Westinghouse WBRC 140F Series Installation manual

WHL-015 REV. 1.13.17
Gas Fired
Residential
Combi Boiler
Floor Mount
INSTALLATION / START-UP
MAINTENANCE / PARTS
WARRANTY
WBRC**140F / WBRC**199F Models
**”NG” Refers to Natural Gas Operation
“LP” Refers to Propane Gas Operation
Heat Exchanger Bears the ASME “H” Stamp
NOTICE: Westinghouse reserves the right to make product changes or updates without notice and will not be held liable for
typographical errors in literature.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
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.
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.
California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth defects, or
other reproductive harm.

2
WHL-015 REV. 1.13.17

3
WHL-015 REV. 1.13.17
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.

4
WHL-015 REV. 1.13.17
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.
The hydronic supply and return connections of these products are for installation in closed loop systems ONLY! Use of this
product in any manner other than described in this manual may result in premature product failure, substantial property damage, severe
personal injury, or death. Damage or failure of this product (or the system in which it is installed) due to unauthorized use IS NOT
COVERED BY WARRANTY.
TABLE OF CONTENTS
PART 1 –ITEMS SHIPPED WITH THE APPLIANCE.................................................................................................................7
PART 2 –SAFETY REGULATIONS ...........................................................................................................................................8
A. OPERATION AND INSTALLATION WARNINGS.......................................................................................................................8
B. IMPROPER COMBUSTION .......................................................................................................................................................9
C. GAS............................................................................................................................................................................................9
D. WHEN SERVICING THE APPLIANCE.......................................................................................................................................9
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.

5
WHL-015 REV. 1.13.17
E. WATER CHEMISTRY...............................................................................................................................................................10
F. FREEZE PROTECTION...........................................................................................................................................................10
G. SCALDING...............................................................................................................................................................................10
H. HIGH ELEVATION INSTALLATIONS.......................................................................................................................................11
PART 3 –TECHNICAL SPECIFICATIONS...............................................................................................................................11
PART 4 –PREPARE APPLIANCE LOCATION........................................................................................................................14
A. UNCRATING THE APPLIANCE...............................................................................................................................................14
B. BEFORE LOCATING THE APPLIANCE ..................................................................................................................................15
C. LEVELING................................................................................................................................................................................16
D. CLEARANCES FOR SERVICE ACCESS................................................................................................................................16
E. RESIDENTIAL GARAGE AND CLOSET INSTALLATIONS .....................................................................................................17
F. EXHAUST VENT AND INTAKE PIPE.......................................................................................................................................17
G. PREVENT COMBUSTION AIR CONTAMINATION.................................................................................................................18
H. REMOVING AN APPLIANCE FROM A COMMON VENT SYSTEM........................................................................................19
PART 5 –VENTING...................................................................................................................................................................19
A. INTAKE PIPE AND EXHAUST VENT GUIDELINES................................................................................................................19
B. APPROVED VENT MATERIALS..............................................................................................................................................21
C. ALLOWED COMBINED VENT LENGTHS...............................................................................................................................22
D. TIGHTENING APPLIANCE COLLAR TO EXHAUST VENT AND INTAKE PIPE.....................................................................23
E. VENT TERMINATION ..............................................................................................................................................................24
1. Direct Vent, Two Pipe Roof and Sidewall Vent Terminations................................................................................................24
2. Direct Vent, Optional Horizontal and Vertical Vent Kits.........................................................................................................25
3. Screen Installation.....................................................................................................................................................................25
4. Power Venting, Indoor Combustion Air Installation in Confined or Unconfined Space......................................................26
PART 6 –INSTALL THE CONDENSATE DRAIN.....................................................................................................................28
PART 7 –GAS PIPING..............................................................................................................................................................29
A. GAS PIPE SIZING TABLES.....................................................................................................................................................29
1. Gas Pipe Sizing..........................................................................................................................................................................29
2. Natural Gas Pipe Sizing ............................................................................................................................................................29
3. LP (Liquid Propane) Gas Pipe Sizing.......................................................................................................................................30
B. GAS CONNECTION REQUIREMENTS...................................................................................................................................30
PART 8 –WATER PIPING ........................................................................................................................................................32
A. GENERAL PLUMBING CONNECTION GUIDELINES.............................................................................................................32
B. DHW PIPING............................................................................................................................................................................33
C. CENTRAL HEATING PIPING SYSTEM WATER PIPING METHODS.....................................................................................34
D. CIRCULATOR SIZING.............................................................................................................................................................39
E. PRESSURE RELIEF VALVE....................................................................................................................................................39
PART 9 –CONNECT ELECTRICAL POWER / INITIAL STARTUP .........................................................................................40
A. GENERAL OPERATING CONDITIONS...................................................................................................................................40
B. WIRING INFORMATION..........................................................................................................................................................40
C. DIP SWITCHES .......................................................................................................................................................................41

6
WHL-015 REV. 1.13.17
PART 10 –OPERATING SYSTEM INSTRUCTIONS................................................................................................................49
A. CONTROL PANEL ...................................................................................................................................................................49
B. LCD DISPLAY DESCRIPTIONS ..............................................................................................................................................50
C. START-UP SEQUENCE ..........................................................................................................................................................50
D. CHANGING THE DHW SET-POINT ........................................................................................................................................51
E. CHANGING THE TEMPERATURE INDICATOR .....................................................................................................................51
F. CHANGING THE CH SET-POINT............................................................................................................................................51
G. STORAGE MODE....................................................................................................................................................................52
H. STATUS DISPLAY MODE .......................................................................................................................................................52
I. INSTALLER MODE....................................................................................................................................................................53
J. ERROR MODE .........................................................................................................................................................................55
K. ERROR TREE ANALYSIS........................................................................................................................................................58
1. FLAME DETECTION...................................................................................................................................................................58
2. GAS DETECTION .......................................................................................................................................................................58
3. APS / BURNER OVERHEAT LIMIT / CONDENSATE BLOCK SWITCH...................................................................................59
4. STORAGE / DHW / OP / CH OVERHEAT / EXHAUST OVERHEAT SENSORS.......................................................................59
L. OUTDOOR TEMPERATURE MODE (OPTIONAL)...................................................................................................................59
M. 0-10 VOLT INPUT....................................................................................................................................................................60
PART 11 –START-UP PREPARATION....................................................................................................................................61
A. CHECK / CONTROL WATER CHEMISTRY.............................................................................................................................61
B. GLYCOL ANTIFREEZE SOLUTIONS......................................................................................................................................61
C. CHECK FOR GAS LEAKS.......................................................................................................................................................62
D. FILL AND TEST WATER SYSTEM..........................................................................................................................................62
E. PURGE AIR FROM CH AND INTERNAL STORAGE TANK....................................................................................................63
F. PURGE AIR FROM DHW SYSTEM .........................................................................................................................................63
G. CHECK THERMOSTAT CIRCUIT(S).......................................................................................................................................64
H. CONDENSATE REMOVAL......................................................................................................................................................64
I. FINAL CHECKS BEFORE STARTING APPLIANCE.................................................................................................................64
J. ADJUSTING GAS PRESSURE AT THE APPLIANCE..............................................................................................................64
K. SETTING AND VERIFYING THE COMBUSTION SETTING ...................................................................................................65
PART 12 –INSTALLATION AND START-UP CHECKLIST......................................................................................................66
PART 13 –TROUBLESHOOTING ............................................................................................................................................68
PART 14 –ANNUAL MAINTENANCE PROCEDURES............................................................................................................69
REPLACEMENT PARTS ................................................................................................................................................................73
Limited Warranty for Combination Appliances...........................................................................................................................83
START-UP REPORT.......................................................................................................................................................................85
MAINTENANCE REPORT .............................................................................................................................................................. 86
MAINTENANCE NOTES.................................................................................................................................................................87
CUSTOMER INSTALLATION RECORD FORM.............................................................................................................................88

7
WHL-015 REV. 1.13.17
PART 1 –ITEMS SHIPPED WITH THE APPLIANCE
ITEM
DESCRIPTION
QUANTITY
Elite Fire Tube Combi
Appliance
140F / 199F
1
Installation and User’s
Information Manuals, H2
Document
1 Each
Condensate Hose
(7855P-089)
1
Condensate Adapters and
Instruction Sheet
(7855P-087)
1 kit
CH Pressure Relief Valve
With ¾” X 1” Bushing
(CH Line ¾” 30 psi)
(7855P-077)
1 Each.
Vent Screens (3”)
(7855P-085)
2 Screens
Outdoor Sensor with
Screws and Anchors
(7855P-084)
1
Venting Kit for Combi
3” CPVC
(S7855-002)
6” Length
½” X ¾” Bell Coupling
for Gas Line
(7855P-086 –140W Models)
1
Spare Parts Kit
(Gaskets and O-Rings)
(7855P-088)
1
OPTIONAL PARTS (Not Included)
ITEM
DESCRIPTION
QUANTITY
Threaded ¾” DHW Tankless
Isolation Valves
(7850P-090)
2

8
WHL-015 REV. 1.13.17
Vent Screens (2” Mesh)
(7850P-088)
2 Screens
Table 1 –Items Included with the Appliance
PART 2 –SAFETY REGULATIONS
A. OPERATION AND INSTALLATION WARNINGS
To avoid serious injury or death, read, understand, and follow all the precautions listed here.
Vapors from flammable liquids will explode and can cause a fire, resulting in personal injury or death. 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.
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.

9
WHL-015 REV. 1.13.17
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.
NOTE: When inquiring about service or troubleshooting, reference the model and serial numbers from the appliance rating label.
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.
B. IMPROPER COMBUSTION
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.
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 an 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.

10
WHL-015 REV. 1.13.17
E. WATER CHEMISTRY
Chemical imbalance of the water supply may affect efficiency and cause severe damage to the appliance and associated equipment.
Water quality must be professionally analyzed to determine whether it is necessary to treat the water. Various solutions are available to
adjust water quality. Adverse water quality will affect the reliability of the system. In addition, operating temperatures above 135oF will
accelerate the build-up of lime scale and possibly shorten appliance service life. Failure of an appliance 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) as shown in the
table below. If the water contains contaminants higher than outlined by the EPA, water treatment is recommended and additional, more
frequent maintenance may be required.
If you suspect that your water is contaminated in any way, discontinue use of the appliance and contact an authorized technician or
licensed professional.
Contaminant
Maximum Allowable Level
Contaminant
Maximum Allowable Level
Total Hardness
(Residential Use - Below 140oF water
temperature)
200 mg/l
(12 grains/gallon)
Manganese
0.05 mg/l or PPM
Total Hardness
(Commercial Use - 140oF and above
water temperature)
120 mg/l
(7 grains/gallon)
pH
6.5-8.5
Aluminum
0.05 to 0.2 mg/l or PPM
Sulfate
205 mg/l or PPM
Chloride
100 mg/l or PPM
Total Dissolved Solids (TDS)
500 mg/l or PPM
Copper
1 mg/l or PPM
Zinc
5 mg/l or PPM
Iron
0.3 mg/l or PPM
Dissolved Carbon Dioxide
(CO2)
15 mg/l or PPM
Table 2 –Water Chemistry Specifications
F. FREEZE PROTECTION
Consider appliance piping and installation when determining appliance location.
NOTE: Damages resulting from incorrect installation or from use of products not approved by
Westinghouse ARE NOT covered by warranty.
G. SCALDING
This heater can deliver scalding water. Be careful whenever using hot water to avoid scalding
injury. Certain appliances, such as dishwashers and automatic clothes washers may require
increased water temperature. By setting the thermostat on this heater to obtain the increased
water temperature required by these appliances, you may create the potential for scald injury.
To protect against injury, you should install a mixing valve in the water system. This valve will
reduce point of discharge temperature 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.
Table 3 –Time and Temperature Relationship in Scalds
APPROXIMATE TIME / TEMPERATURE RELATIONSHIPS IN SCALDS
120oF
More than 5 minutes
125oF
1 ½ to 2 minutes
130oF
About 30 seconds
135oF
About 10 seconds
140oF
Less than 5 seconds
145oF
Less than 3 seconds
150oF
About 1 ½ seconds
155oF
About 1 second