Westinghouse Premium WBCMC 500 Series Installation manual

Commercial
Gas Fired Boilers
Installation
Start-Up
Maintenance
Parts
Warranty
WBCMC**500 / 700 / 850 Models*
* “NG”Denotes Natural Gas Operation
“LP” Denotes Propane Gas Operation
“HL” Denotes Installed High and Low Gas Pressure Switches
“FS” Denotes Installed Flow Switch
“WL” Denotes Installed High Temperature Water Limit
This manual must only be used by a qualied 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.
www.westinghousewaterheating.com whl-445 Rev. 000 Rel. 014 Date 7.21.20
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
California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth
defects, or other reproductive harm.

whl-445 Rev. 000 Rel. 014 Date 7.21.20
2
WARNING: If the information in these instructions is not followed exactly, a re or explosion may result causing property damage, personal
injury or death.
• Do not store or use gasoline or other ammable vapors and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU 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 re department.
• Installation and service must be provided by a qualied installer, service agency or the gas supplier.
Improper installation, adjustment, alteration, service, or maintenance can cause injury, property damage, or death. Refer to this
manual. Installation and service must be performed by a qualied installer, service agency, or gas supplier.

whl-445 Rev. 000 Rel. 014 Date 7.21.20
3
The following dened terms are used throughout this manual to
bring attention to the presence of hazards of various risk levels or
to important product information.
DANGER indicates an imminently hazardous situation which, if
not avoided, will result in serious personal injury or death.
WARNING indicates a potentially hazardous situation which, if
not avoided, could result in personal injury or death.
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in moderate or minor personal injury.
CAUTION used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, may result
in property damage.
NOTICE is used to address practices not related to personal injury.
Foreword
This manual is intended to be used in conjunction with other
literature provided with the boiler. This includes all related control
information. It is important that this manual, all other documents
included in this system, and additional publications including the
National Fuel Gas Code - ANSI Z223.1 (latest versions), be reviewed in
their entirety before beginning any work.
Installation should be made in accordance with the regulations of
the Authority Having Jurisdiction, local code authorities, and utility
companies which pertain to this type of water heating equipment.
For the Installer
This boiler must be installed by qualied 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 codes, preference should be given to the National Fuel
Gas Code - ANSI Z223.1, latest version.
Installations Must Comply With:
Local, state, provincial, and national codes, laws, regulations, and
ordinances.
The latest version of the National Fuel Gas Code, ANSI Z223.1, from
American Gas Association Laboratories, 8501 East Pleasant Valley
Road, Cleveland, OH 44131.
In Canada - CGA No. B149 (latest version), from Canadian Gas
Association Laboratories, 55 Scarsdale Road, Don Mills, Ontario,
Canada M3B 2R3. Also, Canadian Electrical Code, C 22.1, from Canadian
Standards Association, 5060 Spectrum Way, Suite 100, Mississauga,
Ontario, Canada L4W 5N6.
The latest version of the National Electrical Code, NFPA No. 70.
NOTE: The gas manifold and controls met safe lighting and other
performance criteria when undergoing tests specied in ANSI Z21.13
- latest edition.
Authority Having Jurisdiction (AHJ) – The AHJ may be a federal, state,
local government, or individual such as a re chief, re marshal, chief
of a re prevention bureau, labor department or health department,
building ocial or electrical inspector, or others having statutory
authority. In some circumstances, the property owner or his/her agent
assumes the role, and at government installations, the commanding
ocer or departmental ocial may be the AHJ.
NOTE: Westinghouse reserves the right to modify product technical
specications and components without prior notice.

whl-445 Rev. 000 Rel. 014 Date 7.21.20
4
Table of Contents
Part 1 - General Safety Information 5
A. Improper Combustion 6
B. Gas 6
C. When Servicing the Boiler 6
D. Boiler Water 6
E. Freeze Protection 6
F. High Elevation Installations 6
Part 2 - Before You Start 6
A. What’s in the Box 6
B. How the Boiler Operates 6
C. Optional Equipment 7
Part 3 - Prepare the Boiler 7
A. Locating the Boiler 7
B. Flooring 8
C. Leveling 9
D. Clearances for Service Access 9
E. Residential Garage and Closet Installations 9
F. Exhaust Vent and Intake Pipe 9
1. Direct Vent of Exhaust and Intake 10
2. Indoor Combustion Air in Conned or Unconned Space 10
G. Carbon Monoxide Detectors 10
H. Prevent Combustion Air Contamination 10
I. Removing a Boiler from a Common Vent System 11
J. Water Chemistry Requirements* 11
K. Technical Specications 13
Part 4 - Piping 14
A. General Plumbing Information 14
B. Relief Valve 14
C. Backow Preventer 14
D. Expansion Tank 14
E. Circulators 15
F. Hydronic Piping with Circulators, Zone Valves, and Multiple Boilers
15
G. Circulator Sizing 16
H. Check / Control Water Chemistry 17
I. Plumbing 18
J. Fill and Purge Heating System 18
K. Freeze Protection Fluids 18
L. Zoning with Zone Valves 18
M. Zoning with Circulators 18
N. Multiple Boilers 18
O. Applications* 19
Part 5 - Venting 21
A. General 21
B. Approved Materials for Exhaust Vent and Intake Pipe 22
C. Additional Requirements for Installation in Canada 22
D. Exhaust Vent and Intake Pipe Location 23
E. Exhaust Vent and Intake Pipe Sizing 24
F. Longer Vent Runs 24
G. Exhaust Vent and Intake Pipe Installation 24
H. Applications 25
1. Direct Vent Installation of Exhaust and Intake 25
2. Room and Indoor Combustion Ventilation Requirements 28
Part 6 - Condensate Removal 29
Part 7 - Wiring 30
A. Installation Must Comply With 30
B. Field Wiring Terminations 30
The CSD-1 ASME Code, Section CW-400 requires that hot water
heating and supply boilers have a) a UL 353 temperature control
device, b) at least one (1) temperature-actuated control to shut
o the fuel supply when system water reaches a preset operating
temperature, c) a high temperature limit control that prevents
the water temperature from exceeding the maximum allowable
temperature by causing a safety shutdown and lockout, and d) its
own sensing element and operating switch.
The temperature control system integrated into the 926 control
provided with this heating appliance complies with the requirements
of CSD-1 Section CW-400 as a temperature operation control. The
control monitors the temperature dierence between the inlet
and the outlet sensor, which is aected by boiler water ow. If this
temperature dierence exceeds 55°F (typically because of low water
ow or very low heat load), the control will reduce the maximum fan
speed. If the temperature dierence exceeds 60°F, the control will
eectively sense there is little or no water ow or heat load and shut
the boiler down. The controller will restart automatically once the
temperature dierence has dropped below 55°F and the minimum
o time (anti-cycle time) 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, substantial property damage,
severe personal injury, or death. Damage or failure of this product (or
the system in which it is installed) due to unauthorized use IS NOT
COVERED BY WARRANTY.
IMPORTANT
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.
These features include:
• A modulating combustion system that adjusts ring rate
based on heat demand.
• Adjustment of boiler set point based on inferred heat
load as determined by an outdoor sensor. The outdoor
sensor is supplied by Westinghouse with this boiler.
• This boiler does not include a standing pilot.
• This boiler is designed and shipped to assure the highest
eciency operation possible. Such high eciency is
achieved by limiting heating circuit water temperature to
140°F when there is no anticipated heat load, based upon
the outdoor sensor and the Outdoor Reset Curve (sensor
response curve) in the boiler software.
• This feature may be over-ridden as described below in
specic installations:
• The boiler control is equipped with an outdoor sensor
override for use with building management systems or in
cascaded systems (for systems with total input of 300,000
BTU/hr or greater).
See statement below for an important notice on the use of the
override.
IMPORTANT
In accordance with Section 325 (f) (3) of the Energy Policy and
Conservation Act, this boiler is equipped with a feature that
saves energy by reducing the boiler water temperature as
the heating load decreases. This feature is equipped with an
override which is provided primarily to permit the use of an
external energy management system that serves the same
function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST
ONE OF THE FOLLOWING CONDITIONS IS TRUE:
• An external energy management system is installed that
reduces the boiler water temperature as the heating load
decreases.
• This boiler is not used for space heating.
• This boiler is part of a modular or multiple boiler system
having a total input of 300,000 BTU/hr or greater.
• This boiler is equipped with a tankless coil.

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5
C. Field Wiring 30
D. Line Voltage Wiring for Standard Boiler 30
E. Alarm Connections 31
F. Low Voltage Connections for Standard Boiler 31
G. Thermostat 31
H. Outdoor Sensor 31
I. Indirect Sensor 31
J. Optional 0-10 Volt Building Control Signal 31
K. Optional High Gas Pressure Switch 32
L. Optional Low Gas Pressure Switch 32
M. Optional Flow Switch 32
N. Optional UL353 Low Water Cut-O Interface Kit 32
O. Wiring of Cascade System Communication Bus 32
P. Cascade Master Pump and Sensor Wiring 33
Q. Cascade Follower Pump and Sensor Wiring 33
Part 8 - Gas Connections 35
A. Gas Piping 36
B. Gas Table 36
C. Check Inlet Gas Pressure 37
D. Boiler Gas Valve 38
Part 9 - Start-Up Preparation 39
A. Check / Control Water Chemistry 39
B. Check for Gas Leaks 39
C. Freeze Protection (When Used) 39
D. Fill and Test Water System 39
E. Purge Air from Water System 40
F. Check Thermostat Circuit(s) 40
G. Condensate Removal 40
H. Final Checks Before Starting Boiler 40
I. Setting Up a Single Boiler 40
J. Setting Up a Cascaded System 41
K. Lockout Condition 41
L. Cascade System Programming 41
Part 10 - Start-Up Procedure 42
A. Control Overview 42
B. Navigation of the Display 42
C. Operating Instructions 42
D. Programming Boiler Settings 42
E. Programming the System Setting 43
F. System Setting Program Navigation 43
G. Resetting the Maintenance Schedule 46
Part 11 - Start-Up Procedures for the Installer 46
A. Boiler Control Status Menu 46
B. Cascade Menu 48
C. Boiler Test Mode 49
Part 12 - Troubleshooting 49
A. Boiler Error and Fault Codes 49
B. Boiler Error 49
C. Boiler Fault 49
D. User Interface Display 50
Part 13 - Maintenance 55
A. Procedures 55
B. Combustion Chamber Coil Cleaning Instructions 55
C. Cleaning Water Side of Heat Exchanger 56
Part 14 - Installation Checklist 57
Part 15 - Maintenance Report 57
Part 16 - Replacement Parts 59
Limited Warranty 63
Maintenance Notes 65
Customer Installation Record Form 66
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
Installer - Read all instructions in this manual before installing.
Perform steps in the given order.
User - This manual is for use only by a qualied heating installer /
service technician. Have this boiler serviced / inspected annually by
a qualied 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 qualied 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 qualied 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 re
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 ood 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.
NOTE: Obey all local codes. Obtain all applicable permits before
installing the boiler.
NOTE: Install all system components and piping in such a manner
that does not reduce the performance of any re rated assembly.
Do not use this boiler for anything other than its intended purpose
(as described in this manual). Doing so could result in property
damage and WILL VOID product warranty.
High heat sources (sources generating heat 100oF / 37oC or greater,
such as stove 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” from high heat sources. Observe heat
source manufacturer instructions, as well as local, state, provincial,
and national codes, laws, regulations and ordinances when installing
this boiler and related components near high heat sources.
door or removable panel is acceptable front clearance.) This boiler has
been approved for closet installation and installation on combustible
ooring. 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. Use only
Category IV vent systems.
Due to low water content of the boiler, improperly sizing the boiler
in regard to potable water heating load will result in excessive boiler
cycling and accelerated component failure.Westinghouse DOES NOT
warrant failures caused by improperly sized boiler applications. DO
NOT oversize the boiler to the system. Modular boiler installations
greatly reduce the likelihood of boiler oversizing.