Gas Fired Boiler Residential and Commercial Models INSTALLATION START-UP MAINTENANCE PARTS WBR Models* 055 / 080 / 110 / 155 / 199 / 285 / 399 Model Names with “LP” denote propane gas, “N” denote natural gas, and “PU” denote included pump Heat Exchanger Bears the ASME “H” Stamp This manual must only be used by a qualified heating installer/service technician. Read all instructions in this manual before installing. Perform steps in the order given.
IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER BOILER. WHAT TO DO IF YOU SMELL GAS Do not try to light any boiler. Do not touch any electrical switch. Do not use any phone in your building. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important product information. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Code for the installation of Heat Producing Boilers (latest version), from American Insurance Association, 85 John Street, New York, NY 11038. The latest version of the National Electrical Code, NFPA No. 70. NOTE: The gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21.13 – latest edition.
TABLE OF CONTENTS PART 1 – GENERAL SAFETY INFORMATION .......................................................................................................................... 8 A. PRECAUTIONS .......................................................................................................................................................................... 8 B. IMPROPER COMBUSTION .......................................................................................................................
L. GLYCOL ANTIFREEZE SOLUTIONS ....................................................................................................................................... 33 M. ZONING WITH ZONE VALVES ............................................................................................................................................... 33 N. ZONING WITH CIRCULATORS ...........................................................................................................................................
E. PURGE AIR FROM WATER SYSTEM ..................................................................................................................................... 61 F. CHECK THERMOSTAT CIRCUIT(S) ....................................................................................................................................... 61 G. CONDENSATE REMOVAL ......................................................................................................................................................
PART 1 – GENERAL SAFETY INFORMATION A. PRECAUTIONS This boiler is for indoor installations only. Clearance to combustible materials: 6” top, bottom, and sides, 0” back. Left side has all boiler mechanical connections. Front must have room for service, 24” recommended. (A combustible door or removable panel is acceptable front clearance.) This boiler has been approved for closet installation. Do not install this boiler directly on carpeting. For installation on combustible flooring.
Do not use petroleum-based cleaning or sealing compounds in boiler system. Gaskets and seals in the system may be damaged, possibly resulting in substantial property damage. Do not use “homemade cures” or “boiler patent medicines”. Substantial property damage, damage to boiler, and/or serious personal injury may result. Continual fresh make-up water will reduce boiler life. Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure.
Exhaust PVC Coupling with Screens Installation Manual Warranty CSD-1 Form H-2 Data Sheet NAT to LP Conversion Kit (Included with NAT models) B. HOW BOILER OPERATES Condensing technology intelligently delivers hydronic heating while maximizing efficiency. Outlined below are the features of the system and how they operate: Stainless Steel Heat Exchanger - The highly efficient stainless steel heat exchanger is designed to extract all available heat from the supply line before it is exhausted.
Condensate Flue Check System – The check system prevents exhaust from the heat exchanger from backing up into cabinet. Pump Service Mode – Allows manual operation of pumps to commission system and check pump operation. The Vision II System (Optional) – Allows the user to supply mixed temperatures in up to eight zones. The Vision II system controls the temperature to each zone by employing three way mixing valves.
environments, boilers must not be installed using direct vent systems which draw outdoor air for combustion. Such boilers must be installed using room air for combustion. Indoor air will have a much lower relative humidity and, hence, potential corrosion will be minimized. This boiler is certified for indoor installations only. Do not install the boiler outdoors. Failure to install this boiler indoors could result in substantial property damage, severe personal injury, or death. 2.
Figure 1 – Required Clearances Space must be provided with combustion/ventilation air openings correctly sized for all other boilers located in the same space as the boiler. The boiler cover must be securely fastened to prevent it from drawing air from the mechanical room. This is particularly important if the boiler is in a room with other boilers. Failure to comply with the above warnings could result in substantial property damage, severe personal injury, or death.
SPECIFICATIONS AND DIMENSIONS Figure 2 – Specifications and Dimensions WHL-016 REV. 3.4.
D. RESIDENTIAL GARAGE, CLOSET, AND ALCOVE INSTALLATIONS Check with your local Authority Having Jurisdiction for requirements when installing boiler in a garage, closet, or alcove. Please read the entire manual before attempting installation. Failure to properly take factors such as boiler venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.
appliance is installed in areas where indoor air is contaminated (see Table 2) it is imperative that the appliance be installed as direct vent so that all combustion air is taken directly from the outdoors into the appliance intake connection. Unconfined space is space with volume greater than 50 cubic feet per 1,000 Btu/hour (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space.
NOTE: DAMAGE TO THE BOILER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY. (Refer to the limited warranty for complete terms and conditions). G. REMOVING AN BOILER FROM A COMMON VENT SYSTEM Do not install the boiler into a common vent with any other boiler. This will cause flue gas spillage or boiler malfunction, resulting in possible substantial property damage, severe personal injury, or death.
Figure 4 – Pallet with Mounting Bracket Affixed Figure 5 –Boiler Mounted to Bracket B. WALL MOUNTING CONSIDERATIONS These boilers are wall mounted. Use only the wall mounting instructions included in this manual. Ensure the wall that the boiler is intended to be mounted on is comprised of cement, brick, block, or wooden studs spaced 16” apart from center.
b. The provided mounting bracket must be mounted directly to the center of at least 2 studs using standard steel or stainless steel ¼” x 2 ½” lag bolts for all models. Be sure the bracket is level and mark the hole location of the bracket height and horizontal stud location. Ensure the marked holes are located in the center of the building frame (studs). c. For all models, 2 ½” is the minimum lag bolt length if the bracket is directly on stud.
Never use dielectric unions or galvanized steel fittings when connecting to a stainless steel storage tank or boiler. Failure to follow this instruction can lead to premature failure of the boiler system. Such failures ARE NOT covered by warranty. Plumbing of this product should only be done by a qualified, licensed plumber in accordance with all local plumbing codes. The boiler may be connected to a storage tank to supply domestic hot water.
C. BACKFLOW PREVENTER Use a backflow preventer specifically designed for hydronic installations. This valve should be installed on the cold water fill supply line per local codes (see Piping Details, Part 5, Section G). D. SYSTEM WATER PIPING METHODS EXPANSION TANK AND MAKE-UP WATER 1. Ensure that the expansion tank is designed and sized to correctly handle system water volume and temperature.
F. HYDRONIC PIPING WITH CIRCULATORS, ZONE VALVES, AND MULTIPLE BOILERS This boiler is designed to function in a closed loop hydronic system. It is recommended to install a temperature and pressure gauge (not included with the boiler) to allow the user to monitor system pressure and outlet temperature from the boiler. It is important to note that the boiler has a minimal amount of pressure drop that must be calculated when sizing the circulators.
Figure 7 – Near Boiler Piping* – NOTE: This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. *Top / Bottom Supply / Return Connections available on 155, 199, 285, and 399 Models ONLY. NOTE: In piping applications utilizing a single zone, it is recommended that the installer use flow / check valves with weighted seats at or near the boiler to prevent gravity circulation. WHL-016 REV. 3.4.
Figure 8 – Piping Symbol Legend WHL-016 REV. 3.4.
Figure 9 – Standard Piping with Zone Valves and DHW Priority - NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameters center to center spacing. 3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. 4. The minimum pipe size for connecting a indirect water heater is 1” 5.
Figure 10 - Standard Piping with Pumps and DHW Priority - NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameters center to center spacing. 3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. 4. The minimum pipe size for connecting a indirect water heater is 1” 5.
Figure 11 – Primary/Secondary Boiler Piping – Zone Valves and DHW Priority – Outdoor Reset - NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameters center to center spacing. 3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. 4.
Figure 12 – Primary/Secondary Boiler Piping – Pumps and DHW Priority – Outdoor Reset - NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameters center to center spacing. 3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. 4.
Figure 13 – Multiple Boilers – Primary/Secondary Piping – Circulators - NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameters center to center spacing. 3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. 4. The minimum pipe size for connecting a indirect water heater is 1” 5.
H. PIPING INSTALLATION This boiler should not be operated as a potable hot water heater. It should not be used as a direct hot water heating device. Basic steps are listed below that will guide you through the installation of the boiler. 1. Connect the system return marked “Boiler Return”. 2. Connect the system supply marked “Boiler Supply”. 3. Install a purge and balance valve or shut off valve and drain on the system return to purge air out of each zone. 4.
The chart below represents the various system design temperature rise through the boiler along with their respective flows and friction loss, which will aid in circulator selection. Table 5 – Boiler Flow Rates In addition, the boiler heat exchanger has a minimum total water volume that must be taken into account when sizing the circulator. Minimum boiler flow rates are listed in the table below.
ACIDITY CONDUCTIVITY CHLORIDE IRON COPPER SODIUM HARDNESS 6 to 8 pH Less than 400 uS/cm at 25oC Less than 100 ppm Less than 0.5 mg/L Less than 0.1 mg/L Less than 20 mg/L Less than 7 Grains Table 8 – Water Quality Requirements Clean system to remove sediment* 1. You must thoroughly flush the system (without boiler connected) to remove sediment. The high-efficiency heat exchanger can be damaged by buildup or corrosion due to sediment. 2.
For installations that incorporate standing iron radiation and systems with manual vents at the high points, follow the previous section and, starting with the nearest manual air vent, open the vent until water flows out. Then close the vent. Repeat the procedure, working your way toward the furthest air vent. It may be necessary to install a basket strainer in an older system where larger amounts of sediment may be present. Annual cleaning of the strainer may be necessary.
PART 6 – VENTING, COMBUSTION AIR, AND CONDENSATE REMOVAL The boiler must be vented as detailed in this Venting Section. Ensure exhaust vent and intake piping complies with these instructions regarding vent system. Inspect finished exhaust vent and intake piping thoroughly to ensure all joints are well secured, airtight, and comply with all applicable code requirements, as well as with the instructions provided in this manual.
B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE Item Exhaust vent or Intake pipe and fittings Pipe cement/primer APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL Standards for Installation in: Material United States Canada PVC schedule 40/80 ANSI/ASTM D1785 PP, CPVC, and PVC venting must be ULC-S636 Certified. IPEX is an PVC-DWV* ANSI/ASTM D2665* approved manufacturer in Canada, CPVC schedule 40/80 ANSI/ASTM F441 supplying vent material listed to ULCPolypropylene UL-1738 S636.
Cellular foam core piping may be used on air inlet piping only. You must not use “B” vent in an exhaust application. “B” vent is for intake applications ONLY. Using “B” vent in an exhaust application will result in serious injury or death. D. EXHAUST VENT AND INTAKE PIPE LOCATION Figure 14 – ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada – Exit Terminals for Direct-Vent Venting Systems DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION – FIGURE 14 NOTES: A.
NOTE: Due to potential moisture build-up, sidewall venting may not be the preferred venting option. Carefully consider venting installation and location to save time and cost. You must insert the provided exhaust and intake screens at your vent termination to prevent blockage caused by debris or birds. The building owner is responsible for keeping the exhaust and intake terminations free of snow, ice, or other potential blockages, as well as scheduling routine maintenance.
CONDENSATE TRAP INSTALLATION INSTRUCTIONS The condensate trap assembly MUST BE PROPERLY INSTALLED according to these instructions when operating the boiler. Operating the boiler without the condensate trap assembly will cause flue gases to leak and result in serious personal injury or death. 1. Ensure all parts shown in Figure 15-1, Condensate Detail, are included with the condensate trap. If any parts are missing, DO NOT install the trap. Replace the entire condensate assembly.
Figure 16 - Condensate Piping Suggestions NOTES: 1. Condensate line must be pitched at least 1/4" per foot to properly drain. If this cannot be done, or a very long length of condensate hose is used, you must increase the condensate line to a minimum of 1” ID and place a tee in the line after the condensate neutralizer to properly reduce vacuum lock in the drain line. 2. Plastic pipe should be the only material used for the condensate line.
Figure 17 – Piping Exhaust around Obstructions – Suggested Condensate Removal E. EXHAUST VENT AND INTAKE PIPE SIZING 1. The exhaust vent and intake pipes are 3” for 055/080/110/155/199/285 models, and 4” for the 399. 2. The total equivalent length of exhaust vent and intake pipe should not exceed 200 feet for all models EXCEPT the 285. Total equivalent length for the 285 should not exceed 150 feet. a. The equivalent length of friction loss in elbows, tees, and other fittings are listed in Table 11.
o b. For example: If the 3” exhaust vent has two short 90 elbows and 10 feet of PVC pipe we will calculate: Exhaust Vent Equivalent Length = (2x5) + 10 = 20 feet. o o Further, if the 3” intake pipe has two short 90 elbows, one 45 elbow, and 10 feet of PVC pipe, the following calculation applies: Intake Pipe Equivalent Length = (2x5) + 3 + 10 = 23 feet. The Exhaust Vent Equivalent Length + the Intake Pipe Equivalent Length equal the Total Equivalent Length.
10. Horizontal lengths of exhaust vent must slope back towards the boiler not less than ¼" per foot to allow condensate to drain from the vent pipe. 11. The exhaust vent must terminate where vapors cannot make accidental contact with people or pets, or damage shrubs or plants. 12. In vacant chimney applications, install and seal a rain cap over existing chimney openings. 13. All piping must be fully supported.
Figure 19 – Two Pipe Roof and Sidewall Venting with Tee (Intake) and Coupling (Exhaust) NOTE: Drawing is meant to demonstrate system venting ONLY. The installer is responsible for all equipment and detailing required by local codes. Figure 20 – Venting with Optional Kits (NOT INCLUDED WITH THE BOILER) NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.
Figure 21 – Unbalanced Flue/Vertical Vent - NOTE: Drawing is meant to demonstrate system venting ONLY. All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the heater to allow drainage of condensate. When placing support brackets on vent piping, the first bracket must be within 1 foot of the water heater and the balance at 4 foot intervals on the vent pipe.
Figure 22 – Horizontal Venting - NOTE: Drawing is meant to demonstrate system venting ONLY. NOTES: A. For every 1” of overhang, the exhaust vent must be located 1” vertical below overhang (overhang means top of building structure and not two adjacent walls [corner of building]). B. Typical installations require 12” minimum separation between bottom of exhaust outlet and top of air intake. C. Maintain 12” minimum clearance above highest anticipated snow level or grade (whichever is greater). D.
Do not install the heater into a common existing vent with any other appliance. This will cause flue gas spillage or heater malfunction, resulting in substantial property damage, severe personal injury, or death. Contractors must check state and local codes before installing through an existing vent opening. State and local codes always take precedence over manufacturer’s instructions.
3. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE This heater requires fresh, uncontaminated air for safe operation and must be installed in a mechanical room where there is adequate combustion and ventilating air. NOTE: To prevent combustion air contamination, see Table 2. Combustion air from the indoor space can be used if the space has adequate area or when air is provided through a duct or louver to supply sufficient combustion air based on the water heater input.
Figure 25 – 1, 25 - 2 NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. WHL-016 REV. 3.4.
PART 7 – GAS PIPING FAILURE TO FOLLOW ALL PRECAUTIONS IN THIS SECTION COULD RESULT IN FIRE, EXPLOSION, OR DEATH! A. GAS CONNECTION The gas supply shall have a maximum inlet pressure of less than 14" w.c. (3.5 kPa), and a minimum of 3.5" w.c. (.87 kPa). The entire piping system, gas meter and regulator must be sized properly to prevent pressure drop greater than 0.5" (.12 kPa) as stated in the National Fuel Gas Code. This information is listed on the rating label.
4. It is important to support gas piping as the boiler is not designed to structurally support a large amount of weight. 5. Purge all gas lines thoroughly to avoid start up issues with air in the lines. 6. Sealing compound (pipe dope) must be used and approved for gas connections. Apply sparingly, and only to the male threads. Care must be taken when applying compound to prevent blockage or obstruction of gas flow which may affect the operation of the boiler.
may be undersized or in need of service. You can attach a manometer to the incoming gas drip leg after removing the cap. The gas pressure must remain between 3.5" (.87 kPa) and 14" (3.5 kPa) during stand-by (static) mode and while in operating (dynamic) mode. If an in-line high gas pressure regulator is used, it must be installed a minimum of 10 feet from the boiler. It is very important that the gas line is properly purged by the gas supplier or utility.
Strain on the gas valve and fittings may result in vibration, premature component failure and gas leakage, and result in fire, explosion, property damage, severe personal injury, or death. Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated combustion analyzer capable of measuring CO2 and CO. Failure to follow this instruction could result in fire, explosion, property damage, severe personal injury, or death.
D. LINE VOLTAGE WIRING FOR STANDARD BOILER NOTE: A termination plug is included in the CAT 3 / CAT 5 Bus Connection Point, labeled J3 in Figure 29. DO NOT REMOVE THIS PLUG! Doing so will affect boiler operation and void warranty. 1. Connect the incoming power wiring to the line voltage terminal strip in the electrical junction box at terminals 120V, Neutral, Ground (shown in Figure 29). 2.
H. OUTDOOR SENSOR NOTE: If the system requires a fixed operating temperature, the outdoor sensor is not required and should not be installed. There is no connection required if an outdoor sensor is not used in the installation. 1. Use a minimum 22 AWG wire for runs of 100 feet or less and minimum 18 AWG wire for runs of up to 150 feet. 2.
NOTE: When a 0-10 volt building management system is installed, the return sensor temperature cannot be monitored through the boiler display. NOTE: Ensure that the polarity of the connections from the external modulating boiler controller to the boiler is correct. Reversed polarity could lead to erratic and/or no response from the boiler controller. K.
Figure 31 – Cascade Resistor Plug Installation Detail M. CASCADE MASTER PUMP AND SENSOR WIRING 1. Connect the system pump hot wire to the terminal marked 8. 2. Connect the system pump neutral to the 2 terminal and the pump ground wire to the 3 terminal. 3. Connect a jumper wire from the 120 VOLT terminal to the 9 terminal. 4. Connect the boiler pump to the terminals marked 1 (HOT), 2 (NEUT) and 3 (GND). 5. Connect the system pipe sensor to the terminals marked 10 and 11.
Figure 32 – Cascade Master and Follower Wiring WHL-016 REV. 3.4.
Figure 33 – Internal Connection Diagram – LP-293-J WHL-016 REV. 3.4.
PART 9 – START-UP PREPARATION Thoroughly clean and flush any system that has used glycol before installing the boiler. Provide the customer with a material safety data sheet (MSDS) on the fluid used. A. CHECK / CONTROL WATER CHEMISTRY Chemical imbalance of your water can cause severe damage to your boiler and associated equipment, and may also affect efficiency. You may have to have your water quality professionally analyzed to determine whether you need to install a water softener.
2. Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time. Follow all fluid manufacturer instructions. NOTE: BOILER FAILURE DUE TO IMPROPER WATER CHEMISTRY IS NOT COVERED BY WARRANTY. B. CHECK FOR GAS LEAKS Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove boiler front door and smell interior of boiler enclosure.
E. PURGE AIR FROM WATER SYSTEM IMPORTANT! While commissioning the system, the air vent on top of the boiler must remain fully open to allow the boiler to properly fill. Failure to keep the air vent open could lead to improper boiler and system operation. To purge air from the system: a. Connect a hose to the purge valve and route hose to an area where water can drain and be seen. b. Close the boiler or system isolation valve between the purge valve and fill connection to the system. c.
Condensate is slightly acidic (typically with a pH of 3 to 5) and must be piped with the correct materials. Never pipe the condensate using steel, copper, brass or other materials that will be subject to corrosion. Plastic PVC or CPVC pipe are the only approved materials. A condensate neutralizer, if required by local authorities, may be purchased from Westinghouse (7450P-212). 2. The boiler is equipped with a ¾ female socket weld fitting connection that must be piped to a local drain.
J. LOCKOUT CONDITION If any boilers, including the master boiler in the cascade system, are in a lockout condition, the master control will recognize the lockout condition and skip over the boiler in the firing sequence. Each boiler in the cascade system is responsible for its own safety functions. So, if any individual boiler control senses an unsafe condition, it will extinguish the burner and, if necessary, go to a lockout condition.
ENTER key to accept the code entered. If the code is correct, the readout will change to the appropriate screen. If the programming code is not accepted, the readout will continue to display as shown above. The ENTER key is also used to enable a function for editing. After the user navigates to the desired function, the user would hold down the ENTER key for one second. When the ENTER key is released, the function value will begin to blink. The function can now be changed using the ▼▲ ARROW keys.
DHW SET POINT o 119 F Function: Adjusts the indirect tank set point. Default: 119oF (Range: 70oF to 185oF). DHW DIFF SET POINT o 7 F Function: Adjusts the indirect tank differential set point. Default: 7oF (Range: 1oF to 30oF). TEMP DISPLAY C OR F Function: Adjusts the temperature measurement in F = Fahrenheit to C = Celsius (Default is Fahrenheit). o F Table 18 – Boiler Setting Screen Descriptions Clock Settings (NOTE: The clock will reset if the boiler is powered off for more than a week.
SCREEN Function 1 MODE INDIRECT 1 Function 3 DHW TANK MAX TEMP o 180 F 3 Function 6 DESCRIPTION Factory Program Mode This screen indicates that the control is configured correctly. Do not change this setting. DHW Tank Max Temp This is the maximum temperature that can be selected for the DHW indirect tank set point in the boiler menu. Default: 180oF (Range: 95oF to 180oF).
Function 24 CASCADE ROTATION 48 HOURS 24 Function 25 NOT USED NOT USED 25 Function 26 Cascade Rotation SYS FREEZE PROT PROTECT OFF 26 NOTE: This parameter is only present if the boiler is a cascade master. Allows the user to set the freeze protection when a system pump is used. Factory Default: OFF. Selection of temperature activates freeze protection. (Range: OFF, -40oF – 104oF).
G. RESETTING THE MAINTENANCE SCHEDULE When the system control flashes MAINTENANCE REQUIRED, it is advisable that you call for service. After the service is performed, reset the schedule for the next required service by using the following steps. Press ENTER on the display for 3 seconds. The Menu code will appear as 000. This does not change. Press ENTER again. SERVICE SCHEDULE RESET will be displayed. Using the right arrow key scroll to the selection of year or hours.
Press the ▼ key once. DHW SET DHW o 119 F o 117 F This screen displays the domestic hot water temperature set point on the top line. The actual temperature measured by the tank or return line sensor (Westinghouse 7250P-325) is displayed on the bottom line.
Press the ▼ key once. This screen displays the eighth oldest lockout fault that occurred in the boiler controller. The top line will alternate between the words ‘FAULT HISTORY’ and the fault encountered. The bottom line displays the date and time the fault occurred. FAULT HISTORY 8 08/28/2009 Fr 5:19A Press the ▼ key once. This screen displays the ninth oldest lockout fault that occurred in the boiler controller. The top line will alternate between the words ‘FAULT HISTORY’ and the fault encountered.
create a heat demand so the test mode operation will not be interrupted. To enter test mode, press the ▲ and ENTER keys simultaneously. To exit, press ▲ and ▼ simultaneously. SERVICE RUN 3400 RPM PUMP ON 4:49P NOTE: The boiler will automatically exit test mode after 20 minutes of operation.
PART 13 – TROUBLESHOOTING A. BOILER ERROR CODE If any of the sensors detect an abnormal condition, or an internal component fails during the operation of the boiler, the display may show an error message and error code. This message and code may be the result of a temporary condition, in which case the display will revert to its normal readout when the condition is corrected, or it may be a condition that the controller has evaluated as not safe to restart the boiler.
D. USER INTERFACE DISPLAY Cascade Control FAULT Codes SCREEN Fault Code EO3 System Sensor Failure SYS SUPPLY SENSOR PUMP OFF E03 DESCRIPTION This screen shows that there is a problem with the system sensor circuit. The circuit could be open or shorted. Possible reasons for this error are: There is no system sensor connected to the Master Boiler. The system sensor is faulty.
SCREEN Fault Code F01 DESCRIPTION FLUE TEMP/WAT LV F01 PUMP ON This display indicates that the flue temperature limit switch of the boiler has tripped or that the water level in the boiler is low (this will only occur if the optional UL353 LWCO is installed). This code indicates a serious safety issue. The boiler will not restart until the flue cools down sufficiently or the water level is restored.
Fault Code F09 1. Watch the igniter through the observation window provided. 2. If there is no spark, check the spark electrode for the proper .156” (3.96 mm) gap (See Figure 34). 3. Remove any corrosion from the spark electrode and flame rectifier probe. 4. If there is a spark but no flame, check the gas supply to the boiler. 5. If there is a flame, check the flame sensor. 6. Check any flue blockage or condensate blocks.
SCREEN Fault Code F20 CONDENSATE FULL F20 PUMP ON DESCRIPTION POSSIBLE REMEDY The condensate trap is full. The red light will display and the word LOCKOUT will flash. This code indicates a serious safety issue. The boiler will not restart until the cause is determined by a technician and he pushes the RESET button on the display. During this lockout fault, the pump will be off as indicated on the second line of the display. 1. Check condensate lines for obstructions. 2.
Table 30 PART 14 – MAINTENANCE A. MAINTENANCE PROCEDURES Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is operating safely and efficiently. The owner should make necessary arrangements with a qualified heating contractor for periodic maintenance of the boiler. The installer must also inform the owner that a lack of proper care and maintenance of the boiler may result in a hazardous condition.
The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).” Avoid breathing dust and contact with skin and eyes. Use NIOSH certified dust respirator (N95).
2. Close isolation valves on the return and supply connections to the boilers as shown in the piping diagrams within this manual. Slowly open the ball valves and release pressure into a bucket. Once pressure is released, connect a hose to the water line to flush the boiler. Scale removing solution may be used, but must be approved for use with stainless steel and FDA approved for use in a potable water system. 3. Thoroughly flush the heat exchanger before commissioning the boiler back in service. D.
Do not install the condensate assembly if a component is lost or missing. Replace the entire assembly. Failure to follow this warning could result in property damage, serious personal injury, or death. 6. Fill the condensate trap with fresh water prior to reassembly on the boiler. 7. Slide the condensate trap adapter onto the drain tube until the holes line up with the groove. 8. Insert stainless steel hitch pin to lock condensate adapter to the drain tube. 9.
055 / 080 / 110 PARTS BREAKDOWN Figure 36 - Replacement Parts - LP-387-J WHL-016 REV. 3.4.
055 / 80 / 110 PARTS BREAKDOWN Figure 37 – Replacement Parts - *#20 – Switch on the Left is the Blocked Flue Pressure Switch, Switch on the Right is the Blocked Condensate Pressure Switch – Both share same Part Number WHL-016 REV. 3.4.
155 / 199 / 285 / 399 PARTS BREAKDOWN Figure 38 - Replacement Parts - LP-387-KK WHL-016 REV. 3.4.
155 / 199 / 285 / 399 MODEL PARTS BREAKDOWN Figure 39 - Replacement Parts - LP-387-JJ – 155 - 399 Models - *#15 – Switch on the Left is the Blocked Flue Pressure Switch, Switch on the Right is the Blocked Condensate Pressure Switch – Both share same Part Number WHL-016 REV. 3.4.
BOILER START-UP REPORT LIGHT OFF ACTIVITIES 1) Fill the heating system 2) Check gas pipe 3) Check combustion 4) Verify system operation 5) Record ionization current 6) Indirect water heater 7) Convert the boiler 8) Record system settings Notes: DATE COMPLETED ________________ Check all piping and gas connections, verify all are tight Pressurize system (12 – 15 psi) Add water to prime condensate cup Percentage of glycol in system (0 – 50%) Verify near boiler piping is properly supported Leak test u
INSPECTION ACTIVITIES PIPING Near boiler piping Vent Gas SYSTEM Visual Functional Temperatures Temperatures ELECTRICAL Connections Smoke and CO detector Circuit Breakers Switch and Plug CHAMBER/BURNER Combustion Chamber Spark Electrode Flame Probe CONDENSATE Neutralizer Condensate trap and hose GAS Pressure Pressure Drop Check gas pipe for leaks COMBUSTION CO/CO2 Levels SAFETIES ECO (Energy Cut Out) Thermistors FINAL INSPECTION Check list Homeowner DATE LAST COMPLETED 1st YEAR 2nd YEAR 3rd YEAR
WHL-016 REV. 3.4.
WHL-016 REV. 3.4.
MAINTENANCE NOTES WHL-016 REV. 3.4.
CUSTOMER INSTALLATION RECORD FORM The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document.
