Westinghouse WBMC**500 Manual Download Page 1 | Manualshive

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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.

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-033 Rev. 1.29.16

Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause
property damage, severe personal injury, or death.

This Manual For Use With Boilers Manufactured After

August 13, 2013

Heat Exchanger Bears the ASME “H” Stamp

Commercial

Gas-Fired Boilers

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Summary of Contents for WBMC**500

Page 1: ...lt in substantial 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 NOTETO CONSUMER PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE WHL 033 Rev 1 29 16 Improper installation adjustment alteration service or maintenance could void product warranty and ...

Page 2: ...VICINITY OFTHIS OR ANY OTHER APPLIANCE WHATTO DO IFYOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be provided by a qualified installer ...

Page 3: ...idual such as a fire chief fire marshal chief of a fire prevention bureau labor department or health department building official or electrical inspector or others For the Installer This boiler must be installed by qualified and licensed personnel The installer should be guided by the instructions furnished with the boiler and by local codes and utility company requirements In the absence of local...

Page 4: ...has expired In addition if the control senses that the outlet water temperature has reached 210 F the boiler is put into a hard lockout and requires manual reset to restart The hydronic supply and return connections of these products are for installation in closed loop systems ONLY Use of this product in any manner other than described in this manual may result in premature product failure substan...

Page 5: ... Instructions 57 C CleaningWater Side of Heat Exchanger 58 Part 13 Installation Checklist 63 Part 14 Maintenance Report 63 LimitedWarranty 67 Maintenance Notes 69 Customer Installation Record Form 70 Part 1 General Safety Information This boiler is approved for indoor installations only and is not intended for use as a pool heater Clearance to combustible materials 0 top bottom sides and back Left...

Page 6: ...he system Modular boiler installations greatly reduce the likelihood of boiler oversizing D Boiler Water If you have an old system with cast iron radiators thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by build up or corrosion due to sediment Westinghouse recommends a suction strainer in this type of system Do not use petr...

Page 7: ...ture System Return Temperature and Pressure Gauge Allows the user to monitor system temperature and pressure Electrical field connections with terminal strips The electrical cover allows easy access to the clearly marked line voltage and low voltage terminal strips to facilitate wiring the boiler Condensate Collection System This boiler is a high efficiency appliance and will produce condensate Th...

Page 8: ...ting ventilation openings Ensure a minimum 1 clearance around hot water and exhaust vent pipes NOTE To prevent condensing in the fan it is recommended to avoid prolonged exposure to temperatures below 45oF This boiler has a condensate disposal system that may freeze if exposed to sustained temperatures below 32oF Precautions should be taken to protect the condensate trap and drain lines from susta...

Page 9: ...n are sufficient to support the full installed weight of the boiler including water content of the heat exchanger and related piping Failure to ensure the floor and structure of the installation location are structurally sound before installation of the boiler can result in structural failure substantial property damage severe personal injury or death C Leveling In order for the condensate to prop...

Page 10: ...ry 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 1 DirectVent of Exhaust and Intake If installing a direct vent option combustion air must be drawn from the outdoors d...

Page 11: ...ng fluorocarbons Dry cleaning laundry areas and establishments Permanent wave solutions Swimming pools Chlorinated waxes cleaners Metal fabrication plants Chlorine based swimming pool chemicals Beauty shops Calcium chloride used for thawing Refrigeration repair shops Sodium chloride used for water softening Photo processing plants Refrigerant leaks Auto body shops Paint or varnish removers Plastic...

Page 12: ... affect thereliabilityofthesystem Inaddition operatingtemperatures above 140oF will cause the boiler to operate continuously accelerating the build up of lime scale and possibly shortening the service life of the boiler Failure of a boiler due to lime scale build up low pH or other chemical imbalance IS NOT covered by the warranty Sodium less than 20 mGL Water pH between 6 0 and 8 0 Maintain water...

Page 13: ...WHL 033 Rev 1 29 16 13 Figure 5 Boiler Dimensions NOTE All Dimensions Are Approximate VWH in Model Number DenotesVolume Water Heater Model ...

Page 14: ...e freezing Connect discharge piping to a safe disposal location by following these guidelines RE INSPECTION OF T P RELIEF VALVES T P valves should be inspected AT LEAST ONCE EVERY THREE YEARS and replaced if necessary by a licensed plumbing contractor or qualified service technician to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and disc...

Page 15: ...ficient flow F Hydronic Piping with Circulators Zone Valves and Multiple Boilers The boiler is designed to function in a closed loop hydronic system The included temperature and pressure gauge allows the user to monitor system pressure and outlet temperature from the boiler It is important to note that the boiler has a minimal amount of pressure drop that must be calculated when sizing the circula...

Page 16: ...Δt 30 Δt Model Friction Ft Flow Rate GPM Friction Ft Flow Rate GPM Friction Ft Flow Rate GPM 500 19 50 11 40 8 33 850 35 85 26 65 18 54 Table 5 Temperature Rise Friction Ft and Flow Rate 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 The boiler heat exchanger d...

Page 17: ...boiler or operate with water containing chlorine in excess of 100 ppm NOTE It is recommended to clean the heat exchanger at least once a year to prevent lime scale buildup To clean the heat exchanger follow the maintenance procedure in this manual H Check Control Water Chemistry Hardness Less than 7 grains Chloride levels Less than 100 ppm pH levels 6 8 TDS Less than 2000 ppm Sodium Less than 20 m...

Page 18: ...culator 5 A 50 mixture of glycol will result in a BTU output loss of 30 with a 50 increase in head against the system circulator Basic steps are listed below that will guide the installation of the boiler 1 Connect the system return marked Boiler Return 2 Connect the system supply marked Boiler Supply 3 Install purge and balance valve or shut off valve and drain on system return to purge air out o...

Page 19: ...ng circulator zoning connect the boiler to the system as shown in Applications NOTE The boiler circulator cannot be used for a zone It must only supply the boiler loop 2 Install a separate circulator for each zone 3 Connect DHW domestic hot water piping to indirect storage water heater as shown in Applications N Multiple Boilers 1 Connect multiple boilers as shown in Applications 2 All piping show...

Page 20: ... all closely spaced tees 5 PipingshownisPrimary 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 8 System flow Secondary Loop must be greater than the boiler s Primary Loop flow 9 Installations must comply with all local codes 10 In Massachusetts a vacuum relief valve must be installed on the cold...

Page 21: ...ing concept only 2 Install a minimum of 12 diameters of straight pipe upstream of all circulators 3 Install a minimum of 6 diameters of straight pipe up and downstream of all closely spaced tees 4 Piping shown is Primary Secondary 5 The minimum pipe size for connecting a boiler is 2 6 System flow Secondary Loop must be greater than the boiler s Primary Loop flow 7 Installations must comply with al...

Page 22: ...ugh an unheated space such as an alcove or attic the space must be heated or the pipe must be insulated The insulation must have an R value sufficient to prevent freezing of the condensate Improper seating of vent pipe gaskets can cause eventual gasket failure and exhaust gas leakage Ensure the exhaust vent pipe is properly beveled and seated before insertion into the flue adapter Failure to do so...

Page 23: ...roved Materials for ExhaustVent and Intake Pipe C Additional Requirements for Installation in Canada 1 Installations must be made with a vent pipe system certified to ULC S636 IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC S636 Additionally you may use AL29 4C stainless steel venting to comply with Canadian requirements 2 The first three 3 feet of vent pipe f...

Page 24: ...er to center Minimum distance between exhaust vents and intake pipes on multiple boilers is 10 0 255 m center to center L When adjacent to a public walkway locate exit terminal at least 7 feet above grade In addition Total length of vent piping shall not exceed the limits specified in this manual The vent piping for this direct vented appliance is approved for zero clearance to combustible constru...

Page 25: ...IONS Foam core piping may be used on air inlet piping only 2 Remove all burrs and debris from joints and fittings 3 When using PVC or CPVC pipe all joints must be properly cleaned primed and cemented Use only cement and primer approved for use with the pipe material Cement must conform to ASTM D2564 for PVC and ASTM F493 for CPVC pipe NOTE DO NOT CEMENT POLYPROPYLENE PIPE 4 Ensure the vent is loca...

Page 26: ... given in theVenting section of this manual When installing a combustion air intake from outdoors care must be taken to utilize uncontaminated combustion air NOTE To prevent combustion air contamination seeTable 1 Take extra precaution to adequately support the weight of vent pipes terminating through the roof Failure to properly support roof terminated piping could result in property damage serio...

Page 27: ...4 foot intervals on the vent pipe Venting must be readily accessible for visual inspection from the first three feet from the boiler 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 B Typical installations require 12 minimum separation between bottom of exhaust outlet an...

Page 28: ...y 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 Figure 15 UnbalancedVenting Roof Exhaust and Sidewall Intake An unbalanced vent system can be installed ONLY when the exhaust is in the vertical position Failure to do so could result in serious personal injury or death Figure 16 ...

Page 29: ...ir is taken from the outdoors using a duct to deliver the air to the mechanical room each of the two openings should be sized based on a minimum free area of one square inch per 2000 BTU hr input See Figure 18 3 If air is taken from another interior space combined with the mechanical room a Two spaces on same story Each of the two openings specified should have a net free area of one square inch f...

Page 30: ...e to follow these instructions could result in property damage or personal injury Combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the boiler See Table 1 for a list of combustion air contaminants These chemicals when burned form acids which quickly attack the stainless steel heat exchanger headers flue connectors and ...

Page 31: ...llow these instructions could result in component or product failure serious injury or death Such product failure IS NOT covered by warranty Jumping out control circuits or components WILL VOID productwarrantyandcanresultinpropertydamage personal injury or death Label all wires prior to disconnecting them when servicing the boiler Wiring errors can cause improper and dangerous operation Failure to...

Page 32: ...r is in lockout mode F Low Voltage Connections for Standard Boiler 1 All low voltage cables should enter the electrical junction box through the provided knock out holes as shown in Figure 23 2 Connect all low voltage field devices to the low voltage terminal strip located in the electrical junction box G Thermostat 1 Connect the room thermostat to the terminals marked THERMOSTAT in the electrical...

Page 33: ...ctrical box inside of the boiler cabinet Remove and discard the jumper plug from one of the unused pigtails 3 Connect the low gas pressure switch to the pigtail that you removed the jumper plug from M Optional Flow Switch NOTE Follow the more detailed instructions included with the flow switch kit for proper installation steps 1 Attach the correct flow paddle to the flow switch 2 Thread brass tee ...

Page 34: ...he boilers and create a neat installation Do not run unprotected cables across the floor where they may become wet or damaged Avoid running communication cables parallel and close to or against high voltage 120 volt or greater wiring Westinghouse recommends that the maximum length of communication bus cables not exceed 200 feet 4 Route the communication cables through one of the knockouts in the c...

Page 35: ...e alarm contacts are rated 5 amps at 120 VAC To connect an alarm device connect the power for the device Figure 26 Cascade Master and FollowerWiring to theALARMCOM terminal Connect the alarm device hot wire to theALARM NO terminal Connect the neutral or return of the alarm device to the neutral or return of the power for the alarm device To connect a device that should be powered off during a boil...

Page 36: ...WHL 033 Rev 1 29 16 36 Figure 27 Internal Connection Diagram ...

Page 37: ...tant to support gas piping as the unit is not designed to structurally support a large amount of weight Support gas supply piping with hangers not by the boiler or its accessories The boiler gas valve and blower will not support the weight of the piping Make sure the gas piping is protected from physical damage and freezing where required Failure to follow these instructions could result in gas le...

Page 38: ... off and shut off gas supply at the manual gas valve before disconnecting the hose from the gas monitoring device Tighten screw on the pressure tap and turn gas on Check for leaks with soapy solution Bubbles will appear on the pipe to indicate a leak is present Ensurethepressuretapscrewisproperlytightenedtoprevent gas leaks Failure to do so could cause substantial property damage severe personal i...

Page 39: ... Strainonthegasvalveandfittingsmayresult in vibration premature component failure and gas leakage and result in fire explosion property damage severe personal injury or death Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated combustion analyzer capable of measuring CO2 and CO Failure to follow this instruction could result in fire explosi...

Page 40: ...ll near the floor and around the boiler for gas odorant or any unusual odor Remove boiler front door and smell interior of boiler enclosure Do not proceed with startup if there is any indication of a gas leak Repair any leaks at once PROPANE BOILERS ONLY The propane supplier mixes an odorant with the propane to make its presence detectable In some instances the odorant can fade and the gas may no ...

Page 41: ...e up line e Open purge valve f Open the isolation valves one zone at a time Allow water to run through the zone pushing out the air Run water until no noticeable air flow is present Close the zone isolation valves and proceed with the next zone Follow this procedure until all zones are purged g Close the quick fill water valve and purge valve and remove the hose Open all isolation valves Watch the...

Page 42: ...te the LED fault indicator and close the alarm relay contacts to aid in recognition of the condition diagnosis and repair J Setting Up a Cascaded System If the boiler is part of a cascaded system the operation is somewhat different The control of each boiler in a cascaded system completes its own power up system check One of the boilersinthecascadesystemisdesignatedasthemasterboiler After the mast...

Page 43: ...he floor 3 WHATTO DO IFYOU SMELL GAS Do not try to light any boiler Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions If you cannot reach your gas supplier call the fire department Turn off the gas shutoff valve located outside the boiler so that the handle is crosswise to the gas ...

Page 44: ...oiler set point from 50F to 190oF Factory Default 180oF CENTRAL DIFF SET 30 oF Adjusts the boiler differential set point from 5oF to 30oF Factory Default 30oF DHW SETPOINT 119 oF Adjusts the indirect tank set point from 70oF to 185oF Factory Default 119oF DHW DIFF SETPOINT 7 oF Adjusts the DHW differential set point from 1oF to 30oF Factory Default 7oF TEMP DISPLAY C OR F oF Adjusts the temperatur...

Page 45: ... setting CLOCK MONTH 08 28 2009 Fr 10 01A Adjusts the month setting CLOCK DATE 08 28 2009 Fr 10 01A The clock is set Function 6 DHW Post PumpTime DHW POST PUMP TIME 0 MINUTES 6 The indirect pump has the ability to post purge energy from the boiler to run the pump after the set point has been achieved Please note that running the pump for a time greater than 5 minutes may cause tank energy to be re...

Page 46: ...0 Screen Description Function 23 Cascade Mode CASCADE MODE VISION 3 23 Allows the user to select cascade mode Select VISION 3 if boiler is operating alone or using an older Vision 3 control panel for cascade operation Select ALL 926 to establish a cascaded system WITHOUT common vent In cascaded systems WITH a common vent select the number of cascaded boilers in the system on the cascade master 2 B...

Page 47: ...ation NOTE For the following functions you must have your maintenance function turned on To change these functions press ENTER The left most digit will begin to blink Use the or v arrows to change the digit Use the arrow keys to switch between digits When you ve made your selection press ENTER again Screen Description Function 33 Year SERVICE SCHEDULE YEAR 00 00 2000 33 Allows the user to set the ...

Page 48: ...ral heat demand set for the cascade system Press v once 0 10 SIGNL ON Shows if 0 10 volt is enabled Press v once This screen appears only when the boiler is set as a Master Boiler CAS SET 190oF SYSTEM 112oF This screen displays the cascade set point maximum 190oF on the top line The system sensor reading is on the second line The control will cascade the boilers up to this set point depending on d...

Page 49: ...l alternate between the words FAULT HISTORY and the actual fault encountered The bottom line will display the date and time that the fault occurred Press v once FAULT HISTORY 4 08 28 2009 Fr 5 19A This screen displays the fourth oldest boiler control lockout fault The top line will alternate between the words FAULT HISTORY and the actual fault encountered The bottom line will display the date and ...

Page 50: ...ring The bottom line shows the status of the system pump output contacts Press v once CASCADE PWR 100 PRESENT 01234567 This screen displays overall cascade power output The range of this value is the number of boilers communicating with the Master x 100 For example if 8 boilers are connected and firing the maximum cascade power is 800 The second line shows which boiler addresses are communicating ...

Page 51: ...to run in an attempt to cool the boiler 2 Note the displayed fault code and refer to Section D for an explanation of the message along with several suggestions for corrective actions 3 Press RESET to clear the fault and resume operation Be sure to observe the operation of the unit for a period of time to assure correct operation and no reoccurrence of fault message DO NOT USE THIS APPLIANCE IF ANY...

Page 52: ...cause the water temperature measured by the supply sensor is higher than the tank temperature ignition diff setting Thismessagewillstaypresentuntilthewatertemperature measured by the supply sensor is less than the tank temperature ignition diff setting TEMPER BLOCKING PUMP ON DHW DHW indicates there is a demand for heat on the boiler from the DHW circuit the pump is powered on and the supply senso...

Page 53: ... is ok and this code is still present and the water is not excessively hot replace the ECO sensor Screen Description Possible Remedy FLUE TEMP WAT LV F01 PUMP ON This code indicates that one of the safety interlock switches present in the unit has tripped There are several interlock switches that could possibly trip and cause this error The following four switches are installed and are standard eq...

Page 54: ...chart should be close to the temperature in the flue If not replace the flue sensor Screen Description Possible Remedy SUPPLY TEMP HIGH F05 PUMP ON F05 indicates the boiler supply temperature is excessive When accompanied by the red FAULT light and LOCKOUT flashing on the display this code indicates the supply sensor temperature has exceeded 230oF and a serious safety issue exists The boiler will ...

Page 55: ...urner and its sealing gaskets FALSE FLAME SIG F11 PUMP ON There is flame when the control is not telling the boiler to run This is a serious safety issue as indicated by the illuminated red light and the word LOCKOUT flashing on the display The boiler will not restart until a technician determines and repairs the cause and pushes RESET on the display During this lockout fault the pump will be on 1...

Page 56: ...eft in a locked out mode Press RESET for at least 1 second to use the control OUTDOOR SENSOR FOU PUMP ON 1 45P There is an issue with the outdoor sensor It is shorted damaged or disconnected from the boiler 1 Check outdoor sensor connections and wiring Ensure the sensor and wiring are intact and that the sensor is connected to the boiler 2 Checktheoutdoorsensorresistancewithanohmmeter SeeTable 26 ...

Page 57: ...ystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 Avoid breathing dust and contact with skin and eyes Use a NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written Other types of respirators may be needed depending on job site conditi...

Page 58: ...r is operating properly h Reconnectthecondensatepipingtotheoutsidecondensate connection Do not use solvents to clean any of the burner components The components could be damaged resulting in unreliable or unsafe boiler operation substantial property damage severe personal injury or death Figure 31 Heat Exchanger Detail C Cleaning Water Side of Heat Exchanger 1 Make sure power is turned off to the ...

Page 59: ...WHL 033 Rev 1 29 16 59 Figure 32 500 Combustion System Replacement Parts Model ...

Page 60: ...WHL 033 Rev 1 29 16 60 Figure 33 850 Combustion System Replacement Parts Model ...

Page 61: ...WHL 033 Rev 1 29 16 61 Figure 34 Water Side Replacement Parts All Models ...

Page 62: ...WHL 033 Rev 1 29 16 62 Figure 35 Cabinet Replacement Parts All Models ...

Page 63: ...he Boiler 500 ONLY If necessary convert the boiler to the proper fuel type Locate the stickers in the appropriate locations on the boiler Verify combustion settings after gas conversion Carbon Dioxide CO2 High Fire CO2 Low Fire Verify combustion settings after gas conversion Carbon Monoxide ppm CO High Fire ppm CO Low Fire Mail in conversion registration Notes Table 27 Installation Checklist Allow...

Page 64: ...probe with plumbers cloth to remove oxides Combination Ignitor and Flame Probe Check ionization in uA d7 in Status Menu in Start Up Procedures Record high fire and low fire Clean probe with plumbers cloth to remove oxides Condensate 1stYear 2ndYear 3rdYear 4thYear Neutralizer Check condensate neutralizer Replace if necessary Condensate Pipe Disconnect condensate pipe Clean out dirt Fill with water...

Page 65: ...ONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wi...

Page 66: ...ENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting syst...

Page 67: ...G This warranty extends only to boilers utilized in closed loop heating applications that have been properly installed based upon the manufacturer s installation instructions The use of the boiler as a potable water heating appliance shall void any coverage under this warranty H Replacement parts will be warranted for ninety 90 days OWNER S RESPONSIBILITIES To avoid the exclusion list in this warr...

Page 68: ...stated below 1 774 417 6000 SERVICE LABOR AND SHIPPING COSTS This warranty does not extend to shipping charges delivery expenses or administrative fees incurred by the purchaser in repairing or replacing the Commercial Gas Fired Boiler This warranty does not extend to labor costs beyond the coverage specified in this warranty document LIMITATIONS OF YOUR WESTINGHOUSE WARRANTY AND REMEDIES THE FORE...

Page 69: ...WHL 033 Rev 1 29 16 69 Maintenance Notes ...

Page 70: ...of Installation Installation Address Product Name Serial Number s Comments Installer s Code Name Installers Phone Number Signed by Installer Signed by Customer Installation Notes IMPORTANT Customer Please only sign after the installer has fully reviewed the installation safety proper operation and maintenance of the system If the system has any problems please call the installer If you are unable ...

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