LION LEB dc 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.
TM
LION
BOILERS
LEB dc
dcdc
dc Series Boiler
Installation Manual
LEB dc V5.0 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.
The installation of this boiler 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. All 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).
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 modulating the elements on or o as required. The temperature
is set by the aquastat control on the lower le corner of the control board. 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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Specifications
Model kW Volts Phase Amps Minimum Breaker Size Wire Size (Amps)
LEB-3 3 240 1 12.5 20 16
LEB-4 4 240 1 16.7 30 24
LEB-5 5 240 1 20.8 30 24
LEB-6 6 240 1 25.0 40 32
LEB-7 7 240 1 29.2 40 32
LEB-8 8 240 1 33.3 50 40
LEB-9 9 240 1 37.5 50 40
LEB-10 10 240 1 41.7 60 48
External Control Voltage ( Thermostat ) 24 Volts AC
Tank Capacity – Approx. 1 Gallon
Shipping Weight – about 50 pounds
Inlet and Outlet pipe size 3/4” NPT
Pump Switch Rating, 120 Volt, 1 HP
Floor heating temperatures are generally 90º F to 110º F
Minimum Recommended Operating Pressure 12 PSI
arning: The control transformer is sized to power only the internal
controls. External devices must be powered from a separate power source.
New 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, and ttings.
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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 system should be designed using parallel loops. If too many 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.
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 and bottom require only enough room for plumbing and
electrical connections (see Fig. 2). The rear of the unit is considered a “Zero Clearance”
face (see Fig. 2). When mounting the boiler on the wall, ensure that the wall can
withstand the weight of the unit including water (approximately 60 lbs.). Mounting tabs
are pro ided on top for 3/8” bolts or screws, these are for wall mounting.
(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 wall mount, only the rear face indicated as “Zero
Clearance” may be mounted against combustible surfaces.
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(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) 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.
(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 to the inlet and outlet. 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 tank 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). 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.
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hermostat 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 T1 and T2 on the control circuit board (see Fig. 4). 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. 5).
Thermostats described as “Power Stealing” or as “Parasitic Thermostats”
must not be used.
hermostat 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.
emperature Control Setting (Aquastat)
The boiler has a temperature control knob know as an aquastat on the lower le corner of the
control board. 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 you need to set it to will be determined by the type of
heating system the boiler is installed in. The range of the aquastat is from 10 to 54º C (50
to 130º F).
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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) Electrical supply connections complete.
Maintenance
At the start of each heating season 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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roubleshooting Guide
Problem Correction
Boiler not heating, water cool. Check power supply, fuses or breakers.
Check thermostat setting.
Check temperature control inside the boiler.
Boiler heating pipes cool. Check for air in system.
Check pump circulation.
Check all al es.
Check for ow stoppage, or air locks.
Boiler rapid cycles. Check anticipator setting.
Check pump circulation.
Boiler operates continuously. Check anticipator setting.
Boiler noisy. O ersized pump.
Flow rate too high.
Flow rate too low.
Pump location incorrect.
Boiler not heating enough Insucient capacity.
Burnt Elements.
Flow rate too low.
Pressure too high. Defecti e expansion tank.
Defecti e automatic ll al e.
Expansion tank too small.
Safety relief al e dripping. Check expansion tank.
Flush relief al e.
See the troubleshooting step by step procedure at the end of this manual for additional
information.
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Lion Boilers Limited Warranty
Concept Manufacturing Inc. (the "Manufacturer") warrants its Hydronic Boiler (the "Boiler") to
be free from defects in material and workmanship under normal use and maintenance for a
period of two (2) years from the date of original installation. The Manufacturer further
warrants the tank to be free from defects in material and workmanship under normal use and
maintenance for an additional eight (8) years for a total of ten (10) years from the date of
original installation.
If any part of the Boiler is found by the Manufacturer, as sole judge, to be defecti e in material
or workmanship, the Manufacturer, at its sole discretion, agrees to:
(i) Repair any defect;
(ii) replace any defecti e Boiler; or
(iii) refund the original purchase price of the Boiler.
The Manufacturer, at its sole discretion, reser es the right, at any time during the warranty
period, to refund the original purchase price to the current owner of the Boiler regardless of
any prior attempt by the Manufacturer to repair or replace that Boiler.
The obligation of the Manufacturer to repair, replace or refund the purchase price exists
pro ided the defecti e part or complete unit is returned to the Manufacturer. ANY AND ALL
TRANSPORTATION COSTS WILL BE BORNE BY THE PURCHASER.
Repair, replacement or refund of any defecti e part or unit shall be considered as complete
fulllment of this warranty.
THIS WARRANTY DOES NOT APPLY TO:
1. Labor or other costs incurred for diagnosing, repairing, remo ing, installing, reinstalling,
shipping, ser icing or handling of any defecti e part or complete unit;
2. Costs incurred for normal maintenance;
3. The workmanship of any installer of the Boiler. In addition, this warranty does not assume
any liability of any nature for unsatisfactory performance caused by improper installation;
4. Damage or repair as a consequence of storage and handling, improper or careless
installation, improper maintenance, or misuse or neglect as determined by the Manufacturer as
sole judge;
5. Damage as a consequence of misapplication, abuse, improper ser icing, unauthorized
alteration, improper operation or usage contrary to the Manufacturer's direction, design or
specications, as to any and all of which the Manufacturer shall be the sole judge;
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6. Damage as a consequence of electrical surges, inadequacy or interruption of electrical
ser ices or corrosion, whether caused by chemicals or the en ironment;
7. Damages as a consequence of oods, winds, res, lightning, freezing conditions or other
conditions beyond the control of the Manufacturer.
LIMITATION OF ARRANTY
THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS
OR IMPLIED, AND ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION
IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED
WARRANTY.
THE MANUFACTURER'S LIABILITY ON ANY CLAIM OF ANY KIND, INCLUDING
NEGLIGENCE, WITH RESPECT TO THE GOODS OR SERVICES COVERED HEREUNDER,
SHALL IN NO WAY EXCEED THE PURCHASE PRICE OF THE BOILER, OR PART THEREOF,
WHICH GIVES RISE TO THE CLAIM. IN NO EVENT SHALL THE MANUFACTURER BE
LIABLE FOR SPECIAL, INCIDENTAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, OR ANY
DAMAGES IN THE NATURE OF PENALTIES. ALL WORK UNDER THE TERMS OF THIS
WARRANTY SHALL BE PERFORMED DURING NORMAL WORKING HOURS.
ALL REPLACEMENT PARTS OR UNITS, WHETHER NEW OR REMANUFACTURED,
ASSUME AS THEIR WARRANTY PERIOD ONLY THE REMAINING TIME PERIOD OF THIS
WARRANTY.
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roubleshooting Step By Step Procedure
The following is a step by step procedure to help in troubleshooting any problems with this
boiler. These steps should be performed only by qualied personnel with experience in
hydronic heating systems, and electrical heating equipment. You are working with high
oltages and should be extremely careful.
Before energizing boiler, ensure system is full of water.
(1) Make sure that there is power to the boiler. There must be power to the boiler to
complete these troubleshooting steps.
a) There should be power at the main terminal block. You should read 120 olts
between L1 and N, 120 olts between L2 and N, and 240 olts between L1 and L2.
b) Disconnect the thermostat wires from terminals T1 and T2. Measure the oltage at
the top of the boiler at each heating element. If you read oltage at any of the
elements, then the element relays for that element are stuck on and need to be
replaced.
c) Next measure the oltage from the N terminal of the main terminal block to each
terminal of each heating element. If you read oltage at any of the elements, then a
single element relay for that element is stuck on and needs to be replaced.
(2) Check the fuse.
a) Remo e the fuse located inside the boiler. Check it for continuity. Replace with a
new fuse of the correct type if necessary.
b) Otherwise replace the existing fuse.
(3) Check that there is 24 olt AC power on the secondary side of the transformer. There
must be 24 olt AC power on the secondary side of the transformer for the boiler to
operate. If there is no power the transformer needs to be replaced. When there is 24 olt
power to the board the “Power On” light on the board should be on.
(4) With the thermostat wires still disconnected, connect a jumper wire from terminal T1 to
terminal T2. The “Thermostat On” light should now be on.
a) This should energize the pump relay to the right of the control board, you should
hear a click. If not check that there is 24 olt DC power on the two relay terminals
with purple wires.
b) If there is no power at the relay, the control board needs to be replaced.
c) If there is power, but the relay is not turning on, replace the relay.
(5) When the relay is energized, it will supply 120 olt power for running the pump.
a) There should now be 120 olt AC power to the terminals labeled PL and PN.
b) If there is no power, replace the relay.
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(6) The circuit board is now acti ated, the 24 olt power light and the thermostat light will
be on. The element relays may now start to turn on. If they ha e not started to come on
as yet, temporarily turn up the temperature on the aquastat to the maximum setting, it
should be returned to the normal setting when you are nished troubleshooting. The
element relays should now start to turn on. As the relays turn on, the element relay
lights on the control board should come on at the same time.
a) If the element relays and indicator lights ha e not come on, look at the high limit
indicator light on the board. It should also on. It should be on anytime the
thermostat light is on.
b) If the high limit indicator light is not on, temporarily (no more than one second)
place a jumper wire across the two terminals on the high limit control.
c) If the high limit light now comes on, the hi limit control will need to be replaced.
d) If the element relay indicator lights do not come on, disconnect the temperature
sensor by pulling out the connector at the control board (the one with the two gray
wires).
e) If the element indicator lights and element relays now come on the temperature
sensor needs to be replaced.
) If they still do not come on then the control board needs to be replaced.
(7) If all the relays energize and there is no heat, then check for oltage at each of the
heating elements. There should be 240 olts at each element.
a) With all the relays energized, check that there is power to each of the elements with
a olt meter. If there is no oltage reading, one or both of the relays connected to
that element will need to be replaced.
b) If there is power to the elements, but no heat, then with the all the power
disconnected to the boiler, check the resistance of each element with an ohm meter,
and replace any elements, as necessary.
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If you ha e gone through the abo e steps, and the boiler is still not working, please contact us
for assistance.
Concept Manufacturing Inc.
Box 23008 RPO McGilli ray
Winnipeg, Manitoba, Canada
R3T 5S3
Phone: [phone]
Fax: [phone]
E-mail [e-mail]
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