Westinghouse WBR 055 Manual
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Westinghouse WBR 055 Manual

Westinghouse WBR 055 Manual

Installation start-up maintenance parts gas fired boiler residential and commercial models
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Installation
Start-Up
Maintenance
Parts
Warranty
WBR Models*
055 / 080 / 110
155 / 199 / 285
WBC Model*
399
* Models with:
"N" Denote Natural Gas Operation
"LP" Denote Propane Gas Operation
"PU" Denote Included Pump
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.
Gas Fired Boiler
Residential and
Commercial Models
Heat Exchanger Bears the ASME "H" Stamp
WHL-016 Rev. 4.14.16

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Summary of Contents for Westinghouse WBR 055

  • 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

    I. Plumbing G. Resetting the Maintenance Schedule J. Fill and Purge Heating System Part 10 - Start-Up Procedures for the Installer K. Glycol Antifreeze Solutions A. Boiler Control Status Menu L. Zoning with Zone Valves B. Cascade Menu M. Zoning with Circulators C.

  • Page 6: Improper Combustion

    Gaskets and seals in an Act of God, and IS NOT covered under product warranty. the system may be damaged, possibly resulting in Altering any Westinghouse boiler with parts not manufactured substantial property damage. by Westinghouse WILL INSTANTLY VOID the boiler warranty •...

  • Page 7: What's In The Box

    C. Optional Equipment point temperature in order to adjust heating input from the Optional equipment available from Westinghouse (and Part #): connected boilers. Each cascaded boiler will have its own • System Sensor (7250P-324) pump to provide maximum flow and control heat exchanger •...

  • Page 8: Part 3 - Prepare The Boiler

    • UL 353 Compliant Low Water Cut-Off Interface Kit with A. Locating the Boiler Manual Reset (055/80/110 - 7600P-104, All other Models - 7600P-990) • Manual Reset High Limit (7450P-217) This boiler is certified for indoor use only. DO NOT INSTALL •...

  • Page 9: Structure

    number. NOTE: A combustible door or removable panel is acceptable High heat sources (generating heat 100 F / 37 C or greater, front clearance. such as boiler flue pipes, space heaters, etc.) may damage B. Structure plastic components of the boiler as well as plastic vent pipe materials.

  • Page 10: Wall Mounting Considerations

    Always take future maintenance into consideration when locating the boiler. If the boiler is located in an installation location with limited clearances, it may be necessary to remove the boiler from the space to perform maintenance. Failure to consider maintenance when determining installation location Figure 4 - Wall Mounting Bracket - NOTE: Drawing for could result in property damage.

  • Page 11: Mounting To A Metal Frame

    Required Amount of Bolts for Wall-Mounting the Boiler Model Amount of Bolts The space must be provided with correctly sized combustion/ ventilation air openings for all other appliances located in the 055 - 110 space with the boiler. For power venting installations using 155 - 285 room air for combustion, refer to the boiler venting section, this manual, for descriptions of confined and unconfined spaces.

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

    Failure to provide an adequate supply of fresh combustion air can cause poisonous flue gases to enter the living space, resulting in severe personal injury or death. To prevent combustion air contamination, see Table 2. I. Prevent Combustion Air Contamination Install intake air piping for the boiler as described in the Venting Section, this manual.

  • Page 13: Water Chemistry Requirements

    Dry cleaning / laundry areas and cause severe damage to the boiler and associated fluorocarbons and establishments equipment. Westinghouse recommends having water quality Permanent wave solutions Swimming pools professionally analyzed to determine whether it is necessary to Chlorinated waxes / cleaners Metal fabrication plants install a water softener.
  • Page 14 Figure 6 - Boiler Dimensions - NOTE: All Dimensions Are Approximate WHL-016 Rev. 4.14.16...

  • Page 15: Part 4 - Piping

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

  • Page 16: Circulators

    Westinghouse (Part # 7600P-104 for of the expansion tank. 55 – 110 models, 7600P-990 for 155 – 399 models). Check with Expansion Tank Sizing local codes for additional requirements.
  • Page 17 Figure 7 - Boiler Pressure Drop The chart below represents various system design temperature rise through the boiler along with respective flows and friction loss. This is provided to aid in circulator selection. System Temperature Rise Chart 20°Δt 25°Δt 30°Δt Model Friction Ft Flow Rate (GPM)

  • Page 18: Check / Control Water Chemistry

    through the boiler, causing inadvertent short cycling and poor H. Check / Control Water Chemistry system performance. NOTE: Boiler failure due to improper water chemistry is not Check Valves covered by warranty. Field supplied. Check valves are recommended for installation Water Chemistry* as shown in Applications.

  • Page 19: Fill And Purge Heating System

    The boiler cannot be drained completely of water without • A 30% mixture of glycol will result in a BTU output loss of purging the unit with an air pressure of 15 PSI. 15% with a 5% increase in head against the system circulator. 10.

  • Page 20: Applications

    O. Applications* CAUTION Mixing valves are required for the protection of low temperature loops. Figure 8 - Near Boiler Piping* - NOTE: This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. *Top / Bottom Supply / Return Connections Available on 155 / 199 / 285 / and 399 Models ONLY. NOTE: In piping applications utilizing a single zone, it is recommended that the installer use flow / check valves with weighted seats at or near the appliance to prevent gravity circulation.
  • Page 21 Figure 9 - Piping Symbol Legend WHL-016 Rev. 4.14.16...
  • Page 22 Figure 10 - Standard Piping with Zone Valves and Indirect Priority NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameters center to center spacing. 3.
  • Page 23 Figure 11 - Standard Piping with Pumps and Indirect Priority NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameters center to center spacing. 3.
  • Page 24 Figure 12 - Primary / Secondary Piping with Zone Valves and Indirect Priority NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameters center to center spacing. 3.
  • Page 25 Figure 13 - Primary / Secondary Piping with Pumps and Indirect Priority NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameters center to center spacing. 3.
  • Page 26 Figure 14 - Multiple Boilers - Primary / Secondary Piping with Pumps and Indirect Priority NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameters center to center spacing. 3.

  • Page 27: 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 28: 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 29: 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 15 - Exit Terminals for Direct Vent Systems - ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada In addition: DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION –...

  • Page 30: Exhaust Vent And Intake Pipe Sizing

    E. Exhaust Vent and Intake Pipe Sizing 1. The exhaust vent and intake pipe size is 3” for 55 - 285 models and 4” for the 399 model. 2. The maximum total equivalent length of exhaust vent and intake pipe should not exceed 200 feet for all models EXCEPT the 285 model.

  • Page 31: 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 available from Westinghouse: Description Stock Code 6/23/15 3” PVC Concentric Termination Kit...

  • Page 32: Sidewall Venting

    Sidewall Venting with Kit Sidewall Venting with Concentric Vent SIDE VIEW FRONT VIEW Roof Venting with Concentric Vent FRONT VIEW Figure 18 - 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 33: Venting Through An Existing System

    Concentric 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 34: 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 21 - 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 35: 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 EL-80/110/150/220/299/301, Part # 7350P-611 for EL-399).
  • Page 36 - 4.5. To avoid long term damage to the drainage system and 3. Slide the condensate trap adapter onto the drain tube until to meet local code requirements, Westinghouse recommends the holes line up with the groove. neutralizing the condensate with a Condensate Neutralizer Kit 4.
  • Page 37 Figure 26 - Condensate Piping Suggestions NOTES: 1. Condensate line must be pitched at least ¼” per foot to properly drain. If this cannot be done, or a very long length Power to the optional condensate pump is continuous. When of condensate hose is used, increase the condensate line the boiler is powered off the condensate pump will remain on.

  • Page 38: Part 6 - Wiring

    Wiring must be NEC Class 1. If original wiring supplied with the boiler must be replaced, use only TEW 105 C wire or equivalent. Boiler must be electrically grounded as required by the National Electrical Code, ANSI/NFPA 70 - Latest Edition.

  • Page 39: Alarm Connections

    Westinghouse 7250P-325 tank sensor. When a tank sensor pump draw of 3 amps at 120 volts. If the pump requires more is used, the boiler control will automatically detect its presence...

  • Page 40: Optional 0-10 Volt Building Control Signal

    (120 volt or greater) interprets the 0-10 volt signal as follows; when wiring. Westinghouse recommends that the maximum length of communication bus cables not exceed 200 feet. the signal is between 0 and 1.5 volts, the boiler...

  • Page 41: Cascade Master Pump And Sensor Wiring

    5. Connect the boilers in a daisy chain configuration as shown (NEUT), and 3 (GND). below. It is best to wire the boilers using the shortest wire 2. An alarm bell or light can be connected to the alarm contacts runs rather than trying to wire them in the order that they of the follower boiler.
  • Page 42 Figure 33 - Internal Connection Diagram WHL-016 Rev. 4.14.16...

  • Page 43: Part 7 - Gas Connections

    6. Sealing compound must be approved for gas connections. Part 7 - Gas Connections Care must be taken when applying compound to prevent blockage or obstruction of gas flow which may affect the operation of the unit. Failure to follow all precautions could result in fire, explosion, severe injury, or death.

  • Page 44: Check Inlet Gas Pressure

    4. Turn on the gas and power up the unit. by Westinghouse. Failure to use a conversion kit when 5. Put the unit into manual test mode (details on test mode are converting the boiler to fire on Natural or Propane gas will in Part 10).

  • Page 45: Boiler Gas Valve

    Sodium less than 20 mGL C. Boiler Gas Valve Water pH between 6.0 and 8.0 1. Maintain boiler water pH between 6.0 and 8.0. Check with litmus paper or have it chemically analyzed by a water treatment company. 2. If the pH differs from above, consult local water treatment company for treatment needed.

  • Page 46: Freeze Protection (When Used)

    acceptable by sample testing. PROPANE BOILERS ONLY – The propane supplier mixes an It is important to purge the system of air to avoid damage to odorant with the propane to make its presence detectable. In the boiler. some instances the odorant can fade, and the gas may no longer have an odor.

  • Page 47: Check Thermostat Circuit(S)

    Westinghouse the LED fault indicator, and close the alarm relay contacts to aid (554200).

  • Page 48: Lockout Condition

    begin a demand sequence as described above. Once the boiler f. Exit the installer menu. ignites, the master boiler control will increase the firing rate NOTE: The temperature set point of the master must match command to that boiler until the system sensor temperature is the follower boiler set point in order for the system to operate at the set point temperature plus the differential, or that boiler is properly.

  • Page 49: Part 9 - Start-Up Procedure

    ENTER – The ENTER key is used to access parameter Part 9 - Start-Up Procedure programming mode. To access this mode, hold down the ENTER key for more than 4 seconds. The readout will change to: ENTER MENU CODE FOR YOUR OWN SAFETY READ BEFORE OPERATING 1.

  • Page 50: Programming Boiler Settings

    D. Programming Boiler Settings CLOCK MINUTE Adjusts the minute setting. Boiler Setting Program Access 08/28/2009 Fr 10:01A Note: Programming the boiler control is not possible when the CLOCK DAY OF WEEK boiler is firing. Make sure any input which can create a demand Adjusts the day of the week.
  • Page 51 Screen Description Function 16 Optional Inputs Function 6 DHW Post Pump Time Allows the user to select optional inputs to control or monitor the The indirect pump has the ability to OPTIONAL INPUT system. Default: RETURN (Range: post purge energy from the boiler RETURN SEN Off / Booster Board / 0-10 Volt / DHW to run the pump after the set point...
  • Page 52 10,000 hours, if required. Function 30 Extra Boiler Mode Hours Allows for a non Westinghouse boiler to be controlled when the Allows the user to set the middle two SERVICE SCHEDULE EXTRA BOILER MODE cascade output has risen above the digits of the amount of run hours 10000’s 000000...
  • Page 53 Displays the current tank temperature set point on the top line. The actual temperature measured by the tank or return sensor (Westinghouse 7250P- 325) is displayed on the bottom line. If a DHW SET mechanical aquastat is used in place of the recommended sensor, the second line will display ‘OFF’...
  • Page 54 The top line displays the voltage on This screen displays the fourth oldest 0-10 V 0.0V the optional input. This voltage is only boiler control lockout fault. The top BOILER relevant if an external 0-10 volt signal is line will alternate between the words FAULT HISTORY being used to control the boiler.
  • Page 55 This screen displays overall cascade B. Cascade Menu power output. The range of this This menu is accessed by pressing < at the default menu or > at value is the number of boilers the status menu. communicating with the Master x CASCADE PWR 100% Screen...
  • Page 56 correct operation and no reoccurrence of fault message. Combustion Settings on All Models Natural Gas (NG) Propane (LP) Fan Speed Low Ignition High Low Ignition High When servicing or replacing components that are in direct Carbon contact with boiler water, be certain that: Monoxide 5-50 60-100...
  • Page 57 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 58 1. Check line voltage. It must be between 100 and 128 volts. 2. If available, connect a PC and use Westinghouse service software to check the 24v supply display in the lower left corner of the screen. The number displayed here must be greater than 128 and should be no greater than 250.
  • Page 59 F03 indicates the return temperature sensor of the boiler has failed. The boiler will not 1. Check circulator pump operation. restart until a technician replaces the sensor 2. Ensure adequate flow through the boiler by accessing RETURN SENSOR F03 and pushes RESET on the display. This is the status menu and determining there is less than a 50 PUMP ON a serious safety issue as indicated by the...
  • Page 60 1. Watch the igniter through the observation window. 2. If there is no spark, check the spark electrode for the proper .156” (3.96 mm) gap. See below. 3. Remove any corrosion from the spark electrode and flame rectifier probe. 4. If there is a spark but no flame, check the gas supply to the boiler.
  • Page 61 The fan is not running at the speed 1. Check the combustion fan wiring. determined by the control. Fan speed has 2. Measure DC voltage from the red fan wire to ground been more than 30% faster or slower than while it is connected to the fan.
  • Page 62 e. Remove the combustion assembly. Part 12 - Maintenance 2. Spray water or solution into the combustion assembly and monitor the flow through the combustion system. Liquid A. Procedures should flow freely through each tube. If there is an obstruction, Periodic maintenance should be performed once a year by a increase the flow on the tube to force blockage out.
  • Page 63 C. Cleaning Water Side of Heat Exchanger 1. Make sure power is turned off to the boiler. Run water through the hot water system ensure below room temperature. 2. Close isolation valves on the return and supply connections to the boilers as shown in the piping diagrams in this manual.
  • Page 64 depressing and holding the RESET button for more than 1 second will remove the lockout state so additional trials for ignition can be performed. The unit will try to re-light once Do not operate the boiler without the clear hose attached every 6 minutes.
  • Page 65 Figure 37 - Combustion System Replacement Parts - 55 - 110kBTU Models WHL-016 Rev. 4.14.16...
  • Page 66 Figure 38 - Replacement Parts - 55 - 110kBTU Models - *#20 - Switch on the Left is the Blocked Flue Pressure Switch on the Right is the Blocked Condensate Pressure Switch - Both share same Part Number WHL-016 Rev. 4.14.16...
  • Page 67 Figure 39 - Combustion System Replacement Parts - 155 - 399kBTU Models WHL-016 Rev. 4.14.16...
  • Page 68 ITEM EFT-155 EFT-199 EFT-285 EFT-399 DESCRIPTION 7600P-007 7600P-007* WATER PRESSURE SWITCH 7450P-030 7600P-150 3"/4" INTAKE ADAPTER 7600P-499 7600P-119 3"/4" EXHAUST ASSEMBLY 7600P-043 PVC PLUG - 1/4" 7600P-045 COMBINATION SUPPLY/HIGH TEMPERATURE SWITCH 7450P-122 926 CONTROL BOARD (w/RIBBON CABLE) 7350P-070 FIELD CONNECTION BOARD 7250P-739 FLUE SWITCH 7500P-087...
  • Page 69 Part 14 - 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. Percentage of glycol in system (0 - 50%) Verify near boiler piping is properly supported.
  • Page 70 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 71 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 72 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 73 Preventive maintenance can help COVERAGE avoid any unnecessary breakdown of the boiler and keep it running A. During the first year after the date of installation, Westinghouse at optimum efficiency. warrants that it will repair or replace, at its option, any defective or 2.
  • Page 74 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 75 Maintenance Notes WHL-016 Rev. 4.14.16...
  • Page 76 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:

Wbr 285Wbr 080Wbc 399Wbr 199Wbr 110Wbr 155

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