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Installation
Start-Up
Maintenance
Parts
Warranty
WBMC**500 / WBMC**850 Models*
*"NG" Denotes Natural Gas Operation
"LP" Denotes Propane Gas Operation
"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.
Gas-Fired Boilers
This Manual For Use With Boilers Manufactured After
August 13, 2013
Heat Exchanger Bears the ASME "H" Stamp
Commercial
WHL-033 Rev. 1.29.16
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Table of Contents
Related Manuals for Westinghouse WBMC**500
Summary of Contents for Westinghouse WBMC**500
- 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...
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Page 4: Table Of Contents
Part 2 - Before You Start In accordance with Section 325 (f) (3) of the Energy Policy A. What’s in the Box and Conservation Act, Westinghouse has provided this boiler B. How the Boiler Operates with multiple features designed to save energy by reducing C. -
Page 5: Part 1 - General Safety Information
Act of God, and IS NOT covered under product warranty. Part 10 - Start-Up Procedures for the Installer Altering any Westinghouse boiler with parts not manufactured A. Boiler Control Status Menu by Westinghouse WILL INSTANTLY VOID the boiler warranty B. -
Page 6: Improper Combustion
E. Freeze Protection in excessive boiler cycling and accelerated component NOTE: Consider piping and installation when determining failure. Westinghouse DOES NOT warrant failures caused by boiler location. improperly sized boiler applications. DO NOT oversize the boiler to the system. Modular boiler installations greatly reduce the likelihood of boiler oversizing. -
Page 7: Optional Equipment
C. Optional Equipment Text Display and Operational LED Light Indicators Optional equipment available from Westinghouse (and Part #): The display allows the user to change system parameters and • System Sensor (7250P-324) monitor system outputs. -
Page 8: Locating The Boiler
is rough, take care when moving the boiler into position, as catching the leveling feet could damage the boiler. This boiler has a condensate disposal system that may freeze if exposed to sustained temperatures below 32 COLD WEATHER HANDLING - If the boiler has been stored in a Precautions should be taken to protect the condensate trap very cold location (BELOW 0 F) before installation, handle with... -
Page 9: Flooring
High heat sources (generating heat 100 F / 37 C or greater, such as boiler flue pipes, space heaters, etc.) may damage plastic components of the boiler as well as plastic vent pipe materials. Such damages ARE NOT covered by warranty. It is recommended to keep a minimum clearance of 8”... -
Page 10: Residential Garage Installation
Vents must be properly supported. Boiler exhaust and intake connections are not designed to carry heavy weight. Vent support brackets must be within 1’ of the boiler and the balance at 4’ intervals. Boiler must be readily accessible for visual inspection for first 3’ from the boiler. Failure to properly support vents could result in property damage, severe personal injury, or death. -
Page 11: Prevent Combustion Air Contamination
cubic feet per 1,000 BTU/hr (4.8 cubic meters per kW) of the Areas Likely Have Products to Avoid total input rating of all fuel-burning appliances installed in Contaminants that space. Rooms connected directly to this space through Spray cans containing Dry cleaning / laundry areas and openings not furnished with doors are considered part of the fluorocarbons... -
Page 12: 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 chemistry... - Page 13 Figure 5 - Boiler Dimensions - NOTE: All Dimensions Are Approximate - VWH in Model Number Denotes Volume Water Heater Model WHL-033 Rev. 1.29.16...
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Page 14: Part 4 - Piping
DAMAGE, SEVERE PERSONAL INJURY, OR DEATH. The boiler may be connected to an indirect water heater to supply domestic hot water. Westinghouse offers indirect water heaters in either stainless steel or glass-lined construction. Do not thread a cap or plug into the relief valve or relief valve line under any circumstances! Explosion and property A. -
Page 15: Circulators
when sizing the circulators. Each boiler installation must have an air elimination device that will remove air from the system. Expansion tanks must be sized according to total system Install the boiler so the gas ignition system components volume. This includes all length of pipe, all fixtures, boilers, are protected from water (dripping, spraying, etc.). -
Page 16: 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) Table 3 - Minimum Flow Rates The boiler heat exchanger does have a pressure drop which must be considered in system design. -
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) 500 boilers with a design of 30 F temperature rise with each boiler having an individual flow rate of 33 GPM. -
Page 18: Plumbing
Piping Components Minimum Pipe Size Heating System Piping All Models 2” NPT System piping MUST be sized per technical pipe requirements Table 7 - Minimum Pipe Size listed in Tables 6 and 7. Reducing pipe size can restrict flow rate through the boiler, causing inadvertent short cycling and poor J. -
Page 19: Zoning With Zone Valves
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.). Carefully figure the additional friction loss in the system as well as the reduction in heat transfer coefficients. L. -
Page 20: Applications
5. Piping shown is Primary/Secondary. 6. The minimum pipe size for connecting an Westinghouse indirect fired water heater is 1”. 7. The minimum pipe size for connecting a boiler is 2”. - Page 21 *NOTE: Systems shown 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.
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Page 22: 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 23: 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 24: 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 10 - Exit Terminals for Direct Vent Systems - ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada zero clearance to combustible construction. -
Page 25: Exhaust Vent And Intake Pipe Sizing
Standard E. Exhaust Vent and Intake Pipe Sizing Increased Vent Size Vent Connection and Reducing 1. The exhaust vent and intake pipe size is 4” for the 500 and and Maximum Total Maximum Total Coupling 6” for the 850. Equivalent Length Equivalent Length 2. -
Page 26: Applications
over existing chimney openings. Two Pipe Roof Venting with 13. All piping must be fully supported. Use pipe hangers at a Intake (Elbow) and minimum of 4 foot intervals to prevent sagging of the pipe Exhaust (Coupling) where condensate may form. 14. -
Page 27: Sidewall Venting
Sidewall Venting with Kit Figure 13 - Venting with Optional Kits (NOT INCLUDED WITH THE BOILER) NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. SIDE VIEW FRONT VIEW All vent pipes must be glued, properly supported, and the exhaust pitched a minimum of 1/4”... - Page 28 Figure 15 - Unbalanced Venting - Roof Exhaust and Sidewall Intake NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. Ensure the terminations are screened to prevent blockage caused by debris or birds.
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Page 29: Room And Indoor Combustion Ventilation Requirements
2. Room and Indoor Combustion Ventilation Requirements 12” of the ceiling. The minimum dimension of air openings When using an indoor combustion air installation, the should not be less than 3”. mechanical room MUST be provided with properly sized openings, and/or be of sufficient volume to assure adequate combustion air and proper ventilation for all gas fired appliances in the mechanical room to assure adequate combustion air and proper ventilation. -
Page 30: Condensate Removal System
The result is improper - 4.5. To avoid long term damage to the drainage system and combustion and premature boiler failure. Such failure IS NOT to meet local code requirements, Westinghouse recommends covered under warranty. neutralizing condensate with a Condensate Neutralizer Kit EXHAUST FANS: Any fan or appliance which exhausts air from (Part # 7350P-611). -
Page 31: Part 6 - Wiring
2. PVC or CPVC pipe should be the only material used for condensate line. Steel, brass, copper, and other metals will be It is of extreme importance that this unit be properly grounded. It subject to corrosion or deterioration. is very important that the building system ground is inspected by 3. -
Page 32: Line Voltage Wiring For Standard Boiler
1. The boiler will operate an indirect fired water heater with the device it is connected to. See the instruction manual of the either a thermostat type aquastat installed in the indirect connected devices for further information. tank, or an Westinghouse 7250P-325 tank sensor. When a WHL-033 Rev. 1.29.16... -
Page 33: Optional 0-10 Volt Building Control Signal
If a flow switch and a low water cutoff are control the set point necessary for the installation, purchase and install the optional temperature UL353 LWCO (available from Westinghouse, Part # 7350P-601). boiler. control In this installation, it is recommended to install the flow switch interprets the 0-10 volt kit first. -
Page 34: Wiring Of Cascade System Communication Bus
(120 volt 7. If the pigtail located in step 5 is connected to a gas pressure or greater) wiring. Westinghouse recommends that the switch, disconnect it from the gas pressure switch and connect... -
Page 35: Cascade Follower Pump And Sensor Wiring
Q. Cascade Follower Pump and Sensor Wiring to the ALARM COM terminal. Connect the alarm device hot wire 1. If it is desired to have the boiler control the boiler pump, to the ALARM NO terminal. Connect the neutral or return of the connect the boiler pump to the BOILER HOT, BOILER NEUT, alarm device to the neutral or return of the power for the alarm and BOILER GND terminals. - Page 36 Figure 27 - Internal Connection Diagram WHL-033 Rev. 1.29.16...
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Page 37: Part 7 - Gas Connections
5. Purge all gas lines thoroughly to avoid start up issues with air Part 7 - Gas Connections in the lines. 6. Sealing compound must be approved for gas connections. Care must be taken when applying compound to prevent blockage or obstruction of gas flow which may affect the Failure to follow all precautions could result in fire, explosion, operation of the unit. -
Page 38: Gas Table
supplier, qualified installer, or service agency to determine correct action that is needed to provide proper gas pressure Never use an open flame (match or lighter) to check for gas to the unit. If Gas Pressure is within normal range proceed to leaks. -
Page 39: Boiler Gas Valve
D. Boiler Gas Valve Do not do a gas conversion on this boiler without an officially approved conversion kit and instructions supplied by Westinghouse. Failure to use a conversion kit when converting the boiler to fire on Natural or Propane gas will result in extremely dangerous burner operation, leading to fire, explosion, severe personal injury, or death. -
Page 40: Part 8 - Start-Up Preparation
3. Flush system until water runs clean and you are sure piping Part 8 - Start-Up Preparation is free of sediment. *NOTE: It is recommended you clean heat exchanger at least once a year to prevent lime scale buildup. Follow the Thoroughly clean and flush any system that has used glycol maintenance procedure to clean the heat exchanger in the before installing the boiler. -
Page 41: Purge Air From Water System
The central heating pump will come on. If you then press the installer or you may purchase a condensate neutralizer from ^ key, the central heating pump will shut off. The display will Westinghouse (7350P-611). read: 2. The boiler is equipped with a ¾ female socket weld fitting connection that must be piped to a local drain. -
Page 42: Final Checks Before Starting Boiler
Westinghouse repair. (554200). This pump is equipped with two leads that can be J. -
Page 43: Cascade System Programming
every boiler in the system has its individual safety controls vented. If the cascade system IS to be common vented, set intact and operational, even if the firing of the boiler is under Function 23 to “COMMON FLUE”. control of the master boiler. f. -
Page 44: Operating Instructions
RESET – The RESET button has two functions. in the back of this manual. – Resets any lockout error code D. Programming Boiler Settings – Returns the user to the default display screen. Boiler Setting Program Access ENTER – The ENTER key is used to access parameter Note: Programming the boiler control is not possible when programming mode. -
Page 45: Programming The System Setting
CLOCK MINUTE Function 6 DHW Post Pump Time Adjusts the minute setting. 08/28/2009 Fr 10:01A The indirect pump has the ability to CLOCK DAY OF WEEK post purge energy from the boiler Adjusts the day of the week. 08/28/2009 Fr 10:01A to run the pump after the set point has been achieved. - Page 46 Function 16 Optional Inputs Screen Description Allows the user to select optional Function 23 Cascade Mode inputs to control or monitor the Allows the user to select cascade OPTIONAL INPUT system. Default: RETURN (Range: mode. Select VISION 3 if boiler RETURN SEN Off / Booster Board / 0-10 Volt / DHW is operating alone or using an...
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Page 47: Resetting The Maintenance Schedule
10,000 hours, if MOD). required. Function 30 Extra Heater Mode Hours Allows for a non Westinghouse Allows the user to set the middle two boiler to be controlled when the SERVICE SCHEDULE digits of the amount of run hours EXTRA BOILER MODE cascade output has risen above the 10000’s 000000... -
Page 48: Part 10 - Start-Up Procedures For The Installer
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 49: Cascade Menu
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 50: Boiler Test Mode
Screen Description This screen displays overall cascade power output. The range of this This screen displays when the boiler value is the number of boilers is configured as a Cascade Master communicating with the Master x and the system is ready to accept CASCADE PWR 100% 100. -
Page 51: Part 11 - Troubleshooting
Combustion Settings on All Models Natural Gas (NG) Propane (LP) When servicing or replacing components that are in direct Fan Speed Low Ignition High Low Ignition High contact with boiler water, be certain that: • There is no pressure in the boiler. (Pull the release on the Carbon Monoxide 5-50... -
Page 52: 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 53 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 54 F02 indicates the supply temperature sensor 1. Check the electrical connection to the thermistor on of the boiler has failed. The boiler will not the outlet manifold. Verify 5 VDC by checking the Molex restart until a technician replaces the sensor connector.
- Page 55 1. Watch the igniter through the observation window. 2. If there is no spark, check the spark electrode for the proper .196” (5.0 mm ± 1mm) gap. See below. 3. Remove any corrosion from the spark electrode and flame rectifier probe. 4.
- Page 56 1. Check flue system for obstructions. 2. Check proper communication between boilers. FLAP CLOSED Flapper valve physically stuck closed. 3. Check operation of flapper valve. 4. Check wiring between valve and controller. 5. Replace valve-flapper. 1. Check flue system for obstructions. 2.
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Page 57: Part 12 - Maintenance
E19 indicates the line voltage frequency is Inspect power wiring to the boiler and repair as necessary. out of range. This could happen if the boiler If connected to line voltage, notify the power company. LINE VOLTAGE is being powered from a small gasoline If connected to an alternate power source such as PUMP OFF powered generator that is overloaded or not... -
Page 58: Cleaning Water Side Of Heat Exchanger
4. Spray the coils again with clear tap water. Confine the spray 3. Thoroughly flush the heat exchanger before commissioning to the area being cleaned. Flush the combustion chamber with the unit back in service. fresh water until it runs clear from the condensate reservoir. At this point, the boiler should be ready to be reassembled. - Page 59 Model Figure 32 - 500 Combustion System Replacement Parts WHL-033 Rev. 1.29.16...
- Page 60 Model Figure 33 - 850 Combustion System Replacement Parts WHL-033 Rev. 1.29.16...
- Page 61 Figure 34 - Water Side Replacement Parts - All Models WHL-033 Rev. 1.29.16...
- Page 62 Figure 35 - Cabinet Replacement Parts - All Models WHL-033 Rev. 1.29.16...
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Page 63: 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 (12 - 15 psi). 1. Fill the Heating System Add water to prime condensate cup. Verify near boiler piping is properly supported. - Page 64 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.
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Page 65: 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 66 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 67 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 68 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 69 Maintenance Notes WHL-033 Rev. 1.29.16...
- Page 70 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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