Westinghouse WBRE80 User Manual
  1. Manuals
  2. Brands
  3. Westinghouse Manuals
  4. Boiler
  5. WBRE80
  6. User manual
Westinghouse WBRE80 User Manual

Westinghouse WBRE80 User Manual

Premier high efficiency boilers
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Installation
Start-Up
Maintenance
Parts
Warranty
WBRE**80 / 110 / 150 / 220 / 299 / 301 / 399
Models*
* "NG" Denotes Natural Gas Operation
"LP" Denotes Propane Gas Operation
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.
Premier
High Efficiency
Heat Exchanger Bears the ASME "H" Stamp
Boilers
WHL-052 Rev. 4.28.16

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the WBRE80 and is the answer not in the manual?

Questions and answers

Related Manuals for Westinghouse WBRE80

Summary of Contents for Westinghouse WBRE80

  • 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

    In accordance with Section 325 (f) (3) of the Energy Policy heat load), the control will reduce the maximum fan speed. and Conservation Act, Westinghouse has provided this boiler If the temperature difference exceeds 60°F, the control with multiple features designed to save energy by reducing will effectively sense there is little or no water flow or heat the boiler water temperature as heating load decreases.

  • Page 5: Part 1 - General Safety Information

    M. Zoning with Circulators C. Boiler Test Mode N. Multiple Boilers Part 11 - Troubleshooting O. Applications* A. Boiler Error and Fault Codes Part 5 - Venting and Condensate Removal B. Boiler Error A. General C. Boiler Fault B. Approved Materials for Exhaust Vent and Intake Pipe 25 D.

  • Page 6: Improper Combustion

    Westinghouse recommends a suction assembly. strainer in this type of system. Altering any Westinghouse boiler with parts not manufactured • Do not use petroleum-based cleaning or sealing by Westinghouse WILL INSTANTLY VOID the boiler warranty compounds in boiler system.

  • Page 7: How The Boiler Operates

    C. Optional Equipment connected boilers. Each cascaded boiler will have its own Optional equipment available from Westinghouse (and Part #): pump to provide maximum flow and control heat exchanger • Wall Mount Bracket (7450P-211) flow rate.

  • Page 8: Part 3 - Prepare The Boiler

    • Condensate Neutralizer (80/110/150/220/299/301 Models - 7450P-212, 399 Model - 7350P-611) This boiler has a condensate disposal system that may • Condensate Removal Pump (554200) freeze if exposed to sustained temperatures below 32 • Flow Switch Kit (80/110/150/220 Models - 7450P-213, Precautions should be taken to protect the condensate trap 299/301 Models - 7450P-214, 399 Model - 7450P-215) and drain lines from sustained freezing conditions.

  • Page 9: Flooring

    6. Clean and flush system when reinstalling a boiler. D. Clearances for Service Access NOTE: When installing in a zero clearance location, it may not be possible to read or view some product labeling. It is recommended to make note of the boiler model and serial number.

  • Page 10: Exhaust Vent And Intake Pipe

    burner and ignition devices are well off the floor. 2. Power Venting, Indoor Combustion Air in Confined or • When raising the boiler ensure the entire bottom and Unconfined Space This boiler requires fresh, uncontaminated air for safe fully filled weight of the boiler are fully supported. operation and must be installed in a mechanical room where •...

  • Page 11: Removing A Boiler From A Common Vent System

    Garages and workshops detergents, and cleaning solvents equipment. Westinghouse recommends having water quality professionally analyzed to determine whether it is necessary Adhesives used to fasten building to install a water softener. It is important that the water...
  • Page 12 • Chlorine concentration less than 100 ppm *NOTE: It is recommended to clean the heat exchanger at • Using chlorinated fresh water should be acceptable as least once a year to prevent lime scale buildup. To clean the levels are typically less than 5 ppm. heat exchanger, follow the maintenance procedure in this manual.
  • Page 13 Figure 5 - Boiler Dimensions - NOTE: All Dimensions Are Approximate WHL-052 Rev. 4.28.16...

  • Page 14: 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 a wide range of gallon sizes in either stainless steel or RESULTING IN POSSIBILITY OF SUBSTANTIAL PROPERTY glass-lined construction.

  • Page 15: Expansion Tank

    Westinghouse (Part # 7450P-904). Check with of the expansion tank. local codes for additional requirements. If the boiler supplies hot...
  • Page 16 Heat Exchanger Pressure Drop Flow Rate in GPM and Corresponding Pressure Drop in Feet (Δ P’) Model 10’ 14’ 17’ 21’ 26’ 15’ 17’ 22’ 25’ 33’ 12’ 15’ 17’ 19’ 22’ 27’ 8’ 10’ 11.5’ 13’ 15’ 16.5’ 17’ 19’...

  • Page 17: 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) 220 Model boilers with a design of 20°Δt degree temperature rise with each boiler having an individual flow rate of 22 GPM.

  • Page 18: Plumbing

    pressure gauge when operating. It should read a minimum Test/replace freeze protection fluid pressure of 12 psi. 1. For systems using freeze protection fluids, follow fluid 6. Install a circulator as shown in Applications (this manual). manufacturer’s instructions to verify inhibitor level and that Make sure the circulator is properly sized for the system and other fluid characteristics are satisfactory.

  • Page 19: Zoning With Zone Valves

    • 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.

  • Page 20: Applications

    O. Applications* *NOTE: Systems shown are primary/secondary piping systems. These recommended systems have a primary (boiler) loop, and secondary circuits for heating. The primary loop and secondary circuits have separate circulators. The use of other near boiler piping configurations could result in improper flow rates, leading to inadvertent boiler high limit shutdowns and poor system performance.
  • Page 21 Secondary Circuit Primary Loop Primary Loop Cascade with Indirect Priority on One Boiler Figure 8 - Cascaded Boilers with Indirect Priority on a Single Boiler NOTES: 1. This drawing is meant to show system piping concept only. 2. A mixing valve is recommended if the DHW temperature is set above 119 3.
  • Page 22 Secondary Circuit Primary Loop Single Boiler Space Heating Figure 9 - Space Heating NOTES: 1. This drawing is meant to show system piping concept only. 2. Install a minimum of 12 diameters of straight pipe upstream of all circulators. 3. Piping shown is Primary/Secondary. 4.
  • Page 23 Secondary Circuit Primary Loop Primary Loop Cascaded Boilers Space Heating Only Figure 10 - Cascaded Space Heating NOTES: 1. This drawing is meant to show system piping concept only. 2. Install a minimum of 12 diameters of straight pipe upstream of all circulators. 3.

  • Page 24: 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 25: 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 26: Exhaust Vent And Intake Pipe Location

    D. Exhaust Vent and Intake Pipe Location Area Where Terminal Is Not Permitted Exhaust Vent Terminal Intake Pipe Terminal Figure 11 - Exit Terminals for Direct Vent Systems - ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION –...

  • Page 27: Exhaust Vent And Intake Pipe Sizing

    E. Exhaust Vent and Intake Pipe Sizing 1. The exhaust vent and intake pipe size is 3” for 80 - 220 mod- els and 4” for 299 - 399 models. 2. The maximum total equivalent length of exhaust vent and intake pipe should not exceed 200 feet.

  • Page 28: Applications

    16. Ensure the outdoor intake pipe termination is screened to prevent blockage caused by debris or birds. The following table lists optional exhaust/intake terminations 6/23/15 available from Westinghouse: TWO PIPE SIDEWALL VENTING WITH TEE (INTAKE) AND COUPLING (EXHAUST) Description Stock Code 3”...

  • Page 29: Sidewall Venting

    Sidewall Venting with Kit Sidewall Venting with Concentric Vent SIDE VIEW FRONT VIEW Roof Venting with Concentric Vent FRONT VIEW Figure 14 - Venting with Optional Kits (NOT INCLUDED WITH THE BOILER) NOTE: These drawings are meant to demonstrate system LP-325-PP 03/03/11 venting only.

  • Page 30: Venting Through An Existing System

    NOTE: The following instructions refer only to venting through an existing vent system, and not to venting with Westinghouse’s optional concentric vent kits. Refer to Concentric Vent Kit installation manual (LP-166) for further information on venting with the optional concentric vent kits.

  • Page 31: Power Venting, Indoor Combustion Air In Confined Or Unconfined Space

    Concentric Venting Through an Existing System Concentric Venting Through an Existing System Chase Venting Through an Existing System INTAKE EXISTING VENT AIR INTAKE W/ SCREEN AIR INTAKE W/ SCREEN Figure 17 - 1, 2 - Concentric Venting Through an Existing System, 3, Chase Venting Through an Existing System NOTE: These drawings are meant to demonstrate system venting only.

  • Page 32: Condensate Removal System

    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 a Condensate Neutralizer Kit (Part # 7450P-212 for 80/110/150/220/299/301 Models, Part # 7350P- 611 for 399 Models).

  • Page 33: Part 6 - Wiring

    3. A frozen condensate line could result in a blocked vent condition. It is very important to protect the condensate It is of extreme importance that this unit be properly grounded. It line from freezing temperatures or any type of blockage. is very important that the building system ground is inspected by In installations that may encounter sustained freezing a qualified electrician prior to making this connection.

  • Page 34: Alarm Connections

    Westinghouse 7250P-325 tank sensor. When a tank sensor system if the boiler goes into a lockout condition. The circuit...

  • Page 35: Optional 0-10 Volt Building Control Signal

    1. A signal from a building parallel and close to or against high voltage (120 volt or greater) management system wiring. Westinghouse recommends that the maximum length of may be connected to communication bus cables not exceed 200 feet. the boiler to enable 4.
  • Page 36 used to turn a device off if the boiler goes into lockout mode. boiler lockout condition, follow the same instructions as above The alarm contacts are rated 5 amps at 120 VAC. except use the ALARM NC terminal rather than the ALARM NC To connect an alarm device, connect the power for the device terminal.
  • Page 37 Figure 25 - Internal Connection Diagram WHL-052 Rev. 4.28.16...

  • Page 38: Part 7 - Gas Connections

    operation of the unit. 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 Failure to follow all precautions could result in fire, explosion, support the weight of the piping.

  • Page 39: Check Inlet Gas Pressure

    Never use an open flame (match or lighter) to check for gas Ensure the pressure tap screw is properly tightened to prevent leaks. Use a soapy solution to test connection. Failure to use gas leaks. Failure to do so could cause substantial property a soapy solution test or check gas connection for leaks can damage, severe personal injury, or death.

  • Page 40: Boiler Gas Valve

    Westinghouse. Failure to use a conversion kit when converting fire, explosion, property damage, severe personal injury, or the boiler to fire on Natural or Propane gas will result in extremely death.

  • Page 41: Part 8 - Start-Up Preparation

    2. For zoned systems, flush each zone separately through a Part 8 - Start-Up Preparation purge valve. (If purge valves and isolation valves are not already installed, install them to properly clean the system.) 3. Flush system until water runs clean and you are sure piping is Thoroughly clean and flush any system that has used glycol free of sediment.

  • Page 42: Fill And Test Water System

    D. Fill and Test Water System The central heating pump will come on. If you then press the Ensure the boiler is full of water before firing the burner. Failure ^ key, the central heating pump will shut off. The display will to do so will damage the boiler.

  • Page 43: Final Checks Before Starting Boiler

    LED fault indicator, and close the alarm relay contacts to aid a condensate removal pump, available from Westinghouse in recognition of the condition, diagnosis, and repair. (554200). This pump is equipped with two leads that can be J.

  • Page 44: Cascade System Programming

    lockout condition and skip over the boiler in the firing sequence. Part 9 - Start-Up Procedure Each boiler in the cascade system is responsible for its own safety functions. So, if any individual boiler control senses an unsafe condition, it will extinguish the burner and, if necessary, FOR YOUR OWN SAFETY READ BEFORE OPERATING go to a lockout condition.

  • Page 45: Operating Instructions

    ENTER – The ENTER key is used to access parameter D. Programming Boiler Settings programming mode. To access this mode, hold down the Boiler Setting Program Access ENTER key for more than 4 seconds. The readout will change Note: Programming the boiler control is not possible when the boiler is firing.

  • Page 46: Programming The System Setting

    CLOCK HOUR Allows the user to adjust the hour Screen Description 08/28/2009 Fr 10:01A setting. Function 6 DHW Post Pump Time CLOCK MINUTE The indirect pump has the ability to Adjusts the minute setting. 08/28/2009 Fr 10:01A post purge energy from the boiler to run CLOCK DAY OF WEEK the pump after the set point has been Adjusts the day of the week.
  • Page 47 ERROR OUTD SENSOR sensor is open or shorted. NOTE: This Allows for a non Westinghouse boiler error does not stop the boiler from to be controlled when the cascade running. Factory Default: OFF (Range:...
  • Page 48 for Maximum Outdoor Temperature Setting. 10V = CH (or Function 37 Modbus Mode cascade) temperature setting. This number will vary with the Enables Modbus Mode outdoor temperature so that the user can know what setpoint appliance. Factory Default: temperature the boiler is trying to achieve. (Range: OFF, ON, AUTO).

  • Page 49: Resetting The Maintenance Schedule

    Function 34 Month Part 10 - Start-Up Procedures for the Installer If the date function was selected, this function programs the month. If SERVICE SCHEDULE you selected the run hour function, MONTH 00/00/2000 you will need to program 10,000 hours, if required. Hours Allows the user to set the middle SERVICE SCHEDULE...
  • Page 50 Screen Description The top line displays the voltage on the optional input. This voltage is This is the first screen that appears 0-10 V 0.0V only relevant if an external 0-10 volt after pressing >, and shows the BOILER signal is being used to control the actual temperatures measured...
  • Page 51 Press v once. Press v once. This screen displays the third oldest This screen displays the tenth oldest boiler control lockout fault. The top boiler control lockout fault. The top line will alternate between the words line will alternate between the words FAULT HISTORY FAULT HISTORY ‘FAULT HISTORY’...

  • Page 52: Cascade Menu

    This screen displays the eighth This screen displays information about oldest boiler control blocking error. cascade status. The TT in the center BLOCKING HISTORY The top line will alternate between of the top line shows that cascade 08/28/2009 Fr 5:19A the words ‘BLOCKING HISTORY’...

  • Page 53: Boiler Test Mode

    Press v once. Part 11 - Troubleshooting BOILER A10 This screen is not applicable. A. Boiler Error and Fault Codes BOILER B11 If any of the sensors detect an abnormal condition, or an Press v once. internal component fails during the operation of the boiler, BOILER C12 the display may show an error message and error code.

  • Page 54: User Interface Display

    Label all wires prior to disconnecting them when servicing DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN the boiler. Wiring errors can cause improper and dangerous SUBMERGED IN WATER. Immediately call a qualified service operation. Failure to follow these instructions may result in technician.
  • Page 55 The dual flue sensor contains two sensing elements within single body. 1. Inspect the dual flue sensor for physical damage, indicates that one or both halves of the blockage, or corrosion and replace it if necessary. flue temperature sensor has failed OR the 2.
  • Page 56 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 57 1. Check boiler feed water system to be sure it is supplying make-up water to the boiler system. 2. Ensure all air is bled from the system. 3. Check for leaks in the boiler and system piping and LOW WATER BOILER Water level in the boiler is low.
  • Page 58 The control has been programmed by a CONTROL PROGRAMED PP technician or the factory. After programming, Press RESET for at least 1 second to use the control. the control is left in a locked out mode. 1. Check outdoor sensor connections and wiring. Ensure the sensor and wiring are intact and that the sensor is There is an issue with the outdoor sensor.
  • Page 59 1. Check the flue for obstructions and any sign of damage, especially signs of excessive heat. Repair as necessary. E07 indicates the flue sensor temperature 2. Run the boiler and check the flue temperature with is excessive and above 205 F.

  • Page 60: Part 12 - Maintenance

    motor. Part 12 - Maintenance f. Remove the six (6) 10MM nuts from the burner plate assembly. A. Procedures g. Pull the entire burner plate assembly with blower still Periodic maintenance should be performed once a year by a attached towards you, while removing or pushing aside any qualified service technician to assure that all the equipment wiring to allow removal of the assembly.

  • Page 61: Maintaining The Condensate System

    must be approved for use with stainless steel and FDA approved for use in a potable water system. 3. Thoroughly flush the heat exchanger before commissioning the unit back in service. D. Maintaining the Condensate System 1. Ensure the boiler is powered off and has had time to cool.
  • Page 62 Figure 30 - Combustion System Replacement Parts - 80 - 220kBTU Models WHL-052 Rev. 4.28.16...
  • Page 63 Figure 31 - Combustion System Replacement Parts - 299 - 399kBTU Models WHL-052 Rev. 4.28.16...
  • Page 64 Figure 32 - Cabinet Replacement Parts - All Models WHL-052 Rev. 4.28.16...
  • Page 65 Figure 33 - Cabinet Replacement Parts - All Models WHL-052 Rev. 4.28.16...

  • Page 66: Part 13 - Installation Checklist

    Part 13 - Installation Checklist Light Off Activities Date Completed: Check all piping and gas connections. Verify all are tight. Pressurize system. 1. Fill the Heating System Add water to prime condensate cup. Verify near boiler piping is properly supported. Leak test using locally approved methods (consult jurisdictional code book).
  • Page 67 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 68: Rev

    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 69 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 70 B. During the first through seventh year after the date of installation, 4. Use the boiler in a closed system with a properly sized and Westinghouse warrants that it will repair or replace, at its option, any installed thermal expansion tank.
  • Page 71 Westinghouse via the local distribution channels where original purchase was made. NOTE: Any parts or boilers returned to Westinghouse for warranty analysis will become the property of Westinghouse and will not be returned, even if credit is denied.
  • Page 72 Maintenance Notes WHL-052 Rev. 4.28.16...
  • Page 73 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...

This manual is also suitable for:

Wbre220Wbre110Wbre301Wbre399Wbre150Wbre299

Table of Contents