Westinghouse WBRC 140 Series, Installation, Start-Up, Maintenance, Parts, Warranty

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whl-648 Rev. 001 Rel. 003 Date 10.8.19
5
D. Piping the Boiler 20
E. Applications 21
F. CH and DHW Pressure Relief Valves 28
Part 5 - Venting 29
A. General 29
B. Approved Materials for Exhaust Vent and Intake Pipe 30
C. Additional Requirements for Installation in Canada 30
D. Exhaust Vent and Intake Pipe Location 31
E. Exhaust Vent and Intake Pipe Sizing 32
F. Tightening Boiler Collar to Exhaust Vent and Intake Pipe 32
G. Exhaust Vent and Intake Pipe Installation 32
H. Applications 33
1. Direct Vent Installation of Exhaust and Intake 33
2. Venting Through an Existing System 36
3. Power Venting, Indoor Combustion Air in Confined or Unconfined
Space
37
Part 6 - Installing the Condensate Drain 38
Part 7 - Connecting Electrical Service 39
A. Wiring 39
B. Dip Switches 39
Part 8 - Gas Connections 44
A. Gas Pipe Sizing Tables 44
1. Gas Pipe Sizing 44
2. Natural Gas Pipe Sizing 44
3. LP (Liquid Propane) Gas Pipe Sizing 44
B. Gas Connection Requirements 44
C. Additional Precaution for Excess Flow Valve (EFV) 45
D. Checking Gas Pressure at the Boiler for Proper Operation 45
E. Setting and Verifying the Combustion Setting 45
Part 9 - Controls 46
A. Control and Display Overviews 46
B. Start-Up Sequence 46
C. Changing the DHW Set-Point 47
D. Changing the Temperature Indicator 47
E. Changing the CH Set-Point 47
F. Storage Mode 47
G. Lock Function 47
H. Status Display 48
I. Installer Mode 49
J. Outdoor Temperature Mode (Optional) 50
K. 0-10 Volt Input 51
Part 10 - Troubleshooting 52
A. Error Code 52
B. Error Tree Analysis 55
1. Flame Detection 55
2. Air Pressure Switch / Burner Overheat Limit / Condensate Block Switch
55
3. DHW / Operating Temperature / CH Overheat / Exhaust Sensors 55
C. Suggested Corrective Actions 56
Part 11 - Start-Up 58
A. Check / Control Water Chemistry 58
B. Check for Gas Leaks 58
C. Freeze Protection (When Used) 59
D. Fill and Test Water System 59
E. Purge Air from CH and Internal Storage Tank 59
F. Purge Air from DHW System 60
G. Check Thermostat Circuit(s) 60
H. Condensate Removal 60
Part 12 - Installation Checklist 61
Part 13 - Maintenance 62
Part 14 - Moving Adapters from Left to Right (Floor Models) 67
Part 15 - Replacement Parts 67
Limited Warranty for WBRC Appliances 79
Notes 81
Customer Installation Record Form 85
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. Boiler must have room for service: 24” front,
18” top, 12” bottom, and 0” back are minimum recommended service
clearances. Minimum recommended side clearances depend on
model and installation options. (A combustible door or removable
panel is acceptable front clearance. A 3” minimum clearance must
be provided from the boiler front cover to the removable panel or
combustible door.) 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 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. The appliance
is rated Category IV (pressurized vent, likely to form condensate in
the vent) and requires a special vent system designed for pressurized
venting. Use only Category IV vent systems.
WARNING
!
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 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:
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 fire rated assembly.
A. Operation and Installation Warnings
To avoid serious injury or death, read, understand, and follow all of the
precautions listed here.
DANGER
!
Vapors from flammable liquids will explode and can cause a fire,
resulting in personal injury or death. The boiler has a burner that
can come on at any time and ignite vapors. DO NOT use or store
flammable liquids around the boiler.
Improper venting can cause a build-up of carbon monoxide.
Breathing carbon monoxide can result in brain damage or death. DO
NOT operate the boiler unless it is properly vented to the outside
and has an adequate fresh air supply for safe operation. Inspect the
exterior exhaust gas outlet port and fresh air inlet port on a regular
basis to ensure they are functioning properly.
A concentration of carbon monoxide as small as .04% (400 parts
per million) in the air can be fatal. When making high fire or low
fire adjustments, CO levels must be monitored using a calibrated
combustion analyzer such that a CO level of no more than 150 ppm
is exceeded at any time during operation.
Adjusting the “low fire offset” or the “main flow restrictor” in small
increments can result in a significant increase in CO concentration.
To avoid serious injury or death, DO NOT make any adjustments
to the gas valve without monitoring the exhaust gases with a fully
functional and calibrated combustion analyzer.
Failure to follow these instructions will result in property damage,
severe personal injury, or death.
After installation, all boiler safety devices should be tested.
WARNING
!