LION CEBR Series User manual

Warning: Use only water or an
appropriate antifreeze. Do not use any
other liquids especially methanol,
automotive antifreeze or any kind of oil.
Do not exceed 50% antifreeze.
LION
BOILERS
CEBR Series Boiler
Installation Manual
CEBR V12.0 Printed in Canada

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Before You Begin
Please read this manual thoroughly before you begin. If you encounter problems please see the
troubleshooting section near the end of this manual. This boiler should only be installed and
tested by qualied personnel with experience in hydronic heating systems, and electrical
installations. This boiler should not be modied or altered in any manner. Any modication or
alteration may cause the boiler to malfunction and cause serious damage and injury, and will
oid the manufacturers warranty.
All wiring must comply with local regulations and codes. Verify the
“Name Plate” rating to properly size conductors, and overcurrent
protection.
(1) Before installation, ensure that the local electrical inspection authority will accept
connection of this boiler to the existing panel.
(2) This boiler may only be installed and tested by qualied personnel.
(3) The electrical power supply should be checked for adequacy for the additional load of
the boiler. 240 olt models require connection of 240 olt single phase power to
terminals L1 and L2, and connection of a neutral conductor to the N terminal (see Fig.
4). Three phase models require connection of three phase power of the correct oltage
to the L1, L2, and L3 terminals, and a 120 olt 15 amp supply to the terminals SL and SN
(see Fig. 5).
Introduction
Your Electric Boiler has been designed to exacting specications to pro ide controlled ecient
heating and maximum ser ice life. The boiler is controlled internally by an electronic control
board. The boiler is energized when the external thermostat wired to the control board calls for
heat. The circulation pump is started rst to pro ide ow through the heating system, then the
heating elements are staged on as required. A temperature sensor mounted in the tank
monitors the water temperature, and the internal control board maintains the temperature of
the water exiting the boiler by staging the elements on or o as required. This is know as
modulating. The temperature is set by the aquastat control on the side of the boiler. The
modulating control strategy built into the control board uses only the minimum number of
elements necessary to maintain the desired temperature, resulting in maximum comfort.
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Outdoor Reset Control
This model also has Outdoor Reset control. An outdoor temperature sensor is used to monitor
the outside temperature. The electronic controls then regulate the water temperature based on
both the aquastat setting and the outside temperature to ne tune the boilers heat output. As
the temperature outside increases, the boiler control will decrease the target water temperature
set on the aquastat. By modulating the boilers heat output based on both the indoor and
outdoor temperature, your CEBR model pro ides you with the ultimate in indoor comfort.
The graph below is an example with the aquastat set to 35º C. During colder weather, below -
20º C, the boiler will maintain the heat output at the aquastat setting, but as the temperature
increases outdoors, the heat output of the boiler will be decreased. For example when it is -10º
C outside the water temperature will be 32º C, and when it is 5º C outside the water
temperature will be 27º C.
Target Water Temperature Example ( Temperature in degrees C)
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Specifications
Model kW Volts Phase Amps Minimum Breaker Size Wire Size (Amps)
CEBR-3 3 240 1 12.5 20 16
CEBR-5 5 240 1 20.8 30 24
CEBR-6 6 240 1 25.0 40 32
CEBR-8 8 240 1 33.3 50 40
CEBR-9 9 240 1 37.5 50 40
CEBR-10 10 240 1 41.7 60 48
CEBR-12 12 240 1 50.0 70 56
CEBR-15 15 240 1 62.5 100 80
CEBR-18 18 240 1 75.0 100 80
CEBR-19 19 240 1 79.2 100 80
CEBR-20 20 240 1 83.3 125 100
CEBR-23 23 240 1 95.8 125 100
CEBR-24 24 240 1 100.0 125 100
CEBR-25 25 240 1 104.2 150 120
CEBR-28 28 240 1 116.7 150 120
CEBR-208-9 9 208 3 25.0 40 32
CEBR-208-11 11.25 208 3 31.2 40 32
CEBR-208-15 14.7 208 3 40.8 60 48
CEBR-208-22 22.5 208 3 62.5 100 80
CEBR-208-30 29.4 208 3 81.6 125 100
CEBR-600-9 9 600 3 8.7 15 12
CEBR-600-15 14.7 600 3 14.1 20 16
CEBR-600-18 18 600 4 17.3 30 24
CEBR-600-24 23.7 600 5 22.8 30 24
CEBR-600-30 29.4 600 3 28.3 40 32
Control Voltage 24 Volts AC
Tank Capacity – Approx. 2 Gallons
Shipping Weight – about 85 pounds
Inlet and Outlet pipe size 1 1/4” NPT
Pump Switch Rating, 120 Volt, 1 HP
Maximum Recommended Operating Temperature 180º F
Floor heating temperatures are generally 90º F to 110º F
Recommended Operating Pressure 15 PSI
Warning The control transformer is sized to power only the internal
controls. External devices must be powered from a s eparate power
source.
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Ne Boiler Inspection
All Boilers are inspected and tested at the factory prior to shipment. On receipt of your new
boiler, be sure to check for any damage that may ha e occurred during shipping. Any such
damage should be reported to the carrier immediately.
Never install a damaged boiler.
Unpacking
The Boiler is shipped to you in one carton, which contains the boiler, a pressure & temperature
gauge, pressure relief al e, air ent, outdoor temperature sensor, and ttings.
System Design
For proper operation of the heating system, the boiler, the radiation system, and maximum
heat loss of the building must be considered. The boiler selected should pro ide between 110%
and 130% of the maximum design heat loss of the building. The radiation system should be
designed to properly dissipate the heating capacity of the boiler at the radiation system design
temperature.
The recommended cold ll pressure of the system is 12 psi; this pressure should lea e at least 4
psi at the highest point in the heating system. Pressure will decrease at a rate of 0.433 psi per
foot abo e the ll point. An expansion tank must be included to allow for approximately 4%
expansion of the water in the entire heating system. As the water in the system is heated the
pressure will increase, but a properly sized expansion tank will pre ent the pressure from
exceeding the recommended operating pressure.
The radiators or oor system should be designed with parallel loops. If too many radiators or
oor loops are connected in series, the accumulated heat loss may cause une en heating. The
minimum recommended ow rate must be used, but higher ow rates may gi e more e en
heating. If a number of parallel heating circuits are used, al es are usually required to balance
the ow in each circuit to pro ide uniform heating.
A zoned heating system is also possible with separate heating zones and indi idual
thermostats in each zone. Indi idual thermostats in each zone can control a zone al e, or a
circulation pump pro iding ow to that zone. End switches on the zone al es can be wired in
parallel to the thermostat connection of the boiler.
The entire heating system must comply with any local codes or regulations.
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Installation
Location
(1) The site selected for installation of your boiler should lea e at least 24” of clear space in
front of the unit. The sides require only enough room for plumbing and electrical
connections (see Fig. 2). The rear of the unit is considered as a “Zero Clearance” face
(see Fig. 2). If wall mounting is chosen ensure that the wall can withstand the weight of
the unit including water (approximately 115 lbs.). Two brackets are pro ided on top and
are drilled for 3/8” bolts or screws, these are for wall mounting. Optional “Mounting
Feet” are a ailable for oor mounting. Holes are also pro ided in these feet for oor
mounting.
(1) To install the optional feet, the two outside #10 screws at the bottom on each side are
remo ed. Each of the feet are then lined up with the holes, then the screws are
tightened back in place holding the feet in place.
(2) The space selected should be well entilated and kept normally below 77º F or 25º C. It
must be clean, and dry. The boiler must not be subjected to water leakage, drips,
splashes, or spray. Flammable materials must not be used or stored anywhere near the
boiler.
(3) Though the unit is suitable for oor or wall mount, only faces indicated as “Zero
Clearance” may be mounted against combustible surfaces.
(4) Units must be mounted straight as shown in Fig. 2 with the outlet at the top, and the
inlet on the bottom. See “Up Arrow” on label on side of boiler.
(5) The circulation pump should be connected to the outlet side of the boiler (see Fig. 3).
Mechanical Installation
(1) Refer to Fig. 3 for a typical system before installation.
(2) Packed with your boiler are the following.
a) Temperature & Pressure Gauge
b) Pressure Relief Val e
c) Air Vent
d) Outdoor Temperature Sensor
e) Necessary ttings.
(3) Mount unit as per instructions under “Location”
(4) Install Pressure Relief Val e and Pressure & Temperature Gauge. These must be
connected directly to the boiler as shown in Fig. 1
(5) A discharge line must be attached to the outlet of the pressure relief al e. The
discharge line will direct water or steam from the pressure relief al e should it open.
The discharge line must be as short as possible, not ha e any al es or restrictions, not
be smaller than the outlet of the pressure relief al e, slope downwards, and the end
must be open to the atmosphere. The discharge line should terminate at a drain 6 inches
abo e the oor le el.
(6) Install inlet and outlet piping.
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(7) An expansion tank must be installed (see Fig. 3) to allow for water expansion as the
system is heated.
Dissimilar Metals
Do not connect dissimilar metals on the inlet and outlet nipples. Dielectric Unions should be
used. Another solution is to use brass or cast iron ttings between the boiler and any copper
ttings that you may be using. Failure to do so will result in gal anic corrosion and cause the
inlet and/or outlet nipples to fail o er time.
This is not covered under the warranty.
Pump Installation
The circulation pump should be positioned as close to the boiler as possible, with the deli ery
arranged to pump out of the tank outlet on the upper le side of the boiler (see Fig. 3)
The pump is powered by the boiler through terminals PL and PN located on the 120 olt
terminal block (lower right terminal block see Fig. 4 and Fig. 5). The pump starts when the
thermostat terminals on the control board are closed, and stops when these terminals are
opened.
If desired, the pump may be operated continuously during the heating season. Should you
decide to wire the pump in this manner, it should be wired to the same supply circuit as the
boiler to pre ent the pump from being turned o while the boiler is still powered.
Thermostat Connection
The thermostat connection is 24 olt AC. Only connect the thermostat aer all
other work is complete, and the entire heating system is thoroughly
purged of air. The thermostat is connected to the terminals “STAT 1” on the control circuit
board (see Fig. 4 and Fig. 5). In zoned systems, the end switches of all the zone al es may be
connected in parallel and hooked up to the thermostat connection on the control board. For a
typical system (see Fig. 6).
Thermostats described as “Power Stealing” or as “Parasitic Thermostats”
must not be used.
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Thermostat Anticipator
The thermostat anticipator setting recommended is 0.2 amps. Failure to correctly adjust this
setting may result in unsatisfactory comfort conditions, and could result in damage to the
thermostat.
This setting may ha e to be adjusted slightly to ideally match the boiler control system to the
thermostat, as well as o ercome the normal inertia of the radiation system. A setting to low
will be characterized by a short cycle, which does not allow the room temperature to be
satised before the boiler shuts down. A setting too high will be characterized by a long cycle,
which allows the room temperature to rise too high before the boiler shuts down. Adjustments
should be made to the setting, if required, but should not exceed 0.1 amps per adjustment.
Newer electronic thermostats typically ha e pro isions for the cycle length, and type of
heating system. The instructions for the thermostat should be followed.
In zoned systems where the thermostat is controlling a zone al e, or circulation pump and not
the boiler, the anticipator should be set to match the current draw of the zone al e being used.
Temperature Control Setting
The boiler has a temperature control knob know as an aquastat on the le hand side. This sets
the maximum temperature that the boiler will operate at. The internal control system monitors
the water temperature in the tank and modulates the heating elements to maintain the water
temperature. Note that the setting on the knob only sets the maximum temperature, it is
normal for the boiler to operate at lower temperatures than this setting at times, this is
especially true in the spring and fall when it is not so cold outside. The actual temperature
setting will be determined by the type of heating system the boiler is installed in.
Outdoor Temperature Sensor Connection
The outdoor temperature sensor should be mounted in a suitable location outside the building
where it will be exposed to the outside air. Mount the sensor high enough so it will not be
co ered by snow or ice, and in a location where it will not be exposed to direct sunlight.
The outdoor temperature sensor is connected to the terminals “OD STAT” on the control
circuit board (see Fig. 4 and Fig. 5).
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Start Up
A new system must be thoroughly cleaned, ushed and drained, then relled with clean water.
Foreign material circulating through the system could be detrimental to the pump and to the
heat transfer eciency of the system and may lead to future problems. The system must be
thoroughly purged of air before it is energized for the rst time. Elements will burn
out if the boiler is not full of water when the boiler is turned on. Do not connect the
thermostat wires until the entire system is full of water, and thoroughly purged of
air.
The automatic air ent is to assist in remo ing air from the top of the tank to pre ent elements
from burning out. It alone is not sucient in remo ing air from the entire heating system.
Additional air vents must be installed throughout the system to eliminate any air
that may enter the system.
Check List
(1) Plumbing complete.
(2) System ushed.
(3) System free of air (purged).
(4) Pump rotates freely.
(5) Thermostat connected.
(6) Thermostat anticipator set.
(7) Outdoor Sensor connected.
(8) Electrical supply connections complete.
Maintenance
At the start of each heating system it is ad isable to ha e a qualied technician check and
inspect the boiler and the heating system for proper operation.
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