Westinghouse WBRU 100W Series Installation, Start-Up And Maintenance Instructions Download Page 78

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WHL-032 REV. 6.2.16

Figure 62

– Cabinet Replacement Parts – 175 – 199W Models

NUMBER

DESCRIPTION

PART

NUMBER

DESCRIPTION

PART

NUMBER

Cabinet Assembly

7855P-410

Air Vent Adapter

7855P-453

Top Wall Mount Bracket

7850P-068

8-1

Air Vent Grommet

7855P-339

Bottom Wall Mount Bracket

7850P-092

Control Board Bracket

7855P-412

Exhaust Adapter Sealing Gasket

7850P-041

Air Pressure Switch

7855P-262

Exhaust Duct (Assembly)

7855P-002

Ignition Transformer

7855P-007

5-1

Exhaust / Intake Duct Clamps

7855P-332

Display Panel Bracket

7855P-413

5-2

Exhaust / Intake Gaskets

7850P-210

Terminal Blocks Bracket

7855P-434

5-3

Exhaust Duct

7855P-333

Control Board

175W

7855P-404

199W

7855P-405

5-4

Combustion Analyzer Port Plug O-Ring

7855P-334

Display Panel

7855P-344

5-5

Combustion Analyzer Port Plug

7855P-335

Manual Power Switch

7855P-014

5-6

Intake and Exhaust Adapter O-Ring

7855P-256

Condensate Block APS

7855P-017

5-7

Exhaust Duct Inner Adapter

7855P-004

Terminal Block

7855P-345

5-8

Exhaust Adapter O-Ring

7855P-254

Transformer

7855P-346

Air Intake Assembly

7855P-411

Cabinet Front Cover

7855P-414

6-1

Air Intake Cap

7855P-337

Display Panel Cover

7850P-023

6-2

Air Intake Inner Adapter

7855P-004

Wire Gland

7855P-348

Air Vent

7855P-063

CH Pressure Gauge

7855P-222

Table 36

– Cabinet Replacement Parts – 175 – 199W Models

Summary of Contents for WBRU 100W Series

Page 1: ... 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 BOILER 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...

Page 2: ...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 SAFETY INSTRUCTIONS NOTICE is used to address practices not related to personal injury SA...

Page 3: ...ould be given to the National Fuel Gas Code ANSI Z223 1 2002 INSTALLATIONS MUST COMPLY WITH Authority Having Jurisdiction 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...

Page 4: ...iple appliance system having a total input of 300 000 BTU hr or greater This appliance is equipped with a tankless coil NOTICE 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 off the fuel supply when system water reaches a preset operating temperature c a high temp...

Page 5: ...3 E VENT TERMINATION 24 1 Direct Vent Two Pipe Roof and Sidewall Vent Terminations 24 2 Direct Vent Optional Horizontal and Vertical Vent Kits 25 3 Snorkel Venting 26 4 Power Vent Indoor Combustion Air Installation in Confined or Unconfined Space 27 5 Screen Installation 29 PART 6 INSTALL THE CONDENSATE DRAIN 29 PART 7 GAS PIPING 30 A ADDITIONAL PRECAUTION FOR EXCESS FLOW VALVE EFV 31 B GAS PIPE S...

Page 6: ...ERROR TREE ANALYSIS 63 1 FLAME DETECTION 63 2 GAS DETECTION 63 3 APS BURNER OVERHEAT LIMIT CONDENSATE BLOCK SWITCH 64 4 STORAGE OP CH OVERHEAT EXHAUST OVERHEAT SENSORS 64 PART 11 START UP PREPARATION 64 A BOILER WATER CHEMISTRY 65 B GLYCOL ANTIFREEZE SOLUTIONS 65 C CHECK FOR GAS LEAKS 65 D FILL AND TEST WATER SYSTEM 66 E PURGE AIR FROM SYSTEM 67 F CHECK THERMOSTAT CIRCUIT S 67 G CONDENSATE REMOVAL...

Page 7: ...nuals 1 Each Condensate Hose Part 7855P 089 1 Anchors and Wall Mounting Bracket Part 7850P 084 4 Outdoor Sensor with Screws and Anchors Part 7855P 084 1 Spare Parts Kit Gaskets and O Rings Part 7855P 383 1 30 PSI Pressure Relief Valve Part 7855P 077 1 1 X 1 X Tee steel Part 7855P 313 3 4 Street Elbow steel Part 7350P 084 1 3 CPVC Part 7855P 101 6 Length Vent Screens 3 Part 7855P 085 2 Screens Tabl...

Page 8: ...usting the low fire offset on the gas valve in even 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 flue gas analyzer Failure to follow these statements will result in property damage severe personal injury or death This...

Page 9: ...th NOTICE Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee This boiler provides a overheat shutdown limit In the event the boiler water exceeds the set point of the control limit the cutoff will trip and the boiler will shut down Certain local codes require additional temperature limits In addition certain types of systems ...

Page 10: ...tial property damage Do not use homemade cures or boiler patent medicines Substantial property damage damage to boiler and or serious personal injury may result Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen from make up water can cause internal corr...

Page 11: ...40 PVC CPVC PP Weight lbs 90 100 110 Gas Supply Pressure NG 3 5 to 14 WC LP 3 5 to 14 WC Power Supply Main Supply 120V 60 Hz 6a Maximum Power Consumption 160W General Operating Conditions Temperature Ambient Temperature Range 33 104 o F 0 6 40 o C Operating Relative Humidity Up to 90 at 140 o F 40 o C Shipping and Storage Temperature Range 4 176 o F 20 80 o C Input Ratings Power Supply and Communi...

Page 12: ... Adapter D Condensate Adapter E Intake Pipe Connection 3 F Exhaust Vent Connection 3 MODEL G H I J K L M N O P Q R S T U V W X 80W 100W 17 5 28 75 34 7 9 5 3 3 5 2 4 5 8 11 7 14 9 3 0 9 8 2 1 2 7 10 7 14 1 10 5 15 4 120W 140W 175W 199W 19 7 31 9 37 7 2 5 1 3 2 3 75 5 8 12 5 17 5 4 0 11 1 2 1 2 2 11 7 15 8 11 8 16 8 Table 4 Specifications ...

Page 13: ...ure Gauge 32 Automatic Air Vent Table 5 Component List How the Boiler Operates Condensing technology intelligently delivers hydronic heating while maximizing efficiency Outlined below are the features of the system and how they operate Stainless Steel Heat Exchanger The highly efficient 316L stainless steel fire tube heat exchanger with internal aluminum is designed to extract all available heat f...

Page 14: ...in the heat exchanger optic flame sensor monitors flame quality Flue Sensor monitors flue temperature Condensate Pressure Switch monitors pressure to ensure condensation does not back up into boiler Manual Air Vent Each boiler is equipped with an air vent to discharge air from the system during start up Intake and Exhaust Adapters The boiler is equipped with adapters to ease connection to the vent...

Page 15: ...still cannot be met the Master will continue firing more Followers until either the heat demand is met or all boilers on the Cascade are firing As the heat demand decreases all boilers on will modulate down according to the heating load The first boiler to modulate down to 40 will shut off The same principle will be applied to the remaining boilers in operation until the heating demand or system s...

Page 16: ... and property damage and could result in serious personal injury or death 2 Check for nearby connections to System water piping Venting connections Gas supply piping Electrical power Condensate drain Locate the boiler where any leakage from the relief valve related piping tank or connections will not result in damage to surrounding areas or lower floors of the building The boiler should be located...

Page 17: ...consideration when locating the boiler If the boiler is located in an installation location with limited clearances it may be necessary to remove the boiler 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 ...

Page 18: ...CTS 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 Refrigeration repair shops Sodium chloride used for water softening Photo processing plants R...

Page 19: ... 110 lbs when fully plumbed and full of water Installing the boiler on a wall which cannot support its weight could result in property damage personal injury or death The boiler may be installed on any suitable internal wall suitable sound proofing may be required when installing onto a stud partition wall This boiler is too heavy for one person to lift It is highly recommended to install the boil...

Page 20: ...listed system must not be interchanged with other vent systems or unlisted pipes or fittings All plastic components and specified primers and glues must be from a single system manufacturer and must not be intermixed with another system manufacturer s products Clean and dry all applicable surfaces before applying cement 3 This appliance is designed to be installed in a power vent using indoor air ...

Page 21: ...h deck or balcony 1 foot 1 foot B Clearance to window or door that may be opened 1 foot 3 feet C Clearance to permanently closed window D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside corner G Clearance to inside corner H Clearance to each side ...

Page 22: ...sing adapters specifically designed for the purpose by the manufacturer Covering non metallic vent pipe and fittings with thermal insulation is prohibited 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...

Page 23: ...FORE venting the boiler could result in product damage severe personal injury or death This boiler uses 3 diameter adapters for exhaust vent 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 3 pipe into the boiler adapter See Figure 7 for details 1 Clean and dry the boiler c...

Page 24: ...ued properly supported and the exhaust must be pitched a minimum of per foot back to the boiler to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the boiler and the balance at 4 foot intervals on the vent pipe Boiler venting must be readily accessible for visual inspection for the first three feet from the boiler ...

Page 25: ...ly supported and the exhaust must be pitched a minimum of per foot back to the boiler to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the boiler and the balance at 4 foot intervals on the vent pipe Boiler venting must be readily accessible for visual inspection for the first three feet from the boiler ...

Page 26: ...r intake C Maintain 12 minimum clearance above highest anticipated snow level or grade whichever is greater D Minimum 12 between vents when installing multiple vents E 12 minimum beyond air intake All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of per foot back to the boiler to allow drainage of condensate When placing support brackets on vent piping the f...

Page 27: ...s per kW of the total 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 connec...

Page 28: ...28 WHL 032 REV 6 2 16 Figure 13 1 13 2 NOTE These drawings are meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes ...

Page 29: ... Canadian applications use CSA or ULC certified PVC or CPVC pipe fittings and cement 3 Local building codes may require an in line neutralizer to be installed not included to treat the condensate Follow all the installation instructions included with the neutralizer If a neutralizer is installed periodic replacement of the limestone or neutralizing agent will be required The rate of depletion of t...

Page 30: ... for use with condensing boilers and furnaces The pump should have an overflow switch to prevent property damage from condensate spillage It is very important that the condensate piping be no smaller than To prevent sagging and maintain pitch condensate piping should be supported with pipe supports and pitched per foot to allow for proper drainage The condensate line must remain unobstructed allow...

Page 31: ... Pipe Sch 40 Metallic in Feet Pipe Size Cubic Feet per Hour 0 60 Specific Gravity 0 5 WC Pressure Drop 10 20 30 40 50 60 80 100 150 200 360 247 199 170 151 137 117 104 83 71 1 678 466 374 320 284 257 220 195 157 134 1 1390 957 768 657 583 528 452 400 322 275 1 2090 1430 1150 985 873 791 677 600 482 412 2 4020 2760 2220 1900 1680 1520 1300 1160 928 794 2 6400 4400 3530 3020 2680 2430 2080 1840 1480...

Page 32: ...y line measure the size of the supply line according to the COMBINED total maximum BTUH draw for the appliances as if they were operating at the same time 3 Measure the length of the gas supply line from the gas meter to the water heater Water heater must be installed downstream of the gas meter to ensure adequate gas supply Use the tables in this manual or refer to the gas line manufacturer s siz...

Page 33: ...ould damage the boiler Such damages ARE NOT covered by product warranty See Table 16 for minimum CH pipe sizing To ease future maintenance isolation valves are recommended on both the CH and DHW loops All piping should be insulated Use at least the MINIMUM pipe size for connecting the boiler Failure to follow these guidelines could result in system problems increased installation cost and possible...

Page 34: ... wasted time money and possible property damage personal injury or death Undersized expansion tanks cause system water to be lost from the relief valve causing make up water to be added Eventual boiler failure can result due to excessive make up water addition SUCH FAILURE IS NOT COVERED BY WARRANTY 2 The expansion tank must be located following recognized design methods See expansion tank manufac...

Page 35: ...d FT Flow Rate GPM Head FT Flow Rate GPM Head FT 80W 1 7 6 3 1 5 1 1 8 3 8 1 2 100W 9 5 4 7 6 3 2 3 4 8 1 7 120W 11 4 5 4 7 6 2 5 5 7 1 6 140W 13 3 7 3 8 9 3 5 6 7 2 1 175W 1 16 6 8 5 11 1 4 0 8 3 2 5 199W 18 9 11 0 12 6 5 0 9 5 3 0 Table 16 Boiler Flow Rates MODEL Number of Units Cascaded 2 3 4 5 6 7 8 80W 1 1 1 2 2 2 3 100W 1 1 2 2 2 3 3 120W 1 1 2 2 3 3 3 140W 1 1 2 3 3 3 3 175W 1 1 3 3 3 3 3 1...

Page 36: ...rs 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 Install a minimum of 12 diameters of straight pipe upstream of all circulators 7 VERY IMPORTANT Minimum flow rates outlined in this manual must be maintained through the heat exchanger to minimize short cycling 8 In a valve based sy...

Page 37: ...inimum pipe size of DHW piping should be diameter See Table 16 for minimum CH pipe sizing 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 Install a minimum of 12 diameters of straight pipe upstream of all circulators 7 VERY IMPORTANT Minimum flow rates outlined in this...

Page 38: ...all 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 boiler 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 cy...

Page 39: ... 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 boiler s primary loop flow 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 VERY IMPORTANT Minimum f...

Page 40: ...e sizing 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 boiler s primary loop flow 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 VERY IMPORTANT M...

Page 41: ...l 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 boiler 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 ...

Page 42: ...42 WHL 032 REV 6 2 16 Figure 28 Wiring Zoning with Zone Valves and Indirect Water Heating Figure 29 Wiring Zoning with Pumps and Indirect Water Heating ...

Page 43: ...l parts Discharge line shall terminate plain not threaded with a material serviceable for temperatures of 375 o F or greater Do not pipe discharge to any location where freezing could occur No shutoff valve may be installed between the relief valve and boiler or in the discharge line Do not plug or place any obstruction in the discharge line Test the operation of the relief valve after filling and...

Page 44: ...Humidity Up to 90 at 104 o F 40 o C B WIRING INFORMATION 1 This boiler must be properly grounded Ensure the electrical outlet 120V 15 Amp minimum that the boiler will be plugged into is properly grounded 2 Do not attach the ground wire to either the gas or water piping as plastic pipe or dielectric unions may isolate the boiler electrically This boiler is equipped with a three prong plug It should...

Page 45: ...DIP SWITCH GROUP DIP SWITCH OFF ON 1 3 NOT USED NOT USED 4 Vent Size 2 3 5 Gas Type LP NG 6 High Fire Normal Operation High Fire 7 Low Fire Normal Operation Low Fire Table 18 DIP Switches 4 7 SYSTEM CONTROL SETTINGS MAXIMUM FLAME DETECTING VOLTAGE 2 4V PRE PURGE TIME Tp Maximum 10 seconds minimum 1 second SAFETY TIME IGNITING TIME Ts 3 5 seconds IGNITING INTERVAL TIME 20 seconds POST PURGE TIME Ti...

Page 46: ...or sensor 0 10V should be wired to the low voltage terminal strip marked for the outdoor sensor 0 10V If the outdoor sensor 0 10V is connected the Master control will calculate the water temperature set point based on the programmed reset curve parameters If the outdoor sensor 0 10V is not connected the Master control will maintain the fixed water temperature set point programmed into the control ...

Page 47: ...47 WHL 032 REV 6 2 16 Figure 38 Electrical Wiring Diagram ...

Page 48: ...48 WHL 032 REV 6 2 16 Figure 39 Ladder Diagram ...

Page 49: ...S485 Cascade Connection SELV 5V DC 2 RS485 3 4 RS485 5 RS485 CN4 LWD1140 06 1 FAN NOT USED 2 GND SELV 14V DC 3 VDD 4 Fan power start coil SELV 8 26VAC 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 9 2 LWL Water Level Sensor 10 3 HD Central Heating Demand T T...

Page 50: ...3 DH S Exhaust Temperature Sensor 10 4 I S Return Water Temperature Sensor 11 5 BG S External DHW Temperature Sensor Aquastat 12 6 ST S External System Temperature Sensor 13 7 SP S Over Heat Temperature Sensor 14 CN14 SMW250 09 1 9 IWM NOT USED SELV 5V CN3 SMW250 06 1 6 FLUX1 NOT USED CN5 SMW250 10 1 RPM Fan RPM Check 2 GND Table 21 Boiler Wiring 2 Figure 41 Low Voltage Wiring Detail ...

Page 51: ...ay has timed out for approximately 2 minutes C START UP SEQUENCE After the boiler is powered ON the LCD display shows a sequence of information The icons will flash followed by various indicators that describe the boiler controller and software versions It will take the boiler roughly 15 seconds to cycle through the Start Up Sequence NOTE When the boiler is powered ON the fan will operate at maxim...

Page 52: ... the Set Point Temperature Changing the Time Status Display Mode Installer Mode Error Mode Outdoor Temperature Mode D CHANGING THE CH SET POINT Press the button when the display panel is powered ON The display will appear as follows The set point will flash when the CH Set Point can be changed Figure 45 CH Set Point Screen Factory CH Set Point is 180 o F 82 o C CH Set Point range is 86 180 o F 30 ...

Page 53: ...kwise and clockwise to scroll through the displayed parameters To view parameter details press the button at the appropriate screen Press the or buttons to leave the parameter Press the button again to return to Operation Mode To turn on Lock Mode press the button at the d Lc parameter Turn the dial counterclockwise or clockwise to scroll On or Off Press the button to save the selection and return...

Page 54: ... boilers are connected and communicating the maximum cascade power is 800 Range 0 100 F1 F19 Capacity of individual boilers percentage This icon will only be displayed when the units are in cascade mode Percentage of each cascade units running Ex M F1 F2 N St System Temperature Cascade Mode If Sensor is Not Connected Screen will Display 0F or 0C NOTE This index will only be shown in cascade mode C...

Page 55: ...the Outdoor Temperature reset curve Range 5 15F Default 10F 11 bl 20 MIN Boost Interval Sets the interval time when the boiler will increase the temperature by the Boost Degree Ex Initial Boost 10F After 20 MIN Interval Boost will increase CH set point temperature another 10F After another 20 MIN Interval Boost will increase CH set point temperature another 10F This will continue until the boiler ...

Page 56: ...de System temperature Range 95F 180F 32 Cd 10 F Cascade System Temperature Differential burner ON Cascade System Temperature Differential burner ON Range 5 30 F 33 HA HA 0 High Elevation Mode This boiler may be installed at elevations up to 10 000 feet and operate on either Natural or LP The appliance will de rate by 4 for each 1000 feet above sea level Select the appropriate installation location...

Page 57: ...ecure 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 clear the Error Code If E...

Page 58: ...sists replace the main control Er 32 DHW Sensor Short NOTE This error will only appear if an aquastat is installed and SEnS is selected in Installer Mode 39 or a sensor is used and it is shorted This Error Code will go away if an aquastat is installed AquA is selected in Installer Mode 39 and the boiler is powered OFF and ON or the DHW sensor is repaired or replaced 1 Check DHW sensor If an aquast...

Page 59: ...heck the boiler cover Ensure it is secure Flame detection sensor can detect an external light source 2 Check flame detection sensor Ensure connections are secure Normal operating settings are more than 2 5DC before ignition less than 2 5DC after ignition 3 If the problem persists replace the main control Er 76 Poor Communication This Error Code will go away when the condition is remedied If Error ...

Page 60: ...cuit breaker to power boiler Is there 120V at the service switch Troubleshoot and correct the power supply to the manual switch Is the ON OFF switch inside the boiler cabinet is turned on Turn ON the manual power switch inside the boiler cabinet Check for 120V at the line voltage terminal block located inside the boiler cabinet Correct wiring inside the boiler cabinet using the wiring diagram in t...

Page 61: ...on required if an outdoor sensor is not used in the installation 1 Use a minimum 22 AWG wire for runs of 100 feet or less and minimum 18 AWG wire for runs of up to 150 feet 2 Mount the outdoor sensor on 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 ...

Page 62: ... not connected to the boiler 0 10 V INPUT TABLE When outside voltage is applied to the connector 2 in the wiring diagram 1 The Outdoor temperature sensor does not work 2 Symbol is displayed 3 The heating temperature is automatically set according with the external voltage input NOTE 0 10V is prioritized over T T If input voltage is less than 1 5V then T T will operate The range of input voltage is...

Page 63: ...63 WHL 032 REV 6 2 16 M ERROR TREE ANALYSIS 1 FLAME DETECTION Figure 52 Flame Detection Error Analysis Tree 2 GAS DETECTION Figure 53 Gas Detection Error Analysis Tree ...

Page 64: ...ystem to remove sediment 1 You must thoroughly flush the system without the boiler connected to remove sediment The high efficiency heat exchanger can be damaged by buildup or corrosion due to sediment 2 For zoned systems flush each zone separately through a purge valve If purge valves and isolation valves are not already installed install them to properly clean the system 3 Check return Y straine...

Page 65: ...of this manual ACIDITY 6 to 8 pH CONDUCTIVITY Less than 400 uS cm at 25 o C CHLORIDE Less than 100 ppm IRON Less than 0 5 mg L COPPER Less than 0 1 mg L SODIUM Less than 20 mg L HARDNESS Less than 7 Grains Table 28 Water Quality Requirements B GLYCOL ANTIFREEZE SOLUTIONS Use only inhibited propylene glycol solutions which are specially formulated for hydronic systems Ethylene glycol is toxic and c...

Page 66: ...nt condensate trap control replacement etc Failure to follow these instructions could result in property damage serious personal injury or death If you discover any evidence of a gas leak shut down the boiler at once Find the leak source with a bubble test and repair immediately Do not start the boiler again until the leak is repaired Failure to comply could result in substantial property damage s...

Page 67: ...out all entrapped air Some good indicators that air is removed include the absence of gurgling noises in the pipes and pump operation becoming very quiet Test mode will stop automatically after the set time default is five minutes or press the button to leave it manually m Then use the dial to scroll to cP2 off Press the button to turn on test mode Turn the dial counterclockwise to lower or clockw...

Page 68: ...2 Fill the condensate trap with water 3 Verify electrical connections are correct and securely attached 4 Inspect exhaust vent and intake piping for signs of deterioration from corrosion physical damage or sagging Verify exhaust vent and intake piping are intact and correctly installed per Venting Section this manual and local codes I ADJUSTING GAS PRESSURE AT THE BOILER NOTE Refer to Figure 56 wh...

Page 69: ... with those stated in Table 29 NOTE If the boiler makes a whistling sound harmonics at low fire adjust the offset screw in a clockwise positive direction approximately 1 8 turn Check your combustion values and ensure they agree with those stated in Table 29 before proceeding It is very important that the installation be set within the recommended CO measurements listed in Table 29 Visually looking...

Page 70: ...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 boiler rating plate Has gas supply line pressure been measured between 3 5 and 14 WC Has the gas supply line been leak tested per lo...

Page 71: ...3782 23 42790 59 15711 32 23998 32 10990 32 32930 68 12493 41 19261 41 8824 41 25550 77 10000 50 15562 50 7131 50 19990 86 8056 59 12655 59 5800 59 15760 95 6530 68 10353 68 4747 68 12510 104 5324 77 8520 77 3906 77 10000 113 4365 86 7051 86 3233 86 8050 122 3599 95 5867 95 2690 95 6520 131 2982 104 4908 104 2250 104 5310 140 2483 113 4125 113 1891 113 4350 149 2079 122 3485 122 1598 122 3590 158 ...

Page 72: ...re to perform the service and maintenance or follow the directions in this manual could damage the boiler or system components resulting in substantial property damage severe personal injury or death Check the Surrounding Area To prevent the potential of substantial property damage severe personal injury or death eliminate all the materials listed in Table 7 from the area surrounding the boiler an...

Page 73: ... near the opening If you notice flue gas leaking from the opening this indicates a dry condensate drain trap If problem persists contact a qualified service technician to inspect the boiler and condensate line and refill the condensate trap If applicable check the condensate neutralizer and ensure it is full of condensate neutralizing marble chips Check Primary and Gas Piping Remove the boiler cov...

Page 74: ...s D3 to the circulation pump outlet and the cold water inlet line to valve V4 Connect the other hose D2 to the circulation pump inlet and place the free end in the bucket 4 Pour tankless cleaning solution into the bucket Use an FDA approved cleaner for potable systems on the heat exchanger Place the drain hose D1 and hose D2 to the pump inlet in the cleaning solution 5 Open service valves V3 and V...

Page 75: ... the condensate trap from the drain tube Do not operate the boiler without the clear hose attached from the hose barb to the pressure switch Failure to follow this warning could result in property damage serious personal injury or death 8 If a condensate neutralizer kit is installed with the boiler check the assembly when cleaning the condensate trap and replenish the limestone chips if necessary ...

Page 76: ...B 3 M4 X 8 TH Self Tapping 7855P 386 B 12 M4 X 15 PW 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 N 1 M4 Nut 7855P 398 B 8 M4 X 10 Flat Head 7855P 391 N 2 M5 Nut 7855P 399 B 9 M4 X 12 PH M S 7855P 39...

Page 77: ... 7850P 210 14 Control Board 80W 7855P 308 100W 7855P 309 120W 7855P 310 140W 7855P 311 5 3 Exhaust Duct 7855P 333 15 Display Panel 7855P 344 5 4 Combustion Analyzer Port Plug O Ring 7855P 334 16 Manual Power Switch 7855P 014 5 5 Combustion Analyzer Port Plug 7855P 335 17 Condensate Block APS 7855P 017 5 6 Intake and Exhaust Adapter O Ring 7855P 256 18 Terminal Block 7855P 345 5 7 Exhaust Duct Inne...

Page 78: ...7850P 210 13 Terminal Blocks Bracket 7855P 434 5 3 Exhaust Duct 7855P 333 14 Control Board 175W 7855P 404 199W 7855P 405 5 4 Combustion Analyzer Port Plug O Ring 7855P 334 15 Display Panel 7855P 344 5 5 Combustion Analyzer Port Plug 7855P 335 16 Manual Power Switch 7855P 014 5 6 Intake and Exhaust Adapter O Ring 7855P 256 17 Condensate Block APS 7855P 017 5 7 Exhaust Duct Inner Adapter 7855P 004 1...

Page 79: ...7 CH Supply Pipe 80W 100W 7855P 358 120W 140W 7855P 353 120W 140W 7855P 359 32 1 Burner Body Assembly 7855P 354 37 1 CH Supply Pipe Gasket 7855P 074 32 2 Burner Overheat Sensor 7855P 066 38 CH Return Pipe 7855P 361 32 3 Burner Body 7855P 067 38 1 CH Return Pipe Gasket 7855P 074 32 4 Burner Gasket 7855P 266 39 CH Return Sensor 7855P 097 32 5 Ceramic Fiber Burner 7855P 069 39 1 CH Return Sensor Gask...

Page 80: ...et 7855P 418 35 Flame Sensor 7855P 031 32 Heat Exchanger Assembly 7855P 416 36 Flame Sensor Bracket 7855P 356 32 1 Burner Body Assembly 7855P 417 36 1 Flame Sensor Cover 7855P 357 32 2 Burner Overheat Sensor 7855P 066 37 CH Supply Pipe 7855P 421 32 3 Burner Body 7855P 606 37 1 CH Supply Pipe Gasket 7855P 074 32 4 Burner Gasket 7855P 419 38 CH Return Pipe 7855P 422 32 5 Ceramic Fiber Burner 7855P 4...

Page 81: ...Pipe to Gas Valve 7855P 380 48 Fan 7855P 025 59 Gas Valve Assembly 7855P 381 49 Fan O Ring 7855P 371 59 1 Gas Valve Outlet Adapter 7855P 232 50 Mixer Model NG LP 59 2 Gas Valve O Ring 7855P 076 80W 7855P 300 7855P 301 100W 7855P 302 7855P 303 120W 7855P 316 7855P 305 140W 7855P 317 7855P 307 51 Air Intake Hose Top Clamp 7855P 372 59 3 Gas Valve 7855P 034 52 Air Intake Hose 80W 100W 7855P 373 59 4 ...

Page 82: ...nlet Adapter 7850P 077 50 Fan and Mixer Assembly 7855P 427 55 5 Gas Valve Bracket 7855P 436 50 1 Fan 7855P 025 56 Gas Pipe Gasket 7855P 221 50 2 Fan O Ring 7855P 371 57 Gas Orifice NG 8 3 mm 7855P 610 50 3 Air Gas Mixer Inner Part 7855P 609 Gas Orifice LP 6 3 mm 7855P 435 50 4 Air Gas Mixer Gasket 7855P 428 58 Gas Pipe to Mixer 7855P 432 50 5 Air Gas Mixer Outer Part 7855P 608 59 Gas Pipe to Gas V...

Page 83: ...allation 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 exclusion list in this warranty the owner or installer must 1 Maintain the boiler in accordance with the maintenance procedure listed in the manufacturer s provided...

Page 84: ...t 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 by the owner in repairing or replacing the boiler or part s This warranty does not extend to labor costs ...

Page 85: ...ssure 3 5 to 14 W C ____ in w c Static Locate the stickers in the appropriate locations on the boiler If applicable have all dip switches been set and verified to match system requirements What is the drop on light off No more than 1 W C ____ in w c Dynamic 4 Venting Has the boiler been vented with 3 PVC CPVC Polypropylene or AL294C Stainless for Cat IV boilers Ensure no ABS or PVC Cellular core h...

Page 86: ...eratures Indirect Verify boiler settings or Anti Scald Valve settings Temperatures Boiler 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 breaker...

Page 87: ...87 WHL 032 REV 6 2 16 ...

Page 88: ...88 WHL 032 REV 6 2 16 ...

Page 89: ...89 WHL 032 REV 6 2 16 MAINTENANCE NOTES ...

Page 90: ...e 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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Westinghouse WBRU 100W Series, Installation, Start-Up And Maintenance Instructions

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