Cemline Corporation EHB, Installation And Maintenance Manual

Page 1: ...one 724 274 5430 FAX 724 274 5448 www cemline com Installation Operation and Maintenance Manual CEMLINE CORPORATION Electric Water Heaters Series EHB FTB and Electric Water Steam Boilers EHB Series Water Heaters FTB SeriesWater Heaters Water and Steam Boilers ...

Page 2: ...ing the Unit 12 Mounting the Unit 12 Familiarization with the Unit and Components 13 Connecting the Cold Water Source and Hot Boiler Water Outlet 13 Connecting the Electric Power Source 14 Piping the Relief Valve to Vent and Drain 15 Completing Installation 16 Operation 17 Startup Procedures 17 Shutdown Procedures 19 Daily Operation Electric Water Heaters and Water Boilers 19 Daily Operation Elect...

Page 3: ... Replacement 48 Maintenance Electric Boilers Only 50 Contactor Coils Replacement 50 Gauge Glass Replacement Electric Steam Boilers Only 51 High Pressure Cut Off Switches Replacement Electric Steam Boilers Only 51 Step Controller Including Replacement of Individual Component Boards Replacement 53 Potentiometer Replacement 55 Solid State Step Controller Thermistor Replacement 56 Water Feeder or Pump...

Page 4: ...and Boilers i e valves controls gauges components etc CEMLINE strives to use only the highest quality components in building Electric Water Heaters and Boilers However CEMLINE has no direct control over their manufacture or their consistent quality CEMLINE is not responsible for injury to personnel or product damage due to the improper installation operation and or maintenance of CEMLINE Electric ...

Page 5: ... Electric Water and Steam Boilers Power Requirements For Heating Water CEMLINE Electric Water Heaters and Boilers depending on the specific unit can be configured to require 208 240 415 or 480 volts for heating water The following table lists the voltage and phase configurations available Type of Unit Available Voltages Phase Requirements EHB Series Water Heaters 208 240 415 480 3 Phase 3 Phase 3 ...

Page 6: ...d with the National Board of Boiler and Pressure Vessel Inspectors STONESTEEL tanks are lined with hydraulic cement using the exclusive CEMLINE patented process This time proven process prevents rust and corrosion common to metal tanks and helps guarantee exceptionally long life Electric Boilers CEMLINE Electric Boilers are equipped with Carbon Black tanks Each tank is designed and constructed in ...

Page 7: ...CEMLINE Electric Water Heaters consist of one or more copper or incoloy sheathed removable immersion rods mounted in standard A N S I FTB Series or nonferrous EHB Series flanges These rods are grouped together as three 3 phase deltas to achieve the required total kilowatt Each rod contains resistance wire surrounded by an ample thickness of compressed magnesium oxide Individual rods are removable ...

Page 8: ...ncluded in CEMLINE Electric Water Heaters and Boilers have been specifically selected to meet the individual design specifications of the unit Each component is judged to be of the highest quality to provide long life and superior performance ...

Page 9: ...range of configurations and capacities v Configured to utilize 208 240 415 or 480 volts for heating water Warranty Information STONESTEEL tanks are warranted for ten 10 years from date of purchase first 5 years non pro rated second 5 years pro rated All other components used in CEMLINE Electric Water Heaters and Boilers are warranted for one 1 year from startup or eighteen 18 months from date of p...

Page 10: ...CORPORATION at the address listed above or call toll free USA Phone 800 245 6268 Note Please include the model and serial number of the unit for which the parts are being ordered If ordering by phone please have this information readily available ...

Page 11: ...ers and Boilers are designed for indoor use only unless otherwise required by design specifications Each unit requires at least two feet 2 of clearance around and above the unit It should be located on a level surface no more than one half degree º of slope capable of supporting the total weight of the unit when filled to capacity The unit should be mounted to the floor following applicable archit...

Page 12: ...All precautions contained in the warnings should be carefully followed to reduce the chance of injury Note Throughout this manual warnings will be denoted by the symbol t All documentation for each major component has been included with the unit It is strongly recommended that each document be reviewed before attempting any installation operation or maintenance procedures The documentation for eac...

Page 13: ...aces heating elements hot water outlet lines etc to cool before starting the procedure 3 assure that all incoming and outgoing water lines have been turned off at the manual shutoff valves and 4 completely drain the tank after allowing the water time to cool t Hot boiler water presents a situation that can be very dangerous due to the fact it is under pressure and at very high temperatures To avoi...

Page 14: ... and requires only connection to water and a power source to be ready for operation Each Electric Water Heater employs a STONESTEEL tank and each Electric Boiler employs a Carbon Black tank providing years of trouble free service All components used in the unit are of highest quality and meet or exceed all customer design specifications and A S M E Code regulations Each Electric Water Heater and B...

Page 15: ...capacity If crated when shipped once the unit has been set in place the crating should be carefully removed Examining the Unit After the unit has been set in place and uncrated it should be carefully examined to assure that neither the main unit nor any of the components have been damaged during shipping If any evidence of damage is detected that could affect the safe operation of the unit contact...

Page 16: ...ng Diagrams that indicate the location and specifications for each connection that must be made In addition the drawings will enable the installer s to determine the flow direction of the water Connecting the Cold Water Source and Hot Boiler Water Outlet Note Before making any connections of cold water inlet or hot boiler water outlet to the unit assure that all piping is clean and free of foreign...

Page 17: ...ase the unit must be disconnected from the system The shutoff valve should be in the closed position and remain so until the installation is complete Note Refer to local codes and specifications for site specific shutoff and check valve requirements For all piping connections the use and or type of joint compound or sealer on the joint should be determined by referring to local codes accepted prac...

Page 18: ...r leads can be determined from the detailed Wiring Diagrams supplied with the unit Typical Wiring Diagrams are contained in Appendix A of this manual If in doubt of the exact location for the connections contact CEMLINE CORPORATION for assistance Connect the proper size ground wire to the unit by means of the pressure connector supplied with the unit Before turning on the power supply it is strong...

Page 19: ...d be piped to a to a suitable drain Piping the relief valve to a suitable vent or drain will prevent both water and heat damage to the unit as well as reduce the risk of injury from released steam All pressure relief venting and piping should comply with local codes It is the responsibility of the purchaser installing contractor to assure this compliance Completing Installation Installation of the...

Page 20: ...ed to assure they are set to the desired operating temperature The temperature for all of the individual thermostats is set by turning the black dials to the desired temperature This temperature is normally set in the range of 130 to 140 degrees 130 to 140 The unit is equipped with one 1 individual thermostat for each set of three 3 heating elements Note All individual thermostats should be set to...

Page 21: ...t for leakage These can be viewed within the electric control cabinet If a leak is detected shut off the cold water inlet valve and check the tightness of the bolts used to mount the heating element flange s to the tank If after tightening any loose bolts water continues to leak contact CEMLINE CORPORATION for assistance If the unit has filled to the correct level and no leaks are detected close a...

Page 22: ... the power supply in an approved manner before proceeding t The combination of electricity and water can pose a very dangerous situation Assure that all power has been shut off disconnected and locked out in an appropriate manner before attempting any installation or maintenance procedures 2 Turn off the cold water inlet and hot boiler water outlet shutoff valves 3 Relieve the pressure within the ...

Page 23: ...lem exists that should be investigated Daily Operation Electric Steam Boilers CEMLINE Electric Steam Boilers are equipped with a gauge glass and water feeder or pump to insure proper water level within the unit The water level within the unit should be checked via the gauge glass at least twice a day ...

Page 24: ... contacting CEMLINE CORPORATION Note Replaceable Parts may vary depending on design specifications of the unit Replaceable Parts CEMLINE Electric Water Heaters and Boilers Vertical and Horizontal Operating Thermostats High Temperature Limit Thermostat Manual Reset Auxiliary High Temperature Limit Thermostat Automatic Reset Contactors Fuses Power Circuit Fuses Transformer Heating Element EHB Type C...

Page 25: ... Parts For One 1 Year of Duty Because of the built in quality and long life of CEMLINE Electric Water Heaters and Boilers there are no spare parts suggested for stock during the first year of service For Five 5 Years of Duty It is recommended that the user stock a replacement heating element s and gasket s for possible replacement during the first five 5 years of duty If suggested maintenance proc...

Page 26: ...CEMLINE CORPORATION P O Box 55 Cheswick PA 15024 Phone 800 245 6268 Fax 724 274 5448 Note Replacement parts can also be ordered through your authorized sales agent Please include the model and serial number of the unit for which the parts are being ordered If ordering by phone please have this information readily available ...

Page 27: ... Monthly Quarterly Semi Annually Annually Contactors ü ü Fuses Power Circuits ü ü Fuses Transformer ü ü Gauges Pressure and Temperature ü ü Heating Element s and Gasket s ü ü Lines Inlet and Outlet ü ü Low Water Cut Off Control ü ü Pilot Light s ü ü Power Connections and Leads ü ü Relief Valve Pressure and Temperature ü ü Shutoff Valves Manual ü ü Thermostat Auxiliary High Temperature Limit ü ü Th...

Page 28: ...s Only ü ü minimum High Pressure Cut Off ü ü Potentiometer ü ü Pump Steam Boilers Only Some Models ü ü minimum Step Controller ü ü Step Controller Thermistor ü ü Water Feeder Steam Boilers Only Some Models ü ü minimum If any problems are detected during inspections refer to either the Troubleshooting page 26 or Maintenance page 29 sections of this manual for specific actions and instructions ...

Page 29: ...ct the problem Electric Water Heaters and Boilers Symptom Probable Cause and Remedy 1 2 3 4 5 6 7 8 9 10 11 The unit does not maintain the required temperature at the rated capacity ü ü ü ü ü ü ü ü ü ü Outlet temperature is too high ü ü ü ü Pressure temperature relief valve pops ü ü ü ü The unit does not maintain the design pressure ü ü ü ü A loud banging in the unit or primary piping not to be co...

Page 30: ...s been wired for damage or malfunction 5 A heating element has shorted and is no longer functioning n Replace the heating element Reference heating element replacement procedure on page 34 6 The pressure temperature relief valve is malfunctioning n Replace the pressure temperature relief valve Reference pressure temperature relief valve replacement procedure on page 45 7 Water pressure supplied to...

Page 31: ...nt procedure on page 58 11 The solid state step controller or thermistor probe is malfunctioning n Check and replace the step controller or internal boards and thermistor if found to be defective Reference the step controller and board replacement procedure on page 53 reference the step controller thermistor replacement procedure on page 56 ...

Page 32: ...the unit to be taken off line before the procedure is performed and put back on line after the procedure is completed It is recommended that the maintenance personnel performing these procedures review the startup and shutdown procedures detailed on pages 17 to 19 of this manual before attempting any maintenance procedure Any component s directly connected or linked to the component being replaced...

Page 33: ...and are accessible through the electric control cabinet door While the operating and auxiliary high temperature limit thermostats are similar is physical appearance the operating thermostats have a black dial for setting temperature preference while the auxiliary high temperature limit thermostat has a red dial There is one 1 operating thermostat for each set of three 3 heating elements There is o...

Page 34: ...ocate the thermostat to be replaced and tag the wires attached to the thermostat to assure proper reconnection after the new thermostat has been installed 4 Disconnect the wires from the thermostat terminals 5 Trace the capillary tube leading from the thermostat to the tank It may be necessary to move a small portion of the fiberglass insulation to gain access to the location on the tank where the...

Page 35: ...onnections 13 Tighten the body of the compression fitting with the correct size wrench A socket can not be used to tighten the fitting because of the attached capillary tube Do not tighten the compression fitting cap nut 14 Gently withdraw any extra length of the capillary tube from the tank pulling the temperature probe snug against the inside of the compression fitting body Note If the temperatu...

Page 36: ... that the power has been turned off and locked out unlock and open the electric control cabinet door 3 Locate the defective contactor and tag the connected wires to assure proper reconnection after the new contactor is installed Disconnect the wires from the contactor 4 Remove the contactor from its mounting 5 Verify that the new contactor is rated the same as the contactor being replaced 6 Mount ...

Page 37: ... it can be removed by pulling it out from the receptacle 5 Insert the new fuse by aligning it with the receptacle and pushing it into place 6 After assuring that all tools and other foreign matter have been removed from the electric control cabinet and that all personnel are clear turn on the power 7 If the replaced fuse blows again refer to the appropriate maintenance section for the component wh...

Page 38: ... correct reconnection 4 Using 9 16 socket remove the four 4 mounting bolts that secure the heating element flange to the tank mounting flange 5 Remove the electric heating element from the tank by pulling straight out from unit 6 Thoroughly clean the face of the flange to remove any particles of gasket or sealer that remain This will help assure a proper seal when the new heating element and gaske...

Page 39: ... above 14 Refill the tank completely with water carefully checking each gasket and element for signs of leakage If leakage is detected check to assure that the bolts have been tightened to the proper torque If this does not stop the leakage replace the gasket or element 15 Check to make sure all electrical connections are tight 16 After checking to make sure all tools foreign matter has been remov...

Page 40: ...socket and ratchet remove the mounting bolts and nuts that secure the heating element flange to the tank mounting flange Note Because of the various sizes of FTB heating elements available the number and size of the mounting bolts will vary 7 After removing all mounting bolts and nuts remove electric heating element from the tank by pulling straight out from unit Note If the entire heating element...

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Page 42: ...ators nuts and jumper bars to their original element configuration 17 If the entire heating element is to be replaced with a new unit confirm that the rating of the replacement element matches that of the element being replaced Each heating element has the rated voltage and wattage listed on the face plate 18 Thoroughly clean the face of flange on the tank 19 Slide the new gasket over the heating ...

Page 43: ...g sequence etc for CEMLINE Electric Water Heaters and Boilers Reference the applicable drawing for the unit being serviced d Apply torque in twenty percent 20 1 5 steps of required final torque loading all bolts at each step before proceeding to the next step The following tables list ANSI approved target torques for both Grade A and Grade 5 bolts The correct target torque can be determined by the...

Page 44: ...pplicable sequential order 0 180 90 270 45 225 135 315 etc at each step until final target torque is reached see applicable diagram contained in Appendix B f Use rotational tightening until all bolts are stable at final torque level Two 2 complete times around is usually required 22 Using an Ohm meter check from the terminals to ground to assure that no short circuit exists 23 Reconnect the leads ...

Page 45: ...any installation or maintenance procedures 2 After assuring that the power has been turned off and locked out unlock and open the electric control cabinet door 3 Tag the wires connected to the isolation transformer to assure proper reconnection after the new transformer is installed Disconnect the wires from the transformer 4 Remove the transformer from its mounting 5 Verify that the new transform...

Page 46: ...ing from the low water cut off If necessary consult the Wiring Diagram s supplied with the unit to determine the correct wires to detach Feed the wires out of the electric control cabinet housing 4 Break the joints above and below the low water cut off control Note Depending on the specific unit it may be necessary to break the joints of other components to allow removal of the low water cut off c...

Page 47: ...ocedures 2 Unlock the door of the electric control cabinet Make a sketch of how the wires from the low water cut control off are connected within the panel 3 Disconnect the wires leading from the low water cut off control See the wiring diagram s supplied with the unit to determine the correct wires to detach 4 Remove the low water cut off control from its mounting 5 Verify the new low water cut o...

Page 48: ...ew the relief valve from the port in the tank 4 Install the new valve by screwing it into the relief valve port in the tank Follow recommendations contained in the manufacturer s documentation local codes or accepted contractor practices as to the use and or type of joint compound or sealer at the connections 5 Reconnect the drain line leading from the relief valve to drain Note For Electric Steam...

Page 49: ...llow Steps 1 through 5 of the shutdown procedure page 19 to take the unit off line before attempting to replace the pressure gauge t The combination of electricity and water can pose a very dangerous situation Assure that all power has been shut off disconnected and locked out in an approved manner before attempting any installation or maintenance procedures 2 After assuring that the power has bee...

Page 50: ...Remove the switch from its mounting 5 Verify that the new switch is rated the same as the switch being replaced 6 Mount the new switch in the same position as the original switch 7 Reconnect the wires in the same position from which they were removed from the original switch 8 After assuring that all tools and foreign materials have been removed from the electric control cabinet and that all perso...

Page 51: ...they were removed 6 Turn on the power and check to assure that the pilot light illuminates Circuit Breaker Replacement If a circuit breaker has been determined to be defective and must be replaced follow the procedures outlined below 1 Turn off and lock out the power in an approved manner t The combination of electricity and water can pose a very dangerous situation Assure that all power has been ...

Page 52: ...he original circuit breaker 8 After assuring that all tools and foreign materials have been removed from the electric control cabinet and that all personnel are clear of the unit turn on the power As the power is turned on visually inspect for signs of arcing If any arcing is detected immediately turn off the power examine the wires and assure the tightness of all connections 9 If no arcing is det...

Page 53: ...cked out unlock and open the electric control cabinet door 3 Locate the defective contactor coil and tag the connected wires to assure proper reconnection after the new contactor coil is installed Disconnect the wires from the coil 4 Remove the contactor coil from its mounting 5 Verify that the new contactor coil is rated the same as the contactor coil being replaced 6 Mount the new contactor coil...

Page 54: ...unscrew the fittings from the tank until the gauge glass assembly is free 4 Install the new gauge glass assembly by screwing the fittings into the tank Follow recommendations contained in the manufacturer s documentation local codes or accepted contractor practices as to the use and or type of joint compound or sealer at the connections 6 Follow the startup procedures page 17 to put the unit back ...

Page 55: ...ow 1 Follow Steps 1 through 5 of the shutdown procedure page 19 to take the unit off line before attempting to replace the switch t The combination of electricity and water can pose a very dangerous situation Assure that all power has been shut off disconnected and locked out in an approved manner before attempting any installation or maintenance procedures 2 Assure that the power has been turned ...

Page 56: ...ividually replaced Boards are available directly from CEMLINE CORPORATION Those available are n Mother Board n Black Board SC End Board n White Boards SC Heat Stages n Yellow Board Step Delay and n Green Board Input Conditioner The following procedures detail both changing individual boards as well as replacing the solid state step controller If any questions are not clearly addressed contact CEML...

Page 57: ... removed from the step controller remove the screws securing the step controller to its housing Remove the step controller unit 8 Assure that the new step controller is rated the same as the one being replaced In addition check to make sure that the individual boards contained in the new step controller correspond exactly with those contained in the original controller 9 Position the new step cont...

Page 58: ...2 Locate the box mounted on the exterior of the boiler housing the solid state step controller and potentiometer Remove the cover 3 Tag the wires connected to the potentiometer to assure proper reconnection after the new potentiometer is installed Disconnect the wires Note Care should be taken not to damage the solid state step controller or any of its component boards during these procedures 4 Re...

Page 59: ...situation Assure that all power has been shut off disconnected and locked out in an approved manner before attempting any installation or maintenance procedures 2 After assuring that the power has been turned off and locked out the pressure bled from the tank the water drained and the unit has cooled unlock and open the electric control cabinet door 3 Open the electric control cabinet and locate t...

Page 60: ...ler at the connections 11 Tighten the body of the compression fitting with the correct size wrench A socket can not be used to tighten the fitting because of the wires attached to the thermistor Do not tighten the compression fitting cap nut 12 Gently withdraw any extra length of the wires from the tank pulling the thermistor so that 1 of the probe is exposed on the outside of the fitting Note If ...

Page 61: ...eplaced in the same position after installation of the new component Remove the wires after tagging 3 Break the joints above and below the component Note Depending on the exact design of the unit it may be necessary to break additional components loose to provide access for removing the water feeder or pump controller from the system If this is the case care should be taken to not damage any other...

Page 62: ...59 9 If no leaks are found follow the startup procedures page 17 to put the unit back on line ...

Page 63: ...60 Appendix A Typical Wiring Diagrams Figure A 1 Typical Wiring Diagram For Electric Water Heaters ...

Page 64: ...61 Appendix A cont d ...

Page 65: ...62 Appendix A cont d ...

Page 66: ... Appendix B Bolt Torque Procedure SEQUENTIAL ORDER ROTATIONAL ORDER 1 2 1 3 4 5 5 6 3 7 8 7 2 6 4 8 SEQUENTIAL ORDER ROTATIONAL ORDER 1 2 1 3 4 5 5 6 9 7 8 3 9 10 7 11 12 11 2 6 10 4 8 12 8 BOLTS 12 BOLTS ...

Page 67: ... ORDER ROTATIONAL ORDER 1 2 1 3 4 9 5 6 5 7 8 13 9 10 3 11 12 11 13 14 7 15 16 15 2 10 6 14 4 12 8 16 SEQUENTIAL ORDER ROTATIONAL ORDER 1 2 1 3 4 13 5 6 5 7 8 17 9 10 9 11 12 3 13 14 15 15 16 7 17 18 19 19 20 11 2 14 6 18 10 4 16 8 20 12 16 BOLTS 20 BOLTS ...

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