HydroTherm EW2-1203, Installation, Operation & Maintanance Manual

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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-65 LP 2 52 52 53 53 53 53 53 54 54 54
EW-85 NG 2 32 33 34 35 35 36 36 37 38 40
EW-85 LP 2 49 50 50 50 51 51 51 52 52 52
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