Westinghouse WBRCNG140F, WBRCLP140F Installation Manual

Gas Fired

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

IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

WHAT TO DO IF YOU SMELL GAS

 Do not try to light any appliance.  Do not touch any electrical switch.  Do not use any phone in your building.  Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.  If you cannot reach your gas supplier, call the fire department. Installation and service must be provided by a qualified installer,

service agency, or the gas supplier.

Residential

Combi Boiler

Floor Mount

INSTALLATION / START-UP

MAINTENANCE / PARTS

WARRANTY

Models

WBRCNG140F

WBRCLP140F

Heat Exchanger Bears the ASME “H” Stamp

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

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

WHL-015 REV. 12.17.14

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important product information.

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

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

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

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

damage.

NOTICE

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

SAFETY INSTRUCTIONS

SAFETY INSTRUCTIONS (or equivalent) signs indicate specific safety related instructions or procedures.

NOTE: Contains additional information important to a procedure.

WHL-015 REV. 12.17.14

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.

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

FOREWORD

This manual is intended to be used in conjunction with other literature provided with the appliance. This includes all related control information. It is important that this manual, all other documents included with this system, and additional publications including the National Fuel Gas Code, ANSI Z223.1-2002, be reviewed in their entirety before beginning any work.

Installation should be made in accordance with the regulations of the Authority Having Jurisdiction, local code authorities, and utility companies which pertain to this type of water heating equipment.

Authority Having Jurisdiction (AHJ) – The Authority Having Jurisdiction may be a federal, state, local government, or individual such as a fire chief, fire marshal, chief of a fire prevention bureau, labor department or health department, building official or electrical inspector, or others having statutory authority. 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: Westinghouse reserves the right to modify product technical specifications and components without prior notice.

FOR THE INSTALLER

This appliance must be installed by qualified and licensed personnel. The installer should be guided by the instructions furnished with the appliance, and with local codes and utility company requirements. In the absence of local codes, preference should be given to the National Fuel Gas Code, ANSI Z223.1-2002.

INSTALLATIONS MUST COMPLY WITH:

Local, state, provincial, and national codes, laws, regulations and ordinances. The latest version of the National Fuel Gas Code, ANSI 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.

Code for the installation of Heat Producing Appliances (latest version), from American Insurance Association, 85 John Street, New York, NY 11038.

The latest version of the National Electrical Code, NFPA No. 70. NOTE: The gas manifold and controls met safe lighting and other performance criteria when the appliance underwent tests specified in

ANSI Z21.13 – latest edition.

TABLE OF CONTENTS

PART 1 – ITEMS SHIPPED WITH THE APPLIANCE ................................................................................................................. 7

PART 2 – SAFETY REGULATIONS ........................................................................................................................................... 8

A. OPERATION AND INSTALLATION WARNINGS ....................................................................................................................... 8

B. IMPROPER COMBUSTION ....................................................................................................................................................... 9

C. GAS .......................................................................................................................................................................................... 10

D. WHEN SERVICING THE APPLIANCE ..................................................................................................................................... 10

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E. WATER QUALITY .................................................................................................................................................................... 10

F. FREEZE PROTECTION ........................................................................................................................................................... 10

PART 3 – TECHNICAL SPECIFICATIONS ............................................................................................................................... 11

PART 4 – PREPARE APPLIANCE LOCATION ........................................................................................................................ 13

A. UNCRATING THE APPLIANCE ............................................................................................................................................... 13

B. BEFORE LOCATING THE APPLIANCE .................................................................................................................................. 14

C. LEVELING ................................................................................................................................................................................ 15

D. CLEARANCES FOR SERVICE ACCESS ................................................................................................................................ 16

E. RESIDENTIAL GARAGE, CLOSET, AND ALCOVE INSTALLATIONS .................................................................................... 16

F. EXHAUST VENT AND INTAKE PIPE ....................................................................................................................................... 17

G. PREVENT COMBUSTION AIR CONTAMINATION ................................................................................................................. 17

H. REMOVING A APPLIANCE FROM A COMMON VENT SYSTEM ........................................................................................... 17

PART 5 – VENTING ................................................................................................................................................................... 18

A. INTAKE PIPE AND EXHAUST VENT GUIDELINES ................................................................................................................ 18

B. APPROVED VENT MATERIALS .............................................................................................................................................. 20

C. ALLOWED COMBINED VENT LENGTHS ............................................................................................................................... 20

D. TIGHTENING APPLIANCE COLLAR TO EXHAUST VENT AND INTAKE PIPE ..................................................................... 21

E. VENT TERMINATION .............................................................................................................................................................. 22

1. Two Pipe Roof and Sidewall Vent Terminations ..................................................................................................................... 22

2. Direct Vent, Optional Horizontal and Vertical Vent Kits ......................................................................................................... 23

3. Screen Installation ..................................................................................................................................................................... 23

PART 6 – INSTALL THE CONDENSATE DRAIN ..................................................................................................................... 24

PART 7 – GAS PIPING .............................................................................................................................................................. 25

A. GAS PIPE SIZING TABLES ..................................................................................................................................................... 25

1. Gas Pipe Sizing .......................................................................................................................................................................... 25

2. Natural Gas Pipe Sizing ............................................................................................................................................................ 25

3. LP (Liquid Propane) Gas Pipe Sizing ....................................................................................................................................... 26

B. GAS CONNECTION REQUIREMENTS ................................................................................................................................... 26

PART 8 – WATER PIPING ........................................................................................................................................................ 27

A. GENERAL PLUMBING CONNECTION GUIDELINES ............................................................................................................. 27

B. DHW PIPING ............................................................................................................................................................................ 28

C. CENTRAL HEATING PIPING SYSTEM WATER PIPING METHODS ..................................................................................... 29

D. CIRCULATOR SIZING ............................................................................................................................................................. 32

E. PRESSURE RELIEF VALVE .................................................................................................................................................... 33

PART 9 – CONNECT ELECTRICAL POWER / INITIAL STARTUP ......................................................................................... 34

A. GENERAL OPERATING CONDITIONS ................................................................................................................................... 34

B. WIRING INFORMATION .......................................................................................................................................................... 34

C. DIP SWITCHES ....................................................................................................................................................................... 35

PART 10 – OPERATING SYSTEM INSTRUCTIONS ................................................................................................................ 40

A. CONTROL PANEL ................................................................................................................................................................... 40

B. LCD DISPLAY DESCRIPTIONS .............................................................................................................................................. 40

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C. START-UP SEQUENCE .......................................................................................................................................................... 40

D. CHANGING THE DHW SET-POINT ........................................................................................................................................ 41

E. CHANGING THE TEMPERATURE INDICATOR ..................................................................................................................... 41

F. CHANGING THE CH SET-POINT ............................................................................................................................................ 41

G. STORAGE MODE .................................................................................................................................................................... 42

H. STATUS DISPLAY MODE ....................................................................................................................................................... 42

I. INSTALLER MODE .................................................................................................................................................................... 43

J. ERROR MODE ......................................................................................................................................................................... 45

K. ERROR TREE ANALYSIS ........................................................................................................................................................ 48

1. FLAME DETECTION ................................................................................................................................................................... 48

2. GAS DETECTION ....................................................................................................................................................................... 48

3. APS / BURNER OVERHEAT LIMIT / CONDENSATE BLOCK SWITCH ................................................................................... 49

4. STORAGE / DHW / OP / CH OVERHEAT / EXHAUST OVERHEAT SENSORS ................................ ....................................... 49

L. OUTDOOR TEMPERATURE MODE (OPTIONAL)................................................................................................................... 49

M. 0-10 VOLT INPUT .................................................................................................................................................................... 50

PART 11 – START-UP PREPARATION.................................................................................................................................... 51

A. CHECK / CONTROL WATER CHEMISTRY ............................................................................................................................. 51

B. CHECK FOR GAS LEAKS ....................................................................................................................................................... 51

C. FILL AND TEST WATER SYSTEM .......................................................................................................................................... 52

D. PURGE AIR FROM CH AND INTERNAL STORAGE TANK .................................................................................................... 53

E. PURGE AIR FROM DHW SYSTEM ......................................................................................................................................... 53

F. CHECK THERMOSTAT CIRCUIT(S) ....................................................................................................................................... 53

G. CONDENSATE REMOVAL ...................................................................................................................................................... 54

H. FINAL CHECKS BEFORE STARTING APPLIANCE................................................................................................................ 54

I. ADJUSTING GAS PRESSURE AT THE APPLIANCE ............................................................................................................... 54

J. SETTING AND VERIFYING THE COMBUSTION SETTING .................................................................................................... 55

PART 12 –INSTALLATION AND START-UP CHECKLIST ...................................................................................................... 56

PART 13 – TROUBLESHOOTING ............................................................................................................................................ 57

PART 14 – ANNUAL MAINTENANCE PROCEDURES ............................................................................................................ 58

REPLACEMENT PARTS ................................................................................................................................................................ 63

Limited Warranty for Combination Appliances ........................................................................................................................... 66

MAINTENANCE REPORT .............................................................................................................................................................. 68

MAINTENANCE NOTES ................................................................................................................................................................. 72

CUSTOMER INSTALLATION RECORD FORM ............................................................................................................................. 73

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ITEM

DESCRIPTION

QUANTITY

Residential Floor Mount Combi

Boiler

Installation and User’s

Information Manuals, H2

Document

1 Each

Condensate Hose

Condensate Adapters and

Instruction Sheet

1 kit

CH Pressure Relief Valve

With ¾” X 1” Bushing

(CH Line ¾” 30 psi)

1 Each.

Vent Screens (3”)

2 Screens

Outdoor Sensor with Screws and Anchors

3” CPVC

6” Length

½” X ¾” Bell Coupling

for Gas Line

Spare Parts Kit

(Gaskets and O-Rings)

Propane (LP) Conversion Kit

PART 1 – ITEMS SHIPPED WITH THE APPLIANCE

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OPTIONAL PARTS (Not Included)

ITEM

DESCRIPTION

QUANTITY

PART NUMBER

Threaded 1” CH Tankless

Isolation Valves

7850P-089

Threaded ¾” DHW Tankless

Isolation Valves

7850P-090

Vent Screens (2” Mesh)

2 Screens

7850P-088

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

Improper venting can cause a build-up of carbon monoxide. Breathing carbon monoxide can result in brain damage or death. DO NOT operate the appliance unless it is properly vented to the outside and has an adequate fresh air supply for safe operation. Inspect the exterior exhaust gas outlet port and fresh air inlet port on a regular basis to ensure they are functioning properly.

A concentration of carbon monoxide as small as .04% (400 parts per million) in the air can be fatal. When making high fire or low fire adjustments, CO levels must be monitored using a flue gas analyzer such that a CO level of no more than 400 ppm is exceeded at any time during operation.

Adjusting the “low fire offset” on the gas valve in even small increments can result in a significant increase in CO concentration. To avoid serious injury or death, DO NOT make any adjustments to the gas valve without monitoring the exhaust gases with a fully functional and calibrated flue gas analyzer.

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

This appliance must be installed by a licensed plumber, licensed gas fitter, and/or professional service technician. Improper installation and/or operation can cause a potentially hazardous situation, which, if not avoided, could result in serious injury or death, and will void the warranty.

Westinghouse cannot anticipate every circumstance that might involve a potential hazard. Each 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 professional service technician.

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

Make sure the user knows the location of the gas shut-off valve and how to operate it. Immediately close the gas shut-off valve if the appliance is subjected to fire, overheating, flood, physical damage, or any other damaging condition that might affect the operation of the unit. Have the appliance checked by a qualified technician before resuming operation.

Do not power up the unit unless the gas and water supply valves are fully opened. Make sure the fresh air intake port and exhaust gas port are open and functional.

No one but a professional service technician should attempt to install, service, or repair this appliance. There are no serviceable parts which can be changed by the user / owner. User / Owner: Contact the original professional service technician if the appliance needs repair or maintenance. If the original technician is unavailable, ask your gas supplier for a list of qualified service providers.

Keep the area around the appliance clean and free of all materials that can burn. DO NOT store or place gasoline, oils, spray paint, or other flammable products near the appliance.

Table 1 – Items Included with the Appliance

PART 2 – SAFETY REGULATIONS

A. OPERATION AND INSTALLATION WARNINGS

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

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DO NOT use spray paint, hair spray, or any other flammable spray near the appliance or near the exterior fresh air intake port. DO NOT place any items in or around the exterior exhaust gas outlet port and/or fresh air inlet port that could restrict or block the flow in or out of the vent system.

DO NOT store or place newspapers, laundry, or other combustible items near the appliance or the exterior exhaust gas outlet and/or fresh air inlet port.

The owner should inspect the system monthly for damage, water stains, signs of rust, corrosion, and exhaust vent and air intake blockage. If inspection of the unit shows signs of damage, the appliance should be shut off until the problem is repaired by a qualified technician.

After installation, all appliance safety devices should be tested.

This appliance is certified for indoor installations only. The appliance consists of gas ignition system components which must be protected from water (dripping, spraying, etc.) during operation and service. Carefully consider installation location and the placement of critical components (circulators, condensate neutralizers, etc.) before installing the appliance.

DO NOT allow children to operate this unit. DO NOT use this unit if it does not appear to be operating correctly. A qualified technician should service and inspect the appliance annually.

The appliance DHW temperature is factory set to 125oF (51oC). To avoid scalding, always check the temperature of the hot water before bathing, showering, washing, etc. DO NOT adjust the water temperature while the appliance is being used by other persons.

If the appliance is exposed to the following, do not operate until all corrective steps have been made by a qualified service technician:

1. FIRE

2. DAMAGE

3. WATER

This appliance is equipped with a three prong plug. It should only be plugged directly into a properly grounded three prong receptacle. DO NOT remove the ground plug from the plug.

DO NOT alter or modify the appliance or appliance controls. This can be dangerous and WILL VOID the warranty.

Failure to follow these statements could result in property damage, severe personal injury, or death.

NOTICE

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

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

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualified service technician. The appliance MUST BE replaced if it has been submerged. Attempting to operate an appliance that has been submerged could create numerous harmful conditions, such as a potential gas leakage causing a fire and/or explosion, or the release of mold, bacteria, or other harmful particulates into the air. Operating a previously submerged appliance could result in property damage, severe personal injury, or death.

NOTE: Appliance damage due to flood or submersion is considered an Act of God, and IS NOT covered under product warranty.

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

Due to the low water content of the appliance, improper sizing of the appliance with regard to heating system load will result in excessive cycling and accelerated component failure. Westinghouse DOES NOT warrant failures caused by improperly sized appliance applications. DO NOT oversize the appliance to the system. Modular appliance installations greatly reduce the likelihood of appliance oversizing.

Do not obstruct the flow of combustion and ventilating air. Adequate air must be provided for safe operation. Failure to keep the exhaust vent and intake pipe clear of ice, snow, or other debris could result in property damage, serious personal injury, or death.

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

B. IMPROPER COMBUSTION

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Contaminant

Maximum Allowable Level

Contaminant

Maximum Allowable Level

Total Hardness

200 mg/l (12 grains/gallon)

Manganese

0.05 mg/l

Aluminum

0.05 to 0.2 mg/l

6.5-8.5

Chloride

250 mg/l

Sulfate

205 mg/l

Copper

1 mg/l

Total Dissolved Solids (TDS)

500 mg/l

Iron

0.3 mg/l

Zinc

205 mg/l

Consider appliance piping and installation when determining appliance location.

C. GAS

Should overheating or gas supply fail to shut off, do not turn off or disconnect electrical supply to the circulator. Instead, shut off the gas supply at a location external to the appliance.

D. WHEN SERVICING THE APPLIANCE

 To avoid electric shock, disconnect electrical supply before performing maintenance.  To avoid severe burns, allow appliance to cool.  Do not use petroleum-based cleaning or sealing compounds in a appliance system. Gaskets and seals in the system may be

damaged, possibly resulting in substantial property damage.

 Do not use “homemade cures” or “patent medicines”. Substantial property damage, damage to appliance, and/or serious

personal injury may result.

 Always verify proper operation after servicing the appliance.

E. WATER QUALITY

Potable water is defined as drinkable water supplied from utility or well water in compliance with EPA secondary maximum contaminant levels (40 CFR Part 143.3) as shown in Table 2. It is important to ensure the water quality is within these determined limits. If your water contains contaminants higher than outlined by EPA, then water treatment is recommended and additional maintenance may be required. If you suspect that your water is contaminated in any way, discontinue use of the appliance and contact an authorized technician or licensed professional.

Table 2 – Water Quality Specifications

F. FREEZE PROTECTION

NOTE: Damages resulting from incorrect installation or from use of products not approved by Westinghouse ARE NOT covered by warranty.

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MODEL

Residential Combi Boiler

Installation

Indoor, Floor Stand, Fully Condensing

Minimum / Maximum Input (Btu/Hr)

28,000 / 140,000

AFUE

92.7%

Hot Water Capacity

35oF Rise

7.1 Gal

45oF Rise

5.5 Gal

77oF Rise

3.2 Gal

Flue System

Sealed Combustion Direct Vent

Combined Vent Length

2” (50 feet), 3” (100 feet)

Shipping Weight (lbs est.)

250

Orifice Size

0.232” (5.9 mm)

0.185” (4.7 mm)

Gas Supply Pressure

3.5” to 14” WC

Manifold Pressure

Min (2” / 3” Vent)

NG: -0.0039” / -0.002” WC

Max (2” / 3” Vent)

NG: -0.374” / -0.216” WC

Power Supply

Main Supply

120V 60 Hz / 6A

Maximum Power

Consumption

160W

Ignition System

Direct Electronic Ignition / Automatic Flame Sensing

Burner System

Single Orifice Premixed Fuel Modulation Ceramic Fiber Infrared

Gas Valve System

Combination Modulating (Current Proportional)

Internal Pipe Material

Copper

Dimensions

W 15.7” – H 53” – D 26.8”

Storage Tank Water Capacity (DHW)

Under 15 Gallons

Main Controller / Control Panel

GTX-920C / P-920C_CB-HTP

CH Pressure

Min 15 PSI - Max 30 PSI

DHW Pressure

Max 150 PSI

Connection

Sizes

DHW Inlet / Hot Water Outlet

¾” NPT

CH Supply / Return

1” NPT

Gas Inlet

½” NPT (1/2” X ¾” Bell Coupling Provided to Upsize Gas Line)

Materials

Cabinet

Cold Rolled Carbon Steel

Heat Exchanger

Primary Heat Exchanger: Stainless Steel

Storage Tank: Stainless Steel

Safety Devices

Flame Rod, Overheat Cut Off Device, Gas Valve Operation Detector, Exhaust

Temperature High Limit Sensor, Water Temperature High Limit Sensor

PART 3 – TECHNICAL SPECIFICATIONS

Table 3 – Technical Specifications

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DESCRIPTION

DIAMETER (ALL NPTM)

Gas Connection Adapter

½” NPT (½” X ¾” Bell Coupling Provided to Upsize Gas Line)

CH Supply Adapter

1”

CH Return Adapter

1”

DHW Outlet Adapter

¾”

DHW Inlet Adapter

¾”

Condensate Adapter

½”

Drain Adapter

½”

Exhaust Vent Connection

3”

Intake Pipe Connection

3”

Figure 1 – Specifications and Dimensions

Table 4 – Adapter Specifications

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NUMBER

COMPONENT DESCRIPTION

NUMBER

COMPONENT DESCRIPTION

Exhaust Vent Adapter

Condensate Trap

BLDC Fan

DHW Inlet Adapter

Flame Detection Window

DHW Outlet Adapter

Main PCB

Condensate Hose 2

Flame Detection Sensor

CH Return Adapter

Control Panel

APS (Air Pressure Switch)

Manual ON/OFF Power Switch

CH Supply Adapter

Exhaust Pipe

Heat Exchanger

Internal CH Pump

Gas Inlet Adapter

Mixing Valve

Gas Valve

Internal Recirculation Pump (DHW)

Air Vent

Water Discharge Adapter

Ignition Transformer

Water Discharge Valve

Igniter

Internal Storage Tank

Air Intake Pipe

Condensate Trap Adapter

Air Intake Adapter

Condensate Hose 1

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

Figure 2 – Components

Table 5 – Component List

PART 4 – PREPARE APPLIANCE LOCATION

A. UNCRATING THE APPLIANCE

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Cold weather handling – If appliance has been stored in a very cold location (below 0oF) before installation, handle with care until the plastic components come to room temperature.

Carefully consider installation when determining appliance location. Please read the entire manual before attempting installation. Failure to properly take factors such as appliance venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.

Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk. Ensure that the appliance installation location adheres to the information included in this manual. Failure to do so could result in property damage, serious personal injury, or death.

Failure of appliance or components due to incorrect operating conditions IS NOT covered by product warranty.

The service life of the appliance’s exposed metallic surfaces, such as the casing, as well as internal surfaces, such as the heat exchanger, are directly influenced by proximity to damp and salty marine environments. In such areas, higher concentration levels of chlorides from sea spray coupled with relative humidity can lead to degradation of the heat exchanger and other appliance components. In these environments, appliances must not be installed using direct vent systems which draw outdoor air for combustion. Such appliances must be installed using room air for combustion. Indoor air will have a much lower relative humidity and, hence, potential corrosion will be minimized.

This appliance is certified for indoor installations only. Do not install the appliance outdoors. Failure to install this appliance indoors could result in substantial property damage, severe personal injury, or death.

Locate the appliance where any leakage from the relief valve, related piping, tank, or connections will not result in damage to surrounding areas or lower floors of the building. The appliance should be located near a floor drain, or installed in an adequately drained drain pan. Westinghouse WILL NOT be held liable for leakage damages.

To conserve water and energy, insulate all water piping, especially the hot and recirculation water lines.

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

Remove all sides of the shipping crate to allow the appliance to be lifted into its installation location. If surface flooring is rough, take care when sliding appliance into position, as you could damage the appliance.

B. BEFORE LOCATING THE APPLIANCE

1. Installation Area (Mechanical Room) Operating Conditions

 Ensure ambient temperatures are higher than 32oF/0oC and lower than 104oF/40oC.  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

2. Check for nearby connections to:

 System water piping  Venting connections  Gas supply piping  Electrical power  Condensate drain

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

WHL-015 REV. 12.17.14

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

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

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

Do not use this appliance only for space heating applications.

Circulators suitable for DHW applications must be used.

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

In order for the condensate to properly flow out of the collection system, the appliance must be installed level. Failure to ensure the appliance is installed level will result in improper appliance operation.

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

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

 System leaks  Location that could cause the system and appliance to freeze and leak.  Incorrectly-sized expansion tank

6. Clean and flush system when reinstalling an appliance. NOTE: When installing in a zero clearance location, it may not be possible to read or view some product labeling. It is recommended to

make note of the appliance model and serial number.

C. LEVELING

Figure 3 – Proper Leveling

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Space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the appliance. The appliance cover must be securely fastened to prevent it from drawing air from the appliance room. This is particularly important if the appliance is in a room with other appliances. Failure to comply with the above could result in substantial property damage, severe personal injury, or death.

MINIMUM CLEARANCES

Installation Clearances

from Non-Combustibles /

Combustibles

Recommended Service and Proper

Operation Clearances

Top

18 in. (45.7 cm)

Back

0 in. (0 cm)

Front

24 in. (60.9 cm)

Right Side

Left Side

6 in. (15.2 cm)

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

Check with your local Authority Having Jurisdiction for requirements when installing boiler in a garage, closet, or alcove. Please read the entire manual before attempting installation. Failure to properly take factors such as boiler venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.

For closet or alcove installations, a two pipe venting system must be used. Failure to follow this warning could result in substantial property damage, severe personal injury, or death.

The space must be provided with correctly sized combustion/ventilation air openings for all other boilers located in the space with the boiler. Do not install the boiler in an attic. Failure to comply with these warnings could result in substantial property damage, severe personal injury, or death.

Figure 4 – Minimum Service Clearances

D. CLEARANCES FOR SERVICE ACCESS

See Figure 4 and Table 6 for recommended service clearances. If these minimum clearances are not provided, it may not be possible to service the appliance without removing it from the space.

Table 6 – Minimum Installation and Service Clearances NOTE: For closet installations, a combustible door or removable panel is

acceptable front clearance. MINIMUM CLEARANCES FROM COMBUSTIBLE MATERIALS

 Hot water pipes – at least 1” from combustible materials.  Exhaust vent pipe – at least 1” from combustible materials.

E. RESIDENTIAL GARAGE, CLOSET, AND ALCOVE INSTALLATIONS

PRECAUTIONS

If the boiler is located in a residential garage, it should be installed per the latest edition of the National Fuel Gas Code, ANSI Z223.1, and CGA-B149 Installation Code in Canada.

 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.

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Vents must be properly supported. The appliance exhaust and intake connections are not designed to carry heavy weight. Vent support

brackets must be within 1’ of the appliance and the balance at 4’ intervals. Venting must be readily accessible for visual inspection for the first 3’ from the appliance.

Ensure that the intake air will not contain any of the contaminants below. For example, do not pipe intake near a swimming pool. Avoid areas subject to exhaust fumes from laundry facilities. These areas always contain contaminants. Contaminated air will damage the appliance, resulting in possible substantial property damage, severe personal injury, or death.

PRODUCTS TO AVOID

AREAS LIKELY TO HAVE CONTAMINANTS

Spray cans containing fluorocarbons

Dry cleaning/laundry areas and establishments

Permanent wave solutions

Swimming pools

Chlorinated waxes/cleaners

Metal fabrication plants

Chlorine-based swimming pool chemicals

Beauty shops

Calcium chloride used for thawing

Refrigeration repair shops

Sodium chloride used for water softening

Photo processing plants

Refrigerant leaks

Auto body shops

Paint or varnish removers

Plastic manufacturing plants

Hydrochloric or Muriatic acid

Furniture refinishing areas and establishments

Cements and glues

New building construction

Antistatic fabric softeners used in clothes dryers

Remodeling areas

Chlorine-type bleaches, laundry detergents, and cleaning solvents

Garages and workshops

Adhesives used to fasten building products

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

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

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

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

F. EXHAUST VENT AND INTAKE PIPE

The appliance is rated ANSI Z21.13 Category IV (pressurized vent, likely to form condensate in the vent), and requires a special vent system designed for pressurized venting.

You must also install air intake piping from outdoors to the appliance flue adaptor. The resultant installation is categorized as direct vent (sealed combustion).

NOTE: To prevent combustion air contamination, see Table 7 in this section when considering exhaust vent and intake pipe termination.

Exhaust vent and intake pipe may be vented vertically through the roof or out a side wall. Venting methods are detailed in the Venting Section. Do not attempt installation using any other means. Be sure to locate the appliance so exhaust vent and intake piping can be routed through the building and properly terminated. Exhaust vent and intake piping lengths, routing, and termination method must comply with methods and limits given in the venting section.

G. PREVENT COMBUSTION AIR CONTAMINATION

Install intake piping for the appliance as described in the Venting section. Do not terminate exhaust in locations that can allow contamination of intake air.

Table 7

H. REMOVING A APPLIANCE FROM A COMMON VENT SYSTEM

When removing an existing appliance, the following steps must be followed.

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

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Vent this appliance in accordance with these instructions. Failure to do so will result in property damage, severe personal injury, or death.

DO NOT mix vent systems or materials unless specifically told to do so in this manual.

DO NOT thermally insulate the exhaust vent or intake pipes.

DO NOT use an electric damper, vent damper, or draft hood with this appliance.

DO NOT locate the exhaust vent or intake pipe terminations where exposed to prevailing winds.

Moisture will be produced by the exhaust vent. Take precautions when determining exhaust vent termination. Moisture may fall from the vent termination to the ground and turn to ice in freezing conditions. Moisture or ice can produce a hazardous condition.

Exhaust condensate is acidic, and could deteriorate the surface below the exhaust vent termination. Ensure this surface is in good repair (sealed, painted, etc.) to prevent deterioration.

Pitch the exhaust vent pipe ¼” back to the appliance. This ensures that condensate in the exhaust vent returns to the appliance and drains properly.

For closet and alcove installations: CPVC, polypropylene, or stainless steel venting material MUST BE USED. Failure to follow this statement could result in product damage, severe personal injury, or death.

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

Figure 5 - CO Warning Label

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 all doors between the common venting system and other spaces in the building. Turn on clothes dryers and any appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, at maximum speed. Do not operate a summer exhaust fan. Close all 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 common venting system properly vents when tested as outlined, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous condition of use.

7. Any improper operation of the common venting system should be corrected so the installation conforms to the National Fuel Gas Code, ANSI Z223.1. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code, ANSI Z 223.1.

PART 5 – VENTING

A. INTAKE PIPE AND EXHAUST VENT GUIDELINES

1. Vent system must be installed in accordance with local codes, or, in absence of local codes, the National Fuel Gas Code, ANSI Z223.1 / NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Code.

2. For installation in Canada, installer supplied plastic vent piping must comply with CAN/CGA B149.1 and be certified to the Standard for Type BH Gas Venting Systems, ULC-S636. Components of this listed system must not be interchanged with other vent systems or unlisted pipes or fittings. All plastic components and specified primers and glues must be from a single system manufacturer and must not be intermixed with another system manufacturer’s products. Clean and dry all applicable surfaces before applying cement.

3. This appliance is designed to be installed as a direct vent (sealed combustion) type. Combustion air must be supplied directly from the outdoors to the burner, and the flue (exhaust) gases should be vented directly to the outdoors through the wall or roof.

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DESCRIPTION

CANADA

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

1 foot

Clearance to window or door that may be opened

1 foot

3 feet

Clearance to permanently closed window

Vertical clearance to ventilated soffit located above the

terminal within a horizontal distance of 2 feet from the center

line of the terminal

Clearance to unventilated soffit

* F Clearance to outside corner

Clearance to inside corner

Clearance to each side of center line extended above meter

/ regulator assembly

3 feet with a height 15 feet

above meter / regulator assembly

Clearance to service regulator vent outlet

3 feet

Clearance to non-mechanical air supply inlet to building or

the combustion air inlet to any other appliance

1 foot

3 feet

Clearance to a mechanical air supply inlet

3 feet above if within 10 feet

horizontally

6 feet

Clearance above paved sidewalk or driveway located

7 feet

Clearance under veranda, porch, deck, or balcony

1 foot

4. This appliance uses 2” or 3” diameter pipe for exhaust vent and intake pipe. It is important to ensure an airtight seal from the appliance collar to the vent terminations. See Table 9 for a list of Approved Vent Materials.

5. Do not install venting system components on the exterior of the building except as specifically required by these instructions.

 Vent terminals must be at least 1 foot from any door, window, or gravity inlet into the building.  Maintain the correct clearance and orientation between the exhaust vent and intake pipe terminals.  The exhaust vent and air intake terminals must be at the same height and their center lines must be spaced apart 1 foot

minimum.

 The bottom of the exhaust vent and intake pipe terminals must be at least 1 foot above the normal snow accumulation level. In

no case should these terminals be installed less than 1 foot above normal snow accumulation level.

 Do not install the exhaust vent terminals directly above windows or doors.  Intake pipe terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming

pools.

 For sidewall venting, the minimum horizontal distance between adjacent exhaust vent terminations is 1 foot. It is

recommended this distance be greater than 1 foot to better avoid frost damage to building surfaces.

 For roof venting, minimum horizontal distance between any adjacent exhaust vent termination is 1 foot.

Figure 6 – Vent Termination Detail

Table 8 – Vent Termination Clearances - *NOTE: For clearances not specified in ANSI Z223.1/NFPA 54 or CAN/CSA-B 149.1, please use clearances in accordance with local installation codes and the requirements of the gas supplier.

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NOTICE

Consult Table 9 or the most recent edition of ANSI Z223.1/NFPA 54 or CAN/CGA B149.1 as well as all applicable local codes and regulations when selecting vent pipe materials.

APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL

Item

Material

Standards for Installation in:

United States

Canada

Exhaust vent or Intake

pipe and fittings

CPVC schedule 40

ASTM-D2846

PP, CPVC, and PVC venting must be

ULC-S636 Certified. IPEX is an approved

manufacturer in Canada, supplying vent

material listed to ULC-S636.

PVC schedule 40

ANSI/ASTM D1785

Polypropylene

ULCS636

Stainless Steel AL29-4C

Certified for Category IV and direct vent appliance venting

Certified for Category IV and direct vent

appliance venting

Pipe cement/primer

PVC

ANSI/ASTM D2564

IPEX System 636 Cements & Primers

CPVC

ANSI/ASTM F493

 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 warranty.

 PVC/CPVC pipe and fittings of the same diameter are considered interchangeable.  DO NOT use Foam Core Pipe (CPVC cellular core, Radel, etc.) in any portion of the exhaust piping from this appliance.  DO NOT connect PVC/CPVC to PP without an approved vent connector.  When installing AL29-4C vent piping, install a PVC-to-stainless adapter at the appliance vent connection, and at the

termination when using an PVC termination kit. DO NOT mix AL-29-4C piping from different manufacturers unless using adapters specifically designed for the purpose by the manufacturer.

 DO NOT insulate non-metallic exhaust vent pipe or fittings.  DO NOT obstruct the flow of combustion or ventilation air.  When using Pipe Cement/Primer, follow the instructions included with the Cement/Primer closely. Clean and dry all applicable

surfaces before applying.

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

Vent adaptors are not designed as load-bearing devices, and must not be used to support exhaust vent piping. All vent pipes must be properly connected, supported, and the exhaust must be pitched a minimum of ¼” per foot back to the appliance to allow drainage of condensate. Failure to properly support vent piping and follow the information in this statement could result in product damage, severe personal injury, or death.

High heat sources (sources generating heat 100oF / 37oC or greater, such as stove pipes, space heaters, etc.) may damage plastic components of the appliance as well as plastic vent pipe materials. Such damages ARE NOT covered by warranty. It is recommended to keep a minimum clearance of 8” from high heat sources. Observe heat source manufacturer instructions, as well as local, state, provincial, and national codes, laws, regulations and ordinances when installing this appliance and related components near high heat sources.

2” COMBINED VENT LENGTH

3” COMBINED VENT LENGTH

MAXIMUM

50’ (15M)

100’ (30M)

B. APPROVED VENT MATERIALS

Table 9 – Approved Venting Materials

C. ALLOWED COMBINED VENT LENGTHS

Table 10 – Approved Vent Lengths NOTE: When using more than 1 elbow, reduce maximum allowable length:

 5 feet (1.5M) for each additional 3” 90o elbow  2.5 feet (.75M) for each additional 3” 45o elbow

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Failure to properly install the included 6” length of 3” CPVC pipe BEFORE venting the appliance could result in product damage, severe personal injury, or death.

 8 feet (2.4M) for each additional 2” 90o elbow  4 feet (1.2M) for each additional 2” 45o elbow

D. TIGHTENING APPLIANCE COLLAR TO EXHAUST VENT AND INTAKE PIPE

NOTE: The included 6” length of 3” CPVC pipe MUST BE INSTALLED in the exhaust vent connection BEFORE venting the appliance.

This appliance uses 2” or 3” diameter pipe for exhaust vent and intake pipe. In order to use 2” pipe, it is required to reduce pipe size in a vertical length of pipe with a reducing coupling (not included). Follow the steps below to install 2” or 3” pipe into the appliance collar. See Figure 7 for additional details.

1. Clean and dry the appliance connection. DO NOT use primer or cement on the appliance connection.

2. Push the included 6” length of CPVC pipe into the connection until it touches the bottom of the fitting.

3. Tighten the clamps using a screwdriver.

4. Ensure the pipe is secure before continuing installation.

5. For 2” installations, install a reducing coupling in a vertical section of pipe. See Figure 8.

Figure 7 – Installing the 6” Length of CPVC into the Exhaust Vent Connection

Figure 8 – Transitioning from 3” to 2” Vent Pipe

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All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the appliance to allow drainage of condensate. When placing support brackets on vent piping, the first bracket must be within 1 foot of the appliance and the balance at 4 foot intervals on the vent pipe. Appliance venting must be readily accessible for visual inspection for the first three feet from the appliance.

E. VENT TERMINATION

1. Two Pipe Roof and Sidewall Vent Terminations

Figure 9 – Direct Vent, Roof and Sidewall Vent Terminations

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