Westinghouse WBR080 Series Installation, Start-Up And Maintenance Instructions
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Westinghouse WBR080 Series Installation, Start-Up And Maintenance Instructions

Gas fired boiler
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Gas Fired
Boiler
Residential and Commercial Models
INSTALLATION
START-UP
MAINTENANCE
PARTS
WBR Models*
055 / 080 / 110 / 155 / 199 / 285 / 399
Model Names with "LP" denote propane gas,
"N" denote natural gas, and "PU" denote included pump
Heat Exchanger Bears the ASME "H" Stamp
This manual must only be used by a qualified heating installer/service technician. Read all instructions in this manual before installing.
Perform steps in the order given. Failure to comply could result in substantial property damage, severe personal injury, or death.
NOTICE: 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.
WHL-016 REV. 12.18.14

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  • Page 1 Perform steps in the order given. Failure to comply could result in substantial property damage, severe personal injury, or death. NOTICE: 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 BOILER. WHAT TO DO IF YOU SMELL GAS ...
  • Page 3 In some circumstances, the property owner or his/her agent assumes the role, and at government installations, the commanding officer or departmental official may be the AHJ. NOTE: Westinghouse reserves the right to modify product technical specifications and components without prior notice. FOR THE INSTALLER This manual must only be used by a qualified heating installer/service technician.
  • Page 4 COVERED BY WARRANTY. NOTICE In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, Westinghouse has provided this boiler with multiple features designed to save energy by reducing the boiler water temperature as heating load decreases.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS PART 1 – GENERAL SAFETY INFORMATION .......................... 8 A. PRECAUTIONS ..................................8 B. IMPROPER COMBUSTION ............................... 8 C. GAS ......................................8 D. WHEN SERVICING THE BOILER.............................. 8 E. BOILER SYSTEM ..................................8 F. BOILER WATER CHEMISTRY ..............................9 G.
  • Page 6 L. GLYCOL ANTIFREEZE SOLUTIONS ............................33 M. ZONING WITH ZONE VALVES ............................... 33 N. ZONING WITH CIRCULATORS ............................... 33 O. MULTIPLE BOILERS ................................33 PART 6 – VENTING, COMBUSTION AIR, AND CONDENSATE REMOVAL ................34 A. GENERAL ....................................34 B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE ..................35 C.
  • Page 7 E. PURGE AIR FROM WATER SYSTEM ............................. 63 F. CHECK THERMOSTAT CIRCUIT(S) ............................63 G. CONDENSATE REMOVAL ..............................63 H. FINAL CHECKS BEFORE STARTING BOILER ........................64 I. CASCADE SYSTEM .................................. 64 J. LOCKOUT CONDITION ................................65 PART 10 – START-UP PROCEDURE ............................65 A.

  • Page 8: Part 1 - General Safety Information

    Due to the low water content of the boiler, improper sizing of the boiler with regard to heating system load will result in excessive cycling and accelerated component failure. Westinghouse DOES NOT warrant failures caused by improperly sized boiler applications. DO NOT oversize the boiler to the system.

  • Page 9: Boiler Water Chemistry

    Consider boiler piping and installation when determining boiler location. NOTE: Damages resulting from incorrect installation or from use of products not approved by Westinghouse ARE NOT covered by warranty. PART 2 – BEFORE YOU START A.

  • Page 10: How Boiler Operates

     Exhaust PVC Coupling with Screens  Installation Manual  Warranty  CSD-1 Form  H-2 Data Sheet  NAT to LP Conversion Kit (Included with NAT models) B. HOW BOILER OPERATES Condensing technology intelligently delivers hydronic heating while maximizing efficiency. Outlined below are the features of the system and how they operate: Stainless Steel Heat Exchanger - The highly efficient stainless steel heat exchanger is designed to extract all available heat from the supply line before it is exhausted.

  • Page 11: Optional Equipment

    The Vision II also controls the output temperature of the boiler to assure accurate temperature delivery to all connected zones. C. OPTIONAL EQUIPMENT Below is a list of optional equipment available from Westinghouse. These additional options may be purchased through your Westinghouse distributor: ...

  • Page 12: Leveling

    environments, boilers must not be installed using direct vent systems which draw outdoor air for combustion. Such boilers must be installed using room air for combustion. Indoor air will have a much lower relative humidity and, hence, potential corrosion will be minimized.
  • Page 13 Figure 1 – Required Clearances Space must be provided with combustion/ventilation air openings correctly sized for all other boilers located in the same space as the boiler. The boiler cover must be securely fastened to prevent it from drawing air from the mechanical room. This is particularly important if the boiler is in a room with other boilers.
  • Page 14 SPECIFICATIONS AND DIMENSIONS Figure 2 – Specifications and Dimensions WHL-016 REV. 12.18.14...

  • Page 15: Residential Garage, Closet, And Alcove Installations

    D. RESIDENTIAL GARAGE, CLOSET, AND ALCOVE INSTALLATIONS Check with your local Authority Having Jurisdiction for requirements when installing boiler in a garage, closet, or alcove. Please read the entire manual before attempting installation. Failure to properly take factors such as boiler venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.

  • Page 16: Prevent Combustion Air Contamination

    appliance is installed in areas where indoor air is contaminated (see Table 2) it is imperative that the appliance be installed as direct vent so that all combustion air is taken directly from the outdoors into the appliance intake connection. Unconfined space is space with volume greater than 50 cubic feet per 1,000 Btu/hour (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space.

  • Page 17: Removing An Boiler From A Common Vent System

    NOTE: DAMAGE TO THE BOILER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY. (Refer to the limited warranty for complete terms and conditions). G. REMOVING AN BOILER FROM A COMMON VENT SYSTEM Do not install the boiler into a common vent with any other boiler. This will cause flue gas spillage or boiler malfunction, resulting in possible substantial property damage, severe personal injury, or death.

  • Page 18: Wall Mounting Considerations

    Figure 4 – Pallet with Mounting Bracket Affixed Figure 5 –Boiler Mounted to Bracket B. WALL MOUNTING CONSIDERATIONS These boilers are wall mounted. Use only the wall mounting instructions included in this manual. Ensure the wall that the boiler is intended to be mounted on is comprised of cement, brick, block, or wooden studs spaced 16” apart from center.

  • Page 19: Mounting To A Metal Frame

    b. The provided mounting bracket must be mounted directly to the center of at least 2 studs using standard steel or stainless steel ¼” x 2 ½” lag bolts for all models. Be sure the bracket is level and mark the hole location of the bracket height and horizontal stud location. Ensure the marked holes are located in the center of the building frame (studs).

  • Page 20: General Piping Information

    Plumbing of this product should only be done by a qualified, licensed plumber in accordance with all local plumbing codes. The boiler may be connected to a storage tank to supply domestic hot water. Westinghouse offers 60/80/119/175 gallon size storage tanks in either stainless steel or glass-lined construction.

  • Page 21: Backflow Preventer

    C. BACKFLOW PREVENTER Use a backflow preventer specifically designed for hydronic installations. This valve should be installed on the cold water fill supply line per local codes (see Piping Details, Part 5, Section G). D. SYSTEM WATER PIPING METHODS EXPANSION TANK AND MAKE-UP WATER 1.

  • Page 22: Hydronic Piping With Circulators, Zone Valves, And Multiple Boilers

    On a boiler installed above radiation level, some states and local codes require a low water cut off device, which is an optional part available through Westinghouse (Part # 7600P-104 for 055 – 110 models, 7600P-990 for 155 – 399 models). Check with local codes for additional requirements.
  • Page 23 Figure 7 – 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.
  • Page 24 Figure 8 – Piping Symbol Legend WHL-016 REV. 12.18.14...
  • Page 25 Figure 9 – Standard Piping with Zone Valves and DHW 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 10 - Standard Piping with Pumps and DHW 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 Figure 11 – Primary/Secondary Boiler Piping – Zone Valves and DHW Priority – Outdoor Reset - 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.
  • Page 28 Figure 12 – Primary/Secondary Boiler Piping – Pumps and DHW Priority – Outdoor Reset - 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 29 Figure 13 – Multiple Boilers – Primary/Secondary Piping – Circulators - 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 30: Piping Installation

    H. PIPING INSTALLATION This boiler should not be operated as a potable hot water heater. It should not be used as a direct hot water heating device. Basic steps are listed below that will guide you through the installation of the boiler. 1.

  • Page 31: Check/Control Water Chemistry

    The chart below represents the various system design temperature rise through the boiler along with their respective flows and friction loss, which will aid in circulator selection. Table 5 – Boiler Flow Rates 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.

  • Page 32: Fill And Purge Heating System

    ACIDITY 6 to 8 pH CONDUCTIVITY Less than 400 uS/cm at 25 CHLORIDE Less than 100 ppm IRON Less than 0.5 mg/L COPPER Less than 0.1 mg/L SODIUM Less than 20 mg/L HARDNESS Less than 7 Grains Table 8 – Water Quality Requirements Clean system to remove sediment* 1.

  • Page 33: Glycol Antifreeze Solutions

    For installations that incorporate standing iron radiation and systems with manual vents at the high points, follow the previous section and, starting with the nearest manual air vent, open the vent until water flows out. Then close the vent. Repeat the procedure, working your way toward the furthest air vent.

  • Page 34: Part 6 - Venting, Combustion Air, And Condensate Removal

    PART 6 – VENTING, COMBUSTION AIR, AND CONDENSATE REMOVAL The boiler must be vented as detailed in this Venting 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 with the instructions provided in this manual.

  • Page 35: Approved Materials For Exhaust Vent And Intake Pipe

    B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL Standards for Installation in: Item Material United States Canada PVC schedule 40/80 ANSI/ASTM D1785 PP, CPVC, and PVC venting must be ULC-S636 Certified. IPEX is an PVC-DWV* ANSI/ASTM D2665* approved manufacturer in Canada,...

  • Page 36: Exhaust Vent And Intake Pipe Location

    Cellular foam core piping may be used on air inlet piping only. You must not use “B” vent in an exhaust application. “B” vent is for intake applications ONLY. Using “B” vent in an exhaust application will result in serious injury or death. D.
  • Page 37 NOTE: Due to potential moisture build-up, sidewall venting may not be the preferred venting option. Carefully consider venting installation and location to save time and cost. You must insert the provided exhaust and intake screens at your vent termination to prevent blockage caused by debris or birds. The building owner is responsible for keeping the exhaust and intake terminations free of snow, ice, or other potential blockages, as well as scheduling routine maintenance.
  • Page 38 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 the condensate with a Condensate Neutralizer Kit (Part # 7450P-212). The neutralizer kit connects to the drain system and contains limestone chips that neutralize the pH level of the water vapor.
  • Page 39 Figure 16 - Condensate Piping Suggestions NOTES: 1. Condensate line must be pitched at least 1/4" per foot to properly drain. If this cannot be done, or a very long length of condensate hose is used, you must increase the condensate line to a minimum of 1” ID and place a tee in the line after the condensate neutralizer to properly reduce vacuum lock in the drain line.

  • Page 40: Exhaust Vent And Intake Pipe Sizing

    Figure 17 – Piping Exhaust around Obstructions – Suggested Condensate Removal E. EXHAUST VENT AND INTAKE PIPE SIZING 1. The exhaust vent and intake pipes are 3” for 055/080/110/155/199/285 models, and 4” for the 399. 2. The total equivalent length of exhaust vent and intake pipe should not exceed 200 feet for all models EXCEPT the 285. Total equivalent length for the 285 should not exceed 150 feet.

  • Page 41: Longer Vent Runs

    b. For example: If the 3” exhaust vent has two short 90 elbows and 10 feet of PVC pipe we will calculate: Exhaust Vent Equivalent Length = (2x5) + 10 = 20 feet. Further, if the 3” intake pipe has two short 90 elbows, one 45 elbow, and 10 feet of PVC pipe, the following calculation applies: Intake Pipe...

  • Page 42: Venting Drawings

    14. A screened straight coupling is provided with the boiler for use as an outside exhaust termination. 15. A screened inlet air tee is provided with the boiler to be used as an outside intake termination. The following information on Table 13 lists optional exhaust/intake terminations available from Westinghouse: DESCRIPTION STOCK CODE 3”...
  • Page 43 Figure 19 – Two Pipe Roof and Sidewall Venting with Tee (Intake) and Coupling (Exhaust) NOTE: Drawing is meant to demonstrate system venting ONLY. The installer is responsible for all equipment and detailing required by local codes. All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the boiler to allow drainage of condensate.
  • Page 44 Figure 20 – 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. All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the boiler to allow drainage of condensate.
  • Page 45 Figure 21 – Unbalanced Flue/Vertical Vent - NOTE: Drawing is meant to demonstrate system venting ONLY. All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the heater to allow drainage of condensate.

  • Page 46: Venting Through An Existing System

    Figure 22 – Horizontal Venting - NOTE: Drawing is meant to demonstrate system venting ONLY. NOTES: A. For every 1” of overhang, the exhaust vent must be located 1” vertical below overhang (overhang means top of building structure and not two adjacent walls [corner of building]).
  • Page 47 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 48: Indoor Combustion Air Installation In Confined Or Unconfined Space

    Figures 23 – 1, 23 – 2 Concentric Venting Through an Existing System, 23 – 3 Chase Venting Through an Existing System NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. 3.
  • Page 49 If the confined space is within a building of tight construction, air for combustion must be obtained from the outdoors as outlined in the Venting section of this manual. See Figure 25. Figure 24 – LP-325-X WHL-016 REV. 12.18.14...
  • Page 50 Figure 25 – 1, 25 - 2 NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. WHL-016 REV. 12.18.14...

  • Page 51: Part 7 - Gas Piping

    PART 7 – GAS PIPING FAILURE TO FOLLOW ALL PRECAUTIONS IN THIS SECTION COULD RESULT IN FIRE, EXPLOSION, OR DEATH! A. GAS CONNECTION The gas supply shall have a maximum inlet pressure of less than 14" w.c. (3.5 kPa), and a minimum of 3.5" w.c. (.87 kPa). The entire piping system, gas meter and regulator must be sized properly to prevent pressure drop greater than 0.5"...

  • Page 52: Check Inlet Gas Pressure

    4. It is important to support gas piping as the boiler is not designed to structurally support a large amount of weight. 5. Purge all gas lines thoroughly to avoid start up issues with air in the lines. 6. Sealing compound (pipe dope) must be used and approved for gas connections. Apply sparingly, and only to the male threads. Care must be taken when applying compound to prevent blockage or obstruction of gas flow which may affect the operation of the boiler.

  • Page 53: Boiler Gas Valve

    Figure 27 – Gas Valve Detail 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 LP gas will result in extremely dangerous burner operation, leading to fire, explosion, severe injury or death.

  • Page 54: Part 8 - Field Wiring

    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 CO and CO.

  • Page 55: Line Voltage Wiring For Standard Boiler

    D. LINE VOLTAGE WIRING FOR STANDARD BOILER NOTE: A termination plug is included in the CAT 3 / CAT 5 Bus Connection Point, labeled J3 in Figure 29. DO NOT REMOVE THIS PLUG! Doing so will affect boiler operation and void warranty. 1.

  • Page 56: Outdoor Sensor

    1. The boiler will operate an indirect fired water heater with either a thermostat type aquastat installed in the indirect tank or an Westinghouse 7250P-325 tank sensor. When a tank sensor is used, the boiler control will automatically detect its presence and a demand for heat from the indirect water heater will be generated when the tank temperature falls below the user set point by more than the user selectable offset.

  • Page 57: Optional Ul353 Low Water Cut-Off Interface Kit

    (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 58: Cascade Master Pump And Sensor Wiring

    Figure 31 – Cascade Resistor Plug Installation Detail M. CASCADE MASTER PUMP AND SENSOR WIRING 1. Connect the system pump hot wire to the terminal marked 8. 2. Connect the system pump neutral to the 2 terminal and the pump ground wire to the 3 terminal. 3.
  • Page 59 Figure 32 – Cascade Master and Follower Wiring WHL-016 REV. 12.18.14...
  • Page 60 Figure 33 – Internal Connection Diagram – LP-293-J WHL-016 REV. 12.18.14...

  • Page 61: Part 9 - Start-Up Preparation

    PART 9 – START-UP PREPARATION Thoroughly clean and flush any system that has used glycol before installing the boiler. Provide the customer with a material safety data sheet (MSDS) on the fluid used. A. CHECK / CONTROL WATER CHEMISTRY Chemical imbalance of your water can cause severe damage to your boiler and associated equipment, and may also affect efficiency. You may have to have your water quality professionally analyzed to determine whether you need to install a water softener.

  • Page 62: Check For Gas Leaks

    2. Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time. Follow all fluid manufacturer instructions. NOTE: BOILER FAILURE DUE TO IMPROPER WATER CHEMISTRY IS NOT COVERED BY WARRANTY. B. CHECK FOR GAS LEAKS Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove boiler front door and smell interior of boiler enclosure.

  • Page 63: Purge Air From Water System

    E. PURGE AIR FROM WATER SYSTEM IMPORTANT! While commissioning the system, the air vent on top of the boiler must remain fully open to allow the boiler to properly fill. Failure to keep the air vent open could lead to improper boiler and system operation. To purge air from the system: a.

  • Page 64: Final Checks Before Starting Boiler

    If the condensate outlet on the boiler is lower than the drain, you must use a condensate removal pump, available from Westinghouse (554200). This pump is equipped with two leads that can be connected to an alarm or another type of warning device to alert the user of a condensate overflow, which, if not corrected, could cause property damage.

  • Page 65: Lockout Condition

    J. LOCKOUT CONDITION If any boilers, including the master boiler in the cascade system, are in a lockout condition, the master control will recognize the lockout condition and skip over the boiler in the firing sequence. 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, go to a lockout condition.

  • Page 66: Operating Instructions

    ENTER key to accept the code entered. If the code is correct, the readout will change to the appropriate screen. If the programming code is not accepted, the readout will continue to display as shown above. The ENTER key is also used to enable a function for editing. After the user navigates to the desired function, the user would hold down the ENTER key for one second.

  • Page 67: Programming The System Setting

    Function: Adjusts the indirect tank set point. Default: 119 F (Range: 70 F to 185 DHW SET POINT Function: Adjusts the indirect tank differential set point. Default: 7 F (Range: 1 F to 30 DHW DIFF SET POINT Function: Adjusts the temperature measurement in F = Fahrenheit to C = Celsius (Default is Fahrenheit). TEMP DISPLAY C OR F Table 18 –...
  • Page 68 SCREEN DESCRIPTION Function 1 Factory Program Mode This screen indicates that the control is configured correctly. Do not change this setting. MODE INDIRECT Function 3 DHW Tank Max Temp This is the maximum temperature that can be selected for the DHW indirect tank set point in the boiler menu. Default: DHW TANK MAX TEMP F (Range: 95 F to 180...

  • Page 69: Resetting The Maintenance Schedule

    Function 30 Extra Boiler Mode EXTRA BOILER MODE Westinghouse Allows for a non boiler to be controlled when the cascade output has risen above the percent of the cascade firing rate set in this parameter. Factory Default: Off (Range: 50% - 100%).

  • Page 70: Part 11 - Start-Up Procedures For Installer

    Press ENTER on the display for 3 seconds. The Menu code will appear as 000. This does not change. Press ENTER again. SERVICE SCHEDULE RESET will be displayed. Using the right arrow key  scroll to the selection of year or hours. Select enter to reset the mode you are in.
  • Page 71 This screen displays the domestic hot water temperature set point on the top line. The actual temperature Westinghouse measured by the tank or return line sensor ( 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’ in place of the temperature if the aquastat measures close to its set temperature, or ‘ON’...

  • Page 72: Cascade Menu

    Press the ▼ key once. This screen displays the ninth oldest lockout fault that occurred in the boiler controller. The top line will alternate FAULT HISTORY between the words ‘FAULT HISTORY’ and the fault encountered. The bottom line displays the date and time the 08/28/2009 Fr 5:19A fault occurred.

  • Page 73: Part 12 - Shutdown

    SERVICE 3400 RPM PUMP ON 4:49P NOTE: The boiler will automatically exit test mode after 20 minutes of operation. COMBUSTION SETTINGS ON ALL MODELS Natural Gas Propane LP Fan Speed Ignition High Ignition High 5 – 50 5 – 50 Carbon Monoxide PPM 60 - 100 <...

  • Page 74: Part 13 - Troubleshooting

    PART 13 – TROUBLESHOOTING A. BOILER ERROR CODE If any of the sensors detect an abnormal condition, or an internal component fails during the operation of the boiler, the display 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 is corrected, or it may be a condition that the controller has evaluated as not safe to restart the boiler.

  • Page 75: User Interface Display

    WARNING: Do not use jumper to remedy an FLU error. Faulty switch MUST be replaced. Failure to do so could result in serious injury or death. Fault Code LOU 1. Check line voltage. It must be between 100 and 128 volts. Westinghouse 2. If available, connect PC, and using service software check the 24v This display indicates that supply display in the lower left corner of the screen.
  • Page 76 SCREEN DESCRIPTION POSSIBLE REMEDY Fault Code F01 1. If the boiler has a UL353 LWCO, check if the red LED on the This display indicates that the flue temperature LWCO control box is illuminated. If so, correct the low water con- limit switch of the boiler has tripped or that the dition and press the reset button on the LWCO control box to reset water level in the boiler is low (this will only occur...
  • Page 77 Fault Code F09 1. Watch the igniter through the observation window provided. 2. If there is no spark, check the spark electrode for the proper .156” (3.96 mm) gap (See Figure 34). 3. Remove any corrosion from the spark electrode and flame rectifier probe. 4.
  • Page 78 SCREEN DESCRIPTION POSSIBLE REMEDY Fault Code F20 The condensate trap is full. The red light will 1. Check condensate lines for obstructions. display and the word LOCKOUT will flash. This 2. Check wiring from condensate reservoir to 926 control. Verify the code indicates a serious safety issue.

  • Page 79: Part 14 - Maintenance

    Table 30 PART 14 – MAINTENANCE A. MAINTENANCE 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 80: Combustion Chamber Coil Cleaning Instructions For Boiler

    The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).”...

  • Page 81: Maintaining The Condensate System

    2. Close isolation valves on the return and supply connections to the boilers as shown in the piping diagrams within this manual. Slowly open the ball valves and release pressure into a bucket. Once pressure is released, connect a hose to the water line to flush the boiler. Scale removing solution may be used, but must be approved for use with stainless steel and FDA approved for use in a potable water system.
  • Page 82 Do not install the condensate assembly if a component is lost or missing. Replace the entire assembly. Failure to follow this warning could result in property damage, serious personal injury, or death. 6. Fill the condensate trap with fresh water prior to reassembly on the boiler. 7.
  • Page 83 055 / 080 / 110 PARTS BREAKDOWN Figure 36 - Replacement Parts - LP-387-J WHL-016 REV. 12.18.14...
  • Page 84 055 / 80 / 110 PARTS BREAKDOWN Figure 37 – Replacement Parts - *#20 – Switch on the Left is the Blocked Flue Pressure Switch, Switch on the Right is the Blocked Condensate Pressure Switch – Both share same Part Number WHL-016 REV.
  • Page 85 155 / 199 / 285 / 399 PARTS BREAKDOWN WHL-016 REV. 12.18.14...
  • Page 86 Figure 38 - Replacement Parts - LP-387-KK WHL-016 REV. 12.18.14...
  • Page 87 155 / 199 / 285 / 399 MODEL PARTS BREAKDOWN WHL-016 REV. 12.18.14...
  • Page 88 Figure 39 - Replacement Parts - LP-387-JJ – 155 - 399 Models - *#15 – Switch on the Left is the Blocked Flue Pressure Switch, Switch on the Right is the Blocked Condensate Pressure Switch – Both share same Part Number WHL-016 REV.

  • Page 89: Boiler Start-Up Report

    BOILER START-UP REPORT LIGHT OFF ACTIVITIES DATE COMPLETED ________________ 1) Fill the Check all piping and gas connections, verify all heating are tight system Pressurize system (12 – 15 psi) ____ PSI Add water to prime condensate cup Percentage of glycol in system (0 – 50%) ____ % Verify near boiler piping is properly supported 2) Check gas...
  • Page 90 INSPECTION ACTIVITIES DATE LAST COMPLETED PIPING YEAR YEAR YEAR YEAR* Near boiler piping Check boiler and system piping for any sign of leakage. Continual fresh make-up water will reduce boiler life. Leaking pipes could cause property damage. Make sure all piping is properly supported.
  • Page 91 WHL-016 REV. 12.18.14...
  • Page 92 WHL-016 REV. 12.18.14...

  • Page 93: Maintenance Notes

    MAINTENANCE NOTES WHL-016 REV. 12.18.14...

  • Page 94: Customer Installation Record Form

    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: Installation Address: Date of Installation:...

This manual is also suitable for:

Wbr055 seriesWbr110 seriesWbr155 seriesWbr199 seriesWbr285 seriesWbr399 series ... Show all

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