WIXLIB

Draft Controlmust be provided to an open area within thebuilding or to the outside. If the building is oftight construction with exhaust fans, an outsideair supply that is ducted into the boiler roommay be required.1. The amount of heat produced and level of fire inthis boiler is controlled by a non-electrical, metalbellows, immersion type of temperature sensingcontrol. A 3/4" tapping is provided, in the upperright hand corner on the boiler front, to mountthis control. Refer to Figure 10 when mountingcontrol. Take care not to damage the control byover-tightening. Make sure on the final tighteningthat the red mark on the control body and thehexagon screw are on top.2. The mounting and adjustment of the control armis to be done when the boiler is up to desiredtemperature. Refer to section under “ControlSettings” for proper adjustment of the draftcontrol.To Set Up Boiler1. The WCB Boiler must be located on a level,solid, non-combustible surface adequate tosupport unit weight (approximately 700 pounds).2. Locate boiler to maintain a minimum of 36inches clearance on the front, 18 inches to therear, both sides and top to any obstructions orcombustible material. Locate close to chimneyto keep flue pipe as short as possible, whilemaintaining recommended clearances.3. Refer to Figures 4 or 5 when piping boiler tosystem. Refer to Figure 3 for proper location ofconnections to the boiler and control locations.4. A circulator (not provided) should be installed toprovide forced circulation between the twoboilers to equalize the water temperaturethroughout both boilers. See Figure 4. Thecirculator may be set up to run continuously or itmay be controlled by an aquastat control (notprovided).5. Provide valves so the add-on boiler can beisolated from the heating system when not inuse.6. Be sure to mount a pressure relief valve on theadd-on boiler, the release pressure on the valvemust not exceed 30 PSI.7. An optional domestic hot water coil can beinstalled and piped to an existing hot waterheater. See Fig. 4.8. When adding the boiler to an existing system,the water capacity of the system is increased by17 gallons plus the water in the added piping.Check existing expansion tank size. It may benecessary to add an additional tank or changethe existing tank to a larger one toaccommodate the add-on boiler.9. After all piping is complete and controls aremounted (including the draft control - seeparagraph under “Draft Control”), fill the boilerand system with water. Purge and bleed all airfrom system. Pressurize boiler to 30 PSI and checkfor leaks.10. It is essential that the boiler be installed with atleast one “dump zone” in which hot boiler wateris dumped on a temperature over-ride. SeeFigure 9 for wiring diagram.Flue Pipe Installation1. A barometric draft control is not supplied withthis boiler. A barometric draft control is requiredby code in some areas. The damper, if used,must be set to maintain a minimum draft of .04in./water. This amount of draft is required forproper firing. In cases of marginal draft, thisdamper may impair boiler operation, resulting insmoking or gas-back when fueling the boiler, lowheat output, and excessive creosote formationwhen firing with wood. See Fig. 1 for location ofbarometric draft control.2. The flue pipe must be 7" nominal dia. (24 Ga.minimum thickness). The flue pipe should be asshort as possible (while maintainingrecommended clearances), with a minimum ofelbows and must pitch upward to the chimneyconnection. Maintain 18 inches clearance(minimum) between pipe and combustiblematerial. Secure each flue pipe joint and boilerflue outlet connection with sheet metal screws.Seal opening at chimney connection with boilerputty. See Fig. 1. Install the flue pipe so that it iseasily removed for cleaning.3. Manual flue dampers must not be installedbetween the boiler and chimney.Electrical Installation1. All wiring must be in accordance with localcodes or in the absence of a local code mustcomply 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 WCBBoiler as an add on to an existing boiler withconstant water circulation between the twoboilers. Use Figure 7 for same installation withoutcirculation between the two boilers. Figure 8 is3

Boiler Operationused when the WCB Boiler is used as anindividual heating unit with forced watercirculation. Use Figure 9 when the WCB Boiler isinstalled on a system with zone valves.3. No electrical connections are required if theWCB Boiler is installed on a gravity hot watersystem.4. Use 14 Ga. copper wire for all wiring. Route allwiring to avoid hot surfaces. Be sure all electricalcomponents are well grounded electrically.Wood Firing1. Three refractory blocks are furnished for woodfiring. Lay these blocks evenly spaced, over thegrate bars.2. Before starting a fire: Be sure that the draftdamper (on the ash pit door) is fully open. Pulloverfire baffle handle outward as far as it willtravel. Caution: Flammable liquids must never beused to start or to rekindle a solid fuel fire.3. To build a fire: Place a small amount o crumpledpaper on the refractory blocks. This should becovered with kindling wood and a few smallsticks of wood. The paper is then ignited. Once adraft has been created in the flue, larger piecesof wood can be added to the fire. If smoke puffsout into the room, the draft damper should bepartially closed until the smoke clears and thechimney vents properly.4. When a steady fire is established and the flue isup to operating temperature, push overfire bafflehandle in toward boiler as far as it will go. Setdraft control to maintain desired heat output.5. This boiler is provided with a cast iron baffle,inside front end of combustion chamber. Thisbaffle ducts preheated air over the fire bed toassure complete combustion of the releasedunburned gases from the fire bed. A round swivelcover on the boiler above the ash door can beused to admit additional over fire air if desired.Loosen screw, swing cover to desired openingand lock in place by tightening screw.6. Frequent additions of a small amount of woodwill result in more even burning and themaintenance of a continuous hot fire. This willreduce the tendency to produce creosote.7. When loading the boiler with wood, DO NOTmaintain a fire bed above the top of thefirebrick lining.8. It is not unusual to have a little smoke come intothe room as you open the door to add morewood. You can generally avoid this by openingthe door slightly for a moment before you openit completely. Pulling the overfire baffle handleoutward as far as it will go, before the door isopened, is also helpful.9. Small gas explosions may occur when refuelingany wood-burning device, always open the firingdoor very carefully and keep your face awayfrom the door until it is completely open.10. It is best to always maintain an ash bed underthe fire. When this bed gets too thick, use a pokeror stick to poke ashes through the grate (throughspaces between the refractory blocks) into theash pan.11. Always keep fire door and ash pit door closedwhen boiler is in operation, maintain all seals ingood condition.Control Settings1. Immersion Draft Control: Since this control ismounted in a horizontal position on the WCB, thered numerals are used when adjusting. Thiscontrol will maintain the boiler watertemperature at the point set on the control. Thedraft control is calibrated in celsius temperaturemarkings. Refer to table below for Fahrenheitequivalents.F C F C F C 170772101002. Set control at desired water temperature. Startfire in boiler and raise boiler water temperatureto point set on control. Observe the watertemperature using the supplied temperaturepressure gage. The suggested setting is 180 F.3. With water temperature in boiler at control setpoint, slide draft control arm into hole on control(hole with wooden plug). The longer part of thearm (end with knob) must project forward on ahorizontal plane or slightly below horizontal.Position arm above hole in draft door on the ashpit door, use the hexagon screw to lock the armin place. See Fig. 10. Note: Do not remove thewooden plug before inserting the control arm.Press the control arm into the hole, graduallypushing out the wooden plug.4. Connect chain between draft control arm anddraft door. See Fig. 10. Shorten chain to a pointthat the draft door will be open approximately1/16" with boiler up to temperature as set oncontrol.5. The draft control will now raise and lower the fireto maintain the desired water temperature.6. Set the dial on the L4006B aquastat on the addon boiler at 200 F.7. Set the high limit at 150 F. and the low limit at140 F. on the primary boiler.8. Set thermostat at normal desired temperature.4

Boiler Operationpieces of ash or clinkers, it may be necessary tobreak up the ash with a poker, so that it may beshaken more easily through the grates.10. Always keep fire door and ash pit door closedwhen boiler is in operation. Maintain all seals ingood condition.Coal FiringWarning: All coal fires produce some carbonmonoxide, a highly poisonous gas. Improper care oroperation can cause carbon monoxide to escapefrom the boiler, smokepipe or flue. Some conditionswhich can cause carbon monoxide to escape are:blocked chimney or smoke pipe, poor chimneydraft, build up of ashes, or the use of too much fuel.1. The three refractory blocks, used on the gratesfor wood firing, are to be removed for coal firing.2. Before starting a fire: Be sure that the draftdamper (on the ash pit door) is fully open. Pulloverfire baffle handle outward as far as it willtravel. Caution: Flammable liquids must never beused to start or to rekindle a solid fuel fire.3. To build a fire: Place a small amount ofcrumpled paper on the grates. This should becovered with kindling wood and a few smallsticks of wood. The paper is then ignited. Afterthe fire is started place some coal on the fire. Asthe coal ignites, keep adding additional coal.4. When a steady fire is established and the flue isup to operating temperature, push overfire bafflehandle in toward boiler as far as it will go. Setdraft control to maintain desired heat output.5. The swivel cover (referenced in Item 5 underWood Firing) does not have to be used whencoal firing.6. As the burning progresses, a suitable bed ofglowing coal is produced. The coals are overlaidwith fresh coal at intervals as needed, and theglowing coals ignite the volatile gases in thefresh coal before the gases accumulate.However, if the bed of coals is allowed tobecome too cool before fresh coal is added,the gases can accumulate before being ignitedby the low temperature coal bed. These gasescan escape into the dwelling or a mild explosioncan occur. Charging the fire with too much coalat one time can also cause this condition.7. When loading the boiler with coal: DO NOTmaintain a fire bed above the top of thefirebrick lining. It is advisable to leave a glowingarea of already burning coal exposed.8. Always maintain an ash bed between the fireand the grates. This is done to preventoverheating of the grates which can causethem to warp or burn out.9. The ashes are dropped into the ash pan byshaking the grates. A grate shaker handle isprovided for this purpose. When shaking thegrates: Do not try to force the shaker handle. Thegrates are furnished with a linkage bar thatrestricts the amount the bars can be moved. It isonly necessary to vibrate the grates rapidly toshake down the ash bed. When cleaning largeOperation DuringPower Failure1. An electrical power failure will not affect theoperation of the boiler if it is installed on agravity feed hot water system, since there is noelectrical connections to the boiler under thistype of operation.2. On a circulating hot water system, the flowcontrol valve can be manually opened to usethe boiler as a gravity feed unit. In this type ofoperation, the amount of heat available in thedwelling will be dependent on the size andlength of piping. For this reason, someexperimenting with the fire level will have to bedone to determine the safe fire level to maintainwithout allowing the boiler water temperature toreach the boiling point. It is advisable to lowerthe draft control from the normal setting (in therange of 150 F. to 160 F.) until the electricalpower is restored. With no power there are nomeans to pump the water from the boiler on ahigh limit condition. For this reason it is imperativethat the level of fire be maintained very carefullyand under constant attention.Periodic Maintenance1. In order for a solid fuel heating system tooperate efficiently and safely, the entire systemmust be properly maintained. This means thatthe boiler, chimney connectors and joints, andthe chimney flue must be in proper workingorder and clean.2. At the end of each heating season, the chimneyflue and boiler smokepipe should be thoroughlycleaned of soot and other residues. Then the flueshould be inspected for any needed repairs andany accumulations of creosote. If creosote doesaccumulate, it should be scraped off with along-handled scraper. Creosote is difficult toremove, so care must be taken to preventdamage to the mortar joints.3. The inside surfaces of the boiler should also becleaned thoroughly each year at the end of theheating season. These surfaces can be reachedreadily through the fire door. Use a wire brushand a scraper to remove all accumulation ofsoot, creosote and other residues. Whencleaning the boiler, remove the sliding overhead5

Chimney Firebaffle by removing the set screw which securesthe baffle handle to the baffle. Remove handleby pulling outward. Drop baffle and removethrough fire door. After thoroughly cleaning allinside surfaces of boiler and baffle, check thegrate bars and fire brick lining. Replace warpedgrate bars or damaged fire brick. Whenreassembling the baffle, be sure the set screwlines up with flat portion on handle rod. This flatprovides a seat for the set screw and preventshandle rod from slipping out of the baffle whenbaffle is pulled forward.4. If wood is the main fuel used, the abovecleaning procedures may have to be doneseveral times during the heating season. In anyevent the boiler should be inspected on regularbasis to check for accumulation of soot orcreosote.5. During the summer months, it is advisable toopen the fire door and ash pit door slightly toallow air to circulate through the boiler toprevent condensation and resulting in corrosionon the inside surfaces of the boiler. Cleaning theboiler immediately after the heating seasonalong with air circulation aids greatly in reducingthe tendency for corrosion to develop.1. A chimney fire can be very frightening althoughin many cases it will sound much worse than itreally is due to the loud roar and flying sparks. Ifyou should have a chimney fire, call the FireDepartment immediately. Then while waiting forthe arrival of fire fighters, the fire can usually becontrolled and possibly extinguished bydumping a large quantity of coarse salt on thefire in the boiler. Be sure to close the fire door, ashpit door and draft door to exclude the air fromthe chimney flue. If possible, avoid introducingwater into the chimney itself. The water coulddamage the relatively brittle heated flue liner.6

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efm Sales CompanyEmmaus, PA 1804913

14PARTS LIST EFMMODEL WCB BOILER

CC-7578

This boiler is primarily intended to be an "Add-On" unit to an existing oil or gas fired forced hot water boiler. This boiler is not intended to be the sole source of heat except for the storage buildings, cabins, etc. where constant steady heat is not required. See instructions under heading "To Set Up Boiler" for proper application.