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WHL-016 Rev. 4.14.16

62

Part 12 - Maintenance

A. Procedures

Periodic  maintenance  should  be  performed  once  a  year  by  a 
qualified  service  technician  to  assure  that  all  the  equipment 
is  operating  safely  and  efficiently.  The  owner  should  make 
necessary  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  this  manual. 
Failure to do so could result in death or serious injury.

The  combustion  chamber  insulation  in  this  product  contains 
ceramic  fiber  material.  Ceramic  fibers  can  be  converted 
to  cristobalite  in  very  high  temperature  applications.  The 
International  Agency  for  Research  on  Cancer  (IARC)  has 
concluded,  “Crystalline  silica  inhaled  in  the  form  of  quartz 
or  cristobalite  from  occupational  sources  is  carcinogenic  to 
humans (Group 1).”

• 

Avoid breathing dust and contact with skin and eyes.

• 

Use  a  NIOSH  certified  dust  respirator  (N95).  This  type 
of  respirator  is  based  on  the  OSHA  requirements  for 
cristobalite at the time this document was written. Other 
types  of  respirators  may  be  needed  depending  on  job 
site  conditions.  Current  NIOSH  recommendations  can 
be  found  on  the  NIOSH  website:  http://www.cdc.gov/
niosh/homepage.html.  NIOSH  approved  respirators, 
manufacturers, and phone numbers are also listed on this 
website.

• 

Wear long-sleeved, loose fitting clothing, gloves, and eye 
protection.

• 

Apply enough water to the combustion chamber lining to 
prevent dust.

• 

Wash  potentially  contaminated  clothes  separately  from 
other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.

• 

Eye: Irrigate immediately.

• 

Breathing: Fresh air.

B. Combustion Chamber Coil Cleaning Instructions

*Before beginning this procedure, have on hand the following 
items:

• 

a nylon, stainless steel, or brass brush (not steel)

• 

an FDA approved liquid lime scale remover in a spray bottle

• 

gloves and eye protection

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 gas lines from the venture attached 
to the fan.
d.  Loosen  the  nuts  that  hold  the  burner  plate  to  the  heat 
exchanger.

e. Remove the combustion assembly.

2. Spray water or solution into the combustion assembly and 
monitor  the  flow  through  the  combustion  system.  Liquid 
should flow freely through each tube. If there is an obstruction, 
increase the flow on the tube to force blockage out.
3.  Once  complete,  reinstall  the  combustion  assembly  with 
gaskets and secure nuts. Tighten properly.

a.  Reconnect  all  wire  and  piping  connections.  Once 
connected, apply power and disconnect the wire harness 
with  the  white-blue-red-black  wires  to  run  fan  and  dry 
combustion assembly. Let fan run for five minutes. When 
finished, reconnect harness to the fan.
b.  Connect  the  thermostat  wires  to  the  field  connection 
board,  or  turn  up  thermostat  to  fire  the  combustion 
system. Check for leaks in the combustion system. Observe 
operation for 5 to 10 minutes.

If boiler is operating properly, condensate is flowing normally, 
and  no  gas  leaks  are  detected,  combustion  coil  cleaning  is 
complete.

Do not use solvents to clean any of the burner components. 
The components could be damaged, resulting in unreliable or 
unsafe boiler operation, substantial property damage, severe 
personal injury, or death.

Outdoor Sensor 

(7250P-319)

Supply Temperature Sensor

(7250P-324)

Boiler Sensor

(7250P-667)

Indirect Sensor

(7350P-325)

Outside 

Temperature 

(

o

F)

Resistance 

(ohms)

High / Low 

Temp Sensor 

Temp. (

o

F)

Resistance (Ohms)

-22

171800

32

32550

-13

129800

41

25340

-4

98930

50

19870

5

76020

59

15700

14

58880

68

12490

23

45950

77

10000

32

36130

86

8059

41

28600

95

6535

50

22800

104

5330

59

18300

113

4372

68

14770

122

3605

77

12000

131

2989

86

9804

140

2490

95

8054

149

2084

104

6652

158

1753

113

5522

167

1481

176

1256

185

1070

194

915

202

786

212

667

Table 27 - Sensor Temperature Resistance

Содержание WBC 399

Страница 1: ...re installing Perform steps in the given order Failure to do so could result in substantial property damage severe personal injury or death Westinghouse reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature NOTETO CONSUMER PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE WHL 016 Rev 4 14 16 Improper installation adj...

Страница 2: ...VICINITY OFTHIS OR ANY OTHER APPLIANCE WHATTO DO IFYOU SMELL GAS Do not try to light any appliance 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 ...

Страница 3: ...idual 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 For the Installer This boiler must be installed by qualified and licensed personnel The installer should be guided by the instructions furnished with the boiler and by local codes and utility company requirements In the absence of local...

Страница 4: ...e the highest efficiency operation possible Such high efficiency is achieved by limiting heating circuit water temperature to 140 F when there is no anticipated heat load based upon the outdoor sensor and the Outdoor Reset Curve sensor response curve in the boiler software This feature may be over ridden as described below in specific installations The boiler control is equipped with an outdoor se...

Страница 5: ...he Installer 53 A Boiler Control Status Menu 53 B Cascade Menu 55 C BoilerTest Mode 55 Part 11 Troubleshooting 56 A Boiler Error and Fault Codes 56 B Boiler Error 56 C Boiler Fault 56 D User Interface Display 57 Part 12 Maintenance 62 A Procedures 62 B Combustion Chamber Coil Cleaning Instructions 62 C CleaningWater Side of Heat Exchanger 63 D Maintaining the Condensate System 63 Part 13 Shutdown ...

Страница 6: ...uce boiler life Mineral buildup in the heat exchanger reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen from make up water can cause internal corrosion in system components Leaks in the boiler or piping must be repaired at once NOTE DO NOT add cold make up water to the system when the boiler is hot Thermal shock can potentially cause cracks in...

Страница 7: ... suction from the blower allowing gas to flow only if powered and combustion air is flowing All Metal IntegratedVenturi Controls air and gas flow into the burner Burner The high grade stainless steel burner uses premixed air and gas to provide a wide range of firing rates Spark Ignition The burner is ignited by applying high voltage through the system spark electrode The spark from the electrode i...

Страница 8: ... Figure 1 Pallet with Mounting Bracket Affixed Figure 2 Boiler Mounted to Mounting Bracket on Pallet This boiler is certified for indoor use only DO NOT INSTALL OUTDOORS Outdoor installations ARE NOT covered by warranty Failure to install the boiler indoors could result in property damage severe personal injury or death A Locating the Boiler 1 Installation Area Mechanical Room Operating Conditions...

Страница 9: ...the boiler where any leakage from the relief valve related piping tank or connections will not result in damage to surrounding areas or lower floors of the building The boiler should be located near a floor drain or installed in a drain pan Leakage damages ARE NOT covered by warranty Do not mount the boiler to a hollow wall Mount to the studs only Use extreme care not to drop the boiler or cause b...

Страница 10: ...ardsteelorstainless steel x 2 lag bolts for all models Be sure the bracket is level and mark the hole location of the bracket height and horizontal stud location Ensure the marked holes are located in the center of the building frame studs c For all models 2 is the minimum lag bolt length if the bracket is directly on stud Increase lag bolt length for any materials covering the studs d Predrill pi...

Страница 11: ...is securely mounted before leaving it unsupervised H Exhaust Vent and Intake Pipe The boiler is rated ANSI Z21 13 Category IV pressurized vent likely to form condensate in the vent and requires a special vent system designed for pressurized venting NOTE The venting options described here and further detailed in the Venting section this manual are the lone venting options approved for this boiler F...

Страница 12: ...ustion Air in Confined or Unconfined Space I Prevent Combustion Air Contamination Install intake air piping for the boiler as described in the Venting Section this manual Do not terminate exhaust in locations that can allow contamination of intake air Ensure that the intake air will not contain any of the contaminants in Table 2 Contaminated air will damage the boiler resulting in possible substan...

Страница 13: ...recommends having water quality professionally analyzed to determine whether it is necessary to install a water softener It is important that the water chemistry on both the domestic hot water and central heating sides are checked before installing the boiler as water quality will affect the reliability of the system Failure of a boiler due to lime scale build up low pH or other chemical imbalance...

Страница 14: ...WHL 016 Rev 4 14 16 14 Figure 6 Boiler Dimensions NOTE All Dimensions Are Approximate 055 080 ...

Страница 15: ...ain making discharge clearly visible The discharge line shall terminate plain not threaded with a material serviceable for temperatures of 375oF or greater Do not pipe discharge to any location where freezing could occur No valve may be installed between the relief valve and boiler or in the discharge line Do not plug or place any obstruction in the discharge line Test the operation of the relief ...

Страница 16: ...s Model Minimum Flow GPM 055 3 5 080 5 4 110 7 155 9 7 199 12 5 285 17 9 399 25 Table 4 Minimum Flow Rates In addition the heat exchanger has a minimum total water volume that must be taken into account when sizing the circulator Minimum flow rates are listed in the table below The heat exchanger has a pressure drop that must be considered in your system design Refer to Figure 7 for pressure drop ...

Страница 17: ...e Rise Friction Ft and Flow Rate Figure 7 Boiler Pressure Drop The chart below represents the combined flow rates and pipe sizes when using multiple boilers to design the manifold system for the primary circuit To size simply add up the number of boilers and the required flow rates for the system design temperature Example 5 055 boilers with a design of 20 Δt degree temperature rise with each boil...

Страница 18: ...cing pipe size can restrict flow rate through the boiler causing inadvertent short cycling and poor system performance CheckValves Field supplied Check valves are recommended for installation as shown in Applications IsolationValves Field supplied Full port ball valves are required Failure to use full port ball valves could result in a restricted flow rate through the boiler Anti Scald MixingValve...

Страница 19: ...y damage severe personal injury or death due to scalds 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 The glycol solution should be tested at least once a year or as recommended by the glycol manufacturer Anti freeze sol...

Страница 20: ...ar the appliance to prevent gravity circulation CAUTION Mixing valves are required for the protection of low temperature loops Figure 8 Near Boiler Piping NOTE This drawing is meant to show system piping concept only Installer is responsible for all equipment and detailing required by local codes Top Bottom Supply Return Connections Available on 155 199 285 and 399 Models ONLY ...

Страница 21: ...WHL 016 Rev 4 14 16 21 Figure 9 Piping Symbol Legend ...

Страница 22: ...rge 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 119oF 8 Piping shown is Standard VERY IMPORTANT Minimum flow rates outlined in the manual must be maintained to minimize short cycling 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 VERY IMPORTANT Minimum fl...

Страница 23: ...tive 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 119oF 8 Piping shown is Standard 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 VERY IMPORTANT Minimum flow rates outlined in this manual must be maintai...

Страница 24: ...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 119oF 8 Piping shown is Primary Secondary System flow secondary loop must be greater than the boiler s primary loop flow 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 VERY IMPORTANT Minimum flow ra...

Страница 25: ...ll 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 119oF 8 Piping shown is Primary Secondary System flow secondary loop must be greater than the boiler s primary loop flow 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 VERY IMPORTANT Minimum flow...

Страница 26: ... 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 119oF 8 Piping shown is Primary Secondary System flow secondary loop must be greater than the boiler s primary loop flow 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 VERY IMPORTANT Minimum flow rates ou...

Страница 27: ...tamination often contained in indoor air it is best to pipe all intake combustion air directly to the outdoors NOTE If exhaust vent pipe system passes through an unheated space such as an alcove or attic the space must be heated Improper seating of vent pipe gaskets can cause eventual gasket failure and exhaust gas leakage Ensure the exhaust vent pipe is properly beveled and seated before insertio...

Страница 28: ...Table 8 Approved Materials for ExhaustVent and Intake Pipe C Additional Requirements for Installation in Canada 1 Installations must be made with a vent pipe system certified toULC S636 IPEXisanapprovedventmanufacturerinCanada supplying vent material listed to ULC S636 Additionally you may use AL29 4C stainless steel venting to comply with Canadian requirements 2 The first three 3 feet of vent pip...

Страница 29: ...enter Minimum distance between exhaust vents and intake pipes on multiple boilers is 10 0 255 m center to center L When adjacent to a public walkway locate exit terminal at least 7 feet above grade In addition Total length of vent piping shall not exceed the limits specified in this manual The vent piping for this direct vented appliance is approved for zero clearance to combustible construction T...

Страница 30: ... death 1 Use only solid PVC CPVC or stainless steel pipe or a Polypropylene vent system approved for use withCategory IV appliances FOAM CORE PIPING IS NOT APPROVED FOR EXHAUST VENT APPLICATIONS Foam core piping may be used on air inlet piping only 2 Remove all burrs and debris from joints and fittings 3 When using PVC or CPVC pipe all joints must be properly cleaned primed and cemented Use only c...

Страница 31: ...detailed in this manual 1 Side Wall Venting 2 RoofVenting and 3 UnbalancedVenting Be sure to locate the boiler such that the exhaust vent and intake pipe can be routed through the building and properly terminated Different vent terminals can be used to simplify and eliminate multiple penetrations in the building structure see Optional Equipment in Venting Section The exhaust vent and intake pipe l...

Страница 32: ...within 1 foot of the boiler and the balance of 4 foot intervals on the vent pipe Venting must be readily accessible for visual inspection from the first three feet from the boiler NOTES A For every 1 of overhang the exhaust vent must be located 1 vertical below overhang overhang means top of building structure and not two adjacent walls corner of building B Typical installations require 12 minimum...

Страница 33: ...rty damage and add significantly to installation costs If an existing venting system is converted for use with this boiler the installer must ensure that the existing venting system is clean and free from particulate contamination that could damage the boiler Failure to do so could result in property damage and boiler failure Such failure IS NOT covered under warranty ConcentricVentingThrough an E...

Страница 34: ...irect vent so that all combustion air is taken directly from the outdoors into the boiler 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 with doors are considered part of...

Страница 35: ... up into the combustion system There is a flexible line that must be piped to a drain or condensate pump Condensate from the boiler is slightly acidic with a pH of 3 2 4 5 To avoid long term damage to the drainage system and to meet local code requirements Westinghouse recommends neutralizing condensate with aCondensate Neutralizer Kit Part 7450P 212 for EL 80 110 150 220 299 301 Part 7350P 611 fo...

Страница 36: ...E The use of PVC orCPVC 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 ...

Страница 37: ... line vent may be required NOTE To clean out condensate trap see Maintenance section The condensate line must remain unobstructed If allowed to freeze in the line or obstructed in any other manner condensate can exit from the boiler tee resulting in potential water damage to property When installing a condensate pump select one approved for use with condensing boilers and furnaces The condensate p...

Страница 38: ...l codes 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 unit Multiple knockout locations are available to route field wires into and out of the electrical junction box C Field Wiring The control used in the boiler is capable of directly controlling 1 pump in standard mode and 2 pumps when config...

Страница 39: ...powerrequirements of the device s See the instruction manual of the connected device s for further information H Outdoor Sensor There is no connection required if an outdoor sensor is not used or the system requires a fixed operating temperature 1 Use a minimum 22AWG wire for runs of 100 feet or less and minimum 18 AWG wire for runs of up to 150 feet 2 Mount the outdoor sensor on an exterior surfa...

Страница 40: ...ponse from the boiler controller K Optional UL353 Low Water Cut Off Interface Kit If an optional UL 353 Low Water Cut Off LWCO Interface Kit is used the control box of the kit should be mounted to the left side of the boiler cabinet near the low water cut off probe which is located on the outlet nipple of the boiler Follow the complete instructions included in the kit for proper installation L Wir...

Страница 41: ... will be no open communication connection ports 1 Connect the boiler pump to the terminals labeled 1 HOT 2 NEUT and 3 GND 2 An alarm bell or light can be connected to the alarm contacts of the follower 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 120VAC To connect an alarm device connect the po...

Страница 42: ...WHL 016 Rev 4 14 16 42 Figure 33 Internal Connection Diagram ...

Страница 43: ...ort gas piping as the unit is not designed to structurally support a large amount of weight 5 Purge all gas lines thoroughly to avoid start up issues with air in the lines Support gas supply piping with hangers not by the boiler or its accessories The boiler gas valve and blower will not support the weight of the piping Make sure the gas piping is protected from physical damage and freezing where ...

Страница 44: ... properly sized for the total gas load If you experience a pressure drop greater than 1 w c 87 kPa the meter regulator or gas line may be undersized or in need of service Youcan attach amanometerto theincoming gasdriplegafter removing the cap The gas pressure must remain between 3 5 87 kPa and 14 3 5 kPa during stand by static mode and while in operating dynamic mode If an in line regulator is use...

Страница 45: ...onnect the boiler to directly heat a swimming pool or spa water 3 Do not fill boiler or operate with water containing chlorine in excess of 100 ppm Hardness Less than 7 grains Chloride levels Less than 100 ppm pH levels 6 8 Conductivity Less than 400 uS cm at 25oC Sodium Less than 20 mGL Copper Less than 0 1 mg Iron Less than 0 5 mg L Clean system to remove sediment 1 You must thoroughly flush the...

Страница 46: ...e the system of air to avoid damage to the boiler E Purge Air from Water System 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...

Страница 47: ...vere personal injury or death 3 Fill condensate trap with water 4 Verifyelectricalconnectionsarecorrectandsecurelyattached 5 Inspectexhaustventandintakepipingforsignsofdeterioration 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 th...

Страница 48: ...f the system sensor is reached If the system sensor temperature reaches tank set point and differential before all boilers are at highfire themastercontrolwillmodulatethecascadecommand signal to maintain the system sensor at set point and differential until the demand is complete When the system sensor is equal to the set point temperature demand is complete and the master boiler control will exti...

Страница 49: ...d 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 the boiler or boilers if a cascade system is used...

Страница 50: ...tter A or P after the time will blink Press the up or down arrow key once and the letter will disappear Press ENTER to save the new setting CLOCK HOUR 08 28 2009 Fr 10 01A Allows the user to adjust the hour setting CLOCK MINUTE 08 28 2009 Fr 10 01A Adjusts the minute setting CLOCK DAY OF WEEK 08 28 2009 Fr 10 01A Adjusts the day of the week CLOCK DATE MODE 08 28 2009 Fr 10 01A Allows the user to s...

Страница 51: ...Default 48 hours Range 0 240 hours Function 25 Cascade DHW Mode NOT USED NOT USED 25 Not applicable on this product Screen Description Function 6 DHW Post PumpTime DHW POST PUMP TIME 0 MINUTES 6 The indirect pump has the ability to post purge energy from the boiler to run the pump after the set point has been achieved Please note that running the pump for a time greater than 5 minutes may cause ta...

Страница 52: ...le 18 System Setting Program Navigation Function 37 Modbus Mode MODBUS MODE OFF 37 Enables Modbus Mode on the appliance Factory Default OFF Range OFF ON AUTO NOTE TurningModbusMode ON willopen a number of additional parameters to customize Modbus installation See Modbus Instructions lp 372 for details NOTE Turning this Mode ON without a connected and powered Modbus communication adapter p n 7350P ...

Страница 53: ...he top line The system sensor reading is on the second line The control will cascade the boilers up to this set point depending on demand Press v once DHW SET 119oF DHW 117oF Displays the current tank temperature set point on the top line The actual temperature measured by the tank or return sensor Westinghouse 7250P 325 is displayed on the bottom line If a mechanical aquastat is used in place of ...

Страница 54: ...boiler control lockout fault The top line will alternate between the words FAULT HISTORY and the actual fault encountered The bottom line will display the date and time that the fault occurred Press v once FAULT HISTORY 4 08 28 2009 Fr 5 19A This screen displays the fourth oldest boiler control lockout fault The top line will alternate between the words FAULT HISTORY and the actual fault encounter...

Страница 55: ...e system pump output contacts Press v once CASCADE PWR 100 PRESENT 01234567 This screen displays overall cascade power output The range of this value is the number of boilers communicating with the Master x 100 For example if 8 boilers are connected and firing the maximum cascade power is 800 The second line shows which boiler addresses are communicating with the Master Press v once CASCADE SYST 1...

Страница 56: ...so activate Most fault conditions cause the CH pump to run in an attempt to cool the boiler 2 Note the displayed fault code and refer to Section D for an explanation of the message along with several suggestions for corrective actions 3 Press RESET to clear the fault and resume operation Be sure to observe the operation of the unit for a period of time to assure DO NOT USE THIS APPLIANCE IF ANY PA...

Страница 57: ... measured by the supply sensor is higher than the boiler temperature ignition diff setting Thismessagewillstaypresentuntilthewatertemperature measured by the supply sensor is less than the boiler temperature ignition diff setting TEMPER BLOCKING PUMP ON DHW This display indicates a temporary hold on the burner There is a demand on the boiler from the DHW circuit for heat the pump is powered on but...

Страница 58: ... replace the ECO sensor FLUE TEMP WAT LV F01 PUMP ON F01 indicates that the flue temperature limit switch of the boiler has tripped or that the water level in the boiler is low this will only occur if the optional UL353 LWCO is installed This code indicates a serious safety issue The boiler will not restart until the flue cools down sufficiently or the water level is restored A technician must rep...

Страница 59: ...ue exists The boiler will not restart until a technician determines and repairs the cause of excessive temperature and pushes RESET on the display If the FAULT light is not illuminated and this message is displayed the supply tem perature of the boiler is at or above 199oF The message will clear automatically when the temperature drops below 194oF During the time that this fault is displayed the p...

Страница 60: ...l on the display It should be above 1 0 when the boiler is firing 5 If the signal reads less than 1 microampere clean the flame rectifier and spark probe 6 If the problem persists and the FLAME signal is still less than 1 0 replace the flame probe and spark igniter probe 7 The flame signal should be steady after the boiler has been firing for 1 minute and is normally at 5 0 to 9 0 If the flame sig...

Страница 61: ...ming the control is left in a locked out mode Press RESET for at least 1 second to use the control OUTDOOR SENSOR FOU PUMP ON 1 45P FOU indicates an issue with the outdoor sensor It is shorted damaged or disconnected from the boiler 1 Check outdoor sensor connections and wiring Ensure the sensor and wiring are intact and that the sensor is connected to the boiler 2 Checktheoutdoorsensorresistancew...

Страница 62: ...er in a spray bottle gloves and eye protection 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 ...

Страница 63: ...to leak and result in serious personal injury or death 1 Ensure the boiler is powered off and has had time to cool 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 drain tube 3 Remove the bottom cap from the condensate trap 4 Flush trap with fresh water to remove debris from the trap NOTE Ensure the float...

Страница 64: ...ating disconnect the electrical supply If the burner is operating lower the set point value to 70oF and wait for the burner to shut off Continue to wait for the combustion blower to stop so all latent combustion gases are purged from the system This should take a maximum of 40 to 90 seconds B Vacation Procedure If there is danger of freezing change the set point to 70oF DO NOT turn off electrical ...

Страница 65: ...WHL 016 Rev 4 14 16 65 Figure 37 Combustion System Replacement Parts 55 110kBTU Models ...

Страница 66: ...016 Rev 4 14 16 66 Figure 38 Replacement Parts 55 110kBTU Models 20 Switch on the Left is the Blocked Flue Pressure Switch on the Right is the Blocked Condensate Pressure Switch Both share same Part Number ...

Страница 67: ...WHL 016 Rev 4 14 16 67 Figure 39 Combustion System Replacement Parts 155 399kBTU Models ...

Страница 68: ... 7500P 087 POWER SWITCH 10 7500P 037 CONDENSATE OUTLET 11 7250P 154 S S HOSE BARB w O RING 12 7450P 026 FLUE TEMPERATURE SENSOR 13 7250P 059 7250P 667 THERMISTOR w O RING 14 7600P 006 CONDENSATE ASSEMBLY 15 7600P 502 PRESSURE SWITCH w SCREWS 16 7350P 129 FUSE 3 15A CUSTOMER CONNECTION BOARD 17 7600P 904 7600P 905 LOW VOLTAGE WIRING HARNESS not shown 18 7600P 906 7600P 907 120V WIRING HARNESS not s...

Страница 69: ... Boiler If necessary convert the boiler to the proper fuel type Locate the stickers in the appropriate locations on the boiler 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 conversion registration 10 Record heating curve Record steps 8 9 10 11 Notes T...

Страница 70: ...loth to remove oxides Combination Ignitor and Flame Probe Check ionization in uA d7 in Status Menu in Start Up Procedures Record high fire and low fire Clean probe with plumbers cloth to remove oxides Condensate 1stYear 2ndYear 3rdYear 4thYear Neutralizer Check condensate neutralizer Replace if necessary Condensate Pipe Ensurethecondensatetrapisfilledwithwater Disconnect condensate hose Clean out ...

Страница 71: ...ONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wi...

Страница 72: ...ENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting syst...

Страница 73: ...the heating appliance H This warranty extends only to heating appliances utilized in closed loop heating applications that have been properly installed based upon manufacturer s installation instructions I It is expressly agreed between Westinghouse and the original consumer purchaser that repair replacement or refund are the exclusive remedies of the original consumer purchaser OWNER S RESPONSIBI...

Страница 74: ...xtend to shipping charges delivery expenses or administrative fees incurred by the purchaser in repairing or replacing the Gas Fired Boiler This warranty does not extend to labor costs beyond the coverage specified in this warranty document LIMITATIONS OF YOUR WESTINGHOUSE WARRANTY AND REMEDIES THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIE...

Страница 75: ...WHL 016 Rev 4 14 16 75 Maintenance Notes ...

Страница 76: ...of Installation Installation Address Product Name Serial Number s Comments Installer s Code Name Installers Phone Number Signed by Installer Signed by Customer Installation Notes IMPORTANT Customer Please only sign after the installer has fully reviewed the installation safety proper operation and maintenance of the system If the system has any problems please call the installer If you are unable ...

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