Electro Industries EB-CX Installation Manual
ELECTRO-BOILER
Commercial Series
INSTALLATION & OPERATING INSTRUCTIONS
Model EB-CX Series
APPLICATION: This Electro-Boiler is factory equipped with WarmFlo smart controller.
WarmFlo automatically regulates outlet water temperature at the temperature
level set on the front panel. This is a dial switch having eight positions. Setting
of this dial is dependent upon the setup configuration of the controller included
with the Electro-Boiler being installed. Two possible control strategies exist:
Non-outdoor reset – this control strategy does not utilize an outdoor
temperature sensor. Setting the dial is a fixed value, 90° F to 176° F.
Outdoor reset – this control strategy utilizes an outdoor sensor, thus the
boiler output target temperature will shift based on the outdoor
temperature. See outdoor reset curve detailed in this manual for more
information.
Primary application is any hydronic water heating system where reduced flow or
radiation can cause overheat conditions (example, zones). However, if it is a
mixture of large and small zones, the sudden capacity and flow changes may
cause some internal timing/over temp conditions. With the mixture of zones the
Electro Industries’ zone controller option is highly recommended.
This series is equipped for load management interrupt and can apply to standard
baseboard radiation, dual heat combinations, under floor radiant, wood boiler
supplement, etc.
ACCESSORIES: Attached BL001 lists various accessory or option items which are not part of
basic Electro-Boiler.
Note: This product meets the requirements of the ASME Boiler and Pressure Vessel Code.
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TABLE OF CONTENTS
Description Page
Table 1, Specific Model Number, Specific Information 1
Introduction 2
System or Water Flow 3
Multiple Zones & Radiant Temperatures 3
Zone Controller 3
Room Thermostat Placement 4
Multiple Boilers 4
Two-Temperature Operation or Feature 4
Installation Requirements 6
Mechanical Installation
Under-Floor Radiant 8
Dual Heat 9
Electrical Hookup 10
Water Fill Procedure 11
Controller Setup 12
Operational Tips 14
Replacement Parts List 16
Troubleshooting/Repair Helps 17
WarmFlo Operational Information 18
Drawings:
Basic Mechanical and Piping BX503, BX504
Hookup BH514, BH515
Internal Wiring Schematic UAW419, UAW420,
UAW421, UAW422
Low Voltage Wiring Diagram UAW849
Boiler Accessories BL001
Warranty – Single Phase Models XX017
Warranty – 3-Phase Models XX024
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Model
EB-CX-18-60
EB-CX-24-60
EB-CX-30-60
EB-CX-36-60
EB-CX-45-60
EB-CX-54-60
EB-CX-18-48
EB-CX-36-48
EB-CX-54-48
EB-CX-27-20
EB-CX-40-20
EB- CX-27-24
EB-CX-40-24
EB-CX-31
EB-CX-36
EB-CX-40
EB-CX-44
Table 1 – Specific Model Number, Specification Information
Stages – kW Flow Rate
Voltage
Rating
600V
3-phase
600V
3-phase
600V
3-phase
600V
3-phase
600V
3-phase
600V
3-phase
480V
3-phase
480V
3-phase
480V
3-phase
208V
3-phase
208V
3-phase
240V
3-phase
240V
3-phase
240V
Single
phase
240V
Single
phase
240V
Single
phase
240V
Single
phase
kW
Rating
18 61,500 18 30 3 3 6 6 6 4 8
24 82,000 23 30 3 6 4 4 8 8 4 11
30 102,500 29 45 3 6 5 5 10 10 4 14
36 123,000 35 45 3 6 6 6 12 12 4 16
45 153,500 44 60 3 9 5 10 15 15 4 20
54 184,500 52 70 3 9 6 12 18 18 4 24
18 61,500 22 30 3 3 6 6 6 - 4 8
36 123,000 44 60 3 6 6 6 12 12 4 16
54 184,500 65 80 3 9 6 12 18 18 4 24
27 92,000 75 100 3 6 4.5 4.5 9 9 4 12
40.5 138,000 113 150 3 9 4.5 9 13.5 13.5 4 18
27 92,000 65 80 3 6 4.5 4.5 9 9 4 12
40.5 138,000 98 125 3 9 4.5 9 13.5 13.5 4 18
31.5 107,500 131 80 + 100 2 + 2 7 9 9 9 4.5 4 14
36 123,000 150 100 + 100 2 + 2 8 9 9 9 9 4 16
40 136,500 167 125 + 125 2 + 2 8 10 10 10 10 4 18
44 150,000 183 125 + 125 2 + 2 8 11 11 11 11 4 20
Btu/h Amps
Disconnect
CB
Source
Terminals
Element
Qty
1 2 3 4
@15° ΔT
Min
GPM
Max
GPM
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INTRODUCTION
With this WarmFlo configuration, the electric heating elements are automatically controlled to establish a
fixed outlet water temperature. This outlet temperature is sensed by the WarmFlo controller and is
controlled to achieve and maintain the boiler’s set point temperature.
Even though this WarmFlo configured unit adjusts outlet temperature independent of water flow and
prevents high limiting even with marginal water flow, it is still very important that the hydronic system be
correctly designed for the building, the total heat loss requirement, and proper hydronics design and
installation practices. This boiler is the energy source for the water flow and radiation system. If the
water flow and radiation systems are not adequate for the Btu/h heat loss of the building, installing the
Electro-Boiler with WarmFlo will not necessarily supply the comfort and heating for the building.
“Cold boiler” notation – do not, under any circumstances, simply jumper R and W and allow the
temperature sensing controller to operate this Electro-Boiler as a “hot boiler”. Unless there is at least 4
GPM flow, the staging delays will cause temperature overshoot and could open up the manual reset
limits.
In most dual heat installations this Electro-Boiler is plumbed in parallel with an existing oil, gas, or wood
boiler. If piped in series, the Electro-Boiler is generally at the gas/oil outlet; but for wood boiler systems,
the Electro-Boiler must be on the inlet sides. The standby boiler cannot be operated as “hot boiler”. This
will defeat the Electro-Boiler. Rewire as required using the included standby boiler interface (brown
wires).
In the case of existing fossil fuel boiler conversions, it is assumed the expansion tank, valving, air
bleeder, and circulation pump are in place, in good operating condition, and adequate for the overall
system design.
In the case of new installation (floor radiant or baseboard), use standard hydronics water heating practices
for the necessary expansion tank, air bleeder, valving, water pump, etc., sized for the total capacity of the
system. The Electro-Boiler is turned on with an “R and W” closure from the zone system wiring.
The Table 1 model number identification shows the design rating and voltage source required for the
specific model. If you do not use the voltage source required for the specific model, performance derating may need to be taken into consideration. Also damage can result if the specific model is not
serviced with the voltage source shown in Table 1.
This EB-CX-** model series is low pressure (30 psig maximum) hydronic hot water with an operating
range between 90° F and 176° F, supply temperature.
APPROVED TUBING/PIPING
When plumbing this boiler and its peripheral parts to the loop system, all plumbing parts and/or tubing
must be sealed to prevent entrance of oxygen.
Use only tubing or polyethylene tubing with oxygen Diffusion Barrier.
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SYSTEM OR WATER FLOW
In order to prevent hi-limiting and assure full 20+ years parts life, the piping system/basic
plumbing/circulator pump must be arranged to provide flow greater than minimum GPM shown in Table
1. If zoned system, this applies when the smallest zone is operating.
MULTIPLE ZONES AND RADIANT TEMPERATURES
Same water temperature all zones – in this case the system can be setup as one pump with the water
circulated through the boiler and directly to a manifold containing the various zone valves. Although this
model series has a built-in outlet sensing and controller mechanism for staging the elements, also consider
the next section, Zone Controller. If not using zone controller, the end switches of all of the zone valves
are paralleled and directly control R and W to turn on the boiler.
Various water temperature requirements – if this is the case, a primary loop with mixing valve for the
various zone temperature requirements is necessary. Injection pump techniques can also be used.
However, usually injection pump techniques come with a controller which is designed to protect a gas
boiler from cool water return. This is simply not needed and a duplication with the temperature sensing
controller within this Electro-boiler and the injection pump controller will be of no benefit within the
operating system. The zone valve/zone pump control strategy must be wired to provide the boiler “R and
W” contact closure and the primary pump is connected to the boiler pump contacts. This assures the
primary pump is active and running whenever the boiler is turned on via contact closure on “R and W”.
At least one zone must be open before turning on the primary pump/Electro-Boiler. Do not design a
system where the Electro-Boiler is supposed to operate as a “hot boiler” based upon its outlet sensor
without the primary pump circulating water, minimum 4 GPM is required.
Electro Industries’ Zone Controllers – the Electro Industries’ zone controller priority zone has the
ability to communicate with this TS Series boiler and it will automatically switch to a low mass high
water temperature (150 or 180) during zone 1, priority switch on, operation. With this feature the TS
boiler can automatically take care of two temperature requirements thus eliminating the need for the
technique described in the paragraph above.
ZONE CONTROLLER
This EB-CX Series boiler controls the electric elements based upon
water temperature independent of flow; therefore, in theory, a staging
zone controller is not required; however, there are three suggestions or
reasons why a zone controller can simplify the installation and enhance
overall performance.
1. Zone wiring and troubleshooting convenience – the addition of the zone board allows for easy terminal
block and point to point wiring for each zone thermostat and each zone valve. Also there are LED’s
associated with the thermostat action and the zone valve action. This greatly simplifies wiring and future
troubleshooting with a neat terminal block wiring arrangement and the onboard LED’s.
2. Prevents over control or false staging up and down when the temperature sensors are attempting to
regulate – since Electro Industries’ zone controller also has staging “smarts”, the addition of the zone
controller will provide smoother boiler temperature control. The zone board has a dial switch for each
zone and the installer selects one of four zone capacity sizes. When dialing in the size closest to the zone
Btu/h capacity, the zone controller “smarts” only allows the appropriate boiler stage which can handle that
capacity. Also this is additive if more than one zone calls at any one time
3. Two temperature system with unbalanced zones – if the application includes zone one requiring high
temperature (fin tube, air handler, etc.) and the remaining zones are radiant floor low temperature, this zone
controller will automatically raise the output of the high temperature zone. This is a priority arrangement,
zone 1 holds off the other zones while the high temperature output is heating. If at the end of the high
temperature zone there is a call on any of the low temperature zones (up to three plus slav e 4), there will be
a pump only function until the outlet temperature drops below the front panel dial setting.
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ROOM THERMOSTAT PLACEMENT
Fin tube radiation, fan coil, etc. – heat only wall t-stat, connected to operate zone valves (see previous
section) or for single zone the t-stat is connected directly to Electro-Boiler R and W.
Floor radiant – comfort and proper space heating response is a direct relationship to the thermostat type
and the placement of the thermostat sensing bulb. Typically an under floor heating system can be broken
down into three categories.
A. Energy storage, water tubing is under the concrete or within the
sand base – the controlling thermostat must have a remote bulb, and
this remote bulb must sense the concrete slab temperature (slab stat).
Coordinated with the concrete pour, install a ¾” PVC, minimum bend
radius of 7 inches, and locate at approximately center (vertical) of the
concrete slab. The thermostat sensing bulb can later be pushed down
this PVC conduit. If the slab is already poured without conduit for slab
stat, use electronic remote sensing thermostat.
B. Floor covering, medium to high insulation – use slab stat as described in paragraph A above.
C. Quick response, hydronic tubing just under the concrete surface, no flooring material over
the concrete – in this case, heated water can directly radiate into the room, a standard wall mount
room thermostat is adequate. Mount room thermostat on an inside wall similar to most heating
systems.
MULTIPLE BOILERS
This boiler series now includes a method for automatically staging any
number of parallel-plumbed boilers. Order plug-in relay EB-C-STG5.
The thermostat is connected only to the first boiler, when all stages are
on for more than 5 minutes, this new plug-in relay module turns on the
next boiler (R and W), and a second EB-C-STG5 could be used to turn
on the third, etc. (reference BH507).
TWO-TEMPERATURE OPERATION OR FEATURE
When using Electro’s zone controller in priority mode, the boiler
system can automatically raise the outlet temperature with zone 1
calling. This is setup for default of 150° or pulling a jumper peg the
high temperature value is 176°. See appropriate zone controller
installation manual for details.
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Outdoor Reset Option
The EB-CX-** boiler comes equipped with an outdoor sensor (shipped loose). This sensor can be
connected to the board to allow for outdoor reset function.
What is Outdoor Reset?
Outdoor reset is where the Electro Boiler DT (desired water temperature) shifts up and down based on the
outdoor temperature. The water temperature coming out of the boiler will be higher when it’s cold outside
and lower when it’s warmer outside. The idea is to have the boiler work with the building heat loss to
maintain a more even BTU delivery to the space. This helps with overall system efficiency as well.
Outdoor Reset Activation
If it is determined that outdoor reset is required for this application, it needs to be activated.
Follow this sequence to activate outdoor reset:
Step 1: Power down the Electro-Boiler
Step 2: Connect the outdoor sensor
Red wire to “RED”
Black wire to “OT”
White wire to “COM”
Step 3: Power up the Electro-Boiler
See: CONTROLLER SETUP for more information on outdoor reset.
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INFORMATION/WATER FLOW CALCULATIONS
Water flow, GPM, can easily be calculated if the temperature rise across the electric boiler can be
measured.
The formula below can only be used when the temperature rise is stable and the boiler is not hi-limiting.
In other words, verify constant current draw and stable outlet temperatures for at least 15 minutes.
GPM – Single Phase
GPM =
Volts x Amps x 3.4
500 x Temp. rise
GPM – 3-Phase
GPM =
Volts x Amps x 1.732 x 3.4
500 x Temp. rise
INSTALLATION REQUIREMENTS
1. All installation work must be performed by trained, qualified contractors or technicians. Electro
Industries, Inc., sponsors installation and service schools to assist the installer. Visit our web site at
electromn.com for upcoming service schools.
WARNING
ALL ELECTRICAL WIRING MUST BE IN ACCORDANCE WITH NATIONAL ELECTRIC CODE
AND LOCAL ELECTRIC CODES, ORDINANCES, AND REGULATIONS.
WARNING
OBSERVE ELECTRIC POLARITY AND WIRING COLORS. FAILURE TO OBSERVE COULD
CAUSE ELECTRIC SHOCK AND/OR DAMAGE TO THE EQUIPMENT.
CAUTION
This unit can only be used for its intended design as described in this manual. Any internal
wiring changes, modifications to the circuit board, modifications or bypass of any controls, or
installation practices not according to the details of this manual will void the product warranty,
the CSA/us certification label, and manufacturer product liability. Electro Industries, Inc.,
cannot be held responsible for field modifications, incorrect installations, and conditions which
may bypass or compromise the built-in safety features and controls.
2. This installation manual and Electro-Boiler products relate only to the addition of the Electro-Boiler
to the hydronics system. The owner/ installer assumes all responsibility and/or liability associated
with any needed installation of the gas/oil boiler, pump, plumbing, system design, hydronics systems
or backup gas/oil boiler, etc. Any instructions or comments made within this manual (or factory
phone assistance) relating to the gas/oil furnace are provided as comments of assistance and “helps”
only.
CAUTION
Hazards or unsafe practices could result in property damage, product damage, severe personal
injury and/or death.
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3. Remember, safety is the installer’s responsibility and the installer must know this product well
enough to instruct the end user on its safe use.
Safety is a matter of common sense - - a matter of thinking before acting. Professional installers have
training and experienced practices for handling electrical, sheet metal, and material handling
processes. Use them.
CLEARANCES
MINIMUM CLEARANCE FROM
COMBUSTIBLE SURFACES
BACK 0 INCH 0 MM 0 INCH 0 MM
LEFT 1 INCH 25 MM 16 INCHES 406 MM
RIGHT 1 INCH 25 MM 6 INCHES 152 MM
FRONT 1 INCH 25 MM 24 INCHES 610 MM
TOP 1 INCH 25 MM 24 INCHES 610 MM
BOTTOM REQUIRED CLEARANCE – 16 INCHES/406 MM
SUGGESTED MINIMUM
SERVICE CLEARANCE
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MECHANICAL INSTALLATION – UNDER-FLOOR RADIATION
CAUTION
Electro Industries Inc. requires the use of dielectric isolation between the boiler vessel supply
and return piping when the boiler is plumbed using copper or any other dissimilar metal.
Damage to the vessel caused by galvanic corrosion voids Electro Industries’ warranty.
Reference drawing BX503
1. With the typical radiant floor system, a dual heat backup boiler is uncommon. If a backup boiler is
required, please reference “Mechanical Installation – Dual Heat” section.
2. Unpack the Electro-Boiler, the safety relief and pipe fittings are packed within a small carton. The
safety relief is plumbed to the ¾” pipe as shown on BX503 (or may be part of other components
shown on BX503).
3. The Electro-Boiler must be positioned with the vessel vertical. The water IN/OUT ports must be at the
top. The unit will not function properly with the vessel in a horizontal position.
NOTE: Mount at least 20 inches above the floor to allow element removal and service at the bottom.
4. The plumbing components and plumbing layout shown on drawing BX503 have been very carefully
chosen and should be plumbed as shown. When following this diagram, the water fill procedure
becomes very simple and almost guarantees the removal of all air or prevents air locking problems.
Experienced hydronic heating installers may be able to eliminate some components but the inclusion
of these components guarantees installation and initial operating success.
5. The vessel is factory constructed with an “air trap” chamber at the top of the vessel, connected to the
¾” pipe and arrangement shown on BX503.
6. The key mechanical components required include:
Expansion Tank – as a closed loop hydronic heating system, a minimal expansion tank is
required. This can be an air diaphragm tank as provided in the plumbing kit or a basic
“empty” tank where air is compressed at the tank top.
Inlet Temperature Gauge – recommended to observe the operation of the system.
Air Vent – install with the pressure relief valve as shown on drawing BX503.
Inline Air separator – this can be installed ahead of the pump with the expansion tank
moved to this point. However, the vessel designed air trap and the piping arrangement
leading to the air bleeder works very well.
Pressure Safety Valve – this is required and is furnished as a loose component with the
boiler unit itself. Failure to install the provided, 30 PSI, pressure relief valve as shown void
warranty and the product listing. During purging there is a requirement to bleed out the
initial air within this ¾” pipe leg by manually holding open the relief valve. Add the
necessary pipe extension to the relief valve to prevent water damage on this unit or
surrounding area.
Gate Valve/Drain Valve – these are for servicing and easy fill purposes.
Circulating Pump – depending upon system lift and system loop resistance, the proper
circulating pump is required to guarantee the minimum GPM flow as specified in Table I, page 1.
Comment: Circulator pump can be in the outlet or inlet. Newer, higher quality pumps seem to
work better in the “supply” line, plus pumping away from the expansion tank is preferred.
7. To ensure safe boiler operation adequate system pressure must be maintained. Some expansion tanks
may have an integral regulator and “port” for water source hookup.
8. Depending upon water conditions, determine whether water additives are necessary.
9. Purge and fill water system. Do not allow the electric element to come on until the system is purged
and you have verified proper water circulation. If the pump is needed, jumper the two orange wires
in order to operate the pump directly from its own 120 volt source.
10. Purge each loop individually, one at a time.
11. Check for leaks.
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MECHANICAL INSTALLATION – DUAL HEAT
CAUTION
Electro Industries Inc. requires the use of dielectric isolation between the boiler vessel supply
and return piping when the boiler is plumbed using copper or any other dissimilar metal.
Damage to the vessel caused by galvanic corrosion voids Electro Industries’ warranty.
Reference drawing BX504
1. Unpack the Electro-Boiler. The safety relief and pipe fittings are packed within a small carton.
2. In most dual heat installations this Electro-Boiler is plumbed in parallel with an existing oil, gas, or
wood boiler. If piped in series, the Electro-Boiler is generally at the gas/oil outlet; but for wood
boiler systems, the Electro-Boiler must be on the inlet sides. The standby boiler cannot be operated
as “hot boiler”. This will defeat the Electro-Boiler. Rewire as required using the included standby
boiler interface (brown wires).
3. Standard hydronic hot water heating practices apply. This procedure assumes adequate piping size to
meet the flow requirements of the specific boiler model, expansion tank, pump, zones, etc. are
properly designed and installed.
4. The Electro-Boiler must be positioned with the vessel vertical. The water IN/OUT ports must be at
the top. The unit will not function properly with the vessel in a horizontal position.
NOTE: Mount at least 20 inches above the floor to allow element removal and service at the
bottom.
5. Typically this unit is wall hung next to the existing boiler.
6. Use the ¾” pipe fittings to install the safety relief valve and air vent. Add the necessary piping to the
safety relief valve so that water damages do not occur in the surrounding area.
7. Connect the “hot” water line from the fossil fuel boiler to the Electro-Boiler "inlet". Connect the
Electro-Boiler "outlet" to the main feed line. When facing the Electro-Boiler vessel, the "outlet" is on
the LEFT.
NOTE: Wood applications, plumb so electric feeds the wood boilers.
8. If piping contains any "U" bend, an air vent may be required at the top.
9. When possible, isolating ball valves are recommended for easy servicing.
10. To ensure safe boiler operation and prevent element damage, the system should contain a pressure
regulator and an automatic water fill valve. Expansion tank may have an integral regulator and “port”
for water source hookup.
11. Depending upon water conditions, determine whether water additives are necessary.
12. Purge and fill water system. Do not allow the electric element to come on until the system is purged
and you have verified proper water circulation. If the pump is needed, short out the two orange wires
in order to operate the pump directly from its own 120 volt source.
13. Check for leaks.
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