Introduction
This manual provides essential information for the installation, operation, and maintenance of the HydroStat EW-202 Extended Electro-Well. This component is designed to enable the low water cut-off function in HydroStat Controls, specifically for tankless coil boilers. Proper installation and adherence to these guidelines are crucial for safe and efficient operation.
The HydroStat EW-202 is a 3/4" NPT extended electro-well featuring a long nut, designed for seamless integration with compatible HydroStat control systems to monitor water levels and prevent boiler damage due to low water conditions.
Setup and Installation
Safety First: Before beginning any installation, ensure the boiler system is completely de-energized and depressurized. Allow the system to cool down to prevent burns.
- Prepare the Boiler: Locate the designated port for the electro-well on your tankless coil boiler. Ensure the area is clean and free of debris.
- Apply Thread Sealant: Apply an appropriate thread sealant (e.g., PTFE tape or pipe dope) to the 3/4" NPT threads of the EW-202 electro-well.
- Install the Electro-Well: Carefully thread the EW-202 into the boiler's designated port. Use a wrench to tighten the electro-well securely, ensuring a watertight seal. Do not overtighten.
- Connect to HydroStat Control: Connect the wiring from the EW-202 to the appropriate terminals on your HydroStat control unit, following the wiring diagram provided with your HydroStat control. Ensure all electrical connections are secure and insulated.
- System Re-pressurization and Testing: Once installed, slowly re-pressurize the boiler system and check for leaks around the electro-well connection. Restore power to the system and verify the proper functioning of the low water cut-off feature according to your HydroStat control's instructions.
Figure 1: Angled view of the HydroStat EW-202 Extended Electro-Well, showing the brass body and copper probe.
Operation
The HydroStat EW-202 functions as a critical sensor for the HydroStat low water cut-off system. When installed, its internal probe extends into the boiler's water chamber. The HydroStat control continuously monitors the electrical conductivity between the probe and the boiler's metal body.
Normal Operation: When the water level is above the probe, electrical conductivity is maintained, indicating a safe operating water level. The boiler operates normally.
Low Water Condition: If the water level drops below the tip of the probe, the electrical circuit is interrupted. The HydroStat control detects this loss of conductivity and immediately activates the low water cut-off safety feature, shutting down the boiler to prevent damage from overheating due to insufficient water.
Figure 2: Side view of the HydroStat EW-202, highlighting the threaded connection and the extended copper probe.
Maintenance
Regular maintenance ensures the longevity and reliable operation of the HydroStat EW-202 and the associated low water cut-off system. It is recommended to perform these checks annually or as part of your boiler's routine maintenance schedule.
- Visual Inspection: Periodically inspect the electro-well for any signs of corrosion, leaks, or physical damage. Ensure the wiring connections are secure and free from fraying or damage.
- Probe Cleaning: Over time, mineral deposits or sediment can accumulate on the probe, potentially affecting its conductivity. If the system experiences nuisance trips or erratic behavior, it may be necessary to drain the boiler, remove the electro-well, and gently clean the copper probe with a non-abrasive brush or cloth. Ensure the boiler is completely cool and depressurized before removal.
- System Testing: Regularly test the low water cut-off function as per the instructions provided with your HydroStat control. This typically involves manually lowering the water level to verify the system shuts down as intended.
Figure 3: Top-down angled view of the HydroStat EW-202, showing the NPT threads and the extended probe.
Troubleshooting
If you encounter issues with your HydroStat EW-202 or the associated low water cut-off system, consider the following common troubleshooting steps:
| Problem | Possible Cause | Solution |
|---|---|---|
| Boiler shuts down unexpectedly (nuisance trip). |
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| Boiler does not shut down on low water. |
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| Leakage around the electro-well. |
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Important: For complex issues or if you are unsure about any step, always consult a qualified HVAC technician. Do not attempt repairs beyond your skill level.
Specifications
| Attribute | Detail |
|---|---|
| Product Name | HydroStat EW-202 Extended Electro-Well |
| Part Number | 48-202 |
| Brand | Hydrolevel |
| Connection Type | 3/4" NPT (National Pipe Taper) |
| Application | Enables low water cut-off function for HydroStat Controls in Tankless Coil Boilers |
| Compatibility | Used with HydroStat Controls |
| ASIN | B08V5BT71K |
| First Available | January 27, 2021 |
Warranty Information
Specific warranty details for the HydroStat EW-202 are not provided in this document. For information regarding product warranty, please refer to the documentation included with your purchase or contact Hydrolevel directly through their official website or customer service channels.
Customer Support
For technical assistance, troubleshooting beyond this guide, or inquiries about replacement parts, please contact Hydrolevel customer support. Contact information can typically be found on the manufacturer's official website or on the product packaging.
When contacting support, please have your product model (EW-202) and part number (48-202) readily available.
