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Operation Manual

1. Ref Name of Part Part EW 45 EW 65 EW 100 EW 125 EW 145 EW 165 Jacket Complete BM 9630 1 Jacket Complete BM 9631 1 1 Jacket Complete BM 9632 1 Jacket Complete BM 9633 1 1 1 Lower Front Inner Panel 03 1519 1 1 1 1 1 1 2 Front Door Panel 03 1515 1 Front Door Panel 03 1516 1 1 1 Front Door Panel 03 1517 1 1 3 Jacket Side Panel LH 03 1503 1 Jacket Side Panel LH 03 1504 1 1 1 Jacket Side Panel LH 03 1505 1 1 4 Jacket Top Panel 03 1512 1 1 1 Jacket Top Panel 03 1513 1 Jacket Top Panel 03 1514 1 1 5 Jacket Rear Panel 03 1509 1 Jacket Rear Panel 03 1510 1 1 1 Jacket Rear Panel 03 1511 1 1 6 Jacket Side Panel 03 1500 1 Jacket Side Panel 03 1501 1 1 1 Jacket Side Panel 03 1502 1 1 7 Vent Damper 5 02 5869 1 1 1 Vent Damper 6 Effikal 02 5870 1 1 Vent Damper 7 Effikal 02 5871 1 8 Draft Hood 03 8140 1 1 1 03 8141 1 03 8142 1 03 8145 1 9 Spill Switch Manual Reset 275 F 58 2524 1 1 1 Spill Switch Manual Reset 250 F 58 2522 1 1 1 10 Dome Bracket 55 1404 2 2 2 2 2 2 11 Dome 5 01 2100 1 1 1 Dome 6 01 2102 1 Dome 7 01 2103 1 1 12 Pressure Relief Valve 22 1203 1 1 1 1 1 1 13 Vent Fitting 56 5430 1 1 1 1 1 1 14 Nipple 3 4 x 9 53 1133 1 1 1 1 1 1 15 T Baffles BM 9629 1 1 1 1 1 1 16 Pipe Plug 1 2 56 4601 2 2 2 2 2 2 17 Section Top BM
2. OPERATING SEQUENCE FOR BOILERS EQUIPPED WITH VENT DAMPER STANDING PILOT AND L48148E MOTOR DRIVES VENT DAMPER TO CLOSED POSITION AND REMAINS CLOSED DURING STANDBY STANDING PILOT REMAINS LIT SENSING CIRCUIT 15 CONTINUOUSLY MONITORED THERMOSTAT OR OPERATING CONTROL CALLS FOR HEAT DAMPER BLADE OPENS DAMPER END SWITCH CLOSES PROVING VENT DAMPER OPEN MAIN VALVE IS ENERGIZED UNIT OPERATES UNTIL THERMOSTAT OR OPERATING CONTROL IS SATISFIED SYSTEM RETURNS TO STANDBY WITH DAMPER CLOSED FACTORY WIRED FIELD WIRED 0 RULES mcer T L8148E TT NIS erro A a THERMOSTAT OR OPER 7 CIRC CONTROL b l en B1 B2 L1 L2 T2 BLUE 7 12 115V60HZ SPILL 7 GND M4 BLUE 16 BLK rom ROLLOUT GAS VALVE vent 2 WHT SWITCH DAMPER RED 4 gt STH 7 BLUE E TR IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE BOILER MUST BE REPLACED USE A SIMILIAR WIRE OF 105 C RATING T2 115 86 GND 1 m CIRC MOTOR 12 224 5 o o ao 115 24V CYYYYA 1 tA m BE Le 6 1K2 HI LIMIT SPILL SWITCH B2 vent 20 DAMPER 557 TH TR 1 N GAS VALVE SWITCH TS VIT N THERMOSTAT z w OR OPER TTL lt CONTROL SPILL AND ROLLOUT SWITCHES USED
3. ais VAG 12 115V60HZ 2 otov GND L1 T CIRC MOTOR 2 Le olo aka L J 115 24V B R i 2 AE V MANUAL RESET SPILL SWITCH D 0 vent V las qu DAMPER 3e TR MV PV MV PV M o 45 TH TR GND ROLLOUT GAS VALVE ME T SWITCH 6 24 GND do 24 IGNITOR SENSOR Te SPARK 2t WU w u 2 THERMOSTAT 1K tle OR OPER i 2 CONTROL SPILL AND ROLLOUT SWITCHES USED WHEN INPUT 55 55 75 42 5767 IS LESS THAN 300 000 BTUH OPERATING SEQUENCE FOR BOILERS EQUIPPED WITH VENT DAMPER AND HONEYWELL ELECTRONIC IGNITION CONTROL MOTOR DRIVES VENT DAMPER TO CLOSED POSITION AND REMAINS CLOSED DURING STANDBY SENSING CIRCUIT 15 CONTINUOUSLY MONITORED THERMOSTAT OR OPERATING CONTROL CALLS FOR DAMPER BLADE OPENS DAMPER END SWITCH CLOSES PROVING DAMPER OPEN IF NO FAILURE EXISTS THE PILOT VALVE AND IGNITOR ARE ENERGIZED PILOT IS IGNITED AND SENSOR SENSES FLAME MAIN VALVE IS ENERGIZED AND IGNITOR DE ENERGIZED UNIT OPERATES UNTIL THERMOSTAT OR OPERATING CONTROL IS SATISFIED SYSTEM RETURNS TO STANDBY WITH DAMPER CLOSED FACTORY WIRED THERMOSTAT FIELDWIRED OR OPER CONTROL BLUE BLUE Ti 2 E HILIMIT SPILL Cups as 29 SWITCH 115 24V TRA
4. 24 1106 1 24 1107 1 1 1 35 Pilot with Fittings BM 3395 1 1 1 1 1 1 36 Gas Valve VR8204H 1006 1 2 Nat 02 1543 1 1 1 1 1 1 Gas Valve VR8204H 1022 1 2 LP 02 1546 1 1 1 1 1 1 Gas Valve VR8200H 1129 1 2 Nat 02 1540 1 1 1 1 1 1 Gas Valve VR8200H 1103 1 2 LP 02 1541 1 1 1 1 1 1 37 Burner Nat LP 03 7114 1 1 2 3 3 3 37 Burner w Pilot Bracket 03 7118 1 1 1 1 1 1 38 RH Manifold Bracket 03 7154 1 1 1 1 1 1 39 Door Insulated BM 3324 1 1 1 1 1 40 LH Manifold Bracket 03 7153 1 1 1 1 1 1 41 LH Insulated Side Plate BM 3340 1 1 1 1 1 1 42 Drain Valve 51 1201 1 1 1 1 1 1 43 1 1 4 x 3 4 x 1 1 4 Tee 56 1603 1 1 1 1 1 1 44 1 1 4 x 3 Nipple 53 1250 1 1 1 1 1 1 45 Taco Circulator Flange 09 1921 1 1 1 1 1 1 46 Oval Gasket 59 1001 1 1 1 1 1 1 47 Rollout Switch Manual Reset 350 F 58 2527 1 1 1 1 1 1 48 Junction Box 58 1800 1 1 1 1 1 1 49 Transformer 20 VA Basler 26 3005 1 1 1 1 1 1 50 Temperature Pressure Indicator 20 1014 1 1 1 1 1 1 51 L4080B 1212 Aquastat w o well 02 2702 1 1 1 1 1 1 L8148E Aquastat Relay 02 2406 1 1 1 1 1 1 52 Heat Shield INT only 03 3140 1 1 1 1 1 1 53 Ignition Control S8600F INT only BM 8142 1 1 1 1 1 1 54 Inner Front Panel 03 1506 1 Inner Front Panel 03 1507 1 1 1 Inner Front Panel 03 1508 1 1 55 Well 1 2 02 3415 1 1 d Well 1 2 02 3413 1 1 1 56 Push Nipple 53 1310 2 3 3 3 4 4 57 1 1 4 x 14 Nipple 53 1264 1 1 1 1 1 1 1 1 4 x 16 Nipple 53 1256 1 1 1 1 1 1 1 1 4 x 21 1 2 Nipple
5. 10 Step 5 Wiring 12 START UP amp OPERATION Safety 15 Start Up 4 Adjustments 15 Water Treatment 18 Freeze 18 Before Each Heating 5 18 How To Change Orifices 19 Troubleshooting 19 Appendix French Vent Damper 20 DESIGN IN UNITED STATES 260 NORTH ELM ST WESTFIELD 01085 413 564 5515 FAX 413 568 9613 IN CANADA 5211 CREEKBANK RD MISSISSAUGA ONT L4W 1R3 905 625 2991 FAX 905 625 6610 AVERTISSMENT Assurez vous de bien suivre les instructions donn es dans cette notice pour r duire au minimum le risque d incendie ou d explosion ou pour viter tout dommoge mat riel toute blessure ou la mort Ne pas entreposer ni utiliser d essence ou ni d autres vapeurs ou liquides inflammables proxim it de cet appareil ou de tout autre appareil QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ Ne pas tenter d allumer d appareil Ne touchez aucun interrupteur ne pas vous servir des t l phones se trouvant dans le b timent Appelez imm diatement votre fournisseur de gas depuis un voisin Suivez les intruc tions du fournisseur Si vous ne purvez rejoindre le fournis
6. MOTOR DRIVES VENT DAMPER TO CLOSED POSITION AND REMAINS CLOSED DURING STANDBY STANDING PILOT REMAINS LIT SENSING CIRCUIT IS CONTINUOUSLY MONITORED THERMOSTAT OR OPERATING CONTROL CALLS FOR HEAT DAMPER BLADE OPENS DAMPER END SWITCH CLOSES PROVING VENT DAMPER OPEN IF NO FAILURE EXISTS THE MAIN VALVE IS ENERGIZED UNIT OPERATES UNTIL THERMOSTAT OR OPERATING CONTROL IS SATISFIED SYSTEM RETURNS TO STANDBY WITH DAMPER CLOSED FACTORY WIRED FIELD WIRED THERMOSTAT OR OPER CONTROL HI LIMIT BLUE BLUE I SPILL SWITCH 115 24V TRANSF WHT BK BLK GND sr NA DAMPER RED 30 1 BLUE A 3 ROLLOUT SWITCH 24V GAS VALVE IF OF THE ORIGINAL WIRE AS SUPPLIED WITH THE BOILER MUST BE REPLACED USE A SIMILIAR WIRE OF 105 C RATING T2 Li GND 115V AC UJAJ 115 24V THERMOSTAT OR OPER SPILL CONTROL SWITCH HI LIMIT qe J TH DAMPER 3 gt ka ROLLOUT SWITCH GAS VALVE SPILL AND ROLLOUT SWITCHES USED WHEN INPUT IS LESS THAN 300 000 BTUH 42 5768 FIGURE 1 18 WIRING DIAGRAM amp OPERATION SEQUENCE FOR BOILERS WITH STANDING PILOT amp VENT DAMPER 12
7. 7 Follow System Start Up amp Adjustments procedures in the Start up amp Operation section of this manual HOW CHANGE ORIFICES NAT GAS L P GAS 1 Shut off power supply and gas supply to the boiler MODEL DRILL SIZE DRILL SIZE 2 Remove burner access panel To remove burners lift EW 65 26000 2 up amp to rear until burners are disengaged from orifices ENS 32 49 EW 100 37 1 65MM 3 Check orifices for proper drill size Size is stamped EW 125 39 1 60MM onto the body of the brass orifice The size can also be EW 145 35 51 checked by using a pin gauge see Figure 3 1 All ori EW 165 32 1 85MM fices are screwed into the manifold and may be removed FIGURE 3 1 by using a 5 8 wrench or socket 4 Reverse above procedures to install orifices amp burn ers BE SURE TO INSTALL BURNERS WITH BURNER PORTS ON TOP SURFACE UPRIGHT EQUIVALENT ORIFICE SIZES AT HIGH ALTITUDES INCLUDES 4 INPUT REDUCTION FOR EACH 1 000 FEET Orifice Size Model Fuel Type Orifice Qty Sea Level 2000 ft 3000 ft 4000 ft 5000 ft 6000 ft 7000 ft 8000 ft 9000 ft 10000 ft EW 65 NG 2 2 60mm 39 40 41 41 42 42 43 43 44 EW 65 LP 2 52 52 53 53 53 53 53 54 54 54 EW 85 NG 2 32 33 34 35 35 36 36 37 38 40 EW 85 LP 2 49 50 50 50 51 51 51 52 52 52 EW 100 NG 3 37 38 39 39 40 41 42 42 43 43 EW 100 LP 3 1 65mm 52 53
8. HydroTherm EW2 1203 42 9510 MODEL EW SERIES INSTALLATION OPERATION amp MAINTENANCE MANUAL Gas Fired Water Cast Iron Boilers 65 000 to 165 000 Btuh Input WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier WARNING Installation and service must be performed by a qualified installer service agency or the gas supplier in accordance with all local national codes Failure to comply with this warning can result in a fire or explosion causing property damage personal injury or loss of life BOILER INSTALLATION Introduction 2 Step 1 Locating amp Setting Boiler 4 Step 2 Installing Purging Water Piping 5 Step 3 Venting 8 Step 4 Installing Testing Gas Piping
9. 53 1265 1 1 1 1 1 1 58 Gasket Circulator Fitting 59 1019 1 1 1 1 1 1 59 Taco Pump 007 09 1507 1 1 1 1 1 1 Stainless Steel Jacket Polish 4 oz 70 3398 23 260 NORTH ELM STREET 5211 CREEKBANK ROAD WESTFIELD MA 01085 HydroTherm MISSISSAUGA ONT CANADA LAW 1R3 413 564 5515 FAX 413 568 9613 905 625 2991 FAX 905 625 6610
10. 53 53 53 53 54 54 54 EW 125 NG 4 39 40 41 41 42 42 43 43 44 44 EW 125 LP 4 1 60mm 1 60mm 53 53 53 53 53 54 54 54 EW 145 NG 4 35 36 36 37 37 38 39 40 41 42 EW 145 LP 4 51 51 52 52 52 52 53 53 53 54 EW 165 NG 4 32 33 34 35 35 36 36 37 38 40 EW 165 LP 4 1 85mm 50 50 50 51 51 51 52 52 52 TROUBLESHOOTING NO HEAT OVERHEATING 2 Air shutter misadjustment 1 Blown fuse or circuit breaker 1 Wrong thermostat anticipator setting 3 Wrong orifices 2 Power switch turned off 2 Bad thermostat location 4 Burning in burner mixing tube 3 Vent damper not open 3 Bad thermostat 5 Inadequate combustion air 4 Circulator not running 6 Inadequate draft flue blockage 5 Air in lines and radiation ODOR EXCESSIVE MOISTURE IN 6 Tripped rollout switch BUILDING NOISE 7 Tripped spill switch 1 Leak in piping 1 Ignition incorrect air shutter adjust INSUFFICIENT HEAT 1 Incorrect t stat anticipator setting 2 Hi limit control setting too low 3 Boiler undersized or underfired 4 Insufficient radiation 5 Air traps in lines or radiation 2 Carbon build up in flueways 3 Blocked chimney 4 Downdrafts incorrect termination YELLOW FLAME CARBON BUILD UP 1 Unit overfired ment 2 Whistle due to burr on orifices 3 Burner fluteing air shutter open ing too wide CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper oper
11. 9685 1 1 1 1 1 1 18 Section Middle BM 9684 1 2 2 2 3 3 19 Section Bottom BM 9681 1 1 1 Section Bottom BM 9680 1 1 1 20 Absorption Unit BM 3116 1 Absorption Unit BM 3117 1 1 Absorption Unit BM 3118 1 Absorption Unit BM 3119 1 1 21 Tie Rod 44 1109 2 Tie Rod 44 1110 2 2 2 Tie Rod 44 1111 2 2 22 Tie Rod Nuts 57 2602 6 6 6 6 6 6 23 Tie Bracket 55 2603 2 2 2 2 2 2 24 Rear Tie Plate Insulated BM 3327 1 1 1 1 1 1 25 Front Tie Plate Insulated BM 3328 1 1 1 1 1 1 26 RH Insulated Side Plate BM 3341 1 1 1 1 1 1 27 Bracket Burner 03 7132 1 1 1 1 1 Bracket Burner 03 7133 1 28 Base Pan 03 4315 1 1 1 1 1 1 29 Front Tie Bar 03 7873 1 1 1 1 1 1 30 Burner w Pilot Brkt Nat LP 03 7118 1 1 1 1 1 1 31 Pilot Assy INT Q3451B 1103 62 3668 1 1 1 1 1 1 31 Pilot Assy CON Q314A Nat LP K16R BM 8072 1 1 1 1 1 1 22 Boiler Model Ref Name of Part Part EW 45 EW 65 EW 100 EW 125 EW 145 EW 165 32 Pilot Orifice NG 62 3326 1 1 1 1 1 1 Pilot Orifice LP 62 3327 1 1 1 1 1 1 33 Burner Orifice 2 60 mm 25 1141 2 Orifice 32 Natural 25 1132 2 4 Orifice 37 Natural 25 1121 3 Orifice 39 Natural 25 1125 4 Orifice 35 Natural 25 1126 4 Orifice 52 LP 25 1129 2 Orifice 47 LP 25 1127 2 Orifice 1 65 MM LP 25 1139 3 Orifice 1 60 MM LP 25 1142 4 Orifice 51 LP 25 1124 4 Orifice 1 85 MM LP 25 1140 4 34 Manifold 24 1105 1 1
12. TRANSF ZV1 ZONE VALVE R1 AQUASTAT RELAY L8148E GV TH1 ZONE T STAT ZV2 ZONE VALVE GV GASVALVE 0008 TH2 ZONE T STAT ZV3 ZONE VALVE TH3 ZONE T STAT FIGURE 1 20 WIRING DIAGRAM FOR ZONING WITH ZONE VALVES FACTORY WIRING T1 GAS VALVE FIELD WIRING zi TO 115V ADDITIONAL 1R 2 ZONES H1 BOILER CIRCUIT BLACK C2 WHITE EXTERNAL CIRCUIT C1 ZONE CIRCULATOR ZR1 ZONE RELAY RA832A H1 HI LIMIT AQUASTAT 1R 1 1R 2 ZR1 CONTACTS C2 ZONE CIRCULATOR OR EQUIVALENT GV GAS VALVE 2R 1 2R 2 ZR2 CONTACTS TH1 ZONE T STAT ZR2 ZONE RELAY RA832A T1 24V TRANSFORMER TH2 ZONE T STAT OR EQUIVALENT T2 T3 TRANSF IN RELAYS FIGURE 1 21 WIRING DIAGRAM FOR ZONING WITH CIRCULATORS 14 START UP amp OPERATION SAFETY CONTROLS The spill switch see Figure 2 1 detects the escape of combustion products through the draft hood relief open ing and interrupts the power to the gas valve preventing unsafe boil er operation Escape of flue products could be caused by a blocked or collapsed chimney or by inade quate chimney draft This is a manual re set type device and can be reactivated by depressing the spill switch reset button FIGURE 2 1 SPILL SWITCH ROLLOUT SWITCH The flame rollout switch see Figure 2 1 prevents flame rollout from the boiler com bustion chamb
13. WHEN INPUT IS LESS THAN 300 000 BTUH 42 5769 FIGURE 1 19 WIRING DIAGRAM amp OPERATION SEQUENCE FOR BOILERS WITH STANDING PILOT VENT DAMPER amp L8148E AQUASTAT RELAY OPERATING SEQUENCE FOR BOILERS EQUIPPED WITH VENT DAMPER ELECTRONIC PILOT CONTROL AND L48148E MOTOR DRIVES VENT DAMPER CLOSED POSITION AND REMAINS CLOSED DURING STANDBY SENSING CIRCUIT 15 CONTINUOUSLY MONITORED THERMOSTAT CALLS FOR DAMPER BLADE OPENS DAMPER END SWITCH CLOSES PROVING DAMPER OPEN IF FAILURE EXISTS THE PILOT VALVE AND IGNITOR ARE ENERGIZED PILOT IS IGNITED AND SENSOR SENSES FLAME MAIN VALVE IS ENERGIZED AND IGNITOR DE ENERGIZED UNIT OPERATES UNTIL THERMOSTAT IS SATISFIED SYSTEM RETURNS TO STANDBY WITH DAMPER CLOSED FACTORY WIRED FIELD WIRED 7 THERMOSTAT OR OPER AQUA RELAY 125 CONTROL 18148 SPILL _ 5 SWITCH GAS VALVE 1 Ke _ 58600 TH TR PV MV TR SURE 9 MV PV PV 1 ol v 2 BLUE BLK DAMPER 3 RED 24 GND js 4 2 24V ROLLOUT IGNITOR 5 SWITCH SENSOR IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE BOILER MUST BE REPLACED USE A SIMILIAR WIRE OF 105 C RATING T2
14. and cast iron dome Using a flash light examine all flue passageways a If passageways are free of soot and obstructions replace dome and seal with furnace cement or high tem perature silicone adhesive sealant b If passageways need cleaning remove burners as described in paragraph 3 below Insert long handle bris tle flue brush down between section tubes and upward through sections from combustion chamber in both diag onal directions to remove carbon from finned surfaces Vacuum debris Replace dome and seal with furnace cement or high temperature silicone adhesive sealant c Reinstall jacket top panel and draft hood 3 Check and clean burner assembly Remove burner access panel To remove burners lift up and to rear until burners are disengaged from orifices Brush top of burn ers with soft bristle brush blow out with air or vacuum 4 Check gas manifold for proper position and reassem ble burners to the manifold Line up holes in burners with the orifices and slide assembly back into position BE SURE TO REINSTALL BURNER WITH PORTS ON THE TOP SURFACE UPRIGHT 5 When a low water cut off has been utilized follow the manufacturer s maintenance instructions As a mini mum test electronic control operation at least once a year Float type controls should be flushed twice a year 6 Lubricate circulator motor according to manufacturer s instructions This information may be contained in label ing on the pump frame
15. central burner tubes behind the base door 8 knob on gas control counterclockwise to Pilot posi tion 9 Push down and hold the red button next to the control knob Immediately light the pilot with a match Continue to hold the red button down for about one 1 minute after the moo pilot is lit Then turn knob to ON position If it goes out repeat steps 4 through 9 If button does not pop up when released stop immedi ately and call your service technician or gas supplier If the pilot will not stay lit after several tries turn the gas control OFF and call your service technician or gas supplier 10 Replace the base door 11 Turn gas control knob counterclockwise to ON 12 Turn on all electric power to the appliance 13 Set thermostat to desired setting GAS CONTROL KNOB SHOWN IN OFF POSITION RESET BUTTON OPERATING INSTRUCTIONS Intermittent Pilot Honeywell VR8204 Natural or Propane Gas STOP Read the safety information above Set the thermostat to lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Turn gas control knob clockwise to OFF Do not force Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you then smell gas STOP Follow A in the safety information above If you don t smell gas go
16. to next step 7 gas control knob counterclockwise to ON 8 Turn on all electric power to the appliance Suo Mr 9 Set thermostat to desired setting 10 If the appliance will not operate follow the instructions Turn Off Gas To Boiler on next page and call your service technician or gas supplier GAS CONTROL KNOB SHOWN IN OFF POSITION TO TURN OFF GAS TO BOILER 1 Set thermostat to lowest setting 2 Turn off all eletrical power to the appliance if service is to be performed 3 Turn gas control knob clockwise to OFF position MAINTENANCE This boiler has been designed to provide years of trou ble free performance in normal installations Examina tion by the homeowner at the beginning of each heating season and in mid heating season should assure con tinued good performance In addition the boiler should be examined by a qualified service professional at least once every year DANGER To avoid fire and explosion hazards Do not store anything against boiler or allow dirt debris to accumulate in area immediately surrounding boiler Keep boiler area clear and free from com bustible materials gasoline and other flammable vapors and liquids Do not allow lint paper or rags to accumulate near burners Do not place clothing on boiler to dry NOTE Boiler is not for use in systems where water is replenished Do not draw water from system for cleaning Minerals in water can build up
17. 00 1 1 4 1 380 1 050 730 590 500 440 400 370 350 320 305 275 250 225 210 1 1 2 1 610 1 600 1 100 890 760 670 600 560 530 490 460 410 380 350 320 2 2 067 3 050 2 100 1 650 1 450 1 270 1 150 1 500 990 930 870 780 710 650 610 2 1 2 2 469 4 800 3 300 2 700 2 300 2 000 1 850 1 700 1 600 1 500 1 400 1 250 1 130 1 050 980 3 3 026 8 500 5 900 4 700 4 100 3 600 3 250 3 000 2 800 2 600 2 500 2 200 2 000 1 850 1 700 4 4 026 17 50012 000 9 700 8 300 7 400 6 800 6 200 5 800 5 400 5 100 4 500 4 100 3 800 3 500 Maximum Capacity of Pipe in Thousands of Btu per Hour of Undiluted Liquefied Petroleum gases at 11 Inches of Water Column Inlet Pressure Based of a Pressure Drop of 0 5 Inch Water Column Nominal Iron Pipe Length of Pipe Feet Size 10 20 30 40 50 60 70 80 90 100 125 150 Inches 1 2 275 189 152 129 114 103 96 89 83 78 69 63 3 4 567 393 315 267 237 217 196 185 173 162 146 132 1 1071 732 590 504 448 409 378 346 322 307 275 252 1 1 4 2205 1496 1212 1039 937 834 771 724 677 630 567 511 1 1 2 3307 2299 1858 1559 1417 1275 1180 1086 1023 967 866 787 2 6221 4331 3465 2992 2646 2394 2205 2047 1921 1811 1606 1498 FIGURE 1 16 10 gt PROCEDURE Connect gas piping from meter to boiler following good piping practices Pipe joint compound must be compatible with LP gas Check local codes and utilities for any additional requirements ALL PIPING MUST BE SUPPORTED ERS NOT BY BOILER OR ACCESSORIES
18. Equipment and with Standard C S A C22 1 Canadian Electrical Code Part 1 and Part 2 and or local codes In the Commonwealthof Massachusetts the installation must be performed by a licensed plumber or gas fitter WARNING Installers must follow local regulations with respect to the installation of CO detectors and follow the manufacturer s stated maintenance schedule for this boiler ATTENTION Observer les r glements r gional l egard des d tecteurs de monoxyde de carbone et observer entretien de manufacturier pour cette chaudi re BOILER SHIPMENT Each boiler is shipped in a single carton There is a vent damper packed separately with the boiler BOILER DIMENSIONS MODEL A B EW 65 24 3 4 13 1 8 14 1 4 45 1 16 5 6 1 16 EW 85 27 1 2 13 1 8 14 3 4 48 5 16 5 6 1 16 EW 100 27 1 2 13 1 8 14 3 4 48 5 16 5 6 1 16 FE EW 125 27 1 2 13 1 8 19 53 6 6 1 2 i EW 145 31 13 1 8 31 68 1 2 6 6 1 2 EW 165 31 13 1 8 30 1 16 8 7 OH t 8 i 7 1 16 1 PRESS RELIEF VALVE EW 65 145 165 1 1 2 SUPPLY EW 85 100 125 EN EW 85 100 12 dure 85 100 125 RETURN ES AIR ELIMINATION TAPPIN
19. G mL SPILL SWITCH 1 oy D HI LIMIT AQUASTAT CIRCULATOR EXPANSION TANK PACKAGED TAPPING BOILERS 4 1 1 2 SUPPL BoE T O PRESS RELEF VALVE D EW 65 145 165 DRAIN VALVE ROLLOUT SWITCH 8 32 1 2 _ MODEL BOILER DIMENSIONS BOILER INSTALLATION STEP 1 LOCATING amp SETTING THE BOILER gt PROCEDURE A Check that provisions for combustion air are in accordance with National Fuel Gas Code ANSI Z223 1 latest edition and all applicable local codes In Canada follow CAN CGA B149 0 1 or 2 installation codes WARNING This boiler must be supplied with combustion air in accordance with Section 5 3 Air for Combustion amp Ventilation of the latest edi tion of the National Fuel Gas Code ANSI 2223 1 and all applicable local building codes Failure to provide adequate combustion air for this appli ance can result in excessive levels of carbon monoxide which can result in severe personal injury or death If boiler is installed in an unconfined space quate air will be available via normal infiltration gt PROCEDURE Check minimum clearances to combustibles are proper as shown If boiler is installed in a confined space a space with a volume of less than 50 cubic feet per 1000 Btu hr of gas input for a
20. NSF T2 BLK 12 115V60Hz P GND GAS VALVE 8600 TH TR E y 5 mv CR BRN MV PV PURP ie BK oJ vent War dl DAMPER 2 24 GND 3 C gt 24V 5 BLUE 3 46 2 ROLLOUT IGNITOR y SENSOR n SWITCH IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE BOILER MUST BE REPLACED USE A SIMILIAR WIRE OF 105 C RATING 6 H 115V 24V m CYYYY E THERMOSTAT OR OPER BELIMIT SWITCH CONTROL e T e I eene oto TT 1 TEE D a E Sad A 1 GAS VALVE 1e S8600 BLK vent 20 TH ces 9 MV DAMPER 30 TR ETT gt MV PV 4o 5 m 2 TH TR py ot I H 1 24 GND 2av 2 IGNITOR SWITCH SENSOR SPARK SPILL AND ROLLOUT SWITCHES USED WHEN INPUT IS LESS THAN 300 000 BTUH 42 5766 FIGURE 1 22 WIRING DIAGRAM amp OPERATION SEQUENCE FOR BOILERS WITH IID VENT DAMPER amp L8148E AQUASTAT RELAY 13 FIGURE 1 23 WIRING DIAGRAM amp OPERATION SEQUENCE FOR BOILERS WITH IID VENT DAMPER gt TO CIRC C1 C2 O 12 N 115V H YEL RED _____ 2 24V
21. PROCEDURE Test Gas Piping BEAM RISER TO OTHER 4 APPLIANCES PIPE CLAMP GAS METER MANUAL MAIN SHUTOFF VALVE UNION SEDIMENT TRAP FIGURE 1 17 DANGER Before placing gas piping into service carefully test it to ensure every joint is gas tight Leak test all joints with a soap solution NEVER TEST WITH AN OPEN FLAME AS FIRE OR EXPLOSION MAY RESULT For any pressure testing in excess of 1 2 psi the boiler and its individual shutoff valve must be isolated from the piping system by disconnecting them and capping the outlet s For any pressure testing equal to or less than 1 2 psi the boiler must be isolated from the piping system by closing its manual shutoff valve Minimum pressure required at the gas valve inlet is 5 W C for natural gas and 11 W C for propane Maximum pressure allowable at the gas valve inlet is 12 W C If the gas pressure is above this limit a pressure regulator must be installed If the gas pressure is below these limits contact the local utility When testing has been completed close main gas shut off valve amp set boiler combination gas valve in off position STEP 5 WIRING THE BOILER WARNING Turn off electric power supply before servicing Contact with live electric components can cause shock or d
22. al pitch and deter mine there is no blockage or restriction leak age corrosion and other deficiencies which USE VENT SUPPORT S AS REQUIRED TO PREVENT SAGGING DES could cause an unsafe condition 3 Insofar as is practical close all building 6 FT doors and windows and all doors between the APART space in which the appliances remaining con nected to the common venting system are located and other spaces of the building Turn Li 3 on clothes dryers any appliance not nected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers MAXIMUM SINGLE WALL OR TYPE B FLUE PIPE 65 5 gt 85 5 100 5 125 6 EW 145 6 165 7 INSTALL FLUSH WITH INSIDE CHIMNEY LINER PITCH 1 4 PER FOOT SECURE FLUE PIPE TO VENT DAMPER FURNACE CEMENT 4 Place in operation the appliance being in spected Follow the lighting instructions Ad just thermostat so appliance will operate con tinuously SEAL WITH 1 5 Test for spillage at draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or
23. ation after servicing 19 APPENDIX M THOD D INSTALLATION pour le volet motoris de ventilation Danger Le volet de ventilation doit servir seulement la chaudi re Ne pas l utilser pour ventiler d autres appareils sinon cela pourrait provoquer un incindie ou causer un empoisonnment par le monoxyde de carbone 1 Monter le volet de ventilation sur la partie 2 Fixer le volet de ventilation au coupe tirage sup rieure du coupe tirage LA FLECHE DE DIRECTION DE LECOULEMENT POINTE VERS LE HAUT ATTACHER LA PARTIE INF RIEURE DU VOLET DE VENTILATION AU L COUPE TIRAGE AIDE HH 4 DE VIS DE 1 2 OU PLUS SASSURER QUE MONTER LE VOLET A S LE MOTEUR SOIT DE VENTILATION SITUE A GAUCHE AU DESSUS DU COUPE TIRAGE FIGURE 1 12 FIGURE 1 13 3 Brancher le faisceau de fils ENFICHER DANS LA PRISE MOLEX A L INTERIEUR DU MOTEUR DU VOLET DE FES VENTILATION DU VOLET DE X VENTILATION I Sig we PT C ENFICHER DANS LA PRISE MOLEX SUR LE DEVANT DE LA CHAUDIERE FIGURE 1 14 LE REGISTRE DOIT TRE EN POSITION OUVERTE LORSQUE LE BR LEUR PRINCIPAL EST EN MARCHE f CLOS OUVERTE SENS DE DEBIT FIGURE 2 2 20 RU NN NWN A NS Boiler Model
24. e aquastat s differential to the maximum 25 30 F will minimize short cycling MERE 115 volts EE reverse aquastat circulator 24 volts REVERSE AQUASTAT SET AT 120 F operating aquastat FIGURE 1 8 gt PROCEDURE For combination heating and cooling installations only 8 2 NOTE VALVES OPENED HEATING WITH VALVES hot water boiler is installed in connection with a GllOSER REVERSE PROCEDURE ON COOLING water chiller the chilled water must be piped in paral EXE Me lel with the boiler using appropriate valves to prevent ji the chilled medium from entering the boiler Figure 1 9 When boilers are connected to heating coils locat RELIEF ed in air handling units where they may be exposed to VALVE refrigerated air circulation the boiler piping system shall be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle DRAIN DRAIN BOILER CHILLER FIGURE 1 9 gt PROCEDURE D Completely fill 8 purge Vines heating system Make sure that all heat ing system manual air vents are closed 1 Check that flow direction arrows on m hydronic components are facing in proper RETURN direction VALVE F VALVE 2 Attach hose to drain valve B Figure VALVE B 1 10 and close valve A Open valves ay
25. eath All electrical wiring must be in accordance with require ments of authority having jurisdiction or in absence of such requirements to National Electric Code NFPA 70 latest edition If external source is utilized boiler must be electrically grounded in accordance with the require ments of authority having jurisdiction or in absence of such requirements with National Electric Code NFPA 70 latest edition UL listed power limited circuit cable is almost universally approved for safety controls on heat ing equipment either internally or externally without protection of conduits or raceways For Canada all electrical connections are to be made in accordance with Standard C S A 022 1 Canadian Elec trical Code Part 1 and Part 2 and or local codes 11 NOTE If any original wire supplied with the boiler must be replaced use similar wire of 105 C rating Otherwise insulation may melt or degrade expos ing bare wire NOTE The boiler transformer must not be used to power external accessories such as zone valves or relays Otherwise boiler transformer will be over loaded and will burn out A separate 115V 60Hz power supply is recommended for the boiler Use standard 15 amp fuse and 14 gauge wire from power supply to boiler Follow the wiring diagram for your particular installation as shown in Figures 1 18 through 1 28 OPERATING SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT VENT DAMPER AND HI LIMIT
26. ement etc WARNING Never install boiler on combustible flooring without combustible flooring pan or on carpeting as heat damage and or fire may result CAUTION Locate boiler so horizontal connecting flue pipe is as short as possible Maximize height of vertical flue connector CAUTION Do not loosen tie rods on absorption unit They accommodate thermal expansion Loss of boiler structural integrity and water leaks damage gt PROCEDURE Check component positioning 1 Remove all packing material from boiler 2 Check that burners and controls are in the proper position 3 Check proper seating of baffle grid or baffle inside of dome opening see Figure 1 2 may result _ BAFFLE GRID FIGURE 1 2 STEP 2 INSTALLING amp PURGING WATER PIPING CAUTION Boiler must not be used without forced circulation as overheating or failure of cast iron sections may result PROCEDURE A Install vent tapping assembly components and relief valve discharge piping For Models EW 85 100 amp 125 supply outlet is on the top front of the boiler and vent fitting assembly tapping is at top rear of boiler Relief Valve Discharge Piping Must terminate 6 above floor amp be same size or larger than valve outlet Figure 1 3 WARNING No valve of any type may be installed between the boiler and relief valve or an explosion from over pres sure may occur CAUTION Piping must be installed from relief
27. er caused by blocked boiler flue passage ways by interrupting power to the gas valve to prevent unsafe boiler operation This is either a single use device and must be replaced if it is tripped or a man ual reset type device that can be reset by depressing the reset button Flue passages must be inspected by a qualified installer prior to switch replacement if a prob lem occurs DANGER If flame rollout switch or spill switch trips repeatedly during start up or operation it indicates a hazardous condition that must be corrected immediately WARNING If boiler cannot restored to normal operation after resetting of spill switch or if flame rollout switch has tripped do not attempt to put the boiler in operation Immediately contact a qualified service professional START UP amp ADJUSTMENTS Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in ANSI Z21 13 latest edition WARNING Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids Otherwise fire or explosion may result 1 Bleed all heating system air vents starting on lowest floor Open vents one at a time until water squirts out Close vent and repeat procedure with remaining vents 15 2 Make sure boiler combination gas valve is in OFF position Then open main gas shutoff
28. ete F1 D and drain valve Fill system with water until water runs out of the hose in a steady stream no visible air bubbles SUPPLY VALVE E i W 8 Close valves and D Open valve When water runs out of the hose in a steady stream no visible air bubbles close drain valve B FIGURE 1 10 FOR WATER TREATMENT amp FREEZE PROTECTION REQUIREMENTS SEE MAINTENANCE IN THIS MANUAL STEP 3 VENTING THE BOILER DANGER Draft hood and vent outlet must not be altered as proper operation would be jeopardized flame rollout fire or carbon monoxide poisoning will result NOTE Additional venting and chimney requirements are provided on page 8 gt PROCEDURE A Mount draft hood and spill switch 5 on boiler 2 5 INSTALL CONNECT INSTALL 1 Install draft hood on boiler draft hood shroud has SWITCH WIRE MOUNTING a hole near the relief opening mount draft hood so IN OPENING LEADS BRACKET hole faces to the front of the boiler 2 EW boilers are equipped with factory mounted spill xe ON DRAFTHOOD ON DRAFTHOOD switch harness mounting bracket assembly spill switch is provided bag boiler front 3 Install mounting bracket on outside surface of draft hood shroud with the screws
29. f less than 0 3 W C for natural gas or 0 5 W C for propane following example below Example Boiler Model EW 125 is to be installed Distance from existing gas meter to installation site is 20 ft What pipe size must be used Local utility indicates heating value of natural gas being supplied is 1020 Btu per cu ft Determine cubic feet of gas per hour for above boiler model 125 000 Btu per hour 122 ft h 1020 Btu per cu ft ala 1 20 ft in upper portion of the table for natural gas under Length of Pipe Feet heading 2 Moving down the column match required capacity Higher capacity acceptable In our case it is 190 cu ft 3 Move to left hand column Nominal Iron Pipe Size Inches read required pipe size In our case it is 4 4 Take into account the effects of pipe fittings when determining the correct pipe size Maximum Capacity of Pipe in Cubic Feet of Natural Gas per Hour for Gas Pressures of 0 5 Psig or Less and a Pressure Drop of 0 3 Inch Water Column Based on a 0 60 Specific Gravity Gas Nominal Iron Pipe Internal Size Diameter Inches Inches Length of Pipe Feet 10 20 30 40 50 60 70 80 90 100 125 150 175 200 1 4 326 32 22 18 15 14 12 11 11 10 9 8 8 7 6 3 8 493 72 49 40 34 30 27 25 23 22 21 18 17 15 14 1 2 622 132 92 73 63 56 50 46 43 40 38 34 31 28 26 3 4 824 278 190 152 130 115 105 96 90 84 79 72 64 59 55 1 1 049 520 350 285 245 215 195 180 170 160 150 130 120 110 1
30. for most gas conditions typically found in the U S Occasionally however the local gas characteristics may not allow the unit to be properly adjusted for input If this is the case the local utility or Hydrotherm may recommend the orifices be changed When changing orifices follow the procedures in the Maintenance Section of this manual 13 Start and stop burners several times by raising and lowering the thermostat setting 14 After the boiler has been firing long enough to raise the boiler water temperature to above the minimum setting of the high limit check the high limit by turning its setting from maximum to minimum setting This should turn the boiler off Return high limit to desired setting 15 Check boiler safety shut off controls a For boilers with standing pilot with boiler firing disconnect thermocouple lead from the valve The valve should close b For boilers with intermittent pilot with boiler firing dis connect wire connection to the PV terminal on Hon eywell S8600 control The gas valve should close 16 WARNING If you do not follow these instructions exactly a fire or explosion may result with property damage personal injury or loss of life A Before lighting smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do to light any appliance Do not touch an
31. itch opens see the information on Safety Controls on this page 8 Observe pilot and main burner flame see Figure 2 3 All burner ports should be ignited and burn with a steady blue flame CAUTION Never leave the job with yellow burning flames This condition indicates poor combustion and will quickly carbonize the boiler reducing effi ciency and boiler life It may also be an indication of improper venting or combustion air supply If unable to adjust flame properly consult your local utility V S Q345A Q314A Q309A INTERMITTENT CONSTANT PILOT IGNITION PILOT MODELS MODELS o 0 NORMAL PILOT FLAME 96 o NORMAL LIFTING YELLOW HARD FLAME TOO MUCH AIR TIPPING FLAME MARGINAL TOO LITTLE AIR MAIN BURNER FLAMES FIGURE 2 3 9 Boilers are shipped from the factory with the primary air shutters on the main burner wide open It is recom mended these air shutters be left in the wide open posi tion unless there is lifting of the flame above the burner ports If there is lifting the air shutters should be gradu ally closed until the lifting is eliminated It may also be necessary to adjust the primary air shutters if the input rate is reduced by a change in the orifices 10 After burner has been in operation for about 10 min utes check gas input rate to boiler as follows a Make sure that all appliances served by the gas meter are t
32. ll fuel burning equipment or building construction is unusually tight adequate air for combustion must be provided by two openings one located about 6 below the ceiling the other about 6 above the floor When communicating directly with the outside each opening must have a minimum free area of one square inch per 4000 Btu hr of gas input When ventilation air is provided by openings in doors etc to adjoining spaces having adequate infiltration each opening must have a minimum free area of one square inch per 1000 Btu hr of gas input NOTE Boiler employs atmospheric combustion Combustion air must not be contaminated with halogenated hydrocarbon vapors aerosol propel lants or freon otherwise heat exchanger will be subject to corrosion reducing boiler life Local requirements RER yO L 4 may specify greater 1 clearances amp must be VENT DAMPER adhered to E 48 gt Boiler shall be install ed such that the gas igniti FRONT ignition system com ER SS ponents are protected be uu He Le 6 Le go from water dripping RECOMMEND FOR spraying rain etc ACCESS TO UE i i during appliance oper Ht ALES ation and service cir POSITION culator replacement Tr condensate trap con FIGURE 1 1 trol replac
33. on heat transfer surfaces and cause overheating and subse quent failure of cast iron sections WARNING Do not obstruct the flow of combustion and ventilation air Failure to comply with this warn ing can result in carbon monoxide poisoning NOTE If boiler is equipped with a low water cutoff follow manufacturer s maintenance instructions WATER TREATMENT Water treatment is recommended in areas where water quality is a problem A local water treatment company should be consulted to determine the requirements for your particular system FREEZE PROTECTION Where absolutely necessary system antifreeze can be utilized It must be compatible with hydronic heating sys tems System must be designed to accommodate nec essary changes in heat transfer pump head flow rate amp expansion For more information consult The Hydronics Institute Technical Topics Number 2A publication Note Never use an RV type antifreeze protection solution nor an automotive type antifreeze as dam age to the boiler and other system components may result 18 BEFORE EACH HEATING SEASON 1 Remove and inspect draft hood and vent piping con necting draft hood to chimney or vent for obstructions soot accumulation rust or corrosion Clean and replace as necessary Check tightness of joints seal all joints where necessary 2 Check boiler flue passageways in the boiler sections for any blockage or soot accumulation Remove draft hood jacket top
34. provided HARNESS MUST BE ON OUTSIDE OF SHROUD Install spill FIGURE 1 11 switch in hole in shroud on outside surface with the screws provided Figure 1 11 4 Plug wiring leads from harness bracket assembly NOTE Boiler will not operate unless wiring leads onto flat terminals on spill switch to spill switch are connected gt PROCEDURE B Install vent damper For French version see Appendix A at rear of manual DANGER Only the boiler may be served by the vent damper Do not use it to vent an additional this will cause fire or carbon monoxide poisoning 1 Mount damper on top of draft hood FLOW DIRECTION ARROW POINTS UP 3 Connect wire harness PLUG INTO MOLEX A MOUNT RECEPTACLE INSIDE MAKE SURE DAMPER MOTOR MOTOR IS DAMPER LOCATED N DAMPER ON LEFT SIDE DRARTHOOD WIRE HARNESS FIGURE 1 12 cy 2 Secure damper to draft hood 4 LOWER PORTION PLUG INTO MOLEX VENT DAMPER RECEPTACLE ON FRONT L DRAFTHOOD FIGURE 1 14 OF BOILER WITH 1 2 OR SHORTER SCREWS OR POP RIVETS FIGURE 1 13 1 Seal all unused openings in common vent gt PROCEDURE Install flue pipe between vent damper and ing system chimney A 6 minimum clearance is required between flue pipe and all combustible con struction 2 Visually inspect the venting system for proper size and horizont
35. r venting of appliances remaining connected to it At time of removal of existing boiler following steps shall be followed with each appliance remaining connected to the common vent ing system placed in operation while other appliances remain ing connected to common venting system are not in operation system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code ANSI Z223 1 latest edition For Canada the provisions of CAN CGA B149 1 or 2 shall apply ADDITIONAL CHIMNEY REQUIREMENTS Chimney condi tion is of paramount importance for a safe and efficient boiler installation All installations must include a chimney inspection by a qualified individual or agency Chimney construction materials must be compatible with the fuel being used Particular attention should be paid on all oil to gas conver sions Soot may have accumulated in the chimney and or degraded the chimney liner Most utilities require complete chimney cleaning Others may require installation of a new liner or other chimney upgrades Check with local utility for required safety precautions DANGER A chimney which does not meet modern safety standards will result in a fire or deadly car bon monoxide poisoning of the building residents STEP 4 INSTALLING amp TESTING GAS PIPING gt PROCEDURE A Select gas pipe size which will result in a pressure drop o
36. regulate the amount of flow that will be diverted to the return plug valve offers the best control for this application Although other valves may be less expensive a plug valve will be easier to set accurately In the absence of a flow indicator set the metering valve using temperature as a guide The accompanying dia gram suggests one scenario This addition requires only two tees a plug valve and a small amount of pipe and offers the simplest approach to reliably controling con densation For this system and those that follow be aware that you are using a percentage of the pump capacity to blend but the friction loss for the entire pump flow has been reduced In most cases the stan dard pump packaged with the boiler has enough capaci ty to feed the baseboard distribution system and the bypass line SYSTEM BYPASS FIGURE 1 5 PUMP AWAY BYPASS For systems that use a single circulator to pump away from the boiler the bypass should be installed on the discharge side of the circulator see Fig 1 6 Full tem perature water supplies the baseboard distribution sys tem as before Half of the circulators volume moves through the bypass blending and heating the cooler return water Again the cost of installing the bypass is small and setting it by temperature can be accomplished with a contact thermometer V SUPPLY RETURN PUMP AWAY PYPASS FIGURE 1 6 PUMPED BLEND An additional circulator can al
37. seur appelez le service des incendies L installation et l entretien doivent tre assur s par un installateur ou un service d entretien qualifi ou par le fournisseur de gaz The following terms are used throughout this manual to bring attention to the presence of potential hazards or to important information concerning the product DANGER Indicates an imminently hazardous sit CAUTION Indicates a imminently hazardous situa uation which if not avoided will result in death tion which if not avoided may result in minor serious injury or substantial property damage injury or property damage CHa ET CE NOTE Used to notify of special instructions on uation which if not avoided could result in installation operation or maintenance which are important to equipment but not related to personal damage injury hazards ANSI ASME CODE COMPLIANCE Installation must conform to requirements of authority having jurisdiction or in absence of such requirements to National Fuel Gas Code ANSI Z223 1 latest edition and to National Electric Code NFPA 70 latest edition Where required by authority having jurisdiction installation must also con form to Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 For Canada the installation must be in accordance with Standards CAN CGA B149 1 or 2 Installation Codes for Gas Burning Appliances and
38. smoke from cigarette cigar or pipe 6 After it has been determined that each ap pliance remaining connected to common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to previous con ditions of use 7 Any improper operation of the common _1 1111111 FIGURE 1 15 venting system should be corrected so instal lation conforms with the National Fuel Gas Code ANSI Z223 1 latest edition When resizing any portion of the common venting ADDITIONAL VENTING REQUIREMENTS When connecting to gas vents or chimneys vent installations shall be in accor dance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 latest edition or applicable provisions of the local building codes Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure When two or more appliances vent into a common flue the area of the common flue should be at least equal to the area of the largest flue plus 50 of the areas of the additional flue or vent connectors When an existing boiler is removed from a common venting system common venting system is likely to be too large for prope
39. so be used to provide a return water temperature blend This method works well with systems with multiple zones with circulators see Fig 1 7 The dedicated bypass circulator provides a strong blending flow without diminishing the flow avail able to any heating zone Any residentially sized circula tor is adequate for this purpose Each of these bypass solutions also has the added ben efit of increasing circulation in the boiler which will maxi mize tankless coil output and increase the accuracy of temperature sensing controls PUMPED BYPASS FIGURE 1 7 REVERSE ACTING AQUASTATS An alternative for existing systems experiencing conden sation that does not require re piping the boiler utilizes a reverse acting aquastat one that makes on temperature rise This approach works best in single zone systems Wired in series with the circulator this control holds the circulator off until the boiler reaches an acceptable tem perature and then starts system circulation see Fig 1 8 The most commonly available reverse acting aquastat is a Honeywell L4006B The aquastat should be mounted in an immersion well directly installed in the boiler The use of heat conductive grease Honeywell part 972545 in the immersion well is strongly recommend ed for fast and accurate temperature response Set this adjustable aquastat to make at no less than 130 F While this method can cause the circulator to cycle more frequently setting th
40. urned off during timing of gas input rate to the boiler b Measure the time in seconds that it takes for the boil er to use10 cubic feet of gas Divide 36 000 by the number of seconds this is the number of cubic feet of gas used per hour Multiply this figure by the heating value of the gas to obtain the input in Btu per hour Example An HC 125E boiler takes 4 minutes 54 sec onds to use 10 cubic feet of natural gas Local utility indicated heating value of the natural gas being supplied is 1020 Btu cu ft Therefore 54 4x60 294 seconds 36 000 294 x 1020 124 898 Btu hr Therefore the boiler input is correct NOTE Before calculating the input of the heating equipment obtain the heating value of the gas from the local utility 11 If boiler input needs to be corrected adjust the combi nation gas valve pressure regulator Regulator is factory set at 3 5 W C for natural gas or 10 W C for propane Turn adjusting screw clockwise to increase gas flow increase input Turn adjusting screw counterclockwise to decrease gas flow decrease input In no case should final manifold pressure setting vary more than 2 from factory set pressures rated input cannot be obtained with regulator adjustment gas supply pressure or orifice size may be the cause Consult your local utility and Hydrotherm 12 The gas burner orifices supplied with the boiler have been carefully designed to provide the correct gas input rate
41. valve allowing gas to flow to boiler 3 Set thermostat heat anticipator at 8 amp when therm ostat is controlling boiler directly When zone con trolled set heat anticipator to amp draw of zone valve s or circulator pump relay 4 Set thermostat to call for heat and turn on electrical power to boiler Observe that vent damper position indicator has rotated to open position see Figure 2 2 Damper must be in open position when boil er main burner is Operating In case of a damper malfunction the damper blade may be manually placed in the full open position to permit burner operation To accomplish this follow the instructions on the damper DAMPER POSITION INDICATOR MUST BE IN VISIBLE LOCATION FOLLOWING INSTALLATION 4 CLOSED 1 OPEN t FLOW DIRECTION FIGURE 2 2 5 Allow circulator to run 15 to 30 minutes which should purge any leftover air from system Check automatic air vent for the proper operation and the entire system for any leaks Make sure all air is purged from system before lighting boiler 6 Set thermostat to no longer call for heat Observe that damper position indicator rotates to the closed position 7 Set thermostat to lowest setting and light boiler follow ing lighting instructions in Figure 2 4 Boiler is equipped with flame rollout switch to shut down boiler in case of sustained flame roll out or excessive heat be hind front panel If sw
42. valve dis PRESS RELIEF VALVE RELIEF VALVE DISCHARGE PIPING charge so there will be no danger of scalding personnel 1 2 TAPPING 4 gt PROCEDURE B Install supply and return water piping For Models EW 85 100 amp 125 supply outlet is on top front of boiler and vent fitting assembly tapping is at top rear of boiler Figure 1 4 If boiler is installed above level of radiation a low water cut off must be used NOTE ALL EXTERNAL PIPING MUST BE SUPPORTED BY HANG ERS NOT BY BOILER OR ACCES SORIES CAUTION To prevent damage due to excessive condensation one of the following piping options should be used see next page VERTICAL EXPANSION TANK ARRANGEMENT PREFERRED MAY BE PIPED TO EITHER SIDE OF BOILER HORIZONTAL EXPANSION TANK ARRANGEMENT M MAY BE SCREWED INTO TAPPING FIGURE 1 3 SHUT OFF VALVE 1 1 4 7 1 SHUT OFF VALVE PRESS REDUCING SHUT OFF FILL VALVE DRAIN VALVE VALVE SHUT OFF 4 VALVE H SHUT OFF VALVE 5 1 1 2 25 ne CIRCULATOR oib WATER c INLET FIGURE 1 4 GU nn LT SYSTEM BYPASS For systems using a circulator on the return as either a single zone or multiple zones with zone valves install a system bypass line between the supply and return on the suction side of the circulator see Fig 1 5 Install a metering valve in this bypass line to
43. y electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department B Use only your hand to turn the gas control knob Never use tools If the knob will not 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 C Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been underwater LIGHTING CONTINUOUS PILOT INSTRUCTIONS Honeywell VR8200 Natural or Propane Gas This appliance has a pilot which must be lit by hand When lighting the pilot follow these instructions exactly STOP Read the safety information above on this page Set the thermostat to lowest setting Turn off all electric power to the appliance Turn gas control knob clockwise to OFF position Do not force 5 Wait five 5 minutes to clear out any gas then smell for gas including near the floor If you smell gas STOP Fol low A in the safety information above If you don t smell gas go to the next step 6 Remove the base door covering the top of the burners and enclosing the pilot 7 Find pilot Follow metal tube from gas control The pilot is between the

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