TriangleTube IONIC WCB Series Installation & Service Manual
  1. Manuals
  2. Brands
  3. TriangleTube Manuals
  4. Boiler
  5. IONIC WCB Series
  6. Installation & service manual

TriangleTube IONIC WCB Series Installation & Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Low NOx certified to SCAQMD 1146.2
399W
CB 299W-
-470W-500W
E93.1608.034 - E126100001

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the IONIC WCB Series and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for TriangleTube IONIC WCB Series

Summary of Contents for TriangleTube IONIC WCB Series

  • Page 1 Low NOx certified to SCAQMD 1146.2 399W CB 299W- -470W-500W E93.1608.034 - E126100001...
  • Page 3 Customer must register unit within thirty (30) days of installation in order to gain warranty coverage. See Warranty Card for details NOTICE Leave all documentation received with appliance with the owner for future reference. WARNING: To maintain the safety & longevity of your appliance, read and follow the maintenance schedule information throughout this manual.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS IMPORTANT WARNINGS ..............................8 SAFETY GUIDELINES ..............................10 INTRODUCTION................................16 TECHNICAL DATA IONIC CB BOILERS ........................17 BOILER DIMENSIONS ..............................21 UNPACKING AND ACCESSORIES ..........................24 INSTALLATION LOCATION OF THE CB ........................26 CONNECTIONS................................29 8.2.1 Gas line connection ............................29 8.21.1 Example of a single boiler heating circuit with low loss header ...............
  • Page 5 CIRCULATOR CHARACTERISTICS ..........................39 9.1.1 Boiler resistance graph CB 299W ........................39 9.1.2 Boiler resistance graph CB 399W ........................39 9.1.3 Boiler resistance graph CB 470W ........................40 9.1.4 Boiler resistance graph CB 500W ........................40 9.5.1 Delta temperature modulation ......................... 42 9.5.2 PID calculation scaling ............................
  • Page 6 13.6.1 Service overdue logging ..........................85 13.6.2 Reset the service reminder ..........................85 13.6.3 Menu’s and parameters........................... 85 13.7.1 Circulator start every 24 hours ........................86 13.7.2 Frost protection ............................... 86 13.7.3 Flue temperature protection ..........................86 13.8.1 Control functions ............................. 88 13.8.2 On board HMI and LED colors ........................
  • Page 7 ADJUSTING AND SETTING THE BOILER ......................... 124 19.1.1 Combustion table ............................124 19.1.2 Combustion table Low NOx .......................... 125 19.1.3 Setting screws venturi- and gas valves: drawings ..................126 INSPECTION, MAINTENANCE AND SERVICE......................132 20.3.1 Mounting the burner door ..........................140 20.3.2 Boiler room check ............................

  • Page 8: Important Warnings

    1 IMPORTANT WARNINGS Definitions IMPORTANT READ ALL OF THE FOLLOWING WARNINGS AND STATEMENTS BEFORE READING THE INSTALLATION INSTRUCTIONS DANGER Danger Sign: indicates the presence of an imminently hazardous situation that will cause death, serious personal injury or substantial property damage. WARNING Warning Sign: indicates the presence of a hazardous situation which can cause death, serious personal injury or substantial property damage.
  • Page 9 General warnings WARNING This Boiler must be installed by a licensed and trained Heating Technician, a qualified installer, service agency, or the gas supplier or the Warranty is void. Failure to properly install this unit could result in property damage, serious injury to occupants, or possibly death.

  • Page 10: Safety Guidelines

    2 SAFETY GUIDELINES English version Use only your hand to turn the manual shutoff valve. Never use tools. If the manual valve will not turn by hand, don’t try to repair it, call a qualified sevice technician. Force or attempted repair may result in a fire or explosion STOP! Read the safety information above on Wait five (5) minutes to clear out any gas.
  • Page 11 Version français N’utilisez que votre main pour tourner la vanne d’arrêt manuelle. N’utilisez jamais d’outils. Si la vanne manuelle ne tourne pas à la main, n’essayez pas de la réparer, appelez un technicien sevice qualifié. La force ou la tentative de réparation peut entraîner un incendie ou une explosion.
  • Page 12 Avertissement Une installation, un réglage, une modification, une réparation ou un entretien non conforme aux normes peut entraîner des dommages matériels, des blessures (exposition à des matières dangereuses) ou la mort. L'installation et l'entretien doivent être effectués par un installateur ou un service d'entretien qualifié ou le fournisseur de gaz (qui doivent avoir lu les instructions fournies avant de faire l'installation, l'entretien ou l'enlèvement de la chaudière et les respecter.
  • Page 13 Specific warnings This boiler is equipped with a pressure switch in the event of a blocked vent; the boiler will lockout. No attempt by the user/owner shall be made to put the boiler back into operation. A qualified service technician must be notified of the issue. The boiler should only be reset by a qualified service technician after they have diagnosed and corrected the issued that caused CAUTION the safety lockout of the boiler.
  • Page 14 To meet commercial hot water requirements, the tank setpoint is adjustable up to 185°F. However, water temperatures over 125°F can cause severe burns instantly or death from scalds. This is the preferred starting point for setting the control for supplying general purpose hot water. WARNING: Water temperatures over 125 °F (52 °C) can cause severe burns instantly or death from scalding.
  • Page 15 for installations in the Commonwealth of Massachusetts The following local requirements apply in addition to all other applicable NFPA requirements: For direct- vent boilers, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the intake is installed below four feet above grade the following requirements must comply: 1) If not present on each floor level where there are bedrooms, a carbon monoxide detector and alarm must be placed in a living area outside the bedrooms.

  • Page 16: Introduction

    Make sure to reference the unit’s model number and serial number from the rating label when inquiring about service or troubleshooting. Triangle Tube reserves the right to change the technical characteristics, components and features of its products without prior notice. Check for an updated version of this manual at www.triangletube.com. WCB installation manual...

  • Page 17: Technical Data Ionic Cb Boilers

    4 TECHNICAL DATA IONIC CB BOILERS Functional introduction The Ionic WCB boilers are central heating boilers with a maximum high efficiency. Such a performance can be reached by, amongst other things, using a special heat exchanger made of stainless steel. This allows the flue gases to cool down below the condensation point, and so release extra heat.
  • Page 18 Technical specifications datasheet GENERAL Boiler category IV, direct vent BOILER MODEL CB 299W CB 399W CB 470W CB 500W Dimensions (h x w x d) inch (mm) 33.3 x 17.4 x 21.1 (846 x 442 x 535) Gallon Water content 1.77 (6.7) 2.19 (8.3) 2.74 (10.4)
  • Page 19 Model boiler CB 299W CB 399W CB 470W CB 500W ELECTRIC Maximum power consumption Power supply V/Hz 120 / 60 Protection class IPX4D NOTES Power consumption is measured without circulation pump For gas appliances type B23(P) only class IPX4D with special air inlet (see § 6.2 "Accessories"), otherwise the protection class is IP20.
  • Page 20 AHRI Specifications IONIC WCB series AHRI Thermal Combustion Input, MBH Model Output AFUE Net Ratings Efficiency, Efficiency, number Water, MBH CB 299W 46.0 95.1 CB 399W 72.0 95.5 95.4 CB 470W 83.0 95.6 95.1 CB 500W 83.0 95.1 94.5 Listed Input and Output ratings are at minimum vent lengths at Sea Level. Numbers will be lower with longer venting and/or altitudes greater than 2000 feet [610 m].

  • Page 21: Boiler Dimensions

    5 BOILER DIMENSIONS CB 299W Vent connection Connections CB 299W NPT 1½” Supply NPT 1½” Return Condensate Flexible hose Ø 1.06” (26.9 mm) NPT 1” Table 5.1 Figure 5.1 WCB Installation manual...
  • Page 22 CB 399W Vent connection Connections CB 399W NPT 1½” Supply NPT 1½” Return Condensate Flexible hose Ø 1.06” (26.9 mm) NPT 1” Table 5.2 Figure 5.2 WCB installation manual...
  • Page 23 CB 470W and CB 500W Vent connection Connections CB 470W and CB 500W NPT 1½” Supply NPT 1½” Return Condensate Flexible hose Ø 1.06” (26.9 mm) NPT 1” Table 5.3 Figure 5.3 WCB Installation manual...

  • Page 24: Unpacking And Accessories

    6 UNPACKING AND ACCESSORIES Unpacking The Ionic WCB boiler will be supplied with the following documents and accessories:  One “Installation, and service instructions” manual for the installer (inside the boiler, at the sidepanel)  One User Manual (inside the boiler, at the sidepanel) ...
  • Page 25 UL approved flowswitch E361100008 24V manual reset LWCO with test function E361100007 External manual reset high limit E361100009 ASME CSD-1 kit: 3 parts together, E361100007, E361100008 and E361100009 E361000002 UPS 43-100 F (requires one of the following options: Circulator relay kit for 3 circulators E361100004, Circulator relay kit for 2 circulators E361100005, or Circulator relay kit for 1 CIR01 circulator E361100006)

  • Page 26: Installation Location Of The Cb

    7 INSTALLATION LOCATION OF THE CB Installation Clearances On all sides of the boiler at least 2” of clearance must be applied to walls or wall units, 14” above the top side of the boiler and 10” from the bottom of the boiler. Clearances to wall, ceiling and floor Distances –...
  • Page 27 Boiler Installation Location Requirements:  The installation of this boiler when installed using room air must comply to the latest edition of ANSI Z223.1/NFPA 54 and/or the CAN/CSA B149.1 Natural gas and propane installation code.  The flue gas exhaust pipes must be connected to the outside wall and/or the outside roof. (“Flue gas instructions”...
  • Page 28 Mounting the boiler Before mounting and installing the boiler the following connections must be considered:  Flue gas system and the flue gas pipe connections  Air supply system and connections  Supply and return pipe connections  Condensate and pressure relief valve drainage ...

  • Page 29: Connections

    8 CONNECTIONS Boiler connections 1 – Water outlet / Flow 2 – Water inlet / Return 3 – Gas 4 – Condensate trap clean out. 5 – Condensate drain 6 – Automatic air drain. 4 5 6 Figure 8.1 Gas pipe connection The gas supply piping must conform to all local codes and regulations and/or National Fuel Gas Code, ANSI Z223.1/NFPA 54.
  • Page 30 Create an installation layout such that the piping does not interfere with the vent pipe, or any other serviceable components. The appliance shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain etc.) during installation, operation and servicing. No appreciable drop in line pressure should occur when any unit (or in the instance of a cascade installation when all of the installed units) lights or runs.
  • Page 31 Condensate drain connection The condensate drain is placed at the center and at the bottom of the boiler and has a ¾ inch hose discharge. Connect this flexible hose to the sewer system. Use only plastic parts with the condensate drain. Metal lines are not allowed.
  • Page 32 Flow and return connections Use T-pieces for externally mounting the pressure relief valve and the boiler drain valve for servicing the boiler. We advise to install two service ball valves in the flow and return pipes BOILER underneath the boiler, so the boiler can be isolated from the heating system and eventually disconnected, when needed.
  • Page 33 Chilled Water and Refrigeration Systems The boiler, when used in connection with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler The boiler piping system of a hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.
  • Page 34 Boiler water quality The pH value is reached with the steady Contaminant Maximum allowable level Units conditions. These steady conditions will 7.5 to 9.5 occur, when after filling the heating system Hardness 50 to 150 ppm CaCo3 (pH about 7) with fresh water, the water 2.9 to 8.8 Grains/gallon loses its air because of air bleeding...
  • Page 35 The use of 50% glycol in the boiler system will result in an increase in the viscosity of the water/glycol mixture and a decrease in the heat transfer. When the boilers are used in a system with 50% glycol the following requirements must be followed at all times.
  • Page 36 Flush the system with fresh water The water of the boiler and heating circuit must be free of any particles, debris and pollution. Therefore, the complete installation must always be thoroughly flushed with clean water before installing and using the boiler(s). Plastic piping in the heating system When plastic pipes without oxygen barrier are used in the central heating system, these must be separated from the boiler system by using a plate heat exchanger.
  • Page 37 The following scheme below shows the behavior of the 3-way valve and boiler circulator during one whole cycle of De-Air sequence with a DAir_Repetition_OnOff set to 2. Boiler Circulator Figure 8.8 Relevant variables: Specific Parameters Level (Default) Value Range De_Air_Config 2: Installer 0…1 0 = DAir disabled;...

  • Page 38: Example Of A Single Boiler Heating Circuit With Low Loss Header

    Installation examples 8.21.1 E XAMPLE OF A SINGLE BOILER HEATING CIRCUIT WITH LOW LOSS HEADER Boiler circulator valve Heating circulator air separator Flow/System temperature sensor BOILER dirt separator strainer (water filter) pressure relief valve HEATING ZONE T & P condensate trap circulator automatic air vent expansion vessel...

  • Page 39: Circulator Characteristics

    9 CIRCULATOR CHARACTERISTICS Hydraulic graphs 9.1.1 B CB 299W OILER RESISTANCE GRAPH Figure 9.1 9.1.2 B CB 399W OILER RESISTANCE GRAPH Figure 9 2 WCB Installation manual...

  • Page 40: Boiler Resistance Graph Cb 470W

    9.1.3 B CB 470W OILER RESISTANCE GRAPH Figure 9.3 9.1.4 B CB 500W OILER RESISTANCE GRAPH Figure 9.4 WCB installation manual...
  • Page 41 Minimum required circulator head The hydraulic graphs presented in §9.1 show the pressure loss of the boiler only. When selecting a circulator, it is important to take also into account the piping to and from the low loss header. Also tees and bends add to the total pressure loss. NOTICE Grundfos Circulator Sizing Boiler type / ΔT...

  • Page 42: Delta Temperature Modulation

    9.5.1 D ELTA TEMPERATURE MODULATION The variable speed control is designed to ensure that the delta T across the boiler’s heat exchanger matches the set delta T in the boiler control ensuring efficient temperature control and maximizing both electrical energy efficiency and the percentage of time the boiler operates in a condensing mode.

  • Page 43: Flue Gas And Air Supply System

    10 FLUE GAS AND AIR SUPPLY SYSTEM General venting. The boiler has a positive pressure vent system. The boiler is for either direct vent installation or for installation using indoor combustion air, category IV, appliance with sealed combustion requiring certain venting systems. All combustion air is drawn from outdoors or indoor. All products of combustion are vented directly outdoors.

  • Page 44: Vent And Air Inlet Resistance Table

    10.1.2 V ENT AND AIR INLET RESISTANCE TABLE Minimum and maximum allowable combined vent and air inlet length: - Minimum venting length: two feet (2 ft) for all boilers - Maximum venting length: see table below. Maximum Exhaust Length / Maximum Combustion Air Intake Length CB 299W CB 399W CB 470W / CB 500W...

  • Page 45: Approved Manufacturers

    10.2.1 A PPROVED MANUFACTURERS CPVC venting: * IPEX System 636, Polypropylene venting: * Duravent - PolyPro Stainless steel venting: * Duravent - FasNSeal, FasNSeal W2, FasNSeal Flex, Duraseal DS, DSD, DSID * Security Chimneys - Secure seal SS/SSD/SSID * Heat Fab - Saf-T EZ Seal Other manufacturers are allowed, as long as they comply to table 10.4 (paragraph 10.2 (page 42)) and comply to local codes and regulations.

  • Page 46: Instructions For Cementing Pvc/ Cpvc Pipe Connections

    PVC exhaust venting: When using PVC venting, the first part of exhaust venting is required to always be approved CPVC. This starter piece must have a minimum length (in linear feet) according to table 10.7. If a fitting (elbow or coupling) is needed it does not count toward the total linear feet: Required CPVC Starter Venting When reducing to 4"...
  • Page 47 Near boiler PVC/ CPVC venting. The starter piece must have a minimum length according to table 10.7 "PVC Exhaust Venting" on page 45. IN CPVC Never insert a PVC/CPVC street elbow directly into the vent adapter on the appliance, doing so could result in substantial property damage, serious injury, or death.

  • Page 48: Reducer

    Contact approved polypropylene vent manufacturer for a copy of their installation instructions. Read, understand and follow all of the vent manufacturer’s instructions before beginning the installation. Contact vent manufacturer if you require any technical support. WARNING Failure to properly install and support the vent system can cause the venting system to fail, resulting in substantial property damage, serious injury, or death.
  • Page 49 All vent connections MUST be secured by the vent manufacturer's locking clamp. The installer must use a specific vent starter adapter at the flue collar connection. The adapter is supplied by the vent manufacturer to adapt to its vent system. Installations must comply with applicable national, state, and local codes.
  • Page 50 Stainless steel vent. This product has been approved for use with stainless steel vent using the manufacturers listed. Approved stainless steel vent pipe and fittings. SUPPLIER TYPE Duravent FasNSeal, FasNSeal W2, FasNSeal Flex, Duraseal DS, DSD and DSID Security Chimneys Secure Seal SS/SSD/SSID Heat Fab Saf-T EZ Seal / EZ 316...

  • Page 51: Combustion Air Quality

    Sealed Combustion Air supply When an air supply pipe is connected from the outside of the building to the boiler, the boiler will operate as a sealed combustion boiler. The air supply duct can be made of PVC, CPVC, PP or Stainless steel. 10.6.1 C OMBUSTION AIR QUALITY Combustion air must be free of contaminants.

  • Page 52: Air Inlet Pipe Materials

    10.6.4 A IR INLET PIPE MATERIALS The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list: - PVC, CPVC or PP - Flexible propylene air intake - Galvanized steel vent pipe with joints and seams sealed as specified in this section. - Type “B”...

  • Page 53: Air Contamination

    Room air Commercial applications utilizing the boiler can be installed as a category IV appliance with a single pipe carrying the flue products to the outside while using combustion air from the equipment room. In order to use the room air venting option, the following conditions and considerations must be followed.
  • Page 54 Corrosive Contaminants and Sources Products to avoid: Spray cans containing chloral/fluorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid/muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry...
  • Page 55  The boiler must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also sections "Determine vent location"...
  • Page 56 Direct venting options Two pipe wall Two pipe vertical See § 10.11 for more details. See § 10.12 for more details. Figure 10.6 Figure 10.5 Single pipe wall (room air) Single pipe roof (room air) See § 10.7 for more details See §...
  • Page 57 Concentric wall - two pipe to boiler Concentric wall - concentric to boiler Boilers CB 299W, CB 399W only. Boilers CB 299W, CB 399W only. See § 10.11 for more details. See § 10.11 for more details. Figure 10.9 Figure 10.10 Concentric vertical - two pipe to boiler.

  • Page 58: Vent/Air Termination - Wall

    Wall (Horizontal) direct venting. 10.11.1 V AIR TERMINATION WALL Follow instructions below when determining vent location to avoid possibility of substantial property damage, severe personal injury, or death. A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks.

  • Page 59: Positions

    4. Properly support the PVC/CPVC using pipe metal strap hangers or equivalent pipe hangers suitable for plastic pipe. 5. The installer must comply with all local codes for isolating the vent pipe as it passes through floors and walls. 6. The installer must seal all exterior openings around penetration with an exterior silicon caulk 10.11.4 P OSITIONS Maintain clearances as stated in this manual.
  • Page 60 note 1: In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code note 2: In accordance with the current CAN/CSA-B149.1 Installation Codes note 3: Maintain 12” of clearance above the highest anticipated snow level or grade or, whichever is greater. Please refer to your local codes for the snow level in your area note 4: For clearances not specified in ANSI Z223.1 / NFPA 54, clearance is in accordance with local installation codes and the requirements of the gas supplier.
  • Page 61 Figure 10.17 Multiple vent/air terminations 1. When terminating multiple boilers, terminate each vent/air connection as described in this manual (Figure 10.18). All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death, or substantial property damage. WARNING 2.
  • Page 62 Wall termination – low profile Description and usage: Two pipe termination. Both combustion air and exhaust vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown below in Figure 10.19.
  • Page 63 Sidewall termination installation: - Determine the best location for the termination kit (see Figure 10.13). - Reference § 10.11.2 of this manual for general termination considerations. Ensure termination location clearance dimensions are as shown in Figure 10.21 or 10.22. NOTICE DO NOT use field-supplied couplings to extend concentric terminations.

  • Page 64: Vent/Air Termination - Vertical

    Roof (Vertical) direct venting. 10.12.1 V – AIR TERMINATION VERTICAL Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage. WARNING 10.12.2 D ETERMINE LOCATION Locate the vent/air terminations using the following guidelines: 1.
  • Page 65 8. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment. Multiple vent/air terminations 1. When terminating multiple boilers, terminate each vent/air connection as described in this manual (figures 10.23, 10.24 and 10.25).
  • Page 66 Concentric Vertical Termination: boilers CB 299W and CB 399W only Minimum clearance above snow level (18” for Canada) Maximum 24” above roof or snow level. Figure 10.26 Do Not Install U-Bend or elbow on a concentric termination Figure 10.27 Do not operate the appliance with the rain cap removed on the concentric terminations or recirculation of combustion products can occur.
  • Page 67 Concentric vent and combustion air vertical termination multiple boilers. NOTICE: a minimum distance of 24 in. (61 cm) to wall or parapet. Figure 10.28 60“ MIN Figure 10.29 WCB Installation manual...

  • Page 68: Common Vent Cascading

    11 COMMON VENT CASCADING Introduction All CB boilers have an internal flue gas valve for a positive pressure category IV common vent. This device is needed to prevent recirculation of the flue gases. If common venting is required contact Triangle Tube. Triangle Tube offers a factory supplied certified common venting system designed by Duravent to work with the boilers.
  • Page 69 Existing Common Venting Guidelines. Do not common vent the WCB boiler with the vent pipe of any other boiler or appliance. However, when an existing boiler is removed from an existing common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.

  • Page 70: Electrical Installation

    12 ELECTRICAL INSTALLATION General  For operation, the boiler needs a dedicated 120 VAC / 15A service.  The boiler mains supply connection is polarity sensitive.  The wiring for the connections should be routed at the bottom of the boiler through the wiring knockouts. ...

  • Page 71: Additional Safety Limits

    12.3.1 A DDITIONAL AFETY IMITS The boiler has low voltage connections for three external safety limits that can be field wired, LWCO Extern, Safety Switch 1, and Safety Switch 2. All three create manual reset lockouts in the control. The following accessory safety limits are available from the factory: ...
  • Page 72 Explanation of the low voltage connections. OUTDOOR SENSOR If an outdoor temperature sensor is connected, the boiler will control the supply water temperature by using a calculated setting based on outdoor reset curve, which is related to the outdoor temperature. An outdoor sensor is provided with every boiler from the factory.
  • Page 73 Explanation of the mains voltage connections. 1-2-3-PE DIVERTER VALVE DHW indirect tank / DHW PUMP If an indirect domestic hot water tank is installed, a 3-way valve or a circulator (P2) can be used to divert hot water to the heating coil of the tank. This 3-way valve will open, or circulator will power on, when the indirect tank has a heat demand.
  • Page 74 Electrical schematics Figure 12.3 WCB installation manual...
  • Page 75 Figure 12.4 WCB Installation manual...
  • Page 76 Ladder / logic diagram Figure 12.5 WCB installation manual...
  • Page 77 Sensor availability The following table shows the sensor availability for all CH and DHW control modes. Sensors not mentioned in the table are optionally available for other functions CH Mode T_Supply T_Return T_DHW T_Outdoor 0-10 Volt Water Flow DHW RT Switch M = Mandatory, O = Optional, --- = Disabled.
  • Page 78 Programmable in- and outputs It is possible to re-program some in- and outputs to other functions. To do this use list below and go to: Menu\settings\boiler settings\"1122" (installer password)\boiler parameters boiler parameter name default setting description terminal (117) Prog. Input 2. DHW flow switch LV 16-17 (118)

  • Page 79: Boiler Controller And Display

    13 BOILER CONTROLLER AND DISPLAY. 100.0 °F 170.0 °F Figure 13.1 Explanation of the buttons ON/OFF. On/off switch. Switches electrical power to the boiler COMPUTER. Connector for computer cable RESET. Reset lockout error MENU. Enter the main menu ESCAPE. Escape / Return to the status overview RIGHT.
  • Page 80 Display configuration. The Status overview has three different sections that show specific information: 13:56 Header Figure 12.2 Standby Middle section T3:98 °F 55 Psi Footer 90 °F Actual setpoint Figure 13.3 Header Left: For cascade systems the cascade icon is shown, with the cascade manager indication (M) or the dependent number.

  • Page 81: Set Ch Setpoint/ Dhw Setpoint Directly Via The Status Overview

    Starting the boiler If the boiler is not on make sure the gas valve beneath the boiler is open and the power is wired into the mains, use the on/off button to switch the boiler on. The following screen will occur: Initializing Figure 13.4 This screen is active during power up until communication with the main Control has been established.

  • Page 82: Set The Setpoint By The Menu Button

    13.3.2 S MENU ET THE SETPOINT BY THE BUTTON Enter the menu by pressing the MENU button once. The header in the display shows you are inside the main menu. While scrolling through the menu you will see that the selected menu item is shown in a white rectangle. Central Heating (CH) Domestic Hot Water (DHW) Information...

  • Page 83: Language Settings

    Enter the password with the following steps: 1. Use the UP/DOWN ↑↓ button to adjust the first number 2. Press CONFIRM or RIGHT → to confirm and to go to the following number Repeat this action for all numbers to enter the password. After the password is entered in correctly press ENTER/RIGHT to confirm and access the menu item.
  • Page 84 Boiler history The boiler history found in the information menu displays several history counters that keep track of the boiler usage. The history cannot be erased and will continue for the burner controller life cycle. The following boiler history data is available: (Sub) Menu item Description Successful Ignitions...

  • Page 85: Service Overdue Logging

    The error log screen will show on the first line: Boiler ID for which boiler the error was detected (cascade system only), Error Code, (internal) Error Number, Error Type (Lockout/Blocking). The second line will show the Error Description. The bottom line will show the Time Stamp (date and time) when the error was detected (in the format as configured in the Date Time Settings menu), and also the selected error index from the total number of errors in the (filtered) error log.

  • Page 86: Circulator Start Every 24 Hours

    General The boiler controller is designed to function as a standalone control unit for intermittent operation on heating appliances with a premix (modulating) burner and a pneumatic air-gas system. Fuses Line input 1 x 5AT, 120V Flame establishing period 2 seconds 5 seconds Safety time Ignition attempts...
  • Page 87 Ignition cycle During the ignition cycle multiple safety checks are active Figure 13.16 The table below shows the states of the burner ignition cycle, as shown in the diagram above: Burner state Actions INIT  Controller initialization RESET  Software reset (and initialization) STANDBY ...

  • Page 88: Control Functions

    During the ignition cycle multiple safety checks are active, none of the initiation timing settings are adjustable: False flame detection If a flame is detected at the end of the pre-spark period (Pre_Ignit) a lockout error will occur. Re-ignition If at the end of the safety period no flame is detected the control will go to Post_Purge to remove any unburnt gas.

  • Page 89: On Board Hmi And Led Colors

    13.8.2 O N BOARD COLORS On the burner controller a basic on-board Human Interface (HMI) is available which consists of a push button (reset) and a 2 color (red/green) LED. These are used to indicate basic status information about the control. Status LED Reset button Figure 13.18...

  • Page 90: With Room Thermostat Only; Ch Mode 0

    Control functions Dependent on the required functions of the appliance and connected sensors and components, several operation modes for Central Heating (CH) and Domestic Hot Water (DHW) can be selected. 13.9.1 CH ; CH WITH ROOM THERMOSTAT ONLY MODE For this mode no outdoor sensor is needed. If the room thermostat closes, the boiler and system circulators are switched ON.

  • Page 91: With An Outdoor Temperature Reset And Thermostat; Ch Mode 1 (Factory Default Setting)

    13.9.2 CH THERMOSTAT; CH WITH AN OUTDOOR TEMPERATURE RESET AND MODE FACTORY DEFAULT SETTING If the parameter CH_Mode is set to 1, the “Outdoor temperature reset with room thermostat” mode is selected. This mode will only function when an outdoor temperature sensor is connected. If the outdoor sensor is not connected, the boiler automatically uses Design_Supply_Max._Limit (par.
  • Page 92 Setpoint adjustment It is possible to adjust the calculated setpoint with parameter CH_Setpoint_Diff. The calculated setpoint can be increased or decreased with a maximum of 18°F (10°C). The CH setpoint limits (Design_Supply_Min._Limit and Design_Supply_Max._Limit) are respected while adjusting the setpoint. Apart from the calculated setpoint the functionality is the same as described in §...

  • Page 93: With Full Outdoor Temperature Reset; Ch Mode 2

    13.9.3 CH ; CH WITH FULL OUTDOOR TEMPERATURE RESET MODE When CH_Mode is set to 2, full weather compensator is chosen. For this mode an outdoor sensor has to be connected. The CH_Setpoint is calculated on the same way as described in § 13.9.2. However, the demand does not depend on the Room Thermostat input but on the outdoor temperature and the outdoor reset setpoint.

  • Page 94: With Analog Input Control Of Setpoint; Ch Mode 4

    13.9.5 CH ; CH WITH ANALOG INPUT CONTROL OF SETPOINT MODE In mode 4 of operation, the boiler CH setpoint is controlled by an analog input signal provided by a remote means such as a Building Management System or a system controller. The analog input 0-10 Vdc is used to adjust the boiler setpoint between the CH_Min_Setpoint and the CH_Max_Setpoint settings.

  • Page 95: With Analog Input Control Of Power Output; Ch Mode 5

    13.9.6 CH ; CH WITH ANALOG INPUT CONTROL OF POWER OUTPUT MODE In this mode of operation, the temperature needs to be controlled by an external temperature controller. When the boiler has a supply temperature of 203⁰F (95⁰C) the boiler switches off and shows the blocking code “High Temp Error”...

  • Page 96: No Domestic Hot Water; Dhw Mode 0 (Factory Default Setting)

    Demand for Domestic Hot Water HOT WATER CAN SCALD! Water temperature over 125ºF can cause severe burns instantly or death from scalds. - Children, disabled and elderly are at highest risk of being scalded. - Never leave them unattended in or near shower, bathtub or sink. - Never allow small children to use a hot water faucet or draw their own bath.

  • Page 97: Dhw Storage With Thermostat; Dhw Mode 2

    Because of the presence of the tank sensor (T_Store) the control can detect demand for holding the indirect tank hot. If the tank sensor drops below DHW_Store_Setpoint minus DHW_Tank_Hold_Warm the boiler starts at minimum power. The boiler stops if the tank sensor is higher than DHW_Store_Setpoint plus DHW_Tank_Hyst_Up. Relevant variables Parameters Parameter number...

  • Page 98: Anti-Legionella Protection

    Based on a DHW temperature rise of 100 °F following minimum and maximum DHW flows are advised: Boiler model Minimum flow (gpm) Maximum flow (gpm) CB 299W CB 399W CB 470W CB 500W Table 13.24 Relevant variables Parameters Parameter no. Level Default value Range...
  • Page 99 When the control is powered the anti-legionella algorithm will be initialized when enabled. The initial wait time before an anti-legionella cycle is started is initialized as following:  Anti-legionella enabled AND T_Store < Anti_Legionella_Setpoint – 5°F. Anti-legionella wait time initialized to 120 [min]. ...

  • Page 100: Display Menu Structure Summary

    13.10.6 D ISPLAY MENU STRUCTURE SUMMARY Menu structure Display: Access Description: level 1. Central Heating (CH) User Enter the Central Heating (CH) menu 2. Domestic Hot Water (DHW) User Enter the Domestic Hot Water (DHW) menu 3. Information User Enter the Information menu 4.
  • Page 101 3.2 Boiler status min. max. Default unit Access Description: level Flow Temperature °F (°C) User Actual supply flow temperature Flow 2 Temperature °F (°C) User Actual supply 2 flow temperature Return Temperature °F (°C) User Actual return temperature DHW Temperature °F (°C) User Actual DHW temperature...
  • Page 102 4.1 General settings min. max. Default unit Access Description: level 4.1.1 Language User Enter the Language menu 4.1.2 Unit Type User Enter the Unit Type menu 4.1.3 Date & Time User Enter the Date & Time menu 4.1.4 Cascade Mode User Enter the Cascade Mode menu 4.1.5 Other Settings...
  • Page 103 4.1.4 Cascade mode min. max. Default unit Access Description: level Full Full Installer Select full cascade mode for more data for max 8 boilers Basic Installer Select basic cascade mode for 9 to 16 boilers 4.1.5 Other settings min. max. Default unit Access...
  • Page 104 4.2.1 Boiler parameters min. max. Default unit Access Description: Dis- level play CH mode Installer Set the CH mode CH Setpoint °F Installer Set the CH setpoint (20) (90) (82) (°C) Calc. Setp. Offset °F Installer Set the offset for CH mode 1 / 2 (-10) (10) (°C)
  • Page 105 cont: min. max. Default unit Access Description: Dis- 4.2.1 Boiler parameters level play DHW Tank PID P 1275 Installer Set the DHW tank PID P factor DHW Tank PID I 1275 Installer Set the DHW tank PID I factor DHW Setpoint °F Installer Set the DHW setpoint...
  • Page 106 4.2.2 Module Cascade min. max. Default unit Access Description: Dis- Settings level play Burner Address Stand Installer Set the cascade burner address alone Permit Emergency Mode Yes / Installer Enable/disable the cascade emergency mode Emergency Setpoint °F Installer Set the emergency mode setpoint (90) (70) (°C)
  • Page 107 Parameters for cascade operation are found in the Module cascade settings menu, located in the Boiler settings menu. Parameters in the below Boiler cascade settings menu must not be used. NOTICE 4.2.3 Boiler Cascade Settings min. max. Default unit Access Description: Dis- level...

  • Page 108: Temperature Protection

    14 TEMPERATURE PROTECTION The difference between Supply temperature and Return Temperature is continuously monitored. A too big difference can indicate a defective pump or a clogged heat exchanger. To protect the boiler, the burner controller reduces the input when this temperature difference ΔT becomes too high: At maximum boiler input ΔT is limited to 63°F (35°C) (Hx_Diff_DeltaT_Max).
  • Page 109 Lockout codes Lock Error Description Cause Solving code EEPROM Read Error Internal software error wrongly programmed BCU reset BCU or replace BCU and or or PB display unit Ignition Error Five unsuccessful ignition no gas, wrongly adjusted check gas supply and adjust gas attempts in a row gas valve valve, reset BCU...
  • Page 110 Lock Error Description Cause Solving code Instruction Error Internal software error wrongly programmed BCU or reset BCU or replace BCU and or display unit Ion Check Failed Internal software error wrongly programmed BCU or reset BCU or replace BCU and or display unit Flame Out Too Late Flame still present 10...
  • Page 111 Blocking codes Blocking Error Description Cause Solving code WD Error Ram Internal software error wrongly programmed reset BCU or replace BCU and / BCU or PB or display unit WD Error Rom Internal software error wrongly programmed reset BCU or replace BCU and / BCU or PB or display unit WD Error Stack...
  • Page 112 Lockout Error Description Cause Solving code T Flue Open Flue sensor open malfunctioning flue check connection to BCU or sensor or not check resistance NTC sensor connected T Outdoor Open Outdoor sensor open malfunctioning outdoor check connection to BCU or sensor or not check resistance NTC sensor or connected or wrong...
  • Page 113 Warnings Error no. Error Description Cause Solving Comm. Lost with Cascade System: Managing connection between Check wiring between boiler or module cascade control lost cascaded boilers is distance between boilers is too big communication with one of the interrupted or wiring is Check cascade parameter 147 depending.

  • Page 114: Cascading

    16 CASCADING System setup NOTE: for proper functioning of the system, some settings have to be changed, see § 16.5.2 "Emergency mode". The boiler controller can control multiple boilers in a cascade setup. A system sensor is necessary to measure the cascade system supply temperature.

  • Page 115: Set The Boiler Address

    Select correct CH mode on managing boiler only Parameter: Menu - Settings - Boiler settings - Boiler parameters - Parameter 1 (CH mode) CH mode 0 – Central Heating demand with thermostat control CH mode 1 – Central Heating with an outdoor temperature reset and thermostat control CH mode 2 –...

  • Page 116: Setting Of The Cascade Parameters

    The managing boiler of the cascade system is connected to the AL-BUS connection on terminals 20-21 This connection also provides the power for the communication bus. The depending boilers are all parallel connected to the managing boiler communication bus. The bus power is provided by the managing boiler on terminals 20-21, switch S1 must be set in the OFF position (all controls).

  • Page 117: Cascade - Heating Only Managing Boiler

    16.3.3 C – H ASCADE EATING ONLY ANAGING BOILER When a boiler is set as "Managing" (Address = 1), the controller of this boiler will drive the cascade. The CH mode of this managing boiler applies to all other boilers. It is only required to set the CH mode on the managing boiler. •...

  • Page 118: Cascade - Start/Stop Sequence

    16.3.6 C – S ASCADE TART STOP SEQUENCE The managing boiler sends the calculated Cascade_Setpoint to the dependent boilers. The power of the boilers is PID controlled based on the Calculated_Setpoint and T_Supply. Depending on the temperature difference between T_System and Cascade_Setpoint (CH or DHW) the dependent boilers will start or stop using different algorithms.

  • Page 119: Cascade Frost Protection

    Cascade Error handling 16.5.1 C ASCADE ROST PROTECTION Frost protection on a cascade is active on two levels 1. Frost protection for burner cascade The ‘frost protection’ function for a module cascade is related to the system sensor temperature. When the sensor value is below: Spec.

  • Page 120: System Test

    17 SYSTEM TEST For testing the system at fixed power rates, a system test can be activated via the Installer menu. Via the system test the boiler can be started without CH or DHW being present. The system test has priority. The following modes are available: System test mode Description...

  • Page 121: Commissioning The Boiler

    18 COMMISSIONING THE BOILER First: flushing the boiler with water After installation of the boiler the first step, before commissioning, is to flush the boiler and the whole heating installation with fresh water to remove pollution, debris and other materials that might cause a blocking. This must also be done with heating installations, where only the boiler is replaced.
  • Page 122 Mounting Condensate Trap When mounting the bottom part of the condensate trap, before commissioning the boiler and/or after maintenance, it must ALWAYS be completely filled with water. This is a safety measure: the water in the condensate trap keeps the flue gases from leaking out of the heat exchanger via the condensate drain.
  • Page 123 Firing for the first time After the commissioning of the boiler and the described previous actions, the boiler display will show the following graph. Initializing Figure 18.2 This screen is active during power up until communication with the main Control has been established. After communication has been established the Dair mode is running and the following screen appears: DAir Running Actual Setpoint...

  • Page 124: Adjusting And Setting The Boiler

    19 ADJUSTING AND SETTING THE BOILER Before carrying out any adjusting of the burner, carefully read this complete chapter. The initial lighting of the appliance must be performed by a licensed Gas Technician. Failure to follow these instructions can result in property damage, serious injury or death. As soon as the appliance has been fully installed (with regard to hydraulics, filling and de- aeration of installation, gas, flue gas, air intake, wiring etc.) according to the preliminary WARNING...

  • Page 125: Combustion Table Low Nox

    19.1.2 C OMBUSTION TABLE Table 2: O and CO values for maximum and minimum load, where NO values are less than 20 ppm at 3% O gas type boiler type / CO / CO High Fire Low Fire natural gas CB 299W, CB 399W 5.3 / 8.8 5.3 / 8.8...

  • Page 126: Setting Screws Venturi- And Gas Valves: Drawings

    19.1.3 S ETTING SCREWS VENTURI AND GAS VALVES DRAWINGS Location of the setting screws: Gas pressure High Fire: nipple [3] screw [2] Low Fire: screw [1] Figure 19.1 High Fire: venturi adjustment screw: use hex key 4 mm (5/32 Allen wrench) High Fire: screw [2] Figure 19.2 Low Fire: gas valve adjustment screw: Torx T40.
  • Page 127 Adjustment procedures Procedure 1: adjust at High Fire Carry out the next steps: 1. From status screen, press MENU . Menu options are Central Heating / Information / Settings / System Test 2. Press UP/DOWN ↑↓ to select "System Test" 3.
  • Page 128 Venturi Replacement Adjustment A new venturi is shipped with an unknown setting. It must be adjusted before it can be used in the boiler.  First, turn setting screw [2] on the venturi clockwise until you feel resistance. This means that the valve is fully open, do not try to turn the screw any further.
  • Page 129 2. Set fan speed The fan speed must be changed in the software of the boiler according to table 19.5: fan speed high fire Fan speed low fire parameter 92 parameter 93 Water heater type Propane G31 Nat. gas Propane G31 Nat.
  • Page 130 Telephone number Telephone number Boiler information After filling in form please Model send a copy by e-mail to: info@triangletube.com or Serial number send a copy to address: Installation date Triangle Tube New boiler or replacement 1240 Forest Parkway, Suite 100...
  • Page 131 Number of elbows Number of tees Temperature rise between inlet and outlet after 5 min. cold-start operating max. power °C / °F Water temperature setpoint Test of Water Flow Switch (DHW) ? (YES / NO) Minimum required water pressure in system set to 14.5 psi (1.0 bar) ? (YES / NO) **Gas valve Pressure Nipple...

  • Page 132: Inspection, Maintenance And Service

    20 INSPECTION, MAINTENANCE AND SERVICE. General For a good, safe and long-time operation of the boiler and to maintain warranty it is mandatory to carry out inspection, maintenance and service on the boiler at least once a year and/or after 2000 burning hours maximum, whichever comes first.
  • Page 133 Crystalline Silica - Certain components in the combustion chamber can contain this potential carcinogen. Read warnings and handling instructions pertaining to Refractory Ceramic Fibers before commencing service work in the combustion chamber. Take all necessary precautions and use recommended personal protective equipment as required see Table 20.1.
  • Page 134 Inspection, maintenance and service. Inspection, maintenance and service including the replacement of boiler parts must only be carried out by a licensed professional, service agency or the gas supplier. Apart from the maintenance proceedings it is required to maintain a service log for each boiler that includes all of the following information: ...
  • Page 135 Dismount complete burner unit The complete burner unit consists of the fan, venturi, gas valve, the burner plate and the internal burner. To make more space to transport the burner unit pull down the burner controller unit. To dismount this part for an internal heat exchanger check: remove the six M6 nuts, the ignition cable, the thermal fuse cables and the gas valve cable.
  • Page 136 Ignition / ionization electrode When the burner unit is removed, it is very easy to check the ignition electrode. First check if the distances between the electrodes and between the electrode and the burner are according to the figure below. When these are not correct, try to bend the electrodes into the right position.
  • Page 137 Burner door gasket If any part of the gasket has discolored, changed texture, or hardened, the rubber has cured and/or has damages, these gaskets must be replaced. Notice: only use the gaskets that are supplied by the boiler manufacturer. Burner door gasket replacement: Figure 20.5 - Remove the old gasket - Place a new gasket in its groove.
  • Page 138 Warning Crystalline Silica – Read instructions of § 20.2 carefully Rear wall insulation disk If the insulation disk has been degraded or damaged, it has to be replaced. - be sure the heat exchanger has cooled down, wait a few hours after burning. In this way, the protective film on the new insulation disk will not stick to the rear side of the heat exchanger.
  • Page 139 When the fan blades are polluted and dirty, carefully clean the blades with a soft brush. Notice: do not use too much force on the blades or else the fan might be out of balance and run irregularly, causing noises and fan failures.

  • Page 140: Mounting The Burner Door

    20.3.1 M OUNTING THE BURNER DOOR IMPORTANT: Before mounting the burner door, make sure that its gaskets and insulation are in excellent shape. If any signs of damage or ageing are present, these parts must be replaced. The burner door must be mounted back on the heat exchanger as follows: Place the burner door with its holes over the six threaded studs.
  • Page 141 Maintenance Checklist Allowing the boiler to operate with a dirty combustion chamber will affect operation. Failure to clean the heat exchanger as required by the manual and dictated by the operating location could result in boiler failure, property damage, personal injury, or death. WARNING Such product failures ARE NOT covered under warranty.

  • Page 142: User Instructions

    21 USER INSTRUCTIONS After installing and commissioning of the boiler, the installer is obliged to do the following:  Demonstrate the operation of the entire heating system to the end-user;  Make the user familiar with all safety precautions of the boiler and the installation ...
  • Page 143 Low Voltage Connections BOILER Name Wire terminal HEATING Room thermostat 12-13 ZONE Outdoor temperature sensor System temperature sensor Low loss header Line voltage Connections Boiler circulator 6-7-PE System heating circulator 4-5-PE EHS.D0501.B Figure 22.3 System Example 4 Low Voltage Connections BOILER Name Wire terminal...
  • Page 144 System Example 5 Low Voltage Connections Name Wire terminal BOILER Room thermostat 12-13 HEATING ZONE System temperature sensor Outdoor temperature sensor DHW Tank thermostat or sensor Low loss header DHW indirect Tank Non-return valve (low resistance type) Line voltage Connections Boiler circulator 6-7-PE DHW primary circulator...
  • Page 145 BOILER 1 BOILER 2 BOILER 3 BOILER 4 managing depending 1 depending 2 depending 3 HEATING ZONE EHS.D0501.B Low Voltage Connections Name Wire terminal Room thermostat 12-13 Outdoor temperature sensor System temperature sensor DHW Tank thermostat or sensor DHW indirect Tank Non-return valve (low resistance type) Low loss header Line voltage Connections...

  • Page 146: Spare Parts

    23 SPARE PARTS. CB 299W and CB 399W Figure 23.1 WCB installation manual...
  • Page 147 Figure 23.2 WCB Installation manual...
  • Page 148 CB 470W and CB 500W Figure 23.3 WCB installation manual...
  • Page 149 Figure 23.4 WCB Installation manual...
  • Page 150 Part numbers CB 470W POS. DESCRIPTION Part Number CB 299W CB 399W CB 500W Set. Universal maintenance kit E153000001 Set. Electronics holder E144000001 Set. Anchoring bar CB 299W E111000001 Set. Anchoring bar CB 399W E111000003 Set. Anchoring bar CB 470W & CB 500W E111000004 Clip for WPS 10bar E115100001...
  • Page 151 CB 470W POS. DESCRIPTION Part Number CB 299W CB 399W CB 500W Venturi CB 299W E158100002 Venturi CB 399W E158100003 Venturi CB 470W & CB 500W E158100004 Modulating gas valve VR4615 (120VAC) E158000004 Radial Blower RG148/300W (120VAC) E152000002 Mounting plate silencer E114100001 Wall mounting plate E114000002...
  • Page 152 CB 470W POS. DESCRIPTION Part Number CB 299W CB 399W CB 500W Ty-Rap Heat resistant 3,5x200 mm E115100007 Hose clamp Ø20,62 (DW13) E137100004 Hose clamp Ø11,6-12,3 E115100008 Cable tie with rivet E115100009 PVC bracket Ø60 E114100003 NPT Male Connector 3/8 E116100001 NPT Female Connector 3/8 E116000001...
  • Page 154 E126100001...

This manual is also suitable for:

Ionic cb 299wIonic cb 399wIonic cb 470wIonic cb 500w

Table of Contents