Westinghouse WBRC 140 Series, Installation, Start-Up, Maintenance, Parts, Warranty

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whl-648 Rev. 001 Rel. 003 Date 10.8.19
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C. Freeze Protection (When Used)
WARNING
!
NEVER use automotive or standard glycol antifreeze. Do not use
ethylene glycol made for hydronic systems. Use only freeze-
protection fluids certified by fluid manufacturer as suitable for
use with stainless steel boilers, verified in the fluid manufacturer’s
literature. Thoroughly clean and flush any system that has used
glycol before installing the new boiler. Provide the boiler owner
with a material safety data sheet (MSDS) on the fluid used.
1. Determine the freeze protection fluid quantity using total system
water content following the fluid manufacturer’s instructions.
Remember to include expansion tank water content.
2. 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.
4. Glycol in hydronic applications should include inhibitors that
prevent the glycol from attacking metallic system components.
Make certain that the system fluid is checked for the correct glycol
concentration and inhibitor level.
5. The glycol solution should be tested at least once a year or as
recommended by the glycol manufacturer.
6. Anti-freeze solutions expand more than water. For example: A
50% by volume solution expands 4.8% in volume for a temperature
increase from 32 - 80
o
F, while water expands 3% over the same
temperature rise. Allowances must be made in system design for
expansion.
7. A 30% mixture of glycol will result in a BTU output loss of 15% with
a 5% increase in head against the system circulator.
8. A 50% mixture of glycol will result in a BTU output loss of 30% with
a 50% increase in head against the system circulator.
NOTE:
BTU losses apply to both CH and DHW.
D. Fill and Test Water System
WARNING
!
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 CH residential system is 12
psi.
b. Pressure will rise when boiler is turned on and system water
temperature increases. Operating pressure of the CH system
should never exceed 25 psi, and 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.
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 must carefully calculate
the additional friction loss in the system as well as the reduction in
heat transfer coefficients.
CAUTION
WARNING
!
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.
CAUTION
E. Purge Air from CH and Internal Storage Tank
1. 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 terminal block. Apply power to the boiler. After the
control goes through the start-up sequence, the display will turn off.
i. Press and hold the
button for five seconds. Then scroll to 29:AP
by turning the dial . Press the button. AP:cP will show
on the display. Press the button to change the test time. The
default is five minutes. Turn the dial counterclockwise to lower
or clockwise to raise the displayed value. Press the button again
to save any changes.
j. Then use the dial
to scroll to cP:off. Press the button to
turn on test mode. Turn the dial counterclockwise to lower or
clockwise to select on. Press the button again to start test mode.
k. The CH and internal circulation pumps will come on. To bleed air
IMPORTANT!
While commissioning the system, the air vent on top
of the boiler must remain fully open to allow the boiler to properly
fill. Failure to keep the air vent open could lead to improper boiler
and system operation.
CAUTION