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Vapor Power International LLC

551 S. County Line Road, Franklin Park, Il 60131

Phone: 630-694-5500 Fax: 630-694-2230

Instruction Manual

HWR MODEL

‘RESISTO-FLO’

ELECTRIC BOILER

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Summary of Contents for HWR Series

Page 1: ...Page 1 of 16 Vapor Power International LLC 551 S County Line Road Franklin Park Il 60131 Phone 630 694 5500 Fax 630 694 2230 Instruction Manual HWR MODEL RESISTO FLO ELECTRIC BOILER ...

Page 2: ...a compact packaged unit requiring a minimum of electrical and plumbing connections at the jobsite When installed according to these instructions the boiler will provide years of reliable low maintenance service Review both the installation and electrical drawings thoroughly before installing this boiler A description of this boiler can be found in Bulletin 300 which is included at the end of this ...

Page 3: ...hat it is in accordance with the minimum spacing specified on the UL label if provided CAUTION ALL BOILERS EXCEPT MODELS HWR 1638 THRU 1654 ARE TO BE MOUNTED ON NONCOMBUSTIBLE FLOORING 1 2 MECHANICAL CLEARANCES The clearances shown below are required for perimeter servicing of the boiler Note Front clearance to be 42 if opposing wall is conductive 36 F R O N T 18 18 MODELS HWR 1638 THRU HWR 1654 3...

Page 4: ...S Minimum thermal clearances should be maintained If the boiler is UL listed minimum clearances will be indicated on the UL Label Otherwise consult local codes and use good engineering judgment CAUTION THE BOILER ROOM TEMPERATURE SHOULD NOT EXCEED 30º C 86ºF WHICH SHOULD LIMIT THE TEMPERATURE WITHIN THE CONTROL CABINET TO A MAXIMUM OF 40ºC 104ºF ...

Page 5: ... system overpressure is supplied with the boiler This valve should be factory set at or below maximum working pressure of the boiler as stated on the boiler nameplate NOTE THE SYSTEM OPERATING PRESSURE MAY BE LIMITED BY THE SYSTEM COMPONENTS OTHER THAN THE BOILER IT IS THEREFORE ADVISABLE TO CHECK THE SAFE WORKING PRESSURE OF ALL COMPONENTS IN THE SYSTEM AND IF NECESSARY REPLACE THE SAFETY VALVE W...

Page 6: ...tatic test at a pressure equal to the safety valve setting of the entire boiler system be performed prior to boiler start up All leaks both boiler and piping should be stopped at this time NOTE SMALL LEAKS LESS THAN 2 DROPS PER MINUTE BETWEEN THE BODIES OF THE ELEMNT COMPRESSION FITTING AND THE ELEMENT FLANGES USUALLY STOP DURING THE FIRST FEW DAYS OF BOILER OPERATION LARGER LEAKS HOWEVER MAY NECE...

Page 7: ...e conductors per phase be certain that phasing is correct and that circuits are not mixed before energizing the boiler 3 2 GROUNDING Connect an equipment ground minimum copper wire size is indicated on both the wiring schematic and the panel near the grounding lug to the grounding lug located within the control cabinet NOTE ELECTRICAL INSTALLATION MUST BE MADE IN STRICT ACCORD WITH 1 THE BOILER S ...

Page 8: ...umulated during installation All such materials must be removed from the boiler prior to start up D All power wiring connections should be checked to assure tight connections NOTE HYDRO STEAM INDUSTRIES AS MANUFACTURER OF THIS BOILER WILL NOT BE RESPONSIBLE FOR DAMAGES INCURRED AT THE TIME BOILERS ARE STARTED UP UNLESS THE ABOVE STEPS HAVE BEEN TAKEN TO ASSURE THE BOILERS ARE PROPERLY PREPARED FOR...

Page 9: ...les while still maintaining the required responsiveness of the control Check the vendor supplied literature provided at the rear of this manual 4 2 3 TEMPERATURE CONTROL Boilers supplied with one or more control thermostats Smaller HWR boilers are provided with one or more independent control thermostats which switch on or off heating elements in accordance with their temperature setting The diffe...

Page 10: ... branch circuit power switch if a control circuit transformer is provided remove both the primary and secondary fuses and jump a 120V power supply to the secondary of the control transformer A Switch the control circuit power on the switch should light to indicate that the control circuit power is energized B Circuits of heating elements will now be switched on by the step controller or pressure c...

Page 11: ...ble switches gradually switch on the circuits Individually check each element circuit to assure that each leg is drawing its rated current NOTE SOME POWER FUSES MY BLOW AT STARTING DUE TO WATER OR OTHER CONTAMINATION ON THE ELEMENT TERMINALS SINCE THIS CONTAMINATION USUALLY BURNS FREE MERELY CHECK THE CIRCUIT FOR A SHORT AND THEN REPLACE THE FUSE IF A SHORT EXISTS HOWEVER REPLACE THE DEFECTIVE ELE...

Page 12: ...ck cutout action of the limit thermostats by individually rotating the dials to below the boiler water temperature The step control should reset to no load after each trip 5 2 2 Low Water Cutoff The LWCO level probe should be periodically checked If there is any seepage between the conductor and its insulator or between the insulator and the compression fitting replace the probe If the boiler is s...

Page 13: ...off power to the boiler 2 Drain boiler below level of flange containing defective element 3 Number and tag element wires and terminals to assure proper reassembly 4 Disconnect element wires to the flange 5 Remove flange from boiler nozzle 6 Remove buss bars 10 32 nuts insulators and washers from the defective element 7 Remove compression nut which holds the element in the flange 8 Slide element th...

Page 14: ...new gasket 15 Refill boiler and purge air from system 16 Check for leaks both before and after system is pressurized DETAIL ELEMENT INSTALLATION FERRULE 10 32 NUT COPPER BUSS 10 32 NUT FLAT WASHER 10 CERAMIC RUBBER ELEMENT FLANGE ELEMENT TIGHTEN 70 FT LBS MAX BRASS 110 FT LBS MAX S S TIGHTEN ENOUGH TO BULGE RUBBER SEAT IN FLANGE 5 4 CLEANING THE BOILER Boiler should be drained and cleaned periodic...

Page 15: ...Page 15 of 16 Vapor Power International LLC 551 S County Line Road Franklin Park Il 60131 Phone 630 694 5500 Fax 630 694 2230 ...

Page 16: ...Page 16 of 16 Vapor Power International LLC 551 S County Line Road Franklin Park Il 60131 Phone 630 694 5500 Fax 630 694 2230 ...

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