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Westinghouse WBRCNG140F Installation Manual

1. NUMBER DESCRIPTION NUMBER NUMBER DESCRIPTION NUMBER 31 Fan Assembly 5 51 Flow Sensor Clip 7855P 042 31 1 Fan 7855P 025 52 Flow Sensor O Ring 7855P 047 31 2 A Gas Orifice Nozzle NG 7855P 024 53 DHW Flow Sensor 7855P 083 31 2 B Gas Orifice Nozzle LP 7855P 079 54 Drain Pipe Connector 1 7855P 048 31 3 Air Gas Mixer 7855P 027 55 Drain Valve 7855P 049 32 1 Outlet Gas Pipe 7855P 090 56 Drain Pipe Connector 2 7855P 050 32 2 Inlet Gas pipe 7855P 091 57 Condensate Drain Hose 7855P 051 33 7855 029 58 Condensate Outlet Fitting 7855P 052 34 Flame Sensor 7855P 031 59 Condensate Trap ASSY 7855P 053 35 CH Supply Temperature Sensor 7855P 030 60 Condensate Trap Inlet Clamp 7855P 054 36 Gas Valve ASS Y 7855P 032 61 Condensate Hose EPDM 7855P 055 36 1 Gas Outlet 7855 033 62 Condensate Collector Pan Clamp 7855P 056 36 2 Gas Valve 7855P 034 63 Storage Temperature Sensor 7855P 057 37 CH Water Supply 1 Upper 7855P 036 64 Water Storage Tank Bracket 7855P 058 38 CH Water Supply 2 Lower 7855P 037 65 DHW Tank ASSY 7855P 059 39 Internal Primary CH Pump 7855P 081 66 Heat A Bolt Set 7855P 060 40 CH Return Pipe 7855P 038 67 Condensate Collector Pan 7855P 061 41 1 Storage Tank Outlet Pipe Upper 7855P 039 68 Air Vent Pipe 7855P 062 41 2 Storage Tank Inlet Pipe Lower 7855P 040 69 Air Vent 7855P 063 42 Internal DHW Circulation Pump 7855P 081 70 Heat Exchanger ASSY 7855P
2. se scdeetoesdenesenteesnduvedeaeenneceondessueeetnerscedededeesuaseccaeduaeeeeees 26 GAS CONNECTION 26 8 a aeaea Laaa iaa 27 GENERAL PLUMBING CONNECTION GUIDELINES 27 28 CENTRAL HEATING PIPING SYSTEM WATER PIPING 8 20 200 0000400 00 29 D CIRGULATOR SIZING a E a e EE a raa a 32 F PRESSURE hh oe ees 33 PART 9 CONNECT ELECTRICAL POWER INITIAL STARTUP s csseeeseeeeeeeeeeaeeeneeeeeeeeeeseeeaeeeaeeeeesseeseeeseeeneeeeaeenaeeees 34 A GENERAL OPERATING CONDITIONS chin succeeds Mi he A Ye ee ee 34 22 ten teed yee nea ee teh cede et ie 34 C DIP SWITCHES lesen ite abba ele eval ev a deci ee A ae a 35 PART 10 OPERATING SYSTEM INSTRUCTIONS ccsccesceeeeeeeeeeeeeeeeeeeeese
3. ede 20 ALLOWED COMBINED VENT LENGTH S 20 D TIGHTENING APPLIANCE COLLAR TO EXHAUST VENT AND INTAKE PIPE 2 c2 ccecceeceeeeeeeeeeeeeeeecececeeesaeeeaeeeeeenseeeneeas 21 VENT TERMINATION crient deliv Aven BV da ee ett 22 1 Two Pipe Roof and Sidewall Vent Terminations cccccsceeeeeseseeeeeeeeneeeeeeneenseeeneeeenseaseeeeeaeeeseeeeeaeeasseeesaeeeseeeaenseaseeeeenseaeeeeees 22 2 Direct Vent Optional Horizontal and Vertical Vent Kits 23 SCreen installato 23 PART 6 INSTALL THE CONDENSATE 11 11 1 eae seeeseseeeseaeeeaesneeseeesseeseeeseeeseeeseeeeaeeees 24 25 lt 25 Ax GAS PIPE SIZING TABLES tentene needs et es eco 25 12 Gas 1 121 0 25 2 Natural Gas Pipe Sizing TE sacag ences esdesdsacedsncsveties E aes ddedenucevstereste 25 3 LP Liquid Propane Gas Pipe SIZING
4. 250 ifice Si NG 0 232 5 9 mm Orifice Size LP os Gas Supply Pressure NG 3 5 to 14 WC LP 3 5 to 14 WC Manifold Pressure Min 27 3 Vent NG 0 0039 0 002 WC 2 3 Vent NG 0 374 0 216 WC Main Supply Power Supply 120V 60 Hz 6A Maximum Power Consumption 160W Ignition System Direct Electronic Ignition Automatic Flame Sensing Burner System Single Orifice Premixed Fuel Modulation Ceramic Fiber Infrared Gas Valve System Internal Pipe Material Combination Modulating Current Proportional Copper Dimensions W 15 7 53 D 26 8 Storage Tank Water Capacity DHW Main Controller Control Panel Under 15 Gallons GTX 920C P 920C_CB HTP CH Pressure Min 15 PSI Max 30 PSI DHW Pressure Max 150 PSI Connection DHW Inlet Hot Water Outlet NPT Sizes CH Supply Return 1 NPT Gas Inlet 1 2 X Bell Coupling Provided to Upsize Gas Line Cabinet Cold Rolled Carbon Steel Materials Heat Exchanger Primary Heat Exchanger Stainless Steel Storage Tank Stainless Steel Safety Devices Table 3 Technical Specifications Flame Rod Overheat Cut Off Device Gas Valve Operation Detector Exhaust Temperature High Limit Sensor Water Temperature High Limit Sensor WHL 015 REV 12 17 14 Figure 1 Specifications and
5. Verify combustion settings after gas conversion Carbon Monoxide ____ High Fire ____ CO Low Fire What is the drop on light off No more than 1 W C inw c Dynamic 4 Venting Has the appliance been vented with 3 PVC CPVC Polypropylene or AL294C Stainless for Cat IV appliances Ensure no ABS or PVC Cellular core has been used Is the vent sloped upward toward the terminal at a rate of per ft or 2 grade Have all intake and exhaust joints been properly sealed and tested Are all vent runs properly supported Have the termination screens been installed Is the vent termination a min of 12 above grade or the highest anticipated snow level Is the total developed vent length including elbows within the stated max vent length restriction 5 Condensate piping tubing Is the condensate line piped with the approved materials listed in this manual Does the condensate line have an air inlet at the top beginning of the drain Refer to Install the Condensate Drain this manual Has the condensate been piped over to a drain and checked to be free flowing If necessary has a condensate pump and or a neutralizer been installed FINAL SIGNED BY TECHNICIAN DATE WHL 015 REV 12 17 14 MAINTENANCE REPORT 69 CAUTION In unusually dirty or dusty conditions care mu
6. WHL 015 REV 12 17 14 FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped If you cannot reach your gas supplier call the fire with an ignition device which automatically lights the department burner Do not try to light the burner by hand Use only your hand to turn the gas control knob BEFORE OPERATING smell all around the appliance Never use tools If the handle will not turn by hand area for gas Be sure to smell next to the floor don t try to repair it call a qualified service technician because some gas is heavier than air and will settle on Force or attempted repair may result in a fire or the floor explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has been under water Immediately call a qualified service technician Do not try to light any appliance to inspect the appliance and to replace any part of the control system and any gas control which has been Do not touch any electric switch under water do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions OPERATING INSTRUCTIONS 1 STOP Read the safety information above 5 Remove front cover 2 Set the thermostat to lowest setting
7. no action is required 2 Protect the appliance from freezing temperatures or shut off and drain the unit White smoke can be seen coming out of the exterior exhaust gas vent Depending on the outside temperature water vapor can be produced as the exhaust is vented This is normal operation no action is required Table 27 Troubleshooting Chart WHL 015 REV 12 17 14 DIAGNOSTICS AND SUGGESTED CORRECTIVE ACTIONS The appliance control is able to record information about the appliance s condition at the time of the five previous faults or errors This information is available to view in the Installer Mode under the History screen 58 The following screens may be displayed when reviewing the appliance history The table below also includes diagnostic information and possible corrective actions Display Condition Diagnostic Possible Corrective Actions Nothing appears on the display control panel but the blower runs at full speed Control is not receiving power Check wiring for short circuit or incorrect wiring Correct wiring per wiring diagram including connection of transformer to the control Check transformer connection to the control per wiring diagram Check for 12V output of transformer Replace transformer if it is receiving 120V but not outputting 12 VAC Nothing appears on the display control panel and no other appliance components are operating C
8. 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 the appliance underwent tests specified in ANSI 221 13 latest edition WARNING 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 TABLE OF CONTENTS PART 1 ITEMS SHIPPED WITH THE 7 PART 2 SAFETY REGULATIONS 8 A OPERATION AND INSTALLATION 8 IMPROPER COMBUSTION ate deo goede Wants eats ieee ees ea ee oe 9 10 D WHEN SERVICING THE APPLIANGE levi iv ded 10 WHL 015 REV 12 17 14 E WATER QUALITY irisemise roere ineas arvana lentes oe ee ee ea 10 FoRREEZE PROTECTION 10 3
9. Gas Fired QM Residential Combi Boiler Floor Mount INSTALLATION START UP MAINTENANCE PARTS WARRANTY Models WBRCNG140F WBRCLP140F ULTRAJ Low NOx Emissions SCAQMD Rule 1146 2 LEAD FREE Safe Drinking Water Act SDWA Section 1417 05 Listed Intertek Heat Exchanger Bears the ASME H Stamp NOTICE 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 The surfaces of these products contacted by consumable water contain less than 0 25 lead by weight as required by the Safe Drinking Water Act Section 1417 A WARNING 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 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 fire department Installation and service must be provided by a qualified installer service agency or the gas supplier
10. SPECIFICATIONS ii02o2e ccceieecccccteesccescesueccaetscestevcouestcncenpstecascevacdeacenictueveuedcteystessuacauucttcentestaevouendaesutenae 11 PART 4 PREPARE APPLIANCE LOCATION s ccseesseseesseesseecaneceneeanensnenseeneeeseesseeeneeeneesenesaaenaasneesaneeanensuenenenasneeeneeesee 13 A UNGRATING THE APPLIANCE eed eee pctv Pe ee ee E edd eee 13 B BEFORE LOCATING eet 14 GALEN ELE INGA fo 15 555 16 RESIDENTIAL GARAGE CLOSET AND ALCOVE 16 F EXHAUST VENT AND INTAKE PIPE eee E eddie 17 PREVENT COMBUSTION AIR CONTAMINATION ceccceceeeceeeeeeseeceeeeeeececeeeeaeecaeeeaeeaecaeseneceeecaeesaeseaeseaeseseseeeseeesieeeetenees 17 REMOVING A APPLIANCE FROM A COMMON VENT 17 5 VENTING ie 18 INTAKE PIPE AND EXHAUST VENT 18 B APPROVED VENT
11. should service and inspect the appliance annually The appliance DHW temperature is factory set to 125 F 51 C To avoid scalding always check the temperature of the hot water before bathing showering washing etc DO NOT adjust the water temperature while the appliance is being used by other persons If the appliance is exposed to the following do not operate until all corrective steps have been made by a qualified service technician 1 FIRE 2 DAMAGE 3 WATER This appliance is equipped with a three prong plug It should only be plugged directly into a properly grounded three prong receptacle DO NOT remove the ground plug from the plug DO NOT alter or modify the appliance or appliance controls This can be dangerous and WILL VOID the warranty Failure to follow these statements could result in property damage severe personal injury or death NOTICE Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee This appliance provides a overheat shutdown limit In the event the appliance water exceeds the set point of the control limit the cutoff will trip and the appliance will shut down Certain local codes require 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
12. AT THE APPLIANCE c ccecccesceeceeeeceeceeecececeeaeeaesenecaeesaeesaeeeaecaecaeesecesaeecaeeeaeseaeteneteneeeeesaes 54 J SETTING AND VERIFYING THE COMBUSTION SETTING 0 2 ccccceecceeececeeeeeeececeeecaeecaeseaesaesecesecesaeeeaeecaeeeaeeeaeseeeseneeaeeeaes 55 PART 12 INSTALLATION AND START UP CHECKLIST 56 PART 13 TROUBLESHOOTING a arer arere arrar E rAr TE rar EEr ar Aa aa ra r ara r aaa aa a aer aaa aa Dearer aap aaa apana Eaei supH aiak 57 PART 14 ANNUAL MAINTENANCE PROCEDUREG cceccsseceeeeeeeeeeeeeeeeeeeeeeeeseeneeeeaeeeneeseeeseesseeeaeeneeeseesseeseeesseeneeeeeeeeaeeea 58 REPLACEMENT PARTS n a sesstesnnesterscesterencectuesiceccuneteesteesteesdecueeenedstuenncecctanisdedvenesescestestreeernuerteniae 63 Limited Warranty for Combination Appliances cccccccesecseseeeeeeeeseeeesseeenseeeeeeeenseeseeeeenseaseeeaeneeesseeeeneeasaeeaeaeeesseeaeaeeasneeeeneeaeeeenes 66 MAIN TENAN CE a seaealecccctatedetectiestavcudenccggusdiuvescedeueandsdeceucstusteceshatseassuievecedaiecckesbevtgens 68 MAINTENANCE NO TE S 22 20 ane anncanenned saat ceoetnedsnzsncuadeesaadantsaecscctencs atutadugacotuarsuesstacsoceyhesscesceetuecateet 72 CUSTOMER INSTALLATION RECORD 73 WHL 015 REV 12 17 14 PART 1 ITEMS SHIPPED WITH THE A
13. Dimensions 12 DESCRIPTION DIAMETER ALL NPTM A Gas Connection Adapter X 34 Bell Coupling Provided to Upsize Gas Line B CH Supply Adapter 1 CH Return Adapter 1 D DHW Outlet Adapter Ya E DHW Inlet Adapter Condensate Adapter G Drain Adapter Exhaust Vent Connection 3 1 Intake Pipe Connection 3 Table 4 Adapier Specifications WHL 015 REV 12 17 14 13 Figure 2 Components COMPONENT DESCRIPTION NUMBER COMPONENT DESCRIPTION 1 Exhaust Vent Adapter 17 Condensate Trap 2 BLDC Fan 18 DHW Inlet Adapter 3 Flame Detection Window 19 DHW Outlet Adapter 4 Main PCB 20 Condensate Hose 2 5 Flame Detection Sensor 21 CH Return Adapter 6 Control Panel 22 APS Air Pressure Switch 7 Manual ON OFF Power Switch 23 CH Supply 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 Waiter 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 5 Component List PART 4 PREPARE APPLIANCE LOCATION A UNCRATING THE APPLIANCE WARNING UNCRATING APPLIANCE Any claims for damage or shortage in shipment must b
14. STORAGE DHW CH OVERHEAT EXHAUST OVERHEAT 5 5 5 4 2 111 49 L OUTDOOR TEMPERATURE MODE 49 0 10 VOLT INPUT tives eect Ae ited ae cele el ieee tv Padi eel dees 50 PART 11 START UP PREPARATION r a a ea era araara ar aae aaar aa paa sled socsubduadsudeduefetendtaveddedeadevunseceactedeetadebdayduecece 51 A CHECK CONTROL WATER 22 22 2 200 0000000110000 51 B GHECK FOR GAS LEAKS s deine 51 C FILEAND TEST WATER SYSTEM weie 66 ele eee Le ee ee eet dere ee 52 D PURGE AIR FROM AND INTERNAL STORAGE TANK 2 c2 ccecceeceeeceeseeceeeeseceeececeeaeecaeesaeseaeseaeceeeseeeseesaeeeeeenaeenseeeeeeas 53 ExPURGE AIR FROM DAW dats See ede ae ae 53 CHECK THERMOSTAT 5 2 777 EPRA 53 G CONDENSATE REMOVAL 22 1 22 8 need iv eA eee bien ele ee eld ev elite ee a elie eens 54 FINAL CHECKS BEFORE STARTING APPLIANCE 2cc ccccceecceeseeeceeeeeeececeeeceeeeaeeeaecaeesacecaeesaeecaeseaeeeeeceeeseeesaeeeaeeeeeeneeeeeeeas 54 ADJUSTING GAS PRESSURE
15. be changed by turning the dial lt P button again to save settings To leave Installer Mode press the BB button again The display will return to power off mode counterclockwise to lower and clockwise to raise the displayed value Press the Display Default Detail Description 1 EH E0 00 Error history up to 10 Check last 10 error codes E0 E9 Select ON to delete error code history 2 Delete Error history Range ON or OFF Select to reset to factory setting 3 In OFF Initialized system Burner operation time Ignition Supply power time will not be Range ON or OFF 4 Fu GA Change unit Range GA or Li volume WHL 015 REV 12 17 14 44 Display Default Detail Description 5 St ON Stored water heating Select OFF to turn off this function function ON OFF Range ON or OFF When used with an outdoor sensor sets the maximum outdoor design temperature for the system design Warm weather shut down will disable the 6 OH 68 F Maximum Outdoor appliance if the programmed outdoor temperature is exceeded Maximum A Temperature outdoor temperature must be set 9 F above the minimum outdoor temperature Range Minimum Outdoor Temperature 9 F to 110 F Sets the minimum outdoor design temperature for the system Minimum Minimum Outdoor outdoor temperature must be set 9 F b
16. 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 WHL 015 REV 12 17 14 23 2 Direct Vent Optional Horizontal and Vertical Vent Kits SIDEWALL VENTING WITH KIT ZOC EVENTING MIR 12 OVER MAXIMUM SNOW EXTERIOR WALL CONCENTRIC VENT KIT mM LEVEL OR 24 WHICHEVER CONCENTRIC VENT KIT IS GREATER PART KGAVO501 CVT 2 KGAVO601CVT 3 VENT KIT PART 500 2 V1000 2000 4 MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER TYP NOTE EXTENDED VENT RUNS WHEN LP 505 A TRANSITIONING TO A LARGER DIAMETER 07 30 14 MUST ALWAYS TAKE PLACE IN A VERTICAL POSITION TO PREVENT CONDENSATE BLOCKAGE 1 505 11 24 14 SIDEWALL VENTING WITH CONCENTRIC VENT KIT IMPORTANT INTAKE LEG MUST BE FACING UP EXHAUST CONCENTRIC VENT KIT PART 5 2 INTAKE KGAV0601CVT 3 MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER T
17. controls NOTE When inquiring about service or troubleshooting reference the model and serial numbers from the appliance rating label A WARNING DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN SUBMERGED IN WATER Immediately call a qualified service technician The appliance MUST BE replaced if it has been submerged Attempting to operate an appliance that has been submerged could create numerous harmful conditions such as a potential gas leakage causing a fire and or explosion or the release of mold bacteria or other harmful particulates into the air Operating a previously submerged appliance could result in property damage severe personal injury or death NOTE Appliance damage due to flood or submersion is considered an Act of God and IS NOT covered under product warranty A WARNING Be sure to disconnect electrical power before opening appliance cabinet or performing service Label all wires while performing service to ensure proper re wiring of the appliance Wiring errors can cause improper or dangerous operation Failure to do so could result in an electrical shock improper appliance operation property damage serious personal injury or death CAUTION Due to the low water content of the appliance improper sizing of the appliance with regard to heating system load will result in excessive cycling and accelerated component failure Westinghouse DOES NOT warrant failures caused by improperly sized appl
18. emissions causing severe personal injury or death When removing an existing appliance the following steps must be followed 1 Seal any unused openings in the common venting system WHL 015 REV 12 17 14 2 Visually inspect the venting system for proper size and horizontal pitch to determine if there is blockage leakage corrosion or other deficiencies that could cause an unsafe condition 3 If practical close all building doors windows all doors between the common venting system and other spaces in the building Turn on clothes dryers and any appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts at maximum speed Do not operate a summer exhaust fan Close all 18 Do not operate heater flood damaged Boon phate accordance with codes and manufacturers installation instructions Do not obstruct heater air intake or i exhaust 5 vent piping per fireplace dampers i 4 operation the appliance being inspected Follow the lighting Ped instructions Adjust the thermostat so the appliance will operate According to NFPA 720 carbon monoxide continuously detectors should be installed outside sech sleeping arsa 5 Test for spillage at the draft hood relief opening after 5 minutes of main Never heater unless 115 burn
19. in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION damage CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property NOTICE is used to address practices not related to personal injury NOTICE SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS or equivalent signs indicate specific safety related instructions or procedures NOTE Contains additional information important to a procedure Vapors from flammable liquids will explode and catch fire causing death or severe burns Do not use or store flammable products such as x solvents or in the same room or area near the water heater Keep flammable products 3 tightly closed and 4 out of childron s amp other rooms to the pilot flame by air currents installation are at least 18 above the Do not install water heater floor This will reduce but not where flammable products will eliminate the risk of vapors be stored or used unless the being ignited by the main main burner and pilot flames bummer or pilot flame Read and follow water heater warnings and instructions owners manual is missing c
20. no leaks 2 Check wiring connections to low water level sensor Ensure all are secure 3 Check low water level sensor resistance If resistance is zero replace the sensor 4 If the problem persists replace the main control Er 94 Exhaust Sensor detects Vent Temperature is Greater than 190 F 88 C This Error Code will go away when the condition is remedied If Error happens again 1 Check if dip switch High Fire setting is ON Switches 6 and 7 should be OFF for normal operation 2 Check exhaust temperature sensor Ensure connections are secure 3 Check sensor resistance If resistance is zero replace the sensor 4 Check exhaust vent for blockage 5 If the problem persists replace the control 6 If the problem persists replace the heat exchanger Table 22 Error Codes with Linked Components Effects and Actions WHL 015 REV 12 17 14 48 ERROR TREE ANALYSIS 1 FLAME DETECTION Operating Conditions YES Blower ON YES NO YES Flame Detection Blower ON GV OFF ERROR E72 Flame Detection Blower OFF Normal Operation GV OFF ERROR E11 Figure 36 Flame Detection Error Analysis Tree 2 GAS DETECTION Blower ON aT Normal Operation OFF ERROR E40 Figure 37 Gas Detection Error Analysis Tree WHL 015 REV 12 17 14 49 3 APS BURN
21. not exceed 30 psig Higher pressure readings may indicate a problem with the expansion tank Ensure the pressure reading the DHW gauge does not exceed 150 psig Higher pressure readings may indicate a problem with the domestic expansion tank e Contact a qualified service technician if problem persists Check Exhaust Vent and Intake Piping Visually inspect the exhaust vent for any signs of blockage leakage or deterioration of the piping Inspect the exhaust vent bracing Ensure bracing is undamaged and in good condition Notify a qualified service technician immediately if any problems are found WARNING Failure to inspect the venting system and have it repaired by a qualified service technician can result in vent system failure causing severe personal injury or death Visually inspect the intake piping for any signs of blockage Inspect the entire length of the intake pipe to ensure piping is intact and all joints are properly sealed Inspect the intake pipe bracing Ensure bracing is undamaged and in good condition Notify a qualified service technician if any problems are found Check Pressure Relief Valve e Visually inspect the primary pressure relief valve and discharge pipe for signs of weeping or leakage e Ifthe 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 Figure 44 Air
22. once by a qualified service technician Failure to comply could result substantial property damage severe personal injury or death Operate Pressure Relief Valve e Before proceeding verify that the relief valve outlet has been piped to a safe place of discharge avoiding any possibility of scalding from hot water WARNING To avoid water damage or scalding due to relief valve operation a discharge line must be connected to the valve outlet and directed to a safe place of disposal This discharge line must be installed by a qualified service technician or heating plumbing installer in accordance with the appliance installation manual The discharge line must be terminated so as to eliminate possibility of severe burns or property damage should the valve discharge e Read the temperature and pressure gauge to ensure the system is pressurized Minimum is 10 psi Maximum is 25 psi Lift the relief valve top lever slightly allowing water to relieve through the valve and discharge piping e f water flows freely release the lever and allow the valve to seat Watch the end of the relief valve discharge pipe to ensure that the valve does not weep after the line has had time to drain If the valve weeps lift the lever again to attempt to clean the valve seat If the valve does not properly seat and continues to weep contact a qualified service technician to inspect the valve and system e If water does not flow from
23. power OFF and ON at the main power switch internal to the appliance 2 Check wiring connections to mixing valve Ensure all are secure 3 Replace mixing valve 4 If the problem persists replace the main control Er 68 Mixing Valve Operation Error Mixing Valve Stuck in Initial Position This Error Code will go away when the condition is remedied If Error happens again 1 Turn power OFF and ON at the main power switch internal to the appliance 2 Check wiring connections to mixing valve Ensure all are secure 3 Replace mixing valve 4 If the problem persists replace the main control Er 70 Register Ram Rom I O Port AD Abnormal Important EPROM Data or Safe Data Abnormal This Error Code will go away when the condition is remedied If Error happens again 1 Turn power OFF and ON at the main power switch internal to the appliance 2 If the problem persists replace the main control Er 72 Flame Signal Detected before Ignition This Error Code will go away when the condition is remedied If Error happens again 1 Check the appliance 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
24. powered off and has had time to cool 2 Remove the hose clamp attaching the condensate trap to the condensate hose from the heat exchanger Remove the clear plastic TOP hose from the hose barb Remove the condensate hose clamp to detach the condensate trap from the drain tube Remove the condensate trap from the appliance ADAPIERGASKET 3 Remove the bottom cap from the condensate trap 4 Flush trap with fresh water to remove debris from the trap TOP CAP O RING NOTE Ensure the float moves freely within the trap If the float does not move DO NOT reinstall the trap 5 When the condensate trap is sufficiently clean reinstall the bottom lt lt HOSE BARE cap on the trap HOSE BARB NOTE Ensure all parts shown in Figure 47 Condensate Detail are installed with the condensate trap If any parts missing DO NOT reinstall the trap Replace the entire assembly CONDENSATE HOSE CLAMP GASKET CONDENSATE A WARNING ES SA CONDENSATE 5 DRAIN HOSE Do not install the condensate assembly if a component is lost or missing Replace the entire assembly Failure to follow this warning CONDENSATE 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 exchange
25. pressure Loosen the screw before checking the gas inlet pressure 1 The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of the system at test pressures greater than psi 3 5 kPa 2 The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 5 psi 3 5 kPa Do not fire operate the appliance until all connections have been completed and the heat exchanger is filled with water Doing so will damage the appliance and void the warranty ADJUSTING GAS PRESSURE AT THE APPLIANCE 1 Open the gas line and water valves 2 Use a Phillips Head screwdriver to remove the appliance top cover Remove the front cover 3 Loosen the gas inlet pressure tap screw three turns with a screwdriver Connect the manometer to the inlet gas pressure port See Figure 41 4 Turn on power to the appliance and open a hot water faucet 5 The minimum and maximum inlet gas line pressures must meet the requirements shown in Table 24 WHL 015 REV 12 17 14 55 5 NATURAL GAS Minimum Pressure 3 5 WC Minimum Pressure 3 5 WC Maximum Pressure 14 WC Maximum Pressure 14 WC Table 24 Gas Pressure Requirements 6 Remove the manometer Close the screw on the gas inlet pressure tap J SETT
26. severe personal injury or death COMBUSTION SETTINGS NATURAL GAS LP GAS FAN SPEED LOW HIGH LOW HIGH CO PPM lt 175 lt 175 lt 175 lt 175 8 10 8 10 9 10 9 10 10 2 5 Figure 42 Gas Valve Offset Screw Table 25 Combustion Settings 2 When low fire settings have been obtained flip DIP switch seven 7 to its original OFF position This will return the appliance to normal mode 3 Flip DIP switch six 6 to ON high fire Again check combustion readings with a combustion analyzer 4 When complete flip DIP switch six 6 to its original OFF position This will return the appliance to normal mode 5 Allow appliance to operate normally Ensure it is operating properly 6 Reinstall the appliance front cover 7 Use a Phillips Head screwdriver to reinstall the appliance top cover WHL 015 REV 12 17 14 PART 12 INSTALLATION AND START UP CHECKLIST 56 LIGHT OFF ACTIVITIES DATE COMPLETED YES NO 1 Fill the Heating System with Water Has the system been cleaned and flushed Does water chemistry meet requirements If water chemistry does not meet requirements have treatment measures been put in place Check all water piping and connections Are all leak free and properly supported Has the CH system been pressure tested and pressurized to 12 25 psi Has the DHW system been 2 Exhaust Vent and Int
27. the system Outlined below are those water quality parameters which need to be met in order for the system to operate efficiently for many years Failure of a heat exchanger due to lime scale build up on the heating surface low pH or other imbalance IS NOT covered by the warranty To assure good extended service life it is recommended that you test your water quality prior to installation Listed below are some guidelines A WARNING Do not use petroleum based cleaning or sealing compounds in the appliance system Damage to elastomer seals and gaskets in the system could occur resulting in substantial property damage Water Quality Potable water is defined as drinkable water supplied from utility or well water in compliance with EPA secondary maximum contaminant levels 40 CFR Part 143 3 as shown in Table 23 It is important to ensure the water quality is within these determined limits If your water contains contaminants higher than outlined by EPA then water treatment is recommended and additional maintenance may be required If you suspect that your water is contaminated in any way discontinue use of the appliance and contact 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 Diss
28. 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 remedied If Error happens again 1 Ensure all valves are open to the appliance and there are no leaks 2 Ensure all air has been purged from the system 3 Check wiring connections to low water level sensor Ensure all are secure 4 Check low water level sensor resistance If resistance is zero replace the sensor 5 If the problem persists replace the main control Er 81 Low Water Level Circuit This Error Code will go away when the condition is remedied If Error happens again 1 Ensure all valves are open to the appliance and there are no leaks 2 Check wiring connections to low water level sensor Ensure all are secure 3 Check low water level sensor resistance If resistance is zero replace the sensor 4 If the problem persists replace the main control Er 85 Freeze Protection Appliance has detected water temperature below 34 F 1 C This Error Code will go away when the freezing condition is remedied If Error happens again 1 Ensure appliance is located in a mechanical room protected from freezing conditions 2 Ensure all valves are open to the appliance there are
29. 064 43 Storage Tank Outlet Pipe 7855P 082 71 Burner ASSY 7855P 065 44 DHW Outlet Pipe 7855P 041 71 1 Burner Overheat Switch 7855P 066 45 Mixing Valve Outlet Clip 7855P 042 71 2 Burner Body 7855P 067 46 Mixing Valve 7855P 043 71 3 Ignition Rod 7855P 068 47 Mixing Valve Outlet O Ring 7855P 044 71 4 Ceramic Fiber Burner 7855P 069 48 Mixing Valve Inlet Clip 7855P 042 72 Burner ASSY Bracket 7855P 070 49 Mixing Valve Inlet O Ring 7855P 045 73 Air intake Pipe 7855P 071 50 DHW Inlet Pipe 7855P 046 Table 30 Combustion System Replacement Parts WHL 015 REV 12 17 14 66 Limited Warranty for Combination Appliances Floor and Wall Mount Models Westinghouse warrants each instantaneous appliance and its parts to be free from defects in materials and workmanship according to the following terms conditions and time periods The replacement appliance will be warranted for the unexpired portion of the applicable warranty period of the original appliance The number of replacement appliances is limited to one 1 per original appliance purchased Replacement parts will be warranted for 90 days UNLESS OTHERWISE NOTED THESE WARRANTIES COMMENCE ON THE DATE OF INSTALLATION This limited warranty is only available to the original owner of this appliance and is non transferable Residential Use Warranty Commercial Use Warranty 10 years Heat Exchanger 5 years Parts 5 years Heat Exchanger 1 Year Parts USE DEFINTIONS Reside
30. 41 37 37 29 26 20 18 y4 192 137 112 97 87 80 69 62 48 44 15 383 269 218 188 168 153 132 118 91 82 1 639 456 374 325 292 267 232 208 171 148 1 1260 888 723 625 559 509 440 393 320 277 28 2930 2080 1700 1470 1320 1200 1040 933 762 661 Table 11 Natural Gas Delivery Capacity Corrugated Stainless Steel Pipe Refer to ANSI 2223 1 National Fuel Gas Code Latest Edition Maximum Natural Gas Delivery Capacity Length of Black Iron 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 80 100 150 200 172 118 95 81 72 65 56 50 40 34 54 360 247 199 170 151 137 117 104 83 71 17 678 466 374 320 284 257 220 195 157 134 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 Table 12 Natural Gas Delivery Capacity Black Iron Pipe Refer to ANSI 2223 1 National Fuel Gas Code Latest Edition WHL 015 REV 12 17 14 26 3 LP Liquid Propane Gas Pipe Sizing The following is intended for use for piping between a Single or Second Stage Low Pressure Regulator and the appliance The following tables list maximum capacity of pipe in cubic feet of gas per hour for an inlet pressure of 11 inches water column and specific pressure drop of 0 5 inches wat
31. 5 volts the appliance will ignite As the signal continues to rise towards its maximum of 10 volts the appliance will increase in set point temperature 2 Connect a building management system or other auxiliary control signal to the terminals marked for this purpose on the appliance terminal block shown in Piping Diagrams 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 appliance controller to the appliance is correct Reversed polarity could lead to erratic and or no response from the appliance controller NOTE Outdoor Temperature Mode Icon on the display will flash if an Outdoor Sensor or 0 10 Volt is not connected to the appliance WHL 015 REV 12 17 14 51 PART 11 START UP PREPARATION 4 WARNING Thoroughly clean and flush any system that has used glycol before installing the appliance A CHECK CONTROL WATER CHEMISTRY CAUTION Chemical imbalance of your water can cause severe damage to your appliance and associated equipment and may also affect efficiency You may have to have your water quality professionally analyzed to determine whether you need to install a water softener It is important that the water chemistry on both the domestic hot water and central heating sides are checked before installing the appliance as water quality will affect the reliability of
32. 6 Turn gas shutoff valve to Handle will be across the piping do not force 3 Turn off all electric power to the appliance 7 Wait five 5 minutes to clear out any gas If you then 4 This appliance is equipped with an ignition device smell gas STOP Follow in the safety which automatically lights the burner Do not try to information above on this label If you don t smell light the burner by hand gas go to next step Turn gas shutoff valve to Handle will be GAS VALVE GAS VALVE in line with piping OFF Install Front Cover Turn on all electric power to appliance Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier TURN OFF GAS APPLIANCE 1 Set the thermostat to lowest setting 4 Turn gas shutoff valve to Handle will be 2 Turn off all electric power to the appliance if service is across the piping Do not force to be performed 5 Install Front Cover 3 Remove Front Cover LP 175 Rev 4 3 11 08 015 12 17 14 levels or to important product information SPECIAL ATTENTION BOXES The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result
33. 7 14 Figure 43 Flame Sight Glass PART 13 TROUBLESHOOTING 57 Visual check hole 44 TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSES POSSIBLE REMEDIES No electrical power to the appliance 1 Is the plug on the power supply cord unplugged from the electrical outlet 2 15 electrical panel s 10 Amp circuit breaker tripped 3 Is the fuse on the circuit board good 4 15 there a power outage to the home 1 Reset the plug 2 Reset the circuit breaker 3 If the display panel is blank unplug the unit or contact an authorized service technician 4 Contact the power company No water available when a faucet is opened 1 Is the water supply valve shut off at the meter do cold water faucets work 2 Is the water supply valve near the unit open 3 Is the water pipe frozen 4 15 an error code flashing on the display panel leak detected 1 Open the closed supply valve 2 Open the water supply valve 3 Turn OFF the unit close all water valves and the gas valve Contact an authorized service technician 4 Refer to error code information and contact an authorized service technician Hot water is not available when the faucet is opened 1 Does the appliance have power plugged in 2 Is the appliance turned ON 3 Is an error code flashing on the display panel 4 Is the gas supply valve open or shut off at the meter do other gas device
34. Control Panel Detail LCD DISPLAY DESCRIPTIONS Lock Modeis Appliance is Heating Operational Anti Freeze Modeis Stored Water Operational Appliance is Operating in CH Mode Icon will Flash if there is a call for heat and DHW or Storage Modeis Operational Outdoor Temperature Mode Shuts Down CH Mode during Warm Weather Conditions Requires Optional Outdoor Sensor NOTE Icon will Flash if Outdoor Sensor or 0 10 Volt is not connected Eight 8 Segment Display with Colon and Decimals Displays Numerals and Operating in DHW Characters Mode Figure 28 LCD Display Detail LCD also features a backlit lamp that will illuminate e When auser action is detected a button is pressed e display has timed out for approximately 2 minutes C START UP SEQUENCE Appliance is in a Communication State Status Display Mode or Installer Modeis Operational Flame On Indicator 080 Either the CH or DHW Pump is Operating Celsius and Fahrenheit Indicators After the appliance is powered ON the LCD display shows a sequence of information The icons will flash followed by various indicators that describe the appliance controller and software versions It will take the appliance roughly 15 seconds to cycle through the Start Up Sequence After start up the display appears as follows Figure 29 Initial Display Screen Example WHL 015 REV 12 17 14 41 NOTE The initial display scre
35. ER OVERHEAT LIMIT CONDENSATE BLOCK SWITCH APS Burner overheat limit Condensate Block Normal Operation IT OFF OFF ERROR E29 Figure 38 APS Burner Overheat Limit Condensate Block Switch Error Analysis Tree 4 STORAGE DHW OP CH OVERHEAT EXHAUST OVERHEAT SENSORS Blower OFF IT OFF Normal operation GV OFF ERROR Figure 39 Storage DHW CH Overheat Exhaust Overheat Sensors Error Analysis Tree L OUTDOOR TEMPERATURE MODE OPTIONAL NOTE If the system requires a fixed operating temperature the outdoor sensor is not required and should not be installed There is no connection 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 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 wires routed in a grounded metal conduit If using shielded cable the shielding should be connected to the common ground of the appliance NOTE Outdoor Temperature Mode I
36. EXCLUSION OF ANY OTHER REMEDIES INCLUDING WITHOUT LIMITATION INCIDENTAL OR CONSE QUENTIAL DAMAGES SAID INCIDENTAL AND CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO PROPERTY DAMAGE LOST PROFIT OR DAMAGES ALLEGED TO HAVE BEEN CAUSED BY ANY FAILURE OF WESTINGHOUSE TO MEET ANY OBLIGATION UNDER THIS AGREEMENT INCLUDING THE OBLIGATION TO REPAIR AND REPLACE SET FORTH ABOVE NO AGREEMENT VARYING OR EXTENDING THE FOREGOING WARRANTIES REMEDIES OR THIS LIMITATION WILL BE BINDING UPON WESTINGHOUSE UNLESS IN WRITING AND SIGNED BY A DULY AUTHORIZED OFFICER OF WESTINGHOUSE THE WARRANTIES STATED HEREIN ARE NOT TRANSFERABLE AND SHALL BE FOR THE BENEFIT OF THE ORIGINAL PURCHASER ONLY NO OTHER WARRANTIES This Westinghouse Warranty gives you specific legal rights and you may also have other rights that vary from state to state Some states do not allow the exclusion or limitation of incidental or consequential damages so this limitation or exclusion may not apply to These are the only written warranties applicable to the commercial appliance manufactured and sold by Westinghouse Westinghouse neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said commercial appliances Westinghouse reserves the right to change specifications or discontinue models without notice WHL 015 REV 12 17 14 START UP REPORT 68 LIGHT OFF ACTIVITIES DATE COMPLETED Yes No 1 Fill the heat
37. GV Gas Valve HT 120V AC 7 2 8 Power Supply Neutral 9 12 Power Line CP2 3WAY NOT USED LW6A4 03 3 1 SELV 5V DC 2 5485 SMW250 05 3 RS 485 GND 4 SELV 54 DC 5 RS485 5V 1 Unused 2 GND SELV 14V DC CN4 3 VDD SELV 14V DC LWD1140 06 4 Fan power start coil SELV 8 26 5V AC 5 Fan power end coil 6 Fan speed feedback signal SELV 14V DC 1 GND CN8 2 ISP Reset Port SMW250 04 3 ISP Data Port SELV ey BC 4 VCC 1 HWL Not Used 2 SELV 12V 10 LWL Low Water Level Leakage Sensor z HD Central Heating Demand SELV 5V DC 4 TH Connect to the Display Control CN11 12 Thermostat 2 APS Air Pressure Switch 5 EL Not Used SELV 14V DC 7 ane 15 BL Burner Limit 8 HL Condensate Block Table 18 Appliance Wiring 1 WHL 015 REV 12 17 14 39 OF LOCATION PIN BOARD SILK DESCRIPTION HT SELV CN7 LWD1140 14 F S Flame Detect Sensor 5 Operating Water Temperature Sensor DH S DHW Temperature Sensor A 1 5 Return Water Temperature Sensor BG S Exhaust Temperature Sensor ST S Storage Temperature Sensor SP S CH Over Heat Temperature Sensor SELV 5V CN14 SMW250 09 DHM GND DHM Stepper Motor Positio
38. ING AND VERIFYING THE COMBUSTION SETTING 1 After the appliance has fired flip DIP switch seven 7 to the ON position low fire Proceed to check appliance combustion values NOTE Use a combustion analyzer to ensure and values are within the range shown in Table 24 A WARNING It is required to use a combustion analyzer to verify final adjustment according to the combustion chart Table 3 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 25 use a 4mm Allen key to adjust the offset screw in a clockwise positive or counterclockwise negative direction approximately 1 4 turn See Figure 42 Check your combustion values Repeat this procedure until the values obtained on the combustion analyzer agree with those stated in Table 25 NOTE If the appliance 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 25 before proceeding A WARNING It is very important that this conversion be set within the recommended CO measurements listed in Table 25 Visually looking at the burner does not determine combustion quality Failure to measure combustion with a Combustion Analyzer and set the throttle within the recommended CO measurements could result in property damage
39. NTS 1 The gas connection fitting the appliance is gt male NPT 5 X Bell Coupling has been provided with the appliance to aid installation NOTE The pipe size must not be less than gt 2 The supply line must be sized for the maximum output of the appliance being installed If there are additional gas appliances from the main supply 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 appliance Appliance 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 sizing information to determine the correct supply pipe size 4 A manual gas shut off valve should be installed in the gas supply line close to the appliance See Figure 14 for detail 5 To facilitate any future maintenance it is also recommended that an approved gas union fitting be installed in the supply line between the shut off valve and the connection on the appliance 6 Test the gas pressure to make sure it meets the minimum standards and does not exceed the maximum standards of the appliance 7 Leak test the gas line pipe before placing the appliance in operation Only use approved leak detector liquid solutions to check for leaks 8 Do not operate the appliance until all connections have been
40. PPLIANCE ITEM DESCRIPTION QUANTITY Residential Floor Mount Combi Boiler Installation and User s Information Manuals H2 Document 1 Each Condensate Hose ibe eti ALa A Condensate Adapters and Instruction Sheet 1 kit CH Pressure Relief Valve With X 1 Bushing CH Line 30 psi 1 Each Vent Screens 3 2 Screens Outdoor Sensor with Screws and Anchors 3 CPVC 6 Length 9 Bell Coupling for Gas Line Spare Parts Kit Gaskets and O Rings Propane LP Conversion Kit WHL 015 REV 12 17 14 OPTIONAL PARTS Not Included ITEM DESCRIPTION QUANTITY PART NUMBER Threaded 1 CH Tankless Isolation Valves Threaded 34 DHW Tankless Isolation Valves 2 Vent Screens 2 Mesh ve 2 Screens 7850P 088 Table 1 Items Included with the Appliance PART 2 SAFETY REGULATIONS A OPERATION AND INSTALLATION WARNINGS To avoid serious injury or death read understand and follow all the precautions listed here A R Vapors from flammable liquids will explode and can cause a fire resulting in personal injury or death The appliance has a burner that can come on at any time and ignite vapors DO NOT use or store flammable liquids around the appliance Improper venting can cause a build up
41. R LEVEL DETECTION TIME lt 6 seconds HIGH AND LOW WATER LEVEL RECOVERY TIME lt 6 seconds Table 17 System Control Settings WHL 015 REV 12 17 14 36 FLOOR MOUNT COMBI BOILER Cator Designations 15 3 11 Of ANSI 14 15 Black Brown 0205 Co EENEN 25020 8 8 8 5 m Exhaust Temperature Sensor Ehe Retum Temperature Sensor DHW Temperature Sensor OP Water Temperature Sensor 2 sensor pozo ee Posen Perf Toot o lt o 8 WHL 015 REV 12 17 14 Electrical Wiring Diagram Figure 24 37 NEUTRAL 4 Relay 5 Gas Valve 2 Power Detector 2 Speed Control Primary AD Test Heat Demand E il Condensate Flame_SENSOR gt ve H eH Power Display MCU Power Display circuit DISPLAY CONTROL Fan RPM Sensor Figure 25 Ladder Diagram WHL 015 REV 12 17 14 38 NO OF LOCATION PIN BOARD SILK DESCRIHIION HISE 1 GROUND 2 L Power Supply Line 3 CP1 Pump 1 Central Heating Pump CN 4 IT Ignitor see 12 5 L HT Pump 2 Recirculation Pump 6
42. Vent Detail Check Vent Condensate Drain System e While the appliance is running check the discharge end of the condensate drain tubing Ensure no flue gas is leaking from the condensate drain tubing by holding your fingers near the opening e f you notice flue gas leaking from the opening this indicates a dry condensate drain trap If problem persists contact qualified service technician to inspect the appliance and condensate line and refill the condensate trap e f applicable check the condensate neutralizer and ensure it is full of condensate neutralizing marble chips Check the Air Vent Loosen cap one counterclockwise turn to allow air vent to operate See Figure 44 If the air vent valve works freely without leaking close the valve by turning clockwise If vent does not operate correctly contact a qualified service technician to replace the vent Check Primary and Gas Piping e Remove the appliance cover and perform a gas leak inspection following Operating Instructions page 2 this manual If gas odor or leak is detected follow procedures on page 2 Call a qualified service technician e Visually inspect for leaks around the internal appliance water connections and around the heat exchanger Visually inspect the external system piping circulators and system components and fittings Immediately call a qualified service technician to repair any leaks WHL 015 REV 12 17 14 60 WARNING Have leaks fixed at
43. YP Figure 10 Direct Vent Vent Terminations With Optional Kits WARNING All vent pipes must be glued properly 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 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 cement the screens into the terminations See Figure 11 for installation detail i 3 Screen Vent 1 4 Figure 11 Screen Installation SAFETY INSTRUCTIONS Do not connect any other appliance vents to the appliance exhaust vent or intake pipes WHL 015 REV 12 17 14 24 PART 6 INSTALL THE CONDENSATE DRAIN 1 Due to its efficient design the appliance produces condensate water as a normal by product This condensate is acidic with a pH level between 3 and 4 This condensate must be drained away from the appliance and disposed in accordance with all local regulations 2 Use corrosion resistant materials approv
44. ake Piping Has the appliance been vented in accordance with the methods and materials listed in this manual and to meet local codes vented in approved materials air supply sufficient for proper operation combined vent length within the maximum vent length restriction vent lengths minimized installed with proper terminations clearances and pitch etc Is vent piping properly supported Has exhaust vent piping been checked for leaks Have the exhaust vent and intake pipes been properly installed into the connectors provided on the appliance 3 Condensate Piping Tubing and Components Have all condensate line components included with the appliance been installed Is the condensate line piped with the approved materials listed in this manual Has the condensate line been routed to a laundry tub or other drain If necessary has 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 gt 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 measured between 3 5 and 14 WC Has the gas supply line been leak tested per locally approved methods 5 Pressure Relief Valves Have you instal
45. ales receipt or the warranty registration the warranty period for the appliance shall then be deemed to have commenced thirty 30 days after the date of manufacture of the appliance and NOT the date of installation of the appliance E This warranty extends only to appliances utilized in heating applications that have been properly installed by qualified professionals based upon the manufacturer s installation instructions OWNER RESPONSIBILITIES To avoid the exclusion list in this warranty the owner or installer must 1 Maintain the appliance in accordance with the maintenance procedure listed in the manufacturer s provided instructions Preventive maintenance can help avoid any unnecessary breakdown of your appliance and keep it running at optimum efficiency 2 Maintain all related system components in good operating condition 3 If the cold water supply line has a backflow preventer then an expansion tank should be installed to allow for water expansion 4 Use the appliance at water pressures not exceeding the working pressure shown on the rating plate WARRANTY EXCLUSIONS This limited warranty will not cover 1 Any appliance purchased from an unauthorized dealer or online retailer 2 Any appliance not installed by a qualified heating installer service technician or installations that do not conform to ANSI CSA and or ETL standards as well as any applicable national or local building codes 3 Service trips to teach you how to install
46. and maintained See Condensate Trap Maintenance section of this manual for instructions on maintaining the trap TO OUTSIDE SOURCE PIPE HANGERS MUST BE USED TO SUPPORT PIPING VERTICAL OR eX HORIZONTAL PIPING REDUCING COUPLING REDUCING COUPLING HOSE ADAPTER HOSE ADAPTER VENT CONDENSATE va HOSE ta HOSE PIPE HANGERS MUST BE USED TO SUPPORT 1 X PVC PIPE PIPING VERTICAL OR HORIZONTAL PIPING SUPPORTS EIN REDUCER SWEAT gt mee PVC PIPE PVC PIPE SWEAT CONNECTIONS SWEAT CONNECTIONS THROUGHOUT THROUGHOUT N1100 CONDENSATE HORIZONTAL LINES MUST NEUTRALIZER BE INSTALLED WITH 1100 CONDENSATE HORIZONTAL LINES MUST NEUTRALIZER EXISTING DRAIN BE INSTALLED WITH A PITCH 554200 LITTLE GIANT OF 4 PER FOOT CONDENSATE PUMP Figure 13 Condensate Piping with Condensate Neutralizer Condensate Piping with Condensate Neutralizer and Pump NOTES 1 Condensate line must be pitched at least 1 4 per foot to properly drain If this cannot be done or a very long length of condensate hose is used you must increase the condensate line to a minimum of 1 ID and place a tee in the line after the condensate neutralizer to properly reduce vacuum lock in the drain line 2 Plastic pipe should be the only material used for the condensate line Steel brass copper or other materials will be subject to corr
47. any obstruction in the discharge line e Test the 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 e 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 e care whenever operating relief valve to avoid scalding injury or property damage e For appliances installed with only a pressure relief valve the separate storage vessel must have a temperature and pressure relief valve installed This relief valve shall comply with Relief Valves for Hot Water Supply Systems ANSI 221 22 CSA4 4 FAILURE TO COMPLY WITH THE ABOVE GUIDELINES COULD RESULT IN FAILURE OF RELIEF VALVE OPERATION RESULTING IN POSSIBILITY OF SUBSTANTIAL PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH PART 9 CONNECT ELECTRICAL POWER INITIAL STARTUP WARNING Install wiring and electrically ground appliance in accordance with the authority having jurisdiction or in the absence of such an authority follow the National Electrical Code NFPA 70 and or CSA C22 1 Electrical Code Part 1 in Canada Failure to follow applicable local state and national regulations mandates and building supply codes for guidelines to install the electrical power supply could result in property damage serious pe
48. ate can exit from the tee resulting in potential water damage to property 10 If the appliance has a condensate pump ensure the pump operates properly before considering maintenance complete WHL 015 REV 12 17 14 REPLACEMENT PARTS Figure 48 Cabinet Replacement Parts 63 PART PART NUMBER DESCRIPTION NUMBER NUMBER DESCRIPTION NUMBER 1 Exhaust Duct 7855P 002 13 2 DHW Pressure Gauge 0 150 PSI 7855P 080 2 Air Intake Cap 7855P 003 14 Manual Power Switch 7855P 014 3 Exhaust and Air Intake Pipe Adapters 7855P 004 15 Terminal Block 7855P 015 4 A S Cover 7855P 005 16 Front Bracket 7855P 016 5 Exhaust Pipe 7855P 006 17 Air Pressure Switch 7855P 017 6 Ignition Transformer 7855P 007 18 Drain Adapter 7855P 018 7 Main Control Board PCB 7855P 008 19 Condensate Adapter 7855P 019 8 Main Control Board PCB Bracket 7855P 009 20 DHW Inlet Adapter 7855P 020 9 21 DHW Outlet Adapter 7855P 021 10 Boiler Heat Exchanger Bracket 7855P 010 22 CH Return Adapter 7855P 022 11 Front Cover 7855P 011 23 CH Supply Adapter 7855P 023 12 Display Panel 7855P 012 24 Cabinet 7855P 024 13 1 CH Pressure Gauge 0 60 PSI 7855P 013 Table 29 Cabinet Replacement Parts WHL 015 REV 12 17 14 64 Figure 49 Combustion System Replacement Parts NOTE See Replacement Parts List following page WHL 015 REV 12 17 14 65
49. before installation could result in wasted time money and possible property damage and personal injury PRECAUTIONS If the boiler is located a residential garage it should be installed per the latest edition of the National Fuel Gas Code ANSI 2223 1 and CGA B149 Installation Code in Canada e Mount the bottom of the boiler a minimum of 18 above the floor of the garage to ensure the burner and ignition devices are well off the floor e Locate or protect the boiler so it cannot be damaged by a moving vehicle A WARNING For closet or alcove installations a two pipe venting system must be used Failure to follow this warning could result in substantial property damage severe personal injury or death A WARNING The space must be provided with correctly sized combustion ventilation air openings for all other boilers located in the space with the boiler Do not install the boiler in an attic Failure to comply with these warnings could result in substantial property damage severe personal injury or death WHL 015 REV 12 17 14 17 EXHAUST VENT AND INTAKE PIPE WARNING Vents must be properly supported The appliance exhaust and intake connections are not designed to carry heavy weight Vent support brackets must be within 1 of the appliance and the balance at 4 intervals Venting must be readily accessible for visual inspection for the first 3 from the appliance Th
50. cifically manufactured for use with propane Follow Gas Conversion Manual instructions separate document Propane ready appliances have the suffix LP after the model serial number Make sure the gas line pressures are within normal limits Pressures outside normal limits can result in poor performance and hazardous operating conditions This appliance must be converted into propane operation unless it is specifically manufactured to operate on propane Propane ready appliances have the suffix LP after the model serial number Failure to ensure 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 Contact the local gas supplier for actual rating 2 Natural Gas Pipe Sizing The following tables list maximum capacity of pipe in cubic feet of gas per hour for gas pressures of 0 5 psi or less and a pressure drop of 0 5 inches water column based on a 0 60 specific gravity for natural gas Maximum Natural Gas Delivery Capacity Length of Corrugated Stainless Steel Pipe 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 ya 82 58 47
51. completed and the heat exchanger is filled with water WHL 015 REV 12 17 14 27 GLOSED POSITION E MANUAL SHUT OFF VALVE m GAS LINE Gas meter 55 Other appliance ___ Sediment Trap Other appliance ___ Sediment Trap Figure 16 LP Gas Piping Installation NOTE Capacity to be Not Less than Total Capacity of Connected Appliances PART 8 WATER PIPING A GENERAL PLUMBING CONNECTION GUIDELINES Pipe material must be suitable to meet local codes and industry standards The pipe must be cleaned and without blemish before any 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 WHL 015 REV 12 17 14 Piping symbol legend 28 circulator lt circulator w isolation flanges w integral check valve globe valve diff pressure bypass ball valve X mixing valve swing check valve 4 gauge spring loaded check valve M 3 way motorized hose bib boiler drain mixing valve 4 way motor
52. con on the display will flash if an Outdoor Sensor or 0 10 Volt is not connected to the appliance See Figure 40 to set your Outdoor Reset Curve check the Target Temperature while using Outdoor Temperature Mode press the button while the appliance is operational and the display panel is powered on WHL 015 REV 12 17 14 50 OUTDOOR RESET CURVE gt w ry N N gt SUPPLY TEMPERATURE F SUPPLY TEMPERATURE F 40 31 22 13 4 5 14 23 32 41 5 OUTSIDE TEMPERATURE F OUTSIDE TEMPERATURE F Figure 40 Outdoor Reset Curve See Installer Mode for Curve Setting Descriptions T 0 59 68 77 86 95 40 31 22 13 4 5 14 23 32 41 50 59 68 77 86 95 0 10 VOLT INPUT 1 signal from building management system may be connected to the appliance to enable remote control This signal should be 0 10 volt positive going DC signal When this input is enabled a building control system can be used to control the set point temperature of the appliance The control interprets the 0 10 volt signal as follows when the signal is between 0 and 1 5 volts the appliance will be in standby mode not firing When the signal rises above 1
53. e and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 lf a voltage reading does occur under any condition check and correct the external wiring This is common problem when using 3 wire zone valves 5 Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to the appliance low voltage terminal strip Allow the appliance to cycle WHL 015 REV 12 17 14 54 CONDENSATE REMOVAL 1 This is a high efficiency condensing appliance Therefore the appliance has a condensate drain Condensate fluid is nothing more than water derived from combustion products similar to that produced by an automobile when it is initially started Condensate is slightly acidic typically with a pH of 3 to 5 and must be piped with the correct materials Never pipe the condensate using steel copper brass or other materials that will be subject to corrosion Plastic PVC or CPVC pipe are the only approved materials A condensate neutralizer if required by local authorities may be purchased from Westinghouse 7450 212 2 The appliance is provided with gt 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 ou
54. e appliance is rated ANSI 721 13 Category IV pressurized vent likely to form condensate in the vent and requires a special vent system designed for pressurized venting You must also install air intake piping from outdoors to the appliance flue adaptor The resultant installation is categorized as direct vent sealed combustion NOTE To prevent combustion air contamination see Table 7 in this section when considering exhaust vent and intake pipe termination Exhaust vent and intake pipe may be vented vertically through the roof or out a side wall Venting methods are detailed in the Venting Section Do not attempt installation using any other means Be sure to locate the appliance so exhaust vent and intake piping can be routed through the building and properly terminated Exhaust vent and intake piping lengths routing and termination method must comply with methods and limits given in the venting section G PREVENT COMBUSTION AIR CONTAMINATION Install intake piping for the appliance as described in the Venting section Do not terminate exhaust in locations that can allow contamination of intake air WARNING Ensure that the intake air will not contain any of the contaminants below For example do not pipe intake near a swimming pool Avoid areas subject to exhaust fumes from laundry facilities These areas always contain contaminants Contaminated air will damage the appliance resulting in possible substantial property dama
55. e filed immediately against the transportation company by the consignee WHL 015 REV 12 17 14 14 CAUTION Cold weather handling If appliance has been stored in a very cold location below 0 F before installation handle with care until the plastic components come to room temperature Remove all sides of the shipping crate to allow the appliance to be lifted into its installation location If surface flooring is rough take care when sliding appliance into position as you could damage the appliance CAUTION Carefully consider installation when determining appliance location Please read the entire manual before attempting installation Failure to properly take factors such as appliance venting piping condensate removal and wiring into account before installation could result in wasted time money and possible property damage and personal injury B BEFORE LOCATING THE APPLIANCE WARNING Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk Ensure that the appliance installation location adheres to the information included in this manual Failure to do so could result in property damage serious personal injury or death CAUTION Failure of appliance or components due to incorrect operating conditions IS NOT covered by product warranty 1 Installation Area Mechanical Room Operating Conditions e Ensure ambient temp
56. e when lit 6 If the problem persists replace the main control Er 11 Ignition has Failed 10 Ten Times Press the Power button to clear the Error Code If Error happens again 1 Monitor the gas pressure to the appliance while in operation Ensure pressure is between 3 5 and 14 WC 2 Check gas valve wire 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 igniter transformer for proper connection 5 Clean the spark igniter with steel wool to remove oxides Ensure proper separation 3 4 mm 6 Replace the spark igniter if damaged 7 Assure that the flame is stable when lit 8 If the problem persists replace the main control Er 16 Operating Temperature Sensor detects Water Temperature Greater than 203 F 95 C Press the Power button to clear the Error Code If Error happens again 1 Check if dip switch High Fire setting is ON Switches 6 and 7 should be OFF for normal operation 2 Check if CH inlet pipe is blocked Ensure there is enough water flowing to the appliance 3 Check Operating Temperature sensor at CH heat exchanger outlet If resistance is zero replace the sensor 4 If the problem persists replace the main control Er 20 Condensate Closed is Normal Open is Fault Condensate Drain Trap Press the Power button to clear the Erro
57. ed or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the service of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a Inthe event that the side wall horizontally vented gas fueled equipment is installed crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision cannot be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above
58. ed by the Authority Having Jurisdiction AHJ to drain condensate In the absence of an AHJ the included flexible plastic hose or field supplied 7 PVC and CPVC drain pipe complying with ASTM D1785 F441 or D2665 may be used Cement and primer must comply with ASTM D2564 or F493 For 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 the limestone varies with usage of the appliance During the first year of appliance operation check the neutralizer every few months for depletion 4 Route the drain line to a nearby floor drain laundry tub or condensate pump NOTE If a nearby laundry tub is used as 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 Figure 12 Internal NOTE This appliance has an internal condensate trap that must be cleaned
59. eeding further WARNING Eliminate all system leaks Continual fresh make up water will reduce appliance life Minerals can build up in the heat exchanger reducing heat transfer overheating the heat exchanger causing heat exchanger failure and possibly resulting in property damage severe personal injury or death 5 The system may have residual substances that could affect water chemistry After the system has been filled and leak tested verify that water pH and chlorine concentrations are acceptable by sample testing CAUTION It is important to purge the system of air to avoid damage to the appliance WHL 015 REV 12 17 14 53 D PURGE AIR FROM AND INTERNAL STORAGE TANK CAUTION IMPORTANT While commissioning the system the air vent on top of the appliance must remain fully open to allow the appliance to properly fill Failure to keep the air vent open could lead to improper appliance and system operation To purge air from the system a Connect a hose to the purge valve and route hose to an area where water can drain and be seen b Close the appliance or system isolation valve between the purge valve and fill connection to the system c Close zone isolation valves d Open quick fill valve on cold water make up line e Open purge valve f Open the isolation valves one zone at a time Allow water to run through the zone pushing out the air Run water until no not
60. elow the maximum outdoor Temperature temperature Range 4 F to Maximum Outdoor Temperature 9 F 1 Adjusts Maximum Fan Speed 8 FH 00 Maximum Fan speed Range 30 30 Adjusts Minimum Fan Speed 9 FL 00 Minimum Fan speed Range 30 30 10 dr NO Initialized burner Select ON to Initialize burner operation time operation time Range NO or YES 11 4 NO Initialized ignition cycle mae This function boosts CH temperature to the maximum if set point is not 12 bt 0 Boost Function reached within the set period of time Range 0 120 min 1 This function delays burner operation during CH mode 13 Ft 1 CH Anti Frequency time Range 0 20 min When set the appliance will operate to heat CH water when water Set differential temperature falls below a differential setting 14 bo 27 temperature to turn Example If setpoint is 180 F and differential is 27 F the appliance will turn burner ON on when CH water temperature falls below 153 F Range 9 27 F 15 OF 68 Warm Weather This warm weather temperature setting will shut down CH Mode Shutdown Range 50 110 F Sets the maximum design supply temperature based on the minimum 16 Maximum supply outdoor design temperature Maximum supply temperature must be set 9 F CH 180 F an temperature above the minimum supply temperature Range Minimum Supply Temperature 9 F 180 F Sets the design supply water temperature based on the maximum outd
61. en will differ depending a number of factors including whether the appliance detects for heat or hot water The Control System can operate through user and service modes that have specific LCD outputs and dedicated controls including e Changing the Set Point Temperature Lock Mode Error Mode Status Display Mode Outdoor Temperature Mode Installer Mode D CHANGING THE DHW SET POINT display shows the 8 icon when the DHW set point be changed Figure 30 DHW Set Point Screens Press the button when the display panel is powered ON to change the DHW Set Point The DHW icon and current set point will display and flash This indicates that the DHW Set Point can be changed Factory DHW Set Point is 125 F 51 C Initial DHW Set Point range is 95 120 F 35 49 C Turn the dial counterclockwise to lower and clockwise to raise the DHW set point After changing the temperature press the lt button to save the set point A To change the DHW Set Point above 121 F 49 5 C press and hold the S button for five seconds when the display panel is powered ON The current DHW set point will display The DHW icon will flash And the scald warning letter H high temperature will display High temperature DHW Set Point range is 121 140 F 49 5 60 Turn the dial counterclockwise to lower and clockwi
62. enseeeaeseeeeeeeaseeaseeseeeseseaesneesneeseeeseeeeseeneeeneeeeaeeee 40 A CONTROL D a Dace 40 DISPLAY DESCRIPTIONS des 40 015 12 17 14 eee needy 40 D CHANGING THE DHW E A 41 CHANGING THE TEMPERATURE INDICATOR 41 SET POINT 3 a ee eee cere eee ceded edie Decrees 41 G STORAGE ee ie 42 5 5 42 INSTALLER 43 J ERROR MODE bese eee eat 45 55 20 ee ee ee a ee ec Re Decne 48 1 FLAME DETECTION e e esnenatl A A ATE A E E E AT 48 re e E A A S 48 3 APS BURNER OVERHEAT LIMIT CONDENSATE BLOCK 49 4
63. ent piping and follow the information in this statement could result in product damage severe personal injury or death WARNING For closet and alcove installations CPVC polypropylene or stainless steel venting material MUST BE USED Failure to follow this statement could result in product damage severe personal injury or death CAUTION High heat sources sources generating heat 100 F 37 C or greater such as stove pipes space heaters etc may damage plastic components of the appliance 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 appliance and related components near high heat sources ALLOWED COMBINED VENT LENGTHS 2 COMBINED VENT LENGTH 3 COMBINED VENT LENGTH MAXIMUM MAXIMUM 50 15M 100 30M Table 10 Approved Vent Lengths NOTE When using more than 1 elbow reduce maximum allowable length e 5 feet 1 5M for each additional 3 90 elbow e 2 5 feet 75M for each additional 3 45 elbow WHL 015 REV 12 17 14 21 e 8 feet 2 4M for each additional 2 90 elbow e feet 1 2M for each additional 2 45 elbow WARNING Vent adaptors are not designed as
64. er NOT use a closed type expansion tank Follow expansion tank manufacturer s specifications to properly size an expansion tank to the installation Failure to properly accommodate thermal expansion could result in property damage severe personal injury or death C CENTRAL HEATING PIPING SYSTEM WATER PIPING METHODS EXPANSION TANK AND MAKE UP WATER 1 Ensure that the expansion tank is designed and sized to correctly handle system water volume and temperature WARNING Expansion tanks must be sized according to total system volume This includes all length of pipe all fixtures appliances etc Failure to properly size system expansion could result in wasted time money and possible property damage personal injury or death CAUTION Undersized expansion tanks cause system water to be lost from the relief valve causing make up water to be added Eventual appliance 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 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 system 4 CAUTION DO NOT install automatic air vents on closed type expansion tank s
65. er have the propane supplier verify the correct odorant level in the gas WHL 015 REV 12 17 14 52 WARNING FOR YOUR OWN SAFETY READ BEFORE OPERATING 1 This appliance does not have pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 2 BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT 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 the handle will not turn by hand don t try to force or repair it call a qualified service technician Force or attempted repair may result in a fire or explosion 4 Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control that has been damaged 5 The appliance shall be installed so the gas ignition system components are protected from water dripping spraying rain etc during appliance
66. er column based on 1 5 specific gravity for liquid propane Maximum Liquid Propane Delivery Capacity Length of Corrugated Stainless Steel Pipe 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 VAN 129 91 74 64 58 53 45 41 31 28 303 216 177 153 137 126 109 98 75 69 605 425 344 297 265 241 208 186 143 129 1 971 661 528 449 397 359 307 270 217 183 1 1990 1400 1140 988 884 805 696 621 506 438 24 4640 3290 2680 2330 2080 1900 1650 1480 1210 1050 Table 13 Liquid Propane Delivery Capacity Corrugated Stainless Steel Pipe Refer to ANSI Z223 1 National Fuel Gas Code Latest Edition Maximum Liquid Propane Delivery Capacity Length of Black Iron 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 80 100 150 200 291 200 160 137 122 110 101 94 84 67 5 608 418 336 287 255 231 212 197 175 140 15 1150 787 632 541 480 434 400 372 330 265 1 4 2350 1620 1300 1110 985 892 821 763 677 543 1 3520 2420 1940 1660 1480 1340 1230 1140 1010 814 2 6790 4660 3750 3210 2840 2570 2370 2200 1950 1570 Table 14 Liquid Propane Delivery Capacity Black Iron Pipe Refer to ANSI Z223 1 National Fuel Gas Code Latest Edition B GAS CONNECTION REQUIREME
67. er operation Use the flame of a match or candle or smoke from a cigarette gy th nt pate trapped a section of vent pipe and 6 After it has been determined that each appliance remaining connected POOE hadnt hl to common venting system properly vents when tested as outlined return doors windows exhaust fans fireplace dampers and any other gas Breathing carbon monoxide can cause brain damage death burning appliance to their previous condition of use Always read and understand Instruction manual LA304 4 28 08 7 Any improper operation of the common venting system should be Figure 5 CO Warning Label corrected so the installation conforms to the National Fuel Gas Code ANSI 2223 1 When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code ANSI Z 223 1 PART 5 VENTING DA i Vent this appliance in accordance with these instructions Failure to do so will result in property damage severe personal injury or death WARNING DO NOT mix vent systems or materials unless specifically told to do so in this manual DO NOT thermally insulate the exhaust vent or intake pipes DO NOT use an electric damper vent damper or draft hood with this appliance DO NOT locate the exhaust vent or intake pipe terminations where ex
68. eratures are higher than 32 F 0 C and lower than 104 F 40 C e Prevent the air from becoming contaminated by the products places and conditions listed in this manual e Avoid continuously high levels of humidity e Never close existing ventilation openings CAUTION The service life of the appliance s exposed metallic surfaces such as the 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 which draw outdoor air for combustion Such appliances must be installed using room air for combustion Indoor air will have a much lower relative humidity and hence potential corrosion will be minimized WARNING This appliance is certified for indoor installations only Do not install the appliance outdoors Failure to install this appliance indoors could result in substantial property damage severe personal injury or death 2 Check for nearby connections to e System water piping Venting connections Gas supply piping Electrical power Condensate drain CAUTION Locate the appliance where any leakage from the relief valve related piping tank or connections will no
69. essure relief valve is not included with the appliance and is to be field supplied and installed Figure 21 Relief Valve Details After installing the relief valve and filling and pressurizing the system test the operation of the valve by lifting the lever Make sure the valve discharges freely If the valve fails to operate correctly replace it with a new relief valve Ensure that the maximum BTU H rating WHL 015 REV 12 17 14 34 on the pressure relief valve is equal to or greater than the maximum input BTU H rating of the combination appliance WARNING To avoid water damage or scalding due to relief valve operation e Discharge line must be connected to relief valve outlet and run to a safe place of disposal Terminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the relief valve discharge e Discharge line must be as short as possible and the same size as the valve discharge connection throughout its entire length e Discharge line must pitch downward from the valve and terminate at least 6 above the floor drain making discharge clearly visible e Discharge line shall terminate plain not threaded with a material serviceable for temperatures of 375 F or greater e Do not pipe discharge to any location where freezing could occur e shutoff valve may be installed between the relief valve and appliance or in the discharge line Do not plug or place
70. feet K Clearance to a mechanical air supply inlet horizontally 6 feet L Clearance above paved sidewalk or driveway located s 7 feet M Clearance under veranda porch deck or balcony i 1 foot Table 8 Vent Termination Clearances NOTE For clearances not specified in ANSI Z223 1 NFPA 54 or CAN CSA B 149 1 please use clearances in accordance with local installation codes and the requirements of the gas supplier WHL 015 REV 12 17 14 20 APPROVED VENT MATERIALS NOTICE Consult Table 9 or the most recent edition of ANSI Z223 1 NFPA 54 CAN CGA B149 1 as well as all applicable local codes and regulations when selecting vent pipe materials APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL Material Standards for Installation in United States Canada CPVC schedule 40 ASTM D2846 PP CPVC and PVC venting must be PVC schedule 40 ANSIVASTM 01785 ULC S636 Certified IPEX is an approved Exhaust vent or Intake manufacturer in Canada supplying vent pipe and fittings Polypropylene ULCS636 material listed to ULC S636 Certified for Category IV and Certified for Category IV and direct vent Stainless Steel AL29 4C direct vent appliance venting appliance venting 7 ANSI ASTM D2564 7 Pipe cement primer lt 5 F493 IPEX System 636 Cements amp Primers DA R e exhaust and intake components installed with this appliance must be used for nea
71. gallon it is recommended to flush the heat exchanger every two to three years FINAL INSPECTION Check list Verify that you have completed entire check list WARNING FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH Homeowner Review what you have done with the homeowner TECH SIGN OFF Table 31 Continue annual maintenance beyond the 4 year as required WHL 015 REV 12 17 14 70 ADDITIONAL INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS In the Commonwealth of Massachusetts the installer or service agent shall be a plumber or gas fitter licensed by the Commonwealth When installed in the Commonwealth of Massachusetts or where applicable state codes may apply the unit shall be installed with a CO detector per the requirements listed below 5 08 Modifications to NFPA 54 Chapter 10 1 Revise NFPA 54 section 10 5 4 2 by adding a second exception as follows Existing chimneys shall be permitted to have their use continued when a gas conversion burner is installed and shall be equipped with a manually reset device that will automatically shut off the gas to the burner in the event of a sustained back draft 2 Revise 10 8 3 by adding the following additional requirements For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure Used in whole or in part for residential purposes including those own
72. ge 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 Refrigeration repair shops Sodium chloride used for water softening Photo processing plants Refrigerant leaks Auto body shops Paint or varnish removers Plastic manufacturing plants Hydrochloric or Muriatic acid Furniture refinishing areas and establishments Cements and glues New building construction Antistatic fabric softeners used in clothes dryers Remodeling areas Chlorine type bleaches laundry detergents and cleaning solvents Garages and workshops Adhesives used to fasten building products Table 7 NOTE DAMAGE TO THE APPLIANCE CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY Refer to the limited warranty for complete terms and conditions REMOVING A APPLIANCE FROM A COMMON VENT SYSTEM DA R Do not install the appliance into a common vent with any other appliance This will cause flue gas spillage or appliance malfunction resulting in possible substantial property damage severe personal injury or death Failure to follow all instructions can result in flue gas spillage and carbon monoxide
73. ges is not covered by the warranty WHL 015 REV 12 17 14 Manual Switch Figure 22 Manual Power Switch and Appliance Plug Details 35 Ensure the Appliance is Properly Grounded Grounded WARNING DO NOT REMOVE Electrical THIS GROUNDING PRONG Outlet FROM THE APPLIANCE PLUG 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 not reset Disconnect the plug and have a qualified technician diagnose the problem DIP SWITCHES There is one set of DIP switches The appliance is default set at the factory to operate on Natural Gas with a 3 vent Figure 23 Dip Switch Detail DIP SWITCH GROUP DIP SWITCH OFF ON 1 3 DO NOT MOVE DO NOT MOVE 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 16 DIP Switch Group SYSTEM CONTROL SETTINGS MAXIMUM FLAME DETECTING VOLTAGE 2 5V PRE PURGE TIME Tp Maximum 10 seconds minimum 1 second SAFETY TIME IGNITING TIME Ts 3 5 seconds IGNITING INTERVAL TIME 10 seconds POST PURGE TIME Tip 2 minutes 1 1 minute 2 1 minute OVER HEATING 1 2 3 PROTECTION DETECTION TIME lt 3 seconds PUMP 1 POST CIRCULATING TIME 1 minute PUMP 2 POST CIRCULATING TIME T2pv 1 minute HIGH AND LOW WATE
74. he appliance must be inspected and serviced annually preferably at the start of the heating season by a qualified service technician In addition the maintenance and 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 Check the Surrounding Area DA R 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 appliance and the vicinity of the combustion air intake If contaminates are found e Remove products immediately from area e f contaminates have been there for an extended period call a qualified service technician to inspect the appliance for possible damage from acid corrosion If products cannot be removed immediately call a qualified service technician to re pipe the combustion air intake piping away from the contaminated areas Combustible Flammable Materials Do not store combustible materials gasoline or other flammable vapors or liquids near the appliance If found remove these materials immediately Air Contaminates If allowed to contaminate co
75. iance applications DO NOT oversize the appliance to the system Modular appliance installations greatly reduce the likelihood of appliance oversizing B IMPROPER COMBUSTION A WARNING Do not obstruct the flow of combustion and ventilating air Adequate air must be provided for safe operation Failure to keep the exhaust vent and intake pipe clear of ice snow or other debris could result in property damage serious personal injury or death WHL 015 REV 12 17 14 10 GAS Should overheating or gas supply to shut off do not turn off disconnect electrical supply to the circulator Instead shut off the gas supply at a location external to the appliance D WHEN SERVICING THE APPLIANCE e To avoid electric shock disconnect electrical supply before performing maintenance e To avoid severe burns allow appliance to cool e Do not use petroleum based cleaning or sealing compounds in a appliance system Gaskets and seals in the system may be damaged possibly resulting in substantial property damage e Do not use homemade cures or patent medicines Substantial property damage damage to appliance and or serious personal injury may result e Always verify proper operation after servicing the appliance E WATER QUALITY Potable water is defined as drinkable water supplied from utility or well water in compliance with EPA secondary maximum contaminant levels 40 CFR Part 143 3 as show
76. iceable air flow is present Close the zone isolation valves and proceed with the next zone Follow this procedure until all 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 After the control goes through the start up sequence the display will turn off i Press and hold the BB button for five seconds Then scroll to 29 AP by turning the dial Press the lt button AP cP will show on the display Press the button to change the test time The default is five minutes Turn the dial counterclockwise to lower or clockwise to raise the displayed value Press the button again to save any changes j Then use the dial O to scroll to cP off Press the lt button to turn on test mode Turn the dial counterclockwise to lower or clockwise to select on Press the lt button again to start test mode k The CH and internal circulation pumps will come on Run pumps as required to help bleed 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 defa
77. imum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size of DHW piping should be diameter 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 all circulators 8 VERY IMPORTANT Minimum flow rates outlined in this manual must be maintained through the heat exchanger to minimize short cycling 9 In a valve based system each heating zone has a zone valve which opens when that zone calls for heat Each zone thermostat is wired to its corresponding zone valve Contacts in the zone valves provide a signal to the appliance to operate when there is a call for heat WHL 015 REV 12 17 14 31 Primary Secondary Piping with Pumps DHW Priority Outdoor Reset make up water Appliance Wiring Figure 19 CH Piping Zoning with Pumps NOTES 1 This drawing is meant to show system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6
78. ing system Check all piping and gas connections verify all are tight Has the system been cleaned and flushed Has the boiler and the system been purged of all air Refer to Start Up Preparation this manual Has the auto air purge feature been used set Refer to Start Up Preparation this manual Pressurize system 12 15 psi CH PSI Pressurize system domestic HW Add water to prime condensate cup Percentage of glycol in system 0 50 Verify proper near boiler piping Primary Secondary 2 Electrical Have the power and control wiring been connected per the wiring diagram in this manual Is the supply voltage 120v and polarity correct 3 Check gas pipe Leak test using locally approved methods consult jurisdictional code book Has the gas supply line been verified to deliver the required BTU of the appliance Has union and shut off valve no less than gt been installed Does the gas type match the type indicated on the rating plate Check incoming gas pressure 3 5 to 14 W C in w c Static If necessary convert the boiler to the proper gas type Locate the stickers in the appropriate locations on the boiler If applicable have all dip switches been set and verified to match system requirements Verify combustion settings after gas conversion Carbon Dioxide 2 High Fire 2 Low Fire
79. iption Internal CH Pump Post Allows the user to set the appliance pump post purge time once the 27 PE 1 Purge Time appliance CH setpoint and thermostat are satisfied T T Satisfied Range 1 5 minutes 28 HA HA 0 N A N A Internal CH Pump and This function sets the time to run both the Internal and Internal DHW AP cP 5 Internal DHW Storage Storage pumps to purge air from the system 29 AP Pump Test Mode Range 1 30 minutes cP off Internal CH Pump and Turn this function on to activate Internal CH and Internal DHW Storage or OFF Internal DHW Storage pump testing cP on Pump Test Mode Only works in installation mode Turns off when in normal mode Table 21 Installer Mode Descriptions J ERROR MODE The following screen will display when the appliance encounters an error Figure 35 Error Mode Screen Error Code Error Code Description Possible Remedies Er 10 Flame has Extinguished 8 Eight Times Press the Power button to clear the Error Code If Error happens again 1 Monitor the gas pressure to the appliance while in operation Ensure pressure is between 3 5 and 14 WC 2 Check gas valve wire 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 stabl
80. is 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 injury or death 6 Clean and flush system when reinstalling an appliance NOTE When installing in a zero clearance location it may not be possible to read or view some product labeling It is recommended to make note of the appliance model and serial number C LEVELING CAUTION In order for the condensate to properly flow out of the collection system the appliance must be installed level Failure to ensure the appliance is installed level will result in improper appliance operation Correct Incorrect Correct Incorrect Figure 3 Proper Leveling WHL 015 REV 12 17 14 16 D CLEARANCES FOR SERVICE ACCESS See Figure 4 and Table 6 for recommended service clearances If these minimum clearances are not provided it may not be possible to service the appliance without removing it from the space WARNING MIN 18 Space must be provided with combustion ventilation air openings correctly sized for all other appliances located in the same space as the appliance The appliance cover must be securely fastened to prevent it from drawing air from the appliance room This is particularly important if the appliance is in a room with other appliances Failure to comply with the above could result in substa
81. ized TRY straight mixing valve urging valve TRV angle pressure relief valve circuit setter A la backflow preventer 4 54 Lal manual 3 way valve Xi float type zone valve union Outdoor temperature sensor air separator aquastat diaphragm type expansion tank radiant manifold with valve actuators P 8 Figure 17 Piping Legend B DHW PIPING flow check valve temperature pressure gate valve Se pressure reducing valve Internal CH Primary Pump DHW Pressure Gauge 0 150 PSI gal 0 30 PSI Internal DHW Storage Pump Domestic Output Isolation A wi 3 PO Pressure HotFeed Cold Feed Relief radiant manifold 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 WHL 015 REV 12 17 14 29 It may be recommended to use back flow preventer check local codes If a back preventer return valve is used thermal expansion tank must be installed on the cold water supply between the appliance and valve WARNING To control thermal expansion a thermal expansion tank suitable for potable water should be installed in systems with an installed backflow prevent
82. l gas 12 Damages malfunctions or failures caused by operating the appliance with modified altered or unapproved parts 13 Damages malfunctions or failures caused by abuse accident fire flood freeze lightning acts of God and the like 14 Tank failures leaks caused by operating the appliance in a corrosive or contaminated atmosphere 15 Damages malfunctions or failures caused by operating the appliance with an empty or partially empty tank dry firing or failures caused by operating the appliance when it is not supplied with potable water free to circulate at all times 16 Failure of the appliance due to the accumulation of solid materials and lime deposits WHL 015 REV 12 17 14 67 17 Any damage or failure resulting from improper water chemistry or heating anything other than potable water DEFINITION OF POTABLE WATER Potable water is defined as drinkable water supplied from utility or well water in compliance with EPA secondary maximum contaminant levels 40 CFR Part 143 3 as shown in the table Westinghouse will warrant the heat exchanger coil for hardness up to 12 Grains per gallon 18 Components of the appliance that are not defective but must be replaced during the warranty period as a result of reasonable wear and tear 19 Damages malfunctions or failures caused by subjecting the appliance to pressures or firing rates greater than those shown on the rating label 20 Damages malfunctions or failures
83. led approved pressure relief valves on the appliance 15 the pressure relief valve in the CH line at least 1 in diameter and rated to 30 psi Is the pressure relief valve in the DHW line at least 32 in diameter and rated to 150 psi 6 Wire the Appliance Have you connected the power and control wiring per appliance wiring diagram this manual Have all DIP switches been set on the main appliance board Is electrical connection polarity within appliance requirements Do power specifications meet appliance requirements 120V AC 7 Start Up Adjust and Test If necessary has the appliance been converted to operate on the proper fuel type Has the appliance been started Has CO2 and CO been checked to ensure proper combustion If necessary has the appliance gas valve been adjusted to achieve proper combustion Has the installation been customized per location requirements Have all customized system parameters been tested Has proper appliance operation been confirmed Has the burner flame been checked Is the burner flame a proper blue color See Figure 43 for flame sight glass window location If the flame does not appear normal the combustion system may need to be cleaned or adjusted by a qualified service technician FINAL INSTALLATION APPROVALS SIGNED BY TECHNICIAN DATE Table 26 Final Installation Checklist WHL 015 REV 12 1
84. led on this appliance When installing observe the following guidelines Failure to comply with these guidelines can result in substantial property damage personal injury or death This appliance is provided with a CH pressure relief valve that complies with the ANSI ASME Appliance and Pressure Vessel Code Section IV Heating Appliances The included 30 psi CH Pressure Relief Valve must be installed on the CH supply line to ensure a compliant installation and safe operation Westinghouse has supplied a X 1 bushing to aid installation of the CH CH 3 4 30psi Relief Valve Pressure Relief Valve The valve is meant to be field installed 3 4 150psi This appliance has high temperature shut off switch built in as standard Relief Valve safety feature Therefore a pressure only relief valve is required DO NOT operate this appliance before the supplied pressure relief valve is installed with sufficient relieving capacity in accordance with the ASME rating plate on the TJ Pressure appliance relief valve Pressure relief valves must be installed as close to the appliance as possible No other valves should be placed between the pressure relief valve and the appliance DO NOT install a CH pipe line relief valve with a pressure rating greater than 30 psi or a DHW relief valve with a pressure rating greater than 150 psi These are the maximum allowable relief valve settings for this appliance A DHW pr
85. load bearing devices and must not be used to support exhaust vent piping All vent pipes must be properly connected supported and the exhaust must be pitched a minimum of per foot back to the appliance to allow drainage of condensate Failure to properly support vent piping and follow the information in this statement could result in product damage severe personal injury or death TIGHTENING APPLIANCE COLLAR TO EXHAUST VENT AND INTAKE PIPE NOTE The included 6 length of 3 CPVC pipe MUST BE INSTALLED in the exhaust vent connection BEFORE venting the appliance WARNING Failure to properly install the included 6 length of 3 CPVC pipe BEFORE venting the appliance could result in product damage severe personal injury or death This appliance uses 2 or 3 diameter pipe 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 2 or 3 pipe into the appliance collar See Figure 7 for additional details Clean and dry the appliance connection DO NOT use primer or cement on the appliance connection Push the included 6 length of CPVC pipe into the connection until it touches the bottom of the fitting Tighten the clamps using a screwdriver Ensure the pipe is secure before continuing installation For 2 installations install a reducing coupling in a ve
86. mbustion air products containing chlorine or fluorine will produce acidic condensate that will cause significant damage to the appliance Read the list of potential contaminates and areas likely to have these contaminates in Table 7 If any of these contaminates are in the room where the appliance is located or combustion air is taken from one of the areas listed the contaminates must be removed immediately or the intake pipe must be relocated to another area WHL 015 REV 12 17 14 59 Ensure the Appliance Cabinet is Closed Ensure the appliance cabinet is closed Tighten the two upper and lower screws to secure it The cabinet must be closed while the appliance is running Check the Power Source Make sure the power cord is properly connected The main power line is connected to the manual switch box inside the appliance Check the Status of the Control Panel Observe the Control Panel to ensure the appliance is powered on and to check for any error codes Clear any debris from the panel Check Exhaust Vent and Intake Pipe Terminations Verify that the appliance exhaust vent and intake pipe terminations are clean and free of obstructions Remove any debris from the exhaust vent or intake pipe openings If removing the debris does not allow the appliance to operate correctly contact your qualified service technician to inspect the appliance and the vent system Check CH and DHW Pressure Gauges e Ensure the pressure reading on the CH gauge does
87. n VDD DHM Stepper Motor Coil X Phase DHM Stepper Motor Coil Y Phase VDD DHM Stepper Motor Coil X Phase DHM Power IWM Stepper Motor Coil Y Phase SELV 14V Unused CN3 SMW250 06 FLUX1 VCC Water Flow Sensor GND CN5 SMW250 10 RPM Fan RPM Check GND SELV 5V Table 19 Appliance Wiring 2 TERMINAL BLOCK Connection Thermostat Connection Figure 26 Terminal Block Wiring Detail Outdoor Sensor Connection WHL 015 REV 12 17 14 PART 10 OPERATING SYSTEM INSTRUCTIONS A CONTROL PANEL 40 Hold this Button More than 5 Seconds When Control Panel Power is ON Status Display Mode When Control Panel Power is OFF Installer Mode Press this Button Less than 5 Seconds Turns Control Power Panel ON OFF Press this Button Less than 5 Seconds Select Menu by Pressing Dial Button Press this Button Less than 5 Seconds Change DHW Set Point Temperature 95 120 F 35 49 C Hold this Button More than 5 Seconds Change DHW Set Point Temperature 121 140 F 49 5 60 C Press this Button Less than 5 Seconds Change CH Set Point Temperature 86 180 F 30 82 C Hold this Button More than 5 Seconds Change Temperature Units from C to F Scroll Values by Turning Dial Clockwise or Counterclockwise Figure 27 Appliance
88. n DO NOT store or place gasoline oils spray paint or other flammable products near the appliance WHL 015 REV 12 17 14 WARNING DO use spray paint hair spray or any other flammable spray near the appliance or near the exterior fresh air intake port DO NOT place any items in or around the exterior exhaust gas outlet port and or fresh air inlet port that could restrict or block the flow in or out of the vent system DO NOT store or place newspapers laundry or other combustible items near the appliance or the exterior exhaust gas outlet and or fresh air inlet port The owner should inspect the system monthly for damage water stains signs of rust corrosion and exhaust vent and air intake blockage If inspection of the unit shows signs of damage the appliance should be shut off until the problem is repaired by a qualified technician After installation all appliance safety devices should be tested This appliance is certified for indoor installations only The appliance consists of gas ignition system components which must be protected from water dripping spraying etc during operation and service Carefully consider installation location and the placement of critical components circulators condensate neutralizers etc before installing the appliance DO NOT allow children to operate this unit DO NOT use this unit if it does not appear to be operating correctly A qualified technician
89. n a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system Components and 2 A complete parts list for the venting system design or venting system MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions A copy of all installation instructions for all Product Approval side wall horizontally vented gas fueled equipment all venting i
90. n 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 Proper care of the appliance is the responsibility Ensure the user carefully reads and understands the User s Information Manual before operating and maintaining the appliance Make sure the user knows the location of the gas shut off valve and how to operate it Immediately close the gas shut off valve if the appliance is subjected to fire overheating flood physical damage or any other damaging condition that might affect the operation of the unit Have the appliance checked by a qualified technician before resuming operation Do not power up the unit unless the gas and water supply valves are fully opened Make sure the fresh air intake port and exhaust gas port are open and functional No one but a professional service technician should attempt to install service or repair this appliance There are no serviceable parts which can be changed by the user owner User Owner Contact the original professional service technician if the appliance needs repair or maintenance If the original technician is unavailable ask your gas supplier for a list of qualified service providers Keep the area around the appliance clean and free of all materials that can bur
91. n in Table 2 It is important to ensure the water quality is within these determined limits If your water contains contaminants higher than outlined by EPA then water treatment is recommended and additional maintenance may be required If you suspect that your water is contaminated in any way discontinue use of the appliance and contact 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 Aluminum 0 05 to 0 2 mg l pH 6 5 8 5 Chloride 250 mg l Sulfate 205 mg l 1 mg l Total Dissolved Solids TDS 500 mg l lron 0 3 mg l Zinc 205 mg l Table 2 Water Quality Specifications FREEZE PROTECTION CAUTION 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 WHL 015 REV 12 17 14 PART 3 TECHNICAL SPECIFICATIONS MODEL Residential Combi Boiler Installation Indoor Floor Stand Fully Condensing Minimum Maximum Input Btu Hr 28 000 140 000 AFUE 92 7 35 F Rise 7 1 Gal Hot Water Capacity 45 F Rise 5 5 Gal 77 F Rise 3 2 Gal Flue System Sealed Combustion Direct Vent Combined Vent Length Shipping Weight Ibs est 2 50 feet 3 100 feet
92. nlet in the cleaning solution 5 Open service valves V3 and V4 on the hot water outlet and cold water inlet lines 6 Turn on the circulation pump Operate the pump and allow the cleaning solution to circulate through the appliance for at least 1 hour at a rate of 4 gallons per minute 7 Rinse the cleaning solution from the DHW heat exchanger as follows a Remove the free end of drain hose D1 from the bucket b Close service valve V4 and open shutoff valve V2 WHL 015 REV 12 17 14 61 not open shutoff valve V1 d Allow water to flow through the appliance for 5 minutes e Close shutoff valve V2 8 Disconnect hoses from DHW lines Properly dispose of used cleaning solution 9 Remove the cold water inlet filter from the appliance and clean out any residues 10 Reinsert the filter and ensure the filter cap is securely tightened 11 Connect electrical power to the appliance Maintaining the Condensate System A DANGER The condensate trap assembly MUST BE PROPERLY INSTALLED according to these instructions when operating the appliance Operating the appliance without the condensate trap assembly will cause flue gases to leak and result in serious personal injury or death WARNING When servicing is complete make sure the condensate collector cap is replaced securely Failure to do so will cause venting issues that will result in serious injury or death TOP CAP 1 Ensure the appliance is
93. nlisted 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 as a direct vent sealed combustion type Combustion air must be supplied directly from the outdoors to the burner and the flue exhaust gases should be vented directly to the outdoors through the wall or roof WHL 015 REV 12 17 14 19 4 This appliance uses 2 or 3 diameter pipe for exhaust vent and intake pipe It is important to ensure airtight seal from the appliance collar to the vent terminations See Table 9 for a list of Approved Vent Materials 5 Do not install venting system components on the exterior of the building except as specifically required by these instructions e Vent terminals must be at least 1 foot from any door window or gravity inlet into the building e Maintain the correct clearance and orientation between the exhaust vent and intake pipe terminals e exhaust vent and air intake terminals must be at the same height and their center lines must be spaced apart 1 foot minimum e bottom of the exhaust vent and intake pipe terminals must be at least 1 foot above the normal snow accumulation level In no case should these terminals be installed less than 1 foot above normal snow accumulation le
94. nstructions all parts lists for venting instructions and or alll venting design instructions shall remain with the appliance or equipment at the completion of the installation LP 172 REV 02 16 06 WHL 015 REV 12 17 14 72 MAINTENANCE NOTES WHL 015 REV 12 17 14 73 CUSTOMER INSTALLATION RECORD FORM The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim After reading the important notes at the bottom of the page please also sign this document Customer s Name Installation Address Date of Installation Installers Code Name Product Serial Number s Combustion Setting at Time of Installation Comments Installers 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 are unable to make contact please contact your Sales Representative Distributor Dealer Please insert contact details WHL 015 REV 12 17 14
95. ntial Use means potable water heating in a single family residence Commercial Use refers to all other applications including any space heating applications COVERAGE A Should a defect or malfunction result in a leakage of water within the above stated warranty periods due to defective material or workmanship malfunction or failure to comply with the above warranty Westinghouse will replace the defective or malfunctioning appliance or part s with a replacement of the nearest comparable model available at the time of replacement B If Westinghouse is unable to repair or replace the appliance or part s so as to conform to this warranty after a reasonable number of attempts Westinghouse will then provide at its option a replacement appliance These remedies are the purchaser s exclusive remedies for breach of warranty If government regulations industry certification or similar standards require the replacement appliance or part s have features not found in the defective appliance or part s the owner will be charged the difference in price represented by those required features If the owner pays the price difference for those required features and or to upgrade the size and or other features available on a new replacement appliance or part s the owner will also receive a complete new limited warranty for that replacement appliance or part s D If at the time of a request for service the owner cannot provide a copy of the original s
96. ntial property damage severe personal injury or death MINIMUM CLEARANCES Installation Clearances from Non Combustibles Combustibles Recommended Service and Proper Operation Clearances Top 18 in 45 7 Back 0 Front 7 Right Side 24 in 60 9 cm Left Side 6 in 15 2 cm Table 6 Minimum Installation and Service Clearances NOTE For closet installations a combustible door or removable panel is Figure 4 Minimum Service Clearances acceptable front clearance MINIMUM CLEARANCES FROM COMBUSTIBLE MATERIALS e Hot water pipes at least 1 from combustible materials e Exhaust vent pipe at least 1 from combustible materials CAUTION Always take future maintenance into consideration when locating the appliance If the appliance is located an installation 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 RESIDENTIAL GARAGE CLOSET AND ALCOVE INSTALLATIONS CAUTION Check with your local Authority Having Jurisdiction for requirements when installing boiler in a garage closet or alcove Please read the entire manual before attempting installation Failure to properly take factors such as boiler venting piping condensate removal and wiring into account
97. of carbon monoxide Breathing carbon monoxide can result in brain damage or death DO NOT operate the appliance 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 flue gas analyzer such that a CO level of no more than 400 ppm is exceeded at any time during operation Adjusting 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 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 A WARNING This appliance must be installed by a licensed plumber licensed gas fitter and or professional service technician Improper installation and or operation can cause a potentially hazardous situation which if not avoided could result in serious injury or death and will void the warranty Westinghouse cannot anticipate every circumstance that might involve a potential hazard Each installatio
98. olved Solids TDS 500 mg l lron 0 3 Zinc 205 mg l Table 23 Water Quality Specifications Clean system to remove sediment 1 You must thoroughly flush the system without the appliance 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 Flush system until water runs clean and you are sure piping is free of sediment NOTE It is recommended you clean heat exchanger at least once a year to prevent lime scale buildup Follow the maintenance procedure to clean the heat exchanger in this manual NOTE APPLIANCE FAILURE DUE TO IMPROPER WATER CHEMISTRY IS NOT COVERED BY WARRANTY B CHECK FOR GAS LEAKS A WARNING Before starting the appliance and during initial operation smell near the floor and around the appliance for gas odorant or any unusual odor Remove appliance front door and smell interior of appliance enclosure Do not proceed with startup if there is any indication of a gas leak Repair any leaks at once WARNING PROPANE APPLIANCES ONLY Propane suppliers mix an odorant with the gas to make its presence detectable In some instances the odorant can fade and the gas may no longer have an odor Before startup and periodically thereaft
99. ontact the retailer or manufacturer ADANGER Water temperature over 125 F can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before setting temperature at water heater Feel water before bathing or showering Temperature limiting valves are available see manual WHL 015 REV 12 17 14 FOREWORD This manual is intended to be used in conjunction with other literature provided with the appliance This includes all related control information It is important that this manual all other documents included with this system and additional publications including the National Fuel Gas Code ANSI Z223 1 2002 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 Authority Having Jurisdiction AHJ The Authority Having Jurisdiction may be a federal state local government or individual such as a fire chief fire marshal chief of a fire prevention bureau labor department or health department building official or electrical inspector or others having statutory authority some circumstances the property owner or his her agent assumes the role and at government installations the commanding officer or departmental official ma
100. ontrol is not receiving 120V power Ensure service switch and or circuit breaker to appliance is turned ON Turn on service switch or circuit breaker to power appliance Is there 120V at the service switch Troubleshoot and correct the power supply to the manual switch Is the ON OFF switch inside the appliance cabinet is turned on Turn ON the manual power switch inside the appliance cabinet Check for 120V at the line voltage terminal block located inside the appliance cabinet Correct wiring inside the appliance cabinet using the wiring diagram in the installation manual Inspect the fuse Replace as necessary Replace the fuse with the proper part found in the replacement part section of this manual If fuse blows again recheck the wiring per diagram Nothing appears on the display control panel but the appliance is operating Occurs when communications is lost from the control to the display Check for loose connections and proper pin alignment engagement on the control s plug Check for continuity on the wire harness from the display to the control See repair parts section for proper replacement part Cycle power off and on using appliance power switch and check for operation Replace with new display module See repair parts section for proper replacement part Table 28 Diagnostics and Suggested Corrective Actions PART 14 ANNUAL MAINTENANCE PROCEDURES T
101. oor 17 86 Minimum supply design temperature Minimum supply temperature must be set 9 F below temperature the maximum supply temperature Range 86 F to Maximum Supply Temperature 9 F 18 dH 140 Maximum DHW set Sets Maximum DHW Setpoint temperature temperature Range 120 140 F Set Heating combustion rate 19 cb 100 Heating capacity Range 50 100 Set DHW combustion rate 20 db 100 DHW capacity Range 50 100 Internal CH Pump Post When appliance CH setpoint is satisfied but is calling for heat the 21 40 Run Timer burner will shut OFF and the CH pump will continue to run for this set T T Calling for Heat amount Range 1 60 minutes 22 Po 5 ee ae This function runs the Internal CH Pump after the Internal CH Pump Post On Run Timer has completed This will cycle the Internal CH Pump again based on the default programmed Off and On cycles and repeats until the Internal CH Pump f 23 10 Overrun Timer central heating call is satisfied Off Range 1 60 minutes 24 SF 158 Internal Storage Sets the Internal DHW Storage Tank Setpoint i Tank Setpoint Range 140 167 F 25 So 27 F Internal DHW Storage Sets the Internal DHW Storage Tank Differential Tank Differential Range 9 36 F Delay time when 26 dt 2 switching from DHW Range 0 2 minutes mode to CH mode WHL 015 REV 12 17 14 45 Display Default Detail Descr
102. operation and service circulator replacement condensate trap control replacement etc Failure to follow these instructions could result in property damage serious personal injury or death WARNING If you discover any evidence of a gas leak shut down the appliance at once Find the leak source with a bubble test and repair immediately Do not start the appliance again until the leak is repaired Failure to comply could result in substantial property damage severe personal injury or death C FILL AND TEST WATER SYSTEM WARNING Ensure the appliance is full of water before firing the burner Failure to do so will damage the appliance Such damage IS NOT covered by warranty and could result in property damage severe personal injury or death 1 Fill the system only after ensuring water chemistry meets the requirements listed in this manual 2 Close the manual and automatic air vents and appliance drain valve 3 Fill to the correct system pressure Correct pressure will vary with each application a Typical cold water fill pressure for a CH residential system is 12 psi b Pressure will rise when appliance is turned on and system water temperature increases Operating pressure of the CH system should never exceed 25 psi and must never exceed the relief valve pressure setting 4 At initial fill and during appliance startup and testing check system thoroughly for leaks Repair all leaks before proc
103. osion or deterioration 3 NEVER install condensate lines outside It is very important that the condensate line is not exposed to freezing temperatures or any type of blockage Damages due to frozen or blocked condensate lines ARE NOT covered by warranty 4 Support of the condensate line may be necessary to avoid blockage of the condensate flow WHL 015 REV 12 17 14 25 CAUTION If using a condensate pump select one approved for use with condensing boilers and furnaces The pump should have an overflow switch to prevent property damage from condensate spillage CAUTION It is very important that the condensate piping be no smaller than 94 To prevent sagging and maintain pitch condensate piping should be supported with pipe supports and pitched 7 per foot to allow for proper drainage CAUTION The condensate line must remain unobstructed allowing free flow of condensate If condensate freezes in the line or if line is obstructed in any other manner condensate can exit from the tee resulting in potential water damage to property PART 7 GAS PIPING A WARNING FIRE AND OR EXPLOSION HAZARD To avoid serious injury or death the gas line installation and the gas line inlet pressure test must be done by a licensed professional Always match the appliance with the type of gas supplied to the unit natural gas or LP gas This appliance must be converted into propane operation unless spe
104. ouse claims department personnel All alleged defective or malfunctioning parts must be returned to Westinghouse via the local distribution channels where original purchase was made NOTE Any parts or appliances returned to Westinghouse for warranty analysis will become the property of Westinghouse and will not be returned 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 by the owner in repairing or replacing the appliance or part s This warranty does not extend to labor costs beyond the coverage specified in this warranty document All such expenses the owner s responsibility LIMITATIONS OF YOUR WESTINGHOUSE WARRANTY AND REMEDIES THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ANY OBLIGATION LIABILITY RIGHT CLAIM OR REMEDY IN CONTRACT OR TORT WHETHER OR NOT ARISING FROM WESTINGHOUSE S NEGLIGENCE ACTUAL OR IMPUTED THE REMEDIES OF THE PURCHASER SHALL BE LIMITED TO THOSE PROVIDED HEREIN TO THE
105. pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size of DHW piping should 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 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 calls for heat WHL 015 REV 12 17 14 32 Primary Secondary Piping with Pumps DHW Priority With Outdoor Reset and Recirculation SU ale E DIRIA brat EELDA MEIE E a A 5 19 Cpa a CD 12 make up water Appliance Wiring cold Figure 20 DHW Priority with Outdoor Reset and Recirculation NOTES 1 This drawing is meant to show system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diame
106. posed to prevailing winds Moisture will be produced by the exhaust vent Take precautions when determining 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 the appliance This ensures that condensate in the exhaust vent returns to the appliance and drains properly For closet and alcove installations CPVC polypropylene or stainless steel venting material MUST BE USED Failure to follow this statement could result in product damage severe personal injury or death Failure to follow these instructions could result in property damage severe personal injury or death A INTAKE PIPE AND EXHAUST VENT GUIDELINES 1 Vent system must be installed in accordance with local codes or in absence of local codes the National Fuel Gas Code ANSI 2223 1 NFPA 54 and or CSA B149 1 Natural Gas and Propane Installation Code 2 For installation in Canada installer supplied plastic vent piping must comply with CAN CGA B149 1 and be certified to the Standard for Type BH Gas Venting Systems ULC S636 Components of this listed system must not be interchanged with other vent systems or u
107. problem persists replace the main control Er 42 Jumped Wire Disconnected Press the Power button to clear the Error Code If Error happens again 1 Ensure the jumped wire is properly connected 2 If the problem persists replace the main control Er 43 Burner Overheat Switch Open Press the Power button to clear the Error Code If Error happens again 1 Check burner overheat switch connections Ensure connections are secure 2 Check switch resistance If resistance is zero replace the switch 3 If the problem persists replace the main control WHL 015 REV 12 17 14 47 Error Code Description Possible Remedies Er 61 Fan Speed Feedback Signal Abnormal This Error Code will go away when the condition is remedied If Error happens again 1 Check the connections to the fan Ensure all are secure 2 If the fan does not rotate during the ignition sequence check for AC8V 26 5V power at the fan connection If AC8V 26 5V power is present at the control replace the fan If the blower does not have AC8V 26 5V power check power at the control If AC8V 26 5V power is not present at the control replace the control 3 If the problem persists replace the main control Er 66 Mixing Valve Initial Value Error Mixing Valve Cannot Return to Initial Position This Error Code will go away when the condition is remedied If Error happens again 1 Turn
108. r Use the hose clamp to secure the trap Attach the clear plastic hose onto the hose barb Reinstall the condensate hose clamp to detach the condensate trap from the drain tube BOTTOM INSERT LP 293 BB BOTTOM CAP 02 06 14 Figure 47 Condensate Detail WARNING Do not operate the appliance 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 WHL 015 REV 12 17 14 62 8 If a condensate neutralizer kit is installed with the appliance check the assembly when cleaning the condensate trap and replenish the limestone chips if necessary When replacing the limestone chips take care to ensure chips no smaller than gt to avoid blockage in condensate piping for piping details refer to condensate neutralizer installation instruction 9 Check condensate piping for sagging and or leakage Repair any sags or leaks before restoring power to the appliance CAUTION It is very important that the condensate piping be no smaller than 94 To prevent sagging and maintain pitch condensate piping should be supported with pipe supports and pitched per foot to allow for proper drainage CAUTION The condensate line must remain unobstructed allowing free flow of condensate If condensate freezes in the line or if line is obstructed in any other manner condens
109. r Code Check Condensate and main controller connections Ensure all are secure Check Condensate sensor resistance If resistance is zero replace the switch Check Condensate hose Ensure it is connected and in good condition Check condensate line and termination for blockages Check exhaust vent for blockages If the problem persists replace the main control 28 Overheat Sensor Open or Short This Error Code will go away when CH temperature decreases If Error happens again 1 Check overheat temperature sensor Ensure connections are secure 2 Check overheat sensor resistance If resistance is zero replace the sensor 3 If the problem persists replace the main control WHL 015 REV 12 17 14 46 Error Code Description Possible Remedies Er 29 APS Open 1 Check APS and connections 2 If APS is open replace the switch 3 If APS is closed and connections are secure check switch resistance If resistance is zero replace the switch 4 Check condensate line and termination for blockages 5 Check exhaust vent for blockages 6 Press the Power button to clear the Error Code and restart appliance 7 lf the problem persists replace the main control Er 30 DHW Storage Temperature Sensor Open or Short This Error Code will go away when stored DHW temperature decreases If Error happens again 1 Check DHW s
110. r appliance piping BEFORE transitioning to the approved materials listed above DO NOT REMOVE these installed components Doing so WILL VOID warranty PVC CPVC pipe and fittings of the same diameter are considered interchangeable DO NOT use Foam Core Pipe CPVC cellular core Radel etc in any portion of the exhaust piping from this appliance DO NOT connect PVC CPVC to PP without an approved vent connector When installing AL29 4C vent piping install a PVC to stainless adapter at the appliance vent connection and at the termination when using an PVC termination kit DO NOT mix AL 29 4C piping from different manufacturers unless using adapters specifically designed for the purpose by the manufacturer e DO NOT insulate non metallic exhaust vent pipe or fittings e NOT obstruct the flow of combustion or ventilation air e 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 severe personal injury or death Table 9 Approved Venting Materials WARNING Vent adaptors are not designed as load bearing devices and must not be used to support exhaust vent piping All vent pipes must be properly connected supported and the exhaust must be pitched a minimum of per foot back to the appliance to allow drainage of condensate Failure to properly support v
111. r source meeting the requirements on the rating plate 2 If problem persists replace the main control Er 37 Abnormal Supply Frequency Supply frequency is too high to operate This Error Code will go away when supply frequency returns to normal operating range If Error happens again 1 Ensure appliance is properly wired to a power source meeting the requirements on the rating plate 2 If problem persists replace the main control Er 38 Error Appears When Control Stores Data but Data is not Saved Press the Power button to clear the Error Code Replace the main control Er 40 Gas Leakage is Detected for Greater than 5 seconds or three times within 10 minutes IMPORTANT If you smell gas STOP Follow the instructions on page 2 this manual and calla qualified service technician or the fuel gas utility Press the Power button to clear the Error Code If Error happens again 1 Check the appliance cover Ensure it is secure 2 Check gas connections for leakage with a soapy solution Fix any leaks 3 Check condition of the burner assembly 4 If the problem persists replace the main control Er 41 Fan Speed too High with Flame On Press the Power button to clear the Error Code If Error happens again 1 Check the vent connections for blockages 2 Check the burner assembly 3 Check fan operation If fan appears to be operating normally but RPMs are too high replace the fan 4 If the
112. requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified LP 172 REV 02 16 06 WHL 015 REV 12 17 14 71 3 SIGNAGE metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless inspection the insoector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 1 through 4 EXEMPTIONS the following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required to Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed i
113. resulting from the use of any attachment s not supplied by Westinghouse 21 Appliances moved from the original installation location 22 Appliances that have had their rating labels removed PROCEDURES FOR WARRANTY SERVICE REQUESTS Any claim for warranty assistance must be made promptly Determine if the appliance is in warranty that is within the applicable warranty period by reviewing a copy of the original sales receipt or warranty registration The owner must present a copy of the original sales receipt or warranty registration for a warranty service request If the appliance is in warranty contact the distributor from whom the EPA DEFINITION OF POTABLE WATER Contaminant Level Aluminum 0 05 to 0 2 mg l Chloride 250 mg l Color 15 color units Copper 1 0 Corrosivity Non corrosive Fluoride 2 0 mg l Foaming Agents 0 5 mg l Iron 0 3 Manganese 0 05 mg l Odor 3 threshold odor number pH 6 5 8 5 Silver 0 1 Sulfate 250 mg l Total Dissolved Solids TDS 500 mg l Zinc 5 mg l appliance was purchased or the installer for assistance Be prepared to provide the retailer or installer with a copy of the original receipt complete model and serial numbers and the date of installation of the appliance in addition to explanation of the appliance problem Warranty coverage is subject to validation of in warranty coverage by Westingh
114. rsonal injury or death WARNING ELECTRICAL SHOCK HAZARD To ensure safety turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard Failure to do so could result in property damage serious personal injury or death A GENERAL OPERATING CONDITIONS e Temperature Operating Ambient Temperature Range 14 140 F 10 to 60 C o Operating Relative Humidity Up to 90 at 104 F 40 C WIRING INFORMATION 1 This appliance must be properly grounded Ensure the electrical outlet 120V 15 Amp minimum that the appliance will be plugged into is properly grounded A WARNING This appliance is equipped with a three prong plug It should only be plugged directly into a properly grounded three prong receptacle DO NOT remove the ground plug from the plug Doing so could result in property damage serious personal injury or death 2 The wiring diagrams contained in this manual are to be used for reference purposes only 3 Refer to these diagrams and the wiring diagrams of any external controls used with the installation when wiring the appliance Read understand and follow all wiring instructions supplied with the controls 4 Do not disconnect the power supply when the appliance is in normal operation NOTE For additional electrical protection the use of a surge protector is recommended Damage caused by power sur
115. rtical section of pipe See Figure 8 Figure 7 Installing the 6 Length of CPVC into the Exhaust Vent Connection NOTE REDUCING VENT SIZE TRANSITIONING FROM 3 TO 2 VENT PIPE MUST ALWAYS TAKE PLACE IN A VERTICAL POSITION TO PREVENT CONDENSATE BLOCKAGE Figure 8 Transitioning from 3 to 2 Vent Pipe WHL 015 REV 12 17 14 22 VENT TERMINATION 1 Two Pipe Roof and Sidewall Vent Terminations TWO PIPE ROOF VENTING WITH TEE INTAKE TWO PIPE SIDEWALL VENTING WITH TEE INTAKE AND COUPLING EXHAUST SCREEN PROVIDED INTO AND COUPLING EXHAUST STRAIGHT COUPLING INSERT INLET EXHAUST SCREENS PROVIDED INTO EACH END OF TEE INSERT INLET EXHAUST EXTERIOR WALL INSERT INLET EXHAUST SCREEN PROVIDED INTO SCREENS PROVIDED INTO STRAIGHT COUPLING EACH END OF TEE COUPLING TEE LP 445 E 1 MIN 12 OVER MAXIMUM 11 24 14 SNOW LEVEL OR 24 17 WHICHEVER IS GREATER EXHAUST MAINTAIN 127 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER TYP LP 505 A LP 445 G 07 30 14 11 24 14 RIGHT SIDE VIEW INTAKE AIR VENT Figure 9 Direct Vent Roof and Sidewall Vent Terminations WARNING All vent pipes must be glued properly supported and the exhaust must
116. s work 1 Restore electrical power to the unit 2 Press and hold the Power button to turn the unit ON 3 Refer to the Diagnostic and Error Codes section in this manual 4 Open the gas supply valve The water temperature is not hot enough or turns cold during use 1 Is the faucet open enough to draw at least 0 6 gallons 2 3L per minute through the appliance 2 Is an error code flashing on the display panel 3 Is the outlet water temperature set too low 1 Open the faucet to allow more water flow 2 Refer to the Diagnostic and Error Codes section in this manual 3 Adjust 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 the water temperature set too low Adjust the temperature setting The water at the faucet is too hot Is the water temperature set too high Adjust the temperature setting A fan can be heard even when the unit is not operating 1 The fan continues to operate after the burner shuts off to clear the exhaust vent of combustion gases 2 The fan may run to help prevent freezing 1 This is normal operation
117. se to raise the DHW set point After changing the temperature press the lt button to save the set point A DANGER Hotter water increases the risk of scald injury Scalding may occur within 5 seconds at a setting of 140 F 60 C Water temperature over 125 F can instantly cause severe burns or death from scalds Children disabled and elderly are at the highest risk of being scalded See instruction manual before setting temperature at appliance Feel water before bathing or showering E CHANGING THE TEMPERATURE INDICATOR t To change the temperature indicator from Fahrenheit to Celsius press and hold the button for more than five seconds when the display panel is powered ON This will toggle the temperature unit indicated on the display F CHANGING THE CH SET POINT Press the button when the display panel is powered ON display will appear as follows The set point will flash when the Set Point can be changed WHL 015 REV 12 17 14 42 Figure 31 Set Point Screen Factory CH Set Point is 180 F 82 C CH Set Point range is 86 180 F 30 82 C Turn the dial counterclockwise lower and clockwise to raise the current CH set point After changing the temperature press the lt P button to save the setting G STORAGE MODE Storage Mode indicates that the appliance is heating stored water in the internal storage tank When Storage Mode is opera
118. st be taken to keep appliance cabinet door in place at all times Failure to do so VOIDS WARRANTY The appliance requires minimal periodic maintenance under normal conditions However in unusually dirty or dusty conditions periodic vacuuming of the cover to maintain visibility of the display and indicators is recommended Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is operating safely and efficiently The owner should make necessary arrangements with a qualified heating contractor for periodic maintenance of the appliance Installer must also inform the owner that the lack of proper care and maintenance of the appliance may result in a hazardous condition INSPECTION ACTIVITIES DATE LAST COMPLETED PIPING 1 YEAR 2 YEAR YEAR 4 YEAR Near appliance piping Check appliance and system piping for any sign of leakage Leaking pipes could cause property damage Make sure all piping is properly supported Vent Check condition of all vent pipes and joints Ensure all vent piping is properly supported Check for obstructions exhaust and intake termination points Gas Check Gas piping test for leaks and signs of aging Make sure all pipes are properly supported SYSTEM Visual Do a full visual inspection of all system components Functional Test all functions of the system central heating water heating safe
119. t result in damage to surrounding areas or lower floors of the building The appliance should be located near a floor drain or installed in an adequately drained drain pan Westinghouse WILL NOT be held liable for leakage damages To conserve water and energy insulate all water piping especially the hot and recirculation water lines 3 Check area around appliance Remove any combustible materials gasoline and other flammable liquids WARNING Failure to keep appliance area clear and free of combustible materials liquids and vapors can result in substantial property damage severe personal injury or death WHL 015 REV 12 17 14 15 4 Gas control system components must be protected from dripping water during operation and service 5 If the appliance is to replace an existing appliance check for and correct any existing system problems such as e System leaks e Location that could cause the system and appliance to freeze and leak e __Incorrectly sized expansion tank A WARNING Do not connect the appliance to any heating systems or components that have been previously used for non potable applications Do not introduce toxic chemicals such as antifreeze 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 th
120. ters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size of DHW piping should 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 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 calls for heat D CIRCULATOR SIZING The heat exchanger has a pressure drop that must be considered in your system design Refer to Table 15 for pressure drop through the heat exchanger WHL 015 REV 12 17 14 33 Pump Performance amp HX Pressure Drop Curves faPUMP MED 2 MPUMP LOW 1 5 8 9 Flow gpm SYSTEM TEMPERATURE CHART 20 F 25 F 30 F Min Flow GPM Head ft Min Flow GPM Head ft Min Flow GPM Head ft 12 9 10 10 3 6 8 6 4 Table 15 System Temperature Chart PRESSURE RELIEF VALVE An external pressure relief valve must be instal
121. the valve when you completely lift the 141 lever the valve or discharge line be blocked Immediately shut V4 the appliance down per instructions on page 2 and call a qualified 1 service technician to inspect the valve and system Figure 45 Valve Detail Check the Burner Clean the exterior of the burner Flushing the DHW Heat Exchanger Flushing the DHW heat exchanger is a complicated procedure that should only be performed by a qualified service technician It is recommended 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 outlet and cold water inlet lines V1 and V2 See Figure 45 3 Connect one hose D1 Figure 46 to the valve V3 and place the free end in a bucket Connect one of the hoses 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 cleaning solution into the bucket Use an FDA approved cleaner for potable Figure 46 Hose Connection Deiail systems on the heat exchanger Place the drain hose D1 and hose D2 to the pump i
122. ties 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 breaker Switch and Plug Verify ON OFF switch and convenience plug are both functional CONDENSATE Neutralizer Check condensate neutralizer Replace if necessary Condensate hose Disconnect condensate hose Clean out dirt and re install NOTE Verify the flow of condensate making sure that the hose is properly connected during final inspection GAS Pressure Measure incoming gas pressure 3 5 to 14 W C Pressure Drop Measure drop in pressure on light off no more than 1 W C Check gas pipe for leaks Check piping for leaks Verify that all are properly supported COMBUSTION CO CO2 Levels Check levels in Exhaust Record at high and low fire SAFETIES ECO Energy Cut Out Check continuity on Flue ECO Replace if corroded DHW SYSTEM It is recommended 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
123. ting the display appears as follows Figure 32 Storage Mode Screen STATUS DISPLAY MODE Status Display Mode will activate when the BB button is pressed and held for five seconds when the display panel is powered ON Figure 33 Status Mode Screens Turn the dial counterclockwise and clockwise to scroll through the displayed parameters To view parameter details press the lt button at the appropriate screen Press the BB lt buttons to leave the parameter Press the BB button again to return to Operation Mode To turn on Lock Mode press the lt button at the d Lc parameter Turn the dial counterclockwise or clockwise to scroll On or Off Press the lt button to save the selection and return to the parameters WHL 015 REV 12 17 14 Press the BB button again to return to Operation Mode 43 NOTE The Control System will not allow the changes if Lock Mode is activated Lock Mode will have to be turned off before making further changes Parameter Detail Description Outdoor temperature Current outdoor sensor temperature A Lior A GA DHW Water flow rate Current flow Li LPM GA GPM b It CH return water temperature Current CH return water temperature C Fr FAN speed RPM Current fan speed RPM Lc Lock func
124. tion Lock Lock Mode ON OFF E oP CH supply temperature Operating temperature Current CH supply temperature F dH DHW outlet temperature Current DHW outlet temperature H Eh Exhaust_temperature Current exhaust temperature I St Internal storage tank temperature Current stored water temperature Parameter Detail Description J oH CH water overheat temperature Current temperature on the overheating sensor 1 Supply power time Unit 100 hour 2 rh Burner Operation Burner operation time Unit 1 hour L rt 3 rH Ti Burner operation time L rt display on sub menu Unit 1 000 hour ime 4 It Ignition cycles Cycle 10 times 5 IH Ignition cycles Cycle 10 000 times Displays output condition for Internal recirculation 1st 2nd 3rd pump and heating lt gt Items Internal DHW 5 Not P Ou Storage pump Pump Used Stop lt gt lt gt lt gt Operation lt gt Table 20 Status Mode Display Screen Descriptions INSTALLER MODE Installer Mode will activate when the BB button is pressed and held for five seconds while the display is powered OFF If the display is powered on press the button to turn it off before pressing holding the BB button for five seconds Figure 34 Installer Mode Screens Toggle through items that can be viewed changed by turning the dial view change an item press the lt button Some displayed items can
125. tlet on the appliance is lower than the drain you must use a condensate removal pump available from Westinghouse 554200 This pump is equipped with two leads that can be connected to an alarm or another type of warning device to alert the user of a condensate overflow which if not corrected could cause property damage Gas Outlet 3 If a long horizontal run is used it may be necessary to create a vent Offset Adjustment in the horizontal run to prevent a vacuum lock in the condensate line CAUTION DO NOT REMOVE OR ATTEMPT TO MAKE ANY 4 Do not expose the condensate to freezing temperatures 9 ADJUSTMENT THIS Gas Outlet SCREW WITHOUT A 5 It is very important you support the condensate line to assure Pressure Tap COMBUSTION ANALYZER proper drainage FINAL CHECKS BEFORE STARTING APPLIANCE 1 Verify the appliance and system are full of water and all system components are correctly set for operation 2 Fill the condensate trap with water 3 Verify electrical connections are correct and securely attached Gas Inlet 5 n Pressure 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 Gas Inlet ADJUSTING GAS PRESSURE AT THE APPLIANCE Figure 41 Gas Valve Detail NOTE Refer to Figure 41 when adjusting gas
126. torage temperature sensor Ensure connections are secure 2 Check DHW storage temperature sensor resistance If resistance is zero replace the sensor 3 If the problem persists replace the main control Er 32 DHW Sensor Open or Short This Error Code will go away when outlet DHW temperature decreases If Error happens again 1 Check DHW outlet temperature sensor Ensure connections are secure 2 Check sensor resistance If resistance is zero replace the sensor 3 If the problem persists replace the main control Er 33 CH Temperature Sensor Open or Short This Error Code will go away when CH temperature decreases If Error happens again 1 Check CH temperature sensor Ensure connections are secure 2 Check CH sensor resistance If resistance is zero replace the sensor 3 If the problem persists replace the main control Er 35 Exhaust Sensor Open or Short This Error Code will go away when exhaust temperature decreases If Error happens again 1 Check exhaust temperature sensor Ensure connections are secure 2 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 powe
127. ult is five minutes or press the BB button to leave it manually After the system has operated for some time eliminate any residual air by using the manual air vents located throughout the system m If purge valves are not installed in the system open manual air vents in the system one at a time beginning with the lowest floor Close vent when water squirts out Repeat with remaining vents n Refill to correct pressure E PURGE AIR FROM DHW SYSTEM 1 Make sure CH and DHW lines to the appliance are open and full of water Turn on all electric power to appliance A WARNING Ensure the appliance is full of water before firing the burner Failure to do so will damage the appliance Such damage IS NOT covered by warranty and could result in property damage serious personal injury or death 2 Open hot water faucets in the DHW system Start with the faucets nearest the appliance 3 Keep faucets open until water runs freely and all air is purged Then move on to faucets further away from the appliance in the system 4 When water flows freely from all hot water faucets DHW purging is complete CHECK THERMOSTAT CIRCUIT S 1 Disconnect the two external wires connected to the appliance thermostat terminals low voltage terminal strip 2 Connect a voltmeter across these two incoming wires with power supplied to the thermostat circuits Close each thermostat zone valve and relay in the external circuit one at a tim
128. use maintain or to bring the appliance installation into compliance with local building codes and regulations 4 Failure to locate the appliance in an area where leakage of the tank or water line connections and the combination temperature and relief valve will not result in damage to the area adjacent to the appliance or lower floors of the structure 5 Any failed components of the heat system not manufactured by Westinghouse as part of the appliance 6 Appliances repaired or altered without the prior written approval of Westinghouse 7 Damages malfunctions or failures resulting from failure to install the appliance in accordance with applicable building codes ordinances or good plumbing and electrical trade practices 8 Damages malfunctions or failures resulting from improper installation failure to operate the appliance at pressures not exceeding the working pressure shown on the rating plate or failure to operate and maintain the appliance in accordance with the manufacturer s provided instructions 9 Failure to operate the appliance in an open system with a properly sized and installed thermal expansion tank 10 Failure or performance problems caused by improper sizing of the appliance expansion device piping or the gas supply line the venting connection combustion air openings electric service voltage wiring or fusing 11 Damages malfunctions or failures caused by improper conversion from natural gas to LP gas or LP gas to natura
129. vel Do not install the exhaust vent terminals directly above windows doors e Intake pipe terminal must not terminate in areas that might contain combustion air contaminates such as near swimming pools e For sidewall venting the minimum horizontal distance between adjacent exhaust vent terminations is 1 foot It is recommended this distance be greater than 1 foot to better avoid frost damage to building surfaces e For roof venting minimum horizontal distance between any adjacent exhaust vent termination is 1 foot Figure 6 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 Clearance to permanently closed window id Vertical clearance to ventilated soffit located above the D terminal within a horizontal distance of 2 feet from the center line of the terminal E Clearance to unventilated soffit i F Clearance to outside corner Clearance to inside corner H Clearance to each side of center line extended above meter 3 feet with a height 15 feet regulator assembly above meter regulator assembly 1 Clearance to service regulator vent outlet 3 feet J Clearance to non mechanical air supply inlet to building or 1 foot 3 feet the combustion air inlet to any other appliance 3 feet above if within 10
130. y be the AHJ NOTE Westinghouse reserves the right to modify product technical specifications and components without prior notice FOR THE INSTALLER DA R This manual must only be used by a qualified heating installer service technician Read all instructions in this manual before installing Perform steps in the order given Failure to comply could result in substantial property damage severe personal injury or death This appliance must be installed by qualified and licensed personnel The installer should be guided by the instructions furnished with the appliance and with local codes and utility company requirements In the absence of local codes preference should be given to the National Fuel Gas Code ANSI 2223 1 2002 INSTALLATIONS MUST COMPLY WITH Local state provincial and national codes laws regulations and ordinances The latest version of the National Fuel Gas Code ANSI 2223 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 2R3 Also Canadian Electrical Code 22 1 from Canadian Standards Association 5060 Spectrum Way Suite 100 Mississauga Ontario Canada L4W 5N6 Code for the installation of Heat Producing Appliances latest version from American Insurance Association 85 John Street New York NY 11038
131. ystems Air must remain in the system and return to the tank to provide an air cushion An automatic air vent would cause air to leave the system resulting in improper operation of the expansion tank DIAPHRAGM OR BLADDER EXPANSION TANK Always install an automatic air vent on top of the air separator to remove residual air from the system CAUTION Use at least the MINIMUM pipe size for all appliance loop piping connecting appliance to and from the primary secondary connection DO NOT pipe the appliance in any configuration other than primary secondary All piping methods shown in this manual use primary secondary connection This is to avoid the possibility of inadequate flow through the appliance Using less than the required minimum pipe size and piping in anything other than a primary secondary installation could result in system problems property damage and premature appliance failure Such problems ARE NOT covered by product warranty Use both thread tape and pipe dope to connect to the 1 heating water outlet and inlet WHL 015 REV 12 17 14 30 Primary Secondary Piping with Zone Valves te tt Appliance Wiring Figure 18 CH and DHW Piping NOTES 1 This drawing is meant to show system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A min

Westinghouse WBRCNG140F Installation Manual

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