Table of Contents
Advertisement
Quick Links
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.
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
Introduction..............................................
Step 1: Locating & Setting Boiler.............
Step 3: Venting Boiler............................... 8
Step 4: Installing/Testing Gas Piping........ 10
Step 5: Wiring Boiler................................ 12
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
EW2-1203
42-9510
2
4
5
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for HydroTherm EW2-1203
Summary of Contents for HydroTherm EW2-1203
-
Page 1: Table Of Contents
EW2-1203 42-9510 MODEL EW SERIES INSTALLATION, OPERATION & MAINTENANCE MANUAL Gas-Fired Water Cast Iron Boilers 65,000 to 165,000 Btuh Input BOILER INSTALLATION WARNING: If the information in this manual is not Introduction..........followed exactly, a fire or explosion may result causing Step 1: Locating &... -
Page 2: Introduction
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 proxim- ité... - Page 3 ANSI/ASME CODE COMPLIANCE: Installation must WARNING: Installers must follow local regulations conform to requirements of authority having jurisdiction with respect to the installation of CO detectors and or, in absence of such requirements, to National Fuel follow the manufacturer's stated maintenance Gas Code ANSI Z223.1-latest edition and to National schedule for this boiler! Electric Code NFPA-70-latest edition.
-
Page 4: Boiler Installation
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. If boiler is installed in a confined space, a space WARNING: This boiler must be supplied with with a volume of less than 50 cubic feet per 1000... -
Page 5: Step 2: Installing/Purging Water Piping
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 &... - Page 6 SYSTEM BYPASS PUMPED BLEND For systems using a circulator on the return as either a An additional circulator can also be used to provide a single zone, or multiple zones with zone valves, install a return water temperature blend. This method works well with systems with multiple zones with circulators (see system bypass line between the supply and return on the suction side of the circulator (see Fig 1.5).
- Page 7 PROCEDURE C: For combination heating and cooling installations only. NOTE: VALVES "H" OPENED ON HEATING WITH "C" VALVES If a hot water boiler is installed in connection with a CLOSED REVERSE PROCEDURE ON COOLING. water chiller, the chilled water must be piped in paral- EXP.
-
Page 8: Step 3: Venting Boiler
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. - Page 9 1. Seal all unused openings in common vent- PROCEDURE C: Install flue pipe between vent damper and ing system. chimney. A 6" minimum clearance is required 2. Visually inspect the venting system for between flue pipe and all combustible con- proper size and horizontal pitch and deter- struction.
-
Page 10: Step 4: Installing/Testing Gas Piping
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. -
Page 11: Wiring The Boiler
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. -
Page 12: Step 5: Wiring Boiler
OPERATING SEQUENCE OPERATING SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT FOR BOILERS EQUIPPED WITH VENT DAMPER VENT DAMPER AND HI-LIMIT STANDING PILOT AND L48148E MOTOR DRIVES VENT DAMPER TO CLOSED POSITION AND MOTOR DRIVES VENT DAMPER TO CLOSED POSITION AND REMAINS CLOSED DURING STANDBY. - Page 13 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.
- Page 14 115V TO CIRC. 115V T2: 24V TRANSF. ZV1: ZONE VALVE R1: AQUASTAT RELAY - L8148E TH1: ZONE T'STAT ZV2: ZONE VALVE GV: GAS VALVE TH2: ZONE T'STAT ZV3: ZONE VALVE TH3: ZONE T'STAT FIGURE 1.20: WIRING DIAGRAM FOR ZONING WITH ZONE VALVES FACTORY WIRING GAS VALVE FIELD WIRING...
-
Page 15: Start-Up & Operation
START-UP & OPERATION SAFETY CONTROLS 2. Make sure boiler combination gas valve is in OFF The spill switch, see Figure 2.1, detects the escape of position. Then, open main gas shutoff valve, allowing combustion products through the draft hood relief open- gas to flow to boiler. - Page 16 If this is b. Measure the time in seconds that it takes for the boil- the case, the local utility or Hydrotherm may recommend er to use10 cubic feet of gas. Divide 36,000 by the the orifices be changed.
- Page 17 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. B. Use only your hand to turn the gas control knob. Never use Be sure to smell next to the floor because some gas is heavier tools.
-
Page 18: Water Treatment
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 trou- BEFORE EACH HEATING SEASON ble free performance in normal installations. -
Page 19: How To Change Orifices
HOW TO CHANGE ORIFICES NAT. GAS L.P. GAS 1. Shut off power supply and gas supply to the boiler. MODEL DRILL SIZE DRILL SIZE 2.60MM EW-65 2. Remove burner access panel. To remove burners, lift EW-85 up & to rear until burners are disengaged from orifices. EW-100 1.65MM 3. - Page 20 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.
- Page 22 Boiler Model Ref # Name of Part Part No. EW-45 EW-65 EW-100 EW-125 EW-145 EW-165 — Jacket Complete BM-9630 Jacket Complete BM-9631 Jacket Complete BM-9632 Jacket Complete BM-9633 Lower Front Inner Panel 03-1519 Front Door Panel 03-1515 Front Door Panel 03-1516 Front Door Panel 03-1517...
- Page 23 Boiler Model Ref # Name of Part Part No. EW-45 EW-65 EW-100 EW-125 EW-145 EW-165 Pilot Orifice NG 62-3326 Pilot Orifice LP 62-3327 Burner Orifice 2.60 mm 25-1141 Orifice #32 Natural 25-1132 Orifice #37 Natural 25-1121 Orifice #39 Natural 25-1125 Orifice #35 Natural 25-1126 Orifice #52 LP...
- Page 24 5211 CREEKBANK ROAD 260 NORTH ELM STREET WESTFIELD, MA 01085 MISSISSAUGA, ONT., CANADA L4W 1R3 (905) 625-2991 • FAX (905) 625-6610 (413) 564-5515 • FAX: (413) 568-9613...
Need help?
Do you have a question about the EW2-1203 and is the answer not in the manual?
Questions and answers