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Westinghouse WBRC**140F, Manual

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5 

 

 

                                                                                    WHL-015 REV. 5.20.16 

E. WATER QUALITY .................................................................................................................................................................... 10

 

F. FREEZE PROTECTION ........................................................................................................................................................... 10

 

G. SCALDING ............................................................................................................................................................................... 10

 

H. HIGH ELEVATION INSTALLATIONS....................................................................................................................................... 10

 

PART 3 

– TECHNICAL SPECIFICATIONS ............................................................................................................................... 11

 

PART 4 

– PREPARE APPLIANCE LOCATION ........................................................................................................................ 14

 

A. UNCRATING THE APPLIANCE ............................................................................................................................................... 14

 

B. BEFORE LOCATING THE APPLIANCE .................................................................................................................................. 15

 

C. LEVELING ................................................................................................................................................................................ 16

 

D. CLEARANCES FOR SERVICE ACCESS ................................................................................................................................ 17

 

E. RESIDENTIAL GARAGE AND CLOSET INSTALLATIONS ..................................................................................................... 17

 

F. EXHAUST VENT AND INTAKE PIPE ....................................................................................................................................... 18

 

G. PREVENT COMBUSTION AIR CONTAMINATION ................................................................................................................. 18

 

H. REMOVING A APPLIANCE FROM A COMMON VENT SYSTEM ........................................................................................... 18

 

PART 5 

– VENTING ................................................................................................................................................................... 19

 

A. INTAKE PIPE AND EXHAUST VENT GUIDELINES ................................................................................................................ 19

 

B. APPROVED VENT MATERIALS .............................................................................................................................................. 21

 

C. ALLOWED COMBINED VENT LENGTHS ............................................................................................................................... 21

 

D. TIGHTENING APPLIANCE COLLAR TO EXHAUST VENT AND INTAKE PIPE ..................................................................... 22

 

E. VENT TERMINATION .............................................................................................................................................................. 23

 

1. Direct Vent, Two Pipe Roof and Sidewall Vent Terminations ................................................................................................ 23

 

2. Direct Vent, Optional Horizontal and Vertical Vent Kits ......................................................................................................... 24

 

3. Screen Installation ..................................................................................................................................................................... 24

 

4. Power Vent, Indoor Combustion Air Installation in Confined or Unconfined Space ........................................................... 25

 

PART 6 

– INSTALL THE CONDENSATE DRAIN ..................................................................................................................... 27

 

PART 7 

– GAS PIPING .............................................................................................................................................................. 28

 

A. GAS PIPE SIZING TABLES ..................................................................................................................................................... 28

 

1. Gas Pipe Sizing .......................................................................................................................................................................... 28

 

2. Natural Gas Pipe Sizing ............................................................................................................................................................ 28

 

3. LP (Liquid Propane) Gas Pipe Sizing ....................................................................................................................................... 29

 

B. GAS CONNECTION REQUIREMENTS ................................................................................................................................... 29

 

PART 8 

– WATER PIPING ........................................................................................................................................................ 31

 

A. GENERAL PLUMBING CONNECTION GUIDELINES ............................................................................................................. 31

 

B. DHW PIPING ............................................................................................................................................................................ 32

 

C. CENTRAL HEATING PIPING SYSTEM WATER PIPING METHODS ..................................................................................... 33

 

D. CIRCULATOR SIZING ............................................................................................................................................................. 38

 

E. PRESSURE RELIEF VALVE .................................................................................................................................................... 38

 

PART 9 

– CONNECT ELECTRICAL POWER / INITIAL STARTUP ......................................................................................... 39

 

A. GENERAL OPERATING CONDITIONS ................................................................................................................................... 39

 

B. WIRING INFORMATION .......................................................................................................................................................... 39

 

C. DIP SWITCHES ....................................................................................................................................................................... 40

 

Summary of Contents for WBRC**140F

Page 1: ...tain less than 0 25 lead by weight as required by the Safe Drinking Water Act Section 1417 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 APPLIANCE WHAT TO DO IF YOU SMELL GAS Do not try to light any appli...

Page 2: ...2 WHL 015 REV 5 20 16 ...

Page 3: ... not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTICE NOTICE is used to address practices not related to personal injury SAFETY INSTRUCTIONS S...

Page 4: ...T 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 Co...

Page 5: ...CE COLLAR TO EXHAUST VENT AND INTAKE PIPE 22 E VENT TERMINATION 23 1 Direct Vent Two Pipe Roof and Sidewall Vent Terminations 23 2 Direct Vent Optional Horizontal and Vertical Vent Kits 24 3 Screen Installation 24 4 Power Vent Indoor Combustion Air Installation in Confined or Unconfined Space 25 PART 6 INSTALL THE CONDENSATE DRAIN 27 PART 7 GAS PIPING 28 A GAS PIPE SIZING TABLES 28 1 Gas Pipe Sizi...

Page 6: ...M 0 10 VOLT INPUT 59 PART 11 START UP PREPARATION 60 A CHECK CONTROL WATER CHEMISTRY 60 B GLYCOL ANTIFREEZE SOLUTIONS 60 C CHECK FOR GAS LEAKS 61 D FILL AND TEST WATER SYSTEM 61 E PURGE AIR FROM CH AND INTERNAL STORAGE TANK 62 F PURGE AIR FROM DHW SYSTEM 62 G CHECK THERMOSTAT CIRCUIT S 63 H CONDENSATE REMOVAL 63 I FINAL CHECKS BEFORE STARTING APPLIANCE 63 J ADJUSTING GAS PRESSURE AT THE APPLIANCE ...

Page 7: ...ndensate Hose 7855P 089 1 Condensate Adapters and Instruction Sheet 7855P 087 1 kit CH Pressure Relief Valve With X 1 Bushing CH Line 30 psi 7855P 077 1 Each Vent Screens 3 7855P 085 2 Screens Outdoor Sensor with Screws and Anchors 7855P 084 1 Venting Kit for Combi Boiler 3 CPVC S7855 002 6 Length X Bell Coupling for Gas Line 7855P 086 140W Models 1 Spare Parts Kit Gaskets and O Rings 7855P 088 1 ...

Page 8: ...ry or death and will void the warranty Westinghouse cannot anticipate every circumstance that might involve a potential hazard Each installation has its own specialized characteristics requirements and possible hazards Therefore all possible incidents are not included in these warnings Proper and safe installation operation and service are the responsibility of the professional service technician ...

Page 9: ... additional temperature limits In addition certain types of systems may operate at temperatures below the minimum set point of the limit provided with the appliance Contact a qualified service technician for additional overheat controls NOTE When inquiring about service or troubleshooting reference the model and serial numbers from the appliance rating label DO NOT USE THIS APPLIANCE IF ANY PART H...

Page 10: ...CTION Consider appliance piping and installation when determining appliance location NOTE Damages resulting from incorrect installation or from use of products not approved by Westinghouse ARE NOT covered by warranty G SCALDING This heater can deliver scalding water Be careful whenever using hot water to avoid scalding injury Certain appliances such as dishwashers and automatic clothes washers may...

Page 11: ...rent Proportional Internal Pipe Material Copper Dimensions W 15 7 H 53 D 26 8 W 15 7 H 53 7 D 26 8 Storage Tank Water Capacity DHW Under 15 Gallons Main Controller Control Panel GTX 920C P 920C_CB HTP CH Pressure Min 12 PSI Max 30 PSI DHW Pressure Max 150 PSI Connection Sizes DHW Inlet Hot Water Outlet NPT CH Supply Return 1 NPT Gas Inlet NPT 1 2 X Bell Coupling Provided to Upsize Gas Line 3 4 NPT...

Page 12: ...L NPTM A Gas Connection Adapter NPT X Bell Coupling Provided to Upsize Gas Line B CH Supply Adapter 1 C CH Return Adapter 1 D DHW Outlet Adapter E DHW Inlet Adapter F Condensate Adapter G Drain Adapter H Exhaust Vent Connection 3 I Intake Pipe Connection 3 Table 5 140F Adapter Specifications ...

Page 13: ...ESCRIPTION DIAMETER ALL NPTM A Gas Connection Adapter NPT B CH Supply Adapter 1 C CH Return Adapter 1 D DHW Outlet Adapter E DHW Inlet Adapter F Condensate Adapter G Drain Adapter H Exhaust Vent Connection 3 I Intake Pipe Connection 3 Table 6 199F Adapter Specifications ...

Page 14: ...upply Adapter 8 Exhaust Pipe 24 Heat Exchanger 9 Internal CH Pump 25 Gas Inlet Adapter 10 Mixing Valve 26 Gas Valve 11 Internal Recirculation Pump DHW 27 Air Vent 12 Water Discharge Adapter 28 Ignition Transformer 13 Water Discharge Valve 29 Igniter 14 Internal Storage Tank 30 Air Intake Pipe 15 Condensate Trap Adapter 31 Air Intake Adapter 16 Condensate Hose 1 Table 7 Component List PART 4 PREPAR...

Page 15: ...he casing as well as internal surfaces such as the heat exchanger are directly influenced by proximity to damp and salty marine environments In such areas higher concentration levels of chlorides from sea spray coupled with relative humidity can lead to degradation of the heat exchanger and other appliance components In these environments appliances must not be installed using direct vent systems ...

Page 16: ...e or appliance treatments into the appliance or any piping meant for potable water purposes Ensure that all piping and components connected to the appliance are suitable for potable water applications Do not use this appliance only for space heating applications Circulators suitable for DHW applications must be used Failure to follow these instructions could result in property damage personal inju...

Page 17: ...location with limited clearances it may be necessary to remove the appliance from the space to perform maintenance Failure to consider maintenance when determining installation location could result in property damage E RESIDENTIAL GARAGE AND CLOSET INSTALLATIONS Check with your local Authority Having Jurisdiction for requirements when installing boiler in a garage or closet Please read the entire...

Page 18: ...sulting in possible substantial property damage severe personal injury or death PRODUCTS TO AVOID AREAS LIKELY TO HAVE CONTAMINANTS Spray cans containing 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 Refriger...

Page 19: ...termining exhaust vent termination Moisture may fall from the vent termination to the ground and turn to ice in freezing conditions Moisture or ice can produce a hazardous condition Exhaust condensate is acidic and could deteriorate the surface below the exhaust vent termination Ensure this surface is in good repair sealed painted etc to prevent deterioration Pitch the exhaust vent pipe back to th...

Page 20: ... from nearest wall and extends level with or above the top of the wall This will ensure flue gas does not get trapped and possibly recirculated into the intake air pipe which could contaminate the combustion air Figure 7 Vent Termination Detail DESCRIPTION US CANADA A Clearance above grade veranda porch deck or balcony 1 foot 1 foot B Clearance to window or door that may be opened 1 foot 3 feet C ...

Page 21: ...fically designed for the purpose by the manufacturer DO NOT insulate non metallic exhaust vent pipe or fittings DO NOT obstruct the flow of combustion or ventilation air When using Pipe Cement Primer follow the instructions included with the Cement Primer closely Clean and dry all applicable surfaces before applying Failure to follow these directions will result in substantial property damage seve...

Page 22: ...t and intake pipe In order to use 2 pipe it is required to reduce pipe size in a vertical length of pipe with a reducing coupling not included Follow the steps below to install 2 or 3 pipe into the appliance collar See Figure 8 for additional details 1 Clean and dry the appliance connection DO NOT use primer or cement on the appliance connection 2 Push the included 6 length of CPVC pipe into the c...

Page 23: ...roperly supported and the exhaust must be pitched a minimum of per foot back to the appliance to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the appliance and the balance at 4 foot intervals on the vent pipe Appliance venting must be readily accessible for visual inspection for the first three feet from the appliance ...

Page 24: ... 4 foot intervals on the vent pipe Appliance venting must be readily accessible for visual inspection for the first three feet from the appliance 3 Screen Installation After connecting the intake air and exhaust vent pipes it is required to install the included screens into the exhaust vent and intake pipe terminations to prevent damages to the unit due to blockages Clean the vent terminations and...

Page 25: ...tal input rating of all fuel burning appliances installed in that space Rooms connected directly to this space through openings not furnished with doors are considered part of the space Confined space is space with volume less 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 Rooms connected directly to th...

Page 26: ...26 WHL 015 REV 5 20 16 Figure 14 NOTE These drawings are meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes ...

Page 27: ... a disposal for waste water from the washing machine draining the condensate into this tub allows the soapy water discharge to neutralize the acidic condensate 5 An error will appear on the appliance display if condensate line is blocked The appliance will not operate with a blocked condensate line It is extremely important to have this condition repaired by a qualified service technician NOTE Thi...

Page 28: ... the appliance is set to operate on the provided gas supply could result in property damage personal injury or death A GAS PIPE SIZING TABLES 1 Gas Pipe Sizing This information is for reference use only Refer to gas pipe manufacturer specifications for actual delivery capacity The DOE standard for Natural Gas is 1100 BTU ft 3 Contact the local gas supplier for actual BTU ft 3 rating 2 Natural Gas ...

Page 29: ...ck Iron Pipe Refer to ANSI Z223 1 National Fuel Gas Code Latest Edition B GAS CONNECTION REQUIREMENTS 1 a On 140F models The gas connection fitting on the appliance is male NPT A X Bell Coupling has been provided with the appliance to aid installation NOTE The pipe size must not be less than b On 199F models The gas connection fitting on the appliance is male NPT NOTE The pipe size must not be les...

Page 30: ... Shut Off Valve Detail Figure 18 Natural Gas Piping Installation NOTE Capacity to be Not Less than Total Capacity of Connected Appliances Figure 19 LP Gas Piping Installation NOTE Capacity to be Not Less than Total Capacity of Connected Appliances ...

Page 31: ... connections are made Do not apply a torch within 12 of the appliance Doing so could damage the appliance Such damages ARE NOT covered by product warranty The size of the hot water pipe should be diameter and the central heating water pipe should be 1 in diameter To ease future maintenance isolation valves are recommended on both the CH and DHW loops All piping should be insulated Figure 20 Operat...

Page 32: ... 16 Figure 21 Piping Legend B DHW PIPING Use both thread tape and pipe dope to connect to the domestic water inlet and outlet A shut off valve between the city water supply and DHW inlet is recommended for ease of service ...

Page 33: ...ddition SUCH FAILURE IS NOT COVERED BY WARRANTY 2 The expansion tank must be located following recognized design methods See expansion tank manufacturer s instructions for details 3 Connect the expansion tank to the air separator only if the air separator is on the suction side of the circulator Always install the system fill connection at the same point as the expansion tank connection to the sys...

Page 34: ...flanges The alternative is standard flanges with full port ball valves Purge valves can be used with circulator flanges as an alternative 6 Piping shown is Primary Secondary System flow secondary loop must be greater than the appliance s primary loop flow 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 VERY IMPORTANT Minimum flow rates outlined in this manual mus...

Page 35: ...er and CH piping should be 1 in diameter 5 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with circulator flanges as an alternative 6 Piping shown is Primary Secondary System flow secondary loop must be greater than the appliance s primary loop flow 7 Install a minimum of 12 diameters of straight pipe upstream of...

Page 36: ...d be diameter and CH piping should be 1 in diameter 5 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with circulator flanges as an alternative 6 Piping shown is Primary Secondary System flow secondary loop must be greater than the appliance s primary loop flow 7 Install a minimum of 12 diameters of straight pipe ...

Page 37: ...ystem flow secondary loop must be greater than the appliance s primary loop flow 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 VERY IMPORTANT Minimum flow rates outlined in this manual must be maintained through the heat exchanger to minimize short cycling 9 Each heating zone of a pump based system has its own circulator with turns on when a zone thermostat cal...

Page 38: ...5 5 5 5 5 1 4 1 5 7 5 5 5 6 5 2 5 5 2 9 5 5 5 5 7 5 9 2 7 2 5 12 5 5 1 10 11 5 3 9 3 5 15 1 1 1 5 15 5 14 5 3 9 3 5 14 1 1 2 12 5 4 12 5 5 21 1 1 2 16 18 5 5 16 6 27 1 5 1 5 3 11 5 23 5 6 19 7 34 2 2 3 5 13 5 26 5 8 29 11 50 3 3 5 12 5 39 Table 18 Pressure Loss in Fittings and Valves Feet E PRESSURE RELIEF VALVE An external pressure relief valve must be installed on this appliance When installing ...

Page 39: ...e operation of the relief valve after filling and pressurizing the system by lifting the lever Make sure the valve discharges freely If the valve fails to operate correctly replace it with a new relief valve Test relief valve at least once annually to ensure the waterway is clear If valve does not operate turn the appliance off and call a plumber immediately Take care whenever operating relief val...

Page 40: ...al operation NOTE For additional electrical protection the use of a surge protector is recommended Damage caused by power surges is not covered by the warranty Figure 27 Manual Power Switch and Appliance Plug Details NOTICE If the appliance display does not come ON first check the plug Then check the electrical panel circuit breaker and reset it if necessary If the circuit breaker trips again do n...

Page 41: ...ING INTERVAL TIME 10 seconds POST PURGE TIME Tip 2 minutes 1 st 1 minute 2 nd 1 minute OVER HEATING 1 2 3 PROTECTION DETECTION TIME 3 seconds PUMP 1 POST CIRCULATING TIME T1pv 1 minute PUMP 2 POST CIRCULATING TIME T2pv 1 minute HIGH AND LOW WATER LEVEL DETECTION TIME 6 seconds HIGH AND LOW WATER LEVEL RECOVERY TIME 6 seconds Table 20 System Control Settings ...

Page 42: ...42 WHL 015 REV 5 20 16 Figure 29 140F Model Electrical Wiring Diagram ...

Page 43: ...43 WHL 015 REV 5 20 16 Figure 30 140F Model Ladder Diagram ...

Page 44: ...44 WHL 015 REV 5 20 16 Figure 31 199F Model Electrical Wiring Diagram ...

Page 45: ...45 WHL 015 REV 5 20 16 Figure 32 199F Model Ladder Diagram ...

Page 46: ...SELV 5V DC 2 RS485 3 GND 4 RS485 SELV 5V DC 5 RS485 CN4 LWD1140 06 1 FAN Unused 2 GND SELV 14V DC 3 VDD SELV 14V DC 4 Fan power start coil SELV 8 26 5V AC 5 Fan power end coil 6 Fan speed feedback signal SELV 14V DC CN8 SMW250 04 1 MCU ISP GND SELV 5V DC 2 ISP Reset Port 3 ISP TOOL0 Data Port 4 VCC CN11 LWD1140 16 1 HWL Not Used SELV 12V AC 8 2 LWL Low Water Level Leakage Sensor 10 3 HD Central He...

Page 47: ...sor 12 6 ST S Storage Temperature Sensor 13 7 SP S CH Over Heat Temperature Sensor 14 CN14 SMW250 09 1 DHM GND SELV 14V 2 DHM Stepper Motor Position 3 VDD 4 DHM Stepper Motor Coil X Phase 5 DHM Stepper Motor Coil Y Phase 6 VDD 7 DHM Stepper Motor Coil X Phase 8 DHM Power IWM Stepper Motor Coil Y Phase 9 Unused CN3 SMW250 06 4 FLUX1 VCC SELV 5V 5 Water Flow Sensor 6 GND CN5 SMW250 10 1 RPM Fan RPM ...

Page 48: ...48 WHL 015 REV 5 20 16 Figure 34 199F Terminal Block Wiring Detail PART 10 OPERATING SYSTEM INSTRUCTIONS A CONTROL PANEL Figure 35 Appliance Control Panel Detail ...

Page 49: ...r Display Remarks LCD Test 1 Sec All segments ON 0 5 Sec All segments OFF Category 140F 199F 1 Sec Pdn 1 Sec 0051 Software Version for Front Panel 1 Sec SPn 1 Sec 00 XX Software Version for Appliance 1 Sec SFn 1 Sec XX XX Hardware Version for Appliance 1 Sec Hdn 1 Sec 00XX Table 23 Start Up Sequence After start up the display appears as follows Figure 37 Initial Display Screen Example NOTE The ini...

Page 50: ...gh temperature will display High temperature DHW Set Point range is 121 140 o F 49 5 60 o C Turn the dial counterclockwise to lower and clockwise to raise the DHW set point After changing the temperature press the button to save the set point Hotter water increases the risk of scald injury Scalding may occur within 5 seconds at a setting of 140 o F 60 o C Water temperature over 125 o F can instant...

Page 51: ...using 0 10V the boiler will automatically change the target temperature based on input voltage NOTE If input voltage is less than 1 5V the 0 10V will be ignored G STORAGE MODE Storage Mode indicates that the appliance is heating stored water in the internal storage tank When Storage Mode is operating the display appears as follows Figure 40 Storage Mode Screen H STATUS DISPLAY MODE Status Display ...

Page 52: ...L rt 1 PH Burner Operation Time Supply power time L rt display on sub menu Unit 100 hour 2 rh Burner operation time Unit 1 hour 3 rH Burner operation time Unit 1 000 hour 4 It Ignition cycles Cycle 10 times 5 IH Ignition cycles Cycle 10 000 times P Ou Displays output condition for Internal recirculation pump and heating pump Items 1st 2nd 3rd Internal DHW Storage pump Internal CH Primary Pump Exte...

Page 53: ...0 o F and differential is 27 o F the appliance will turn on when CH water temperature falls below 153 o F Range 9 27 o F 15 OF 68 F Warm Weather Shutdown Warm weather shut down will shut down CH Mode if the programmed outdoor temperature is exceeded Range 50 110 o F 16 cH 180 F Maximum supply temperature Sets the maximum design supply temperature based on the minimum outdoor design temperature Max...

Page 54: ...e Ensure connection is secure 3 Check flame detection sensor Ensure connections are secure Normal operating settings are more than 2 5DC before ignition less than 2 5DC after ignition 4 Check vent terminations Ensure there are no blockages 5 Assure that the flame is stable when lit 6 If the problem persists replace the main control Er 11 Ignition has Failed 5 Five Times Press the Power button to c...

Page 55: ...Check sensor resistance If resistance is zero replace the sensor 3 Check exhaust vent for blockage 4 If the problem persists replace the main control Er 36 Abnormal Supply Voltage Supply voltage is too low to operate This Error Code will go away when supply voltage returns to normal operating range If Error happens again 1 Ensure appliance is properly wired to a power source meeting the requiremen...

Page 56: ...em persists replace the main control Er 76 Poor Communication This Error Code will go away when the condition is remedied If Error happens again 1 Check connections from main control to display panel 2 If the problem persists replace the display and or the main control Er 80 Low Water Level Sensor Low Water Level Detected Four 4 Consecutive times This Error Code will go away when the condition is ...

Page 57: ...57 WHL 015 REV 5 20 16 K ERROR TREE ANALYSIS 1 FLAME DETECTION Figure 44 Flame Detection Error Analysis Tree 2 GAS DETECTION Figure 45 Gas Detection Error Analysis Tree ...

Page 58: ... an exterior surface of the building preferably on the north side in an area that will not be affected by direct sunlight and will be exposed to varying weather conditions NOTE For correct mounting procedures follow instructions provided with the sensor NOTE If sensor wires are located in an area with sources of potential electromagnetic interference EMI the sensor wires should be shielded or the ...

Page 59: ...ms this manual Caution should be used to ensure that the 0 10 VOLT connection does not become connected to ground NOTE Ensure that the polarity of the connections from the external modulating boiler controller to the boiler is correct Reversed polarity could lead to erratic and or no response from the boiler controller NOTE Outdoor Temperature Mode Icon on the display will flash if an Outdoor Sens...

Page 60: ...tact an authorized technician or licensed professional Contaminant Maximum Allowable Level Contaminant Maximum Allowable Level Total Hardness 200 mg l 12 grains gallon Manganese 0 05 mg l Aluminum 0 05 to 0 2 mg l pH 6 5 8 5 Chloride 250 mg l Sulfate 205 mg l Copper 1 mg l Total Dissolved Solids TDS 500 mg l Iron 0 3 mg l Zinc 205 mg l Table 28 Water Quality Specifications Clean system to remove s...

Page 61: ...TO DO IF YOU SMELL GAS Do not try to light any appliance 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 gas shutoff valve located outside of the appliance so that the handle is crosswise to the gas pipe If t...

Page 62: ...ll zones are purged g Close the quick fill water valve and purge valve and remove the hose Open all isolation valves Watch the system pressure rise to correct cold fill pressure It is recommended that you put the pumps into manual operation to assist in purging the circuits h Disconnect the wires that are connected to the THERMOSTAT terminals of the terminal block Apply power to the appliance Afte...

Page 63: ...thorities may be purchased from Westinghouse 7450P 212 2 The appliance is provided with a X reducing coupling that must be installed on the appliance before the condensate is piped to a local drain It is very important that the minimum condensate line is sloped downward away from the appliance to a suitable inside drain If the condensate outlet on the appliance is lower than the drain you must use...

Page 64: ...9 It is required to use a combustion analyzer to verify final adjustment according to the combustion chart Table 29 Failure to do so could result in serious personal injury or death If the readings obtained are lower or higher than the combustion readings in Table 29 use a 4mm Allen key to adjust the offset screw in a clockwise positive or counterclockwise negative direction approximately 1 4 turn...

Page 65: ...a condensate pump and or neutralizer been installed 4 Gas Piping Has the gas supply line been piped in accordance with the methods listed in this manual supply line no less than in diameter length and diameter adequate to deliver the required BTUs union and shut off valve installed etc Does the gas type match the type indicated on the appliance rating plate Has gas supply line pressure been measur...

Page 66: ...62 4 28409 4 99200 5 48440 5 22152 5 74229 14 38045 14 17408 14 56090 23 30107 23 13782 23 42790 32 23998 32 10990 32 32930 41 19261 41 8824 41 25550 50 15562 50 7131 50 19990 59 12655 59 5800 59 15760 68 10353 68 4747 68 12510 77 8520 77 3906 77 10000 86 7051 86 3233 86 8050 95 5867 95 2690 95 6520 104 4908 104 2250 104 5310 113 4125 113 1891 113 4350 122 3485 122 1598 122 3590 131 2957 131 1356 ...

Page 67: ...ust the outlet water temperature refer to the procedure in this manual It takes a long time before hot water flows from the faucet Is the faucet some distance from the appliance a Allow time for the cold water already in the pipes to flow from the faucet b Have recirculation valves and or plumbing return line s installed and program the unit for recirculation mode The water is not hot enough Is th...

Page 68: ...care of the appliance as outlined in this manual must be performed by the user owner to assure maximum efficiency and reliability Follow the maintenance procedures given throughout this manual Failure to perform the service and maintenance or follow the directions in this manual could damage the appliance or system components resulting in substantial property damage severe personal injury or death...

Page 69: ...ct the primary pressure relief valve and discharge pipe for signs of weeping or leakage If the pressure relief valve often weeps the expansion tank may not be operating properly Immediately contact a qualified service technician to inspect the appliance and system Check Vent Condensate Drain System While the appliance is running check the discharge end of the condensate drain tubing Ensure no flue...

Page 70: ...ommended to flush the DHW heat exchanger annually if water hardness exceeds 12 grains per gallon considered extremely hard water If water hardness falls below 12 grains per gallon it is recommended to flush the heat exchanger every two to three years NOTE Improper maintenance WILL VOID appliance warranty 1 Disconnect electrical power to the appliance 2 Close the shutoff valves on both hot water ou...

Page 71: ...O NOT reinstall the trap Replace the entire assembly 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 appliance 7 Install the condensate trap on the condensate hose from the heat ex...

Page 72: ...M S 7855P 395 B 4 M4 X 8 TH MS 7855P 387 B 13 M4 X 20 TH Self Tapping 7855P 396 B 5 M4 X 10 FH M S 7855P 388 B 14 M5 X 14 Flange Bolts M S 7855P 397 B 6 M4 X 10 TH Self Tapping 7855P 389 B 15 M5 X 10 TH M S 7855P 453 B 7 M4 X 10 TH M S 7855P 390 B 16 M4 X 9 PH PW Self Tapping 7855P 296 B 8 M4 X 10 Flat Head 7855P 391 N 1 M4 Nut 7855P 398 B 9 M4 X 12 PH M S 7855P 392 N 2 M5 Nut 7855P 399 Table 35 R...

Page 73: ...I 7855P 080 12 7 Exhaust Duct Inner Adapter 7855P 080 29 CH Pressure Gauge 0 60PSI 7855P 013 12 8 Exhaust Adapter O Ring 75 Φ 7855P 013 30 Front Access Panel 7855P 128 13 Air Intake Cap Assembly 7855P 110 31 Cabinet 7855P 024 13 1 Air Intake Cap 7855P 111 32 Gas Inlet Adapter 7855P 223 13 2 Air Intake Inner Adapter 7855P 382 33 Wire Gland 7855P 348 14 Access Panel 7855P 348 34 CH Supply Adapter 78...

Page 74: ...74 WHL 015 REV 5 20 16 Figure 57 140F Model Heat Exchanger Replacement Parts NOTE See Replacement Parts List following page ...

Page 75: ...06 71 Condensate Collector Pan Clamp 34P 7855P 054 59 4 Burner Gasket 7855P 266 72 Condensate Hose EPDM 7855P 055 59 5 Ceramic Fiber Burner 7855P 069 73 Clamp 40P 7855P 056 59 6 Burner plate O Ring 7855P 249 74 Condensate Trap Assembly 7855P 053 59 7 Ignition Rod 7855P 068 74 1 Condensate Trap Supporting Clips 7855P 117 59 8 Igniter Gasket 7855P 252 75 Condensate Drain Hose 7855P 051 59 9 Heat Exc...

Page 76: ...as Valve 7855P 034 82 2 Fan O ring 7855 371 87 2 Gas Valve Bracket 7855P 096 82 3 Air Gas Mixer 7855P 027 87 3 Gas Valve O ring 7855 076 82 4 Air Intake Orifice Ø29 5 7855P 130 87 4 Gas Valve Inlet Adapter 7855 033 83 Fan Outlet Mesh 7855 299 88 Ignition Transformer 7855P 007 84 Burner Inlet Chanel Gasket 7855 370 89 Gas Inlet Pipe AL 7855P 091 85 Gas Orifice Nozzle NG 5 9 mm 7855 026 Gas Orifice ...

Page 77: ...55P 112 49 Mixing Valve 7855P 043 43 DHW Tank Clamp 7855P 113 50 DHW Inlet Pipe 7855P 046 44 Storage Temperature Sensor 7855P 057 51 DHW Flow Sensor 7855P 083 45 Water Storage Tank Bracket 7855P 058 52 Drain Pipe Connector 1 7855P 048 46 DHW Tank Cover B K 7855P 129 53 Drain Valve 7855P 049 47 Storage Tank Outlet Pipe 7855P 082 54 Drain Pipe Connector 2 7855P 050 Table 40 140F Model DHW Side Repla...

Page 78: ... 150PSI 7855P 080 12_7 Exhaust Duct Inner Adapter 7855P 004 29 CH Pressure Gauge 0 60PSI 7855P 013 12_8 Exhaust Adapter O Ring 75 Φ 7855P 254 30 Front Access Panel 7855P 110 13 Air Intake Cap Assembly 7855P 411 31 Cabinet 7855P 111 13 1 Air Intake Cap 7855P 337 32 Gas Inlet Adapter 3 4 7855P 382 14 Access Panel 7855P 005 33 Wire Gland 7855P 348 15 FLUE APS 7855P 133 34 CH Supply Adapter 7855P 023 ...

Page 79: ... Pipe 7855P 038 59 2 Burner Body 7855P 606 69 Storage Tank Outlet Pipe 7855P 039 59 3 Burner Gasket 7855P 419 70 Storage Tank Lower Inlet Pipe 7855P 040 59 4 Ceramic Fiber Burner 7855P 420 71 Condensate Collector Pan Clamp 34P 7855P 054 59 5 Ignition Rod 7855P 607 72 Condensate Hose EPDM 7855P 055 59 6 Igniter Gasket 7855P 252 73 Clamp 40P 7855P 056 59 7 Burner Overheat Switch 7855P 066 74 Condens...

Page 80: ... 426 88 2 Air Intake Hose 7855P 430 83 Fan and Mixer Assembly 7855P 427 88 3 Gas Valve O ring 7855P 076 83 1 Fan 7855P 025 88 4 Gas Valve 7855P 034 83 2 Fan O Ring 7855P 371 88 5 Gas Valve Outlet Adapter 7855P 232 83 3 Air Gas Mixer Inner Part 7855P 609 89 Gas Orifice NG 8 3 mm 7855P 610 83 4 Air Gas Mixer Gasket 7855P 428 Gas Orifice LP 6 2 mm 7855P 435 83 5 Air Gas Mixer Outer Part 7855P 608 90 ...

Page 81: ...et 7855P 112 49 Mixing Valve 7855P 043 43 DHW Tank Clamp 7855P 113 50 DHW Inlet Pipe 7855P 046 44 Storage Temperature Sensor 7855P 057 51 DHW Flow Sensor 7855P 083 45 Water Storage Tank Bracket 7855P 058 52 Drain Pipe Connector 1 7855P 048 46 Air Vent 7855P 063 53 Drain Valve 7855P 049 47 Storage Tank Outlet Pipe 7855P 114 54 Drain Pipe Connector 2 7855P 050 Table 44 199F Model DHW Side Replacemen...

Page 82: ...anty extends only to appliances utilized in heating applications that have been properly installed by qualified professionals based upon the manufacturer s installation instructions G It is expressly agreed between Westinghouse and the original consumer purchaser that repair replacement or refund are the exclusive remedies of the original consumer purchaser OWNER RESPONSIBILITIES To avoid the excl...

Page 83: ...ed even if credit is denied If all warranty conditions are satisfied Westinghouse will provide replacement parts to the retailer For questions about the coverage of this warranty please contact Westinghouse at the phone number stated below 1 774 417 6000 SERVICE LABOR AND SHIPPING COSTS This limited warranty does not extend to any shipping charges delivery expenses or administrative fees incurred ...

Page 84: ... in the appropriate locations on the appliance If applicable have all dip switches been set and verified to match system requirements 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 What is the drop on light off No more than 1 W C ____ in w c ...

Page 85: ...ng safeties Temperatures Verify safe settings on appliance or Anti Scald Valve Temperatures Verify programmed temperature settings ELECTRICAL Connections Check wire connections Make sure they are tight Smoke and CO detector Verify devices are installed and working properly Change batteries if necessary Circuit Breakers Check to see that the circuit breaker is clearly labeled Exercise circuit break...

Page 86: ...86 WHL 015 REV 5 20 16 ...

Page 87: ...87 WHL 015 REV 5 20 16 ...

Page 88: ...88 WHL 015 REV 5 20 16 MAINTENANCE NOTES ...

Page 89: ...te of Installation Installer s Code Name Product Serial Number s Combustion Setting at Time of Installation Comments Installer s Phone Number Signed by Installer Signed by Customer IMPORTANT NOTES Customer Please only sign after the installer has reviewed the installation safety proper operation and maintenance of the system In the case that the system has any problems please call the installer If...

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