EW2-1203

42-9510

MODEL EW

SERIES

INSTALLATION,

OPERATION

& 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.

BOILER INSTALLATION

Introduction..............................................

2

Step 1: Locating & Setting Boiler.............

4

Step 2: Installing/Purging Water Piping...

5

Step 3: Venting Boiler...............................

8

Step 4: Installing/Testing Gas Piping........ 10

Step 5: Wiring Boiler................................ 12

START-UP & OPERATION

Safety Controls........................................ 15

Start-Up & Adjustments........................... 15

MAINTENANCE

Water Treatment ...................................... 18

Freeze Protection..................................... 18

Before Each Heating Season .................. 18

How To Change Orifices........................... 19

Troubleshooting ....................................... 19

Appendix A

(French Vent Damper Translation)........... 20

WARNING: Installation and service must be performed by a qualified installer, service agency or the gas supplier in accordance with all local and national codes. Failure to comply with this warning can result in a fire or explosion causing property damage, personal injury or loss of life!

IN UNITED STATES: 260 NORTH ELM ST. • WESTFIELD, MA 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 données dans cette notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommoge matériel, toute blessure ou la mort

Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides inflammables à proximité de cet appareil ou de tout autre appareil.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

• Ne pas tenter d’allumer d’appareil.

• Ne touchez à aucun interrupteur; ne pas vous servir des téléphones se trouvant dans le bâtiment.

• Appelez immédiatement votre fournisseur de gas depuis un voisin. Suivez les intructions du fournisseur.

• Si vous ne purvez rejoindre le fournisseur, appelez le service des incendies.

L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien qualifié ou par le fournisseur de gaz.

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 situation which, if not avoided, will result in death, serious injury or substantial property damage.

WARNING: Indicates a imminently hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage.

CAUTION: Indicates a imminently hazardous situation which, if not avoided, may result in minor injury or property damage.

NOTE: Used to notify of special instructions on installation, operation or maintenance which are important to equipment but not related to personal injury hazards.

2

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 conform 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 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 règlements règional à l'egard des détecteurs de monoxyde de carbone et observer entretien de manufacturier pour cette chaudière!

BOILER SHIPMENT: Each boiler is shipped in a single carton. There is a vent damper packed separately with the boiler.

D

F

C

A

E

BOILER

MODEL

EW-65

EW-85

EW-100

EW-125

EW-145

EW-165

A

24-3/4"

27-1/2"

27-1/2"

27-1/2"

31"

31"

B

13-1/8"

13-1/8"

13-1/8"

13-1/8"

13-1/8"

13-1/8"

DIMENSIONS

C

14-1/4"

14-3/4"

14-3/4"

19"

31"

30-1/16"

D

45-1/16"

48-5/16"

48-5/16"

53"

68-1/2"

68-1/8"

6"

6"

7"

E

5"

5"

5"

F

6-1/16"

6-1/16"

6-1/16"

6-1/2"

6-1/2"

7-1/16"

1-1/4"

RETURN

VENT DAMPER

B

SPILL SWITCH

HI-LIMIT AQUASTAT

CIRCULATOR

(PACKAGED

BOILERS)

TEMP./PRESS.

INDICATOR

DRAIN

VALVE

ROLLOUT

SWITCH

MODEL EW BOILER DIMENSIONS

1-1/2" SUPPLY

EW-65, 145, 165

1-1/2" SUPPLY

EW-85, 100, 125

PRESS./RELEF VALVE

EW-65, 145, 165

32-1/2"

PRESS./RELIEF

VALVE

EW-85, 100, 125

AIR ELIMINATION

TAPPING

EXPANSION TANK

TAPPING

3

BOILER INSTALLATION

STEP 1: LOCATING & SETTING THE BOILER

➤

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 & Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1

and all applicable local building codes. Failure to provide adequate combustion air for this appliance 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, adequate air will be available via normal infiltration.

➤

PROCEDURE B: Check minimum clearances to combustibles are proper as shown.

Local requirements may specify greater clearances & must be adhered to.

6"

6"

VENT

DAMPER

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 all 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 propellants or freon; otherwise, heat exchanger will be subject to corrosion, reducing boiler life.

TOP

48"

Boiler shall be installed such that the gas ignition system components are protected from water, dripping, spraying, rain, etc., during appliance operation and service, circulator replacement, condensate trap, control replacement, etc.

LEFT

6"

FRONT

VIEW

RIGHT

6"

RECOMMEND

MORE FOR

ACCESS TO

VENT

DAMPER

POSITION

INDICATOR

FRONT

CLOSET

6"

SIDE

VIEW

REAR

6"

FIGURE 1.1

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 may result.

DOME

PROCEDURE C: Check component positioning.

BAFFLE GRID

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).

FIGURE 1.2

4

STEP 2: INSTALLING & 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 & 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 & be same size or larger than valve outlet, Figure 1.3

.

PRESS. RELIEF

VALVE

RELIEF VALVE

DISCHARGE

PIPING

WARNING: No valve of any type may be installed between the boiler and relief valve or an explosion from over-pressure may occur.

CAUTION: Piping must be installed from relief valve discharge so there will be no danger of scalding personnel.

AIR VENT

VENT

FITTING

ASS'Y.

1/2" NPT TAPPING

VERTICAL EXPANSION TANK

ARRANGEMENT (PREFERRED)

HORIZONTAL EXPANSION

TANK ARRANGEMENT

MAY BE PIPED TO

EITHER SIDE OF BOILER

MAY BE SCREWED

INTO TAPPING

FIGURE 1.3

➤

PROCEDURE B: Install supply and return water piping. For Models

EW-85, 100 & 125, supply outlet is on top-front of boiler and vent fitting assembly tapping is at toprear 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.

FIGURE 1.4

5

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 regulate the amount of flow that will be diverted to the return. A 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 diagram 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 condensation. 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 standard pump packaged with the boiler has enough capacity to feed the baseboard distribution system and the bypass line.

PUMPED BLEND

An additional circulator can also 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 available to any heating zone. Any residentially sized circulator is adequate for this purpose.

Each of these bypass solutions also has the added benefit of increasing circulation in the boiler which will maximize tankless coil output and increase the accuracy of temperature sensing controls.

100%

160

°

F

200%

160

°

F

SUPPLY RETURN

100%

120

°

F

100%

160

°

F

200%

140

°

F

PUMPED

BYPASS

50%

160

°

F

100%

160

°

F

SUPPLY

RETURN

50%

120

°

F

50%

160

°

F

100%

140

°

F

SYSTEM

BYPASS

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 temperature water supplies the baseboard distribution system as before. Half of the circulator’s 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.

50%

160

°

F

100%

160

°

F

SUPPLY

RETURN

50%

120

°

F

50%

160

°

F

100%

140

°

F

REVERSE ACTING AQUASTATS

An alternative for existing systems experiencing condensation 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 temperature 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 par t

# 972545) in the immersion well is strongly recommended 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 the aquastat’s differential to the maximum (25-30°F) will minimize short cycling.

115 volts reverse aquastat

N.O.

circulator

PUMP AWAY

BYPASS

REVERSE

AQUASTAT

SET AT 120

°

F

T

T

t'stat operating aquastat

N.C.

24 volts

GV

6

➤

PROCEDURE C: For combination heating and cooling installations only.

If a hot water boiler is installed in connection with a water chiller, the chilled water must be piped in parallel with the boiler, using appropriate valves to prevent the chilled medium from entering the boiler, Figure

1.9. When boilers are connected to heating coils located in air handling units where they may be exposed to 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.

FILL

VALVE

NOTE: VALVES "H" OPENED ON HEATING WITH "C" VALVES

CLOSED REVERSE PROCEDURE ON COOLING.

EXP. TANK

VENT

ROOM

UNIT

RELIEF

VALVE

BOILER

H

PUMP

C

H

C

DRAIN

DRAIN

BOILER

CHILLER

FIGURE 1.9

➤

PROCEDURE D: Completely fill & purge heating system. Make sure that all heating system manual air vents are closed.

1. Check that flow direction arrows on hydronic components are facing in proper direction.

2. Attach hose to drain valve “B”, Figure

1.10, and close valve “A”. Open valves “C”,

“D”, “E” and “F” and drain valve “B”. Fill system with water until water runs out of the hose in a steady stream, no visible air bubbles.

3. Close valves “C” and “D”. Open valve

“A”. 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 & FREEZE PROTECTION REQUIREMENTS,

SEE “ MAINTENANCE” IN THIS MANUAL

7

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.

➤

PROCEDURE A: Mount draft hood and spill switch on boiler.

1. Install draft hood on boiler. If draft hood shroud has a hole near the relief opening, mount draft hood so hole faces to the front of the boiler.

INSTALL

SWITCH

IN OPENING

ON DRAFTHOOD

2. EW boilers are equipped with factory-mounted spill switch harness/mounting bracket assembly; spill switch is provided in bag on boiler front.

3. Install mounting bracket on outside surface of draft hood shroud with the screws provided (HARNESS

MUST BE ON OUTSIDE OF SHROUD). Install spill switch in hole in shroud (on outside surface) with the screws provided, Figure 1.11.

CONNECT

WIRE

LEADS

INSTALL

MOUNTING

BRACKET

ON DRAFTHOOD

FIGURE 1.11

4. Plug wiring leads from harness/bracket assembly onto flat terminals on spill switch.

NOTE: Boiler will not operate unless wiring leads to spill switch are connected.

➤

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 appliance; this will cause fire or carbon monoxide poisoning.

1. Mount damper on top of draft hood.

FLOW DIRECTION

ARROW POINTS UP

MAKE SURE

MOTOR IS

LOCATED

ON LEFT SIDE

FIGURE 1.12

MOUNT

VENT DAMPER

OVER

DRAFTHOOD

3. Connect wire harness.

PLUG INTO MOLEX

RECEPTACLE INSIDE

DAMPER MOTOR

VENT

DAMPER

WIRE

HARNESS

2. Secure damper to draft hood.

ATTACH LOWER

PORTION OF

VENT DAMPER

TO DRAFTHOOD

WITH 1/2" OR

SHORTER SCREWS

OR POP RIVETS

FIGURE 1.13

FIGURE 1.14

8

PLUG INTO MOLEX

RECEPTACLE ON FRONT

OF BOILER

➤

PROCEDURE C: Install flue pipe between vent damper and chimney. A 6" minimum clearance is required between flue pipe and all combustible construction.

USE VENT SUPPORT(S) AS REQUIRED TO PREVENT SAGGING

SINGLE WALL

OR TYPE B

FLUE PIPE

EW-65 = 5"

EW-85 = 5"

EW-100 = 5"

EW-125 = 6"

EW-145 = 6"

EW-165 = 7"

MAXIMUM

6-FT

APART

PITCH 1/4"

PER FOOT

SECURE

FLUE PIPE

TO VENT

DAMPER

FIGURE 1.15

ADDITIONAL VENTING REQUIREMENTS: When connecting to gas vents or chimneys, vent installations shall be in accordance 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 proper 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 venting system placed in operation, while other appliances remaining connected to common venting system are not in operation:

INSTALL

FLUSH

WITH

INSIDE

CHIMNEY

LINER

SEAL

WITH

FURNACE

CEMENT

1. Seal all unused openings in common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common 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.

4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

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 smoke from cigarette, cigar or pipe.

6. After it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined above, retur n doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to previous conditions of use.

7. Any improper operation of the common venting system should be corrected so installation conforms with the National Fuel Gas

Code, ANSI Z223.1-latest edition. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in 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 condition 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 conversions. 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 carbon monoxide poisoning of the building residents.

9

STEP 4: INSTALLING & TESTING GAS PIPING

➤

PROCEDURE A: Select gas pipe size which will result in a pressure drop of 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

1020 Btu per cu.ft.

= 122.5 cu.ft. per hour

1. Find 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 3/4

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

Size,

Inches

Internal

Diameter,

Inches

1/4"

3/8"

1/2"

3/4"

1"

1-1/4"

1-1/2"

2"

2-1/2"

3"

4"

10 20 30 40 50

Length of Pipe, Feet

60 70 80 90 100 125 150 175 200

.326

.493

.622

.824

32

72

22

49

18

40

15

34

14

30

12

27

132 92 73 63 56 50

278 190 152 130 115 105

11

25

46

96

11

23

43

90

10

22

40

84

9

21

38

79

8

18

34

72

8

17

31

64

7

15

28

59

1.049

520 350 285 245 215 195 180 170 160 150 130 120 110 100

1.380

1,050 730 590 500 440 400 370 350 320 305 275 250 225 210

1.610

1,600 1,100 890 760 670 600 560 530 490 460 410 380 350 320

2.067

3,050 2,100 1,650 1,450 1,270 1,150 1,500 990 930 870 780 710 650 610

6

14

26

55

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

3.026

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

4.026

17,500 12,000 9,700 8,300 7,400 6,800 6,200 5,800 5,400 5,100 4,500 4,100 3,800 3,500

Nominal

Iron Pipe

Size,

Inches

1/2"

3/4"

1"

1-1/4"

1-1/2"

2"

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)

Length of Pipe, Feet

10 20 30 40 50 60 70 80 90 100 125 150

275 189 152 129 114 103 96 89 83 78 69 63

567 393 315 267 237 217 196 185 173 162 146 132

1071 732 590 504 448 409 378 346 322 307 275 252

2205 1496 1212 1039 937 834 771 724 677 630 567 511

3307 2299 1858 1559 1417 1275 1180 1086 1023 967 866 787

6221 4331 3465 2992 2646 2394 2205 2047 1921 1811 1606 1498

FIGURE 1.16

10

➤

PROCEDURE B: 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 BY HANG-

ERS, NOT BY BOILER OR ACCESSORIES.

FIGURE 1.17

➤

PROCEDURE C: Test Gas Piping:

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

& 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 death.

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, exposing bare wire.

All electrical wiring must be in accordance with requirements of authority having jurisdiction or, in absence of such requirements, to National Electric Code NFPA-70latest edition. If external source is utilized, boiler must be electrically grounded in accordance with the requirements 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 heating equipment, either internally or externally, without protection of conduits or raceways.

NOTE: The boiler transformer must not be used to power external accessories such as zone valves or relays. Otherwise, boiler transformer will be overloaded 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.

For Canada, all electrical connections are to be made in accordance with Standard C.S.A. C22.1 Canadian Electrical Code, Part 1 and Part 2 and/or local codes.

11

OPERATING SEQUENCE

FOR BOILERS EQUIPPED WITH STANDING PILOT

VENT DAMPER AND HI-LIMIT

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

T1

TT

TT

HI-LIMIT

BLUE BLUE

SPILL

SWITCH

THERMOSTAT

OR OPER.

CONTROL

WHT

BLK

115/24V

TRANSF.

VENT

DAMPER

1

2

3

4

BLK

WHT

RED

BLUE

T2

L1

L2

GND

115V 60HZ

ROLLOUT

SWITCH

TH

TR

24V GAS VALVE

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE BOILER

MUST BE REPLACED, USE A SIMILIAR WIRE OF 105˚ C RATING.

HI-LIMIT

H

SPILL

SWITCH

115V AC

T1

TT

TT

N

115/24V

THERMOSTAT

OR OPER.

CONTROL

T2

L1

L2

GND

115V 60HZ

VENT

DAMPER

3

4

2

1

ROLLOUT

SWITCH

SPILL AND ROLLOUT SWITCHES USED WHEN INPUT

IS LESS THAN 300,000 BTUH

TH TR

GAS VALVE

42-5768

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 IS 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

T1

TT

TT

THERMOSTAT

OR OPER.

CONTROL

L8148E

T W TV

Z

C1 C2

B1 B2 L1 L2

CIRC.

T2

L1

L2

GND

VENT

DAMPER

3

4

2

1

BLUE

BLK

WHT

RED

BLUE

SPILL

SWITCH

BLUE

ROLLOUT

SWITCH

115V 60 HZ

GAS VALVE

TH

TR

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE BOILER

MUST BE REPLACED, USE A SIMILIAR WIRE OF 105˚ C RATING.

L1

1K1

115 V AC

CIRC. MOTOR

C1

115/24V

C2

L2

T2

L1

L2

GND

1K2

B

HI-LIMIT

R

B1

SPILL SWITCH

115V 60 HZ

B2

VENT

DAMPER

3

4

2

1

TH TR

GAS VALVE

1

ROLLOUT

SWITCH

Z W

1K

TV

T

T1

TT

TT

SPILL AND ROLLOUT SWITCHES USED WHEN INPUT

IS LESS THAN 300,000 BTUH

THERMOSTAT

OR OPER.

CONTROL

42-5769

FIGURE 1.18: WIRING DIAGRAM & OPERATION

SEQUENCE FOR BOILERS WITH STANDING PILOT

& VENT DAMPER

FIGURE 1.19: WIRING DIAGRAM & OPERATION

SEQUENCE FOR BOILERS WITH STANDING PILOT,

VENT DAMPER & L8148E AQUASTAT RELAY

12

OPERATING SEQUENCE

FOR BOILERS EQUIPPED WITH VENT DAMPER

ELECTRONIC PILOT CONTROL AND L48148E

MOTOR DRIVES VENT DAMPER TO CLOSED POSITION AND

REMAINS CLOSED DURING STANDBY.

SENSING CIRCUIT IS CONTINUOUSLY MONITORED.

THERMOSTAT CALLS FOR HEAT.

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 IS SATISFIED.

SYSTEM RETURNS TO STANDBY WITH DAMPER CLOSED.

FACTORY WIRED

FIELD WIRED

T1

TT

TT

AQUA. RELAY

L8148E

Z

T TV

B1 B2

C1 C2

L1 L2

SPILL

SWITCH

THERMOSTAT

OR OPER.

CONTROL

CIRCULATOR

T2

L1

L2

GND

115V 60HZ

VENT

DAMPER

1

2

3

4

WHT

BLUE

BLK

RED

ROLLOUT

SWITCH

GAS VALVE

(TH-TR)

PV

(TR)

(TH)

MV/PV

MV

IGNITOR

SENSOR

BLK

BRN

PURP

S8600

MV

MV/PV

PV

GND

24(GND)

24V

SPARK

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE BOILER

MUST BE REPLACED, USE A SIMILIAR WIRE OF 105˚ C RATING.

L1

1K1

115 V AC

CIRC. MOTOR

L2

T2

L1

L2

GND

115V 60HZ

C1

115/24V

C2

1K2

B

HI-LIMIT

R

B1

MANUAL RESET

SPILL SWITCH

VENT

DAMPER

1

2

3

4

ROLLOUT

SWITCH

Z W

1K

TV

T

SPILL AND ROLLOUT SWITCHES USED WHEN INPUT

IS LESS THAN 300,000 BTUH

T1

L1

L2

(TH)

(TR)

MV

MV/PV

(TH-TR)

GAS VALVE

PV

IGNITOR

SENSOR

BLK

BRN

PURP

B2

S8600

MV

MV/PV

PV

GND

24(GND)

24V

SPARK

THERMOSTAT

OR OPER.

CONTROL

42-5767

FIGURE 1.22: WIRING DIAGRAM & OPERATION

SEQUENCE FOR BOILERS WITH IID,

VENT DAMPER & L8148E AQUASTAT RELAY

FIGURE 1.23: WIRING DIAGRAM & OPERATION

SEQUENCE FOR BOILERS WITH IID,

VENT DAMPER

13

N

H

115V

T2

ZV1

TH1

YEL RED

YEL RED

ZV2

W

TH2 TV T

YEL RED

2

R1

YEL RED

TO CIRC.

TH3

YEL

ZV3

RED

B1 B2

C1

L1

C2

L2

YEL RED

T2: 24V TRANSF.

TH1: ZONE T'STAT

TH2: ZONE T'STAT

TH3: ZONE T'STAT

ZV1: ZONE VALVE

ZV2: ZONE VALVE

ZV3: ZONE VALVE

R1: AQUASTAT RELAY - L8148E

GV: GAS VALVE

FIGURE 1.20: WIRING DIAGRAM FOR ZONING WITH ZONE VALVES

TH

TR

GV

N

H

115V

FACTORY WIRING

FIELD WIRING

T1 GAS VALVE

COIL

TO

ADDITIONAL

ZONES

115V

1R-2

2R-2

115V

H

N

TH1

2

T

T

ZR1

X

X

1 3

4

C1

C1: ZONE CIRCULATOR

C2: ZONE CIRCULATOR

TH1: ZONE T'STAT

TH2: ZONE T'STAT

TH2

H1

BOILER CIRCUIT

BLACK

2

T

T

ZR2

X

X

1 3 4

1R-1 2R-1

T2

TH1 T3

H1

115V

ZR1 ZR2

CIRC.

1

CIRC.

2

T1

C2

ZR1: ZONE RELAY (RA832A

OR EQUIVALENT)

ZR2: ZONE RELAY (RA832A

OR EQUIVALENT)

GV

TH TR

WHITE

H1: HI-LIMIT AQUASTAT

GV: GAS VALVE

EXTERNAL CIRCUIT

1R-1, 1R-2: ZR1 CONTACTS

2R-1, 2R-2: ZR2 CONTACTS

T1: 24V TRANSFORMER

T2,T3: TRANSF. (IN RELAYS)

TH2

FIGURE 1.21: WIRING DIAGRAM FOR ZONING WITH CIRCULATORS

14

START-UP & OPERATION

SAFETY CONTROLS

The spill switch, see Figure 2.1, detects the escape of combustion products through the draft hood relief opening and interrupts the power to the gas valve preventing unsafe boiler operation. Escape of flue products could

FIGURE 2.1

be caused by a blocked or collapsed chimney or by inadequate chimney draft.

This is a manual reset-type device and can be reactivated by depressing the spill switch reset button.

SPILL

SWITCH

ROLLOUT

SWITCH

The flame rollout switch, see Figure 2.1, prevents flame rollout from the boiler combustion chamber, caused by blocked boiler flue passageways, 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 manual 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 problem 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 be 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.

2. Make sure boiler combination gas valve is in OFF position. Then, open main gas shutoff valve, allowing gas to flow to boiler.

3. Set thermostat heat anticipator at .8 amp when therm-ostat is controlling boiler directly. When zone controlled, 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

DAMPER POSITION INDICATOR

MUST BE IN VISIBLE LOCATION

FOLLOWING INSTALLATION.

CLOSED

must be in open position when boiler main burner is operating.

In case of a damper malfunction, the damper blade may be manually placed

OPEN

FLOW DIRECTION

FIGURE 2.2

in the full open position to permit burner operation. To accomplish this follow the instructions on the damper.

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 following 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 switch opens, see the information on “Safety

Controls” on this page.

START-UP & 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.

8. Observe pilot and main burner flame, see Figure 2.3.

All burner ports should be ignited and burn with a steady blue flame.

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.

CAUTION: Never leave the job with yellow burning flames. This condition indicates poor combustion and will quickly carbonize the boiler, reducing efficiency 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.

15

Q345A

INTERMITTENT

IGNITION PILOT

MODELS

NORMAL PILOT FLAME

Q314A/Q309A

CONSTANT PILOT

MODELS

NORMAL

(HARD FLAME)

LIFTING

(TOO MUCH AIR)

YELLOW

TIPPING

(MARGINAL)

MAIN BURNER FLAMES

YELLOW

FLAME

(TOO LITTLE AIR)

9. Boilers are shipped from the factory with the primary air shutters on the main burner wide open. It is recommended these air shutters be left in the wide open position unless there is lifting of the flame above the burner ports. If there is lifting, the air shutters should be gradually 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 minutes, check gas input rate to boiler as follows:

FIGURE 2.3

11. If boiler input needs to be corrected, adjust the combination 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. If rated input cannot be obtained with regulator adjustment, gas supply pressure or orifice size may be the cause. Consult your local utility and Hydrotherm.

a. Make sure that all appliances served by the gas meter are turned off during timing of gas input rate to the boiler.

b. Measure the time in seconds that it takes for the boiler 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.

12. The gas burner orifices supplied with the boiler have been carefully designed to provide the correct gas input rate 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.

Example: An HC-125E boiler takes 4 minutes, 54 seconds 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

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.

36,000 x 1020 = 124,898 Btu/hr

294

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.

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, disconnect wire connection to the "PV" terminal on Honeywell 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 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.

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.

1.

STOP! Read the safety information above on this page.

2.

Set the thermostat to lowest setting.

3.

Turn off all electric power to the appliance.

4.

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! Follow "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 central burner tubes behind the base door.

8.

Turn knob on gas control counterclockwise to "Pilot" position.

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 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 immediately 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

INLET

OFF

PILOT

ON

RESET BUTTON

GAS CONTROL KNOB

SHOWN IN "OFF" POSITION

OPERATING INSTRUCTIONS

Intermittent Pilot - Honeywell VR8204

Natural or Propane Gas

1.

STOP! Read the safety information above.

2.

Set the thermostat to lowest setting.

3.

Turn off all electric power to the appliance.

4.

This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.

5.

Turn gas control knob clockwise to "OFF". Do not force.

6.

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 to next step.

7.

Turn gas control knob counterclockwise to "ON".

8.

Turn on all electric power to the appliance.

9. Set thermostat to desired setting.

10. If the appliance will not operate, follow the instructions "To

Turn Off Gas To Boiler" on next page and call your service technician or gas supplier.

INLET

GAS

OFF

ON

GAS CONTROL KNOB

SHOWN IN "OFF" POSITION

17

TO TURN OFF GAS TO BOILER

3. Turn gas control knob clockwise to "OFF" position.

1. Set thermostat to lowest setting.

2. Turn off all eletrical power to the appliance if service is to be performed.

MAINTENANCE

This boiler has been designed to provide years of trouble free performance in normal installations. Examination by the homeowner at the beginning of each heating season, and in mid-heating season, should assure continued good performance. In addition, the boiler should be examined by a qualified service professional at least once every year.

BEFORE EACH HEATING SEASON

1. Remove and inspect draft hood and vent piping connecting 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.

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 combustible 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.

2. Check boiler flue passageways in the boiler sections for any blockage or soot accumulation. Remove draft hood, jacket top 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 temperature silicone adhesive/sealant.

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 on heat transfer surfaces and cause overheating and subsequent failure of cast iron sections.

b. If passageways need cleaning, remove burners as described in paragraph 3 below. Insert long-handle bristle flue brush down between section tubes and upward through sections from combustion chamber in both diagonal directions to remove carbon from finned surfaces.

Vacuum debris. Replace dome and seal with furnace cement or high temperature silicone adhesive/sealant.

WARNING: Do not obstruct the flow of combustion and ventilation air. Failure to comply with this warning can result in carbon monoxide poisoning!

c. Reinstall jacket top panel and draft hood.

NOTE: If boiler is equipped with a low water cutoff, follow manufacturer’s maintenance instructions.

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 burners with soft bristle brush; blow out with air or vacuum.

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.

4. Check gas manifold for proper position and reassemble 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.

FREEZE PROTECTION

Where absolutely necessary, system antifreeze can be utilized. It must be compatible with hydronic heating systems. System must be designed to accommodate necessary changes in heat transfer, pump head, flow rate & expansion. For more information, consult The Hydronics

Institute Technical Topics Number 2A publication.

5. When a low water cut-off has been utilized, follow the manufacturer’s maintenance instructions. As a minimum, 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 labeling on the pump frame.

Note: Never use an RV-type antifreeze protection solution nor an automotive-type antifreeze as damage to the boiler and other system components may result.

18

7. Follow “System Start-Up & Adjustments” procedures in the “Start-up & Operation” section of this manual.

HOW TO CHANGE ORIFICES

1. Shut off power supply and gas supply to the boiler.

2. Remove burner access panel. To remove burners, lift up & to rear until burners are disengaged from orifices.

3. Check orifices for proper drill size. Size is stamped onto the body of the brass orifice. The size can also be checked by using a pin gauge, see Figure 3.1. All orifices are screwed into the manifold and may be removed by using a 5/8” wrench or socket.

4. Reverse above procedures to install orifices & burners. BE SURE TO INSTALL BURNERS WITH BURNER

PORTS ON TOP SURFACE, UPRIGHT.

MODEL

EW-65

EW-85

EW-100

EW-125

EW-145

EW-165

NAT. GAS

DRILL SIZE

2.60MM

32

37

39

35

32

FIGURE 3.1

L.P. GAS

DRILL SIZE

52

49

1.65MM

1.60MM

51

1.85MM

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

EW-85

EW-85

EW-100

EW-100

LP

NG

LP

NG

LP

2

2

2

3

3

52

32

49

37

1.65mm

52

33

50

38

52

53

34

50

39

53

53

35

50

39

53

53

35

51

40

53

53

36

51

41

53

53

36

51

42

53

54

37

52

42

54

54

38

52

43

54

54

40

52

43

54

EW-125

EW-125

EW-145

EW-145

EW-165

EW-165

NG

LP

NG

LP

NG

LP

4

4

4

4

4

4

39 40

1.60mm

1.60mm

35 36

51

32

1.85mm

51

33

50

52

34

50

41

53

36

52

35

50

41

53

37

52

35

51

42

53

37

52

36

51

42

53

38

53

36

51

43

53

39

53

37

52

43

54

40

53

38

52

44

54

41

54

40

52

44

54

42

NO HEAT

1. Blown fuse or circuit breaker.

2. Power switch turned off.

3. Vent damper not open.

4. Circulator not running.

5. Air in lines and radiation.

6. Tripped rollout switch.

7. Tripped spill switch.

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.

TROUBLESHOOTING

OVERHEATING

1. Wrong thermostat anticipator setting.

2. Bad thermostat location.

3. Bad thermostat.

ODOR, EXCESSIVE MOISTURE IN

BUILDING

1. Leak in piping.

2. Carbon build-up in flueways.

3. Blocked chimney.

4. Downdrafts- incorrect termination.

YELLOW FLAME, CARBON

BUILD-UP

1. Unit overfired.

2. Air shutter misadjustment.

3. Wrong orifices.

4. Burning in burner mixing tube.

5. Inadequate combustion air.

6. Inadequate draft (flue blockage).

NOISE

1. Ignition-incorrect air shutter adjustment.

2. Whistle due to burr on orifices.

3. Burner “fluteing” -air shutter opening too wide.

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

19

APPENDIX A

MÉTHOD D' INSTALLATION B: pour le volet motorisé de ventilation.

Danger: Le volet de ventilation doit servir seulement à la chaudière. 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 supérieure du coupe-tirage.

'

`

DE LECOULEMENT POINTE

VERS LE HAUT

2. Fixer le volet de ventilation au coupe-tirage.

ATTACHER LA PARTIE

INFERIEURE DU VOLET

DE VENTILATION AU

COUPE-TIRAGE A LAIDE

DE VIS DE 1/2 po OU PLUS

COURTES OU DES RIVETS

AVEUGLES.

LE MOTEUR SOIT

MONTER LE VOLET

DE VENTILATION

AU-DESSUS DU

COUPE-TIRAGE.

FIGURE 1.12

FIGURE 1.13

3. Brancher le faisceau de fils.

ENFICHER DANS LA PRISE

'

'

MOTEUR DU VOLET DE

VENTILATION.

FAISCEAU DE FILS

DU VOLET DE

VENTILATION.

ENFICHER DANS LA PRISE

MOLEX SUR LE DEVANT

DE LA CHAUDIERE.

FIGURE 1.14

^

LE REGISTRE DOIT ETRE EN

POSITION OUVERTE LORSQUE

^

LE BRULEUR PRINCIPAL EST EN

MARCHE.

CLOS

OUVERTE

SENS DE DEBIT

FIGURE 2.2

20

21

16

17

18

19

12

13

14

15

22

23

24

25

26

27

28

29

30

31

31

Ref # Name of Part

—

1

2

3

4

5

6

7

8

9

10

11

20

21

Jacket Complete

Jacket Complete

Jacket Complete

Jacket Complete

Lower Front Inner Panel

Front Door Panel

Front Door Panel

Front Door Panel

Jacket Side Panel - LH

Jacket Side Panel - LH

Jacket Side Panel - LH

Jacket Top Panel

Jacket Top Panel

Jacket Top Panel

Jacket Rear Panel

Jacket Rear Panel

Jacket Rear Panel

Jacket Side Panel - RH

Jacket Side Panel - RH

Jacket Side Panel - RH

Vent Damper 5" Effikal

Vent Damper 6" Effikal

Vent Damper 7" Effikal

Draft Hood

Draft Hood

Draft Hood

Draft Hood

Spill Switch (Manual Reset) 275° F

Spill Switch (Manual Reset) 250° F

Dome Bracket

Dome 5"

Dome 6"

Dome 7"

Pressure Relief Valve

Vent Fitting

Nipple 3/4 x 9

T Baffles

Pipe Plug 1/2"

Section Top

Section Middle

Section Bottom

Section Bottom

Absorption Unit

Absorption Unit

Absorption Unit

Absorption Unit

Tie Rod

Tie Rod

Tie Rod

Tie Rod Nuts

Tie Bracket

Rear Tie Plate - Insulated

Front Tie Plate Insulated

RH Insulated Side Plate

Bracket - Burner

Bracket - Burner

Base Pan

Front Tie Bar

Burner w/ Pilot Brkt - Nat/LP

Pilot Assy INT Q3451B-1103

Pilot Assy CON Q314A Nat/LP / K16R

Part No. EW-45

BM-9630

BM-9631

BM-9632

BM-9633

03-1519

03-1515

03-1516

03-1517

03-1503

03-1504

03-1505

03-1512

03-1513

03-1514

03-1509

44-1110

44-1111

57-2602

55-2603

BM-3327

BM-3328

BM-3341

03-7132

03-7133

03-4315

03-7873

03-7118

62-3668

BM-8072

01-2102

01-2103

22-1203

56-5430

53-1133

BM-9629

56-4601

BM-9685

BM-9684

BM-9681

BM-9680

BM-3116

BM-3117

BM-3118

BM-3119

44-1109

03-1510

03-1511

03-1500

03-1501

03-1502

02-5869

02-5870

02-5871

03-8140

03-8141

03-8142

03-8145

58-2524

58-2522

55-1404

01-2100

1

1

1

1

1

1

1

1

1

1

2

1

1

2

1

1

2

1

1

1

1

1

1

1

6

2

1

1

1

1

1

1

1

EW-65

1

1

1

1

2

1

1

2

1

2

1

1

1

1

1

1

1

1

1

1

1

2

1

1

6

2

1

1

1

1

1

1

1

2

1

1

6

2

1

1

1

1

1

1

1

2

1

2

1

1

1

1

1

Boiler Model

EW-100 EW-125 EW-145 EW-165

1

1

1

1

1

1

1

1

1

1

1 1

1

1

1

1 1

1

1 1

1 1

1 1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

2

1

1

2

1

2

1

2

1

1

1

1

1

1

2

1

2

1

1

1

1

1

3

1

2

1

1

1

3

1

1

1

1

1

1

1 1

2

1

1

6

2

1

1

1

1

1

1

1

2

6

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

6

2

22

48

49

50

51

44

45

46

47

40

41

42

43

37

37

38

39

Ref # Name of Part

32

33

34

35

36

52

53

54

55

56

57

58

59

—

Pilot Orifice NG

Pilot Orifice LP

Burner Orifice 2.60 mm

Orifice #32 Natural

Orifice #37 Natural

Orifice #39 Natural

Orifice #35 Natural

Orifice #52 LP

Orifice #47 LP

Orifice 1.65 MM LP

Orifice 1.60 MM LP

Orifice #51 LP

Orifice 1.85 MM LP

Manifold

Manifold

Manifold

Pilot Line with Fittings

Gas Valve VR8204H-1006 1/2" Nat

Gas Valve VR8204H-1022 1/2" LP

Gas Valve VR8200H-1129 1/2" Nat

Gas Valve VR8200H-1103 1/2" LP

Burner - Nat/LP

Burner w/Pilot Bracket

RH Manifold Bracket

Base Door Insulated

LH Manifold Bracket

LH Insulated Side Plate

Drain Valve

1-1/4 x 3/4 x 1-1/4 Tee

1-1/4 x 3" Nipple

Taco Circulator Flange

Oval Gasket

Rollout Switch (Manual Reset) 350° F

Junction Box

Transformer 20 VA Basler

Temperature/Pressure Indicator

L4080B-1212 Aquastat w/o well

L8148E Aquastat Relay

Heat Shield (INT only)

Ignition Control S8600F (INT only)

Inner Front Panel

Inner Front Panel

Inner Front Panel

Well 1/2"

Well 1/2"

Push Nipple

1-1/4 x 14" Nipple

1-1/4 x 16" Nipple

1-1/4 x 21-1/2" Nipple

Gasket Circulator Fitting

Taco Pump 007

Stainless Steel Jacket Polish 4 oz.

Part No. EW-45

62-3326

62-3327

25-1141

25-1132

25-1121

25-1125

25-1126

25-1129

25-1127

25-1139

25-1142

25-1124

25-1140

24-1105

24-1106

59-1001

58-2527

58-1800

26-3005

20-1014

02-2702

02-2406

03-3140

BM-8142

03-1506

03-1507

03-1508

02-3415

02-3413

53-1310

53-1264

53-1256

53-1265

59-1019

09-1507

70-3398

24-1107

BM-3395

02-1543

02-1546

02-1540

02-1541

03-7114

03-7118

03-7154

BM-3324

03-7153

BM-3340

51-1201

56-1603

53-1250

09-1921

1

1

2

2

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

EW-65

1

1

2

2

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Boiler Model

EW-100

1

1

EW-125

1

1

EW-145

1

1

EW-165

1

1

4

3

4

4

3

1

1

1

3

1

1

1

1

1

4

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

1

1

1

1

1

4

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

1

1

1

1

1

4

1

1

4

1

1

1

1

1

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

23

260 NORTH ELM STREET

WESTFIELD, MA 01085

(413) 564-5515 • FAX: (413) 568-9613

5211 CREEKBANK ROAD

MISSISSAUGA, ONT., CANADA L4W 1R3

(905) 625-2991 • FAX (905) 625-6610