Westinghouse WBCNG399W, Installation, Start-Up And Maintenance Instructions

Page 1: ...CE Westinghouse reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature NOTE TO CONSUMER PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE 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 Failure to ...

Page 2: ...HE 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 If you cannot reach your gas supplier call the fire department Installation and service must be provided by a qualified installer ...

Page 3: ...ndividual such as a fire chief fire marshal chief of a fire prevention bureau labor department or health department building official or electrical inspector or others having statutory authority In some circumstances the property owner or his her agent assumes the role and at government installations the commanding officer or departmental official may be the AHJ NOTE Westinghouse reserves the righ...

Page 4: ... as the heating load decreases This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decreases Th...

Page 5: ...ION OF EXHAUST VENT AND INTAKE PIPE 15 2 INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE 15 F PREVENT COMBUSTION AIR CONTAMINATION 16 G REMOVING AN BOILER FROM A COMMON VENT SYSTEM 17 PART 4 PREPARE BOILER 17 A REMOVE THE BOILER FROM PACKAGING 17 B WALL MOUNTING CONSIDERATIONS 18 C WALL MOUNTING INSTRUCTIONS 18 1 MOUNTING TO A WOOD STUDDED WALL 18 2 MOUNTING TO A METAL FRAME 19 ...

Page 6: ...ON IN CONFINED OR UNCONFINED SPACE 48 PART 7 GAS PIPING 51 A GAS CONNECTION 51 B GAS PIPING 51 C CHECK INLET GAS PRESSURE 52 D BOILER GAS VALVE 53 PART 8 FIELD WIRING 54 A INSTALLATION MUST COMPLY WITH 54 B FIELD WIRING TERMINATIONS 54 C FIELD WIRING 54 D LINE VOLTAGE WIRING FOR STANDARD BOILER 55 E ALARM CONNECTIONS 55 F LOW VOLTAGE CONNECTIONS FOR STANDARD BOILER 55 G THERMOSTAT 55 H OUTDOOR SEN...

Page 7: ...ANCE SCHEDULE 69 PART 11 START UP PROCEDURES FOR INSTALLER 70 A BOILER CONTROL STATUS MENU 70 B CASCADE MENU 72 C BOILER TEST MODE 72 PART 12 SHUTDOWN 73 A SHUTDOWN PROCEDURE 73 B VACATION PROCEDURE 73 C FAILURE TO OPERATE 73 PART 13 TROUBLESHOOTING 74 A BOILER ERROR CODE 74 B BOILER ERROR 74 C BOILER FAULT 74 D USER INTERFACE DISPLAY 75 PART 14 MAINTENANCE 79 A MAINTENANCE PROCEDURES 79 B COMBUST...

Page 8: ...ubmersion is considered an Act of God and IS NOT covered under product warranty Be sure to disconnect electrical power before opening boiler cabinet or performing service Failure to do so could result in an electrical shock that could result in property damage serious personal injury or death NOTE If the boiler is exposed to the following do not operate until all corrective steps have been made by...

Page 9: ...imming pool or spa water o Do not fill boiler or operate with water containing chlorine in excess of 100 ppm NOTE It is recommended to clean heat exchanger at least once a year to prevent lime scale buildup To clean the heat exchanger follow the maintenance procedure in Part 13 Section B of this manual ACIDITY 6 to 8 pH CONDUCTIVITY Less than 400 uS cm at 25 o C CHLORIDE Less than 100 ppm IRON Les...

Page 10: ...ilers Each cascaded boiler will have its own pump to provide maximum flow and control heat exchanger flow rate Text Display and Operational LED Light Indicators The display allows the user to change system parameters and monitor system outputs Gas Valve Senses suction from the blower allowing gas to flow only if powered and combustion air is flowing All Metal Integrated Venturi Controls air and ga...

Page 11: ...22 NOTE When using an optional system sensor pipe insulation must be wrapped around it to improve temperature measurement accuracy and increase overall system efficiency PART 3 PREPARE BOILER LOCATION Carefully consider installation when determining boiler location Please read the entire manual before attempting installation Failure to properly take factors such as boiler venting piping condensate...

Page 12: ...ion and service 5 If the boiler is to replace an existing boiler check for and correct any existing system problems such as System leaks Location that could cause the system and boiler to freeze and leak Incorrectly sized expansion tank 6 Clean and flush system when reinstalling a boiler NOTE When installing in a zero clearance location it may not be possible to read or view some product labeling ...

Page 13: ... with the above warnings could result in substantial property damage severe personal injury or death Always take future maintenance into consideration when locating the boiler If the boiler is located in an installation location with limited clearances it may be necessary to remove the boiler from the space to perform maintenance Failure to consider maintenance when determining installation locati...

Page 14: ...14 WHL 016 REV 12 18 14 SPECIFICATIONS AND DIMENSIONS Figure 2 Specifications and Dimensions ...

Page 15: ...ppliance Failure to vent the appliance in accordance with the provided venting instructions will void the warranty Failure to vent the appliance properly will result in serious personal injury or death Vents must be properly supported Appliance exhaust and intake connections are not designed to carry heavy weight Vent support brackets must be within 1 of the appliance and the balance at 4 interval...

Page 16: ...ction Do not attempt to vent this appliance by any means other than those described in this manual Doing so will void the warranty and may result in severe personal injury or death Failure to provide an adequate fresh combustion air can cause poisonous flue gases to enter living space which could result in severe personal injury or death To prevent combustion air contamination see Table 2 F PREVEN...

Page 17: ...operate continuously 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette 6 After it has been determined that each boiler remaining connected to common venting system properly vents when tested as outlined return doors windows exhaust fans fireplace dampers and any other gas burning boiler to thei...

Page 18: ...eath C WALL MOUNTING INSTRUCTIONS This boiler is too heavy for one person to lift It is highly recommended to install the boiler with two people Use caution as to not drop the boiler which could damage the boiler and cause property damage and or severe personal injury Verify that the boiler is properly and securely mounted before leaving unsupervised Failure to comply with the above and properly m...

Page 19: ...ry maintenance 2 MOUNTING TO A METAL FRAME a The provided mounting bracket must be mounted to the center of at least 2 studs using standard steel or stainless steel toggle bolts 3 16 diameter or larger and at least 2 long for direct mounting on stud for 055 110 models and 3 8 diameter or larger and at least 2 long for 155 399 models for direct mounting on at least 18 gauge studs Be sure the bracke...

Page 20: ...harge line must pitch downward from the valve and terminate at least 6 above the floor drain making discharge clearly visible Discharge line shall terminate plain not threaded with a material serviceable for temperatures of 375 o F or greater Do not pipe discharge to any location where freezing could occur No shutoff valve may be installed between the relief valve and boiler or in the discharge li...

Page 21: ... must be located as shown in Part 5 Boiler Piping or following recognized design methods See expansion tank manufacturer s instructions for details 3 Connect the expansion tank to the air separator only if the air separator is on the side of the circulator Always install the system fill connection at the same point as the expansion tank connection to the system DO NOT install automatic air vents o...

Page 22: ...t off device which is an optional part available through Westinghouse Part 7600P 104 for 055 110 models 7600P 990 for 155 399 models Check with local codes for additional requirements If the boiler supplies hot water to heating coils in air handler units flow control valves or other devices must be installed to prevent gravity circulation of boiler water in the coils during the cooling cycle Chill...

Page 23: ...sponsible 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 ...

Page 24: ...24 WHL 016 REV 12 18 14 Figure 8 Piping Symbol Legend ...

Page 25: ... spaced tees 4 The minimum pipe size for connecting a indirect water heater is 1 5 The minimum pipe size for connecting an 055 or 080 1 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with circulator flanges as an alternative 7 A mixing valve is recommended if the DHW temperature is set above the factory setting...

Page 26: ... minimum pipe size for connecting a indirect water heater is 1 5 The minimum pipe size for connecting an 055 or 080 1 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with circulator flanges as an alternative 7 A mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 8 Pipin...

Page 27: ...ect water heater is 1 5 The minimum pipe size for connecting an 055 080 110 1 155 199 285 1 25 399 1 5 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with circulator flanges as an alternative 7 A mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 8 Piping shown is Prim...

Page 28: ... water heater is 1 5 The minimum pipe size for connecting an 055 080 110 1 155 199 285 1 25 399 1 5 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with circulator flanges as an alternative 7 A mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 8 Piping shown is Primary...

Page 29: ...eater is 1 5 The minimum pipe size for connecting an 055 080 110 1 155 199 285 1 25 399 1 5 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with circulator flanges as an alternative 7 A mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 8 Piping shown is Primary Seconda...

Page 30: ...iping details this section Make sure the circulator is properly sized for the system and friction loss 7 Install an expansion tank on the system supply see Part 5 Section D for water volume Consult the expansion tank manufacturer s instructions for specific information relating to expansion tank installation Size the expansion tank for the required system volume and capacity 8 Install an air elimi...

Page 31: ... 5 3 GPM To correctly size the manifold feeding these 5 boilers you would need a pipe size of 2 MULTIPLE BOILER MANIFOLD PIPING Maximum Flow Rate GPM at 3 feet per second 8 14 19 31 5 45 69 93 120 150 188 271 Schedule 40 Pipe Diameter Inches 1 1 1 2 2 3 3 4 4 5 6 Table 7 J CHECK CONTROL WATER CHEMISTRY NOTE BOILER FAILURE DUE TO IMPROPER WATER CHEMISTRY IS NOT COVERED BY WARRANTY Sodium less than ...

Page 32: ...ler causing inadvertent short cycling and poor system performance Check valves Field supplied Check valves are recommended for installation as shown in Piping Details Water boiler isolation valves Field supplied Full port ball valves are required Failure to use full port ball valves could result in a restricted flow rate through the water boiler Mixing valve Field supplied A mixing valve is recomm...

Page 33: ...lene glycol solutions which are specially formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems Glycol mixtures should not exceed 50 It is highly recommended to carefully follow the glycol manufacturer s recommended concentrations expansion requirements and maintenance recommendations pH additive breakdown inhibitor reduction etc You mus...

Page 34: ...with materials components and systems listed and approved for Category IV boilers Exhaust vent and intake pipes are to be piped separately This boiler cannot share a common exhaust or intake with multiple appliances Failure to follow this instruction will result in substantial property damage severe personal injury or death NOTE To avoid contamination often contained in indoor air it is best to pi...

Page 35: ...ipe and fitting materials primer and cement and adapters specifically designed for the material used as listed in Table 10 Failure to do so could result in property damage severe personal injury or death Exhaust vent adaptors are not designed as load bearing devices and must not be used to support exhaust vent piping All vent pipes must be glued properly supported and the exhaust must be pitched a...

Page 36: ...a height of 15 feet above electrical meters gas meters gas regulators relief equipment exhaust fans and inlets I Provide 4 feet horizontal clearance from electrical meters gas meters gas regulators relief equipment exhaust fans and inlets In no case shall the exit terminal be above or below the aforementioned equipment unless the 4 foot horizontal distance is maintained J This water heater vent sy...

Page 37: ... be placed in the living area outside the bedrooms as well as in the room that houses the boiler Detectors and alarms shall comply with NFPA 720 latest edition Failure to comply with requirements for detectors and alarms could result in property damage severe personal injury or death DETERMINE LOCATION OF CONDENSATE PIPING This is a high efficiency boiler and therefore produces condensate a by pro...

Page 38: ...r CPVC pipe are acceptable materials for condensate piping However use materials approved by the authority having jurisdiction In the absence of other authority PVC and CPVC pipe must comply with ASTM D1785 or D2845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement If pipe is used deburr and chamfer pipe to allow proper m...

Page 39: ...freezing temperatures or any type of blockage Damages due to frozen or blocked condensate lines ARE NOT covered by warranty 4 Support of the condensate line may be necessary to avoid blockage of the condensate flow If using a condensate pump select one approved for use with condensing boilers and furnaces The pump should have an overflow switch to prevent property damage from condensate spillage I...

Page 40: ...nt 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 FRICTION LOSS EQUIVALENT FOR STAINLESS OR PLASTIC PIPING AND FITTINGS FITTING DESCRIPTION 3 4 90 o elbow short radius 5 5 90 o elbow long radius 4 4 45 o elbow 3 3 Coupling 0 0 Tee intake only 0 0 V Series Vent Kit 1 1 AL20 4C Vent Terminal 1 1 Pipe All...

Page 41: ...ncreased diameter vent pipes Excessive length could result in appliance shutdown and property damage G EXHAUST VENT AND INTAKE PIPE INSTALLATION All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into living space 1 Use only solid PVC or CPVC pipe AL29 4C Stainless Steel or a Polypropylene vent system approved for use with Category IV boilers...

Page 42: ...TION OF EXHAUST VENT AND INTAKE PIPE If installing a direct vent option combustion air must be drawn from the outdoors directly into the appliance intake and exhaust must terminate outside There are three basic direct vent options detailed in this manual 1 Side Wall Venting 2 Roof Venting and 3 Unbalanced Venting Be sure to locate the appliance such that the exhaust vent and intake piping can be r...

Page 43: ...d by local codes All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of per foot back to the boiler to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the water boiler and the balance at 4 foot intervals on the vent pipe Boiler venting must be readily accessible for visual inspection for the ...

Page 44: ... by local codes All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of per foot back to the boiler to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the boiler and the balance at 4 foot intervals on the vent pipe Boiler venting must be readily accessible for visual inspection for the first t...

Page 45: ...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 Heater venting must be readily accessible for visual inspection for the first three feet from the heater An unbalanced vent system can be installed ONLY when the exhaust is installed in ...

Page 46: ... All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of 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 Heater venting must be readily accessible for visual inspection for the first three feet...

Page 47: ... AN EXISTING SYSTEM NOTE The following instructions refer only to venting through an existing vent system and not to venting with Westinghouse s optional concentric vent kits Refer to Concentric Vent Kit installation manual LP 166 for further information on venting with the optional concentric vent kits Concentric venting through an existing system must run vertically through the roof See Table 14...

Page 48: ...heater be installed as direct vent so that all combustion air is taken directly from the outdoors into the water heater 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 Rooms connected directly to this space through openings not furnished wit...

Page 49: ...EV 12 18 14 If the confined space is within a building of tight construction air for combustion must be obtained from the outdoors as outlined in the Venting section of this manual See Figure 25 Figure 24 LP 325 X ...

Page 50: ...50 WHL 016 REV 12 18 14 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 ...

Page 51: ...e weight of gas piping with the boiler or its accessories The gas valve and blower will not support the weight of the piping Failure to follow this warning could result in substantial property damage severe personal injury or death The gas connection on the boiler is 3 4 It is mandatory that this fitting is used for connection to a field fabricated drip leg as shown in Figure 26 per the National F...

Page 52: ...SSURE The gas valve is equipped with an inlet gas pressure tap that can be used to measure the gas pressure to the boiler To check gas pressure perform the steps listed below 1 IMPORTANT Before you connect to the inlet pressure shut off the gas and electrical power to boiler 2 Loosen the pressure tap with a small screwdriver Refer to Figure 27 for location 3 Each boiler is equipped with a needle v...

Page 53: ...en a utility company shuts off service to an area to provide maintenance to their lines This gas valve must not be replaced with a conventional gas valve under any circumstances DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure and requires no field adjustment Attempts by the installer to adjust or measure the gas valve outle...

Page 54: ...B FIELD WIRING TERMINATIONS All connections made to the boiler in the field are done inside the electrical junction box located on the left side of the boiler Multiple knockout locations are available to route field wires into and out of the electrical junction box See Figure 28 C FIELD WIRING The control used in the boiler is capable of directly controlling 1 pump in standard mode and 2 pumps whe...

Page 55: ...One light will be on when the boiler is in normal mode and the other light will be on when the boiler is in lockout mode NOTE Isolate 120V wiring from 24V wiring to prevent any electrical noise F LOW VOLTAGE CONNECTIONS FOR STANDARD BOILER 1 All low voltage cables should enter the electrical junction box through the provided knock out holes as shown in Figure 28 2 Connect all low voltage field dev...

Page 56: ... 325 to the terminals marked DHW SENSOR shown in Figure 29 in the electrical junction box Caution should be used to ensure neither of these terminals becomes connected to ground NOTE If sensor wires are located in an area with sources of potential electromagnetic interference EMI the sensor wires should be shielded or the wires routed in a grounded metal conduit If using shielded cable the shieldi...

Page 57: ...lug is to stabilize communication between multiple boilers and reduce electrical noise See Figure 31 for Cascade Bus Termination Plug installation detail 2 Use standard CAT3 or CAT5 computer network patch cables to connect the communication bus between each of the boilers These cables are readily available at any office supply computer electronic department or discount home supply store in varying...

Page 58: ...lower boiler The normally closed alarm contact may be used to turn a device off if the boiler goes into lockout mode The alarm contacts are rated 5 amps at 120 VAC To connect an alarm device connect the power for the device to the ALARM COM terminal Connect the alarm device hot wire to the ALARM NO terminal Connect the neutral or return of the alarm device to the neutral or return of the power for...

Page 59: ...59 WHL 016 REV 12 18 14 Figure 32 Cascade Master and Follower Wiring ...

Page 60: ...60 WHL 016 REV 12 18 14 Figure 33 Internal Connection Diagram LP 293 J ...

Page 61: ...yzed by water treatment company 2 If pH differs from above consult local water treatment company for treatment needed Hardness less than 7 grains Consult local water treatment companies for unusually hard water areas above 7 grains hardness Chlorine concentration less than 100 ppm 1 Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are typically less th...

Page 62: ...ntent DO NOT exceed a 50 50 ratio of antifreeze to water 2 NOTE Local codes may require back flow preventer or actual disconnect from city water supply 3 When using freeze protection fluid with automatic fill install a water meter to monitor water makeup Freeze protection fluid may leak before the water begins to leak causing concentration to drop reducing the freeze protection level D FILL AND TE...

Page 63: ...press the key again the DHW pump will shut off The display will read The system pump will come on Use the and keys to toggle between running each pump in the system as required to help bleed out all entrapped air Some good indicators that air is removed include the absence of gurgling noises in the pipes and pump operation becoming very quiet Pressing and together at any time will return the boile...

Page 64: ...nting Section Part 6 and local codes I CASCADE SYSTEM 1 If a single boiler is installed skip this section 2 Programming the Master Boiler a Make sure there is no demand for heat being supplied to the boiler b Apply power to the boiler c Enter the system setting program navigation following instructions in Part 11 of this manual d Verify that the cascade address function 15 is set to 0 This sets th...

Page 65: ...l be installed so the gas ignition system components are protected from water dripping spraying rain etc during boiler operation and service circulator replacement condensate trap control replacement etc Failure to follow these instructions could result in property damage serious personal injury or death If you discover any evidence of a gas leak shut down the boiler at once Find the leak source w...

Page 66: ...ngs Adjustment and factory defaults are outlined within this section If a cascade system is used it is important that all the boilers have the same boiler settings 4 Next check the system settings Adjustments and factory defaults are outlined within this section If a cascade system is used it is important that the Master Boiler is programmed with the correct system settings 5 Create a demand on th...

Page 67: ...8 28 2009 Fr 10 01A Function Adjusts the month setting CLOCK DATE 08 28 2009 Fr 10 01A The clock is set Table 19 Clock Setting Screens NOTE The clock does not automatically adjust for Daylight Savings Time and requires manual adjustment E PROGRAMMING THE SYSTEM SETTING System Setting Program Access NOTE Programming the boiler control is not possible when the boiler is firing Make sure any input wh...

Page 68: ...s Range 0 10 minutes Function 14 DHW Priority DHW PRIORITY 30 MINUTES 14 Allows the user to set the maximum run time for the indirect fired water heater and the minimum run time for central heating Default 30 minutes Range 0 60 minutes Function 15 Cascade Address CASCADE ADDRESS 0 15 Bus addressing boilers maximum boilers allowed 8 in a cascade system Master Boiler address is 0 and Following Boile...

Page 69: ...e on the display if the boiler is used as a cascade master boiler with no follower boilers connected Factory Default OFF Range ON OFF Function 32 Service Schedule SERVICE SCHEDULE OFF 32 Allows the user to select a service date or time based on the boiler run hours to program the boiler maintenance schedule Factory Default OFF Range Date or Run Hours NOTE Without setting this function Functions 33...

Page 70: ... RETURN SEN 150 o F This screen is displayed after pressing the key as described above This shows the actual temperature that the supply and return sensors are measuring NOTE If the boiler is configured to use a 0 10 volt input the return sensor is disabled and the second line of the display will be blank Press the key once CH SET 180 o F SUPPLY 122 o F The screen displays the current central heat...

Page 71: ...us Menu Screens The following 10 screens display the last ten boiler lockout faults The faults are displayed from most recent to oldest by pressing the key SCREEN DESCRIPTION Press the key once FAULT HISTORY 1 07 27 2009 Mo 5 19A This screen displays the last lockout fault the boiler controller had The top line will alternate between the words FAULT HISTORY and the actual fault encountered The bot...

Page 72: ...eing closed You may also see DHW if the demand is from a DHW sensor or 0 10 if the demand is from a 0 10 volt input The following numbers show which boiler addresses are currently communicating to the master If a boiler address is not used or communicating the number will not show on the display In the example above boiler address 4 is not communicating When a boiler in the system is firing its ad...

Page 73: ... C FAILURE TO OPERATE Should the burner fail to light the control will perform two more ignition trials prior to entering a lockout state Note that each subsequent ignition trial will not occur immediately After a failed ignition trial the blower must run for approximately 10 seconds to purge the system Therefore a time period of approximately 40 to 90 seconds will expire between each ignition tri...

Page 74: ...ection for an explanation of the message along with several suggestions for corrective actions 3 Press the reset key to clear the fault and resume operation Be sure to observe the operation of the boiler for a period of time to assure correct operation and no reoccurrence of fault message When servicing or replacing any components of this boiler be certain that The gas is off All electrical power ...

Page 75: ...ove 10 psig 2 Check for leaks in the system piping Fault Code FLU HIGH FLUE PRESS FLU PUMP ON This display indicates that there is excessive flue pressure This code resets automatically after the high pressure condition is resolved The sec ond line indicates the status of the pump 1 Assure that the flue is not blocked 2 Check the switch wiring by applying a jumper in place of the switch If the cod...

Page 76: ...heck circulator pump operation 2 Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50 F rise from the return thermistor to the supply thermistor 3 Troubleshoot thermistor by following steps in F02 Fault Code F04 FLUE SENSOR F04 PUMP ON This display indicates that the flue temperature sensor of the boiler has failed This is a s...

Page 77: ... burner door and check the burner and its sealing gaskets Fault Code F11 FALSE FLAME SIG F11 PUMP ON There is flame when the control is not telling the boiler to run 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 ...

Page 78: ...orrect outdoor sensor resistance 3 Replace the outdoor sensor NOTE If an outdoor sensor IS NOT used in the installation enter the System Setting Program Navigation go to Function 21 and turn the setting from ON to OFF The following blocking codes will block operation until the control determines the situation safe for boiler operation Blocking Code E07 FLUE TEMP HIGH E07 PUMP OFF TIME This display...

Page 79: ...ary 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 BEFORE EACH HEATING SEASON a trained and qualified service technician should perform the inspections as per the boiler inspection and maintenance schedule in the back of the ...

Page 80: ...tion 1 Shut down the Boiler by using the following steps a Turn off power to the boiler Turn thermostats down to ensure there is no call for heat or disconnect thermostat connections from terminals Close the gas valve inside the boiler cabinet Wait for the boiler to be cool to the touch b Disconnect the wires plugged into the fan spark electrode flame rod and gas valve c Disconnect the flexible ga...

Page 81: ...k and result in serious personal injury or death When servicing is complete make sure the condensate collector cap is replaced securely Failure to do so will cause venting issues that will result in serious injury or death 1 Ensure the boiler is powered off 2 Remove the stainless steel lock pin to release the condensate trap Remove the clear plastic hose from the hose barb Remove the trap from the...

Page 82: ...boiler check the assembly when cleaning the condensate trap and replenish the limestone chips if necessary When replacing the limestone chips take care to ensure chips are no smaller than to avoid blockage in condensate piping for piping details refer to condensate neutralizer installation instruction 11 Check condensate piping for sagging and or leakage Repair any sags or leaks before restoring p...

Page 83: ...83 WHL 016 REV 12 18 14 055 080 110 PARTS BREAKDOWN Figure 36 Replacement Parts LP 387 J ...

Page 84: ...EV 12 18 14 055 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 ...

Page 85: ...85 WHL 016 REV 12 18 14 155 199 285 399 PARTS BREAKDOWN ...

Page 86: ...86 WHL 016 REV 12 18 14 Figure 38 Replacement Parts LP 387 KK ...

Page 87: ...87 WHL 016 REV 12 18 14 155 199 285 399 MODEL PARTS BREAKDOWN ...

Page 88: ...REV 12 18 14 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 ...

Page 89: ...ler Verify combustion settings after gas conversion Carbon Dioxide ____ CO2 High Fire ____ CO2 Low Fire Verify combustion settings after gas conversion Carbon Monoxide ____ppm CO High Fire ____ppm CO Low Fire Mail in the conversion registration 8 Record system settings Record heating curve record steps ____ 8 ____ 9 ____ 10 ____ 11 Notes Table 31 MAINTENANCE REPORT In unusually dirty or dusty cond...

Page 90: ...ube and combustion chamber coils Clean according to maintenance section of manual Vacuum combustion chamber Replace any gaskets that show signs of damage Spark Electrode Clean Set gap at 156 See Figure 34 Flame Probe Clean Check ionization in uA d7 on status menu in Start up Procedures Record high fire and low fire CONDENSATE Neutralizer Check condensate neutralizer Replace if necessary Condensate...

Page 91: ...91 WHL 016 REV 12 18 14 ...

Page 92: ...92 WHL 016 REV 12 18 14 ...

Page 93: ...93 WHL 016 REV 12 18 14 MAINTENANCE NOTES ...

Page 94: ...te of Installation Installer s Code Name Product Serial Number s Combustion Setting at Time of Installation Comments Installer s Phone Number Signed by Installer Signed by Customer IMPORTANT NOTES Customer Please only sign after the installer has reviewed the installation safety proper operation and maintenance of the system In the case that the system has any problems please call the installer If...