Westinghouse Condensing 96% Natural Gas Space Heating Floor Mount Boiler w/Optional Domestic Hot Water Manual

Gas Fired Residential

Floor and Wall Mount

Combi Boilers

Installation

Start-Up

Maintenance

Parts

Warranty

WBRC**140 / 199*

WBRUC**140 / 199* Models

* “F” Denotes Floor Model; “W” Denotes Wall Mount Model, ** “NG” Denotes Natural Gas; “LP” Denotes Propane Gas

Heat Exchanger Bears the

ASME “H” Stamp

!

DANGER

This manual must only be used by a qualified service technician. Read all instructions in this manual before installing. Perform steps in the given order. Failure to do so could result in substantial property damage, severe personal injury, or death.

!

WARNING

Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property damage, severe personal injury, or death.

California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

NOTICE

The manufacturer reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.

The surfaces of these products contacted by potable (consumable) water contain less than 0.25% lead by weight as required by the Safe Drinking Water Act, Section 1417.

NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

www.westinghousewaterheating.com

whl-648 Rev. 001 Rel. 000 Date 4.11.19

2

!

WARNING

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

• Do not store or use 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.

Improper installation, adjustment, alteration, service, or maintenance can cause injury, property damage, or death. Refer to this manual. Installation and service must be performed by a qualified installer, service agency, or gas supplier.

SPECIAL ATTENTION BOXES

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

DANGER indicates an imminently hazardous situation which, if not avoided, will result in serious personal injury or death.

!

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in personal injury or death.

!

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor personal injury.

CAUTION

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE

NOTICE is used to address practices not related to personal injury.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

Foreword

This manual is intended to be used in conjunction with other literature provided with the boiler. This includes all related control information. It is important that this manual, all other documents included in this system, and additional publications including the

National Fuel Gas Code - ANSI Z223.1 (latest versions), 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 AHJ 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. In some circumstances, the property owner or his/ her agent assumes the role, and at government installations, the commanding officer or departmental official may be the AHJ.

NOTE: The manufacturer reserves the right to modify product technical specifications and components without prior notice.

For the Installer

This boiler must be installed by qualified and licensed personnel.

The installer should be guided by the instructions furnished with the boiler, and by local codes and utility company requirements.

In the absence of local codes, preference should be given to the

National Fuel Gas Code - ANSI Z223.1

, latest version.

Installations Must Comply With:

Local, state, provincial, and national codes, laws, regulations, and ordinances.

The latest version of the National Fuel Gas Code, ANSI Z223.1

, from

American Gas Association Laboratories, 8501 East Pleasant Valley

Road, Cleveland, OH 44131.

In Canada - CGA No. B149 (latest version), from Canadian Gas

Association Laboratories, 55 Scarsdale Road, Don Mills, Ontario,

Canada M3B 2R3. Also, Canadian Electrical Code, C 22.1

, from

Canadian Standards Association, 5060 Spectrum Way, Suite 100,

Mississauga, Ontario, Canada L4W 5N6.

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 undergoing tests specified in ANSI

Z21.10.3

- 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.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

3

4

NOTICE

IMPORTANT

In accordance with Section 325 (f) (3) of the Energy Policy and

Conservation Act, Westinghouse has provided this boiler with multiple features designed to save energy by reducing the boiler water temperature as heating load decreases.

These features include:

• A modulating combustion system that adjusts firing rate based on heat demand.

• Adjustment of boiler set point based on inferred heat load as determined by an outdoor sensor. The outdoor sensor is supplied by Westinghouse with this boiler.

• This boiler does not include a standing pilot.

• This boiler is designed and shipped to assure the highest efficiency operation possible. Such high efficiency is achieved by limiting heating circuit water temperature to

140°F when there is no anticipated heat load, based upon the outdoor sensor and the Outdoor Reset Curve (sensor response curve) in the boiler software.

• This feature may be over-ridden as described below in specific installations:

• The boiler control is equipped with an outdoor sensor override for use with building management systems or in cascaded systems (for systems with total input of 300,000

BTU/hr or greater).

See statement below for an important notice on the use of the override.

IMPORTANT

In accordance with Section 325 (f) (3) of the Energy Policy and

Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS

OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE

FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.

• This boiler is not used for space heating.

• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

The CSD-1 ASME Code, Section CW-400 requires that hot water heating and supply boilers have a) a UL 353 temperature control device, b) at least one (1) temperature-actuated control to shut off the fuel supply when system water reaches a preset operating temperature, c) a high temperature limit control that prevents the water temperature from exceeding the maximum allowable temperature by causing a safety shutdown and lockout, and d) its own sensing element and operating switch.

The temperature control system integrated into the 926 control provided with this heating boiler complies with the requirements of CSD-1 Section CW-400 as a temperature operation control. The control monitors the temperature difference between the inlet and the outlet sensor, which is affected by boiler water flow. If this temperature difference exceeds 55°F (typically because of low water flow or very low heat load), the control will reduce the maximum fan speed. If the temperature difference exceeds 60°F, the control will effectively sense there is little or no water flow or heat load and shut the boiler down. The controller will restart automatically once the temperature difference has dropped below 55°F and the minimum off time (anti-cycle time) has expired. In addition, if the control senses that the outlet water temperature has reached 210°F, the boiler is put into a hard lockout and requires manual reset to restart.

!

WARNING

Protection From Damage

1. Boilers generating a glow, spark or flame capable of igniting flammable vapors may be installed in a garage, provided the pilots, burners or heating elements and switches are at least eighteen (18) inches (457 mm) above the floor level.

2. Where such boilers installed within a garage are enclosed in a separate, approved compartment having access only from outside of the garage, such boilers may be installed at floor level provided the required combustion air is also taken from the exterior of the garage. Fuel burning boilers having sealed combustion chambers need not be elevated.

3. All boilers installed in areas where they may be subjected to mechanical damage shall be suitably guarded against such damage by being installed behind adequate barriers or by being elevated or located out of the normal path of a vehicle using any such garage.

4. In seismic zones 3 and 4, boilers shall be anchored or strapped to resist horizontal displacement due to earthquake motion.

Strapping shall be at points within the upper one-third (1/3) and lower one-third (1/3) of its vertical dimensions. At the lower point, a minimum distance of four (4) inches (102 mm) shall be maintained above the controls with the strapping.

5. An boiler supported from the ground shall rest on level concrete or other approved base extending not less than three (3) inches

(76 mm) above the adjoining ground level.

6. Any boiler should be installed in such a manner that if it should leak the resulting flow of water will not cause damage to the area in which it is installed. If the boiler is installed in a location where a leak could cause damage, it is required to provide containment measures.

Table of Contents

Part 1 - General Safety Information

A. Operation and Installation Warnings

B. Improper Combustion

C. Gas

D. When Servicing the Boiler

E. Boiler System

F. Water Chemistry Requirements

G. Freeze Protection

H. Water Temperature Adjustment and Scalding

I. High Elevation Installations

Part 2 - Before You Start

A. What’s in the Box

B. Optional Equipment

Part 3 - Prepare the Boiler Installation

A. Locating the Boiler

B. Leveling

C. Clearances for Service Access

D. Residential Garage and Closet Installations

E. Exhaust Vent and Intake Pipe

1. Direct Vent of Exhaust and Intake

2. Power Venting, Indoor Combustion Air in Confined or Unconfined

Space

F. Carbon Monoxide Detectors

G. Prevent Combustion Air Contamination

H. Removing a Appliance from a Common Vent System

I. Technical Specifications

J. Wall-Mounting (Wall Mount Models Only)

K. Flow Restrictor

Part 4 - Water Piping

A. General Plumbing Guidelines

B. Backflow Preventer

C. Expansion Tank

9

10

9

9

10

10

8

8

7

7

10

11

11

12

6

6

5

5

7

7

12

12

18

19

19

20

20

12

13

14

17

whl-648 Rev. 001 Rel. 000 Date 4.11.19

5

D. Piping the Boiler

E. Applications

F. CH and DHW Pressure Relief Valves

Part 5 - Venting

A. General

B. Approved Materials for Exhaust Vent and Intake Pipe

C. Additional Requirements for Installation in Canada

D. Exhaust Vent and Intake Pipe Location

E. Exhaust Vent and Intake Pipe Sizing

F. Tightening Boiler Collar to Exhaust Vent and Intake Pipe 32

G. Exhaust Vent and Intake Pipe Installation

H. Applications

1. Direct Vent Installation of Exhaust and Intake

31

32

32

33

33

2. Venting Through an Existing System

3. Power Venting, Indoor Combustion Air in Confined or Unconfined

36

20

21

28

29

29

30

30

Space

Part 6 - Installing the Condensate Drain

Part 7 - Connecting Electrical Service

A. Wiring

B. Dip Switches

Part 8 - Gas Connections

A. Gas Pipe Sizing Tables

1. Gas Pipe Sizing

2. Natural Gas Pipe Sizing

3. LP (Liquid Propane) Gas Pipe Sizing

B. Gas Connection Requirements

C. Additional Precaution for Excess Flow Valve (EFV) 45

D. Checking Gas Pressure at the Boiler for Proper Operation 45

E. Setting and Verifying the Combustion Setting

Part 9 - Controls

A. Control and Display Overviews

45

46

46

B. Start-Up Sequence

C. Changing the DHW Set-Point

D. Changing the Temperature Indicator

E. Changing the CH Set-Point

F. Storage Mode

46

47

47

47

47

39

44

44

44

44

37

38

39

39

44

44

G. Lock Function

H. Status Display

I. Installer Mode

J. Outdoor Temperature Mode (Optional)

K. 0-10 Volt Input

Part 10 - Troubleshooting

A. Error Code

B. Error Tree Analysis

1. Flame Detection 55

2. Air Pressure Switch / Burner Overheat Limit / Condensate Block Switch

47

48

49

50

51

52

52

55

55

3. DHW / Operating Temperature / CH Overheat / Exhaust Sensors 55

C. Suggested Corrective Actions

Part 11 - Start-Up

A. Check / Control Water Chemistry

B. Check for Gas Leaks

56

58

58

58

C. Freeze Protection (When Used)

D. Fill and Test Water System

E. Purge Air from CH and Internal Storage Tank

F. Purge Air from DHW System

G. Check Thermostat Circuit(s)

H. Condensate Removal

Part 12 - Installation Checklist

60

61

Part 13 - Maintenance 62

Part 14 - Moving Adapters from Left to Right (Floor Models) 67

Part 15 - Replacement Parts

Limited Warranty for WBRC Appliances

67

79

59

59

59

60

60

Notes 81

Customer Installation Record Form 85

Part 1 - General Safety Information

This boiler is approved for indoor installations only and is not intended for use as a pool heater. Clearance to combustible materials: 0” top, bottom, sides, and back. Boiler must have room for service: 24” front,

18” top, 12” bottom, and 0” back are minimum recommended service clearances. Minimum recommended side clearances depend on model and installation options. (A combustible door or removable panel is acceptable front clearance. A 3” minimum clearance must be provided from the boiler front cover to the removable panel or combustible door.) This boiler has been approved for closet installation and installation on combustible flooring. Do not install directly on carpeting. Install the boiler in a location where relief valve discharge or a leak will not result in damage to the surrounding area. If such a location is not available, install an auxiliary catch pan. The appliance is rated Category IV (pressurized vent, likely to form condensate in the vent) and requires a special vent system designed for pressurized venting. Use only Category IV vent systems.

!

WARNING

Installer - Read all instructions in this manual before installing.

Perform steps in the given order.

User This manual is for use only by a qualified service technician.

Have this boiler serviced / inspected annually by a qualified service technician.

FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE

CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE

PERSONAL INJURY, OR DEATH.

NOTE: Obey all local codes. Obtain all applicable permits before installing the boiler.

NOTE: Install all system components and piping in such a manner that does not reduce the performance of any fire rated assembly.

A. Operation and Installation Warnings

To avoid serious injury or death, read, understand, and follow all of the precautions listed here.

!

DANGER

Vapors from flammable liquids will explode and can cause a fire, resulting in personal injury or death. The boiler has a burner that can come on at any time and ignite vapors. DO NOT use or store flammable liquids around the boiler.

Improper venting can cause a build-up of carbon monoxide.

Breathing carbon monoxide can result in brain damage or death. DO

NOT operate the boiler 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 calibrated combustion analyzer such that a CO level of no more than 150 ppm is exceeded at any time during operation.

Adjusting the “low fire offset” or the “main flow restrictor” in small increments can result in a significant increase in CO concentration.

To avoid serious injury or death, DO NOT make any adjustments to the gas valve without monitoring the exhaust gases with a fully functional and calibrated combustion analyzer.

Failure to follow these instructions will result in property damage, severe personal injury, or death.

!

WARNING

After installation, all boiler safety devices should be tested.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

6

!

WARNING

This boiler must be installed by a qualified 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.

The manufacturer cannot anticipate every circumstance that might involve a potential hazard. Each installation has its own specialized characteristics, requirements, and possible hazards. Therefore, all possible incidents are not included in these warnings. Proper and safe installation, operation, and service are the responsibility of the qualified service technician.

Proper care of the boiler is the user’s responsibility. Ensure the user carefully reads and understands the User’s Information Manual before operating and maintaining the boiler.

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 boiler is subjected to fire, overheating, flood, physical damage, or any other damaging condition that might affect the operation of the unit. Have the boiler 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 qualified service technician should attempt to install, service, or repair this boiler. There are no serviceable parts which can be changed by the user / owner. User / Owner: Contact the original qualified service technician if the boiler 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 boiler clean and free of all materials that can burn. DO NOT store or place gasoline, oils, spray paint, or other flammable products near the boiler.

DO NOT use spray paint, hair spray, or any other flammable spray near the boiler 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 boiler 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 boiler should be shut off until the problem is repaired by a qualified technician.

This boiler is certified for indoor installations only. The boiler 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 boiler.

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 should service and inspect the boiler annually.

NOTICE

This boiler 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.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

NOTICE

This boiler provides a overheat shutdown limit. In the event the boiler water temperature exceeds the set point of the control limit, the cutoff will trip and the boiler will shut down. Certain local codes require additional temperature limits. In addition, certain types of systems may operate at temperatures below the minimum set point of the limit provided with the boiler. Contact the manufacturer for additional overheat controls.

NOTE: When inquiring about service or troubleshooting, reference the model and serial numbers from the boiler rating label.

!

WARNING

DO NOT USE THIS BOILER IF ANY PART HAS BEEN SUBMERGED

IN WATER. Immediately call a qualified service technician. The boiler MUST BE replaced if it has been submerged. Attempting to operate a boiler 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 boiler could result in property damage, severe personal injury, or death.

NOTE: Boiler damage due to flood or submersion is considered an

Act of God, and IS NOT covered under product warranty.

NOTE: If the boiler is exposed to the following, do not operate.

Immediately call a qualified service technician.

1. Fire

2. Damage

3. Water

Failure to follow this information could result in property damage, severe personal injury, or death.

DO NOT alter or modify the boiler or boiler controls. Altering any Westinghouse boiler with parts not manufactured by

Westinghouse WILL INSTANTLY VOID the boiler warranty and could result in property damage, personal injury, or death.

CAUTION

Do not use this boiler for anything other than its intended purpose

(as described in this manual). Doing so could result in property damage and WILL VOID product warranty.

Due to the low water content of the boiler, improper sizing of the boiler with regard to heating system load will result in excessive cycling and accelerated component failure. Westinghouse

DOES NOT warrant failures caused by improperly sized boiler applications. DO NOT oversize the boiler to the system. Modular boiler installations greatly reduce the likelihood of boiler oversizing.

B. Improper Combustion

!

WARNING

Do not obstruct the flow of combustion and ventilating air.

Adequate air is necessary for safe operation. Failure to keep the exhaust vent and combustion air intake clear of ice, snow, or other debris could result in property damage, serious personal injury, or death.

C. Gas

Should overheating or gas supply fail to shut off, turn off the manual gas control valve to the boiler.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

7

D. When Servicing the Boiler

!

WARNING

Be sure to disconnect electrical power before opening boiler cabinet or performing service. Label all wires while performing service to ensure proper re-wiring of the boiler. Wiring errors can cause improper or dangerous operation. Failure to do so could result in an electrical shock, improper boiler operation, property damage, serious personal injury, or death.

discontinue use of the boiler and contact an authorized technician or licensed professional.

Contaminant

Total Hardness

(Residential Use - Below 140 o temperature)

F water

Total Hardness

(Commercial Use - Above 140 o F water temperature)

• To avoid electric shock, disconnect electrical supply before performing maintenance.

• To avoid severe burns, allow boiler and associated equipment to cool before servicing.

• Do not use petroleum-based cleaning or sealing compounds in an boiler system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.

• Do not use “homemade cures” or “patent medicines”.

Damage to the boiler, substantial property damage, and/or serious personal injury may result.

• Always verify proper operation after servicing the boiler.

NOTE: When inquiring about service or troubleshooting, reference the model and serial numbers from the boiler rating label.

Aluminum

Chloride

Copper

Iron

Manganese pH

Sulfate

Total Dissolved Solids (TDS)

Zinc

Dissolved Carbon Dioxide (CO2)

Table 1 - Water Quality Specifications

Maximum Allowable Level

200 mg/l

(12 grains/gallon)

120 mg/l

(7 grains/gallon)

0.05 to 0.2 mg/l or PPM

100 mg/l or PPM

1 mg/l or PPM

0.3 mg/l or PPM

0.05 mg/l or PPM

6.5 - 8.5

205 mg/l or PPM

500 mg/l or PPM

5 mg/l or PPM

15 mg/l or PPM

E. Boiler System

• Thoroughly flush the system (without the boiler connected) to remove sediment. The high efficiency heat exchanger can be damaged by build-up or corrosion due to sediment. The manufacturer recommends a suction strainer in all systems.

• Do not use petroleum-based cleaning or sealing compounds in a boiler system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.

• Do not use “homemade cures” or “patent medicines”.

Damage to the boiler, substantial property damage, and/or serious personal injury may result.

Continual fresh make-up water will reduce boiler life. Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure. Addition of oxygen from make-up water can cause internal corrosion in system components. Leaks in the boiler or piping must be repaired at once.

G. Freeze Protection

CAUTION

Consider piping and installation when determining boiler location.

Damages resulting from incorrect installation or from use of products not approved by the manufacturer ARE NOT covered by warranty.

!

WARNING

NEVER use any toxic chemical, including automotive, standard glycol antifreeze, or ethylene glycol made for hydronic (non-potable) systems. These chemicals can attack gaskets and seals in water systems, are poisonous if consumed, and can cause personal injury or death.

The boiler control is equipped with freeze protection that activates based on internal water temperature. See the table below for details on freeze protection operation.

NOTE: Freeze protection will not be active if the boiler loses power.

F. Water Chemistry Requirements

CAUTION

Chemical imbalance of the water supply may affect efficiency and cause severe damage to the boiler 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. In addition, operating temperatures above 135 o

F will accelerate the build-up of lime scale and possibly shorten boiler service life. Failure of a boiler due to lime scale build-up, low pH, or other chemical imbalance IS NOT covered by the warranty.

The water must be potable, free of corrosive chemicals, sand, dirt, and other contaminates. It is up to the installer to ensure the water does not contain corrosive chemicals or elements that can damage the heat exchanger. 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). If the water contains contaminants higher than outlined by the EPA, water treatment is recommended and additional, more frequent maintenance may be required. See Table 1.

If you suspect that your water is contaminated in any way,

System

Freeze

Protection

(Activates

Based on

Internal

Water

Temperature)

Freeze Protection Operation Range

Stage 1 - If control detects water temperature of 46 o F (8 o C) and below, it turns the internal and external pumps

On for 600 seconds and Off for 30 seconds. This cycle repeats until the control detects inlet water temperature of 50 o F (10 o C) and above.

Stage 2 - If control detects water temperature of 41 o F (5 o C) and below, it turns the burner on to meet a target temperature of 104 o F (40 o C). The burner and internal and external pumps will continuously during this stage until the control detects inlet water temperature of 104 o F (40 o C) and above.

ON or OFF

(Default: ON)

NOTE:

If using boiler for

Snow Melt applications, turn Freeze

Protection

OFF.

Stage 3 - If control detects water temperature of 34 o F (1 o C) and below,

Er: 85 will appear on the display.

Table 2 - Freeze Protection Detail whl-648 Rev. 001 Rel. 000 Date 4.11.19

8

H. Water Temperature Adjustment and Scalding

This boiler can deliver scalding water. Be careful whenever using hot water to avoid scalding injury. Certain boilers such as dishwashers and automatic clothes washers may require increased water temperatures. By setting the thermostat on this heater to obtain the increased water temperature required by these boilers you may create the potential for scald injury.

To protect against injury, install a mixing valve in the water system. This valve will reduce point of use discharge temperatures by mixing cold and hot water in branch supply lines. Such valves are available from your local plumbing supplier.

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.

Approximate Time / Temperature Relationships in Scalds

120 o F

125 o F

130 o F

135 o F

140 o F

145 o F

150 o F

More than 5 minutes

1 1/2 to 2 minutes

About 30 seconds

About 10 seconds

Less than 5 seconds

Less than 3 seconds

About 1 1/2 seconds

155 o F About 1 second

Table 3 - Time and Temperature Relationship in Scalds

I. High Elevation Installations

!

WARNING

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. For natural gas installations above 3,000 ft, call your gas provider to determine the heating value of the supplied natural gas.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

Part 2 - Before You Start

Open the shipping crate of the boiler.

NOTICE

UNCRATING THE BOILER - Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

A. What’s in the Box

Components included with the boiler:

Item Description Quantity

9

Universal Fire Tube Combination Boiler One (1) Floor or Wall Mounted Boiler

User and Installation Manuals,

H2 Document

Condensate Hose (Wall Mount Only)

(Part # - 7855P-089)

Anchors and Wall Mounting Bracket

(Wall Mount Only)

(7850P-084)

Outdoor Sensor with

Screws and Anchors

(7855P-084)

Spare Parts Kit

(Gaskets and O-Rings)

(7855P-258)

LP Conversion Kit

(199 Model ONLY - 7855P-452)

One (1) each

One (1)

One (1) Kit

One (1)

One (1)

One (1)

Vent Screens (3”)

(7850P-085)

Two (2) screens

CH 30 PSI Pressure Relief Valve and

3/4” x 1” Bushing

(7855P-077)

Blue Flow Restrictor

(Limits Flow to 4.5 GPM - 140 Model Only)

(7855P-261)

Combi Venting Kit

(S7855-002)

Table 4 - Included with the Boiler

B. Optional Equipment

Optional equipment available from Westinghouse (and Part #):

Optional Parts

Threaded 3/4” DHW Tankless Isolation

Valves (w/ Pressure Relief Valve)

(7850P-090)

Table 5 - Optional Equipment

Other Optional Equipment

Below is a list of other optional equipment available from

Westinghouse. These additional options may be purchased through your Westinghouse distributor:

• 2” PVC Concentric Vent Kit (Part # KGAVT0501CVT)

• 3” PVC Concentric Vent Kit (Part # KGAVT0601CVT)

• 2” Stainless Steel Outside Termination Vent Kit (Part # V500)

One (1)

One (1) Each

One (1)

1




• 3” Polypro Vent Kit (Part # 8400P-001)

• 3” Polypro Pipe (33’ length Part # 8400P-002, 49.5’ length Part

# 8400P-003)

• Condensate Neutralizer (Part # 7450P-212) whl-648 Rev. 001 Rel. 000 Date 4.11.19

10

• Condensate Removal Pump (Part # 554200)

• 2” Mesh Vent Screens (Part # 7850P-088)

NOTE: When using an optional system sensor, pipe insulation must be wrapped around it to improve temperature measurement accuracy and increase overall system efficiency.

Part 3 - Prepare the Boiler Installation

Remove all sides of the shipping crate to allow the boiler to be moved into its installation location.

CAUTION

COLD WEATHER HANDLING - If the boiler has been stored in a very cold location (BELOW 0 o

F) before installation, handle with care until the components come to room temperature. Failure to do so could result in damage to the boiler.

CAUTION

The service life of the boiler’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 boiler components. In these environments, boilers must not be installed using direct vent systems which draw outdoor air for combustion. Such boilers must be installed using room air for combustion. Indoor air will have a much lower relative humidity, and hence potential corrosion will be minimized.

2. Check for nearby connections to:

Carefully consider installation when determining boiler location.

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.

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

• Condensate drain

3. Check area around boiler. Remove any combustible materials, gasoline, and other flammable liquids.

A. Locating the Boiler

!

This boiler is certified for indoor use only. DO NOT INSTALL

OUTDOORS. Outdoor installations ARE NOT covered by warranty.

Failure to install the boiler indoors could result in property damage, severe personal injury, or death.

Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk. Ensure that the installation location adheres to the information included in this manual.

Failure to do so could result in property damage, serious personal injury, or death. Failure of boiler or components due to incorrect operating conditions IS NOT covered by product warranty.

This boiler must be installed upright in the vertical position as described in this manual. DO NOT attempt to install this boiler in any other orientation. Doing so will result in improper boiler operation and property damage, and could result in serious personal injury or death.

1. Installation Area (Mechanical Room) Operating Conditions

• Ensure ambient temperatures are higher than 32 o lower than 104 o F / 40 o C

F / 0 o C and

• Prevent the air from becoming contaminated by the products, places, and conditions listed in this manual

• Avoid continuously high levels of humidity

• Never close existing ventilation openings

• Ensure a minimum 1” clearance around hot water and exhaust vent pipes

• NOTE: To prevent condensing in the fan, it is recommended to avoid prolonged exposure to temperatures below 45 o F

!

WARNING

WARNING

This boiler has a condensate disposal system that may freeze if exposed to sustained temperatures below 32 o

F. Precautions should be taken to protect the condensate trap and drain lines from sustained freezing conditions.

Do not use this boiler only for space heating applications.

Circulators suitable for DHW applications must be used.

B. Leveling

!

WARNING

Failure to keep the boiler area clear and free of combustible materials, liquids, and vapors can result in substantial property damage, severe personal injury, or death.

4. Gas control system components must be protected from dripping water during operation and service.

5. If the boiler is to replace an existing boiler, check for and correct any existing system problems, such as:

• System leaks

• Location that could cause the system and boiler to freeze and leak

• Incorrectly sized expansion tank

6. Clean and flush system when reinstalling an boiler.

CAUTION

Do not introduce toxic chemicals, such as antifreeze or boiler treatments, into any piping meant for potable water purposes.

Do not connect the boiler DHW connections to any heating systems or components that have been previously used for non-potable applications.

Ensure that all piping and components connected to the boiler are suitable for potable water applications.

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 boiler model and serial number.

CAUTION

In order for the condensate to properly flow out of the collection system, the area where you locate the boiler must be level. Location must also fully support the weight of the filled boiler.

C. Clearances for Service Access

See Table 6 for recommended service clearances. If these minimum clearances are not provided, it may not be possible to service the boiler without removing it from the space.

Failure to take precautions could result in property damage, severe personal injury, or death.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

11

CAUTION

All boilers eventually leak. Locate the boiler where any leakage from the relief valve, related piping, tank, or connections will not result in damage to surrounding areas or lower floors of the building.

Any boiler should be installed in such a manner that if it should leak the resulting flow of water will not cause damage to the area in which it is installed. If the boiler is installed in a location where a leak could cause damage, it is required to provide containment measures. Such measures include but are not limited to: a properly sized drain pan installed beneath the boiler and piped to an open drain line, or installing the boiler on a concrete floor pitched to a free flowing drain. Failure to provide containment measures is the sole responsibility of the owner and/or installer. Leakage damages ARE

NOT covered by warranty.

In addition, water leak detection devices and automatic water shutoff valves are readily available at plumbing supply houses. IT IS HIGHLY

RECOMMENDED BY THE MANUFACTURER TO INSTALL WATER LEAK

DETECTION DEVICES AND AUTOMATIC SHUTOFF VALVES IN ANY

BOILER INSTALLATION WHERE A LEAKAGE OF WATER COULD RESULT

IN PROPERTY DAMAGES.

Correct Installation Incorrect Installation

Figure 1 - Leveled Boiler (Floor Model)

!

WARNING

The space must be provided with combustion / ventilation air openings correctly sized for all other boilers located in the same space as the boiler. The boiler cover must be securely fastened to prevent the boiler from drawing air from the boiler room.

This is particularly important if the boiler is in a room with other boilers. Failure to comply with the above warnings could result in substantial property damage, severe personal injury, or death.

Minimum Clearances

Installation Clearances from Non-

Combustibles / Combustibles

Recommended Service and Proper Operation

Clearances

Top 18” (45.7 cm)

Back

Bottom (Wall Mount Model)

Bottom (Floor Model)

Front

Right or Left Side (Wall Mount Model)

*Side without Adapters (Floor Model)

0” (0 cm)

12” (30.45 cm)

0” (0 cm)

24” (60.9 cm)

3” (7.6 cm)

*Adapter Side (Floor Model) 24” (60.96 cm)

Table 6 - Minimum Installation and Service Clearances - *NOTE: The piping configuration of the Floor Model can be changed from the left to the right side of the boiler.

NOTE: For closet installations, a combustible door or removable panel is acceptable front clearance. A 3” minimum clearance must be provided from the boiler front cover to the removable panel or combustible door.

NOTE: If you do not provide the minimum clearances shown in Table

6 it might not be possible to service the boiler without removing it from the space.

MINIMUM CLEARANCES FROM COMBUSTIBLE MATERIALS

• Hot water pipes - at least 1” from combustible materials

• Exhaust vent pipe - at least 1” from combustible materials

CAUTION

Always take future maintenance into consideration when locating the boiler. If the boiler is located in an installation location with limited clearances, it may be necessary to remove the boiler from the space to perform maintenance. Failure to consider maintenance when determining installation location could result in property damage.

D. Residential Garage and Closet Installations

CAUTION

Check with your local Authority Having Jurisdiction for requirements when installing the boiler 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.

Precautions

If the boiler is located in a residential garage, per ANSI Z223.1:

• 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.

• Locate or protect the boiler so it cannot be damaged by a moving vehicle.

!

WARNING

The space must be provided with correctly sized combustion/ ventilation air openings for all other boilers located in the space with the boiler. For power venting installations using room air for combustion, refer to the venting section, this manual, for descriptions of confined and unconfined spaces. 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.

E. Exhaust Vent and Intake Pipe

The appliance is rated Category IV (pressurized vent, likely to form condensate in the vent) and requires a special vent system designed for pressurized venting.

NOTE: The venting options described here (and further detailed in the Venting section, this manual) are the lone venting options approved for this appliance. Failure to vent the appliance in accordance with the provided venting instructions will void the warranty.

!

DANGER

Failure to vent the appliance properly will result in serious personal injury or death.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

12

!

WARNING

Do not attempt to vent this appliance by any means other than those described in this manual. Doing so will void the warranty and may result in severe personal injury or death.

CAUTION

When drawing combustion air from the outside into the mechanical room, care must be taken to provide adequate freeze protection.

Vents must be properly supported. 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. Appliance must be readily accessible for visual inspection for first 3’ from the appliance. Failure to properly support vents could result in property damage, severe personal injury, or death.

!

WARNING

Failure to provide an adequate supply of fresh combustion air can cause poisonous flue gases to enter the living space, resulting in severe personal injury or death. To prevent combustion air contamination, see Table 7.

The exhaust discharged by this appliance may be very hot. Avoid touching or other direct contact with the exhaust gases of the vent termination assembly. Doing so could result in severe personal injury or death.

1. Direct Vent of Exhaust and Intake

If installing a direct vent option, combustion air must be drawn from the outdoors directly into the appliance intake and exhaust must terminate outdoors. There are three basic direct vent options detailed in this manual: 1. Side Wall Venting, 2. Roof Venting, and 3.

Unbalanced Venting.

Be sure to locate the appliance such that the exhaust vent and intake piping can be routed through the building and properly terminated.

Different vent terminals can be used to simplify and eliminate multiple penetrations in the building structure (see Optional

Equipment in Venting Section). The exhaust vent and intake piping lengths, routing, and termination methods must all comply with the methods and limits given in the Venting Section, this manual.

When installing a combustion air intake from outdoors, care must be taken to utilize uncontaminated combustion air. To prevent combustion air contamination, see Table 7.

2. Power Venting, Indoor Combustion Air in Confined or

Unconfined Space

This appliance 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 7.

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 appliance input.

Never obstruct the supply of combustion air to the appliance. If the appliance is installed in areas where indoor air is contaminated (see

Table 7) it is imperative that the appliance be installed as direct vent so that all combustion air is taken directly from the outdoors into the appliance intake connection.

Unconfined space is space with volume greater than 50 cubic feet per 1,000 BTU/hr (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space through openings not furnished with doors are considered part of the space. See Venting Section for details.

Confined space is space with volume less than 50 cubic feet per

1,000 BTU/hr (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space through openings not furnished with doors are considered part of the space.

When drawing combustion air from inside a conventionally constructed building to a confined space, such space should be provided with two permanent openings: one located 6” (15cm) below the space ceiling, the other 6” (15cm) above the space floor.

Each opening should have a free area of one square inch per 1,000

BTU/hr (22cm 2 /kW) of the total input of all appliances in the space, but not less than 100 square inches (645cm 2 ).

If the confined space is within a building of tight construction, air for combustion must be obtained from the outdoors as outlined in the

Venting section of this manual.

F. Carbon Monoxide Detectors

In the Commonwealth of Massachusetts and As Required by State and Local Codes:

Installation of Carbon Monoxide Detectors: At the time of installation or replacement of the vented gas fueled appliance, the installing plumber or gas fitter 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 appliance is installed, unless the appliance is located in a detached, uninhabitable structure separate from the dwelling, building, or structure used in whole or in part for residential purposes.

In addition, the installing plumber or gas fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on each additional level of the dwelling, building, or structure served by the vented gas appliance. It shall be the responsibility of the property owner to secure the service of qualified service technicians for the installation of hard wired carbon monoxide detectors.

a. In the event that the vented gas fueled appliance is installed in a crawl space or attic, the hard wired carbon monoxide detector with alarm and battery back-up shall be installed on the next adjacent floor level.

b. In the event that these requirements 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 requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

!

WARNING

Do not attempt to vent this appliance by any means other than those described in this manual. Doing so will void the warranty and may result in severe personal injury or death.

Approved Carbon Monoxide Detectors: Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 70 and be ANSI/UL 2034 listed and IAS certified.

G. Prevent Combustion Air Contamination

Install intake air piping for the boiler as described in the Venting

Section, this manual. 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 in Table 7. Contaminated air will damage the boiler, resulting in possible substantial property damage, severe personal injury, or death. For example, do not pipe intake air near a swimming pool or laundry facilities. These areas always contain contaminants.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

13

Products to Avoid

Spray cans containing fluorocarbons

Permanent wave solutions

Chlorinated waxes / cleaners

Areas Likely to Have Contaminants

Dry cleaning / laundry areas and establishments

Swimming pools

Metal fabrication plants

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric or Muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Chlorine-type bleaches, laundry detergents, and cleaning solvents Garages and workshops

Adhesives used to fasten building products

Table 7 - Products and Areas Likely to Have Contaminants

NOTE: DAMAGE TO THE BOILER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY.

(Refer to the limited warranty for complete terms and conditions.)

H. Removing a Appliance from a Common Vent System

!

DANGER

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.

!

WARNING

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

When removing an existing appliance, follow the steps below.

1. Seal any unused openings in the common venting system.

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, and doors between the space in which the appliance remains connected to 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 fireplace dampers.

4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust the thermostat so the appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle or smoke from a cigarette.

6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined, return doors, windows, exhaust fans, fireplace dampers, and any other gas burning appliances to their previous condition of use.

7. Any improper operation of the common venting system should be corrected to conform to the National Fuel Gas Code, ANSI Z223.1.

When resizing any portion of the common venting system, the system should approach the minimum size as determined using the appropriate tables in Appendix G of ANSI Z223.1.

Figure 2 - CO Warning Label whl-648 Rev. 001 Rel. 000 Date 4.11.19

14

I. Technical Specifications

Model

Installation

Minimum /

Maximum Input

(Btu/Hr)

Central Heating (CH)

Domestic Hot Water

(DHW)

Flue System

140 199

Indoor, Wall Mounted Model or Floor Model, Fully Condensing

19,900 / 140,000*

14,000 / 140,000

19,900 / 199,000*

Category IV, Sealed Combustion Direct Vent, Power Vent

Vent Run

AFUE

Hot Water

Capacity

35 o F Rise

45 o F Rise

77 o F Rise

Weight (lbs) Wall Mount Model

Weight (lbs) Floor Model

96%

2” (50 feet), 3” (100 feet), Schedule 40 PVC, CPVC, PP

95%

7.1 GPM

5.5 GPM

3.2 GPM

110

9.9 GPM

7.7 GPM

4.8 GPM

120

140 150

NG 0.327” (8.3mm)

Orifice Size

LP 0.244” (6.2mm)

Gas Supply

Pressure

Power

Supply

NG

LP

Main Supply

Maximum Power

Consumption

3.5” to 14” WC

120V 60 Hz, 6A

160W

General Operating Conditions

Ignition System

Burner System

Gas Valve System

Internal Pipe Material

Wall Mount Model Dimensions

Floor Model Dimensions

Ambient Temperature Range: 33 – 104 o F (0.6 – 40

Operating Relative Humidity: Up to 90% at 140 o o

F (40

C)

Shipping and Storage Temperature Range: -4 – 176 o o C)

F (-20 – 80 o C)

Power Supply and Communication (CN4): 14V DC

Product Approvals and Requirements

EMC: 89/336/EEC

LVD: 73/23/EEC

Direct Electronic Ignition / Automatic Flame Sensing

Premixed Fuel Modulation / Ceramic Fiber Infrared

Combination Modulating (Current Proportional)

W 17.5” - H 34” - D 15.4”

W 19” - H 45” - D 17”

Copper

W 19.7” - H 37” - D 16.8”

W 22” - H 48” - D 18”

Internal Storage Tank Water Capacity (DHW) 1 Gallon 1.5 Gallons

Heat Exchanger Capacity

Minimum Flow Rate

Total Water Capacity

Control Panel / Main Controller

Connection

Sizes

CH Water Pressure

DHW Water Pressure

DHW Inlet / Outlet

CH Supply / Return

Materials

Gas Inlet

Cabinet

(Wall Mount Model)

Cabinet (Floor Model)

4 Gallons

0.5 GPM

5 Gallons

NGTX-900C / P-920C_CB-HTP

Min 12 - Max 30 PSI

Max 150 PSI

3/4” NPT

1” NPT

3/4” NPT

Painted Cold Rolled Carbon Steel

Galvaneal

3.5 Gallons

Heat Exchanger 316L Stainless Steel

Safety Devices

Optical Flame Sensor, Burner Plate High Limit (392 o F), Water Temperature High Limit Sensor (200

Freeze Protection (Three Stage Operation - Activates at 46 o F), o F – See Freeze Protection in Installer Menu for Details), Exhaust Temperature High Limit Sensor (190 o F), Blocked Flue Switch, Condensate Switch,

Built-In Low Water Cut-Off Probe

Table 8 - Technical Specifications - *NOTE: 199 Models offer a maximum BTU/Hr Input of 140,000 as shipped. Maximum BTU/Hr can be increased up to 199,000 BTU/Hr with a larger external pump installed in the primary loop.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

BOTTOM TOP

15

Figure 3 - Wall Mount Model Dimensions

G

H

E

F

C

D

A

B

I

J

Table 9 - Adapter Specifications - All Models

Model K L M N O P

Description

Automatic Air Vent

Air Intake Adapter

Exhaust Vent Adapter

Pressure Relief Valve Adapter

CH Supply Adapter

CH Return Adapter

DHW Outlet Adapter

DHW Inlet Adapter

Gas Inlet Adapter

Condensate Adapter

Diameter

-

3”

3/4” NPTF

1” NPT

3/4” NPT

1/2” NPT (3/4” PVC Socket on Floor Models)

Q R S T U V W X Y Z AA AB AC AD AE

140 17.3

34 15.4

10.6

6.7

4.3

2.8

5.1

11.0

2.3

5.7

8.9

199 19.7

37 16.8

7.8

5.4

4.0

6.3

12.3

2.5

5.9

10.6

Table 10 - Wall Mount Specifications and Dimensions

How the Boiler Operates

Condensing technology intelligently delivers hydronic heating while maximizing efficiency. Outlined below are the features of the system and how they operate:

Stainless Steel Heat Exchanger The highly efficient 316L stainless steel fire tube heat exchanger with internal aluminum is designed to extract all available heat from the combustion process and pass it into heat transfer fluid. The stainless steel construction provides protection for longer service life. The heat exchanger offers greater water content, providing lower system pressure and greater overall system efficiency.

10 to 1 Modulating Combustion System The combustion system is specially designed to provide very high turn down. This combustion system will modulate the burner output to very low levels to match the system demand and achieve better overall control of the heating system for maximum efficiency and reliability.

Control – The integrated control system monitors the system and responds to internal and external signals to regulate fan speed and control output. This allows the boiler to deliver only the amount of heat energy required and nothing more.

The control can be set up to monitor outdoor temperature through

10.8

14.9

15.1

10.5

5.9

2.3

6.8

12.6

3.9

16.6

17.0

12.5

7.0

3.2

9.2

15.1

3.7

an outdoor sensor to regulate boiler set point temperature, increasing overall system efficiency while providing great comfort.

Electronic LCD Display – The high resolution display allows the user to monitor boiler functions. The display also provides the means to program the system parameters to maximize the efficiency of the system design.

Combustion System (Blower – Gas Valve – Mixer – Burner – Spark

Ignition) – The highly efficient spark ignition combustion system uses a variable speed blower to adjust combustion as the system requires more or less energy. The negative regulated gas valve provides only the amount of fuel required to ensure clean combustion. The mixer accurately regulates the combination of gas and air throughout the modulating range to ensure high reliability. The burner is constructed of durable ceramic metal fiber for long service life.

Boiler Sensors (Inlet – Outlet – Flue - Outdoor) - Sensors provide highly accurate temperature monitoring to assure accurate system control. These sensor inputs can be monitored through the boiler control system and display.

Pressure Gauge – Allows the user to monitor system pressure.

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16

Figure 4 - Floor Model Dimensions

Model K L M N O P Q R S T U V W X Y Z AA AB AC AD AE AF

140 17.3 19.1

16.8

12 9.5

7 5.3

3

2.5

4 5 6.5

7.3 9.5

13.5

199 19.7 21.5

18.2

13.3

10.8

8.3

6.6

4.3

Table 11 - Floor Model Specifications and Dimensions

System Safeties – The boiler is provided with many safety features to ensure reliable and safe operation. Each safety is connected to the boiler control. The boiler will alert the user if an unsafe condition occurs and needs to be addressed. The following are provided safeties: Flue Pressure Switch (monitors flue pressure), Burner High

Limit (monitors burner plate temperature), High Limit Water Switch

(monitors boiler temperature), Low Water Sensor (monitors water level in the heat exchanger), optic flame sensor (monitors flame quality), Flue Sensor (monitors flue temperature), Condensate

Pressure Switch (monitors pressure to ensure condensation does not back up into boiler).

Manual Air Vent – Each boiler is equipped with an air vent to discharge air from the system during start–up.

Intake and Exhaust Adapters – The boiler is equipped with adapters to ease connection to the vent system. The adapters are provided with clamps and seals to secure field supplied piping, and test ports to ease monitoring of the combustion system. Each boiler is supplied with a 6 inch piece of CPVC that must be connected into the exhaust vent adapter.

Boiler 1” Return and 1” Supply Connection – Boilers are equipped with both top and bottom piping connections for greater installation flexibility.

Gas Connection – The boiler is equipped with a ¾” gas connection

44.8

12 7.4

4.7

6.8

12.6 5.5

48 14 8.5

3.2

9.2

15.1 5.2

to connect the incoming gas supply.

Field Wiring and Power Switch – Each boiler is supplied with a power switch to cut off power. The boiler is also equipped with two front mounted terminal strips. These terminal strips are separated into low and line voltage to ease system wiring.

Condensate Trap and Hose Assembly – Each boiler has a built-in condensate trap to control the discharge of condensate produced by the boiler during normal operation. A corrugated condensate hose is also provided to ensure proper drainage of condensate into the pump or drain.

Low Water Cut Off Probe – LWCO is provided with each boiler to ensure the boiler has an adequate water level to eliminate overheating and damge to the heat exchanger.

Pump Service Mode – Allows manual operation of pumps to commission system and check pump operation.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

17

Figure 5 - Components

Number

1

2

3

4

5

Component Description

Air Vent

Relief Valve Adapter

Air / Gas Mixing Pipe

Gas Valve

Internal Storage Tank

Number

11

12

13

14

15

Component Description

CH Return Adapter

CH Pressure Gauge

DHW Outlet Adapter

Gas Inlet Adapter

DHW Inlet Adapter with Filter and

Flow Restrictor

Condensate Adapter

Condensate Trap

Number Component Description

21 Control Panel

22

23

Heat Exchanger

Ignition Transformer

24 Flame Detecting Sensor

25 BLDC Fan

6

7

Main PCB

Manual ON/OFF Power Switch

8

Internal Recirculation Pump (DHW) /

CH Internal Primary Pump

9

10

CH Supply Adapter

Table 12 - Component List

CH Return Filter

16

17

18

19

20

Condensate Air Pressure Switch

Mixing Valve

Terminal Block

26

27

28

29

Air Pressure Switch

Exhaust Vent Pipe

Exhaust Vent Adapter

Air Intake Adapter

J. Wall-Mounting (Wall Mount Models Only)

!

WARNING

The boiler must be installed on a wall that can bear its weight (more than 110 lbs. when fully plumbed and full of water). Installing the boiler on a wall which cannot support its weight could result in property damage, personal injury, or death.

The boiler may be installed on any suitable internal wall (suitable sound-proofing may be required when installing onto a stud partition wall).

whl-648 Rev. 001 Rel. 000 Date 4.11.19

18

!

WARNING

This boiler is too heavy for one person to lift. It is highly recommended to install the boiler with two people. Use caution as to not drop the boiler, which could damage the boiler and cause property damage and/or severe personal injury. Verify that the boiler is properly and securely mounted before leaving unsupervised. Failure to comply with the above and properly mount the boiler could result in substantial property damage, severe personal injury, or death.

This wall mounting system is not seismic rated and should not be applied as such. Failure to comply with the above and properly mount the boiler could result in substantial property damage, severe personal injury, or death.

Figure 6 - Wall-Mounting the Boiler

Positioning the Boiler on the Wall

1. Attach the wall bracket on the location where you want to install the boiler. Ensure it is level and on stud (16” centers) before proceeding.

2. Mark the four drill holes with a pencil or marker. Remove the wall bracket.

3. Drill four (4) holes using a 5/32 drill bit at the marked hole locations.

4. Mount the wall bracket to the wall with the four (4) included anchor bolts. Ensure the mounted bracket is level. See Figure 6A.

5. Align the boiler bracket grooves on the back of the boiler with the tongues on the wall bracket and hang the boiler on the bracket.

See Figure 6B.

K. Flow Restrictor

A flow restrictor is installed on this boiler in the DHW inlet adapter to avoid excessive flow at the faucets. See Flow Charts, this manual, for more information.

If it is necessary to further increase flow to the system, replace the factory installed white flow restrictor with the blue included with the boiler by following the instructions below.

!

WARNING

If the boiler is already fully installed, turn the gas, power, and water off to the boiler and drain all water from the boiler BEFORE proceeding. Failure to comply could result in substantial property damage, severe personal injury, or death.

Figure 7 - A - Removing the DHW Inlet Filter, B - Removing the Flow

Restrictor

1. Locate the DHW inlet adapter on the bottom of the boiler.

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 boiler. See Figure 7-B.

4. Reinstall the DHW inlet filter.

5. Reinstall the two pins.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

19

Figure 8 - Water Pressure vs. Flow through the Restrictors - 140 Models

Figure 9 - Water Pressure vs. Flow through the Restrictors - 199 Models

Part 4 - Water Piping

!

WARNING

Failure to follow the instructions in this section WILL VOID the warranty and may result in property damage, severe personal injury, or death.

CAUTION

Do not apply a torch within 12” of the boiler. If sweat connections are used, sweat tubing to the adapter before fitting adapter to the water connections on the boiler. Damages due to improper installation practices ARE NOT covered by warranty.

Dielectric unions or galvanized steel fittings must not be used in a system with this boiler. Doing so WILL VOID the warranty. Use only copper, brass, or stainless steel fittings. Teflon thread sealant must be used on all connections.

A. General Plumbing Guidelines

CAUTION

Use two wrenches when tightening water piping at the boiler. Use one wrench to prevent the boiler return or supply line from turning.

Failure to prevent piping connections from turning could cause damage to boiler components.

The boiler control module uses temperature sensors to provide both high limit protection and modulating temperature control. The control module also provides low water protection by sensing the water level in the heat exchanger. Some codes / jurisdictions may require additional external controls.

The water connections must be installed in accordance with all local and national plumbing codes, or any applicable standard which prevails. whl-648 Rev. 001 Rel. 000 Date 4.11.19

20

• 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.

• The size of the DHW pipes should be 3/4” diameter, and the CH pipes should be 1” diameter.

• Isolation (shutoff valves) should be used on both the CH and

DHW loops to ease future servicing.

• All piping should be insulated.

It is recommended to install a sweat shut-off valve and a union in the return and supply piping to ease future servicing. If there is a backflow preventer or any type of a no return valve in the system, install an additional tee here, suitable for an expansion tank.

B. Backflow Preventer

It may be recommended to use a backflow preventer - check local codes. If a backflow preventer or a no return valve is used, a thermal expansion tank must be installed on the cold water supply between the boiler and the valve.

!

WARNING

To control thermal expansion, a thermal expansion tank should be installed in systems with an installed backflow preventer. DO 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.

D. Piping the Boiler

CAUTION

Use at least the MINIMUM pipe size for all boiler loop piping This is to avoid the possibility of inadequate flow through the boiler.

Using less than the required minimum pipe size and piping could result in system problems, property damage, and premature boiler failure. Such problems ARE NOT covered by product warranty.

Use both thread tape and pipe dope to connect the 3/4” DHW inlet and outlet pipes. A shut off valve between the city water supply and

DHW inlet is recommended for ease of service. Westinghouse offers threaded 3/4” DHW tankless isolation valves with a DHW pressure relief valve for ease of installation and future service.

Use both thread tape and pipe dope to connect the 1” CH return and supply pipes. Isolation valves between are recommended for ease of service.

C. Expansion Tank

Expansion Tank

1. Ensure that the expansion tank is designed and sized to correctly handle system water volume and temperature. Check technical specifications for the water content of this boiler.

!

WARNING

Expansion tanks must be sized according to total system volume.

This includes all length of pipe, all fixtures, boilers, etc. Failure to properly accommodate thermal expansion could result in property damage, severe 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 boiler failure can result due to excessive make-up water addition. SUCH

FAILURE IS NOT COVERED BY WARRANTY.

2. The expansion tank must be located as shown in Applications, this manual, or 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.

CAUTION

DO NOT install automatic air vents on closed type expansion tank systems. 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.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

E. Applications

Figure 10 - Piping Symbol Legend

21 whl-648 Rev. 001 Rel. 000 Date 4.11.19

22

Figure 11 - Primary / Secondary Piping with Zone Valves - DHW Priority and Outdoor Reset

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. Circulators are shown with isolation flanges. The alternative is standard flanges with full port ball valves. Purge valves can be used with circulator flanges as an alternative.

6. Piping shown is Primary/Secondary. System flow (secondary loop) must be greater than the boiler’s primary loop flow.

7. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

8. VERY IMPORTANT – Minimum 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 boiler to operate when there is a call for heat.

10. Unit is equipped with built-in primary pump for the heating loop. This pump is sized to insure proper flow rate through the boiler heat exchanger and related piping. On long pipe runs, it is recommended to keep the pump at maximum speed (setting 3). DO NOT lower it from the factory default.

11. NOTE: DO NOT INSTALL a flow check or a pump with flow check on the return line of the primary loop going to the boiler. This will isolate the boiler from the expansion tank, causing pressure to build up in the unit and the Pressure Relief Valve to discharge.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

23

Figure 12 - Primary / Secondary Piping with Pumps - DHW Priority and Outdoor Reset

NOTES:









9. Each heating zone of a pump-based system has its own circulator with turns on when a zone thermostat calls for heat.



whl-648 Rev. 001 Rel. 000 Date 4.11.19

24

Figure 13 - Primary / Secondary Piping with Pumps - DHW Priority and Outdoor Reset with Recirculation

NOTES:












whl-648 Rev. 001 Rel. 000 Date 4.11.19

25

Figure 14 - Primary / Secondary Piping with Pumps - DHW Priority and Outdoor Reset with Recirculation and Boiler Primary Pump

NOTES:












12. To achieve 199,000 BTU/hr, install a Boiler Primary Pump. NOTE: RECOMMENDED PUMP: TACO 0013 or equivalent.

Boiler Primary Pump Instructions: a. Install pump. Connect the pump to boiler terminal (2A max).

b. Go into installer menu and change 19:cb from 70 (default) to 100.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

26

Figure 15 - Primary / Secondary Piping with Pumps - DHW Priority and Outdoor Reset - Floor Model

NOTES:












whl-648 Rev. 001 Rel. 000 Date 4.11.19

27

Figure 16 - Primary / Secondary Piping with Pumps - DHW Priority and Outdoor Reset with Recirculation and Boiler Primary Pump - Floor Model

NOTES:












12. To achieve 199,000 BTU/hr, install a Boiler Primary Pump. NOTE: RECOMMENDED PUMP: TACO 0013 or equivalent.

Boiler Primary Pump Instructions: a. Install pump. Connect the pump to boiler terminal (2A max).

b. Go into installer menu and change 19:cb from 70 (default) to 100.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

28

F. CH and DHW Pressure Relief Valves

An external pressure relief valve must be installed on this boiler for both the CH and DHW loops. When installing, observe the following guidelines. Pressure relief valves must be installed as close to the boiler as possible. No other valves should be placed between the pressure relief valve and the boiler. Failure to comply with these guidelines can result in substantial property damage, personal injury, or death.

This boiler has a high-temperature shut-off switch built in as a standard safety feature. Therefore, a “pressure only” relief valve is required.

DO NOT operate this boiler before the supplied pressure relief valve is installed with sufficient relieving capacity in accordance with the

ASME rating plate on the boiler.

CH Loop

This boiler is provided with a CH pressure relief valve that complies with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV

(Heating Boilers). 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 ¾” X 1” bushing to aid installation of the CH Pressure Relief Valve. The valve is meant to be field installed. DO NOT install a CH pipe line relief valve with a pressure rating greater than 30 psi. This is the maximum allowable CH relief valve setting for this boiler.

DHW Loop

This boiler must be provided with a DHW pressure relief valve that complies with local codes, but not less than valves certified as meeting the requirements of Relief Valves for Hot Water Supply

Systems, ANSI Z21.22 CSA4.4 by a nationally recognized lab that maintains periodic inspection of production listed equipment. A

DHW pressure relief valve is not included with the boiler, and is to be field supplied and installed. DO NOT install a DHW relief valve with a pressure rating greater than 150 psi. This is the maximum allowable

DHW relief valve setting for this boiler.

After installing the relief valves and filling and pressurizing the system, test the operation of the valves by lifting the levers. Make sure the valves discharge freely. If a valve fails to operate correctly, replace it with a new relief valve. Ensure that the maximum BTU/H rating on the pressure relief valve is equal to or greater than the maximum input BTU/H rating of the combination boiler.

!

WARNING

To avoid water damage or scalding due to relief valve operation:

• 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.

• Discharge line must be as short as possible and the same size as the valve discharge connection throughout its entire length.

• Discharge line must pitch downward from the valve and terminate at least 6” above the floor drain, making discharge clearly visible.

• Discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of 375 o F or greater.

• Do not pipe discharge to any location where freezing could occur.

• No shutoff valve may be installed between the relief valve and boiler or in the discharge line. Do not plug or place any obstruction in the discharge line.

• Test the operation of the relief valve after filling and pressurizing the system by lifting the lever. Make sure the valve discharges freely. If the valve fails to operate correctly, replace it with a new relief valve.

• Test relief valve at least once annually to ensure the waterway is clear. If valve does not operate, turn the boiler “off” and call a plumber immediately .

• Take care whenever operating relief valve to avoid scalding injury or property damage.

• For boilers 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 Z21.22 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.

Do not thread a cap or plug into the relief valve or relief valve line under any circumstances! Explosion and property damage, serious injury, or death may result.

Figure 17 - Pressure Relief Valve

!

WARNING

RE-INSPECTION OF RELIEF VALVES: Valves should be inspected AT LEAST ONCE EVERY THREE YEARS, and replaced if necessary, by a qualified service technician to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occuring conditions may corrode the valve and its components over time, rendering the valve inoperative. Such conditions can only be detected if the valve and its components are physically removed and inspected.

Do not attempt to conduct an inspection on your own.

Contact your plumbing contractor for a re-inspection to assure continued safety.

FAILURE TO RE-INSPECT THE RELIEF VALVE AS DIRECTED

COULD RESULT IN UNSAFE TEMPERATURE AND/OR PRESSURE

BUILD-UP WHICH CAN RESULT IN PROPERTY DAMAGE,

SERIOUS PERSONAL INJURY, OR DEATH.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

29

Part 5 - Venting

!

DANGER

The boiler must be vented as detailed in this section. Ensure exhaust vent and intake piping complies with these instructions regarding vent system. Inspect finished exhaust vent and intake piping thoroughly to ensure all joints are well secured, airtight, and comply with all applicable code requirements, as well as the instructions provided in this manual. Failure to properly install the vent system will result in severe personal injury or death.

A. General

!

DANGER

This appliance is certified as a “Category IV” appliance and requires a special venting system. The vent system will operate with a positive pressure in the pipe. Exhaust gases must be piped directly outdoors using the vent materials and rules outlined in these instructions. Do not connect vent connectors serving appliances vented by natural draft into any portion of mechanical draft systems operating under positive pressure. Follow the venting instructions carefully. Failure to do so will result in substantial property damage, severe personal injury, or death.

Exhaust and intake are to be piped separately. This appliance cannot share a common exhaust or intake with multiple appliances. Failure to follow these instructions will result in substantial property damage, severe personal injury, or death.

1. 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.

2. Install the venting system in accordance with these instructions and with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, CAN/

CGA B149, and / or applicable provisions of local building codes.

3. This appliance must be vented with materials, components, and systems listed and approved for Category IV appliances.

NOTE: To avoid contamination often contained in indoor air, it is best to pipe all intake combustion air directly to the outdoors.

NOTE: Care must be taken to prevent condensate freezing in the exhaust vent pipe system. See local, state, provincial, and national codes for best practices to prevent condensate freezing in the exhaust vent pipe system.

!

WARNING

Improper seating of vent pipe gaskets can cause eventual gasket failure and exhaust gas leakage. Ensure the exhaust vent pipe is properly beveled and seated before insertion into the flue adapter.

Failure to do so could result in property damage, severe personal injury, or death.

!

DANGER

Due to the extreme flammability of most glues, cements, solvents, and primers used to join plastic exhaust vent and intake pipes, explosive solvent vapors must be cleared from all vent piping before start-up. Avoid using excess cement or primer, as this may pool in the vent pipes. Vent assemblies should be allowed to cure for a period of at least 8 hours before powering a connected appliance. Failure to follow these instructions will result in substantial property damage, severe personal injury, or death. It is the installers’ responsibility to understand the hazards associated with explosive solvents and take the necessary precautions to avoid these risks.

!

WARNING

• DO NOT insulate the first three (3) linear feet of the exhaust vent run.

• CPVC, Polypropylene, or Stainless

Within First Three (3) Linear Feet of

Appliance Exhaust Vent Adapter

Steel pipe material MUST be used if the first three (3) linear feet of the exhaust vent run is insulated or passes through an enclosed space

Enclosed

Space greater than 6” in length, such as a wall. NOTE: Only Stainless Steel pipe material may be insulated.

• If CPVC is used to meet these requirements, the balance may be installed with approved PVC pipe.

Exhaust

Length

Greater than

Six (6) Inches

LP-179-JJ

11/30/17

• If Polypropylene or Stainless Steel is used to meet these requirements, the balance of the vent run must be installed with the same material.

• Failure to comply with this warning could result in property damage, severe personal injury, or death.

Exhaust 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 vent must be pitched a minimum of 1/4” per foot back to the boiler 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.

It is required to insert the provided exhaust and intake screens into the vent terminations to prevent blockage caused by debris or birds.

Failure to keep terminations clear could result in property damage, severe personal injury, or death.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

30

B. Approved Materials for Exhaust Vent and Intake Pipe

Item

Pipe and Fittings Approved for Intake ONLY

Material

ABS*

Standards for Installation In:

United States Canada

ANSI/ASTM D2661 NOT PERMITTED

Pipe Approved for

Intake OR Exhaust Vent

Pipe Fittings

PVC Schedule 40/80

PVC-DWV Schedule 40/80

CPVC Schedule 40/80

ANSI/ASTM D1785

ANSI/ASTM D2665

ANSI/ASTM F441

PVC, CPVC, and PP Venting

Must be ULC-S636 Certified.

IPEX is an approved manufacturer in Canada.

Polypropylene UL-1738 or ULC-S636

Stainless Steel AL29-4C Certified for Category IV and Direct Vent Appliance Venting

PVC Schedule 40

PVC Schedule 80

CPVC Schedule 40

CPVC Schedule 80

ANSI/ASTM D2466 or D2665

ANSI/ASTM D2467 or D2665

ANSI/ASTM F438

ANSI/ASTM F439

PVC, CPVC, and PP Venting

Must be ULC-S636 Certified.

IPEX is an approved manufacturer in Canada.

ABS* ANSI/ASTM D2235 NOT PERMITTED

Pipe Cement PVC

CPVC

ANSI/ASTM D2564

ANSI/ASTM F493

IPEX System 636 Cements and Primers

Pipe Primer PVC / CPVC ASTM F656

!

DANGER

• The exhaust and intake components installed with this appliance must be used for near appliance piping BEFORE transitioning to the approved materials listed above. DO NOT REMOVE these installed components. Doing so WILL VOID appliance warranty.

• PVC / CPVC pipe and fittings of the same diameter are considered interchangeable.

®

• The use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel prohibited.

(polyphenolsulfone) in non-metallic venting systems is

• Covering non-metallic vent pipe and fittings with thermal insulation is prohibited.

• DO NOT connect PVC/CPVC to Polypropylene without an approved vent connector.

• Any transition to Polypropylene MUST be done in the vertical within five (5) feet of the appliance.

• When installing AL29-4C vent piping, install a PVC-to-stainless adapter at the appliance vent connection, and at the termination when using a PVC termination kit. DO NOT mix AL29-4C piping from different manufacturers unless using adapters specifically designed for the purpose by the manufacturer.

• A double wall vent or insulated material may be used when using stainless steel vent material in a freezing climate.

• *ABS may be used for air intake applications ONLY. ABS is NOT PERMITTED for use in Canada.

• Contact the venting material manufacturer if there is any question about the applicability of the proposed venting material.

Failure to follow these directions will result in substantial property damage, severe personal injury, or death.

Table 13 - Approved Materials for Exhaust Vent and Intake Pipe

!

DO NOT mix components from different venting systems. The vent system could fail, causing leakage of flue products into the living space. Use only the approved pipe and fitting materials, and primer and cement specifically designed for the material used, as listed in the above table. Failure to do so could result in property damage, serious injury, or death.

WARNING

CAUTION

High heat sources (generating heat 100 o

F / 37 o

C or greater, such as appliance flue pipes, space heaters, etc.) may damage plastic components of the boiler 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 boiler and related components near high heat sources.

NOTE: The use of double-wall vent or insulated material for the combustion air intake pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

!

DANGER

You must not use “B” vent in an exhaust application. “B” vent is for intake applications ONLY. Using “B” vent in an exhaust application will result in serious injury or death.

C. Additional Requirements for Installation in Canada

1. Installations must be made with a vent pipe system certified to ULC-S636. IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC-S636. Additionally, you may use AL29-4C stainless steel venting to comply with Canadian requirements.

2. The first three (3) feet of vent pipe from the boiler flue outlet must be readily accessible for visual inspection.

3. The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe / fittings.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

31

D. Exhaust Vent and Intake Pipe Location

INSIDE CORNER

DETAIL

A

G

E

H

E

B

B

E

C

FIXED

CLOSED

E

D

OPERABLE

FIXED

CLOSED E

OPERABLE

I

E

F

E

K

I

M B

E E

B

E

I

J

A

K I L B

LP-179-CC

03/28/17

E Exhaust Vent Terminal I Intake Pipe Terminal Area Where Intake Terminal Is Not Permitted

Figure 18 - Exit Terminals for Direct Vent Systems - ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada

A

B

DESCRIPTION

Clearance above grade, veranda, porch, deck, or balcony

Clearance to window or door that may be opened

Direct Vent

Power Vent

C Clearance to permanently closed window

D

Vertical clearance to ventilated soffit located above the terminal within a horizontal distance 2 feet (61 cm) from the center line of the terminal

E Clearance to unventilated soffit

F Clearance to outside corner

G Clearance to inside corner

H

Clearance to each side of center line extended above meter / regulator assembly

US

1 foot (30 cm)

1 foot

4 ft below or to side of opening; 1 ft above opening

*

*

*

*

*

*

I Clearance to service regulator vent outlet *

CANADA

3 feet (91 cm)

Above a regulator within 3 feet (91 cm) horizontally of the vertical center line of the regulator vent outlet to a maximum vertical distance of 15 ft (4.5 m)

J

Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance

Direct Vent

Power Vent

1 foot

4 ft below or to side of opening; 1 ft above opening

3 feet (91 cm)

K Clearance to mechanical air supply inlet

L

Clearance above paved sidewalk or paved driveway located on public property

Direct Vent

Power Vent

3 feet above if within 10 feet horizontally

*

7 feet (2.13 m)

6 feet (1.83 m)

7 feet (2.13 m)

M Clearance under veranda, porch deck, or balcony * 1 foot (30 cm)

Table 14 - Vent Termination Clearances - *NOTE: For clearances not specified in ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada, please use clearances in accordance with local installation codes and the requirements of the gas supplier.

!

WARNING

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 boiler 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 boiler. Detectors and alarms shall comply with NFPA 720 (latest edition). Failure to comply with these requirements could result in product damage, severe personal injury, or death.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

32

E. Exhaust Vent and Intake Pipe Sizing

1. The exhaust vent and intake pipe size is 3”.

2. The total equivalent length of 2” exhaust vent and intake pipe should not exceed fifty (50) feet ; 3” exhaust vent and intake pipe should not exceed one hundred (100) feet .

a. The equivalent length of elbows, tees, and other fittings are listed in the Friction Loss Table.

elbows and 10 feet b. For example: If the exhaust vent has two 90 o of PVC pipe we will calculate:

Exhaust Vent Equivalent Length = (2x5) + 10 = 20 feet.

Further, if the intake pipe has two 90 o elbows, one 45 o elbow, and

10 feet of PVC pipe, the following calculation applies:

Intake Pipe Equivalent Length = (2x5) + 3 + 10 = 23 feet.

Finally, if a concentric kit is used we find:

Total Equivalent Length = 20 + 23 + 3 = 46 feet.

The total equivalent length is 46 feet, well below the maximum of

150 feet.

c. Effort should be made to keep a minimum difference in equivalent length between the exhaust vent and intake pipe.

NOTE: Clean and dry the boiler connection. DO NOT use primer or cement on the boiler connection.

1. Push the length of pipe into the connection until it touches the bottom of the fitting.

2. Tighten the clamps using a screwdriver.

3. Ensure the pipe is secure before continuing installation.

4. For 2” installations, install the reducing coupling in a vertical section of pipe. At least a 6” length of 3” pipe MUST BE

INSTALLED before reducing to 2”. See Figure 20.

NOTE: A reducing coupling MUST BE USED when transitioning from 3” to 2” vent pipe. DO NOT use reducing bushings.

!

WARNING

Failure to install the included 6” length of 3” CPVC pipe in the exhaust vent adapter before transitioning to other vent materials could result in property damage, severe personal injury, or death.

Friction Loss Equivalent in Piping and Fittings

Fittings or Piping

2”

Equivalent Feet

3”

90 Degree Elbow*

45 Degree Elbow

5’

3’

5’

3’

Coupling

Air Inlet Tee

Straight Pipe

Concentric Kit

0’

0’

1’

3’

0’

0’

1’

3’

V500 2” Kit

V1000 3” Kit

1’

N/A

N/A

1’

V2000 4” Kit N/A 1’

Table 15 - *Friction loss for long radius elbow is 1 foot less. NOTE: Consult

Polypropylene venting instructions for friction loss and pressure drop equivalents.

3. The minimum total equivalent length is 14 feet.

NOTE: The intake pipe and exhaust vent lengths do not have to be of equal length. There is no balancing requirement between intake and exhaust.

2” Combined Vent Length 3” Combined Vent Length

Minimum Maximum Minimum Maximum

14’ (4.2M) 50’ (15M) 14’ (4.2M)

Maximum # of 90 o Elbows

(2” and 3” Vent Diameters)

100’ (30M)

6

Table 16 - Approved Vent Lengths

CAUTION

Do not exceed the maximum lengths for vent pipes. Excessive length could result in boiler shutdown and property damage.

Failure to provide a minimum total vent length of 14 equivalent feet could result in property damage and improper product operation.

F. Tightening Boiler Collar to Exhaust Vent and Intake Pipe

This boiler 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 3” x 2” reducing coupling (not included). Follow the steps below to install 3” vent pipe into the boiler vent collar. See

Figure 19 for additional details.

Figure 19 - Correct Installation into the Boiler Collar

Figure 20 - Transitioning from 3” to 2” Vent Pipe

G. Exhaust Vent and Intake Pipe Installation

!

WARNING

All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into the living space. Failure to do so could result in property damage, serious injury, or death.

1. Use only solid PVC, CPVC, or stainless steel pipe or a Polypropylene vent system approved for use with Category IV appliances.

ABS pipe material may be used on air intake piping only .

2. Remove all burrs and debris from joints and fittings.

3. When using PVC or CPVC pipe, all joints must be properly cleaned, primed, and cemented. Use only cement and primer approved for use with the pipe material. Cement must conform to ASTM D2564 for PVC and ASTM F493 for CPVC pipe. NOTE: DO NOT CEMENT

POLYPROPYLENE PIPE.

4. Ensure the vent is located where it will not be exposed to prevailing winds.

5. In all roof venting applications, exhaust discharge must point away from the pitch of the roof.

6. To prevent water leakage, install adequate roof flashing where the pipe enters the roof.

7. Do not locate vent over public walkways, driveways, or parking lots. Condensate could drip and freeze, resulting in a slip hazard or damage to vehicles and machinery.

8. Due to potential moisture build-up, sidewall venting may not be the preferred venting option. To save time and cost, carefully consider venting installation and location.

9. Horizontal lengths of exhaust vent must slope back towards the boiler not less than ¼” per foot to allow condensate to drain from whl-648 Rev. 001 Rel. 000 Date 4.11.19

33 the vent pipe.

10. The exhaust vent must terminate where vapors cannot make accidental contact with people or pets, or damage shrubs or plants.

11. In vacant chimney applications, install and seal a rain cap over existing chimney openings.

12. All piping must be fully supported. Use pipe hangers at a minimum of 4 foot intervals to prevent sagging of the pipe where condensate may form.

13. Do not use the boiler to support any piping.

14. Maximum Snow Level Determination: These installation instructions reference snow levels in establishing a minimum height for the installation of exhaust vent or air intake terminations. Snow levels shall be determined as follows: a. The installation location may, by ordinance, designate how snow levels are calculated in that location; or b. In the absence of specific ordinances, snow levels shall be calculated from the average monthly maximum depth of snow accumulation as indicated by the National Weather Service’s 10 year statistics for the installation location/geographical area.

In addition:

• Total length of vent piping shall not exceed the limits specified in this manual.

• The vent piping for this direct vented appliance is approved for zero clearance to combustible construction.

• The flue products coming from the exhaust vent will create a large plume when the boiler is in operation. Avoid venting in areas that will affect neighboring buildings or be considered objectionable.

• DO NOT locate exhaust vent or intake pipe in a parking area where machinery may damage the pipe.

• DO NOT vent near soffit vents, crawl space vents, or other areas where condensate or vapor could create a nuisance or hazard or cause property damage.

• DO NOT vent where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valve, or other equipment.

In the Commonwealth of Massachusetts and as Required by

State and Local Codes:

• The vented gas fueled appliance shall not be installed so its combustion, ventilation, or dilution air is obtained from a bedroom or bathroom.

• Signage: Whenever any through-the-wall (horizontal or sidewall) vent is installed less than seven feet above the finished grade, a metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight feet above grade directly in line with the exhaust vent terminal. The sign shall read, in print no less than 0.5 inches in size, “GAS VENT DIRECTLY BELOW. KEEP

CLEAR OF ALL OBSTRUCTIONS”.

• Marking of Exhaust Vent and Intake Pipe: Piping used for ventilation, make-up, or combustion air intake shall be labeled as follows: a. Throughout the entire developed length: i. Labels must be placed every ten feet for exposed/visible piping; or ii. Labels must be placed every three feet for concealed piping. b. At all changes of direction; c. On each side of a penetration through a partition, wall or ceiling; and d. The labels shall be black lettering that: i. Indicates that the piping is used for ventilation, make-up, or combustion air intake, and ii. The letters shall be sized equal to a minimum of the pipe diameter. However, for piping with a diameter exceeding two inches, said lettering does not need to be larger than two inches.

This table lists optional exhaust/intake terminations available from

Westinghouse:

Description

2” PVC Concentric Termination Kit

3” PVC Concentric Termination Kit

2” Stainless Steel Termination Kit

3” Stainless Steel Termination Kit

3” Polypro Vent Kit

Table 17 - Optional Vent Kits

H. Applications

1. Direct Vent Installation of Exhaust and Intake

If installing a direct vent option, combustion air must be drawn from the outdoors directly into the boiler intake, and exhaust must terminate outside. There are three basic direct vent options detailed in this manual: 1. Side Wall Venting, 2. Roof Venting, and 3. Unbalanced

Venting.

Be sure to locate the boiler such that the exhaust vent and intake pipe can be routed through the building and properly terminated.

Different vent terminals can be used to simplify and eliminate multiple penetrations in the building structure (see Optional Equipment in

Venting Section). The exhaust vent and intake pipe lengths, routing and termination methods must all comply with the methods and limits given in the Venting section of this manual.

When installing a combustion air intake from outdoors, care must be taken to utilize uncontaminated combustion air. NOTE: To prevent combustion air contamination, see Table 7.

!

WARNING

Stock Code

KGAVT0501CVT

KGAVT0601CVT

V500

V1000

8400P-001

All vent pipes must be glued, properly supported, and the exhaust pitched a minimum of 1/4” 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 of 4 foot intervals on the vent pipe. Venting must be readily accessible for visual inspection from the first three feet from the appliance.

Take extra precaution to adequately support the weight of vent pipes terminating through the roof. Failure to properly support roof terminated piping could result in property damage, serious injury, or death.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

34

Two Pipe Sidewall Venting with Elbow (Intake) and Coupling (Exhaust)

1" MIN.

12" MIN.

EXHAUST

INSERT EXHAUST

SCREEN

EXTERIOR WALL

Two Pipe Roof Venting with Elbow (Intake) and Coupling (Exhaust)

MAINTAIN 12" MINIMUM

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL

OR GRADE, WHICHEVER IS

GREATER (TYP)

LP-505-A

06/23/15

INTAKE

INSERT INLET SCREEN

Figure 21 - Direct Vent, Roof and Sidewall Vent Terminations

Sidewall Venting with Kit

VENT KIT

EXTERIOR WALL

CONCENTRIC VENT KIT

Roof Venting with

Concentric

Vent Kit

EXHAUST

12" OVER MAXIMUM SNOW

LEVEL OR 24" - WHICHEVER

IS GREATER

MAINTAIN 12" MINIMUM

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL

OR GRADE, WHICHEVER IS

GREATER (TYP)

LP-505-A

06/23/15

Sidewall Venting with

Concentric Kit

1" MIN.

CONCENTRIC VENT KIT

LP-505-C

05/26/15

NOTE: EXTENDED VENT RUNS WHEN

TRANSITIONING TO A LARGER DIAMETER

MUST ALWAYS TAKE PLACE IN A VERTICAL

POSITION TO PREVENT CONDENSATE BLOCKAGE

IMPORTANT:

INTAKE LEG MUST

BE FACING UP

EXHAUST

INTAKE

MAINTAIN 12" MINIMUM CLEARANCE

ABOVE HIGHEST ANTICIPATED SNOW

LEVEL OR GRADE, WHICHEVER IS

GREATER (TYP.)

LP-505-C

05/26/15

Figure 22 - Direct Vent, Vent Terminations with Optional Kits (NOT INCLUDED WITH THE BOILER)

NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

24.00

EXHAUST

A

B

FRONT VIEW

C

AIR INTAKE

D

35

E

AIR INTAKE

EXHAUST

LP-325-PP

03/31/11

SIDE VIEW F

LP-325-OO

02/04/15

Figure 23 - Horizontal (Snorkel) Venting

NOTES:

A. For every 1” of overhang, the exhaust vent must be located 1” vertical below overhang (overhang means top of building structure and not two adjacent walls [corner of building]).

B. Typical installations require 12” minimum separation between bottom of exhaust outlet and top of air intake.

C. Maintain 12” minimum clearance above highest anticipated snow level or grade (whichever is greater).

D. Minimum 12” between vents when installing multiple vents.

E. 12” minimum beyond air intake.

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. See Figure 24 for installation detail.

Figure 24 - Screen Installation - NOTE: Vent termination elbow is meant to be installed open end facing the ground. Orientation in Figure 24 is meant to demonstrate proper Vent Screen installation ONLY.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

36

2. Venting Through an Existing System

This appliance may be vented through an existing unused vent system. The inner diameter of the existing vent system is utilized for the combustion air source. Two methods have been approved for such venting: Concentric Venting Through an Existing System and Venting as a Chase.

!

DANGER

Do not install the appliance into a common existing vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in substantial property damage, serious personal injury, or death.

CAUTION

Contractors must check state and local codes before installing through an existing vent opening. State and local codes always take precedence over manufacturer’s instructions. Failure to check state and local codes before installing through an existing opening could result in property damage and add significantly to installation costs.

If an existing venting system is converted for use with this appliance, the installer must ensure that the existing venting system is clean and free from particulate contamination that could damage the appliance. Failure to do so could result in property damage and appliance failure. Such failure IS NOT covered under warranty.

Concentric Venting Through an Existing System

NOTE: The following instructions refer only to venting through an existing vent system, and not to venting with Westinghouse’s optional concentric vent kits. Refer to Concentric Vent Kit installation manual

(LP-166) for further information on venting with the optional concentric vent kits.

Concentric venting through an existing system must run vertically through the roof. See Table 18 for proper minimum vent sizing. Use only the approved venting materials specified in Table 13 for piping the system. All instructions listed in this Venting section apply. See

Figures 25-1 and 25-2 for venting demonstrations.

Vent / Air Inlet Size

2”

3”

Minimum Existing Vent / Chase Size

4”

5”

4”

Table 18 - Minimum Existing Vent / Chase Sizing

7”

!

DANGER

The upper and lower vent terminations as well as all joints in the venting system must be properly sealed to ensure that all combustion air is drawn properly and exhaust does not leak from the system. Failure to properly seal the venting system will result in property damage, serious personal injury, or death.

Chase Venting Through an Existing System

When venting as a chase, follow all instructions included in this

Venting section, including those in the previous Concentric Venting

Through an Existing System section. See Figure 25-3 for chase venting demonstration.

Concentric Venting through an Existing System

1

SEAL

EXHAUST

Concentric Venting through an Existing System

2

EXHAUST

SEAL

Chase Venting through an Existing System

3

EXHAUST

24"

INTAKE

COMBUSTION AIR

COMBUSTION

AIR

EXISTING

SEAL

EXISTING

EXISTING

VENT

AIR INTAKE w/SCREEN

SEAL

12" MIN.

AIR INTAKE

(w/SCREEN)

SEAL

SEALED CAP

SEAL

SEALED

CAP

SEAL

CAP

LP-325-MM

03/15/12

LP-325-NN

07/22/13


whl-648 Rev. 001 Rel. 000 Date 4.11.19

37

3. Power Venting, Indoor Combustion Air in Confined or Unconfined Space

This appliance 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 7.

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 appliance input. with doors, are considered part of the space.

Confined space is space with volume less than 50 cubic feet per

1,000 Btu/hour (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space, through openings not furnished with doors, are considered part of the space.

When drawing combustion air from inside a conventionally constructed building to a confined space, such space should be provided with two Never obstruct the supply of combustion air to the appliance.

If the appliance is installed in areas where indoor air is contaminated

(see Figure 26) it is imperative that the appliance be installed as direct vent so that all combustion air is taken directly from the outdoors into the appliance intake connection.

Unconfined space is space with volume greater than 50 cubic feet per 1,000 Btu/hour (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space, through openings not furnished permanent openings: one located 6” (15 cm) below the space ceiling, the other 6” (15cm) above the space floor. Each opening should have a free area of one square inch per 1,000 Btu/hr (22cm2/kW) of the total input of all appliances in the space, but not less than 100 square inches

(645cm2).

If the confined space is within a building of tight construction, air for combustion must be obtained from the outdoors as outlined in the

Venting section of this manual. See Figure 27.

Figure 26 - Do Not Place Boiler Near Dryer

Figure 27 - Power Venting, Indoor and Outdoor Combustion Air - Single Pipe


whl-648 Rev. 001 Rel. 000 Date 4.11.19

38

Part 6 - Installing the Condensate Drain

CAUTION

This condensing high efficiency boiler has a condensate removal system. Condensate is water vapor derived from combustion products, similar to that produced by an automobile when it is initially started. It is very important that the condensate line is sloped down away from the boiler and to a suitable drain.

The condensate line must remain unobstructed. If allowed to freeze in the line or obstructed in any other manner, condensate can exit from the boiler tee, resulting in potential water damage to property.

When installing a condensate pump, select one approved for use with condensing boilers and furnaces. The condensate pump should have an overflow switch to prevent property damage from spillage.

Condensate from the boiler will be slightly acidic (pH from 3.2 to

4.5). Check with your local gas company to determine if combustion condensate disposal is permitted in your area. Install a neutralizing filter if required by local codes.

NOTES:

1. Due to its efficient design, the boiler 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 boiler and disposed in accordance with all local regulations.

2. Condensate line must be pitched at least ¼” per foot to properly drain. If this cannot be done, or a very long length of condensate hose is used, 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.

3. Use corrosion-resistant materials to drain condensate. Use the included flexible plastic hose or ½” PVC and CPVC drain pipe complying with ASTM D1785, F441, or D2665 may be used. Cement must comply with ASTM D2564 for PVC pipe or F493 for CPVC pipe. For Canadian applications, use CSA or ULC certified PVC or CPVC pipe, fittings, and cement.

4. A frozen condensate line could result in a blocked vent condition.

It is very important to protect the condensate line from freezing temperatures or any type of blockage. In installations that may encounter sustained freezing conditions, the use of heat tape is recommended to avoid freezing of the condensate line. It is also recommended to bush up the condensate line size to 1” and terminate condensate discharge as close to the unit as possible. Longer condensate runs are more prone to freezing. Damages due to frozen or blocked condensate lines ARE NOT covered by warranty.

5. Support of the condensate line may be necessary to avoid blockage of the condensate flow.

6. Local building codes may require an in-line neutralizer (1) to be installed (not included) to treat the condensate. If required by local authorities, a condensate filter of lime crystals, marble, or phosphate chips will neutralize slightly acidic condensate

(p/n 7450P-212 available from

Westinghouse). 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

Figure 28 - Internal Condensate

Trap of the boiler. During the first year of boiler operation, check the neutralizer every few months for depletion.

7. Route the drain line to a nearby floor drain (2), laundry tub (3), or condensate pump (4). If the boiler condensate outlet is lower than the drain, you must use a condensate removal pump (kit

Condensate Adapter

(Floor Models)

Figure 30 - Condensate Adapter

(Floor Models) p/n 554200 available from Westinghouse).

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.

8. An error will appear on the boiler display if condensate line is blocked. The boiler will not operate with a blocked condensate line. It is extremely important to have this condition repaired by a qualified service technician.

Figure 29 - Internal Condensate Trap whl-648 Rev. 001 Rel. 000 Date 4.11.19

39

Part 7 - Connecting Electrical Service

!

WARNING

Install wiring and electrically ground boiler 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 all 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 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.

Jumping out control circuits or components WILL VOID product warranty and can result in property damage, personal injury, or death.

It is of extreme importance that this unit be properly grounded. It is very important that the building system ground is inspected by a qualified electrician prior to making this connection. Electrical power must only be turned on when the boiler is completely filled with cold water. Failure to follow these instructions could result in component or product failure, serious injury, or death.

!

CAUTION

Label all wires prior to disconnecting them when servicing the boiler. Wiring errors can cause improper and dangerous operation.

Failure to follow these instructions may result in property damage or personal injury.

1. This boiler must be properly grounded. Ensure the electrical receptacle is properly grounded. Do not remove the grounding prong from the boiler plug.

2. Do not attach the ground wire to either the gas or water piping.

3. The wiring diagrams in this manual are to be used for reference purposes only.

4. Refer to these diagrams and the wiring diagrams of any external controls used with the installation when wiring the boiler. Read, understand, and follow all wiring instructions supplied with the controls.

5. Do not disconnect the power supply when the boiler is in normal operation.

NOTE: For additional electrical protection, the use of a whole house surge protector is recommended. Damage caused by power surges IS

NOT covered by the warranty.

NOTICE

If the boiler display does not turn on, first check the plug. Then check the electrical panel circuit breaker and reset if necessary. If the circuit breaker trips again, do not reset. Disconnect the plug and have a qualified technician diagnose the problem.

B. Dip Switches

There is one set of DIP switches. DIP switches 6 and 7 need to be set to

OFF for the boiler to operate normally.

A. Wiring

The boiler is equipped with a three prong power cord. The boiler is limited to a maximum of 15 amps at 120 volts in use.

Figure 32 - Proper Grounding - Internal Manual Power Switch

Figure 31 - Proper Grounding - Internal Manual Power Switch

1-3

4

5

6

DIP SWITCH

Factory

Vent Size

Gas Type

OFF

Factory Settings - DO NOT CHANGE

2”

LP

ON

3”

NG

High Fire Normal High Fire

7 Low Fire Normal Low Fire

Table 19 - DIP Switch Group - NOTE: DO NOT CHANGE SWITCHES 1-3.

THESE ARE FACTORY SETTINGS.

Maximum Flame Detecting Voltage

Pre-Purge Time (Tp)

2.4V

Maximum 10 seconds,

Minimum 1 second

3.5 seconds

20 seconds

3 minutes

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

Table 20 - System Control Settings

<3 seconds

1 minute

1 minute

<6 seconds

<6 seconds whl-648 Rev. 001 Rel. 000 Date 4.11.19

40 whl-648 Rev. 001 Rel. 000 Date 4.11.19

Figure 33 - Electrical Wiring Diagram

41

Figure 34 - Ladder Diagram whl-648 Rev. 001 Rel. 000 Date 4.11.19

42

No. of Location

CN9

65001WS-12

CN6

LW6A4-03

CN1

SMW250-03

CN4

LWD1140-06

CN8

SMW250-04

CN11

LWD1140-16

Table 21 - Boiler Wiring 1

Connector

Pin

1

4

5

2

3

6

7

8

9-12

5

13

6

14

3

11

4

12

7

15

8

16

2

10

1

8

3

4

1

2

5

6

3

4

1

2

2

3

1

3

1

BL

HL

HD

TH

APS

EL

Board Silk

L

CP1

IT

L/(HT)

GV

N

CP2/3WAY

RS-485

FAN

MCU ISP

HWL

LWL

Description

GROUND

Power Supply Line

External CH Pump Power Supply (Live)

Ignitor Power Supply

Internal Pump Power Supply (Live)

Gas Valve Power Supply

-

Power Supply (Neutral)

AC Power COM Line

3 Way Valve

RS-485 +

GND

RS-485 -

NOT USED

GND

VDD

Fan power (start coil)

Fan power (end coil)

Fan speed feedback signal

GND

ISP / Reset Port

ISP TOOL0 Data Port

VCC

NOT USED

Low Water Level Sensor

Central Heating Demand (T/T)

Display Control

Flue Air Pressure Switch

NOT USED

Burner High Limit


HT Selv

HT (120V~) AC

SELV (5V) DC

-

SELV (14V) DC

SELV (8 - 26.5V) AC

SELV (14V) DC

SELV (5V) DC

SELV (12V~) AC

SELV (5V) DC

SELV (14V) DC whl-648 Rev. 001 Rel. 000 Date 4.11.19

No. of Location

CN7

LWD1140-14

CN14

SMW250-09

CN3

SMW250-06

CN5

SMW250-10

Table 22 - Boiler Wiring 2

8

5

6

9

4

1

2

12

6

13

7

10

4

11

5

Connector

Pin

1

8

2

9

3

6

7

4

5

2

3

14

1

Board Silk

F.S

OP.S

DH.S

I.S

BG.S

ST.S

SP.S

DHM

FLUX1

RPM

Description

Flame Sensor

Operating Water Temperature Sensor

DHW Temperature Sensor

NOT USED

Exhaust Temperature Sensor

NOT USED

Overheat Temperature Sensor

GND

DHM Stepper Motor Position

VDD

DHM Stepper Motor Coil X Phase

DHM Stepper Motor Coil Y Phase

VDD

DHW Stepper Motor Coil / X Phase

DHM Power IWM Stepper Motor Coil

/ Y Phase

NOT USED

VCC

Water Flow Sensor

GND

Fan RPM Check

GND

HT SELV

SELV (5V)

SELV (14V)

-

SELV (5V)

43

Figure 35 - Terminal Block Wiring Detail whl-648 Rev. 001 Rel. 000 Date 4.11.19

44

Part 8 - Gas Connections

!

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.

Ensure the gas on which the boiler will operate is the same type specified on the rating plate (natural gas or LP gas). This boiler must be converted into propane operation unless specifically manufactured for use with propane. Follow Gas Conversion Manual instructions

(separate document). Propane ready boilers have the suffix “LP” after the model serial number. Failure to follow these instructions could result in property damage, personal injury, or death.

Make sure the gas line pressures are within normal limits. Pressures outside normal limits can result in poor performance and hazardous operating conditions. Failure to do so could result in property damage, personal injury, or death.

A. Gas Pipe Sizing Tables

1. Gas Pipe Sizing

This information is for reference use only. Refer to gas pipe manufacturer specifications for actual delivery capacity. The DOE standard for

Natural Gas is 1100 BTU/ft 3 . Contact the local gas supplier for actual BTU/ft 3 rating.

2. Natural Gas Pipe Sizing

The following tables list maximum capacity of pipe in cubic feet of gas per hour for gas pressures of 14” or less and a pressure drop of 0.5 inches water column, based on a 0.60 specific gravity for natural gas.

Pipe Size (in.)

10

360

20

247

30

199

40

170

Length of Pipe (Feet)

50 60 80

117

100

104

150

83

200

71

BTU’s Per

Hour x 1,000

3/4

1 678 466 374 320

151

284

137

257 220 195 157 134 Schedule 40

Metallic Pipe

1 1/4 1390 957 768 657 583 528 452 400 322 275

1 1/2

2

3

2090

4020

11300

1430

2760

7780

1150

2220

6250

985

1900

5350

873

1680

4740

791

1520

4290

677

1300

3670

600

1160

3260

482

928

2610

412

794

2240

(0.60 Specific

Gravity,

0.5 WC

Pressure Drop)

4 23100 15900 12700 10900 9660 8760 7490 6640

Table 23 - Natural Gas Delivery Capacity - Refer to ANSI Z223.1 - National Fuel Gas Code, Latest Edition

5330 4560

3. LP (Liquid Propane) Gas Pipe Sizing

Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure regulator. Adjust propane supply regulator provided by the gas supplier for 14 inches w.c. maximum pressure.

B. Gas Connection Requirements

1. The gas connection fitting on the boiler is ¾” NPT. NOTE: The pipe size must not be less than ¾”.

2. The supply line must be sized for the maximum output of the boiler being installed. If there are additional gas boilers from the main supply line, measure the size of the supply line according to the COMBINED total maximum BTUH draw for the boilers as if they were operating at the same time.

3. Measure the length of the gas supply line from the gas meter to the boiler. Boiler 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. The National Fuel Gas Code (NFPA 54) requires that a sediment trap (drip leg) be installed in the gas line on boilers not so equipped.

The drip leg must be accessible, a minimum of 3” in length, and not subject to freezing conditions. See Figures 36 and 37.

5. A manual gas shut-off valve should be installed in the gas supply line close to the boiler. See Figures 36 and 37 for detail.

6. 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 ¾” NPT connection on the boiler.

7. Use a manometer to test the gas pressure to make sure it meets the minimum standards and does not exceed the maximum standards of the boiler.

8. Leak test the gas line pipe before placing the boiler in operation. Only use approved leak detector liquid solutions to check for leaks.

9. Do not operate the boiler until all connections have been completed and the heat exchanger is filled with water.

Figure 36 - Gas Line with Shut-Off and

Sediment Trap Detail - Wall Model

Figure 37 - Gas Line with Shut-

Off and Sediment Trap Detail

Floor Model whl-648 Rev. 001 Rel. 000 Date 4.11.19

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 boiler and will cause the boiler to malfunction. See Figure 38.

Figure 38 - Excess Flow Valve (EFV)

D. Checking Gas Pressure at the Boiler for Proper

Operation

NOTE: Refer Figure 39 when checking gas pressure. Loosen the bolts before checking the gas inlet pressure.

1. The boiler 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 ½ psi (3.5 kPa).

2. The boiler 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 ½ psi (3.5 kPa).

The minimum and maximum inlet gas line pressures must meet the requirements shown in Table 24.

Natural or LP Gas

Minimum Pressure 3.5” WC

Maximum Pressure

Table 24 - Gas Pressure Requirements

14”WC

NOTICE

Do not fire (operate) the boiler until all connections have been completed and the heat exchanger is filled with water. Doing so will damage the boiler and void the warranty.

!

WARNING

It is required to use a calibrated combustion analyzer to verify final adjustment according to the combustion chart (Table 25). 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 39. Check your combustion values.

Repeat this procedure until the values obtained on the calibrated combustion analyzer agree with those stated in Table 25.

NOTE: If the boiler makes a whistling sound (harmonics) at low fire, adjust the offset screw in a clockwise (positive) direction (approximately

1/8 turn). Check your combustion values and ensure they agree with those stated in Table 25 before proceeding.

2. When low fire settings have been obtained, flip DIP switch seven

(7) to its original (OFF) position. This will return the boiler to normal operation.

3. Flip DIP switch six (6) to ON (high fire). Again check combustion readings with a calibrated combustion analyzer.

NOTE: DO NOT adjust the gas valve offset screw at high fire. The offset screw is only used to adjust combustion values at low fire.

4. When complete, flip DIP switch six (6) to its original (OFF) position.

This will return the boiler to normal operation.

5. Allow boiler to operate normally. Ensure it is operating properly.

6. Use a Phillips Head screwdriver to reinstall the boiler cover.

!

WARNING

It is very important that the combustion system 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 calibrated combustion analyzer and set the throttle within the recommended CO measurements could result in property damage, severe personal injury, or death.

Fan Speed

CO PPM

Natural Gas

Low

<175

High Low

CO 2 (%) 8 - 9 1/2

Table 25 - Combustion Settings

8 1/2 - 10 9 - 10 1/2

LP Gas

<175

High

9 1/2 - 11

Figure 39 - Gas Valve Detail

E. Setting and Verifying the Combustion Setting

1. After the boiler has fired, flip DIP switch seven (7) to the ON position (low fire). Proceed to check boiler combustion values.

NOTE: Use a calibrated combustion analyzer to ensure CO and CO2 values are within the range shown in Table 25.

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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:

• When a user action is detected (a button is pressed)

• The display has timed out for approximately 2 minutes

B. Start-Up Sequence

After the boiler is powered ON, the LCD display shows a sequence of information. The icons will flash, followed by various indicators that describe the boiler controller and software versions. It will take the boiler roughly 15 seconds to cycle through the Start-Up Sequence.

Display Items Time for Display

1 sec

Remarks

All segments “ON”

LCD Test

Category: UFTC

Software Version for

Front Panel

Software Version for

Boiler

0.5 sec

1 sec

1 sec

1 sec

1 sec

1 sec

1 sec

All segments “OFF”

Pdn

0051

SPn

00.xx

SFn xx.xx

Hardware Version for

Boiler

1 sec

1 sec

Hdn

00xx

Table 26 - Start-Up Sequence

NOTE: When the boiler is powered ON, the fan will operate at maximum speed for 1 minute to purge the air and any fumes from the intake and exhaust pipes.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

After start-up, the display appears as follows.

Figure 42 - Initial Display Screen

NOTE: The initial display screen will differ depending on a number of factors, including whether the boiler detects a call for heat or hot water.

The Control System can operate through user and service modes that have specific LCD outputs and dedicated controls, including:

• Changing the Set-Point Temperature

• Lock Function

• Status Display

• Installer Mode

• Error Mode

• Outdoor Temperature Mode

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 180

180 o F (30 – 82 o C).

o F (82 o C). Initial CH Set-Point range is 86 –

Turn the dial counterclockwise to lower and clockwise to raise the

CH set-point. After changing the temperature, press the button to save the set-point.

NOTE: The CH Set-Point cannot be changed by pressing the button if an outdoor sensor or 0-10V is connected to the boiler. When using an outdoor sensor, the boiler will automatically change the target temperature based on the outdoor reset curve. When using

0-10V, the boiler will automatically change the target temperature based on input voltage.

NOTE: If input voltage is less than 1.5V the 0-10V will be ignored.

Figure 43 - DHW Set-Point Screens

The DHW icon and current set-point temperature will flash when the

DHW Set-Point can be changed.

Factory DHW Set-Point is 125 o is 95 – 120 o F (35 – 49 o C).

F (51 o C). Initial DHW Set-Point range

Turn the dial counterclockwise to lower and clockwise to raise the DHW set-point. After changing the temperature, press the button to save the set-point.

To change the DHW Set-Point above 121 o F (49.5

o C), press the button when the display panel is powered ON. The current DHW setpoint will display and the DHW icon will flash. Then press and hold

F. Storage Mode

Storage Mode indicates that the boiler is heating stored water in the internal storage tank. When Storage Mode is operating the display appears as follows.

the button for five seconds. The scald warning letter “H” (high temperature) will display. High temperature DHW Set-Point range is

121 – 140 o F (49.5 – 60 o C).

Turn the dial counterclockwise to lower and clockwise to raise the DHW set-point. After changing the temperature, press the button to save the set-point.

!

DANGER

Hotter water increases the risk of scald injury. Scalding may occur within five (5) seconds at a setting of 140 o

F (60 o

C). Water temperature over 125 o

F can instantly cause severe burns or death from scalds. Children, disabled, and elderly persons are at the highest risk of being scalded. See instruction manual before setting temperature at the boiler. Feel water before bathing or showering!

Figure 45 - Storage Mode Screens

G. Lock Function

To turn on Lock Function, press the button at the d:Lc parameter when scrolling through the Status Display screens. Turn the dial counterclockwise to lower and clockwise to turn Lock Function On or

Off. Press the button to return to normal operation.

NOTE: The control system will not allow changes if Lock Function is activated. Lock Function will have to be turned off before making further changes.

D. Changing the Temperature Indicator

To change the temperature indicator from Fahrenheit to Celsius, press and hold the button for more than five (5) seconds when the display panel is powered ON. This will toggle the temperature unit indicated on the display.

E. Changing the CH Set-Point

Press the button when the display panel is powered ON. The display will appear as follows. The set-point will flash when the CH set-point can be changed.

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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)

O:ot

L:rt

A:Li or A:GA b:It c:Fr d:Lc

E:oP

F:dH

H:Eh

I:St

J:oH

P:Ou

1:PH

2:rh

3:rH

4:It

5:IH

Detail Description

Outdoor Temperature

DHW Water Flow Rate

CH return water temperature

Fan speed (RPM)

Lock Function

CH supply water temperature

(Operating Temperature)

DHW outlet temperature

CH water overheat temperature

Burner

Exhaust temperature

Operation Time

N/A

Power supply

Burner operating time

Burner operating time

Ignition attempts

Ignition attempts

Displays output condition for internal primary pump and three way valve

- Off

- On

Current Outdoor Sensor Temperature

(When --- is displayed, outdoor sensor is not connected.)

Current DHW Flow

(Li: LPM; GA: GPM)

Current CH return water temperature

Current fan speed (RPM)

Turns Lock Function On and Off

Current CH supply water temperature

Current DHW outlet temperature

Current exhaust temperature

Not Used (Default is 0)

Current temperature on the overheat sensor

Time boiler has been powered in 1000 hour units

Time burner has operated in 1 hour units

L:rt on display on sub menu

Time burner has operated in 1000 hour units

Number of ignition attempts: 10 times the displayed unit

Number of ignition attempts: 10,000 times the displayed unit

1st Icon 2nd Icon

External Pump Internal Primary Pump

3rd Icon

3 Way Valve

Table 27 - Status Display Screen Descriptions

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 or buttons to leave the parameter.

Press the button again to return to Operation Mode.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

I. Installer Mode

Installer Mode will activate when button is pressed and held for five seconds while the boiler display is powered Off.

49

Figure 47 - Installer Mode Screens

Display

1:EH

2:cE

Default

E0.00

OFF

3:In

4:Fu

5:St

6:OH

7:OL

8:FH

9:FH

10:dr

11:dl

12:bt

13:Ft

14:bo

15:OF

16:cH

OFF

GA

ON

68F

5F

00

00

NO

NO

0

1

27F

68F

180F

Detail

Error history up to 10

Clear Error History

System Reset

(Factory Setting)

Water Volume Unit

Stored Water Heating Function

Maximum Outdoor

Temperature

Minimum Outdoor

Temperature

Maximum Fan Speed

Minimum Fan Speed

Reset burner operation time

Reset ignition cycle

Boost Function

CH Anti-Frequency Time

Set differential temperature to turn burner “ON”

Warm Weather Shutdown

Maximum Supply Temperature

Description

Check ten most recent Error Codes (E0 - E9)

Select “ON” to Clear Error History. Range: ON or OFF

Select “ON” to restore system to default factory settings

(Burner operation time, Ignition cycles, and Supply power time will not be reset. See

Functions 10 and 11.)

Range: ON or OFF

Range: GA or Li

Select “OFF” to turn off this function

Range: ON or OFF

When used with an outdoor sensor, sets the maximum outdoor design temperature for the system design. Maximum outdoor temperature must be set 9 minimum outdoor temperature.

Range: (Minimum Outdoor Temperature + 9 o F) to 110 o F o F above the

Sets the minimum outdoor design temperature for the system. Minimum outdoor temperature must be set at least 9 o F below the maximum outdoor design temperature.

Range: -4 o F to (Maximum Outdoor Temperature - 9 o F)

Adjusts Maximum Fan Speed

Range: -30 - +30

Adjusts Minimum Fan Speed

Range: -30 - +30

Select YES to reset burner operation time

Range: NO or YES

Select YES to reset ignition cycles

Range: NO or YES

When Outdoor Temperature Mode is used, this function boosts CH temperature to the maximum supply temperature based on the outdoor reset curve if set point is not reached within the set period of time.

Range: 0 - 120 min

NOTE: “0” means Boost Function is OFF.

This function delays burner operation during CH mode.

Range: 0 - 20 min

When set, the boiler will operate to heat CH water when water temperature falls below a differential setting.

Example: If setpoint is 180 o F and differential is 27

Range: 9 - 27 o o F, the boiler will turn on when CH water temperature falls below 153 o

F

F.

Warm weather shut down will shut down CH Mode if the programmed outdoor temperature is exceeded.

Range: 50 - 110 o F

Sets the maximum design supply temperature based on the minimum outdoor design temperature. Maximum supply temperature must be set 9 o F above the minimum supply temperature.

Range: (Minimum Supply Temperature + 9 o F) - 180 o F whl-648 Rev. 001 Rel. 000 Date 4.11.19

50

Display

17:cL

18:dH

19:cb

20:db

21:PP

Default

86F

140F

100

100

40

Detail

Minimum Supply Temperature

Maximum DHW Setpoint

Temperature

Heating capacity

DHW capacity

Internal CH Pump Post Run

Timer, T/T Calling for Heat

Description

Sets the minimum design supply temperature based on the maximum outdoor design temperature. Minimum supply temperature must be set 9 o F above the

Range: 86 maximum supply temperature.

o F (Maximum Supply Temperature - 9 o F)

Sets Maximum DHW Setpoint Temperature

Range: 120 - 140 o F

Sets heating combustion rate

Range: 50 - 100%

NOTE: 199 Models shall be factory set at 70%. The default number will be 70. This percentage can be increased with an additional pump.

Set DHW combustion rate

Range: 50 - 100%

When boiler CH setpoint is satisfied, but T/T is calling for heat, the burner will shut

OFF and the CH pump will continue to run for this set amount of time

Range: 1 - 60 minutes

This function runs the Internal CH Pump after the Internal CH Pump Post 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 central heating call is satisfied.

Range: 1 - 60 minutes

22:Po

23:PF

24:SF

25:So

26:dt

5

0

150F

20F

2

Internal CH Pump Overrun

Timer (On)

Internal CH Pump Overrun

Timer (Off)

Internal DHW Storage Tank

Setpoint


Differential

Delay time when switching from DHW Mode to CH Mode

Sets the Internal DHW Storage Tank Setpoint

Range: 140 - 167 o F

Sets the Internal DHW Storage Tank Differential

Range: 140 - 167 o F

Range: 0 - 2 Minutes

27:PE

28:HA

1

0-2

Internal CH Pump Post-Purge

Time, T/T Satisfied

High Elevation Mode

Allows the user to set the boiler pump post purge time once the boiler CH setpoint and thermostat are satisfied.

Range: 1-5 minutes

This boiler may be installed at elevations up to 10,000 feet and operate on either

Natural or LP. The boiler will de-rate by 4% for each 1000 feet above sea level. Select the appropriate installation location as described below.

Selects Installation Location for Proper Boiler Operation at Altitude:

0-2 for installation locations from sea level to 1999 feet

2-5 for locations from 2000 to 4999 feet

5-8 for locations from 5000 to 7999 feet,

8-10 for locations from 8000 to 10000 feet

Default: 0 – 2

NOTE: Use a calibrated combustion analyzer to ensure CO and CO2 are within the ranges shown in this manual. Adjust the offset screw in the clockwise (positive) or counterclockwise (negative) directions (approximately 1/8 turn) if the measured CO2 value on LOW FIRE is out of range.

This function sets the time to run both the Internal CH and Internal DHW Storage pumps to purge air from the system. Range: 1 – 30 minutes

AP:cP 5

Internal CH Pump and Internal

DHW Storage Pump Test Mode

29:AP cP:oFF or cP:on

OFF

Internal CH Pump and Internal

DHW Storage Pump Test Mode

Table 28 - Installer Mode Descriptions

Turn this function on to activate Internal CH and Internal DHW Storage pump testing. Only works in Installation Mode. Turns off during normal operation.

Turn the dial counterclockwise and clockwise to scroll through the displayed parameters. To view parameter details, press the button at the appropriate screen. Turn the dial press the button.

counterclockwise and clockwise to change the selected parameter. To save the setting

To leave Installer Mode, press the button again. The display will return to power off mode.

J. 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 boiler.

NOTE: Outdoor Temperature Mode Icon on the display will flash if an Outdoor Sensor or 0-10 Volt is not connected to the boiler.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

51

See Figure 48 to set your Outdoor Reset Curve.

To check the CH Target Temperature while using Outdoor Temperature Mode, press the display panel is powered on.

button while the boiler is operational and the

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 boiler to enable remote control. This signal should be a 0-10 volt positive-going DC signal. When the 0-10V input is wired to the boiler terminal strip, a building control system can be used to control the set point temperature of the boiler. The control interprets the 0-10 volt signal as follows; when the signal is between 0 and 1.5 volts, the boiler will be in standby mode, not firing. When the signal rises above 1.5 volts, the boiler will ignite. As the signal continues to rise towards its maximum of 10 volts, the boiler 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 boiler 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 boiler controller to the boiler is correct. Reversed polarity could lead to erratic and/or no response from the boiler controller.

NOTE: Outdoor Temperature Mode Icon on the display will flash if an Outdoor Sensor or 0-10 Volt is not connected to the boiler.

0-10 V INPUT TABLE:

When outside voltage is applied to the connector (2) in the wiring diagram,

1. The outdoor temperature sensor does not work.

2. The 0-10V symbol is displayed.

3. The heating temperature is automatically set according to the external voltage input.

NOTE: 0-10V is prioritized over T/T. If input voltage is less than 1.5V then T/T will operate.

The range of input voltage is approximately 1.5[V] ~ 10[V] and the heating temperature settings according to this range are as follows.

Input voltage[V]

1.5

2.0

2.5

Heat temperature [ o C]

35.0

37.1

39.2

Heat temperature [ o F]

95

98.8

102.7

3.0

9.0

9.5

10

Table 29 - 0-10V Input Voltages and Associated Temperatures

41.3

…

66.6

69

71.1

106.5

152

156.2

160

Voltage exceeding 15V may damage internal parts. Such damages are not covered by product warranty.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

52

Part 10 - Troubleshooting

A. Error Code

When the boiler encounters an error, the display will flash “Er” followed by a numerical code. The boiler 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 boiler shall enter a hard lockout if the condition indicates something more serious (flame, ignition, condensate line, etc.) To clear a hard lockout Error Code, press the Power button. See Figure 49.

The following screen will display when the boiler encounters an error.

Figure 49 - Error Screen

Error Code

Error Code

Description

Er:10

Er:11

Er:16

Er:20

Er:28

Er:29

Possible Remedies

Flame has extinguished 5 (five) times

Ignition has failed 5

(five) times

Operating

Temperature Sensor

Detects Water

Temperature Greater than 203 o F (95 o C)

Condensate - Closed is

Normal, Open is Fault

(Condensate Drain

Trap

Overheat Sensor Open or Short

APS - Closed is Normal,

Open is Fault

Press the Power button to clear the Error Code. The Code will also automatically reset after one hour (up to three

(3) times.

If Error happens again:

1. Monitor the gas pressure to the boiler 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 stable when lit.

6. If the problem persists, replace the main control.

Press the Power button to clear the Error Code. The Code will also automatically reset after one hour (up to three

(3) times.


1. Monitor the gas pressure to the boiler while in operation. Ensure pressure is between 3.5 and 14” WC.

2. Check gas valve wire. Ensure connection is secure.


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.


This Error Code will go away when the DHW temperature decreases.


1. Check if dip switch High Fire setting is ON. Switches 6 and 7 should be OFF for normal operation.

2. Check if DHW inlet pipe is blocked. Ensure there is enough water flowing to the boiler.

3. Check DHW sensor at DHW outlet. If resistance is zero, replace the sensor.

4. Check Operating Temperature sensor at the heat exchanger. If resistance is zero, replace the sensor.


NOTE: During the error state, the pump will operate to cool the boiler until the temperature is below 192 o F.

Press the Power button to clear the Error Code.

1. Check Condensate and main controller connections. Ensure all are secure.

2. Check Condensate resistance. If resistance is not zero, replace the switch.

3. Check Condensate hose. Ensure it is connected and in good condition.

4. Check condensate line and termination for blockages.

5. Check exhaust vent for blockages.


This Error Code will go away when CH temperature decreases.


1. Check overheat temperature sensor. Ensure connections are secure.

2. Check overheat sensor resistance. If resistance is zero, replace the sensor.



1. Check APS and main controller connections. Ensure all are secure.

2. Check APS resistance. If resistance is not zero, replace the switch.

3. Check APS hose. Ensure it is connected and in good condition.

4. Check condensate line and termination for blockages.

5. Check exhaust vent for blockages.


whl-648 Rev. 001 Rel. 000 Date 4.11.19

53

Error Code

Er:31

Er:32

Er:33

Er:35

Er:36

Er:37

Er:38

Er:41

Er:42

Er:43

Er:61

Er:66

Error Code

Description


Return Temperature

Sensor Open or Short

DHW Sensor Open or

Short

CH Temperature Sensor Open or Short

Exhaust Sensor Open or Short

Abnormal Supply

Voltage

Abnormal Supply

Frequency

This Error Code will go away when operating temperature decreases.


1. Check return temperature sensor. Ensure connections are secure.

2. Check return sensor resistance. If resistance is zero, replace the sensor.


This Error Code will go away when outlet DHW temperature decreases.


1. Check DHW outlet temperature sensor. Ensure connections are secure.

2. Check sensor resistance. If resistance is zero, replace the sensor.


This Error Code will go away when CH temperature decreases.


1. Check CH temperature sensor. Ensure connections are secure.



This Error Code will go away when exhaust temperature decreases.


1. Check exhaust temperature sensor. Ensure connections are secure.


3. Check exhaust vent for blockage.


Supply voltage is too high to operate. This Error Code will go away when supply voltage returns to normal operating range.


1. Ensure boiler is properly wired to a power source meeting the requirements on the rating plate.

2. If problem persists, replace the main control.

Supply frequency is too high to operate. This Error Code will go away when supply frequency returns to normal operating range.


1. Ensure boiler is properly wired to a power source meeting the requirements on the rating plate.

2. If problem persists, replace the main control.

Error Appears When

Control Stores Data, but Data is not Saved


Replace the main control.

Fan Speed too high with flame on

Jumped wire disconnected

Burner overheat switch open

Fan Speed Feedback

Signal Abnormal

Mixing Valve Initial

Value Error

(Mixing Valve Cannot

Return to Initial Position)

The Error Code will go away unless it occurs five (5) times in ten (10) minutes. Press the Power button to clear the

Error Code.


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 low or too high, replace the fan.




1. Ensure that the jumper wire is installed and properly connected.




1. Check burner overheat switch connections. Ensure connections are secure.

2. Check switch resistance. If resistance is not zero, replace the switch.


NOTE: During the error state, the fan will operate to cool the burner until the switch closes.

This Error Code will go away when the condition is remedied.


1. Check the connections to the fan. Ensure all are secure.

2. If the fan does not rotate during the ignition sequence, check for 8Vac 26.5Vac power at the fan connection.

If 8Vac 26.5Vac power is present at the control, replace the fan. If the blower does not have 8Vac 26.5Vac power, check power at the control. If 8Vac 26.5Vac power is not present at the control, replace the control.




1. Turn power OFF and ON at the main power switch internal to the boiler.

2. Check wiring connections to mixing valve. Ensure all are secure.

3. Replace mixing valve.


whl-648 Rev. 001 Rel. 000 Date 4.11.19

54

Error Code

Error Code

Description


Er:68

Er:70

Er:72

Er:76

Er:77

Er:80

Er:81

Er:85

Mixing Valve Operation Error

(Mixing Valve Stuck in

Initial Position)

Register, Ram, Rom, I/O

Port, AD Abnormal, Important EPROM Data or Safe Data Abnormal

Flame Signal Detected before Ignition

Poor Communication

Outdoor Sensor

Shorted

Low Water Level

Sensor

(Low Water Level

Detected four [4] Consecutive Times)

Low Water Level Circuit

Freeze Protection

(Boiler has detected water temperature below 34 o F [1 o C])




2. Check wiring connections to mixing valve. Ensure all are secure.

3. Replace mixing valve.








1. Check the boiler cover. Ensure it is secure. Flame detection sensor can detect an external light source.





1. Check connections from main control to display panel (error occurs if there is no communication for ten [10] minutes).

2. If the problem persists, replace the display and/or the main control.

The Error Code will go away when the condition is remedied.


1. Check outdoor sensor. Ensure all wiring connections are intact and secure. If the sensor wires were secured to the wall with staples, the wires may have been damaged.

2. Check outdoor sensor resistance. If resistance is zero, replace the sensor.

3. If the problem persists, replace the outdoor sensor.

NOTE: When this error occurs, the boiler will still operate at the max setting of the Outdoor Reset Curve.



1. Ensure all valves are open to the boiler 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.




1. Ensure the system is filled with water. Ensure all valves are open to the boiler and there are no leaks.




This Error Code will go away when the freezing condition is remedied.


1. Ensure boiler is located in a mechanical room protected from freezing conditions.

2. Ensure all valves are open to the boiler, there are no leaks.




Er:94

Exhaust NTC detects

Vent Temperature is

Greater than 190 o

(88 o C)

F



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.


4. Check exhaust vent for blockage.

5. If the problem persists, replace the control.

6. If the problem persists, replace the heat exchanger.

Table 30 - Error Codes and Suggested Corrective Actions

!

WARNING

This boiler is equipped with a blocked vent shutoff system. If Error Codes Er:29, Er:41, Er: 42, or Er:94 occur, turn off the gas valve at the manual shutoff. Check the vent terminations for obstructions. If no obstructions are found, reset the boiler by pressing the power button.

If the error continues to occur, call a qualified service technician or the gas supplier to check the boiler. Failure to follow these instructions could result in property damage, personal injury, or death.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

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. 001 Rel. 000 Date 4.11.19

56

C. Suggested Corrective Actions

Problem

No electrical power to the boiler

No water available when faucet is opened

Hot water is not available when the faucet is opened

Possible Causes

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. Is an error code flashing on the display panel

(leak detected)?

1. Does the boiler have power (plugged in)?

2. Is the boiler 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 devices work)?


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 a qualified service technician.

4. Contact the power company.

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 a qualified service technician.

4. Refer to error code information and contact an qualified service technician.

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

It takes a long time before hot water flows from the faucet

1. Is the faucet open enough to draw at least 0.6 gallons (2.3L) per minute through the boiler?

2. Is an error code flashing on the display panel?

3. Is the outlet water temperature set too low?

Is the faucet some distance from the boiler?

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).

1. Allow time for the cold water already in the pipes to flow from the faucet.

2. Have recirculation valves and/or plumbing return line(s) installed and program the unit for recirculation mode.

Domestic hot water is too hot or not hot enough

House is not heating up

Is the water temperature set too high or low?

Adjust the temperature setting

A fan can be heard even when the unit is not operating

Is the CH temperature set too low?

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.

Adjust the temperature setting.

1. This is normal operation – no action is required.

2. Protect the boiler 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.

The internal pump is not running

1. No electrical supply

2. The capacitor is damaged.

3. Pump is blocked by debris or dirt.

1. Check the circuit breaker.

2. Replace the capacitor.

3. Use a screwdriver to rotate the rotor. Clean the pump.

Pump or system noise

1. There is air in the system.

2. The inlet presssure is too low.

1. Bleed / purge air from the pump / system.

2. Increase the inlet pressure.

Table 31 - Troubleshooting Chart

DIAGNOSTICS AND SUGGESTED CORRECTIVE ACTIONS

The boiler control is able to record information about the boiler’s condition at the time of the ten previous faults or errors. This information is available to view in the Installer Mode under the History screen.

The following screens may be displayed when reviewing the boiler history. The table below also includes diagnostic information and possible corrective actions.

Display Condition

Nothing appears on the display control panel but the fan runs at full speed

Control is not receiving power

Diagnostic

Check wiring for short circuit or incorrect wiring

Possible Corrective Actions

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 panel wire.

Push the Power button on the control panel.

Replace transformer if it is receiving 120V, but not outputting 12 VAC. whl-648 Rev. 001 Rel. 000 Date 4.11.19

57

Display

Nothing appears on the display control panel and no other boiler components are operating

Nothing appears on the display control panel, but the boiler is operating

Display repeatedly goes through initialization sequence

Condition

Control is not receiving 120V power

Occurs when communication is lost from the control to the display

Occurs when control does not receive signal from fan

Diagnostic

Is there 120V at the service switch

Possible Corrective Actions

Ensure service switch and/or circuit breaker to boiler is turned ON

Turn on service switch or circuit breaker to power boiler

Troubleshoot and correct the power supply to the manual switch

Is the ON/OFF switch inside the boiler cabinet is turned on

Turn ON the manual power switch inside the boiler cabinet

Check for 120V at the line voltage terminal block located inside the boiler cabinet

Inspect the fuse. Replace as necessary

Correct wiring inside the boiler cabinet using the wiring diagram in the installation manual

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

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 boiler power switch and check for operation

Replace with new display module. See repair parts section for proper replacement part.

Cycle power off and on using boiler power switch and check for operation

Replace fan

Table 32 - Diagnostics and Suggested Corrective Actions

CH Return Temperature Sensor (7855P-097)

Exhaust Temperature Sensor (7850P-070)

Storage Tank Temperature Sensor (7855P-057)

Temperature ( o F) Resistance (Ω)

-4 62162

113

122

131

140

77

86

95

104

41

50

59

68

5

14

23

32

149

158

167

176

2157

1854

1600

1386

185

194

1205

1051

203 920

212 808

Table 33 - Temperature Sensor Resistance

8520

7051

5867

4908

4125

3485

2957

2520

48440

38045

30107

23998

19261

15562

12655

10353

CH Supply Temperature Sensor (7855P-030)

DHW Temperature Sensor (7855P-094)

Temperature ( o F)

-4

5

14

23

32

41

50

95

104

113

122

59

68

77

86

167

176

185

194

131

140

149

158

203

212

Resistance (Ω)

28409

22152

17408

13782

10990

8824

7131

5800

4747

3906

3233

2690

2250

1891

1598

733

635

552

482

1356

1155

989

850

421

370

Outdoor Temperature Sensor

(7855P-084)

Temperature ( o F) Resistance (Ω)

-4 99200

5

14

74229

56090

23

32

41

50

42790

32930

25550

19990

95

104

113

122

59

68

77

86

15760

12510

10000

8050

6520

5310

4350

3590 whl-648 Rev. 001 Rel. 000 Date 4.11.19

58

Part 11 - Start-Up

CAUTION

Thoroughly clean and flush any system that has used glycol before installing the boiler. Provide the customer with a material safety data sheet (MSDS) on the fluid used.

A. Check / Control Water Chemistry

CAUTION

Chemical imbalance of the water supply may affect efficiency and cause severe damage to the boiler 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 boiler.

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. In addition, operating temperatures above 135 o F will accelerate the build-up of lime scale and possibly shorten boiler service life. Failure of an boiler due to lime scale build-up, low pH, or other chemical imbalance IS NOT covered by the warranty.

To ensure extended service life, it is recommended to test water quality prior to installation. Listed below are some guidelines.

CAUTION

Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage.

The water must be potable, free of corrosive chemicals, sand, dirt, and other contaminates. It is up to the installer to ensure the water does not contain corrosive chemicals or elements that can damage the heat exchanger. 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). If the water contains contaminants higher than outlined by the EPA, water treatment is recommended and additional, more frequent maintenance may be required. See the table below.

If you suspect that your water is contaminated in any way, discontinue use of the boiler and contact an authorized technician or licensed professional.

Figure 53 - Flame Sight Glass

*NOTE: It is recommended to clean the heat exchanger at least once a year to prevent lime scale buildup. To clean the heat exchanger, follow the maintenance procedure in this manual.

Clean system to remove sediment*

1. You must thoroughly flush the system (without boiler connected) to remove sediment. The high-efficiency heat exchanger can be damaged by buildup or corrosion due to sediment.

2. For zoned systems, flush each zone separately through a purge valve. (If purge valves and isolation valves are not already installed, install them to properly clean the system.)

3. Check return Y strainer (if installed). Remove and clean sediment and debris if necessary.

4. Flush system until water runs clean and you are sure piping is free of sediment.

NOTE: Boiler failure due to improper water chemistry is not covered by warranty.

Contaminant

Total Hardness

(Residential Use - Below 140 water temperature) o F

Total Hardness

(Commercial Use - Above 140 o F water temperature)

Aluminum

Chloride

Copper

Iron

Manganese pH

Maximum Allowable Level

200 mg/l

(12 grains/gallon)

120 mg/l

(7 grains/gallon)

0.05 to 0.2 mg/l or PPM

100 mg/l or PPM

1 mg/l or PPM

0.3 mg/l or PPM

0.05 mg/l or PPM

6.5 - 8.5

B. Check for Gas Leaks

!

WARNING

Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor.

Remove boiler front door and smell interior of boiler enclosure. Do not proceed with startup if there is any indication of a gas leak.

Repair any leaks at once.

PROPANE Boilers ONLY – The propane supplier mixes an odorant with the propane 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 thereafter), have the propane supplier verify the correct odorant level in the gas.

If you discover any evidence of a gas leak, shut down the boiler at once. Find the leak source with a bubble test and repair immediately. Do not start the boiler again until the leak is repaired.

Failure to comply could result in substantial property damage, severe personal injury, or death.

Sulfate


Zinc

205 mg/l or PPM

500 mg/l or PPM

5 mg/l or PPM


Table 34 - Water Quality Specifications

15 mg/l or PPM whl-648 Rev. 001 Rel. 000 Date 4.11.19

59

C. Freeze Protection (When Used)

!

WARNING

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 boilers, verified in the fluid manufacturer’s literature. Thoroughly clean and flush any system that has used glycol before installing the new boiler. Provide the boiler owner with a material safety data sheet (MSDS) on the fluid used.

1. Determine the freeze protection fluid quantity using total system water content following the fluid manufacturer’s instructions.

Remember to include expansion tank water content.

2. Local codes may require back flow preventer or actual disconnect from city water supply.

3. When using freeze protection fluid with automatic fill, install a water meter to monitor water makeup. Freeze protection fluid may leak before the water begins to leak, causing concentration to drop, reducing the freeze protection level.

4. Glycol in hydronic applications should include inhibitors that prevent the glycol from attacking metallic system components.

Make certain that the system fluid is checked for the correct glycol concentration and inhibitor level.

5. The glycol solution should be tested at least once a year or as recommended by the glycol manufacturer.

6. Anti-freeze solutions expand more than water. For example: A

50% by volume solution expands 4.8% in volume for a temperature increase from 32 - 80 o F, while water expands 3% over the same temperature rise. Allowances must be made in system design for expansion.

7. A 30% mixture of glycol will result in a BTU output loss of 15% with a 5% increase in head against the system circulator.

8. 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.

CAUTION

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.

!

WARNING

Eliminate all system leaks. Continual fresh make-up water will reduce boiler life. Minerals can build up in the heat exchanger, reducing heat transfer, overheating the heat exchanger and causing heat exchanger failure.

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 chloride concentrations are acceptable by sample testing.

boiler.

IMPORTANT!

CAUTION

It is important to purge the system of air to avoid damage to the

E. Purge Air from CH and Internal Storage Tank

CAUTION

While commissioning the system, the air vent on top of the boiler must remain fully open to allow the boiler to properly fill. Failure to keep the air vent open could lead to improper boiler and system operation.

1. 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 boiler 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 noticeable 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 boiler. After the control goes through the start-up sequence, the display will turn off. i. Press and hold the button for five seconds. Then scroll to 29:AP

D. Fill and Test Water System

!

WARNING

Ensure the boiler is full of water before firing the burner. Failure to do so will damage the boiler. 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 boiler 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 boiler 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 boiler startup and testing, check system thoroughly for leaks. Repair all leaks before proceeding further.

by turning the dial . Press the 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 to scroll to cP:off. Press the button to turn on test mode. Turn the dial counterclockwise to lower or clockwise to select on. Press the button again to start test mode.

k. The CH and internal circulation pumps will come on. To bleed air whl-648 Rev. 001 Rel. 000 Date 4.11.19

60 from the internal pump:

1. Use a flat head screwdriver and turn the pump bleed screw one

(1) turn counterclockwise.

2. When water comes out the pump has been bled.

3. Turn the screwdriver clockwise and reseat the bleed screw.

Figure 54 - Bleeding the Internal Pump

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 (default is five minutes), or press the button to leave it manually.

l. 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.

q. Refill to correct pressure.

F. Purge Air from DHW System

1. Make sure CH and DHW lines to the boiler are open and full of water.

Turn on all electric power to boiler.

!

WARNING

Ensure the boiler is full of water before firing the burner. Failure to do so will damage the boiler. 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 boiler.

3. Keep faucets open until water runs freely and all air is purged. Then move on to faucets further away from the boiler in the system.

4. When water flows freely from all hot water faucets, DHW purging is complete.

H. Condensate Removal

1. The boiler is a high efficiency condensing boiler. Therefore, the unit has a condensate drain. Condensate fluid is nothing more than water vapor, derived from combustion products, similar to that produced by an automobile when it is initially started.

Condensation 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, can be made up of lime crystals, marble or phosphate chips that will neutralize the condensate. This may be done by the installer or you may purchase a condensate neutralizer from Westinghouse (7450P-

212).

2. The boiler is equipped with a ¾ female socket weld fitting connection that must be piped to a local drain. It is very important that the condensate line is sloped downward away from the boiler to a suitable inside drain. If the condensate outlet on the boiler 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.

3. If a long horizontal run is used, it may be necessary to create a vent in the horizontal run to prevent a vacuum lock in the condensate line.

4. Do not expose the condensate to freezing temperatures.

5. It is very important you support the condensation line to assure proper drainage.

G. Check Thermostat Circuit(s)

1. Disconnect the two external wires connected to the boiler 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. There should NEVER be a voltage reading.

4. If a voltage reading does occur under any condition, check and correct the external wiring. (This is a 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 boiler low voltage terminal strip. Allow the boiler to cycle.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

Part 12 - Installation Checklist

Before Installing

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 boiler location as near the exhaust vent / intake pipe terminations as possible?

Have combustible materials been cleared from the installation location?

Is there a drain close to the boiler?

Water Piping

Does boiler loop piping meet the minimum sizing requirements listed?

NOTE: Smaller piping will cause performance problems.

Has water chemistry been checked?

Does water chemistry meet requirements?

If water chemistry does not meet requirements, have treatment measures been put in place?

Has the system been cleaned and flushed?

Install Exhaust Vent and Intake Piping

Has the boiler been vented with the approved materials listed in this manual or to meet local codes?

Is air supply sufficient for proper boiler operation?

Is total vent piping length within the maximum vent length restriction listed in this manual?

Install Exhaust Vent and Intake Piping

Have venting lengths been minimized?

Are terminations properly spaced from windows, doors, and other intake vents?

Have all vent terminations been installed at least one foot above exterior grade and one foot above normal snow accumulation level?

Is vent piping properly supported?

Has vent piping been checked for leaks?

Has the exhaust vent line been pitched back to the boiler at a rate of 1/4” per foot?

Have the exhaust vent and intake pipes been properly installed to the boiler?

Install Condensate Piping / Tubing and Components

Have all condensate components included with the boiler 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?

Install Gas Piping

Is the gas supply line a minimum of 3/4” in diameter?

Is the gas supply line length and diameter adequate to deliver the required BTUs?

Has gas supply line pressure been measured (between 3.5 and 14” WC)?

Does the gas type match the type indicated on the boiler rating plate?

Has a union and shut-off valve been installed?

Relief Valve

Is the CH Pressure Relief Valve rated to 30 psi properly installed and at least 1” discharge line run to open drain?

Is the DHW Pressure Relief Valve rated to 150 psi properly installed and at least 3/4” discharge line protected from freezing?

Wiring

Has the power and control been wired per boiler wiring diagram, this manual?

Have all DIP switches been set on the main boiler board?

Is the electrical connection polarity within boiler requirements?

Does the power supply voltage agree with the boiler rating plate? 120V AC?

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

61 whl-648 Rev. 001 Rel. 000 Date 4.11.19

62

Start-Up, Adjust, and Test

Has the boiler been started?

If necessary, has the boiler gas valve been adjusted?

Has the installation been customized per installation location requirements?

Have all customized system parameters been tested?

Has proper boiler 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 qualified service technician. See Figure 53 for flame sight glass window location.

Final Installation Approvals

Signed by Technician

Yes No

Yes No

Date

Table 35 - Installation Checklist

Part 13 - Maintenance

!

DANGER

The boiler 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 boiler 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 boiler or system components, resulting in substantial property damage, severe personal injury, or death.

Check the Surrounding Area

!

DANGER

To prevent the potential of substantial property damage, severe personal injury, or death, eliminate all the materials listed in Table

7 from the area surrounding the boiler and the vicinity of the combustion air intake. If contaminates are found:

• Remove products immediately from area.

• If contaminates have been there for an extended period, call a qualified service technician to inspect the boiler 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 boiler. If found, remove these materials immediately.

Air Contaminates

If allowed to contaminate combustion air, products containing chlorine or fluorine will produce acidic condensate that will cause significant damage to the boiler. 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 boiler is located, or combustion air is taken from one of the areas listed, the contaminants must be removed immediately or the intake pipe must be relocated to another area.

Ensure the Boiler Cabinet is Closed

Ensure the boiler cabinet is closed. Tighten the two upper and lower screws to secure it. The cabinet must be closed while the boiler 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 boiler.

Check the Status of the Control Panel

Observe the Control Panel to ensure the boiler is powered on, and to check for any error codes. Clear any debris from the panel.

Check CH and DHW Pressure Gauges

• Ensure the pressure reading on the CH gauge does not exceed

30 psig. Higher pressure readings may indicate a problem with the expansion tank.

• Ensure the pressure reading on the DHW gauge does not exceed 150 psig. Higher pressure readings may indicate a problem with the domestic expansion tank.

• Contact a qualified service technician if problem persists.

Check Exhaust Vent and Intake Pipe Terminations

Verify that the boiler 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 boiler to operate correctly, contact your qualified service technician to inspect the boiler and the vent system.

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.

Check Pressure Relief Valve

• Visually inspect the primary pressure relief valve and discharge pipe for signs of weeping or leakage.

• If the pressure relief valve often weeps, the expansion tank may not be operating properly. Immediately contact a qualified service technician to inspect the boiler and system.

Check the Condensate Drain System

• While the boiler 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.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

63

• If you notice flue gas leaking from the opening, this indicates a dry condensate drain trap. If problem persists, contact a qualified service technician to inspect the boiler and condensate line and refill the condensate trap.

• If applicable, check the condensate neutralizer and ensure it is full of condensate neutralizing marble chips.

Check the Air Vent

Loosen cap one counterclockwise turn to allow air vent to operate.

See Figure 55. If the air vent 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

• Remove the boiler 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.

• Visually inspect for leaks around the boiler 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

!

WARNING

Have leaks fixed at once by a qualified service technician. Failure to comply could result in substantial property damage, severe personal injury, or death.

Operate Pressure Relief Valve

• 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.

• Shut power off to the boiler. To avoid scalding, wait for boiler to cool before operating the relief valve.

!

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 in accordance with the boiler installation manual. The discharge line must be terminated so as to eliminate possibility of severe burns or property damage should the valve discharge.

• Lift the relief valve lever. If 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.

• If water does not flow from the valve when you completely lift the lever, the valve or discharge line may be blocked.

Immediately shut the boiler down per instructions on page 2 and call a qualified service technician to inspect the valve and system.

• If relief valve seats properly, restore power to the boiler. Observe operation for five minutes and ensure it operates properly.

Check the Burner

Clean the exterior of the burner.

Flushing the CH Closed 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 boiler warranty.

Figure 55 - Air Vent Detail

Figure 56 - Flushing the CH Closed Loop Heat Exchanger

1. Initiate a CH thermostat call to position the 3 way valve in CH

Mode.

2. Disconnect electrical power to the boiler when the blower icon appears on the display panel.

3. Close the shutoff valves on both CH supply and CH return lines

(V1 and V2). See Figure 56.

4. Connect one hose (D1, Figure 56) 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.

5. Pour tankless cleaning solution into the bucket. Use an FDA approved cleaner for potable systems on the heat exchanger. Place the drain hose (D1) and hose D2 to the pump inlet in the cleaning solution.

6. Open service valves (V3 and V4) on the hot water outlet and cold water inlet lines.

7. Turn on the circulation pump. Operate the pump and allow the cleaning solution to circulate through the boiler for at least 1 hour at a rate of 4 gallons per minute.

8. Rinse the cleaning solution from the 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.

c. Do not open shutoff valve V1.

d. Allow water to flow through the boiler for 5 minutes.

e. Close shutoff valve V2.

9. Disconnect hoses from lines. Properly dispose of used cleaning solution.

10. Remove the CH filter from the boiler and clean out any residues.

11. Repeat process on the DHW loop of the boiler.

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 boiler warranty.

1. Disconnect electrical power to the boiler.

2. Close the shutoff valves on both hot water outlet and cold water inlet lines (V1 and V2). See Figure 57-A.

3. Connect one hose (D1, Figure 57-B) to the valve (V3) and place the free end in a bucket. Connect one of the hoses (D3) to the circulation whl-648 Rev. 001 Rel. 000 Date 4.11.19

64 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.

Figure 57 - Flushing the DHW Loop

4. Pour tankless cleaning solution into the bucket. Use an FDA approved cleaner for potable systems on the heat exchanger. Place the drain hose (D1) and hose D2 to the pump inlet in the cleaning solution.

5. Open service valves (V3 and 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 boiler for at least 1 hour at a rate of 4 gallons per minute.

7. Rinse the cleaning solution from the 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.

c. Do not open shutoff valve V1.

d. Allow water to flow through the boiler for 5 minutes.

e. Close shutoff valve V2.

8. Disconnect hoses from lines. Properly dispose of used cleaning solution.

9. Remove the DHW inlet filter from the boiler and clean out any residues.

Cleaning the CH and DHW Inlet Filters (Draining the Boiler)

1. Place a bucket under the boiler to collect the residual water inside the boiler.

2. Press the Power button on the control panel to turn off the electrical power to the boiler. Then turn off the gas valve.

3. Valve off the boiler from the system. If the boiler cannot be isolated from the system, turn off the main water valve.

4. Open the hot water faucets in the system to aid in draining the system.

!

WARNING

Water drained from the boiler could be scalding hot. Wait for the boiler to cool before removing the CH or DHW inlet filters. Failure to do so could result in property damage, personal injury, or death.

5. Remove the DHW inlet filter. Then clean it with a toothbrush and clean running water. See Figure 58.

10. Turn on the gas valve. Turn on electrical power to the boiler and press the Power button to turn the boiler on.

11. Reinsert the filter and ensure the filter cap is securely tightened.

12. Connect electrical power to the boiler.

!

DANGER

The condensate trap assembly MUST BE PROPERLY INSTALLED according to these instructions when operating the boiler.

Operating the boiler 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.

Maintaining the Condensate System

1. Ensure the boiler is 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 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 boiler.

3. Remove the bottom cap from the condensate trap.

4. Flush trap with fresh water to remove debris from the trap.

NOTE: Ensure the float moves freely within the trap. If the float does not move, DO NOT reinstall the trap.

Condensate

Trap Top

EPDM

Gasket

Float

Ball

Condensate

Trap Body

Condensate

Trap O-Ring

Hose

Adapter

Hose Adapter

O-Ring

Hose

Adapter

Clip

Condensate

Trap Bottom

Figure 58 - Cleaning the Inlet Filters

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 boiler.

9. Restore water service to the boiler by opening the isolation valves, or turning on the main water valve.

Figure 59 - Condensate Detail

5. When the condensate trap is sufficiently clean, reinstall the bottom cap on the trap.

NOTE: Ensure all parts shown in Figure 59, Condensate Detail, are installed with the condensate trap. If any parts are missing DO NOT reinstall the trap. Replace the entire assembly.

!

WARNING

Do not install the condensate assembly if a component is lost or missing. Replace the entire assembly. Failure to follow this warning could result in property damage, serious personal injury, or death.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

65

6. Fill the condensate trap with fresh water prior to reassembly on the boiler.

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.

!

WARNING

Do not operate the boiler without the clear hose attached from the hose barb to the pressure switch. Failure to follow this warning could result in property damage, serious personal injury, or death.

8. If a condensate neutralizer kit is installed with the boiler, check the assembly when cleaning the condensate trap, and replenish the limestone chips if necessary. When replacing the limestone chips, take care to ensure chips are no smaller than ½” 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 boiler.

CAUTION

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. 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.

10. If the boiler has a condensate pump, ensure the pump operates properly before considering maintenance complete.

Maintenance Report

CAUTION

In unusually dirty or dusty conditions, care must be taken to keep boiler cabinet door in place at all times. Failure to do so VOIDS

WARRANTY!

!

WARNING

Allowing the boiler to operate with a dirty combustion chamber will hurt operation. Failure to clean the heat exchanger as needed by the installation location could result in boiler failure, property damage, personal injury, or death. Such product failures ARE NOT covered under warranty.

The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for

Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).”

• Avoid breathing dust and contact with skin and eyes.

• Use a NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on job site conditions. Current

NIOSH recommendations can be found on the NIOSH website: http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers are also listed on this website.

• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.

• Apply enough water to the combustion chamber lining to prevent dust.

• Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.

• Eye: Irrigate immediately.

• Breathing: Fresh air.

The boiler 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 boiler.

Installer must also inform the owner that the lack of proper care and maintenance of the boiler may result in a hazardous condition.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

66

INSPECTION ACTIVITIES

PIPING

Near boiler piping Check boiler 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.

DATE LAST COMPLETED

1st YEAR 2nd YEAR 3rd YEAR 4th YEAR*

Vent

Gas

Check condition of all vent pipes and joints. Ensure all vent piping is properly supported. Check for obstructions exhaust and intake termination points.

Check Gas piping, test for leaks and signs of aging. Make sure all pipes are properly supported.

SYSTEM

Visual

Functional

Temperatures

Temperatures

ELECTRICAL

Connections

Smoke and CO detector

Circuit Breakers

Do a full visual inspection of all system components.

Test all functions of the system (central heat, water heating, Safeties)

Verify safe settings on boiler or Anti-Scald Valve

Verify programmed temperature settings

Check wire connections. Make sure they are tight.

Verify devices are installed and working properly. Change batteries if necessary.

Ensure the circuit breaker is clearly labeled. Exercise circuit breaker.

Verify ON/OFF switch and convenience plug are both functional Switch and Plug

CHAMBER/BURNER

Combustion

Chamber

Spark Electrode

CONDENSATE

Condensate Trap

Neutralizer

Condensate hose

Homeowner

TECH SIGN OFF

Check burner tube and combustion chamber coils. Clean according to maintenance section of manual. Vacuum combustion chamber.

Clean. Set gap at 1/8”.

Clean debris from the condensate trap. Fill with clean water.

Check condensate neutralizer. Replace if necessary.

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

Pressure Drop

Check for leaks

COMBUSTION

CO/CO2 Levels

Measure incoming gas pressure (3.5” to 14” W.C.)

Measure drop in pressure on light off (no more than 1” W.C.)

Check gas piping for leaks. Verify that all are properly supported.

Check CO and CO2 levels in Exhaust. Record at high and low fire.

SAFETIES

ECO (Energy Cut Out) Check continuity on Flue and Water ECO. Replace if corroded.

CH AND DHW LOOPS

It is recommended to flush the CH and DHW heat exchangers 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.

It is also recommended to clean the CH and DHW inlet filters annually.

FINAL INSPECTION

Check list Verify that you have completed entire check list. WARNING: FAILURE TO

DO SO COULD RESULT IN SERIOUS INJURY OR DEATH.

Review what you have done with the homeowner.

Table 36 - *Continue annual maintenance beyond the 4th year as required.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

Part 14 - Moving Adapters from Left to Right (Floor Models)

1. It is recommended to do this procedure before the appliance is installed. However, if appliance is installed, ensure the water and gas are shut off and all water is drained from the appliance. Disconnect the water, gas, and condensate lines from the appliance.

2. Remove the front panel from the floor stand of the appliance to expose the piping.

3. Use a Phillips Head screwdriver to remove the eight (8) screws securing the right side panel to the appliance stand. Remove the right side panel.

4. Remove all screws attaching adapters to the side panel.

Unscrew the nut securing the condensate adapter to the side panel. Remove the needle barb fitting and disconnect the condensate hose.

5. Use a Phillips Head screwdriver to remove the eight (8) screws securing the left side panel to the appliance stand. Remove the panel.

6. Use a Phillips Head screwdriver to secure the removed right side panel to the left side of the appliance stand with the eight (8) screws removed in Step 3.

7. Use a Phillips Head screwdriver and the eight (8) screws removed in Step 4 to secure the side panel to the appliance stand. NOTE: The condensate adapter should be at the front of the appliance.

8. Secure the condensate adapter to the side panel with the nut removed in Step 5.

Reinstall the needle barb fitting and condensate hose.

9. Use the screws removed in

Step 5 to reinstall the adapters to the side panel. Ensure the adapters are reinstalled in the

10. Install the water, gas, and condensate lines to the appliance. Test for and repair any leaks.

11. Reinstall the appliance front panel to the floor stand

Figure 60 - Moving Adapters from Left to Right

Part 15 - Replacement Parts

NUMBER

B-1

B-2

B-3

B-4

B-5

B-6

B-7

DESCRIPTION

M3 X 6 PH + M/S

M4 X 8 PH + Self Tapping

M4 X 8 TH + Self Tapping

M4 X 8 TH + M/S

M4 X 10 FH + M/S


M4 X 10 TH + M/S

PART NUMBER NUMBER

7855P-384 B-10

7855P-385

7855P-386

B-11

B-12

7855P-387

7855P-388

7855P-389

7855P-390

B-8 M4 X 10 Flat Head 7855P-391

B-9 M4 X 12 PH + M/S 7855P-392

Table 37 - Replacement Bolts and Nuts - See Figures 61 - 70 for Where Used

B-13

B-14

B-15

N-1

N-2

DESCRIPTION

M4 X 12 TH + M/S

M4 X 14 PH + Self Tapping

M4 X 15 PW + M/S


M5 X 14 Flange Bolts + M/S

M5 X 10 TH+ M/S

M4 Nut

M5 Nut

PART NUMBER

7855P-393

7855P-394

7855P-395

7855P-396

7855P-397

7855P-453

7855P-398

7855P-399

67 whl-648 Rev. 001 Rel. 000 Date 4.11.19

68

29

B-6

16

16-1

16-2

16 15

B-6

15

15-1

15-2

15-5

15-4

15-6

15-8

15-3

15-7

28

17

B-10

B-5

19

18

24

B-6

23

B-12

22

B-5

20

B-5

21

B-3

B-6

25

B-13

26

B-8

B-3

27

30

31

B-3

B-3

B-10

32

33

34

B-3

Figure 61 - Cabinet Replacement Parts - 140 Floor and Wall Mount Models

NUMBER DESCRIPTION PART NUMBER NUMBER

15 Exhaust Duct Assembly 7855P-002 21

15-1

15-2

15-3

15-4

Exhaust/Intake Duct Clamps (Φ100)

Exhaust/Intake Gaskets

Exhaust Duct

Combustion Analyzer Port Plug

O-Ring


7855P-332

7850P-210

7855P-333

7855P-334

15-5 7855P-335

15-6

15-7

15-8

16

16-1

16-2

17

18

19

Intake and Exhaust Adapter

O-Ring (Φ85)

Exhaust Duct Inner Adapter

Exhaust Adapter O-Ring (Φ75)

Air Intake Cap Assembly

Air Intake Cap

Air Intake Inner Adapter

Air Vent Grommet

Control Board

Control Panel Bracket

7855P-256

7855P-004

7855P-254

7855P-003

7855P-337

7855P-338

7855P-339

7855P-217

7855P-219

20 Air Pressure Switch 7855P-262

Table 38 - Cabinet Replacement Parts - 140 Floor and Wall Mount Models

22

23

24

25

26

27

32

33

34

28

29

30

31

DESCRIPTION


Control Board Bracket

Power Switch Bracket

Display Panel

Manual Power Switch

Terminal Block

Condensate Block APS

Front Cover

Display Panel Cover

CH Pressure Gauge

Wire Gland

Top Wall Mount Bracket

Cabinet

Bottom Wall Mount Bracket

Wire Harness (Not Shown)

PART NUMBER

7855P-007

7855P-340

7855P-220

7855P-012

7855P-014

7855P-015

7855P-017

7855P-218

7850P-023

7855P-135

7855P-348

7850P-068

7855P-226

7850P-092

7865P-026 whl-648 Rev. 001 Rel. 000 Date 4.11.19

36-1

36-1

36

36-2

36-3

40

36-2 36-3

41

42

58-1

55

58

55-1

55-1

58-2

57-2

B-16

56

57-1

50-1

50

49

46-1

57

59

37-1

37-2

52

37-1

37-2

52

51

37-1

B-3

B-4

53 B-4

54

Figure 62 - Water Piping Replacement Parts - 140 Floor and Wall Mount Models

NUMBER

36

DESCRIPTION

DHW Outlet Pipe

PART NUMBER

7855P-242

NUMBER

47

37-1

37-2

38

39

36-1

36-2

36-3

37

1/2” Pipe Gasket

P18 O-Ring

Clip (DHW Inlet)

DHW Inner Block

P22A O-Ring

Pipe Adapter Clip

DHW Outlet Adapter


7855P-072

7855P-047

7855P-246

7855P-251

7850P-262

7855P-278

7855P-225

7855P-094

42-2

43

44

45

40

41

42

42-1

DHW Inlet Pipe

DHW Flow Sensor

Mixing Valve

P15 O-Ring

P16 O-Ring

DHW Outer Block

DHW Inlet Filter Block

Flow Restrictor (15L)

7855P-241

7855P-083

7855P-043

7855P-044

7855P-075

7855P-259

7855P-257

7855P-261

46 DHW Inlet Filter 7855P-281

46-1 P20 O-Ring 7855P-282


57-1

57-2

58

58-1

55

55-1

56

57

58-2

59

51

52

53

54

48

49

50

50-1

51

36-3

42-1

36-3

42-2

42-1

36-3

46-1

46

45

42-2

36-3

44

47

43

39

B-16

DESCRIPTION

DHW Inlet Block Cap

DHW Inlet Adapter

DHW Inlet Block Cap

CH Return Block with Filter

P22 O-Ring

CH Return Block with Filter Clips

CH Return Adapter

Filter for CH Return Block

CH Filter Clip

CH Return Pipe

3/4” Pipe Gasket

CH Return Temperature Sensor

3 Way Valve Assembly

P25 O-Ring

Pump Clip

CH Supply Lower Pipe

3/4” Pipe Gasket

1” Pipe Gasket

Internal Pump

B-4

42-2

48

B-4

37

37-1

37-2

38

B-4

PART NUMBER

7855P-283

7855P-203

7855P-283

7855P-248

7855P-276

7855P-284

7855P-227

7855P-265

7855P-286

7855P-243

7855P-073

7855P-097

7855P-247

7855P-288

7855P-263

7855P-244

7855P-073

7855P-074

7855P-245

69 whl-648 Rev. 001 Rel. 000 Date 4.11.19

70

For 140kBTU Appliances with Serial Numbers Before 051818SA301041

B-3

66

67

61

68-1

68

69

B-6 64-1

63

62

62-1

B-2

60

B-1

64-2

64-1

N-1

64-3

64-4

64-5

64-6

B-12

64-7

64-8

64-9

68-2

75

64

70

71

72

73

B-11

65 64-10

B-8

74-2

NOTE:

Parts 64-1, 64-9, and

64-10 are not available for field replacement.

74-1

74

B-3

Figure 63 - Heat Exchanger Replacement Parts - 140 Floor and Wall Mount Models


60 Exhaust Pipe Assembly 7855P-237 65

61

62

62-1

63

64

64-1

64-2

Storage Tank Clamp

Exhaust Temperature Sensor Clip

Exhaust Temperature Sensor O-Ring


Heat Exchanger Assembly

Burner Body Assembly

Burner Overheat Switch

7855P-297

7855P-349

7855P-092

7855P-353

N/A

7855P-066

66

67

68

68-1

68-2

69

70

64-3 Burner Body 7855P-067 71

64-4

64-5

64-6

64-7

64-8

64-9

Burner Gasket

Ceramic Fiber Burner

Burner Plate O-Ring

Ignitor

Ignitor Gasket

Heat Exchanger Top

7855P-266

7855P-069

7855P-249

7855P-068

7855P-252

N/A

64-10 Burner Refractory N/A

Table 40 - Heat Exchanger Replacement Parts - 140 Floor and Wall Mount Models

72

73

74

74-1

74-2

75 whl-648 Rev. 001 Rel. 000 Date 4.11.19

DESCRIPTION

Exhaust Pipe Gasket

Storage Tank Bracket

Air Vent

CH Supply Upper Pipe

3/4” CH Supply Pipe Gasket

1” CH Supply Pipe Gasket


CH Supply Temperature Sensor

Water Level Detection Sensor

(Low Water Cut-Off)

Flame Sensor Bracket

Flame Sensor

Condensate Trap Assembly (New Model)

Condensate Trap Assembly (Old Model)

Condensate Trap O-Ring (P22A)

Sight Glass

PART NUMBER

7855P-351

7855P-298

7855P-063

7855P-239

7855P-073

7855P-074

7855P-240

7855P-030

7855P-029

7855P-356

7855P-031

7855P-605

7855P-053

7855P-276

7855P-401

For 140kBTU Appliances with Serial Number 051818SA301041 and After

71



60 Exhaust Pipe Assembly 7855P-237 67

61

62

62-1

63

64

Storage Tank Clamp


Exhaust Temperature Sensor O-Ring



7855P-297

7855P-349

7855P-092

7855P-236

68

68-1

68-2

69

70

64-2 Burner Overheat Switch 7855P-066 71

64-3

64-4

64-5

64-6

Burner Body

Burner Gasket


Burner Plate O-Ring

7855P-440

7855P-634

7855P-069

7855P-249

64-7

64-8

Ignitor

Ignitor Gasket

7855P-068

7855P-252

74-2

75

65 Exhaust Pipe Gasket 7855P-351 76

66 Storage Tank Bracket 7855P-298 95


72

73

74

74-1

DESCRIPTION

Air Vent

CH Supply Upper Pipe






(Low Water Cut-Off)

Flame Sensor Bracket

Flame Sensor

Condensate Trap Assembly (New Model)

Condensate Trap Assembly (Old Model)


Sight Glass

Flame Sensor Cover

Exhaust APS Hose Fitting

PART NUMBER

7855P-063

7855P-239

7855P-073

7855P-074

7855P-240

7855P-030

7855P-029

7855P-356

7855P-031

7855P-605

7855P-053

7855P-276

7855P-401

7855P-357

7855P-444 whl-648 Rev. 001 Rel. 000 Date 4.11.19

72

B-5

88

87

85

84

83

86

B-14

89

B-7

82

90

81

B-2 87

79-3

79-2

79-1

78

80

79 N-2

90

90-1

90-2

91

90-3

90-5

B-4

90-2

90-4

B-9

87

92

B-5

Figure 65 - Combustion System Replacement Parts - 140 Floor and Wall Mount Models

NUMBER

78

DESCRIPTION

Burner Inlet Channel Gasket

PART NUMBER

7855P-370

NUMBER

86

79

79-1

79-2

79-3

80

81

82

83

Burner Inlet Channel (with Damper)

Air Damper 4G

Air Damper Guide

Fan Outlet Gasket

Fan

Fan O-Ring

Mixer

Air Intake Hose Clamp

7855P-367

7855P-368

7855P-369

7855P-425

7855P-025

7855P-371

NG LP

7855P-317 7855P-307

7855P-372

90-2

90-3

90-4

90-5

87

88

89

90

90-1

84 Air Intake Hose 7855P-374 91

85 APS Hose Fitting 7855P-375 92

Table 42 - Combustion System Replacement Parts - 140 Floor and Wall Mount Models

DESCRIPTION

Mixer Clamp

1/2” Gas Pipe Gasket

Gas Pipe (to Mixer)


Gas Valve Assembly

Gas Valve Outlet Adapter

Gas Valve O-Ring

Gas Valve

Gas Valve Inlet Adapter

Gas Valve Bracket

Gas Pipe (to Gas Valve)

Gas Inlet Adapter (3/4”)

PART NUMBER

7855P-376

7855P-221

7855P-437

7855P-379

7855P-381

7855P-232

7855P-076

7855P-034

7855P-033

7855P-234

7855P-235

7855P-382 whl-648 Rev. 001 Rel. 000 Date 4.11.19

73

Figure 66 - Cabinet Replacement Parts - 199 Floor and Wall Mount Models


15 Exhaust Duct Assembly 7855P-002 23

15-1

15-2

15-3

15-4

15-5

15-6

15-7

15-8

16

16-1

17

18

19

19-1

Exhaust/Intake Duct Clamps (Φ100)

Exhaust/Intake Gaskets

Exhaust Duct


O-Ring


Intake and Exhaust Adapter

O-Ring (Φ85)

Exhaust Duct Inner Adapter

Exhaust Adapter O-Ring (Φ75)

Air Intake Assembly

Air Intake Cap

Air Vent

Air Vent Grommet

PRV Ring

PRV Rubber Pad

7855P-332

7850P-210

7855P-333

7855P-334

7855P-335

7855P-256

7855P-004

7855P-254

7855P-411

7855P-337

7855P-063

7855P-339

7855P-269

7855P-339

20

21


Control Board Bracket

7855P-262

7855P-412

22 Display Panel 7855P-012


24

24-1

25

26

27

28

33

34

35

36

37

29

30

31

32

DESCRIPTION

Display Panel Bracket


Ignition Transformer Bracket

Control Board

Terminal Blocks Bracket

Manual Power Switch

Terminal Block 6P - Combi

Condensate Block APS

Front Cover

Display Panel Cover

Exhaust Adapter Sealing Gasket

Top Wall Mount Bracket

Cabinet

Bottom Wall Mount Bracket

Wire Gland

CH Pressure Gauge

Wire Harness (Not Shown)

PART NUMBER

7855P-413

7850P-271

7855P-441

7855P-268

7855P-271

7855P-014

7855P-272

7855P-017

7855P-273

7850P-023

7850P-041

7850P-068

7865P-028

7850P-092

7855P-348

7855P-135

7865P-027 whl-648 Rev. 001 Rel. 000 Date 4.11.19

74



38 DHW Outlet Pipe 7855P-275 49

44-1

44-2

45

46

41

42

43

44

38-1

38-2

38-3

39

39-1

39-2

40

3/4” Pipe Gasket

P18 O-Ring

1/2” Pipe Clip

DHW Inner Block

P22A O-Ring

Pipe Adapter Clip

DHW Outlet Adapter


DHW Inlet Pipe

DHW Flow Sensor

Mixing Valve

P15 O-Ring

P16 O-Ring

DHW Outer Block

DHW Inlet Filter Block

7855P-073

7855P-047

7855P-246

7855P-251

7850P-262

7855P-277

7855P-225

7855P-094

7855P-241

7855P-083

7855P-043

7855P-044

7855P-075

7855P-259

7855P-279

50

51

52

52-1

53

54

55

47

48

Flow Restrictor

DHW Inlet Filter

7855P-280

7855P-281

61

61-1

48-1 P20 O-Ring 7855P-282 62


59

60

60-1

60-2

56

57

58

58-1

DESCRIPTION

DHW Inlet Block Cap

DHW Inlet Adapter

CH Block Cap

CH Return Block with Filter

P22 O-Ring

CH Return Block with Filter Clips

Pressure Gauge Clip

CH Return Adapter

Filter for CH Return Block

CH Filter Clip

CH Return Pipe

3/4” Pipe Gasket

CH Return Temperature Sensor

3 Way Valve Assembly

P25 O-Ring

Pump Clips

CH Supply Lower Pipe

1” Pipe Gasket

Internal Grundfos Pump / DHW Storage Pump

PART NUMBER

7855P-283

7855P-203

7855P-283

7855P-248

7855P-276

7855P-284

7855P-285

7855P-227

7855P-265

7855P-286

7855P-287

7855P-073

7855P-097

7855P-247

7855P-288

7855P-263

7855P-290

7855P-074

7855P-456 whl-648 Rev. 001 Rel. 000 Date 4.11.19

75

For 199kBTU Appliances with Serial Numbers Before 051418SAB00161

NOTE:

Parts 76-1, 76-8, and

76-9 are not available for field replacement.



63 Exhaust Temperature Sensor 75

7855P-092

63-1 Exhaust Temperature Sensor O-Ring 76

64

65

66

67

68


Exhaust Pipe Assembly

Exhaust Pipe Gasket

Storage Tank Clamp


7855P-349

7855P-415

7855P-418

7855P-291

7855P-292

69

69-1

69-2

70

71

72

CH Supply Pipe



Storage Tank



(Low Water Cut-Off)

7855P-293

7855P-073

7855P-074

7855P-294

7855P-030

7855P-029 77-1

73 Flame Sensor Bracket 7855P-356

74 Flame Sensor 7855P-031


94

76-6

76-7

76-8

76-9

77

76-1

76-2

76-3

76-4

76-5

DESCRIPTION

Flame Sensor Cover


Burner Body Assembly

Burner Body

Burner Gasket


Ignition Rod

Igniter Gasket


Heat Exchanger Top

Burner Refractory

Condensate Trap Assembly


Sight Glass

PART NUMBER

7855P-357

7855P-416

N/A

7855P-606

7855P-419

7855P-420

7855P-607

7855P-252

7855P-066

N/A

N/A

7855P-605

7855P-276

7855P-401 whl-648 Rev. 001 Rel. 000 Date 4.11.19

76

For 199kBTU Appliances with Serial Number 051418SAB00161 and After



63 Exhaust Temperature Sensor 74

7855P-092

63-1 Exhaust Temperature Sensor O-Ring 75

68

69

69-1

69-2

64

65

66

67


Exhaust Pipe Assembly

Exhaust Pipe Gasket

Storage Tank Clamp


CH Supply Pipe



7855P-349

7855P-415

7855P-418

7855P-291

7855P-292

7855P-293

7855P-073

7855P-074

70

71

72

Storage Tank



(Low Water Cut-Off)

7855P-294

7855P-030

7855P-029

77-1

94

95

73 Flame Sensor Bracket 7855P-356


76

76-2

76-3

76-4

76-5

76-6

76-7

77

DESCRIPTION

Flame Sensor

Flame Sensor Cover


Burner Body

Burner Gasket


Ignitor

Ignitor Gasket


Condensate Trap Assembly


Sight Glass

Exhaust APS Hose Fitting

PART NUMBER

7855P-031

7855P-357

7865P-029

7855P-606

7855P-419

7855P-420

7855P-607

7855P-252

7855P-066

7855P-605

7855P-276

7855P-401

7855P-444 whl-648 Rev. 001 Rel. 000 Date 4.11.19

77

Figure 70 - Combustion System Replacement Parts - 199 Floor and Wall Mount Models

NUMBER

78

79

80

DESCRIPTION

Burner Inlet Channel (with Damper)

Air Damper 19G

Air Damper Guide

PART NUMBER

7855P-424

7855P-618

7855P-369

NUMBER

86

87

88

81

82

Fan Outlet Gasket

Burner Inlet Channel Gasket

7855P-425

7855P-426

88-1

88-2

83

83-1

83-2

83-3

83-4

Fan and Mixer Assembly

Fan

Fan O-Ring

Air Gas Mixer (Inner Part)

Air Gas Mixer Gasket

7855P-427

7855P-025

7855P-371

7855P-609

7855P-428

88-3

88-4

89

90

83-5

84

Air Gas Mixer (Outer Part)

Air Intake Hose Top Clamp

7855P-608

7855P-429

91

92

85 Air Intake Hose 7855P-430 93

Table 47 - Combustion System Replacement Parts - 199 Floor and Wall Mount Models

DESCRIPTION

Air Intake Hose (Bottom Clamp)

APS Hose Fitting

Gas Valve Assembly

Gas Valve Outlet Adapter

Gas Valve O-Ring

Gas Valve

Gas Valve Bracket


Gas Orifice (NG) 8.3 mm

Gas Orifice (LP) 6.3 mm

Gas Pipe (to Mixer)

Gas Pipe (to Gas Valve)

Gas Inlet Adapter (3/4”)

PART NUMBER

7855P-429

7855P-375

7855P-431

7855P-232

7855P-076

7855P-034

7855P-436

7855P-221

7855P-610

7855P-435

7855P-432

7855P-295

7855P-382 whl-648 Rev. 001 Rel. 000 Date 4.11.19

78

Figure 71 - Floor Model Replacement Parts

Item #

1

2

3

4

Description

Base Assembly, Floor Stand

Screw M5 x 12MM

Anchor and Wall Bracket

Screw M6 x 12MM

(Not Shown)

140 Model

7865P-001

199 Model

7865P-002

7865P-023

7850P-084

7865P-024

7

8

5

6

Right Side Panel w/ Labels

Adapter, 1” x 1”

Adapter, 3/4” x 3/4”

Adapter, 3/4” x 1/2”

9 Adapter PVC, 3/4” x 1/2”

Table 48 - Floor Model Replacement Parts

7865P-010 7865P-011

7865P-012

7865P-013

7865P-019

7450P-086

13

14

15

16

17

18

Item #

10

11

12

Description

Locknut - Electrical - 1/2”

Barb Fitting 1/2”

Screw M4 x 10MM

3/4” ID SS Flex - 22” Long

3/4” ID SS Flex - 24” Long

SS Gas Flex - 18” Long

Condensate Hose

Left Side Panel, Floor Stand

Front Cover Assy, Floor Stand

140 Model 199 Model

7700P-002

7100P-044

7855P-390

7865P-017

7865P-015

7865P-018

7865P-016

7865P-007

7855P-089

7865P-008

7865P-003 7865P-004 whl-648 Rev. 001 Rel. 000 Date 4.11.19

79

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.

purchaser transferable.

UNLESS OTHERWISE NOTED

THESE WARRANTIES COMMENCE ON THE DATE OF INSTALLATION.

This limited warranty is only available to the original consumer

(herinafter “Owner”) of this appliance, and is non-

Residential Use Warranty

Ten (10) years – Heat Exchanger, Five (5) Years – Components

Commercial Use Warranty

Five (5) years – Heat Exchanger, One (1) Year – Components

Use Definitions - Residential Heating means heating a single family dwelling. This dwelling must be either: a) owned and resided in by the original purchaser; or b) a residential rental property that services a single dwelling in which the original purchaser resides on a permanent basis. Commercial Use refers to all other applications.

COVERAGE

A. During the first year after the original date of installation,

Westinghouse warrants that it will repair or replace, at its option, any defective or malfunctioning component of the appliance with a component of equivalent size and current model. Replacement components will be warranted for ninety (90) days.

B. Should a defect or malfunction result in a leakage of water from the appliance within the above-stated warranty periods due to defective material or workmanship, malfunction, or failure to comply with the above warranty, with such defect or malfunction having been verified by an authorized Westinghouse representative,

Westinghouse will replace the defective or malfunctioning appliance with a replacement of the nearest comparable model available at the time of replacement. The replacement appliance will be warranted for the unexpired portion of the applicable warranty period of the original appliance.

C. In the event of a leakage of water of a replacement appliance due to defective material or workmanship, malfunction, or failure to comply with the above warranty, Westinghouse reserves the right to refund to the Owner the published wholesale price available at the date of manufacture of the original appliance.

D. If government regulations, industry certification, or similar standards require the replacement appliance or component(s) to have features not found in the defective appliance or component(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 component(s), the Owner will also receive a complete new limited warranty for that replacement appliance or component(s).

E. If at the time of a request for service the Owner cannot provide a copy of the original sales 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.

F. 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.

G. It is expressly agreed between Westinghouse and the Owner that repair, replacement, or refund are the exclusive remedies of the

Owner.

OWNER RESPONSIBILITIES

The Owner or Qualified Service Technician must:

1. Have a relief valve bearing the listing marks of the American

Society of Mechanical Engineers (ASME) installed with the appliance assembly in accordance with federal, state, and local codes.

2. 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 the appliance and keep it running at optimum efficiency.

3. Maintain all related system components in good operating condition.

4. Use the appliance in an open system, or in a closed system with a properly sized and installed thermal expansion tank.

5. Use the appliance at water pressures not exceeding the working pressure shown on the rating plate.

6. Keep the appliance free of damaging scale deposits.

7. Make provisions so if the appliance or any component or connection thereto should leak, the resulting flow of water will not cause damage to the area in which it is installed.

WARRANTY EXCLUSIONS

This limited warranty will not cover:

1. Any appliance purchased from an unauthorized dealer.

2. Any appliance not installed by a qualified service technician, or installations that do not conform to ANSI, CSA, and/or UL standards, as well as any applicable national or local building codes.

3. Service trips to teach the Owner how to install, use, maintain, or to bring the appliance installation into compliance with local building codes and regulations.

4. The workmanship of any installer. The manufacturer disclaims and does not assume any liability of any nature caused by improper installation, repair, or maintenance.

5. Electricity or fuel costs, or increased or unrealized savings for same, for any reason whatsoever.

6. Any water damage arising, directly or indirectly, from any defect in the appliance or component part(s) or from its use.

7. Any incidental, consequential, special, or contingent damages or expenses arising, directly or indirectly, from any defect in the appliance or the use of the appliance.

8. Failure to locate the appliance in an area where leakage of the tank or water line connections and the relief valve will not result in damage to the area adjacent to the appliance or lower floors of the structure, as well as failure to install the appliance with properly designed containment measures.

9. Any failed components of the system not manufactured by

Westinghouse as part of the appliance.

10. Appliances repaired or altered without the prior written approval of Westinghouse.

11. 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.

12. Damages, malfunctions, or failures resulting from improper installation, failure to operate the appliance at firing rates or pressures not exceeding those on the rating plate, or failure to operate and maintain the appliance in accordance with the manufacturer’s provided instructions.

13. Failure to operate the appliance in a an open system, or in a closed system with a properly sized and installed thermal expansion tank.

14. 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.

15. Damages, malfunctions, or failures caused by improper conversion from natural gas to LP gas or LP gas to natural gas.

16. Damages, malfunctions, or failures caused by operating the appliance with modified, altered, or unapproved components, or any component / attachment not supplied by Westinghouse.

17. Damages, malfunctions, or failures caused by abuse, accident, fire, flood, freeze, lightning, electrochemical reaction, acts of God and the like.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

80

18. Failures (leaks) caused by operating the appliance in a corrosive or contaminated atmosphere.

19. Damages, malfunctions, or failures caused by operating an empty or partially empty appliance (“dry firing”), or failures caused by operating the appliance when it is not supplied with water, free to circulate at all times.

20. Any damage or failure of the appliance due to the accumulation of solid materials or lime deposits.

21. Any damage or failure resulting from improper water chemistry.

See below for water chemistry requirements.

the appliance, in addition to an explanation of the appliance problem.

Warranty coverage is subject to validation of “in-warranty” coverage by Westinghouse claims department personnel. All alleged defective or malfunctioning components must be returned to Westinghouse via the local distribution channels where the original purchase was made. NOTE: Any components 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 components to the retailer.

For questions about the coverage of this warranty, please contact

Westinghouse at the following phone number: 1-774-417-6000.

Contaminant

Total Hardness

(Residential Use - Below 140 temperature) o F water

Total Hardness

(Commercial Use - Above 140 o temperature)

F water

Aluminum

Chloride

Color

Copper

Corrosivity

Fluoride

Foaming Agents

Iron

Manganese

Odor pH

Silver

Sulfate


Zinc


Level

200 mg/l

(12 grains/gallon)

120 mg/l

(7 grains/gallon)

0.05 to 0.2 mg/l

100 mg/l

15 color units

1.0 mg/l

Non-corrosive

2.0 mg/l

0.5 mg/l

0.3 mg/l

0.05 mg/l

3 threshold odor number

6.5 – 8.5

0.1 mg/l

250 mg/l

500 mg/l

5 mg/l

15 mg/l or ppm

22. Any damages, malfunctions, or failures resulting from the use of dielectric unions.

23. Appliances replaced for cosmetic reasons.

24. Components of the appliance that are not defective, but must be replaced during the warranty period as a result of reasonable wear and tear.

25. Components of the appliance that are subject to warranties, if any, given by their manufacturers; Westinghouse does not adopt these warranties.

26. Damages, malfunctions, or failures resulting from the use of any attachment(s) not supplied by Westinghouse.

27. Appliances installed outside the fifty states (and the District of

Columbia) of the United States of America and Canada.

28. Appliances moved from the original installation location.

29. Appliances that have had their rating labels removed.

SERVICE, LABOR AND SHIPPING COSTS

Except when specifically prohibited by the applicable state law, the

Owner, and not the Manufacturer, shall be liable for and shall pay for all charges for labor or other expenses incurred in the removal, repair, or replacement of the appliance or any component part(s) claimed to be defective or any expense incurred to remedy any defect in the product.

Such charges include, but are not necessarily limited to:

1. All freight, shipping, handling, and delivery costs of forwarding a new appliance or replacement part(s) to the owner.

2. All costs necessary or incidental in removing the defective appliance or component part(s) and installing a new appliance or replacement part(s).

3. All administrative fees incurred by the Owner, as well as material required to complete, and/or permits required for, installation of a new appliance or replacement part(s), and

4. All costs necessary or incidental in returning the defective appliance or component part(s) to a location designated by the manufacturer.

LIMITATIONS OF YOUR WESTINGHOUSE WARRANTY AND

REMEDIES

THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND

ACCEPTED TO THE FURTHEST EXTENT UNDER APPLICABLE LAW 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 OWNER SHALL BE LIMITED TO THOSE

PROVIDED HEREIN TO THE EXCLUSION OF ANY OTHER REMEDIES

INCLUDING WITHOUT LIMITATION, INCIDENTAL OR CONSEQUENTIAL

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 OWNER ONLY.

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 retailer from whom the 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

NO OTHER WARRANTIES

This warranty gives the Owner specific legal rights. The Owner 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 the Owner.

These are the only written warranties applicable to this 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 appliances.

Westinghouse reserves the right to change specifications or discontinue models without notice.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

Notes

81 whl-648 Rev. 001 Rel. 000 Date 4.11.19

82

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Left Blank

whl-648 Rev. 001 Rel. 000 Date 4.11.19

This Page Intentionally

Left Blank

whl-648 Rev. 001 Rel. 000 Date 4.11.19

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84

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

Date of Installation

Installation Address

Product Name / Serial Number(s)

Comments

Installer’s Code / Name

Installers Phone Number

Signed by Installer

Signed by Customer

Installation Notes

IMPORTANT

Customer: Please only sign after the installer has fully reviewed the installation, safety, proper operation, and maintenance of the system. If the system has any problems please call the installer. If you are unable to make contact, please call your sales representative.

Distributor / Dealer: Please insert contact details.

whl-648 Rev. 001 Rel. 000 Date 4.11.19

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