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Westinghouse WBCETNG750 Manual

Start-up maintenance parts warranty high mass condensing commercial boilers
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Installation
Start-Up
Maintenance
Parts
Warranty
WBCETNG750 / WBCETNG1000
Models*
*"HL" Denotes Installed High and Low
Gas Pressure Switches
This manual must only be used by a qualified installer / service technician. Read all instructions in this manual before
installing. Perform steps in the given order. Failure to do so could result in substantial property damage, severe
personal injury, or death.
Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause
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.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
Condensing
Commercial Boilers
Heat Exchanger Bears the ASME "H" Stamp
High Mass
WHL-038 Rev. 1.29.16

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  • Page 1 Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause 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.
  • Page 2 IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. WHAT TO DO IF YOU SMELL GAS •...
  • Page 3 AHJ. levels or to important product information. NOTE: Westinghouse reserves the right to modify product technical specifications and components without prior notice. DANGER indicates an imminently hazardous situation...

  • Page 4: Table Of Contents

    E. Freeze Protection In accordance with Section 325 (f) (3) of the Energy Policy Part 2 - Before You Start and Conservation Act, Westinghouse has provided this boiler A. What’s in the Box with multiple features designed to save energy by reducing B.

  • Page 5: Part 1 - General Safety Information

    O. Applications* Part 11 - Start-Up Procedures for the Installer Part 5 - Venting and Condensate Removal A. Boiler Control Status Menu A. General B. Cascade Menu B. Approved Materials for Exhaust Vent and Intake Pipe 23 C. Boiler Test Mode C.

  • Page 6: Improper Combustion

    • Do not use petroleum-based cleaning or sealing Altering any Westinghouse boiler with parts not manufactured compounds in boiler system. Gaskets and seals in by Westinghouse WILL INSTANTLY VOID the boiler warranty the system may be damaged, possibly resulting in and could result in property damage, personal injury, or death.
  • Page 7 Stainless Steel / Steel Heat Exchanger Temperature and Pressure Gauge The highly efficient heat exchanger is designed to use the cold Allows the user to monitor system temperature and pressure. water return from the system and extract the last bit of heat Electrical field connections with terminal strips before it is exhausted.

  • Page 8: Optional Equipment

    C. Optional Equipment Part 3 - Prepare the Boiler Optional equipment available from Westinghouse (and Part #): Remove all sides of the shipping crate to allow the boiler to • System Sensor (7250P-324) be moved into its installation location. The boiler is heavy. At •...

  • Page 9: Locating The Boiler

    3. Check area around boiler. Remove any combustible materials, gasoline, and other flammable liquids. COLD WEATHER HANDLING - If the boiler has been stored in a very cold location (BELOW 0 F) before installation, handle with care until the components come to room temperature. Failure to keep the boiler area clear and free of combustible Failure to do so could result in damage to the boiler.

  • Page 10: Flooring

    B. Flooring All boilers eventually leak. It is recommended to install a catch pan beneath the boiler. This catch pan should be sized This boiler is approved for installation on combustible flooring, with a maximum depth of 2”, and a minimum diameter 2” but must never be installed on carpeting.

  • Page 11: Direct Vent Of Exhaust And Intake

    Figure 3 - Correct and Incorrect Leveling Figure 4 - Recommended Service Clearances NOTE: In multiple boiler installations, ensure an 18” minimum clearance is maintained between boilers. 1. Direct Vent of Exhaust and Intake If installing a direct vent option, combustion air must be drawn from the outdoors directly into the boiler intake and exhaust must terminate outdoors.

  • Page 12: Indoor Combustion Air In Confined Or Unconfined Space

    2. Indoor Combustion Air in Confined or Unconfined Space Areas Likely Have Products to Avoid This boiler requires fresh, uncontaminated air for safe operation Contaminants and must be installed in a mechanical room where there is Spray cans containing Dry cleaning / laundry areas adequate combustion and ventilating air.

  • Page 13: Water Chemistry Requirements

    Chemical imbalance of the water supply may affect efficiency and cause severe damage to the boiler and associated equipment. Westinghouse recommends having water quality professionally analyzed to determine whether it is necessary to install a water softener. It is important that the water...
  • Page 14 Figure 6 - Specifications and Dimensions - NOTE: All Dimensions Are Approximate WHL-038 Rev. 1.29.16...

  • Page 15: Part 4 - Piping

    The boiler may be connected to an indirect water heater to FAILURE TO COMPLY WITH THE ABOVE GUIDELINES supply domestic hot water. Westinghouse offers indirect water COULD RESULT IN FAILURE OF RELIEF VALVE OPERATION, heaters in either stainless steel or glass-lined construction.

  • Page 16: Circulators

    standard on the boiler. Check with local codes for additional requirements. If the boiler supplies hot water to heating coils Expansion tanks must be sized according to total system in air handler units, flow control valves or other devices must volume.

  • Page 17: Circulator Sizing

    G. Circulator Sizing In addition, the boiler heat exchanger has a minimum total water volume that must be taken into account when sizing the circulator. Minimum boiler flow rates are listed in the table below. Minimum Boiler Flow Rates Model Minimum Flow (GPM) 1000 Table 3 - Minimum Flow Rates...

  • Page 18: Check / Control Water Chemistry

    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) 750 boilers with a design of 30 F temperature rise with each boiler having an individual flow rate of 50 GPM.

  • Page 19: Plumbing

    Piping Components Minimum Pipe Size Heating System Piping Model Size System piping MUST be sized per technical pipe requirements listed in Tables 6 and 7. Reducing pipe size can restrict flow 2” NPT rate through the boiler, causing inadvertent short cycling and 1000 2 1/2”...

  • Page 20: Zoning With Zone Valves

    5. A 50% mixture of glycol will result in a BTU output loss of 30% with a 50% increase in head against the system circulator. It is highly recommended that you carefully follow the glycol manufacturer’s recommended concentrations, expansion requirements, and maintenance recommendations (pH additive breakdown, inhibitor reduction, etc.).

  • Page 21: Applications

    5. Piping shown is Primary/ Secondary. 6. The minimum pipe size for connecting Westinghouse indirect fired water heater is 1”. 7. The minimum pipe size for connecting a 750 boiler is 2”. The minimum pipe size for connecting a 1000 boiler is 2 1/2”.
  • Page 22 Figure 9 - Single Boiler Space Heating - Direct Piping Figure 10 - Cascaded Boilers Space Heating - Direct Piping FIGURE NOTES: 1. This drawing is meant to demonstrate system piping concept only. 2. Install a minimum of 12 diameters of straight pipe upstream of all circulators. 3.

  • Page 23: Part 5 - Venting And Condensate Removal

    Part 5 - Venting and Condensate Removal The boiler must be vented as detailed in this section. Ensure exhaust vent and intake piping complies with these instructions regarding vent system. Inspect finished exhaust vent and intake piping thoroughly to ensure all joints are well secured, airtight, and comply with all applicable code requirements, as well as the instructions provided in this manual.

  • Page 24: Approved Materials For Exhaust Vent And Intake Pipe

    B. Approved Materials for Exhaust Vent and Intake Pipe Standards for Installation In: Item Material United States Canada PVC Schedule 40/80 ANSI / ASTM D1785 PVC, CPVC, and PP Venting Must PVC-DWV* ANSI / ASTM D2665 be ULC-S636 Certified. IPEX is Exhaust Vent or Intake an approved manufacturer in CPVC Schedule 40/80...

  • Page 25: Exhaust Vent And Intake Pipe Location

    D. Exhaust Vent and Intake Pipe Location Area Where Terminal Is Not Permitted Intake Pipe Terminal Exhaust Vent Terminal Figure 11 - Exit Terminals for Direct Vent Systems - ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada •...

  • Page 26: Exhaust Vent And Intake Pipe Sizing

    piping only. E. Exhaust Vent and Intake Pipe Sizing 2. Remove all burrs and debris from joints and fittings. 1. The exhaust vent and intake pipe size is 6”. 3. When using PVC or CPVC pipe, all joints must be properly 2.

  • Page 27: Sidewall Venting

    Take extra precaution to adequately support the weight of vent pipes terminating through the roof. Failure to properly support roof terminated piping could result in property damage, serious injury, or death. Two Pipe Sidewall Venting EXTERIOR WALL with Intake (Elbow) and Coupling (Exhaust) 1"...

  • Page 28: Room And Indoor Combustion Ventilation Requirements

    Figure 14 - Unbalanced Venting - Roof Exhaust and Sidewall Intake and the building MUST NOT BE of “Tight Construction”. NOTE: This drawing is meant to demonstrate system venting TIGHT CONSTRUCTION: A building with less than .4 ACH only. The installer is responsible for all equipment and detailing (air changes per hour).
  • Page 29 *”Tight Construction”. manufacturers for exact net free area of louvers. Outside air openings shall communicate with the outdoors. Where two openings are provided, one must be within 12” Combined interior space must be 50 cubic feet per 1,000 BTU/hr input. of the ceiling, and one must be within 12”of the floor of the Buildings MUST NOT be of *”Tight Construction”.

  • Page 30: Condensate Removal System

    - 4.5. To avoid long term damage to the drainage system and freezing of the condensate line. It is also recommended to bush to meet local code requirements, Westinghouse recommends up the condensate line size to 1” and terminate condensate neutralizing condensate with a Condensate Neutralizer Kit (Part discharge as close to the unit as possible.

  • Page 31: Part 6 - Wiring

    The condensate line must remain unobstructed. If allowed Wiring must be NEC Class 1. If original wiring supplied with the to freeze in the line or obstructed in any other manner, boiler must be replaced, use only TEW 105 C wire or equivalent. Boiler must be electrically grounded as required by the National condensate can exit from the boiler tee, resulting in potential water damage to property.

  • Page 32: Alarm Connections

    Westinghouse 7250P-325 tank sensor. When a at .1 amps. If the thermostat is connected to other devices, the...

  • Page 33: Optional 0-10 Volt Building Control Signal

    discard the jumper plug from one of the unused pigtails. 3. Connect the high gas pressure switch to the pigtail that you Failure to use the correct sensor may result in tank removed the jumper plug from. temperature being either above or below set point, and K.

  • Page 34: Optional High Limit Manual Reset

    Avoid running communication cables parallel and close to or against high voltage (120 volt or greater) wiring. Westinghouse recommends that the maximum length of communication bus cables not exceed 200 feet. 4. Route the communication cables through one of the knockouts in the cabinet.
  • Page 35 Figure 24 - Cascade Termination Plug Detail Figure 25 - Cascade Master and Follower Wiring WHL-038 Rev. 1.29.16...
  • Page 36 Figure 26 - Internal Connection Diagram WHL-038 Rev. 1.29.16...

  • Page 37: Part 7 - Gas Connections

    Part 7 - Gas Connections 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 Failure to follow all precautions could result in fire, explosion, physical damage and freezing, where required.

  • Page 38: Gas Table

    or service agency to determine correct action that is needed to provide proper gas pressure to the unit. If Gas Pressure is Never use an open flame (match or lighter) to check for gas within normal range proceed to Step 6. leaks.

  • Page 39: Boiler Gas Valve

    D. Boiler Gas Valve Strain on the gas valve and fittings may result in vibration, premature component failure and gas leakage, and result in fire, explosion, property damage, severe personal injury, or death. Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated combustion analyzer capable of measuring CO2 and CO.

  • Page 40: Check For Gas Leaks

    2. Do not connect the boiler to directly heat a swimming pool or 3. When using freeze protection fluid with automatic fill, install spa water. a water meter to monitor water makeup. Freeze protection 3. Do not fill boiler or operate with water containing chlorine in fluid may leak before the water begins to leak, causing excess of 100 ppm.

  • Page 41: Check Thermostat Circuit(S)

    The display will read: neutralize the condensate. This may be done by the installer or you may purchase a condensate neutralizer from Westinghouse (7350P-611). 2. The boiler is equipped with a ¾ female socket weld fitting connection that must be piped to a local drain.

  • Page 42: Setting Up A Cascaded System

    interval. The control will then be in standby, waiting to process are in a lockout condition, the master control will recognize the next demand for heat. the lockout condition and skip over the boiler in the firing During this process, the control will extinguish the burner sequence.

  • Page 43: Part 10 - Start-Up Procedure

    This section addresses programming features, including Boiler M. Initial Operation - Boiler Door and Seal Settings / System Settings / Maintenance Settings and System Diagnostics, to help in customizing your control. It is important to fully understand control capabilities before customization, as It is important to ensure that the combustion chamber door its factory defaults may already fit your system design and not is properly sealed and installed BEFORE attempting to start...

  • Page 44: Programming Boiler Settings

    3. Next, check the boiler settings. Adjustment and factory Clock Settings defaults are outlined within this section. If a cascade system is (NOTE: The clock will reset if the boiler is powered off for used, it is important that all the boilers have the same boiler more than a week.) settings.
  • Page 45 Screen Description Screen Description Function 1 Factory Program Mode Function 14 DHW Priority This indicates that the control is Allows the user to set the maximum MODE configured correctly. Do not change run time for the indirect fired water INDIRECT DHW PRIORITY this setting.
  • Page 46 Description Function 30 Extra Boiler Mode Function 23 Cascade Mode Allows for a non Westinghouse boiler to be controlled when the Allows the user to select cascade EXTRA BOILER MODE cascade output has risen above the mode. Select OFF if boiler is...

  • Page 47: Resetting The Maintenance Schedule

    NOTE: For the following functions, you must have your Service OA1 Configuration Function 56 Schedule set on either Date or Run Hours. Controls the operation of the To change these functions, press ENTER. The left most digit will 0-10VA output Field begin to blink.

  • Page 48: Part 11 - Start-Up Procedures For The Installer

    The actual temperature measured by the tank or return sensor (Westinghouse 7250P-325) is displayed on the bottom line. If DHW SET a mechanical aquastat is used in place of the recommended sensor, the second line will display ‘OFF’...
  • Page 49 The top line displays the voltage on Press v once. the optional input. This voltage is This screen displays the third oldest 0-10 V 0.0V only relevant if an external 0-10 volt boiler control lockout fault. The top BOILER signal is being used to control the line will alternate between the words FAULT HISTORY boiler.

  • Page 50: Cascade Menu

    This screen displays the tenth This screen displays the eighth oldest boiler control lockout fault. oldest boiler control blocking error. The top line will alternate between BLOCKING HISTORY The top line will alternate between FAULT HISTORY the words ‘FAULT HISTORY’ and 08/28/2009 Fr 5:19A the words ‘BLOCKING HISTORY’...

  • Page 51: Boiler Test Mode

    This screen displays information Press v once. about cascade status. The TT in BOILER 8 the center of the top line shows This screen is not applicable. BOILER 9 that cascade demand is coming from TT contact being closed. You Press v once.

  • Page 52: Boiler Error

    may show an error message and error code. This message and code may be the result of a temporary condition, in which case the display will revert to its normal readout when the condition If overheating occurs or the gas supply fails to shut off, do not is corrected, or it may be a condition that the controller has turn off electrical power to the circulating pump.

  • Page 53: User Interface Display

    D. User Interface Display Cascade Control Fault Codes Screen Description Possible Remedy Disconnect the system sensor from the wiring and measure it’s resistance. Compare the measured resistance E03 indicates a problem with the system to the table in this manual to see if it corresponds to the sensor circuit.
  • Page 54 F04 indicates that the flue temperature Inspect the flue sensor for physical damage or corrosion sensor of the boiler has failed. The boiler will and replace it if necessary. Check the electrical connection not restart until a technician replaces the to the flue sensor and repair as necessary.
  • Page 55 1. Monitor gas pressure to the unit while in operation. 2. Assure the flame is stable when lit. 3. Check if the display readout changes from “GAS VALVE The flame was lost 3 times while the boiler ON” to “RUN” within a few seconds of boiler ignition. was firing during 1 demand call.
  • Page 56 IF EXT LWCO is installed: 1. Check boiler feed water system. Ensure it is supplying make-up water to the boiler system. 2. Be sure all air is bled from the system. This error is generated when the External 3. Check for leaks in the boiler and system piping and Low Water Cutoff is installed and the water repair as necessary.
  • Page 57 1. Inspect the ground wires for damage or loose connections. This error indicates there is an internal fault 2. Inspect the condensate wiring for damage and repair HARD FAULT COND in the circuit within the control connected to as necessary. the condensate switch.
  • Page 58 1. Assure the flue is not blocked. FLU indicates excessive flue pressure. This 2. Check the switch wiring by applying a jumper in place HIGH FLUE PRESS code resets automatically after the high of the switch. If the code clears with the jumper in place, PUMP ON pressure condition is resolved.
  • Page 59 Flue Burner Supply Temperature Boiler Outdoor Sensor Indirect Sensor Temperature Temperature Sensor Sensor (7250P-319) (7350P-325) Sensor Sensor (7250P-324) (7700P-073) (6300P-023) (6300P-036) Temperature ( Resistance (ohms) Temperature ( Resistance (ohms) 171800 32624 129800 25381 98930 19897 76020 15711 58880 12493 45950 10000 36130 8056...

  • Page 60: Part 13 - Maintenance

    Part 13 - 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.

  • Page 61: Replacing The Door Seal

    Figure 33 - Setting the Torque Wrench Figure 36 - Opening / Closing the Combustion Chamber Door 5. Gently remove the used seal. Take care not to damage the door’s ceramic insulation. 6. Carefully wash out the seal pit and rebead with new high temperature silicon (rated to at least 300 Figure 34 - Closing the Combustion Chamber Door Figure 37 - Removing the Combustion Chamber Door Seal...
  • Page 62 Figure 41 - Closed Door with Properly Fitted Seal D. Maintaining the Condensate System 1. Ensure the boiler is powered off and has had time to cool. 2. Remove the hose clamp attaching the condensate trap to the condensate hose from the heat exchanger. Remove the clear plastic hose from the hose barb.
  • Page 63 Part 13 - Shutdown A. Shutdown Procedure If the burner is not operating, disconnect the electrical supply. If the burner is operating, lower the set point value to 70 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.
  • Page 64 REAR OF CONTROL CABINET Item # Part # Description 6300P-018 GASKET - BLOWER ASSEMBLY 6300P-088 MODULATING DAMPER (WITH MOTOR) 6300P-089 MOTOR - MODULATING DAMPER 7100P-266 TEXT DISPLAY ASSEMBLY 6300P-030 BLOWER SCREWS - AIR/GAS MIXER (M8 X 15MM) 6300P-075 NUTS - AIR SHUTTER (1/4-20) 6300P-008 AIR/GAS MIXER 6300P-996 VALVE FLANGE (w/GASKET, SCREWS &...
  • Page 65 Figure 44 - Exterior Replacement Parts WHL-038 Rev. 1.29.16...

  • Page 66: Part 14 - Installing The Optional Jacket

    Part 15 - Installing the Optional Jacket Table 27 - Optional Jacket Replacement Parts WHL-038 Rev. 1.29.16...

  • Page 67: Part 15 - Installation Checklist

    Part 16 - Installation Checklist Light Off Activities Date Completed: Check all piping and gas connections. Verify all are tight. Pressurize system (12 - 15 psi). 1. Fill the Heating System Add water to prime condensate cup. Verify near boiler piping is properly supported.
  • Page 68 Inspection Activities Date Last Completed Piping 1st Year 2nd Year 3rd Year 4th Year* Check boiler and system piping for any sign of leakage; make sure Near boiler piping pipes are properly supported. Check condition of all vent pipes and joints. Ensure the vent piping Vent terminations are free of obstructions and blockages.

  • Page 69: Rev. 02/16/06

    ADDITIONAL INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS In the Commonwealth of Massachusetts, the installer or service agent shall be a plumber or gas fitter licensed by the Commonwealth. When installed in the Commonwealth of Massachusetts or where applicable state codes may apply;...
  • Page 70 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.
  • Page 71 E. If Westinghouse is unable to repair or replace a boiler so as to and operate the boiler in accordance with the printed instructions conform to this warranty after a reasonable number of attempts, that accompany the unit.
  • Page 72 NOTE: Any parts or heaters returned to Westinghouse for warranty analysis will become the property of Westinghouse and will not be returned, even if credit is denied. If all warranty conditions are satisfied, Westinghouse will provide replacement parts to the retailer.
  • Page 73 Maintenance Notes WHL-038 Rev. 1.29.16...
  • Page 74 Customer Installation Record Form The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document. Customer’s Name Date of Installation Installation Address...

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