Electro industries Eb-ms-10 Manual

03/19/2009 BI508

ELECTRO-BOILER

Midsize

INSTALLATION & OPERATING INSTRUCTIONS

Model EB-MS-10

EB-MS-15

EB-MS-20

APPLICATION: This Electro-Boiler series is factory equipped with outlet temperature sensing and

a smart controller which automatically stages the various elements to operate at

the field preset outlet temperature.

Temperature sensing can reduce overheat conditions (example, zones); however,

if it is a mixture of large and small zones, the sudden capacity and flow changes

may cause some internal timing/over temp conditions. With the mixture of zones

the zone controller ZEA-* option is highly recommended (see page 2).

Generally, this series should be used with lower temperature, radiant floor.

Temperature dial position 6 (160°) is the recommended highest value for the type

of staging represented by this model series. The fully modulating series (EB-

MA-** or EB-MO-**) can operate much closer to the mechanical hi-limit and

show a dial position 7 or 180°. Also see page 10 and page 2.

ACCESSORIES: Attached BL001 lists various accessory or option items which are not part of

basic Electro-Boiler. Also page 3 has additional information on slab stat.

Note: This product meets the requirements of the ASME Boiler and Pressure

Vessel Code.

Drawings: BX505

BX504

BH509

BS509

BL001

XX017

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TABLE OF CONTENTS

Description Page

Introduction 1

System or Water Flow 2

Multiple Zones & Radiant Temperatures 2

Zone Controller 2

Room Thermostat Placement 3

Two-Temperature Operation or Feature 3

Multiple Boilers 4

Boiler/Plumbing Kit Placement 4

Installation Requirements 4

Mechanical Installation

Under-Floor Radiant 6

Dual Heat 7

Electrical Hookup 8

Water Fill Procedure 9

Controller Setup 10

Operational Tips 10

Standby Switchover, SOT Timer 11

Replacement Parts List 12

Troubleshooting/Repair Helps 13

Sequence 13

Drawings:

Piping, Install Kits BX505

Plumbing, Dual Boilers BX504

Hookup BH509

Internal Wiring Schematic BS509

Boiler Accessories BL001

Warranty XX017

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INTRODUCTION

With this temperature sensing controller capability, the electric heating element stages are automatically

turned on and off to establish a fixed outlet water temperature. This outlet temperature is sensed at the

outlet pipe, the controller regulates four stages, and attempts to control the water temperature at a value

determined by the setup arrangements. Field setting the outlet temperature at the design or realistic

temperature is required.

Even though this temperature sensing series adjusts outlet temperature independent of water flow and

prevents high limiting; it is still very important that the hydronic system be correctly designed for the

building, the total heat loss requirement, and proper hydronics design and installation practices. This

boiler is the energy source for the water flow and radiation system. If the water flow and radiation

systems are not adequate for the Btuh heat loss of the building, installing the Electro-Boiler with this

temperature control feature will not necessarily supply the comfort and heating for the building.

Control and operate as a “cold boiler” concept. Do not, under any circumstances, simply jumper R and W

and allow the temperature sensing controller to operate this Electro-Boiler as a “hot boiler”. Unless there

is at least 2 GPM flow, the staging delays will cause temperature overshoot and could open up the manual

reset limits.

Standby boiler wiring arrangement is optional, order standby kit EB-S-SB.

In most dual heat installations (with standby kit EB-S-SB) this Electro-Boiler is plumbed in series with

an existing oil, gas, or wood boiler. For gas or oil, the Electro-Boiler is generally at the gas/oil outlet; but

for wood, the Electro-Boiler must be on the inlet sides. The standby boiler cannot be operated as “hot

boiler”. This will defeat the Electro-Boiler. Rewire as required, standby boiler is turned on from the

brown wires.

In the case of existing fossil fuel boiler conversions, it is assumed the expansion tank, valving, air

bleeder, and circulation pump are in place, in good operating condition, and adequate for the overall

system design.

In the case of new installation, use standard hydronics water heating practices with the necessary

expansion tank, air bleeder, valving, water pump, etc., sized for the total capacity of the system. The

Electro-Boiler is turned on with an “R and W” closure from the zone system wiring.

208 Volt application – the elements within the standard product are rated a 240 volts. If operating at

208, there will be approximately 25% reduced capacity. The internal transformer may or may not

adequately operate the control system from a 208 source. Voltage measurements between “R” and “C”

must be 22VAC or greater when the system is in the complete operational mode. True 3-phase, 208-volt,

models are available in the WarmFlo series. Contact factory, models EB-WO-13-2 and EB-WO-27-2.

In the case of under floor radiant heating, the basic components for the electric energy, heating system

typically includes:

1. Electric boiler itself – covered by this manual.

2. Plumbing kit or piping material at the boiler itself – can be ordered as a kit.

EB-PK-M – shown on plumbing installation drawing BX505.

3. Circulating pump – typically sized for head pressure and system flow requirement, typical catalog

number 5586/5582.

4. The under floor circulating tubes and manifolds – provided and manufactured by others, not covered in

this manual.

APPROVED TUBING/PIPING

When plumbing this boiler and its peripheral parts to the loop system, all plumbing parts and/or tubing

must be sealed to prevent entrance of oxygen.

Use only tubing or polyethylene tubing with oxygen Diffusion Barrier.

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SYSTEM OR WATER FLOW

In order to prevent hi-limiting and assure full 20+ years parts life, the piping system/basic

plumbing/circulator pump must be arranged to provide flow greater than minimum GPM shown in Table

1. If zoned system, this applies when the smallest zone is operating.

TABLE 1 - ELECTRO-BOILER SPECIFICATION

240 volts, 60 Hz, single phase

Model Btuh Rating Amp Stages GPM

EB-MS-10 34,000 10 kW 42A 2 2-4

EB-MS-15 51,000 15 kW 63A 3 2-6

EB-MS-20 68,000 20 kW 83A 4 2-8

MULTIPLE ZONES AND RADIANT TEMPERATURES

Same water temperature all zones – in this case the system can be setup as one pump with the water

circulated through the boiler and directly to a manifold containing the various zone valves. Although this

model series has a built-in outlet sensing and controller mechanism for staging the elements, also consider

the next section, Zone Controller. If not using zone controller, the end switches of all of the zone valves

are paralleled and directly control R and W to turn on the boiler.

Various water temperature requirements – if this is the case, a primary loop with mixing valve for the

various zone temperature requirements is necessary. Injection pump techniques can also be used.

However, usually injection pump techniques come with a controller which is designed to protect a gas

boiler from cool water return. This is simply not needed and a duplication with the temp. sensing

controller within this Electro-boiler and the injection pump controller will be of no benefit within the

operating system. The zone valve/zone pump control strategy must be wired to provide the boiler “R and

W” contact closure and the primary pump is connected to the boiler pump contacts. This assures the

primary pump is active and running whenever the boiler is turned on via contact closure on “R and W”.

At least one zone must be open before turning on the primary pump/Electro-Boiler. Do not design a

system where the Electro-Boiler is supposed to operate as a “hot boiler” based upon its outlet sensor

without the primary pump circulating water, minimum 2 GPM is required.

New, improved feature – the EB-ZEA Series zone controller priority zone now has the ability to

communicate with this boiler and it will automatically switch to a low mass high water temperature (150

or 180) during zone 1, priority switch on, operation. With this feature the TS boiler can automatically

take care of two temperature requirements thus eliminating the need for the technique described in the

paragraph above.

ZONE CONTROLLER

This EB-MS series boiler controls the electric elements based upon water temperature independent of

flow; therefore, in theory, a staging zone controller is not required; however, there are three suggestions

or reasons why a zone controller can simplify the installation and enhance overall performance.

1. Zone wiring and troubleshooting convenience – the addition of the zone board allows for easy terminal

block and point to point wiring for each zone thermostat and each zone valve. Also there are LED’s

associated with the thermostat action and the zone valve action. This greatly simplifies wiring and future

troubleshooting with a neat terminal block wiring arrangement and the onboard LED’s – order EB-ZEA-1.

2. Prevents over control or false staging up and down when the temperature sensors are attempting to

regulate – since Electro Industries’ zone controller also has staging “smarts”, the addition of the zone

controller will provide smoother boiler temperature control. The zone board has a dial switch for each

zone and the installer selects one of four zone capacity sizes. When dialing in the size closest to the zone

Btu/h capacity, the zone controller “smarts” only allows the appropriate boiler stage which can handle that

capacity. Also this is additive if more than one zone calls at any one time.

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3. Two temperature system with unbalanced zones – if the application includes zone one requiring high

temperature and the remaining zones are radiant floor low temperature, this zone controller will

automatically raise the output of the high temperature zone. This is a priority arrangement, zone 1 holds

off the other zones while the high temperature output is heating. If at the end of the high temperature zone

there is a call on any of the low temperature zones (up to three plus slave 4), there will be a pump only

function until the outlet temperature drops below the front panel dial setting.

ZONE CIRCULATORS

The EE-5051 switching relay can be used to interface line voltage pumps with the boiler R and W control

terminals, see drawing BH008. However, when using zone controller EB-ZEA-1, these are not required.

ROOM THERMOSTAT PLACEMENT

Floor radiant – comfort and proper space heating response is a direct relationship to the thermostat type

and the placement of the thermostat sensing bulb. Typically an under floor heating system can be broken

down into two categories.

A. Energy storage, water tubing is under the concrete or within the sand base

– the controlling thermostat must have a remote bulb, and this remote bulb must

sense the concrete slab temperature (slab stat). Coordinated with the concrete

pour, install a ¾” PVC, minimum bend radius of 7 inches, and locate at

approximately center (vertical) of the concrete slab. The thermostat sensing

bulb can later be pushed down this PVC conduit. If the slab is already poured

without conduit for slab stat, use electronic remote sensing thermostat such as

Electro Industries’ ES-24-BR. These devices only require a ¼” hole drilled in

the floor at some convenient location (preferably off a center wall, not within 2

feet of outside wall).

B. Floor covering, medium to high insulation – use slab stat as described in paragraph A above.

C. Quick response, hydronic tubing just under the concrete surface, no flooring material over the

concrete – in this case, heated water can directly radiate into the room, a standard wall mount room

thermostat is adequate. Mount room thermostat on an inside wall similar to most heating systems.

TWO-TEMPERATURE OPERATION OR FEATURE

When using Electro’s zone controller in priority mode,

the boiler system can automatically raise the outlet

temperature with zone 1 calling. This is setup for default

of 150° (for this EB-MS series do not recommended the

high temperature 176° selection). See appropriate zone

controller installation manual for details.

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MULTIPLE BOILERS

This boiler series now includes a method for automatically staging any

number of parallel-plumbed boilers. Order plug-in relay EB-C-STG5.

The thermostat is connected only to the first boiler, when all stages are

on for more than 5 minutes, this new plug-in relay module turns on the

next boiler (R and W), and a second EB-C-STG5 could be used to turn

on the third, etc.

BOILER/PLUMBING KIT PLACEMENT

This model series is wall hung and the vessel must be vertical, drawing BX505.

The plumbing kit items are located adjacent to the boiler housing itself as shown on drawing BX505.

For future servicing, the unit itself must be installed 20” or more above the floor, the elements are

screwed in from the bottom.

INFORMATION/WATER FLOW CALCULATIONS

Water flow, GPM, can easily be calculated if the temperature rise across the electric boiler can be

measured.

The formula below can only be used when the temperature rise is stable and the boiler is not hi-limiting.

In other words, verify constant current draw and stable outlet temperatures for at least 15 minutes.

GPM = Volts x Amps x 3.4

500 x Temp. rise

INSTALLATION REQUIREMENTS

1. All installation work must be performed by trained, qualified contractors or technicians. Electro

Industries, Inc., sponsors installation and service schools to assist the installer. Visit our web site at

electromn.com for upcoming service schools.

WARNING

ALL ELECTRICAL WIRING MUST BE IN ACCORDANCE WITH NATIONAL ELECTRIC CODE

AND LOCAL ELECTRIC CODES, ORDINANCES, AND REGULATIONS.

WARNING

OBSERVE ELECTRIC POLARITY AND WIRING COLORS. FAILURE TO OBSERVE COULD

CAUSE ELECTRIC SHOCK AND/OR DAMAGE TO THE EQUIPMENT.

CAUTION

This unit can only be used for its intended design as described in this manual. Any internal

wiring changes, modifications to the circuit board, modifications or bypass of any controls, or

installation practices not according to the details of this manual will void the product warranty,

the CSA/us certification label, and manufacturer product liability. Electro Industries, Inc.,

cannot be held responsible for field modifications, incorrect installations, and conditions which

may bypass or compromise the built-in safety features and controls.

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2. This installation manual and Electro-Boiler products relate only to the addition of the Electro-Boiler

to the hydronics system. The owner/ installer assumes all responsibility and/or liability associated

with any needed installation of the gas/oil boiler, pump, plumbing, system design, hydronics systems

or backup gas/oil boiler, etc. Any instructions or comments made within this manual (or factory

phone assistance) relating to the gas/oil furnace are provided as comments of assistance and “helps”

only.

CAUTION

Hazards or unsafe practices could result in property damage, product damage, severe personal

injury and/or death.

3. Remember, safety is the installer’s responsibility and the installer must know this product well

enough to instruct the end user on its safe use.

Safety is a matter of common sense - - a matter of thinking before acting. Professional installers have

training and experienced practices for handling electrical, sheet metal, and material handling

processes. Use them.

CLEARANCES

MINIMUM CLEARANCE FROM

COMBUSTIBLE SURFACES SUGGESTED MINIMUM

SERVICE CLEARANCE

BACK 0 INCH 0 MM 0 INCH 0 MM

LEFT 1 INCH 25 MM 12 INCHES 305 MM

RIGHT 1 INCH 25 MM 6 INCHES 152 MM

FRONT 1 INCH 25 MM 24 INCHES 610 MM

TOP 1 INCH 25 MM 24 INCHES 610 MM

BOTTOM REQUIRED CLEARANCE – 18 INCHES/457 MM

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MECHANICAL INSTALLATION – UNDER-FLOOR RADIATION

CAUTION

Electro Industries Inc. requires the use of dielectric isolation between the boiler vessel supply

and return piping when the boiler is plumbed using copper or any other dissimilar metal.

Damage to the vessel caused by galvanic corrosion voids Electro Industries’ warranty.

Reference drawing BX505

1. With the typical radiant floor system, a dual heat backup boiler is uncommon. If a backup boiler is

required, please reference “Mechanical Installation – Dual Heat” section.

2. Unpack the Electro-Boiler, the safety relief and pipe fittings are packed within a small carton. The

safety relief is plumbed to the ¾” bushing as shown on BX505.

3. The Electro-Boiler must be positioned with the vessel vertical. The water IN/OUT ports must be at

the top. The unit will not function properly with the vessel in a horizontal position.

NOTE: Mount at least 20 inches above the floor to allow element removal and service at the bottom.

4. The plumbing components and plumbing layout shown on drawing BX505 have been very carefully

chosen and should be plumbed as shown. When following this diagram, the water fill procedure

becomes very simple and almost guarantees the removal of all air or prevents air locking problems.

Experienced hydronic heating installers may be able to eliminate some components but the inclusion

of these components guarantees installation and initial operating success.

5. The vessel is factory constructed with an “air trap” chamber at the top of the vessel, connected to the

1” pipe and arrangement shown on BX505.

6. The key mechanical components required include:

Expansion Tank – as a closed loop hydronic heating system, a minimal expansion tank is

required. This can be an air diaphragm tank as provided in the plumbing kit or a basic

“empty” tank where air is compressed at the tank top.

Inlet Temperature Gauge – recommended to observe the operation of the system.

Air Vent – install with the pressure relief valve as shown on drawing.

Inline Air separator – this can be installed ahead of the pump with the expansion tank

moved to this point. However, the vessel designed air trap and the piping arrangement

leading to the air bleeder.

Pressure Safety Valve – this is required and is furnished as a loose component with the

boiler unit itself. Failure to install the provided, 30 PSI, pressure relief valve as shown void

warranty and the CSA product listing. During purging there is a requirement to bleed out the

initial air within this ¾” pipe leg by manually holding open the relief valve. Add the

necessary pipe extension to the relief valve to prevent water damage on this unit or

surrounding area.

Gate Valve/Drain Valve – these are for servicing and easy fill purposes.

Circulating Pump – depending upon system lift and system loop resistance, the proper

circulating pump is required to guarantee the minimum GPM flow as specified in Table I,

page 1.

Comment: Circulator pump can be in the outlet or inlet. Newer, higher quality pumps seem to

work better in the “supply” line, plus pumping away from the expansion tank is preferred.

7. To ensure safe boiler operation adequate system pressure must be maintained. Some expansion tanks

may have an integral regulator and “port” for water source hookup.

8. Depending upon water conditions, determine whether water additives are necessary.

9. Purge and fill water system. Do not allow the electric element to come on until the system is purged

and you have verified proper water circulation. If the pump is needed, jumper the two orange wires

in order to operate the pump directly from its own 120 volt source.

10. Purge each loop individually, one at a time.

11. Check for leaks.

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MECHANICAL INSTALLATION – DUAL HEAT

CAUTION

Electro Industries Inc. requires the use of dielectric isolation between the boiler vessel supply

and return piping when the boiler is plumbed using copper or any other dissimilar metal.

Damage to the vessel caused by galvanic corrosion voids Electro Industries’ warranty.

Reference drawings BX504

1. Unpack the Electro-Boiler. The safety relief and pipe fittings are packed within a small carton.

2. In most dual heat installations this Electro-Boiler is plumbed in series with an existing oil, gas, or

wood boiler. For gas or oil, the Electro-Boiler is at the gas/oil outlet; but for wood, the Electro-Boiler

must be on the inlet sides. The standby boiler cannot be operated as “hot boiler”. This will defeat the

Electro-Boiler. Rewire as required, standby boiler is turned on from the brown wires.

COMMENT: For this series boiler the control is part of an optional plug-in package, EB-S-SB.

3. Standard hydronic hot water heating practices apply. This procedure assumes adequate piping size to

meet the flow requirements of the specific boiler model, expansion tank, pump, zones, etc. are

properly designed and installed.

4. The Electro-Boiler must be positioned with the vessel vertical. The water IN/OUT ports must be at

the top. The unit will not function properly with the vessel in a horizontal position.

NOTE: Mount at least 20 inches above the floor to allow element removal and service at the bottom.

5. Typically this unit is wall hung next to the existing boiler.

6. Use the 1” pipe fittings to install the safety relief valve and air vent. Add the necessary piping to the

safety relief valve so that water damages do not occur in the surrounding area.

7. Connect the “hot” water line from the fossil fuel boiler to the Electro-Boiler "inlet". Connect the

Electro-Boiler "outlet" to the main feed line. When facing the Electro-Boiler vessel, the "outlet" is on

the LEFT.

NOTE: Wood applications, plumb so electric feeds the wood boilers.

10. If piping contains any "U" bend, an air vent may be required at the top.

11. When possible, isolating ball valves are recommended for easy servicing.

12. To ensure safe boiler operation and prevent element damage, the system should contain a pressure

regulator and an automatic water fill valve. Expansion tank may have an integral regulator and “port”

for water source hookup.

13. Depending upon water conditions, determine whether water additives are necessary.

14. Purge and fill water system. Do not allow the electric element to come on until the system is purged

and you have verified proper water circulation. If the pump is needed, short out the two orange wires

in order to operate the pump directly from its own 120 volt source.

15. Check for leaks.

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ELECTRICAL HOOKUP

Reference drawing BH509

1. 240 Volt Heating Power – route and install the proper current carrying conductors from service

panel fuse or circuit breaker. See page 2 Specification Table and/or product nameplate for ratings.

These models contain built-in circuit breakers and meet the requirement for local disconnect for

appliances greater than 10 kW. Connection is at the circuit breaker terminals. If using single feed

method, single feed bus – order part number 5701.

Only copper wire is allowed.

CB1 is highest priority stage.

2. Grounding – copper conductor is required, size per NEC code relating to the current of each feed.

3. Circulating Pump – the two orange wires connected to a relay on the control board represent a

switch closure (10-amp maximum) to operate an external circulating pump motor. Voltage for the

pump must come from a separate source.

The pump is controlled as a direct function of the R and W input.

If this is connected with a standby boiler, generally the assumption is series plumbing with

the single pump. In this case, the R and W function will operate the pump whether in electric

or standby mode.

If a standby boiler installation has parallel plumbing with two pumps, field wiring and

controls will be necessary to properly operate (and typically check valve isolate) the standby

boiler self-contained pump from the system pump controlled by these two terminal screws.

4. Operating Thermostat – two types can be used. Connection is at the control board bottom.

Standard Mechanical – connect to “R” and “W”, bottom right. Set thermostat internal heat

anticipator to 0.2.

Electro-Stat – (ES-24-BR) 3 wire connection required.

R to R, W to W, C to common

The Electro-Stat remote sensor can be extended as required. This is a three wire cable,

cut and splice, up to 50 feet. Use only stranded wire, shielded cable is not required.

Comment: If zone valve or zone pumps see appropriate sections.

5. Load Management Interrupt Control – this Electro-Boiler series has been pre-wired and designed

for an external utility load management receiver connection. The control board lower left terminal

block marked BLU and BLU/WHT represent the two contact points, extend these wires to the utility

load control device.

As shipped, this unit is only equipped for off-peak = N.C. logic. If reversed logic is required, contact

the factory for modification.

Optional – if load management is not used, simply keep the two blue wires shorted.

Optional – if the power company disconnects 240V for load control, please reference BH029

for special wiring requirements.

6. Zone Valves or Zone Pumps – see page 2 for zone controller options.

WARNING: The end switches from the zone valves must be an isolated contact with no voltage

present on these wires or screw terminals. This is very important to make sure there isn’t any

interference or feedback between the transformer operating the zone valve system and the transformer

within this Electro-Boiler product. Once this has been determined, all end switches are simply

paralleled with the two wires going to “R” and “W”.

7. If this is a dual heat application with standby boiler, optional kit EB-S-SB contains its own wiring

instructions.

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8. Remote Display – an optional remote display (4-wire stat cable) can be added, call factory for

details. Also requires main board upgrade, @EBSTW5623.

WATER ADDITIVES

1. Unless the source water is unusually poor and/or rust elements, additives are not required. It is

recommended the water source as shown on drawing BX505 comes through the household water

softener or use distilled water.

2. Impurities within a closed loop hydronics boiler are considerably less damaging than the typical

domestic water heater. In a closed loop electric boiler, the water impurities “boil out” and the

system essentially makes its own pure water. As a closed system, this “pure water” becomes the

operating mode. In the case of domestic water tank, there is always new water entering with new

impurities.

3. However, if additives are required, use the recommendations and source from your local

professional plumber, specializing in hydronics heating systems.

WATER FILL PROCEDURE

The following procedure applies to non-glycol or antifreeze and prepackaged plumbing kit and/or when

the system is plumbed exactly as shown on drawing BX505.

Caution: If the building supply pressure is connected directly to supply water ball valve without

pressure reducing regulator, user needs to make sure the pressure within the boiler loop does not

exceed 30 PSI. Careful control of the supply water ball valve opening can take care of this. Also at

steps 6 and 10, use caution to make sure the building water supply pressure does not “spike” the

system.

1. Connect the temporary household water supply source (probably hose connection) to the "water

supply connection" input.

NOTE: If water supply connection is permanent, some local building codes may

require special anti-siphon check valve, RPZ, or equivalent between the boiler fill

regulator and the domestic water source or the city water connection.

2. Connect a drain hose to hose bib, "drain valve".

3. Open "drain valve" and close "inlet gate valve" (between drain valve and boiler inlet).

4. Verify “top gate valve” is open.

5. Do not apply 240 heating power during water fill sequence.

6. Open “water supply valve” and open household water supply source.

7. Allow system to circulate, discharging through drain valve, for at least 15 minutes.

8. Put your ear against the metal pipe and listen for air bubbles. If the water flow is consistent and

quiet, the system is probably purged and water filled.

9. Close the "drain valve". Open the "inlet gate valve".

10. The cold system pressure at the gauge should be approximately 10 to 14 PSI.

11. Close “water supply valve” and disconnect water supply.

12. Optional – energize circulating pump during this fill operation. The water pressure from the

household system and as plumbed should typically flow through the circulating pump without the

pump running.

COMMENT: Purge one loop at a time.

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CONTROLLER SETUP

Temperature set point – the front red “knob” allows for field or user setting of the outlet water

temperature. The built-in sensor and controller will attempt to regulate the electric element stages around

this set temperature. The smallest staging increment is 5 kW; therefore, there will some fluctuation

around this set point. Field setting the outlet temperature at the design or realistic temperature required

by the radiation is more efficient.

The front panel allows selection of the operating temperature. The table below should coincide with the

decal on the front panel.

Circulator pump mode – as factory set, the circulator pump is controlled directly from the “W” input

terminal. In this setup the circulator pump continues during load control interrupt (or optional remote

standby switch). There is a provision within the controller board (inside) to allow the circulator pump to

not operate during load control interrupt.

On the inside control board, just above the two bottom

terminal blocks, is a small pin jumper arrangement. The

black “device” sets up the pump mode. Just below this pin

jumper arrangement are W and L lettering. When the two

pin shorting device is in the W position, the pump is a

direct function of R to W input. When the two pin jumper

is in the L position, the pump is interrupted during a load

control.

WARNING: This shorting device must be in one of the two positions for the circulator pump to properly

operate.

OPERATIONAL TIPS

Normal/Standby Switch

If this system does not have a standby operating (gas or oil) boiler, this switch must always be in

the “normal” position.

To activate standby boiler, simply position front panel switch to “standby”.

Heating Cycle

1. External R to W contact closure.

2. Assume the load control receiver device (or remote option standby switch) is in the off-peak or

non-interrupt mode. This is verified by the front panel amber LED being illuminated.

3. Circulator pump starts.

4. 30-second plus delay before staging lights or element relays close. This delay allows the pump to

circulate the system water past the outlet water temperature sensor and allows the controller logic

to determine how many elements to energize. If the water temperature is greater than the set

point, elements will not come on.

Monitor Lights, Front Panel

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HI-LIMIT, red – this will only illuminate when the vessel hi-limit opens due to excessive high

water temperature. This hi-limit is self resetting.

PWR ON, green – basically this is illuminated at all times. It represents 24-volt power source,

good fuse, controller logic is operational, and a good outlet sensor. If the outlet sensor is

inoperative, incorrectly wired, or malfunctioning; this green monitor LED will be in the blinking

or pulsing mode (see page 11).

EL MODE, amber – when illuminated the system is in the electric mode. If it is not illuminated

the utility load control receiver is in the interrupt or on-peak mode. If there is an optional or

remote standby switch, the status of the standby switch is also monitored by this amber LED.

HEAT ON, red – indicates a remote switch closure (t-stat or zoning end switch) is closed between

terminals R and W.

Inside Controller Board

STAGES, red – these four LED’s indicate which electric element stages are on and active.

Manual Reset, Hi-Limit

At the top of the vessel there will be either two or three surface mount hi-limits preset at 205° F. There is

no light indicator associated with these safety hi-limits. Also these 205° F safety limits break the L2

current carrying 240-volt wire going to the elements. Reset involves locating a small shiny lever or metal

tab protruding on the side of the black safety limit base. This small tab is pressed inward approximately

1/8” to “snap in” the contacts.

Safety caution – the wires and screws have 240-volt potential and can be dangerous. Turn off

circuit breakers before investigating or attempting to reset the 205° F safety limits.

Internal Fuse

The fuse on the controller board protects the transformer secondary, external items connected to “R”, and

the circuit board itself. Replace with 2-amp fast blow, AGC2 or equivalent.

Stat Heat Anticipator - If it is a mechanical stat, verify heat anticipator has been set at Ø.2 (non-zone

system).

System Pressure

The side press/temp. gauge should be at approximately 10 to 16 PSI at room temperature water and

should not rise more than approximately 4 PSI at the operating or hot water temperature. If the pressure

change is more than approximately 4 PSI, the expansion tank is too small or there is a problem with the

expansion tank piping, expansion tank itself.

Cold slab, outdoor reset and temperature sensing prevent full boiler on – by adding a temporary

jumper between the lower W screw terminal and the upper left “E” tab, all temperature sensing functions

are bypassed and the control board will step in all the stages. Caution: This jumper shall not be a

permanent function, jumper needs to be removed after slab is approaching normal temperature.

Standby Switchover, SOT Timer

This plug-in option device allows a selection from 40 to 80 minute thermostat operating time for

automatic switchover to standby boiler. Order part number SOT-1.

03/19/2009 12 BI508

REPLACEMENT PARTS

WFSB Outlet sensor, 3 ft.

EB5623S Controller, temp. sensing

UFUSE0440 2-amp fuse, fast blow (AGC2)

5127 Heating relay

5535 Safety hi-limit, manual, 205°

5537 First hi-limit, auto-reset, 185°

5453 Relief valve, 30 PSIG

5456A Gauge press/temp.

5652 60A SQ D circuit breaker

5650 30A SQ D circuit breaker

EB5526 Electric element, 240, 5 kW

5541 Transformer, 24V, 40VA

03/19/2009 13 BI508

TROUBLESHOOTING/REPAIR HELPS

1. This temp. sensing controller contains several interference suppression components, but as an

electronic logic product, unpredictable and unusual transients or interference may sometimes cause

strange results. If the temp. sensing controller is “acting strange”, one immediate step would be

power down reset. Simply turn off boiler power or breaker number 1, when the green LED goes out,

count to 10, and re-energize power supply.

2. Inoperative temperature sensor, if the internal program can detect a bad sensor (shorted, open wire,

etc. – not necessarily bad value) the front panel green LED will be pulsing. In this condition there

should be two short blinks every second.

3. The temperature sensor can be further evaluated with diagnostic program from standard PC or WF

Analyzer software. This includes the ability to “fool” the sensor or set in an offset for various

troubleshooting purposes. This software disk comes with a special cable needed for PC or Palm

hookup.

-WF-ANZ* – Handheld/Analyzer

-ET-SOFT-TS – PC software disk and cable

4. The terminal blocks for control wire hook-up are designed for a wire insertion and screw clamp

down. If there is no wire connected and the screw is loose, the screw may not necessarily make a

good electrical contact to the inside components. Example - If you are jumpering the thermostat

terminals without thermostat wire connection or if you are attempting to measure voltage on the

screw head, you may get erroneous or unpredictable results if the screw is not tightened down.

5. Temperature sensing bypass – the inside control board, left side, contains a “E” tab which can be

used to directly step in the heating stages and in essence bypass the temperature sensing and control

functions. The “E” tab has the highest priority and overrides all temperature sensor functions. In

other words, when jumpering from W to E all four stages are hard on. Note: Verify pump is

operating prior to using the E terminal. Since activating this E terminal causes full electric element

output, this function should only be used to verify all stages or troubleshoot proper 24Ø current at

each element.

6. Use general heating system logic information and basic understanding of the terminal block wiring

functions measure various voltage points to determine proper operation.

TEMPERATURE SENSING CONTROL SEQUENCE

See “Heat Cycle”, page 9. This sequence picks up after the first stage light or element relay comes on.

1. After the 30-second delay, depending upon how close the temperature is to set point, only stages

1 and 3 may come on or all 4 stages may come on.

2. At a fixed time interval (high mass, 4 minutes or low mass, 2 minutes) the outlet temperature is

compared to the set point. If it is below or above the minimum fixed point, there is no change in

staging.

3. If it is below the minimum range (high mass, 5° or low mass, 3°), add the next lowest stage.

4. If it is above the minimum range, drop the lowest stage.

5. If it is a major temperature differential above set point, drop the two lowest stages.

6. Cycle repeats at each time interval.

7. At the start of turn on, a 30-minute SOT timer begins. If the outlet temperature equals set point at

any time, this 30-minute timer is stopped. If the 30-minute timer actually timed-out, all stages are

turned on.

8. There is also a built-in controller or electronic hi-limit (high mass, 150° or low mass, 186°).

NOT

INCLUDED

EB-PK-M

NOT

INCLUDED NOT

INCLUDED

MANIFOLD

RETURN

MANIFOLD

SUPPLY

WATER

SUPPLY

CONNECTION

EB-PK-M

514

NO. PART NUMBER DESCRIPTION QTY.

1 EB-M*-** M-Series Electro-Boiler 1

2 XTEE7060 1" X 1" X 1" TEE 4

3 XNPL7780 1" X 2 1/2" NIPPLE 7

4 XEL7850 1" 90deg ELBOW 3

5 XBSH7180 1" X 3/4" BUSHING 2

6 #5453 RELIEF VALVE 1

7 #5595 AIR ELIMINATOR 1

8 XBSH7190 1" X 1/4" BUSHING 1

9 #5456A PRESS/TEMP GAUGE 1

10 XNPL7781 1" X 20" NIPPLE 2

11 #5591 EXPANSION TANK 1

12 XNPL7783 1" X 6" NIPPLE 1

13 #5503 1" BALL VALVE 3

14 #5548 DRAIN VALVE 1

15 PUMP #5585 (10KW) / #5586 (15-20KW) 1

16 FLANGE KIT #5580 (10KW) / #5582 (15-20KW) 2

EB-M*-** MECHANICAL PIPING

BX505 1/1

Rev.B 06-19-2006

504

55362

ONN

D B

(

)

G B

D B

5453

(

)

(

)

NOU

(

)

509

55362

OUN

D B

R B

R CB

R P

5701

R P

24V

PCB

5623

PCB

5623

120

240

(

R R

)

(

)

(

)

55362

190

205

24V

PCB

5623

PCB

5623

240



R C

D C

ONN

404

S509

R C



5000

55362

5000



R C



S509

405



R C

D C

ONN

240

24V

PCB

5623

PCB

5623

205

190

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