Table of Contents
Advertisement
40
E. Fill and Test Water System
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.
1. Fill the system only after ensuring water chemistry meets the
requirements listed in this manual.
2. Close the manual and automatic air vents and boiler drain valve.
3. Fill to the correct system pressure. Correct pressure will vary with
each application.
a. Typical cold water fill pressure for a residential system is 12 psi.
b. Pressure will rise when boiler is turned on and system water
temperature increases. Operating pressure must never exceed the
relief valve pressure setting.
4. At initial fill and during boiler startup and testing, check system
thoroughly for leaks. Repair all leaks before proceeding further.
Eliminate all system leaks. Continual fresh make-up water will
reduce boiler life. Minerals can build up in the heat exchanger,
reducing heat transfer, overheating the heat exchanger and
causing heat exchanger failure.
5. The system may have residual substances that could affect
water chemistry. After the system has been filled and leak tested,
verify that water pH and chloride concentrations are acceptable by
sample testing.
It is important to purge the system of air to avoid damage to the
boiler.
F. Purge Air from Water System
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. Close zone isolation valves.
d. Open quick-fill valve on cold water make-up line.
e. Open purge valve.
f. Open the isolation valves one zone at a time. Allow water to
run through the zone, pushing out the air. Run water until no
noticeable air flow is present. Close the zone isolation valves and
proceed with the next zone. Follow this procedure until all zones
are purged.
g. Close the quick-fill water valve and purge valve and remove
the hose. Open all isolation valves. Watch the system pressure rise
to correct cold-fill pressure. It is recommended that you put the
pumps into manual operation to assist in purging the circuits.
h. Disconnect the wires that are connected to the THERMOSTAT
terminals of the customer connection board. Apply power to the
boiler. The display will show the temperature of the water in the
boiler. 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 display will read:
whl-428-r1 Rev. 001 Rel. 012 Date 7.21.20
The DHW pump will come on. If the boiler is set up as a cascade
master and you then press the ^ key again, the DHW pump will shut
off. The display will read:
The system pump will come on. 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.
G. 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.
H. 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.
I. 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.
Advertisement
Table of Contents
