41 Figure 34 - Ladder Diagram whl-648 Rev. 000 Rel. 003 Date 3.6.
42 Connector No.
43 Connector No. of Location Pin 1 8 2 9 3 10 CN7 LWD1140-14 4 11 5 12 6 13 7 14 CN14 SMW250-09 CN3 SMW250-06 CN5 SMW250-10 Description Board Silk F.S Flame Sensor OP.S Operating Water Temperature Sensor DH.S DHW Temperature Sensor I.S NOT USED BG.S Exhaust Temperature Sensor ST.S NOT USED SP.
4 Part 8 - Gas Connections 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. Ensure the gas on which the appliance will operate is the same type specified on the rating plate (natural gas or LP gas). This appliance must be converted into propane operation unless specifically manufactured for use with propane. Follow Gas Conversion Manual instructions (separate document).
45 C. Additional Precaution for Excess Flow Valve (EFV) If an excess flow valve (EFV) is in the gas line, check the manufacturer’s minimum and maximum flow capacity ratings. An improperly sized EFV will not allow for a full flow of gas to the appliance and will cause the appliance to malfunction. See Figure 38. It is required to use a calibrated combustion analyzer to verify final adjustment according to the combustion chart (Table 26). Failure to do so could result in serious personal injury or death.
46 Part 9 - Controls A. Control and Display Overviews Figure 40 - Control Panel Detail Figure 41 - LCD Display The LCD display also features a backlit lamp that will illuminate: t When a user action is detected (a button is pressed) t The display has timed out for approximately 2 minutes After start-up, the display appears as follows. B. Start-Up Sequence After the appliance is powered ON, the LCD display shows a sequence of information.
47 C. Changing the DHW Set-Point Press the button when the display panel is powered ON to change the DHW Set-Point. The display will appear as follows. Figure 44 - CH Set-Point Screens Factory CH Set-Point is 180oF (82oC). Initial CH Set-Point range is 86 – 180oF (30 – 82oC). Turn the dial counterclockwise to lower and clockwise to raise the button to CH set-point. After changing the temperature, press the save the set-point.
48 H. Status Display Status Display will activate when button is pressed and held for five seconds at Standby Mode when the display panel is powered ON. Figure 46 - Status Display Screens Display (Main Menu) Display (Sub Menu) Detail Description O:ot Outdoor Temperature Current Outdoor Sensor Temperature (When --- is displayed, outdoor sensor is not connected.
49 I. Installer Mode Installer Mode will activate when button is pressed and held for five seconds while the appliance display is powered Off. Figure 47 - Installer Mode Screens Display Default Detail 1:EH E0.00 Error history up to 10 Check ten most recent Error Codes (E0 - E9) 2:cE OFF Clear Error History Select “ON” to Clear Error History.
50 Display Default Detail Description 17:cL 86F Minimum Supply Temperature Sets the minimum design supply temperature based on the maximum outdoor design temperature. Minimum supply temperature must be set 9oF above the maximum supply temperature.
51 See Figure 48 to set your Outdoor Reset Curve. To check the CH Target Temperature while using Outdoor Temperature Mode, press the the display panel is powered on. button while the appliance is operational and Figure 48 - Outdoor Reset Curve - See Installer Mode for Curve Setting Descriptions K. 0-10 Volt Input 1. A signal from a building management system may be connected to the appliance to enable remote control. This signal should be a 0-10 volt positive-going DC signal.
52 Part 10 - Troubleshooting A. Error Code When the appliance encounters an error, the display will flash “Er” followed by a numerical code. The appliance shall enter a soft lockout condition if the error is such that it can return to normal operation once the condition relieves itself (overheat conditions, NTC open or shorts, etc.). The appliance shall enter a hard lockout if the condition indicates something more serious (flame, ignition, condensate line, etc.
53 Error Code Error Code Description Possible Remedies Er:31 Return Temperature Sensor Open or Short This Error Code will go away when operating temperature decreases. If Error happens again: 1. Check return temperature sensor. Ensure connections are secure. 2. Check return 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.
54 Error Code Error Code Description 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.
55 B. Error Tree Analysis 1. Flame Detection Figure 50 - Flame Detection Error Analysis Tree 2. Air Pressure Switch / Burner Overheat Limit / Condensate Block Switch Figure 51 - APS / Burner Overheat Limit / Condensate Block Switch Error Analysis Tree 3. DHW / Operating Temperature / CH Overheat / Exhaust Sensors Figure 52 - DHW / Operating Temperature / CH Overheat / Exhaust Sensors Error Analysis Tree whl-648 Rev. 000 Rel. 003 Date 3.6.
56 C. Suggested Corrective Actions 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. Is electrical panel’s 10 Amp circuit breaker tripped? 3. Is the fuse on the circuit board good? 4. Is 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 qualified service technician. 4. Contact the power company.
57 Display Condition Diagnostic Possible Corrective Actions Ensure service switch and/or circuit Turn on service switch or circuit breaker to breaker to appliance is turned ON power appliance Troubleshoot and correct the power supply to the manual switch Is there 120V at the service switch Nothing appears on the display control panel and no other appliance components are operating Control is not receiving 120V power Is the ON/OFF switch inside the appliance Turn ON the manual power switch inside cabi
58 Part 11 - Start-Up Thoroughly clean and flush any system that has used glycol before installing the appliance. Provide the customer with a material safety data sheet (MSDS) on the fluid used. A. Check / Control Water Chemistry Chemical imbalance of the water supply may affect efficiency and cause severe damage to the appliance and associated equipment. It is important that the water chemistry on both the domestic hot water and central heating sides are checked before installing the appliance.
59 C. Freeze Protection (When Used) NEVER use automotive or standard glycol antifreeze. Do not use ethylene glycol made for hydronic systems. Use only freezeprotection fluids certified by fluid manufacturer as suitable for use with stainless steel appliances, verified in the fluid manufacturer’s literature. Thoroughly clean and flush any system that has used glycol before installing the new appliance. Provide the appliance owner with a material safety data sheet (MSDS) on the fluid used. 1.
60 q. Refill to correct pressure. F. 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. 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. 2. Open hot water faucets in the DHW system. Start with the faucets nearest the appliance. 3.
61 Part 12 - Installation Checklist Before Installing Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Is there enough space to ensure proper installation? Does installation location allow for proper service clearances? Are water and gas lines properly sized and set at proper pressures for the installation? Is appliance location as near the exhaust vent / intake pipe terminations as possible? Have combustible materials been cleared from the installation location? Is there a drain cl
62 Start-Up, Adjust, and Test Yes No Yes No Has the appliance been started? If necessary, has the appliance gas valve been adjusted? Has the installation been customized per installation location requirements? Have all customized system parameters been tested? Has proper appliance operation been confirmed? Burner Flame Has the burner flame been checked? Have combustion values been verified with a calibrated combustion analyzer? If the flame does not appear normal, it may need to be cleaned by a qualifi
63 t If you notice flue gas leaking from the opening, this indicates a dry condensate drain trap. If problem persists, contact a qualified service technician to inspect the appliance and condensate line and refill the condensate trap. t If 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 54.
64 other hose (D2) to the circulation pump inlet and place the free end in press the Power button to turn the appliance on. the bucket. 11. Reinsert the filter and ensure the filter cap is securely tightened. 12. Connect electrical power to the appliance. Maintaining the Condensate System The condensate trap assembly MUST BE PROPERLY INSTALLED according to these instructions when operating the appliance.
65 5. When the condensate trap is sufficiently clean, reinstall the Maintenance Report bottom cap on the trap. NOTE: Ensure all parts shown in Figure 58, Condensate Detail, are installed with the condensate trap. If any parts are missing DO NOT In unusually dirty or dusty conditions, care must be taken to keep reinstall the trap. Replace the entire assembly. appliance cabinet door in place at all times.
66 INSPECTION ACTIVITIES DATE LAST COMPLETED PIPING 1st 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. Flush tankless heat exchanger annually (more in hard water conditions). See User’s Information manual for instructions. Vent Check condition of all vent pipes and joints. Ensure all vent piping is properly supported.
67 Part 14 - Moving Adapters from Left to Right (Floor Models) Figure 59 - Moving Adapters from Left to Right Part 15 - Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER B-1 M3 X 6 PH + M/S 7855P-384 B-10 M4 X 12 TH + M/S 7855P-393 B-2 M4 X 8 PH + Self Tapping 7855P-385 B-11 M4 X 14 PH + Self Tapping 7855P-394 B-3 M4 X 8 TH + Self Tapping 7855P-386 B-12 M4 X 15 PW + M/S 7855P-395 B-4 M4 X 8 TH + M/S 7855P-387 B-13 M4 X 20 TH + Self Tapping 7855P-
68 Figure 60 - Cabinet Replacement Parts - 140 Floor and Wall Mount Models NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER 15 Exhaust Duct Assembly 7855P-002 20 Air Pressure Switch 7855P-262 15-1 Exhaust/Intake Duct Clamps (Φ100) 7855P-332 21 Ignition Transformer 7855P-007 15-2 Exhaust/Intake G
69 % % % % % % % % Figure 61 - Water Piping Replacement Parts - 140 Floor and Wall Mount Models NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER 36 DHW Outlet Pipe 7855P-242 47 DHW
70 Figure 62 - Heat Exchanger Replacement Parts - 140 Floor and Wall Mount Models NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER 60 Exhaust Pipe Assembly 7855P-237 61 Storage Tank Clamp 7855P-297 65 Exhaust Pipe Gasket 7855P-351 66 Storage Tank Bracket 7855P-298 62 Exhaust Temperature Sensor Clip 7855P
71 Figure 63 - Combustion System Replacement Parts - 140 Floor and Wall Mount Models NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER 78 Burner Inlet Channel Gasket 7855P-370 86 Mixer Clamp 7855P-376 79 Burner Inlet Channel (with Damper) 7855P-367 87 1/2” Gas Pipe Gasket 7855P-221 79-1 Air Damper 4G 7855P-368 88 Gas Pipe (to Mixer) 7855P-437 79-2 Air Damper Guide 7855
72 Figure 64 - Cabinet Replacement Parts - 199 Floor and Wall Mount Models NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER 15 Exhaust Duct Assembly 7855P-002 22 Display Panel 7855P-012 15-1 Exhaust/Intake Duct Clamps (Φ100) 7855P-332 23 Display Panel Bracket 7855P-413 15-2 Exhaust/Intake Gaskets 7850P-210 24 Ignition Transformer 7855P-007 15-3 Exhaust Duct 7855P-333 25 Control Board 7855P-268 15-4 Combustion Analyzer Port Plug O-Ring 7855P-334 26 Terminal Bl
73 % % % Figure 65 - Heat Exchanger Replacement Parts - 199 Floor and Wall Mount Models NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER 38 DHW Outlet Pipe 7855P-275 49 DHW Inlet Block Cap 7855P-
74 Figure 66 - Heat Exchanger Replacement Parts - 199 Floor and Wall Mount Models NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER 63 Exhaust Temperature Sensor 63-1 Exhaust Temperature Sensor O-Ring 64 Exhaust Temperature Sensor Clip 65 Exhaust Pipe Assembly 7855P-415 76-2 Burner Body 7855P-606 66 Exhaust Pipe Gasket 7855P-418 76-3 Burner Gasket 7855P-419 67 Storage Tank Clamp 7855P-291 76-4 Ceramic Fiber Burner 7855P-420 68 Storage Tank Bracket 7855P-292 76-
75 Figure 67 - Combustion System Replacement Parts - 199 Floor and Wall Mount Models NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER 78 Burner Inlet Channel (with Damper) 7855P-424 86 Air Intake Hose (Bottom Clamp) 7855P-429 79 Air Damper 19G 7855P-618 87 APS Hose Fitting 7855P-375 80 Air Damper Guide 7855P-369 88 Gas Valve Assembly 7855P-431 81 Fan Outlet Gasket 7855P-425 88-1 Gas Valve Outlet Adapter 7855P-232 82 Burner Inlet Channel Gasket 7855P-426 88-2
76 Figure 68 - Floor Model Replacement Parts Item # Description 140 Model 199 Model 1 Base Assembly, Floor Stand 7865P-001 7865P-002 2 Screw M5 x 12MM 7865P-023 3 Anchor and Wall Bracket 7850P-084 4 Screw M6 x 12MM (Not Shown) 7865P-024 5 Right Side Panel w/ Labels 7865P-010 7865P-011 Item # Description 140 Model 10 Locknut - Electrical - 1/2” 7700P-002 11 Barb Fitting 1/2” 7100P-044 12 Screw M4 x 10MM 7855P-390 13 3/4” ID SS Flex - 22” Long 7865P-017 14 3/4” ID SS Flex
77 Limited Warranty for WBRC Appliances Westinghouse warrants this appliance and its components to be free from defects in material and workmanship according to the following terms, conditions, and time periods. UNLESS OTHERWISE NOTED THESE WARRANTIES COMMENCE ON THE DATE OF INSTALLATION. This limited warranty is only available to the original consumer purchaser (herinafter “Owner”) of this appliance, and is nontransferable.
78 17. Any damage or failure resulting from improper water chemistry. See below for water chemistry requirements. Contaminant Level Total Hardness (Residential Use - Below 140oF water temperature) 200 mg/l (12 grains/gallon) Total Hardness (Commercial Use - Above 140oF water temperature) 120 mg/l (7 grains/gallon) Aluminum 0.05 to 0.2 mg/l Chloride 100 mg/l Color 15 color units Copper 1.0 mg/l Corrosivity Non-corrosive Fluoride 2.0 mg/l Foaming Agents 0.5 mg/l Iron 0.
79 Notes whl-648 Rev. 000 Rel. 003 Date 3.6.
80 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.
