HydroTherm EW2-1203 Owner's manual

EW2-1203
42-9510
IN UNITED STATES: 260 NORTH ELM ST. • WESTFIELD, MA 01085 • [phone] • FAX [phone]
IN CANADA: 5211 CREEKBANK RD. • MISSISSAUGA, ONT. L4W 1R3 • [phone] • FAX [phone]
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!

2
CAUTION: Indicates a imminently hazardous situa-
tion which, if not avoided, may result in minor
injury or property damage.
The following terms are used throughout this manual to bring attention to the presence of potential hazards
or to important information concerning the product:
DANGER: Indicates an imminently hazardous sit-
uation which, if not avoided, will result in death,
serious injury or substantial property damage.
WARNING: Indicates a imminently hazardous sit-
uation which, if not avoided, could result in
death, serious injury or substantial 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.
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 àproxim-
itéde 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 àaucun interrupteur; ne pas vous servir des téléphones se trouvant dans
le bâtiment.
•Appelez immédiatement votre fournisseur de gas depuis un voisin. Suivez les intruc-
tions 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 qualifiéou par le fournisseur de gaz.

D
C
A
B
F
SPILL SWITCH
32-1/2"
VENT DAMPER
PRESS./RELIEF
VALVE
EW-85, 100, 125
AIR ELIMINATION
TAPPING
EXPANSION TANK
TAPPING
CIRCULATOR
(PACKAGED
BOILERS)
1-1/4"
RETURN
E
ROLLOUT
SWITCH
TEMP./PRESS.
INDICATOR
HI-LIMIT AQUASTAT
DRAIN
VALVE
1-1/2" SUPPLY
EW-65, 145, 165
1-1/2" SUPPLY
EW-85, 100, 125
PRESS./RELEF VALVE
EW-65, 145, 165
3
ANSI/ASME CODE COMPLIANCE: Installation must
conform to requirements of authority having jurisdiction
or, in absence of such requirements, to National Fuel
Gas Code ANSI Z223.1-latest edition and to National
Electric Code NFPA-70-latest edition. Where required by
authority having jurisdiction, installation must also con-
form to Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1.
For Canada, the installation must be in accordance with
Standards CAN/CGA-B149 (.1 or .2) Installation Codes
for Gas Burning Appliances and 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.
.
BOILER SHIPMENT: Each boiler is shipped in a single
carton. There is a vent damper packed separately with
the boiler.
MODEL EW BOILER DIMENSIONS
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!
DIMENSIONS
BOILER
MODEL
EW-65
EW-85
EW-100
EW-125
EW-145
EW-165
A
24-3/4"
27-1/2"
31"
31"
27-1/2"
27-1/2"
B
13-1/8"
13-1/8"
13-1/8"
13-1/8"
13-1/8"
13-1/8"
C
14-1/4"
19"
31"
30-1/16"
14-3/4"
14-3/4"
D
45-1/16"
48-5/16"
53"
68-1/2"
68-1/8"
48-5/16"
E
5"
5"
5"
6"
6"
7"
F
6-1/16"
6-1/16"
6-1/2"
6-1/2"
7-1/16"
6-1/16"

4
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 an unconfined space, ade-
quate air will be available via normal infiltration.
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 propel-
lants or freon; otherwise, heat exchanger will be
subject to corrosion, reducing boiler life.
WARNING: This boiler must be supplied with
combustion air in accordance with Section 5.3,
Air for Combustion & Ventilation, of the latest edi-
tion of the National Fuel Gas Code, ANSI Z223.1
and all applicable local building codes. Failure to
provide adequate combustion air for this appli-
ance can result in excessive levels of carbon
monoxide which can result in severe personal
injury or death!
6" 6"
6" 6"
LEFT RIGHT
VENT
DAMPER TOP
48"
FRONT
CLOSET
6" 6"
REAR
SIDE
VIEW
FRONT
VIEW
RECOMMEND
MORE FOR
ACCESS TO
VENT
DAMPER
POSITION
INDICATOR
FIGURE 1.1
PROCEDURE B: Check
minimum clearances
to combustibles are
proper as shown.
Local requirements
may specify greater
clearances & must be
adhered to.
Boiler shall be install-
ed such that the gas
ignition system com-
ponents are protected
from water, dripping,
spraying, rain, etc.,
during appliance oper-
ation and service, cir-
culator replacement,
condensate trap, con-
trol replacement, etc.
WARNING: Never install boiler on combustible flooring without combustible flooring pan or on carpeting
as heat damage and/or fire may result.
CAUTION: Do not loosen tie rods on absorption unit. They accommodate thermal expansion. Loss of
boiler structural integrity and water leaks/damage may result.
PROCEDURE C: Check component positioning.
1. Remove all packing material from boiler.
2. Check that burners and controls are in the proper position.
3. Check proper seating of baffle grid or baffle inside of dome
opening (see Figure 1.2).
DOME BAFFLE GRID
FIGURE 1.2
➤
➤
➤
CAUTION: Locate boiler so horizontal connecting flue pipe is as short as possible. Maximize height of
vertical flue connector.

5
STEP 2: INSTALLING & PURGING WATER PIPING
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 top-
rear of boiler, Figure 1.4.
If boiler is installed above level of
radiation, a low water cut-off must
be used.
NOTE: ALL EXTERNAL PIPING
MUST BE SUPPORTED BY HANG-
ERS, NOT BY BOILER OR ACCES-
SORIES.
CAUTION: To prevent damage due
to excessive condensation, one of
the following piping options should
be used, see next page.
FIGURE 1.4
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
VENT
FITTING
ASS'Y.
AIR VENT
VERTICAL EXPANSION TANK
ARRANGEMENT (PREFERRED)
1
/2" NPT TAPPING
MAY BE PIPED TO
EITHER SIDE OF BOILER
HORIZONTAL EXPANSION
TANK ARRANGEMENT
MAY BE SCREWED
INTO TAPPING
FIGURE 1.3
WARNING: No valve of any type may be installed between
the boiler and relief valve or an explosion from over-pres-
sure may occur.
➤
➤
CAUTION: Piping must be installed from relief valve dis-
charge so there will be no danger of scalding personnel.

6
SUPPLY RETURN
100%
120°F
200%
140°F
200%
160°F
100%
160°F
100%
160°F
PUMPED
BYPASS FIGURE 1.7
SUPPLY RETURN
50%
120°F
100%
140°F
100%
160°F
50%
160°F
50%
160°F
PUMP AWAY
BYPASS FIGURE 1.6
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 dia-
gram suggests one scenario. This addition requires only
two tees, a plug valve, and a small amount of pipe and
offers the simplest approach to reliably controling con-
densation. For this system and those that follow, be
aware that you are using a percentage of the pump
capacity to blend, but the friction loss for the entire
pump flow has been reduced. In most cases, the stan-
dard pump packaged with the boiler has enough capaci-
ty to feed the baseboard distribution system and the
bypass line.
PUMP AWAY BYPASS
For systems that use a single circulator to pump away
from the boiler, the bypass should be installed on the
discharge side of the circulator (see Fig. 1.6). Full tem-
perature water supplies the baseboard distribution sys-
tem as before. Half of the 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.
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 avail-
able to any heating zone. Any residentially sized circula-
tor is adequate for this purpose.
Each of these bypass solutions also has the added ben-
efit of increasing circulation in the boiler which will maxi-
mize tankless coil output and increase the accuracy of
temperature sensing controls.
REVERSE ACTING AQUASTATS
An alternative for existing systems experiencing conden-
sation that does not require re-piping the boiler utilizes a
reverse acting aquastat, one that makes on temperature
rise. This approach works best in single zone systems.
Wired in series with the circulator, this control holds the
circulator off until the boiler reaches an acceptable tem-
perature and then starts system circulation (see Fig.
1.8).
The most commonly available reverse acting aquastat is
a Honeywell L4006B. The aquastat should be mounted
in an immersion well directly installed in the boiler. The
use of heat conductive grease (Honeywell part
# 972545) in the immersion well is strongly recommend-
ed for fast and accurate temperature response. Set this
adjustable aquastat to make at no less than 130°F.
While this method can cause the circulator to cycle
more frequently, setting the aquastat’s differential to the
maximum (25-30°F) will minimize short cycling.
SUPPLY RETURN
50%
120°F
100%
140°F
100%
160°F
50%
160°F
50%
160°F
SYSTEM
BYPASS FIGURE 1.5
reverse
aquastat
N.O.
T
Tt'stat
GV
115 volts
24 volts
circulator
operating
aquastat
N.C.
REVERSE
AQUASTAT
SET AT 120°F FIGURE 1.8
FIGURE 1.5
FIGURE 1.7
FIGURE 1.8
FIGURE 1.6

7
PROCEDURE D: Completely fill & purge
heating system. Make sure that all heat-
ing 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
If a hot water boiler is installed in connection with a
water chiller, the chilled water must be piped in paral-
lel 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 locat-
ed 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.
PROCEDURE C: For combination heating and cooling installations only.
NOTE: VALVES "H" OPENED ON HEATINGWITH "C" VALVES
CLOSED REVERSE PROCEDURE ON COOLING.
EXP.TANK VENT ROOM
UNIT
DRAIN CHILLER
BOILER
H
C
PUMP
RELIEF
VALVE
FILL
VALVE
DRAIN
C
H
BOILER
FIGURE 1.9
➤
➤
FOR WATER TREATMENT & FREEZE PROTECTION REQUIREMENTS,
SEE “MAINTENANCE”IN THIS MANUAL

8
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.
PROCEDURE B: Install vent damper. (For French version, see Appendix A at rear of manual.)
FLOW DIRECTION
ARROW POINTS UP
MOUNT
VENT DAMPER
OVER
DRAFTHOOD
MAKE SURE
MOTOR IS
LOCATED
ON LEFT SIDE
1. Mount damper on top of draft hood.
FIGURE 1.12
ATTACH LOWER
PORTION OF
VENT DAMPER
TO DRAFTHOOD
WITH 1/2" OR
SHORTER SCREWS
OR POP RIVETS
2. Secure damper to draft hood.
FIGURE 1.13
PLUG INTO MOLEX
RECEPTACLE ON FRONT
OF BOILER
PLUG INTO MOLEX
RECEPTACLE INSIDE
DAMPER MOTOR VENT
DAMPER
WIRE
HARNESS
3. Connect wire harness.
FIGURE 1.14
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.
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.
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.
4. Plug wiring leads from harness/bracket assembly
onto flat terminals on spill switch.
INSTALL
SWITCH
IN OPENING
ON DRAFTHOOD
CONNECT
WIRE
LEADS
INSTALL
MOUNTING
BRACKET
ON DRAFTHOOD
NOTE: Boiler will not operate unless wiring leads
to spill switch are connected.
NOTE: Additional venting and chimney requirements are provided on page 8.
➤
➤
FIGURE 1.11

9
ADDITIONAL VENTING REQUIREMENTS: When connecting
to gas vents or chimneys, vent installations shall be in accor-
dance with Part 7, Venting of Equipment, of the National Fuel
Gas Code, ANSI Z223.1-latest edition, or applicable provisions
of the local building codes.
Vent connectors serving appliances vented by natural draft
shall not be connected into any portion of mechanical draft
systems operating under positive pressure.
When two or more appliances vent into a common flue, the
area of the common flue should be at least equal to the area
of the largest flue plus 50% of the areas of the additional flue
or vent connectors.
When an existing boiler is removed from a common venting
system, common venting system is likely to be too large for
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 vent-
ing system placed in operation, while other appliances remain-
ing connected to common venting system are not in operation:
1. Seal all unused openings in common vent-
ing system.
2. Visually inspect the venting system for
proper size and horizontal pitch and deter-
mine there is no blockage or restriction, leak-
age, 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 con-
nected to the common venting system are
located and other spaces of the building. Turn
on clothes dryers and any appliance not con-
nected to the common venting system. Turn
on any exhaust fans, such as range hoods
and bathroom exhausts, so they will operate
at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
4. Place in operation the appliance being in-
spected. Follow the lighting instructions. Ad-
just thermostat so appliance will operate con-
tinuously.
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 ap-
pliance remaining connected to common
venting system properly vents when tested as
outlined above, return doors, windows,
exhaust fans, fireplace dampers and any
other gas-burning appliance to previous con-
ditions of use.
7. Any improper operation of the common
venting system should be corrected so instal-
lation conforms with the National Fuel Gas
Code, ANSI Z223.1-latest edition. When
resizing any portion of the common venting
system, the common venting system should
be resized to approach the minimum size as
determined using the appropriate tables in Appendix G in the
National Fuel Gas Code, ANSI Z223.1-latest edition. For
Canada, the provisions of CAN/CGA B149.1 or .2 shall apply.
ADDITIONAL CHIMNEY REQUIREMENTS: Chimney condi-
tion is of paramount importance for a safe and efficient boiler
installation. All installations must include a chimney inspection
by a qualified individual or agency. Chimney construction
materials must be compatible with the fuel being used.
Particular attention should be paid on all oil-to-gas conver-
sions. Soot may have accumulated in the chimney and/or
degraded the chimney liner. Most utilities require complete
chimney cleaning. Others may require installation of a new
liner, or other chimney upgrades. Check with local utility for
required safety precautions.
MAXIMUM
6-FT
APART
PITCH 1/4"
PER FOOT
SECURE
FLUE PIPE
TO VENT
DAMPER
USE VENT SUPPORT(S) AS REQUIRED TO PREVENT SAGGING
INSTALL
FLUSH
WITH
INSIDE
CHIMNEY
LINER
SEAL
WITH
FURNACE
CEMENT
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"
PROCEDURE C: Install flue pipe between vent damper and
chimney. A 6" minimum clearance is required
between flue pipe and all combustible con-
struction.
FIGURE 1.15
DANGER: A chimney which does not meet modern
safety standards will result in a fire or deadly car-
bon monoxide poisoning of the building residents.
➤

FIGURE 1.16
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 = 122.5 cu.ft. per hour
1020 Btu per cu.ft.
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.
10
STEP 4: INSTALLING & TESTING GAS PIPING
➤
10 20 30 40 50 60 70 80 90 100 125 150 175 200
10 20 30 40 50 60 70 80 90 100 125 150
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)
.326 32 22 18 15 14 12 11 11 10 9 8 8 7 6
.493 72 49 40 34 30 27 25 23 22 21 18 17 15 14
.622 132 92 73 63 56 50 46 43 40 38 34 31 28 26
.824 278 190 152 130 115 105 96 90 84 79 72 64 59 55
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
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 17,50012,000 9,700 8,300 7,400 6,800 6,200 5,800 5,400 5,100 4,500 4,100 3,800 3,500
1/4"
3/8"
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
Nominal
Iron Pipe
Size,
Inches
Internal
Diameter,
Inches
Length of Pipe, Feet
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
Length of Pipe, Feet
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
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"

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.
PROCEDURE C: Test Gas Piping:
When testing has been completed, close main gas shut-off valve
& set boiler combination gas valve in “off”position.
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
11
STEP 5: WIRING THE BOILER
All electrical wiring must be in accordance with require-
ments of authority having jurisdiction or, in absence of
such requirements, to National Electric Code NFPA-70-
latest edition. If external source is utilized, boiler must
be electrically grounded in accordance with the require-
ments of authority having jurisdiction or, in absence of
such requirements, with National Electric Code NFPA-
70-latest edition. UL listed power limited circuit cable is
almost universally approved for safety controls on heat-
ing equipment, either internally or externally, without
protection of conduits or raceways.
For Canada, all electrical connections are to be made in
accordance with Standard C.S.A. C22.1 Canadian Elec-
trical Code, Part 1 and Part 2 and/or local codes.
NOTE: If any original wire supplied with the boiler
must be replaced, use similar wire of 105 C rating.
Otherwise, insulation may melt or degrade, expos-
ing bare wire.
NOTE: The boiler transformer must not be used to
power external accessories such as zone valves or
relays. Otherwise, boiler transformer will be over-
loaded and will burn out.
A separate 115V, 60Hz power supply is recommended
for the boiler. Use standard 15-amp fuse and 14-gauge
wire from power supply to boiler. Follow the wiring
diagram for your particular installation as shown in
Figures 1.18 through 1.28.
WARNING: Turn off electric power supply before
servicing. Contact with live electric components
can cause shock or death.
➤
➤

12
FIGURE 1.18: WIRING DIAGRAM & OPERATION
SEQUENCE FOR BOILERS WITH STANDING PILOT
& VENT DAMPER
VENT DAMPER AND HI-LIMIT
FOR BOILERS EQUIPPED WITH STANDING PILOT
OPERATING SEQUENCE
42-5768
DAMPER BLADE OPENS.
IS LESS THAN 300,000 BTUH
SPILL AND ROLLOUT SWITCHES USED WHEN INPUT
SYSTEM RETURNS TO STANDBY WITH DAMPER CLOSED.
IS SATISFIED.
MUST BE REPLACED, USE A SIMILIAR WIRE OF 105˚ C RATING.
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE BOILER
IF NO FAILURE EXISTS, THE MAIN VALVE IS ENERGIZED.
DAMPER END SWITCH CLOSES (PROVING VENT DAMPER OPEN).
THERMOSTAT (OR OPERATING CONTROL) CALLS FOR HEAT.
SENSING CIRCUIT IS CONTINUOUSLY MONITORED.
REMAINS CLOSED DURING STANDBY.
MOTOR DRIVES VENT DAMPER TO CLOSED POSITION AND
FACTORY WIRED
FIELD WIRED
SWITCH
ROLLOUT
SWITCH
SPILL
2
DAMPER
4
3
HI-LIMIT
VENT
1
TRTH
GAS VALVE
H
VENT 2
DAMPER
BLUE
RED
4
3
WHT
BLK
1
HI-LIMIT
115/24V
115V AC
24V GAS VALVE
N
SWITCH
ROLLOUT
TH
TR
BLK
WHT
TRANSF.
115/24V
BLUE
SWITCH
SPILL
STANDING PILOT REMAINS LIT.
UNIT OPERATES UNTIL THERMOSTAT (OR OPERATING CONTROL)
TT
TT
T1
GND
L1
T2
L2
T1
TT
TT
GND
L2
L1
T2
115V 60HZ
OR OPER.
CONTROL
THERMOSTAT
115V 60HZ
OR OPER.
CONTROL
THERMOSTAT
BLUE
FIGURE 1.19: WIRING DIAGRAM & OPERATION
SEQUENCE FOR BOILERS WITH STANDING PILOT,
VENT DAMPER & L8148E AQUASTAT RELAY
STANDING PILOT AND L48148E
FOR BOILERS EQUIPPED WITH VENT DAMPER
OPERATING SEQUENCE
42-5769
IS LESS THAN 300,000 BTUH
SPILL AND ROLLOUT SWITCHES USED WHEN INPUT
MUST BE REPLACED, USE A SIMILIAR WIRE OF 105˚C RATING.
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE BOILER
TT
TT
T1
FACTORY WIRED
FIELD WIRED
CIRC. MOTOR
ROLLOUT
ZW1K
VENT
DAMPER
2
3
4
1
T
TV
SWITCH
1K2 HI-LIMIT
B
1K1
L1
SPILL SWITCH
B1
C1
115/24V
C2
115 V AC
B2
L2
GND
L1
T2
L2
L8148E
TV
SYSTEM RETURNS TO STANDBY WITH DAMPER CLOSED.
UNIT OPERATES UNTIL THERMOSTAT (OR OPERATING CONTROL)
DAMPER END SWITCH CLOSES (PROVING VENT DAMPER OPEN).
THERMOSTAT (OR OPERATING CONTROL) CALLS FOR HEAT.
SENSING CIRCUIT IS CONTINUOUSLY MONITORED.
STANDING PILOT REMAINS LIT.
REMAINS CLOSED DURING STANDBY.
MOTOR DRIVES VENT DAMPER TO CLOSED POSITION AND
B2B1
RED
DAMPER
VENT
4
3
2
1
BLUE
BLUE
WHT
BLK
BLUE
SWITCH
SPILL
Z
TW
MAIN VALVE IS ENERGIZED.
DAMPER BLADE OPENS.
IS SATISFIED.
TR
L1 L2
115V 60 HZ
ROLLOUT
SWITCH GAS VALVE
TH
CIRC.
C1 C2
R
GND
L2
T2
L1
T1
TT
TT
1
TH TR
GAS VALVE
THERMOSTAT
CONTROL
OR OPER.
THERMOSTAT
CONTROL
OR OPER.
115V 60 HZ

ELECTRONIC PILOT CONTROL AND L48148E
FOR BOILERS EQUIPPED WITH VENT DAMPER
OPERATING SEQUENCE
42-5767
ARE ENERGIZED.
DAMPER BLADE OPENS.
IS LESS THAN 300,000 BTUH
SPILL AND ROLLOUT SWITCHES USED WHEN INPUT
SYSTEM RETURNS TO STANDBY WITH DAMPER CLOSED.
UNIT OPERATES UNTIL THERMOSTAT IS SATISFIED.
MAIN VALVE IS ENERGIZED AND IGNITOR DE-ENERGIZED.
PILOT IS IGNITED AND SENSOR SENSES FLAME.
MUST BE REPLACED, USE A SIMILIAR WIRE OF 105˚C RATING.
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE BOILER
IF NO FAILURE EXISTS, THE PILOT VALVE AND IGNITOR
DAMPER END SWITCH CLOSES (PROVING DAMPER OPEN).
THERMOSTAT CALLS FOR HEAT.
SENSING CIRCUIT IS CONTINUOUSLY MONITORED.
REMAINS CLOSED DURING STANDBY.
MOTOR DRIVES VENT DAMPER TO CLOSED POSITION AND
TT
TT
T1
FACTORY WIRED
FIELD WIRED
CIRC. MOTOR
CIRCULATOR
MV/PV PURP
ROLLOUT
ZW1K
VENT
DAMPER
2
3
4
1
T
TV
IGNITOR
SENSOR
GAS VALVE
MV
PV
MV/PV
SWITCH
(TR)
(TH)
(TH-TR)
BLK
BRN
PURP
ROLLOUT
1K2 HI-LIMIT
B
1K1
L1
DAMPER
VENT BLUE
WHT
BLK
3
4
1
2
RED
SPILL SWITCH
MANUAL RESET
B1
C1
115/24V
C2
MV
SENSOR
IGNITOR
115 V AC
SWITCH
(TH)
Z
B2
SWITCH
SPILL
BLUE
B1
T
L8148E
AQUA. RELAY
PV
GAS VALVE
(TH-TR)
(TR)
C2
L2L1
TV
C1
115V 60HZ
BRN
BLK
MV/PV
SPARK
24(GND)
24V
MV
MV/PV
PV
GND
S8600
B2
SPARK
L2
24(GND)
24V
GND
PV
S8600
MV
GND
L1
T2
L2
R
GND
L2
T2
L1
T1
L2
L1
OR OPER.
CONTROL
THERMOSTAT
THERMOSTAT
CONTROL
OR OPER.
115V 60HZ
FIGURE 1.22: WIRING DIAGRAM & OPERATION
SEQUENCE FOR BOILERS WITH IID,
VENT DAMPER & L8148E AQUASTAT RELAY
13
FIGURE 1.23: WIRING DIAGRAM & OPERATION
SEQUENCE FOR BOILERS WITH IID,
VENT DAMPER

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
TH1
TH2
N
H115V
TH3
ZV1
ZV2
ZV3
YEL RED
YEL
YEL
YEL
YEL
YEL
RED
RED
RED
RED
RED
T2
R1
TV T
2
W
B1 B2
TH
TR
C1 C2
L2
GV
N
H115V
TO CIRC.
L1
14
C2
C1
231 4
T
T
23
14
X
XTX
TX
TH1 TH2
ZR1 ZR2
N
H
115V
TH TR
GV
T1
TO
ADDITIONAL
ZONES
H1
C1: ZONE CIRCULATOR
TH1: ZONE T'STAT
C2: ZONE CIRCULATOR
TH2: ZONE T'STAT
ZR1: ZONE RELAY (RA832A
OR EQUIVALENT)
ZR2: ZONE RELAY (RA832A
OR EQUIVALENT)
H1: HI-LIMIT AQUASTAT
GV: GAS VALVE
T1: 24V TRANSFORMER
T2,T3:TRANSF. (IN RELAYS)
1R-1, 1R-2: ZR1 CONTACTS
2R-1, 2R-2: ZR2 CONTACTS
FACTORY WIRING
FIELD WIRING T1
115V 1R-2 2R-2
H1
BOILER CIRCUIT
1R-1
T2
2R-1
T3 TH2 TH1
ZR1 ZR2
CIRC.
1CIRC.
2
115V
BLACK
WHITE EXTERNAL CIRCUIT
GAS VALVE
COIL
FIGURE 1.20: WIRING DIAGRAM FOR ZONING WITH ZONE VALVES
FIGURE 1.21: WIRING DIAGRAM FOR ZONING WITH CIRCULATORS

SAFETY CONTROLS
The spill switch, see Figure 2.1, detects the escape of
combustion products through the draft hood relief open-
ing and interrupts the
power to the gas valve
preventing unsafe boil-
er operation. Escape
of flue products could
be caused by a
blocked or collapsed
chimney or by inade-
quate chimney draft.
This is a manual re-
set-type device and
can be reactivated by
depressing the spill
switch reset button.
The flame rollout
switch, see Figure 2.1,
prevents flame rollout
from the boiler com-
bustion chamber,
caused by blocked
boiler flue passage-
ways, by interrupting power to the gas valve to prevent
unsafe boiler operation. This is either a single use
device and must be replaced if it is tripped or a man-
ual reset-type device that can be reset by depressing
the reset button. Flue passages must be inspected by a
qualified installer, prior to switch replacement, if a prob-
lem occurs .
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.
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.
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 con-
trolled, set heat anticipator to amp draw of zone valve(s)
or circulator pump relay.
4. Set thermostat to
call for heat and turn
on electrical power to
boiler. Observe that
vent damper position
indicator has rotated
to open position, see
Figure 2.2. Damper
must be in open
position when boil-
er main burner is
operating.
In case of a damper
malfunction, the
damper blade may
be manually placed
in the full open position to permit burner operation. To
accomplish this follow the instructions on the damper.
5. Allow circulator to run 15 to 30 minutes, which should
purge any leftover air from system. Check automatic air
vent for the proper operation and the entire system for
any leaks. Make sure all air is purged from system
before lighting boiler.
6. Set thermostat to no longer call for heat. Observe that
damper position indicator rotates to the closed position.
7. Set thermostat to lowest setting and light boiler follow-
ing lighting instructions in Figure 2.4. Boiler is equipped
with flame rollout switch to shut down boiler in case of
sustained flame roll-out or excessive heat be-hind front
panel. If switch opens, see the information on “Safety
Controls”on this page.
8. Observe pilot and main burner flame, see Figure 2.3.
All burner ports should be ignited and burn with a
steady blue flame.
START-UP & OPERATION
15
SPILL
SWITCH
ROLLOUT
SWITCH
FIGURE 2.1
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.
WARNING: Keep boiler area clear and free from
combustible materials, gasoline and other
flammable vapors and liquids. Otherwise, fire or
explosion may result.
DAMPER POSITION INDICATOR
MUST BE IN VISIBLE LOCATION
FOLLOWING INSTALLATION.
OPEN
CLOSED
FLOW DIRECTION
FIGURE 2.2
CAUTION: Never leave the job with yellow burning
flames. This condition indicates poor combustion
and will quickly carbonize the boiler, reducing effi-
ciency and boiler life. It may also be an indication of
improper venting or combustion air supply. If
unable to adjust flame properly, consult your local
utility.

9. Boilers are shipped from the factory with the primary
air shutters on the main burner wide open. It is recom-
mended these air shutters be left in the wide open posi-
tion unless there is lifting of the flame above the burner
ports. If there is lifting, the air shutters should be gradu-
ally closed until the lifting is eliminated. It may also be
necessary to adjust the primary air shutters if the input
rate is reduced by a change in the orifices.
10. After burner has been in operation for about 10 min-
utes, check gas input rate to boiler as follows:
a. Make sure that all appliances served by the gas
meter are turned off during timing of gas input rate to
the boiler.
b. Measure the time in seconds that it takes for the boil-
er to use10 cubic feet of gas. Divide 36,000 by the
number of seconds, this is the number of cubic feet of
gas used per hour. Multiply this figure by the heating
value of the gas to obtain the input in Btu per hour.
Example: An HC-125E boiler takes 4 minutes, 54 sec-
onds to use 10 cubic feet of natural gas. Local utility
indicated heating value of the natural gas being supplied
is 1020 Btu/cu ft. Therefore:
54 + (4x60) = 294 seconds
36,000 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.
11. If boiler input needs to be corrected, adjust the combi-
nation gas valve pressure regulator. Regulator is factory set
at 3.5" W.C. for natural gas or 10" W.C. for propane. Turn
adjusting screw clockwise to increase gas flow, increase
input. Turn adjusting screw counterclockwise to decrease
gas flow (decrease input). In no case, should final manifold
pressure setting vary more than .2" from factory-set
pressures. 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.
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.
14. After the boiler has been firing long enough to raise
the boiler water temperature to above the minimum
setting of the high limit, check the high limit by turning its
setting from maximum to minimum setting. This should
turn the boiler off. Return high limit to desired setting.
15. Check boiler safety shut-off controls.
a. For boilers with standing pilot, with boiler firing,
disconnect thermocouple lead from the valve. The
valve should close.
b. For boilers with intermittent pilot, with boiler firing, dis-
connect wire connection to the "PV" terminal on Hon-
eywell S8600 control. The gas valve should close.
16
YELLOW
FLAME
(TOO LITTLE AIR)
YELLOW
TIPPING
(MARGINAL)
LIFTING
(TOO MUCH AIR)
NORMAL
(HARD FLAME)
NORMAL PILOT FLAME
MAIN BURNER FLAMES
Q314A/Q309A
CONSTANT PILOT
MODELS
Q345A
INTERMITTENT
IGNITION PILOT
MODELS
FIGURE 2.3

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.
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! Fol-
low "A" in the safety information above. If you don't smell
gas, go to the next step.
6. Remove the base door covering the top of the burners and
enclosing the pilot.
7. Find pilot. Follow metal tube from gas control. The pilot is
between the central burner tubes behind the base door.
8. Turn knob on gas control counterclockwise to "Pilot" posi-
tion.
9. Push down and hold the red button next to the control
knob. Immediately light the pilot with a match. Continue to
hold the red button down for about one (1) minute after the
pilot is lit. Then turn knob to "ON" position. If it goes out,
repeat steps 4 through 9.
•If button does not pop up when released, stop immedi-
ately and call your service technician or gas supplier.
•If the pilot will not stay lit after several tries, turn the gas
control "OFF" and call your service technician or gas
supplier.
10. Replace the base door.
11. Turn gas control knob counterclockwise to "ON".
12. Turn on all electric power to the appliance.
13. Set thermostat to desired setting.
INLET
GAS CONTROL KNOB
SHOWN IN "OFF" POSITION
GAS ON
OFF
RESET BUTTON
PILOT
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.
INLET
GAS CONTROL KNOB
SHOWN IN "OFF" POSITION
GAS ON
OFF
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.

This boiler has been designed to provide years of trou-
ble free performance in normal installations. Examina-
tion by the homeowner at the beginning of each heating
season, and in mid-heating season, should assure con-
tinued good performance. In addition, the boiler should
be examined by a qualified service professional at least
once every year.
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 subse-
quent failure of cast iron sections.
NOTE: If boiler is equipped with a low water cutoff,
follow manufacturer’s maintenance instructions.
WATER TREATMENT
Water treatment is recommended in areas where water
quality is a problem. A local water treatment company
should be consulted to determine the requirements for
your particular system.
FREEZE PROTECTION
Where absolutely necessary, system antifreeze can be
utilized. It must be compatible with hydronic heating sys-
tems. System must be designed to accommodate nec-
essary changes in heat transfer, pump head, flow rate &
expansion. For more information, consult The Hydronics
Institute Technical Topics Number 2A publication.
Note: Never use an RV-type antifreeze protection
solution nor an automotive-type antifreeze as dam-
age to the boiler and other system components may
result.
18
MAINTENANCE
DANGER: To avoid fire and explosion hazards: Do
not store anything against boiler or allow dirt/debris
to accumulate in area immediately surrounding
boiler. Keep boiler area clear and free from com-
bustible materials, gasoline and other flammable
vapors and liquids. Do not allow lint, paper or rags
to accumulate near burners. Do not place clothing
on boiler to dry.
BEFORE EACH HEATING SEASON
1. Remove and inspect draft hood and vent piping con-
necting draft hood to chimney or vent for obstructions,
soot accumulation, rust or corrosion. Clean and replace
as necessary. Check tightness of joints; seal all joints
where necessary.
2. Check boiler flue passageways in the boiler sections
for any blockage or soot accumulation. Remove draft
hood, jacket top and cast iron dome. Using a flash light,
examine all flue passageways.
a. If passageways are free of soot and obstructions,
replace dome and seal with furnace cement or high tem-
perature silicone adhesive/sealant.
b. If passageways need cleaning, remove burners as
described in paragraph 3 below. Insert long-handle bris-
tle flue brush down between section tubes and upward
through sections from combustion chamber in both diag-
onal directions to remove carbon from finned surfaces.
Vacuum debris. Replace dome and seal with furnace
cement or high temperature silicone adhesive/sealant.
c. Reinstall jacket top panel and draft hood.
3. Check and clean burner assembly. Remove burner
access panel. To remove burners, lift up and to rear until
burners are disengaged from orifices. Brush top of burn-
ers with soft bristle brush; blow out with air or vacuum.
4. Check gas manifold for proper position and reassem-
ble burners to the manifold. Line up holes in burners
with the orifices and slide assembly back into position.
BE SURE TO REINSTALL BURNER WITH PORTS ON
THE TOP SURFACE, UPRIGHT.
5. When a low water cut-off has been utilized, follow the
manufacturer’s maintenance instructions. As a mini-
mum, test electronic control operation at least once a
year. Float type controls should be flushed twice a year.
6. Lubricate circulator motor according to manufacturer’s
instructions. This information may be contained in label-
ing on the pump frame.
7. Follow “System Start-Up & Adjustments”procedures
in the “Start-up & Operation”section of this manual.
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.
WARNING: Do not obstruct the flow of combustion
and ventilation air. Failure to comply with this warn-
ing can result in carbon monoxide poisoning!

19
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 ori-
fices are screwed into the manifold and may be removed
by using a 5/8”wrench or socket.
4. Reverse above procedures to install orifices & burn-
ers. BE SURE TO INSTALL BURNERS WITH BURNER
PORTS ON TOP SURFACE, UPRIGHT.
MODEL
EW-65
NAT. GAS
DRILL SIZE
2.60MM
32
37
39
35
32
L.P. GAS
DRILL SIZE
52
49
1.65MM
1.60MM
51
1.85MM
EW-85
EW-100
EW-125
EW-145
EW-165
FIGURE 3.1
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.
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 adjust-
ment.
2. Whistle due to burr on orifices.
3. Burner “fluteing”-air shutter open-
ing too wide.
TROUBLESHOOTING
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper
and dangerous operation. Verify proper operation after servicing.
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-65LP 2 52525353535353545454
EW-85NG 2 32333435353636373840
EW-85LP 2 49505050515151525252
EW-100 NG 3 37 38 39 39 40 41 42 42 43 43
EW-100 LP 3 1.65mm 52 53 53 53 53 53 54 54 54
EW-125 NG 4 39 40 41 41 42 42 43 43 44 44
EW-125 LP 4 1.60mm 1.60mm 53 53 53 53 53 54 54 54
EW-145 NG 4 35 36 36 37 37 38 39 40 41 42
EW-145 LP 4 51 51 52 52 52 52 53 53 53 54
EW-165 NG 4 32 33 34 35 35 36 36 37 38 40
EW-165 LP 4 1.85mm 50 50 50 51 51 51 52 52 52
EQUIVALENT ORIFICE SIZES AT HIGH ALTITUDES
INCLUDES 4% INPUT REDUCTION FOR EACH 1,000 FEET

APPENDIX A
20
MÉTHOD D' INSTALLATION B: pour le volet motoriséde ventilation.
Danger: Le volet de ventilation doit servir seulement àla 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. 2. Fixer le volet de ventilation au coupe-tirage.
3. Brancher le faisceau de fils.
SASSURER QUE
LE MOTEUR SOIT
SITUE A GAUCHE
MONTER LE VOLET
DE VENTILATION
AU-DESSUS DU
COUPE-TIRAGE.
LA FLECHE DE DIRECTION
DE LECOULEMENT POINTE
VERS LE HAUT
'
`
'
FIGURE 1.12
'
'
FIGURE 1.14
FAISCEAU DE FILS
DU VOLET DE
VENTILATION.
ENFICHER DANS LA PRISE
MOLEX SUR LE DEVANT
DE LA CHAUDIERE.
`
ENFICHER DANS LA PRISE
MOLEX A L INTERIEUR DU
MOTEUR DU VOLET DE
VENTILATION.
`' '
LE REGISTRE DOIT ETRE EN
POSITION OUVERTE LORSQUE
LE BRULEUR PRINCIPAL EST EN
MARCHE.
OUVERTE
CLOS
SENS DE DEBIT
^
^
FIGURE 2.2
FIGURE 1.13
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.
'
'
`