WHL-033 Rev. 1.29.16
5
Part 5 - Venting and Condensate Removal
22
A. General
22
B. Approved Materials for Exhaust Vent and Intake Pipe 23
C. Additional Requirements for Installation in Canada 23
D. Exhaust Vent and Intake Pipe Location
24
E. Exhaust Vent and Intake Pipe Sizing
25
F. Longer Vent Runs
25
G. Exhaust Vent and Intake Pipe Installation
25
H. Applications
26
1. Direct Vent Installation of Exhaust and Intake
26
2. Room and Indoor Combustion Ventilation Requirements
29
I. Condensate Removal System
30
Part 6 - Wiring
31
A. Installation Must Comply With
31
B. Field Wiring Terminations
31
C. Field Wiring
31
D. Line Voltage Wiring for Standard Boiler
32
E. Alarm Connections
32
F. Low Voltage Connections for Standard Boiler
32
G. Thermostat
32
H. Outdoor Sensor
32
I. Indirect Sensor
32
J. Optional 0-10 Volt Building Control Signal
33
K. Optional High Gas Pressure Switch
33
L. Optional Low Gas Pressure Switch
33
M. Optional Flow Switch
33
N. Optional UL353 Low Water Cut-Off Interface Kit
33
O. Wiring of Cascade System Communication Bus
34
P. Cascade Master Pump and Sensor Wiring
34
Q. Cascade Follower Pump and Sensor Wiring
35
Part 7 - Gas Connections
37
A. Gas Piping
37
B. Gas Table
38
C. Check Inlet Gas Pressure
38
D. Boiler Gas Valve
39
Part 8 - Start-Up Preparation
40
A. Check / Control Water Chemistry
40
B. Check for Gas Leaks
40
C. Freeze Protection (When Used)
40
D. Fill and Test Water System
40
E. Purge Air from Water System
41
F. Check Thermostat Circuit(s)
41
G. Condensate Removal
41
H. Final Checks Before Starting Boiler
42
I. Setting Up a Single Boiler
42
J. Setting Up a Cascaded System
42
K. Lockout Condition
42
L. Cascade System Programming
43
Part 9 - Start-Up Procedure
43
A. Control Overview
43
B. Navigation of the Display
43
C. Operating Instructions
44
D. Programming Boiler Settings
44
E. Programming the System Setting
45
F. System Setting Program Navigation
45
G. Resetting the Maintenance Schedule
47
Part 10 - Start-Up Procedures for the Installer
48
A. Boiler Control Status Menu
48
B. Cascade Menu
49
C. Boiler Test Mode
50
Part 11 - Troubleshooting
51
A. Boiler Error and Fault Codes
51
B. Boiler Error
51
C. Boiler Fault
51
D. User Interface Display
52
Part 12 - Maintenance
57
A. Procedures
57
B. Combustion Chamber Coil Cleaning Instructions
57
C. Cleaning Water Side of Heat Exchanger
58
Part 13 - Installation Checklist
63
Part 14 - Maintenance Report
63
Limited Warranty
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 side has all
boiler mechanical connections. Boiler must have room for
service: 24” front is minimum recommended service clearance.
(A combustible door or removable panel is acceptable front
clearance.) This boiler has been approved for closet installation
and installation on combustible flooring. Do not install directly on
carpeting. Install the boiler in a location where temperature and
pressure relief valve discharge or a leak will not result in damage
to the surrounding area. If such a location is not available, install
an auxiliary catch pan. Use only Category IV vent systems.
Installer -
Read all instructions in this manual before installing.
Perform steps in the given order.
User -
This manual is for use only by a qualified heating installer /
service technician. Have this boiler serviced / inspected annually
by a qualified service technician.
FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE
CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE,
SEVERE PERSONAL INJURY, OR DEATH.
NOTE:
If the boiler is exposed to the following, do not operate.
Immediately call a qualified service technician.
1. Fire
2. Damage
3. Water
Failure to follow this information could result in property
damage, severe personal injury, or death.
DO NOT USE THIS BOILER IF ANY PART HAS BEEN
SUBMERGED IN WATER.
Immediately call a qualified
service technician. The boiler MUST BE replaced if it has been
submerged. Attempting to operate a boiler that has been
submerged could create numerous harmful conditions, such as
a potential gas leakage causing a fire and/or explosion, or the
release of mold, bacteria, or other harmful particulates into
the air. Operating a previously submerged boiler could result in
property damage, severe personal injury, or death.
NOTE:
Boiler damage due to flood or submersion is considered
an Act of God, and IS NOT covered under product warranty.
Altering any Westinghouse boiler with parts not manufactured
by Westinghouse WILL INSTANTLY VOID the boiler warranty
and could result in property damage, personal injury, or death.
Summary of Contents for WBMC**500
Page 36: ...WHL 033 Rev 1 29 16 36 Figure 27 Internal Connection Diagram ...
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 ...
