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THERMOSTAT terminals of the customer connection board.
Apply power to the boiler. The display will show READY.
Press the v and ENTER keys simultaneously and hold for 1
second. The display will read:
The central heating pump will come on. If you then press the
^ key, the central heating pump will shut off, the DHW pump
will come on, and the display will read:
If the boiler is set up as a cascade master and you then press
the ^ key again, the DHW pump will shut off, the system
pump will come on, and the display will read:
Use the ^ and v 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 v together at any time
will return the boiler to normal operation.
i. After the system has operated for five minutes, eliminate
any residual air by using the manual air vents located
throughout the system.
j. If purge valves are not installed in the system, open manual
air vents in the system one at a time, beginning with the
lowest floor. Close vent when water squirts out. Repeat with
remaining vents.
k. Refill to correct pressure.
F. Check Thermostat Circuit(s)
1. Disconnect the two external wires connected to the boiler
thermostat terminals (low voltage terminal strip).
2. Connect a voltmeter across these two incoming wires
with power supplied to the thermostat circuits. Close each
thermostat, zone valve and relay in the external circuit one at
a time and check the voltmeter reading across the incoming
wires.
3. There should NEVER be a voltage reading.
4. If a voltage reading does occur under any condition, check
and correct the external wiring. (This is a common problem
when using 3-wire zone valves.)
5. Once the external thermostat circuit wiring is checked and
corrected if necessary, reconnect the external thermostat
circuit wires to the boiler low voltage terminal strip. Allow the
boiler to cycle.
G. Condensate Removal
1. The boiler is a high efficiency condensing boiler. Therefore,
the unit has a condensate drain. Condensate fluid is nothing
more than water vapor, derived from combustion products,
similar to that produced by an automobile when it is initially
started.
Condensation 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, can be
made up of lime crystals, marble or phosphate chips that will
neutralize the condensate. This may be done by the installer or
you may purchase a condensate neutralizer from Westinghouse
(7350P-611).
2. The boiler is equipped with a ¾ female socket weld fitting
connection that must be piped to a local drain. It is very
important that the condensate line is sloped downward away
from the boiler to a suitable inside drain. If the condensate
outlet on the appliance is lower than the drain, you must use
a condensate removal pump, available from Westinghouse
(554200). This pump is equipped with two leads that can be
connected to an alarm or another type of warning device to alert
the user of a condensate overflow, which, if not corrected, could
cause property damage.
3. If a long horizontal run is used, it may be necessary to create
a vent in the horizontal run to prevent a vacuum lock in the
condensate line.
4. Do not expose the condensate to freezing temperatures.
5. It is very important you support the condensation line to
assure proper drainage.
H. Final Checks Before Starting Boiler
1. Read Startup Procedures within this manual for proper steps
to start boiler. (See Startup Report to record steps for future
reference.)
2. Verify the boiler and system are full of water and all system
components are correctly set for operation.
Ensure the boiler is full of water before firing the burner. Failure
to do so will damage the boiler. Such damage IS NOT covered by
warranty, and could result in property damage, severe personal
injury, or death.
3. Fill condensate trap with water.
4. Verify electrical connections are correct and securely attached.
5. Inspect exhaust vent and intake piping for signs of deterioration
from corrosion, physical damage or sagging. Verify exhaust vent
and intake piping are intact and correctly installed per Venting
Section and local codes.
I. Setting Up a Single Boiler
When power is applied to the boiler, the control first completes
a power-up systems check. During this time the combustion fan
may run. The display will initially show the current boiler supply
temperature. If a fault is detected during the power-up test, the
control will display the appropriate fault code. Otherwise, the
display will continue to show the boiler supply temperature and
stand-by, waiting for a demand for heat.
When a demand for heat is received, the control begins the
following demand sequence. The boiler first turns on the pump.
The control will measure the supply temperature. If it is below
the set point temperature minus the ignition differential the
control will ignite the burner.
After the burner is lit, the control modulates the firing rate
to control the supply water temperature and meet the heat
demand. When the
thermostat or indirect water heater
temperature is met, the control will extinguish the burner and
run the combustion fan to purge gasses from the combustion
chamber. In addition, the pump will run for a pump post purge
41
WHL-038 Rev. 1.29.16
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