Warmboard Comfort System User manual

For use with
Warmsource-E electric boiler
WARMBOARD COMFORT SYSTEM
0622
Installation Guide

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GETTING STARTED
Table of Contents
fGetting Started Page 2
fWCS Preparation Page 3
fPlumbing and Mechanical Page 4
fWarmsource-E Preparation Page 5
fWarmsource-E Specification Page 6
fWarmsource-E Installation Page 7
fFilling and Purging Page 8
fConstruction Mode Page 9
fManifold Cabinet Page 10
fThermostats Page 11
fAir Conditioning Page 12
fTesting the System Page 13
Installation Highlights
1This boiler has been sized and engineered
for 240 volt, single-phase residential wiring.
DO NOT use 208 volt. ON LY use copper wiring.
2WCS uses proprietary, plug-and-play controls
including thermostats, Manifold Controllers and
Smart Reset Controller. These items CANNOT
be exchanged with alternative products.
3All wiring and hook-ups MUST be installed by a
licensed electrical or general contractor. Electrical
work MUST be done in accordance with the
National Electrical Code and local ordinances,
regulations and codes.
4All devices communicate via a pre-configured,
wireless network – there’s no need for additional
wiring or knowledge of networking equipment.
5Adequate ventilation MUST be provided to
ensure the ambient air temperature near the
Warmsource-E does not exceed 90ºF (32ºC)
during operation.
6Reference the Electro Boiler Manual for allowable
mineral levels and water quality. Filtered water or
a corrosion inhibitor may be required.
7Installation of a floor drain below the boiler is
highly recommended.
8The Constant Pressure Circulation pump inside
Warmsource-E adjusts flow rates depending on
the needs of each zone.
9When plumbing for the system is complete,
operate WCS in “Construction Mode” (pg. 8).
This feature allows installers to test the boiler
and flow rates, acclimate building products and
provide heat on cold job sites.
10 Disable Construction Mode before installing
actuators, Manifold Controller(s) or thermostats.
Warmboard Comfort System (WCS) MUST
be installed by a licensed general contractor,
heating professional or plumber. Failure to use
a properly licensed installer, failure to use the
required parts and components and/or any
deviation from these installation guidelines will
void any product warranty.
Review this guide and the supplied working
drawings (including floor plan dimensions)
before work begins.
Review this guide and the supplied working
drawings (including the floor plan dimensions)
before work begins.
DO NOT revise tubing loops or zones without
consulting Warmboard. Field changes will impact
operation of the system.

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WARMBOARD COMFORT SYSTEM // ELECTRIC
WCS PREPARATION
WCS is a unique offering that changes many aspects
installers have become accustomed to. Components
are pre-commissioned, temperatures are pre-set,
and network devices are pre-configured; everything
is plug-and-play. Follow the instructions in this guide
and the system will work.
Essential Documents
We highly recommend the general contractor
manage the job site with the appropriate trade
professionals involved. It is important to keep
Warmboard supplied documents on site at all
times as you will need to reference them regularly
for additional information. Below is a list of the
documents:
f24" x 36" Panel and Tubing Design Documents
(found in the Panel Installation Kit)
f24" x 36" WCS Design Drawings
(found in the Panel Installation Kit)
f24" x 36" WCS Mechanical and Controls Diagrams
(found in the Panel Installation Kit)
fPanel Installation Guide
(inside the Panel Installation Kit)
fTubing & Manifolds Installation Guide
(inside the Tubing and Manifolds Installation Kit)
fElectro Boiler Manual (included with Warmsource-E)
Warmboard-S Sequencing
While every project is different, this list can be a
helpful when working with Warmboard-S and WCS.
fFoundation and joist
fInstall Warmboard-S
fInstall tubing (some loops before walls)
fFrame walls, roof sheeting
fInstall tubing, manifolds (some loops)
fInstall all 120 VAC electrical boxes and outlets
(WCS Design Drawings)
fInstall manifold supply and return distribution
lines (WCS Design Drawings)
fPrepare for Warmsource-E
(T&P, water line, 120 and 240 VAC wiring)
fInsulate walls, floors
fDrywall
fInstall Warmsource-E, then plumb in and fire up
using “Construction Mode”
fTape, texture and paint
fFinish carpentry and all finish floors
fThermostats, Manifolds Controller(s) and actuators
Warmboard-R Sequencing
While every project is different, this list can be a
helpful when working with Warmboard-R and WCS.
fEnsure existing subfloor or slab is level and flat
and 100% dried in
fInstall Warmboard-R
fInstall tubing, manifolds
fInstall all 120 VAC electrical boxes and outlets
(WCS Design Drawings)
fInstall manifold supply and return distribution
lines (WCS Design Drawings)
fPrepare for Warmsource-E
(T&P, water line, 120 and 240 VAC wiring)
fInsulate walls, floors
fDrywall
fInstall Warmsource-E, then plumb in and fire up
using “Construction Mode”
fTape, texture and paint
fFinish carpentry and all finish floors
fThermostats, Manifolds Controller(s) and actuators

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PLUMBING & MECHANICAL
Included, Pre-Plumbed
The following components are pre-plumbed
inside the Warmsource-E unit:
fAutomatic air vent
fTaco ECM variable speed circulator
fTemperature and pressure (T&P) relief valve
Included, Not Pre-Plumbed
The following are included with Warmsource-E
but NOT pre-plumbed. Refer to the WCS Design
Drawings for location and pipe sizing:
fPressure reducing valve (maintains a constant
water pressure of 12-18 PSI, and adds “make up”
water for evaporation)
fExpansion tank (preset at 15 PSI, but can be
reset with a bike pump and ball valve in the
closed position)
fBackflow preventer (required by code in many
jurisdictions, prevents water in the closed-loop
system from mixing with the domestic water)
fAir purging valves (a 1 1/4" combo ball valve/hose
bib, along with several smaller valves, for easy air
purging [be sure to install in the correct location
and water flow direction])
WCS Design Drawings
Our WCS Design Drawings list all the necessary
plumbing and mechanical materials. Reference this
document regularly. Before proceeding, make sure
all boiler components are pre-plumbed per the
Electro Boiler Manual, including:
fT&P relief valve discharge
f
1/2" cold water line from the domestic water
supply to the pressure reducing valve
(WCS Design Drawings)

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WARMBOARD COMFORT SYSTEM // ELECTRIC
WARMSOURCE-E PREPARATION
Install Location
Before installing Warmsource-E, it’s important
to consider its location. Like all electric boilers,
Warmsource-E does make a small amount of noise,
which may be disruptive if installed near a bedroom
or common living space. Garages and basements
are the better choice. Installation of a drain pan,
especially in living spaces, is highly recommended.
Installing Distribution Lines
Once the the tubing and manifolds are installed,
it’s time for the manifold distribution lines.
Sizing, layout and length of the piping can be
found in the WCS Design Drawings.
fPressure test all distribution lines for 15 minutes
at 100 PSI (International Mechanical Code,
section 1208.1)
Minimum Clearances
This illustration shows the recommended minimum
dimensions for the Warmsource-E mechanical room.
Note that this view also depicts space needed for
piping and mechanical components. The minimum
depth is 40" for access and serviceability.
46" 14"
14"
62"
1+" 1+"
Install the Warmboard-supplied ball valves and
hose bibs as shown in our WCS Design Drawings
to properly fill and purge air from the system.
Warmsource-E cabinet dimensions:
24
1/2"W x 33 1/2"H x 13 1/4"D
View the boiler page in the WCS Design Drawings
to see how the manifold distribution lines should
be plumbed, and get a better idea of labor costs.

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SPECIFICATION
51/2"
331/2"
33/4"
41/2"
253/8"
1" – 11/4"
conduit
1/2" – 3/4"
conduit
131/4"
51/2"
21/4"61/8"
3"
41/8" 91/2"
Pressure Relief
Drain connection
3/4" NPT
1" – 11/4"
conduit
Air Eliminator
51/2"
331/2"
33/4"
41/2"
253/8"
1" – 11/4"
conduit
1/2" – 3/4"
conduit
131/4"
51/2"
21/4"61/8"
3"
41/8" 91/2"
Pressure Relief
Drain connection
3/4" NPT
1" – 11/4"
conduit
Air Eliminator
51/2"
331/2"
33/4"
41/2"
253/8"
1" – 11/4"
conduit
1/2" – 3/4"
conduit
131/4"
51/2"
21/4"61/8"
3"
41/8" 91/2"
Pressure Relief
Drain connection
3/4" NPT
1" – 11/4"
conduit
Air Eliminator
Top ViewFront View
Bottom View

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WARMBOARD COMFORT SYSTEM // ELECTRIC
WARMSOURCE-E INSTALLATION
Securing Warmsource-E
fDouble check code clearances and minimum
clearance dimensions (pg.4)
fTo secure Warmsource-E to the wall, install two,
2"x 4" x 25" wood sleepers to the wall studs,
then fasten the unit into place (Warmsource-E
weighs 155lbs and requires two individuals to
move safely)
Connections
fPlumb the cold water line to the backflow
preventer and the pressure reducing valve
(WCS Design Drawings)
fInstall all 11/4" copper plumbing and primary
distribution lines
Warmsource-E is heavy and weighs 155lbs.
Use two people to lift and carry.
Wiring can be run from either the left or right
side of the unit.

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Once the system is plumbed and pressure tested with
air (T&M Installation Guide), the next step is to fill the
system with water and purge the air in the lines.
Air in a closed loop heating system can create noise
and inhibit the flow of water. Follow these steps to
save hours or days of frustration.
Purge Air, Fill with Water
Follow these steps to fill and purge air the system.
This should be done one manifold at a time. In this
example, we’ll begin with Manifold 1 (illustration).
fThread a discharge hose on to valve A,
and ensure the other end of the hose reaches
the exterior of the house (or drain)
fOn valve A, make sure the ball valve is closed
and the hose bib is open
fClose all hose bibs and ball valves on
the remaining manifold return lines (B, C)
fOn the supply side, close the hose bib
and open ball valve D
fTo fill Warmsource-E and the manifold 1 loops
with water (city or well supply), lift the fast fill lever
on the pressure reducing valve E
fCheck each loop flow meter on manifold 1 and
confirm good flow is taking place
fContinue filling the system with water for 10–15
minutes until no air is seen, or heard, escaping
the hose
fClose the fast fill lever, then slowly close hose bib A
fEnsure the pressure gauge located inside
Warmsource-E reads 12–18 PSI
fManifold 1 is now complete. Repeat this
process for each manifold (B, C)
Propylene Glycol
In some situations, it may be necessary to add
propylene glycol to prevent freezing. To do this,
open the ball valve D, and add via the hose bib.
We recommend a 10-30% mix, but refer to the
manufacturer’s recommendation. ONLY use
propylene glycol for freeze protection.
To fill the system with a propylene glycol/water
solution, we recommend a Liberty 331 Portable
Transfer Pump, or equivalent (homedepot.com).
To maintain the propylene glycol feed for many years,
we recommend the Axiom MF200 Pressure Pal.
FILLING & PURGING
A
B
C
D
E
F
G
3/4" Combo ball valve/hose bib
3/4" Combo ball valve/hose bib
3/4" Combo ball valve/hose bib
11/4" Combo ball valve/hose bib
Fast fill lever/pressure reducing valve
Backflow preventer
1/2" ball valve E F G
Manifold 1
Manifold 2
Manifold 3
A
C
BManifold 1
Manifold 3
Manifold 2
D
RETURN
SUPPLY
Reference the Electro Boiler Manual for allowable
mineral levels and water quality. Filtered water or
a corrosion inhibitor may be required.

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WARMBOARD COMFORT SYSTEM // ELECTRIC
CONSTRUCTION MODE
Once the system is filled properly with water,
put Warmsource-E in “Construction Mode”, an
operating state that supplies heat to the structure
BEFORE thermostats, Manifold Controller(s) and
actuators are installed. Construction Mode offers
the opportunity to listen for air noises while
confirming all loops are operating with the proper
flow rates and water temperatures. Activating the
system also brings heat to cold working conditions
and helps hasten the release of moisture from various
materials, including paint, plaster, hardwood flooring
and other wood materials.
fStep 1: Set the temperature gauge on the cover
of Warmsource-E to 102˚F
fStep 2: Open the front cover
fStep 3: Locate the Smart Reset Controller (SRC),
then plug the white Construction Mode jumper into
the “Sensor 2” terminal. The boiler temperature
can be adjusted if a higher temperature is desired
(Warmsource-E will reach the target temperature
in about 10 minutes)
fStep 4: Ensure Warmsource-E is hardwired to
the 240 VAC
fStep 5: Close the front cover, and flip the two
electrical breakers to power up the unit
fStep 6:Return to each manifold and adjust the flow
rates of each loop
1Unthread and (discard) the white caps from
the return side of the manifold
2Remove the red caps on the supply side of the
manifold and adjust the black knobs beneath.
Flow rates for each loop should be equal to,
or greater than, those noted in the WCS Design
Drawings. When done, replace the red caps
DO NOT use Construction Mode after any
actuators have been installed.
Connect Warmsource to an appliance timer to
limit the hours the system runs in Construction
Mode and reduce energy use. Be sure to remove
before installing thermostats and actuators.

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Preparation
The electrician should review the electrical page
of your WCS Design Drawings and note necessary
materials, locations, voltage and amperage of all
electrical components.
Tubing and Labeling
Adhere the provided labels to each supply and
return loop beneath the manifold. Appropriate use
of these labels will assist in any diagnostic issues.
These color-coded labels coincide with the color
labels on the side of the Manifold Controller (MC)
and those displayed in your WCS Design Drawings.
Controls
Warmboard Controls consist of the following:
f120 VAC thermostats (one per heating zone)
f120 VAC Manifold Controller (one per manifold)
f24 volt solenoid valve actuators (one per loop)
fSmart Reset Controller (inside Warmsource-E)
Installing the MC
fUse the provided screws to mount each Manifold
Controller (MC) inside the manifold cabinet specified
in the WCS Design Drawings
fPlug the MC into the nearby 120 VAC outlet
Installing the Actuators
fAttach actuators to each port on the return manifold
fConnect each actuator wire to the appropriate port
on the side of the MC, which is pre-labeled and color
coded. Refer to the WCS Design Drawings as needed
MANIFOLD CABINET
Before installing the controls, you MUST disable
Construction Mode by removing the jumper on
the SRC.
Set the temperature gauge on the front of
Warmsource-E to 138˚F, though you may set this
lower if desired.

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WARMBOARD COMFORT SYSTEM // ELECTRIC
T H ER MOSTAT S
Warmboard Comfort System offers 3 different types
of thermostats:
fHeating
Controls the heat in one zone of the house
fCooling/Heating
Controls one cooling zone and one heating zone
(limit 2 per Warmsource-E)
fFloor Warming/Heating
Controls the heat in one bathroom and offers a
warming feature which keeps the floor warm even
when heat is not called for (can be enabled/disabled
by the homeowner)
Thermostat Installation
Every thermostat MUST be installed in the location
specified in the WCS Design Drawings. Failure to
do so will cause the system to behave inaccurately.
If there are any discrepancies regarding the
thermostat or zoning, contact us immediately.
fRemove the appropriate thermostat from the box
fGrip the ”face“ of the thermostat by the sides with
one hand, and the back of the thermostat with the
other hand, then slowly separate the pieces
fSet the face of to the side
fConnect the hot and neutral (black and white) wires
from the back piece to the connections in the junction
box, then fasten into place with the provided screws
– be sure the arrows point “up” (photo)
fSnap the face plate back into place
fRepeat for each thermostat, always checking to
make sure they are installed in the correct location
After texture and paint, each thermostat MUST
be installed in the correct location in order for the
system to perform properly.

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AIR CONDITIONING
AC Installation
Warmboard thermostats offer single-stage air
conditioning. Connecting an AC system to WCS
is very similar to wiring a 24v thermostat from
an AC unit, just follow the steps below.
fRemove the front cover from Warmsource-E
fLocate terminal connection “AC1/Fan” on the
Smart Reset Controller (SRC)
fConnect the wires from the AC unit to the terminal
block accordingly:
RC: 24 volt power (red wire)
Y: Cooling Call (yellow wire)
G: Fan (green wire)
fTo activate the “Fan Only” feature, use a small jumper
wire between the two RC ports on the terminal block
fRepeat for “AC2/Fan” if using air conditioning across
two cooling zones
Some AC solutions require their own proprietary
controls. In these instances, WCS thermostats
CANNOT be used to control the cooling.

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WARMBOARD COMFORT SYSTEM // ELECTRIC
TESTING THE SYSTEM
Prior Steps
It is imperative that all previous tasks have been
completed before testing or operating the system.
fUse of Construction Mode to test the boiler and flow
rates on each loop
fDisable Construction Mode by removing the jumper
from the appropriate sensor port
fSuccessful installation of all electrical components
(Manifold Controllers, actuators, thermostats)
Once these steps have been completed sequentially,
proceed to the next steps.
Testing the Controls
With all components installed, it’s time to test the
thermostats to ensure they are accurately controlling
each zone. The water temperature displayed on the
boiler MUST read 137ºF before proceeding.
To begin, go to the Zone 1 thermostat, then follow
the instructions below.
fTap the thermostat screen
fNext, tap the button in the lower right corner
and choose “Tutorial” to familiarize yourself with
the controls
fOnce complete, go to “Settings” then ”Support”
and tap ”Test Zone”
fGo to the manifold cabinet for this zone. On the
Manifold Controller you will see a green light on the
loops requesting a call for heat
fAfter 5 minutes, the green lights will turn blue,
indicating that the actuators have opened and water
is flowing to the zone
fIf something does not appear to be working properly,
consult your Warmboard Engineered Drawings
fAfter 15 minutes, the test will end
fRepeat this process for each thermostat
Final Checklist
fA flame icon will appear on the thermostat when
there is a call for heat. It will take 5-7 minutes for the
boiler and pump(s) to receive this signal and fire up
fWhen receiving a call for heat, lights on the pump(s)
will engage and water will begin to circulate.
If not, reference the pump installation manual
fWhen there is a call for heat, water temperatures on
the boiler LCD should read between 90–140˚F
fMatch the specifications in the Warmboard Design
Drawings for each loop and zone to ensure the
system operates smoothly
fConfirm the Warmboard-supplied tubing labels are
adhered to each loop to accurately identify each loop
and zone from inside the manifold cabinet
Before proceeding, make sure the indoor
temperature is above 60˚F.
NOTE: Warmboard thermostats have an “Off”
setting of 55˚F for freeze protection.
Make sure all supply and return tubing labels
have been affixed to the appropriate loop at the
manifold location.
After a zone calls for heat, the actuators will
take approximately 5 minutes to open and begin
heat flow.

NOTICE: Customer is solely responsible for determining whether the
products and the information contained in this installation guide are
appropriate for Customer’s use and are in compliance with applicable laws
because the applicable laws related to the installation and use of this
product may vary from one location to another and may change with time.
Customer represents and warrants that Customer is required to check
current local laws, building codes and other local requirements and that all
local requirements will be adhered to in connection with the installation of
this product.
NO EXPRESS WARRANTIES ARE GIVEN EXCEPT FOR ANY APPLICABLE
WRITTEN WARRANTIES SPECIFICALLY PROVIDED BY WARMBOARD.
ALL IMPLIED WARRANTIES INCLUDING THOSE OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY
EXCLUDED. FAILURE TO INSTALL WARMBOARD PRODUCTS ACCORDING
TO MANUFACTURER’S INSTRUCTIONS WILL VOID ALL APPLICABLE
WARRANTIES. IT IS EXPRESSLY UNDERSTOOD THAT WARMBOARD IS
NOT RESPONSIBLE FOR ANY CONSEQUENTIAL OR OTHER DAMAGES
THAT MAY ARISE FROM USING WARMBOARD PRODUCTS OR
COMPONENTS.
Warmboard assumes no obligation or liability for the information contained
in this document. The Customer assumes all risks as to the use of this
product. Customer’s exclusive remedy or any claim (including any claim
for negligence, strict liability, or tort, without limitation) shall be limited
to the warranty coverage expressly provided in Warmboard’s warranty
documents. Failure to stringently adhere to any of the recommended
procedures of this installation guide and/or any other Warmboard
document related to this product shall release Warmboard of all liability
with respect to this product or the use thereof.
For complete warranty information please call 1.800.556.0595
or visit warmboard.com
KEEP OUT OF REACH OF CHILDREN