Gas Fired Residential Combi Boiler Wall Mount Models INSTALLATION / START-UP MAINTENANCE / PARTS WARRANTY Models WBRC**140W WBRC**199W **”NG” Refers to Natural Gas Operation “LP” Refers to Propane Gas Operation 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.
WHL-012 REV. 10.31.
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important product information. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
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.
E. WATER CHEMISTRY............................................................................................................................................................... 10 F. FREEZE PROTECTION ........................................................................................................................................................... 10 G. SCALDING .........................................................................................................................................
B. WIRING INFORMATION .......................................................................................................................................................... 43 C. DIP SWITCHES ....................................................................................................................................................................... 43 PART 10 – OPERATING SYSTEM INSTRUCTIONS .......................................................................................................
PART 1 – ITEMS SHIPPED WITH THE APPLIANCE ITEM DESCRIPTION QUANTITY Elite Fire Tube Combi Appliance 140W / 199W 1 Installation and User’s Information Manuals, H2 Document 1 Each Condensate Hose (7855P-089) 1 CH Pressure Relief Valve With ¾” X 1” Bushing (CH Line ¾” 30 psi) (7855P-077) 1 Each Vent Screens (3”) (7855P-085) 2 Screens Outdoor Sensor with Screws and Anchors (7855P-084) 1 Combi Venting Kit 3” CPVC (S7855-002) ½” X ¾” Bell Coupling for Gas Line 140W Model Only (7855P-086) 6” Len
ITEM OPTIONAL PARTS (Not Included) DESCRIPTION PART NUMBER Threaded ¾” DHW Tankless Isolation Valves (With Pressure Relief Valve) (7850P-090) 2 Vent Screens (2” Mesh) (7850P-088) 2 Screens 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. Vapors from flammable liquids will explode and can cause a fire, resulting in personal injury or death.
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.
• Always verify proper operation after servicing the appliance. E. WATER CHEMISTRY Chemical imbalance of the water supply may affect efficiency and cause severe damage to the appliance and associated equipment. Water quality must be professionally analyzed to determine whether it is necessary to treat the water. Various solutions are available to adjust water quality. Adverse water quality will affect the reliability of the system.
Table 3 details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications. H. HIGH ELEVATION INSTALLATIONS Natural gas at high elevation might contain less heating value than typical 1,000 BTU/cu ft and therefore can cause improper air / gas mix leading to improper combustion.
Figure 1 – 140W Specifications and Dimensions DESCRIPTION A Automatic Air Vent B Intake Pipe Connection C Exhaust Vent Connection D Relief Valve Adapter E CH Supply Adapter F CH Return Adapter G DHW Outlet Adapter H DHW Inlet Adapter I Gas Connection Adapter J Condensate Adapter Table 5 – 140W Adapter Specifications DIAMETER (ALL NPTM) 3” 3” ¾” NPT 1” NPT 1” NPT ¾” NPT ¾” NPT ½” NPT (1/2” X ¾” Bell Coupling Provided to Upsize Gas Line) - WHL-012 REV. 10.31.
Figure 2 - 199W Specifications and Dimensions DESCRIPTION A Automatic Air Vent B Intake Pipe Connection C Exhaust Vent Connection D Relief Valve Adapter E CH Supply Adapter F CH Return Adapter G DHW Outlet Adapter H DHW Inlet Adapter I Gas Connection Adapter J Condensate Adapter Table 6 - 199W Adapter Specifications DIAMETER (ALL NPTM) 3” 3” ¾” NPT 1” NPT 1” NPT ¾” NPT ¾” NPT ¾” NPT ½” NPT WHL-012 REV. 10.31.
Figure 3 – Model Components NUMBER COMPONENT DESCRIPTION 1 Air Vent 2 Air Intake Adapter 3 Air / Gas Mixing Pipe 4 Gas Valve 5 Internal Storage Tank 6 Main PCB 7 Manual ON/OFF Power Switch 8 Internal Recirculation Pump (DHW) / CH Internal Primary Pump 9 CH Supply Adapter 10 CH Return Adapter 11 CH Return Filter 12 CH Pressure Gauge 13 DHW Outlet Adapter 14 Gas Inlet Adapter 15 DHW Inlet Adapter With Filter and Flow Restrictor Table 7 – Component List NUMBER 16 17 18 19 20 21 22 23 24 25 26 27 28 29 CO
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 Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk.
• • Location that could cause the system and appliance to freeze and leak. Incorrectly-sized expansion tank 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.
E. RESIDENTIAL GARAGE AND CLOSET INSTALLATIONS Check with your local Authority Having Jurisdiction for requirements when installing appliance in a garage or closet. Please read the entire manual before attempting installation. Failure to properly take factors such as venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.
H. 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. 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.
6. After it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous condition of use. 7. Any improper operation of the common venting system should be corrected so the installation conforms to the National Fuel Gas Code, ANSI Z223.1.
1. Locate the DHW inlet adapter on the bottom of the appliance. 2. Pull the two pins to release the DHW inlet filter. See Figure 7-A. The flow restrictor is attached to the top of the filter assembly. 3. Remove the installed white flow restrictor and replace it with the blue flow restrictor included with the appliance. See Figure 7-B. 4. Reinstall the DHW inlet filter. 5. Reinstall the two pins.
199W 11 10 9 Flow (GPM) 8 7 6 5 4 3 2 1 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Pressure (PSI) No Restrictor White Restrictor (factory) Figure 9 – Water Pressure vs. Flow Through the Restrictors – 199W Models PART 5 – VENTING Vent this appliance in accordance with these instructions. Failure to do so will result in property damage, severe personal injury, or death. DO NOT mix vent systems or materials unless specifically told to do so in this manual.
3. This appliance is designed to be installed in a power vent (using indoor air for combustion and vented to the outdoors) type, or as a direct vent (sealed combustion) type. In power vent installations, indoor air is used for combustion and exhaust gases are vented directly to the outdoors through a sealed exhaust vent piped through the wall or roof.
The building owner is responsible for keeping the exhaust and intake terminations free of snow, ice, or other potential blockages, as well as scheduling routing maintenance. Failure to keep the vent piping terminations clear and properly maintain the heater could result in property damage, severe personal injury, or death. For each floor containing bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedrooms, as well as in the room that houses the heater.
Figure 10 – Vent Termination Detail A B C D E F G H I J K DESCRIPTION Clearance above grade, veranda, porch, deck, or balcony Direct Vent Clearance to window or door that may be opened Power Vent Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet from the center line of the terminal Clearance to unventilated soffit Clearance to outside corner Clearance to inside corner Clearance to each side of center line
B. APPROVED VENT MATERIALS NOTICE Consult Table 11 or the most recent edition of ANSI Z223.1/NFPA 54 or CAN/CGA B149.1 as well as all applicable local codes and regulations when selecting vent pipe materials. Item Exhaust vent or Intake pipe and fittings Pipe Cement Pipe Primer APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL Standards for Installation in: Material United States Canada PP, CPVC, and PVC venting must be CPVC schedule 40 ASTM-D2846 ULC-S636 Certified.
• • • • 8 feet (2.4M) for each additional 2” 90o elbow 4 feet (1.2M) for each additional 2” 45o elbow Some terminations are considered elbows, and deduction should be applied. For example, a turndown 90 o or an open T termination should be considered a 90 o elbow. For 2” diameter installations, install a reducing coupling in a vertical section of pipe ABOVE the pipe clamp installed on the water heater. See Figure 8. b.
Figure 11 – Installing the 6” Length of CPVC into the Exhaust Vent Connection Figure 12 – Transitioning from 3” to 2” Vent Pipe E. VENT TERMINATION 1. Direct Vent, Two Pipe Roof and Sidewall Vent Terminations Figure 13 – Direct Vent, Roof and Sidewall Vent Terminations All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the appliance to allow drainage of condensate.
2. Direct Vent, Optional Horizontal and Vertical Vent Kits Figure 14 – Direct Vent, Vent Terminations (With Optional Kits) All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” 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.
4. Power Venting, Indoor Combustion Air Installation in Confined or Unconfined Space This heater requires fresh, uncontaminated air for safe operation and must be installed in a mechanical room where there is adequate combustion and ventilating air. NOTE: To prevent combustion air contamination, see Table 9. Combustion air from the indoor space can be used if the space has adequate area or when air is provided through a duct or louver to supply sufficient combustion air based on the heater input.
Figure 17 – NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. WHL-012 REV. 10.31.
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 approved by the Authority Having Jurisdiction (AHJ) to drain condensate.
If using a condensate pump, select one approved for use with condensing appliances and furnaces. The pump should have an overflow switch to prevent property damage from condensate spillage. It is very important that the condensate piping be no smaller than ¾”. To prevent sagging and maintain pitch, condensate piping should be supported with pipe supports, and pitched ¼” per foot to allow for proper drainage. The condensate line must remain unobstructed, allowing free flow of condensate.
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 water column based on 1.5 specific gravity for liquid propane.
Figure 20 – Gas Line with Shut-Off Valve Detail Figure 21 – Natural Gas Piping Installation – NOTE: Capacity to be Not Less than Total Capacity of Connected Appliances Figure 22 – LP Gas Piping Installation – NOTE: Capacity to be Not Less than Total Capacity of Connected Appliances WHL-012 REV. 10.31.
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 ¾” diameter and the central heating water pipe should be 1” in diameter.
Figure 24 – Piping Legend WHL-012 REV. 10.31.
B. DHW PIPING Use both thread tape and pipe dope to connect to the ¾” domestic water inlet and outlet. A shut off valve between the city water supply and DHW inlet is recommended for ease of service. Westinghouse offers threaded ¾” DHW tankless isolation valves with DHW pressure relief valve for ease of installation and future service. See Optional Equipment, this manual, for part numbers. It may be recommended to use a back flow preventer – check local codes.
Figure 25 – 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 minimum 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 ¾” diameter and CH piping should be 1” in diameter. 5.
Figure 26 – 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 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 ¾” diameter and CH piping should be 1” in diameter. 5.
Figure 27 – 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 diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. 4.
Figure 28 – DHW Priority with Outdoor Reset, Boiler Primary Pump, 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 diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. 4.
D. CH AND DHW PRESSURE RELIEF VALVES An external pressure relief valve must be installed on this appliance for both the CH and DHW loops. When installing, observe the following guidelines. 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. Failure to comply with these guidelines can result in substantial property damage, personal injury, or death.
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 • Temperature o Operating Ambient Temperature Range: 14 – 140oF (-10 to 60oC) o Operating Relative Humidity: Up to 90% at 104oF (40oC) B. WIRING INFORMATION 1. This appliance must be properly grounded.
Figure 31 – Dip Switch Detail DIP SWITCH GROUP DIP SWITCH 1–3 4 5 6 7 Table 17 – DIP Switch Group OFF DO NOT MOVE Vent Size Gas Type High Fire Low Fire SYSTEM CONTROL SETTINGS MAXIMUM FLAME DETECTING VOLTAGE PRE-PURGE TIME (Tp) SAFETY TIME (IGNITING TIME) (Ts) IGNITING INTERVAL TIME POST-PURGE TIME (Tip) OVER-HEATING 1,2,3 PROTECTION DETECTION TIME PUMP 1 POST CIRCULATING TIME (T1pv) PUMP 2 POST CIRCULATING TIME (T2pv) HIGH AND LOW WATER LEVEL DETECTION TIME HIGH AND LOW WATER LEVEL RECOVERY TIME Tabl
Figure 32 – Electrical Wiring Diagram WHL-012 REV. 10.31.
Figure 33 – Ladder Diagram WHL-012 REV. 10.31.
CONNECTOR PIN 1 2 3 4 CN9 5 65001WS-12 6 7 8 9-12 1 CN6 LW6A4-03 3 1 CN1 2 SMW250-03 3 1 2 3 CN4 LWD1140-06 4 5 6 1 2 CN8 SMW250-04 3 4 1 8 2 10 3 11 4 12 CN11 LWD1140-16 5 13 6 14 7 15 8 16 Table 19 – Appliance Wiring 1 NO.
CONNECTOR NO. OF LOCATION PIN 1 8 2 9 3 10 4 CN7 LWD1140-14 11 5 12 6 13 7 14 1 2 3 4 CN14 5 SMW250-09 6 7 BOARD SILK F.S Flame Detect 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.
Figure 34 – Terminal Block Wiring Detail PART 10 – OPERATING SYSTEM INSTRUCTIONS A. CONTROL PANEL Figure 35 – Appliance Control Panel Detail WHL-012 REV. 10.31.
B. LCD DISPLAY DESCRIPTIONS Figure 36 – LCD Display Detail LCD also features a backlit lamp that will illuminate: • When a user action is detected (a button is pressed) • The display has timed out for approximately 2 minutes C. START-UP SEQUENCE 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.
• • • • • Lock Mode Error Mode Status Display Mode Outdoor Temperature Mode Installer Mode D. CHANGING THE DHW SET-POINT The display shows the icon when the DHW set-point can be changed. Figure 38 – 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 125oF (51oC).
Figure 39 – CH Set-Point Screen Factory CH Set-Point is 180oF (82oC). CH Set-Point range is 86 – 180oF (30 – 82oC). Turn the dial counterclockwise to lower and clockwise to raise the current CH set-point. After changing the temperature, press the button to save the setting. NOTE: The CH Set-Point cannot be changed by pressing the button if an outdoor sensor or 0-10V is connected to the appliance.
Turn the dial counterclockwise and clockwise to scroll through the displayed parameters. To view parameter details, press the button at the appropriate screen. Press the Press the or buttons to leave the parameter. button again to return to Operation Mode. To turn on Lock Mode, press the button at the d:Lc parameter. Turn the dial Press the button to save the selection and return to the parameters. Press the counterclockwise or clockwise to scroll On or Off.
Display 1: EH Default E0:00 Detail Error history up to 10 2: cE OFF Delete Error history 3: In OFF Initialized system 4: Fu GA 5: St ON Change unit for water volume Stored water heating function “ON”, “OFF” 6: OH 68 F Maximum Outdoor Temperature 7: OL 5F Minimum Outdoor Temperature 8: FH 00 Maximum Fan speed 9: FL 00 Minimum Fan speed 10: dr NO Initialized burner operation time 11: dI NO Initialized ignition cycle 12: bt 0 Boost Function 13: Ft 1 CH Anti-Frequency tim
Internal DHW Storage Tank Setpoint Internal DHW Storage Tank 25: So 27 F Differential Delay time when switching from 26: dt 2 DHW mode to CH mode Display Default Detail Internal CH Pump Post-Purge 27:PE 1 Time, T/T Satisfied 28: HA HA 0 N/A Internal CH Pump and AP: cP 5 Internal DHW Storage Pump Test Mode 29: AP Internal CH Pump and cP: off or OFF Internal DHW Storage cP: on Pump Test Mode Table 23 – Installer Mode Descriptions 24: SF 158 F Sets the Internal DHW Storage Tank Setpoint Range:140 ~ 167oF
Er:20 Condensate APS – Closed is Normal, Open is Fault (Condensate Drain Trap) Er:28 Overheat Sensor Open or Short Er:29 Flue APS Open - Closed is Normal, Open is Fault (Intake / Exhaust) Er:32 DHW Sensor Open or Short Er:33 CH Temperature Sensor Open or Short Er:35 Exhaust Sensor Open or Short Er:36 Abnormal Supply Voltage Er:37 Abnormal Supply Frequency Er:38 Error Appears When Control Stores Data, but Data is not Saved Er:41 Fan Speed too High with Flame On Er:42 Jumped Wire Disc
Error Code Error Code Description Er:66 Mixing Valve Initial Value Error (Mixing Valve Cannot Return to Initial Position) Er:68 Mixing Valve Operation Error (Mixing Valve Stuck in Initial Position) Er:70 Register, Ram, Rom, I/O Port, AD Abnormal, Important EPROM Data or Safe Data Abnormal Er:72 Flame Signal Detected before Ignition Er:76 Poor Communication Er:80 Low Water Level Sensor (Low Water Level Detected Four (4) Consecutive times) Er:81 Low Water Level Circuit Er:85 Freeze Protect
K. ERROR TREE ANALYSIS 1. FLAME DETECTION Figure 44 – Flame Detection Error Analysis Tree 2. GAS DETECTION Figure 45 – Gas Detection Error Analysis Tree WHL-012 REV. 10.31.
3. APS / BURNER OVERHEAT LIMIT / CONDENSATE BLOCK SWITCH Figure 46 – APS / Burner Overheat Limit / Condensate Block Switch Error Analysis Tree 4. DHW / OP / CH OVERHEAT / EXHAUST OVERHEAT SENSORS Figure 47 – DHW / OP / 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.
Figure 48 – Outdoor Reset Curve – See Installer Mode for Curve Setting Descriptions M. 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 010 volt positive-going DC signal. When the 0-10V input is wired to the appliance terminal strip, a building control system can be used to control the set point temperature of the appliance.
PART 11 – START-UP PREPARATION Thoroughly clean and flush any system that has used glycol before installing the appliance. A. CHECK / CONTROL WATER CHEMISTRY Chemical imbalance of the water supply may affect efficiency and cause severe damage to the appliance and associated equipment. Water quality must be professionally analyzed to determine whether it is necessary to treat the water. Various solutions are available to adjust water quality.
• • A 50% mixture of glycol will result in a BTU output loss of 30% with a 50% increase in head against the system circulator. NOTE: BTU losses apply to both CH and DHW. It is highly recommended to carefully follow the glycol manufacturer’s recommended concentrations, expansion requirements, and maintenance recommendations (pH additive breakdown, inhibitor reduction, etc.) You must carefully calculate the additional friction loss in the system as well as the reduction in heat transfer coefficients. C.
4. At initial fill and during appliance startup and testing, check system thoroughly for leaks. Repair all leaks before proceeding further. 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.
4. When water flows freely from all hot water faucets, DHW purging is complete. G. 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 time and check the voltmeter reading across the incoming wires. 3.
NOTICE 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 49. 4.
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. *In order to increase CO2 values on high fire, the gas orifice size can be increased to achieve the maximum CO2 value listed in Table 28. Contact the factory for recommended orifice sizes to achieve the desired setting. WHL-012 REV. 10.31.
PART 12 –INSTALLATION AND START-UP CHECKLIST LIGHT OFF ACTIVITIES 1) Fill the Heating System with Water 2) Exhaust Vent and Intake Piping 3) Condensate Piping / Tubing and Components 4) Gas Piping 5) Pressure Relief Valves 6) Wire the Appliance 7) Start-Up, Adjust, and Test DATE COMPLETED YES NO Has the system been cleaned and flushed? Does water chemistry meet requirements? If water chemistry does not meet requirements, are treatment measures put in place? Check all water piping and connection
Figure 51 – Flame Sight Glass CH Return Temperature Sensor (7855P-097) CH Supply Temperature Sensor Exhaust Temperature Sensor (7855P-030) (7855P-092) DHW Temperature Sensor Storage Tank Temperature Sensor (7855P-094) (7855P-057) Temperature (◦F) Resistance (Ω) Temperature (◦F) Resistance (Ω) -4 62162 -4 28409 5 48440 5 22152 14 38045 14 17408 23 30107 23 13782 32 23998 32 10990 41 19261 41 8824 50 15562 50 7131 59 12655 59 5800 68 10353 68 4747 77 8520 77 3906 86 7051 86 3233 95 5867 95 2690 104 4908 1
PART 13 – TROUBLESHOOTING PROBLEM No electrical power to the appliance No water available when a faucet is opened Hot water is not available when the faucet is opened. The water temperature is not hot enough or turns cold during use. It takes a long time before hot water flows from the faucet. TROUBLESHOOTING CHART POSSIBLE CAUSES POSSIBLE REMEDIES 1. Is the plug on the power supply cord unplugged from 1. Reset the plug. the electrical outlet? 2. Reset the circuit breaker. 2.
the display control panel and no other appliance components are operating receiving 120V power breaker to appliance is turned ON Is there 120V at the service switch Is the ON/OFF switch inside the appliance cabinet is turned on Check for 120V at the line voltage terminal block located inside the appliance cabinet Inspect the fuse.
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.
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.
Flushing the DHW Loop Heat Exchanger Flushing the heat exchanger is a complicated procedure that should only be performed by a qualified service technician. It is recommended to flush the 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.
Figure 56 – Cleaning the Inlet Filter 6. Reinstall the DHW inlet filter. 7. Purge air from the DHW lines by opening a hot water faucet in the system. When water flows freely, all air is purged. 8. Repeat the process on the CH inlet filter on the appliance. 9. Restore water service to the appliance by opening the isolation valves, or turning on the main water valve. 10. Turn on the gas valve. Turn on electrical power to the appliance and press the Power button to turn the appliance on. 11.
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 exchanger. 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.
Figure 58 – Cabinet Replacement Parts – 140W Models NUMBER DESCRIPTION 15 15-1 15-2 15-3 15-5 15-6 15-7 15-8 Exhaust Duct (Assembly) Exhaust/Intake Duct Clamps (Φ100) Exhaust/Intake Gaskets Exhaust Duct Combustion Analyzer port Plug O-ring Combustion Analyzer port Plug Intake/Exhaust Adapter O-Ring (85 Φ) Exhaust Duct Inner Adapter Exhaust Adapter O-Ring (75 Φ) 16 Air Intake Cap (assembly) 15-4 PART NUMBER NUMBER DESCRIPTION PART NUMBER 7855P-002 7855P-332 7850P-210 7855P-333 21 22 23 24 I
Figure 59 – Water Piping Replacement Parts – 140W Models PART NUMBER 36 DHW Outlet Pipe 7855P-242 36-1 1/2" Pipe Gasket 7855P-072 36-2 O-ring 7855P-044 36-3 Clip (DHW Inlet) 7855P-246 37 DHW Inner Block 7855P-251 37-1 O-ring P22A 7850P-262 37-2 Pipe Adapter Clip 7855P-278 38 DHW Outlet Adapter 7855P-225 39 DHW Temperature Sensor 7855P-094 40 DHW Inlet Pipe 7855P-241 41 DHW Flow Sensor 7855P-083 42 Mixing Valve 7855P-043 42-1 P15 O-ring 7855P-044 42-2 P16 O-ring 7855P-075 43 DHW Outer Block 7855P-259 44
Figure 60 – Heat Exchanger Replacement Parts – 140W Models NUMBER DESCRIPTION 60 61 62 62-1 63 64 64-1 Exhaust Pipe Storage Tank Clamp Exhaust Temperature Sensor Clip Exhaust Temperature Sensor O-ring Exhaust Temperature Sensor Heat Exchanger Assembly Burner Body Assembly PART NUMBER 7855P-237 7855P-297 7855P-349 7855P-092 7855P-092 7855P-353 7855P-354 64-2 Burner Overheat Switch 7855P-066 64-3 Burner Body 7855P-067 64-4 Burner Gasket 7855P-266 64-5 Ceramic Fiber Burner 7855P-069 64-6 Burner pla
Figure 61 – Combustion System Replacement Parts – 140W Models NUMBER DESCRIPTION PART NUMBER NUMBER 78 Burner Inlet Chanel 7855P-231 86 79 Burner Inlet Chanel Gasket 7855P-370 80 Fan Outlet Mesh 7855P-299 81 Air Intake hose top clamp (Φ60) 7855P-372 82 Air Intake Hose 7855P-071 83 APS Hose Fitting 7855P-375 84 Fan Assembly 7855P-457 84-1 Fan 7855P-025 84-2 Air intake Chanel Orifice 7855P-458 84-3 Air Gas Mixer 7855P-027 84-4 Fan O-ring 7855P-371 85 Gas Outlet Pipe 7855P-233 Table 37 – Combustion
Figure 62 – Cabinet Replacement Parts – 199W Models NUMBER DESCRIPTION PART NUMBER 15 Exhaust Duct Assy 7855P-002 15-1 Exhaust / Intake Duct Clamps 7855P-332 15-2 Exhaust / Intake Gaskets 7850P-210 15-3 Exhaust Duct 7855P-333 15-4 Combustion Analyzer Port Plug O-Ring 7855P-334 15-5 Combustion Analyzer Port Plug 7855P-335 15-6 Intake / Exhaust Adapter O-Ring 7855P-256 15-7 Exhaust Duct Inner Adapter 7855P-004 15-8 Exhaust Adapter O-Ring 7855P-254 16 Air Intake Assy 7855P-411 16-1 Air Intake Cap 7855P-
Figure 63 – Water Piping Replacement Parts – 199W Models NUMBER DESCRIPTION 38 38-1 38-2 38-3 39 39-1 39-2 40 41 42 43 44 44-1 44-2 45 46 47 48 DHW Outlet Pipe ¾” Pipe Gasket P-18 O-Ring ½” Pipe Clip DHW Inner Block P22A O-Ring Pipe Adapter Clip DHW Outlet Adapter DHW Temperature Sensor DHW Inlet Pipe DHW Flow Sensor Mixing Valve Flow Sensor Clip P15 O-Ring DHW Outer Block DHW Inlet Filter Block Flow Restrictor DHW Inlet Filter PART NUMBER 7855P-275 7855P-073 7855P-047 7855P-246 7855P-251 7855P-276
Figure 64 – Heat Exchanger Replacement Parts – 199W Models NUMBER 63 63-1 64 65 66 67 68 69 69-1 69-2 70 71 DESCRIPTION PART NUMBER 7855P-092 7855P-092 7855P-349 7855P-415 7855P-418 7855P-291 7855P-292 7855P-293 7855P-073 7855P-074 7855P-294 7855P-030 Exhaust Temperature Sensor Exhaust Temperature Sensor O-Ring Exhaust Temperature Sensor Clip Exhaust Pipe Assembly Exhaust Pipe Gasket Storage Tank Clamp Storage Tank Bracket CH Supply Pipe 3/4" CH Supply Pipe Gasket 1" CH Supply Pipe Gasket Storage Tan
Figure 65 – Combustion System Replacement Parts – 199W Models PART NUMBER NUMBER 78 Burner Inlet Chanel (with Damper) 7855P-424 86 79 Air Damper 7855P-618 87 80 Air Damper Guide 7855P-369 88 81 Fan Outlet Gasket 7855P-425 88-1 82 Burner Inlet Chanel Gasket 7855P-426 88-2 83 Fan and Mixer Assembly 7855P-427 88-3 83-1 Fan 7855P-025 88-4 83-2 Fan O-Ring 7855P-371 89 83-3 Air-Gas Mixer (Inner Part) 7855P-609 90 83-4 Air-Gas Mixer Gasket 7855P-428 83-5 Air-Gas Mixer (Outer Part) 7855P-608 91 84 Air Intake Ho
Limited Warranty for Combination Appliances (Floor and Wall Mounted 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. 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.
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.
START-UP REPORT LIGHT OFF ACTIVITIES 1) Fill the heating system 2) Electrical 3) Check gas pipe 4) Venting 5) Condensate piping / tubing FINAL DATE COMPLETED ________________ Yes No Check all piping and gas connections, verify all are tight Has the system been cleaned and flushed? Has the appliance 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.
MAINTENANCE REPORT In unusually dirty or dusty conditions, care must 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.
MAINTENANCE NOTES WHL-012 REV. 10.31.
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.
