Operating instructions

3
must be provided to an open area within the
building or to the outside. If the building is of
tight construction with exhaust fans, an outside
air supply that is ducted into the boiler room
may be required.
To Set Up Boiler
1. The WCB Boiler must be located on a level,
solid, non-combustible surface adequate to
support unit weight (approximately 700 pounds).
2. Locate boiler to maintain a minimum of 36
inches clearance on the front, 18 inches to the
rear, both sides and top to any obstructions or
combustible material. Locate close to chimney
to keep flue pipe as short as possible, while
maintaining recommended clearances.
3. Refer to Figures 4 or 5 when piping boiler to
system. Refer to Figure 3 for proper location of
connections to the boiler and control locations.
4. A circulator (not provided) should be installed to
provide forced circulation between the two
boilers to equalize the water temperature
throughout both boilers. See Figure 4. The
circulator may be set up to run continuously or it
may be controlled by an aquastat control (not
provided).
5. Provide valves so the add-on boiler can be
isolated from the heating system when not in
use.
6. Be sure to mount a pressure relief valve on the
add-on boiler, the release pressure on the valve
must not exceed 30 PSI.
7. An optional domestic hot water coil can be
installed and piped to an existing hot water
heater. See Fig. 4.
8. When adding the boiler to an existing system,
the water capacity of the system is increased by
17 gallons plus the water in the added piping.
Check existing expansion tank size. It may be
necessary to add an additional tank or change
the existing tank to a larger one to
accommodate the add-on boiler.
9. After all piping is complete and controls are
mounted (including the draft control - see
paragraph under “Draft Control”), fill the boiler
and system with water. Purge and bleed all air
from system. Pressurize boiler to 30 PSI and check
for leaks.
10. It is essential that the boiler be installed with at
least one “dump zone” in which hot boiler water
is dumped on a temperature over-ride. See
Figure 9 for wiring diagram.
Draft Control
1
. The amount of heat produced and level of fire in
this boiler is controlled by a non-electrical, metal
bellows, immersion type of temperature sensing
control. A 3/4" tapping is provided, in the upper
r
ight hand corner on the boiler front, to mount
this control. Refer to Figure 10 when mounting
c
ontrol. Take care not to damage the control by
over-tightening. Make sure on the final tightening
that the red mark on the control body and the
hexagon screw are on top.
2. The mounting and adjustment of the control arm
is to be done when the boiler is up to desired
temperature. Refer to section under “Control
Settings” for proper adjustment of the draft
control.
Flue Pipe Installation
1. A barometric draft control is not supplied with
this boiler. A barometric draft control is required
by code in some areas. The damper, if used,
must be set to maintain a minimum draft of .04
in./water. This amount of draft is required for
proper firing. In cases of marginal draft, this
damper may impair boiler operation, resulting in
smoking or gas-back when fueling the boiler, low
heat output, and excessive creosote formation
when firing with wood. See Fig. 1 for location of
barometric draft control.
2. The flue pipe must be 7" nominal dia. (24 Ga.
minimum thickness). The flue pipe should be as
short as possible (while maintaining
recommended clearances), with a minimum of
elbows and must pitch upward to the chimney
connection. Maintain 18 inches clearance
(minimum) between pipe and combustible
material. Secure each flue pipe joint and boiler
flue outlet connection with sheet metal screws.
Seal opening at chimney connection with boiler
putty. See Fig. 1. Install the flue pipe so that it is
easily removed for cleaning.
3. Manual flue dampers must not be installed
between the boiler and chimney.
Electrical Installation
1. All wiring must be in accordance with local
codes or in the absence of a local code must
comply with the National Electric Code.
2. When doing electrical wiring, refer to Figures 6, 7,
8, or 9. Refer to Figure 6 when using the WCB
Boiler as an add on to an existing boiler with
constant water circulation between the two
boilers. Use Figure 7 for same installation without
circulation between the two boilers. Figure 8 is