and except as providedbelow with respect to products or parts not manufacturedby Thermal Solutions, Seller warrants to the original ownerat the original installation site that products manufactured bySeller (“Products”) comply, at the time of manufacture, theheat exchanger with recognized hydronics industry regulatoryagency standards and requirements then in effect and will befree from defects in materials and workmanship for a period of3 years from date of shipment (the “Warranty Period”). Theburner is also covered under the limited warranty for 1 yearfrom date of shipment (the “Warranty” Period). SPECIALNOTE: The warranty of any boiler found to be operating as a“Water Heater” shall revert back to Thermal Solution’s standardwater heater warranty.For products or parts not manufactured by Thermal Solutions,the warranty obligations of Thermal Solutions shall, in allrespects, be limited to one year.REMEDYA. The sole remedy for breach of this warranty is expresslylimited to the repair or replacement of any part found to bedefective under conditions of normal use within the WarrantyPeriod. Labor for removal and/or installation is notincluded.B. Warranty - The owner must notify the original installer ofthe Product and Seller (Attention: Thermal Solutions, P.O.Box 3244, Lancaster, PA 17604-3244), in writing, withinthe Warranty Period, providing a detailed description of allclaimed defects. Transportation to a factory or other designatedfacility for repairs of any products or items allegeddefective shall, in all events, be the responsibility and atthe cost of the owner.EXCLUSIONSSeller shall have no liability for and this warranty does notcover:A. Incidental, special or consequential damages, such as lossof the use of products, facilities or production, inconvenience,loss of time or labor expense involved in repairingor replacing the alleged defective Product.B. The performance of any Product under conditions varyingmaterially from those under which such Product is usuallytested under industry standards as of the time of shipment.C. Any damage to the Product due to abrasion, erosion, corrosion,deterioration, abnormal temperatures or the influenceof foreign matter or energy.D. The design or operation of owner’s plant or equipmentor of any facility or system of which any Product may bemade a part.E. The suitability of any Product for any particular application.F. Any failure resulting from misuse, modification notauthorized by Seller in writing, improper installation orlack of or improper maintenance.G. Equipment furnished by the owner, either mounted orunmounted, or when contracted for by the owner to beinstalled or handled.H. Leakage or other malfunction caused by:1. Defective installations in general and specifically, anyinstallation which is made:a. in violation of applicable state or local plumbinghousing or building codes,b. without a certified ASME, pressure relief valve, orc. contrary to the written instructions furnished withthe unit2. Adverse local conditions in general and, specifically,sediment or lime precipitation in the tubes and/or headersor corrosive elements in the atmosphere.3. Misuse in general and, specifically, operation andmaintenance contrary to the written instructionsfurnished with the unit, disconnection, alteration oraddition of components or apparatus, not approved byseller, operation with fuels or settings other than thoseset forth on the rating plate or accidental or exteriordamage.I. Production of noise, odors, discoloration or rusty water.J. Damage to surrounding area or property caused by leakageor malfunction.K. Costs associated with the replacement and/or repair of theunit including: any freight, shipping or delivery charges,any removal, installation or reinstallation charges, any materialand/or permits required for installation reinstallationor repair, charges to return the boiler and or components.Seller’s liability under this warranty shall not in any case exceedthe amount paid for the Product found to be defective.THIRD-PARTY WARRANTIESFor goods or components not manufactured by Seller, the warrantyobligations of Seller shall, in all respects, conform and belimited to one year from the date of shipmentSEVERABILITYTo the extent that any provision of this warranty would be voidor prohibited under applicable law, such provisions shall belimited in effect to the minimum extent necessary to render theremaining provisions hereof enforceable.75