Home

Westinghouse WGR080LP076 Instructions / Assembly

1. seaaaet 40 PART8 GCGONTROL S i EE 41 A CONTROREANB BISPLAY OVERVIEW distr Po tem d od o Ete em ro ted em AE 41 42 te TURNING WATER HEATER aaa eens ae ohne ee 42 2 RESE FTHNG THE WATER HEATER tas aes dates 42 3 PUTTING THE WATER FIEATER IN ECO 42 A CHANGING Hee S tba cane 43 C ADVANCED CONT ROLAUING TIONS arr eee 43 1 UPPER LEVEL 43 2 TECHNICAE SERVICE AND NAVIGATION Mo teinte nn ic teen tene touts 43 E 44 INQUIRY MODE ANDINA VIGATIO Nie aa iib tud obs bend DEO an 45 2 lS TORY M DE AND NAVIGATION M
2. 26 1 EXHAUST VENT ANDINTAKE PIPEINSTALLA TION tus e Rege 27 5 geek ceca aed 27 VENT JINSTABEEATION OF EXHAUSTJAND INTAIE 27 2 VENTING THROUGH EXISTING 31 INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE 33 CONDENSATE REMOVAL SYSTEM nd ond nie seed eie oS ME LM IM MM 35 PART 6 WIRING e 37 A HNEVOETAGE INPUT a ace cae r aa 37 BLINE VOETAGE CONDENSATE OUT PUT i ees E E ace eae t aao E eum aeta due ae EE T aigu eels 37 C LOW VOLTAGE OUTDOORASENSORTINLET a O r a E EES 37 D INTERNAE WIRING DIAGRAM a E O E O EA a 38 PART7 GAS CONNECTIONS E 38 AGAS PIPING sisien n aa n a a e e a O n 39 BOAS DIABLE sironnan a nes a 39 COGAS VALVE r
3. 45 SN RESET MODE AND NAVIGATION e 46 PARTS STAHT UP PROGEDUBHE 47 OPERATING INSTBUG M PAD I 47 SM zezm e f HN 47 C MAINTENANCE tuii vom dnm unies esata Oe getline ile qute de e nud 48 PART 10 E linge aasad 49 WESS BEBO PROCEDURE T 49 VACATION PROCEDURE Pete sald 49 DUOEAIEUBRE TO OPERA ear snc gare Rae MMC ec PEU Mic es ened ale 49 WHL 001 REV 9 3 14 49 PART TIS TROUBLESHOOTING tired Daci tecta ito E Dee eon e eade denned deenccestecuasind nsadiy 49 A ERROR CODE undi tieni d dedi co a eid quindi di Cad 49 BHESTBERIBEBOP etu Ee MM EI Moa Ed M d tuc LM TM 49 eue EE 49 12 lt MAINTENANGE o
4. lem pu C 17 D BACKFLOW PREVENTE Rosini E ti iu cca duties utn e ttp 17 BPO TAB IEEE eA ol OR TANI hos ence rese Mee 17 ent 18 CONNECTIONS Tc Ern 18 THE HEATER EE 18 19 MHcauehicii TH 20 WHL 001 REV 9 3 14 PART 5 VENTING COMBUSTION AIR AND CONDENSATE 23 PAG NEP sae otros dees 23 B APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE re EEE 24 C REQUIREMENTS FOR INSGTALLATIONUN CANADA it pac opui ceder ata C Rp PO eee on 24 D EXHAUST VENT AND INTAKE PIPE LOGA THON it epe eher Een petente Yet tee yeu hetero ee tme eter teretes 25 ESXEXHAUST e 26 F CONGER VENK RUNS
5. CARTRIDGE REMOVE NEUTRALIZER CARTRIDGE FROM NEUTRALIZER BODY BY SUDING IT TOWARDS THE FRONT OF THE UNIT HOSE BARB SCREW HOSE BARB BACK ONIO IHREADED END OF NEUTRALIZER CARTRIDGE BE SURE REST OF CONDENSATE HOSE IS ASSEMBLED AS SHOWN Figure 16 Removing and Installing the Condensate Neutralizer NOTICE To ensure proper condensate neutralization it is recommended to check the condensate neutralizer cartridge every two years Gently shake the cartridge to ensure it is still filled with neutralization media Replace the condensate neutralizer cartridge if it is empty Failure to do so could result in improper condensate neutralization Please note that if not properly neutralized the slightly acidic condensate could corrode materials subject to corrosion metals concrete stonework etc WHL 001 REV 9 3 14 37 PART 6 WIRING WARNING To avoid electrical shock turn off all power to the heater prior to opening an electrical box within the unit Ensure the power remains off while any wiring connections are being made Failure to follow these instructions could result in component or product failure serious injury or death Such product failure IS NOT covered by warranty personal injury or death A LINE VOLTAGE INPUT The heater must be wired to a 115 volt circuit by a qualified electrician It is recommended that the heater be wired on its own circuit to minimize the possibility of circuit
6. 7 BOW THE MEATER OPERATE 7 C OPTIONAL EQUIP VIE gcc 8 PART 3 PREPARE WATER HEATER LOGATION gcse cess Ue cec eset eect ceu 9 A BEFORE LOCATING THE HEATER HORT S E ERE M MG m UE IM I c Qu MN aes say ea pasties EE Manes 9 B LEVELING es c mE 10 CLEARANCES FOR SERVICE ACCESS a cect foe sce e a ee eee es eel eee 10 RESIDENTIAL GARAGE INS TALEA tpe ta ote EE seca peat ac ee eee 10 E EXHAUST VENT ANBD INTAKE PIBES cesses ei ouo ome eit e dt uti eui 11 T DIRECT VENT INSTALEEATION OR EXHAUSTAND INEAISE to eo eet aues n oret ate auto i ako 11 2 INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE 11 F PREVENT COMBUSTION AIR CONTAMINATION ird aet oe mae een temet rea e Eee em et tene 12 REMOVING A HEATER PROM A COMMON VENT SYSTEM eie tu teen E cepa o 12 HWATER GHEMISTR Y sinon ue NOTE Eu eer MARINE LI nc DA DM DIT IUD EM 13 PARTAS HEATER PIPING me EE 16 A GENERAL PIPING INFORMATION Me 16 cu EE 17 C TEMPERATURE AND PRESSURE RELIEF VALVE x iicet lutto
7. screen appears Installer Mode is active Press twice to find History Mode The control is ready to access the History Mode when the following screen appears on the display Hi Press a at this screen to access the History Mode codes H01 H02 etc Press to advance through the codes Press 4 to return to the previous code To view code value press or once The value will appear Press 0 at this screen to return to the code screen Press at any History Mode code screens to return to the upper level menu Table 13 details the History Mode codes in sequential order Eighth Most Recent Error or Fault Code Table 13 History Mode Codes NOTE Temperature Readings Depend on Temperature Unit Selection 3 RESET MODE AND NAVIGATION Reset Mode allows the installer to reset and clear water heater history This is especially helpful after troubleshooting or repairs have concluded To enter Installer Mode press and hold c3 for five seconds When the screen appears Installer Mode is active Press three times to find Reset Mode The control is ready to access Reset Mode when the following screen appears on the display 5 I Press and hold at this screen for five seconds to reset the water heater history Press s to return to History Mode View History Mode to ensure history has been cleared Press 9 at any History Mode code screens to return to the upper level menu WHL 001 REV 9 3 14 47 PART 9 ST
8. Figure 2 CO Warning Label 2 Visually inspect the venting system for proper size and horizontal pitch to WHL 001 REV 9 3 14 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 water heater 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 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 to conform to the National Fuel Gas Code ANSI 2223 1 When resizing any portion of the common venting system the system should approach the minimum size
9. 5 Check with air handler manufacturer for proper sizing 6 This drawing is meant to demonstrate system piping only The installer is responsible for all equipment and detailing required by local codes In Massachusetts you must install a vacuum relief valve per 248 CMR With air handlers outdoor reset is available with an outdoor sensor See Part 8 Section D 7 Always shut off power to the water heater or isolate the heater from the system if ANY plumbing work is to be done Running the water heater without water will result in dry firing NOTES FOR AIR HANDLER APPLICATION 1 MASSACHUSETTS STATE PLUMBING CODE REQUIRES A DISTANCE NO GREATER THAN 50 FEET FROM THE WATER HEATER TO THE FAN COIL IN THE AIR HANDLER 2 MASSACHUSETTS STATE PLUMBING CODE REQUIRES AN ELECTRONICALLY TIMED CIRCULATOR PUMP TO ACTIVATE EVERY SIX HOURS FOR 60 SECONDS THIS CIRCULATOR IS REQUIRED TO BE BRONZE OR STAINLESS 3 ALL WATER PIPING MUST BE INSULATED 4 YOU MUST INSTALL A VACUUM RELIEF VALVE PER 248 CMR NOTE THIS DRAWING IS MEANT TO DEMONSTRATE SYSTEM PIPING ONLY THE INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES An ASSE 1017 thermostatic mixing valve MUST be installed when using outdoor reset Failure to do so could result in substantial property damage serious injury or death WARNING The piping will not support the weight of the water heater circulator pump Refer to the pump manufacturer s installation instr
10. D OUTDOOR RESET This unit is supplied with outdoor reset wire connection terminals When an outdoor sensor is connected operation of the unit immediately changes Refer to the following steps to properly set up the unit with an outdoor sensor An ASSE 1017 thermostatic mixing valve MUST be installed when using outdoor reset Failure to do so could result in substantial property damage serious injury or death WHL 001 REV 9 3 14 45 1 Connect the outdoor sensor to the terminals marked outdoor 2 Press 9 at this screen to access the Technical Service Parameters codes POO P01 etc Press to advance through the parameters Press to return to the previous parameter 3 4 Goto P06 5 Enter desired MIN Outdoor Temp value 6 Press to advance to the next parameter 7 change parameter value press or once The value will appear Press to decrease or to increase the value 8 Enter desired MAX Outdoor Temp value 9 Press to advance to the next parameter 10 Enter desired MIN Storage Temp value 11 Press to advance to the next parameter 12 Enter desired MAX Storage Temp value 13 Press 09 at this screen to accept the changed value and return to the Installer Parameters 14 Press 09 at any Installer Parameter code screens to return to the upper level menu 1 INQUIRY MODE AND NAVIGATION Inquiry Mode in allows the installer to access water heater operating specifics including temp
11. Failure to follow these instructions could result in property damage serious personal injury or death A OPERATING INSTRUCTIONS If you smell gas STOP Follow listed safety instructions above If you do not smell gas follow the next steps 1 Make sure tank is full with cold water and purge all piping To assure adequate purging open all hot water faucets WARNING Ensure the water heater is full of water before firing the burner Failure to do so will damage the heater Such damage IS NOT covered by warranty and could result in property damage serious personal injury or death RESISTANCE TABLE FOR 2 Turn on all electric power to water heater SUPPLY TEMPERATURE SENSOR HIGH LOW TEMP 3 Remove the Front Panel WARNING label SENSOR TEMP RESISTANCE 4 Adjust the temperature set point of the heater to the desired level The factory default setting is 32 32550 1200F If changes are necessary follow Overall Water Heater and Control Operation in this 41 25340 section 19870 5 If the water heater fails to start refer to the Troubleshooting section in the back of this manual B TEST MODE Test mode is enabled by pressing and together for 5 seconds In this mode the water heater operates without modulation and the combustion system initially runs at the maximum fan speed The SERVICE symbol is displayed on the LCD when Test mode is active Lis X service e 212 Tabl
12. Observe water heater operation If fault code occurs again replace controller WHL 001 REV 9 3 14 The data received from the tank sensors exceeds the difference allowed by the control Tank Sensor Data Not Consistent Dual Temperature Sensor B is out of normal operating range meaning the sensor is either open or shorted Dual Temperature Sensor B Error Dual Temperature Sensor A is out of normal operating range meaning the sensor is either open or shorted Dual Temperature Sensor A Error The control detects an unstable flame Unstable Flame Lockout 2 3 4 5 0 4 5 2 3 4 5 1 2 3 4 5 6 7 52 Manually reset the water heater Observe water heater operation If fault code occurs again Check the Dual Temperature Sensor Ensure it is properly wired to the control and that there are no breaks cuts or other visible issues with the sensor wire Use an ohmmeter to check resistance on first Sensor A then Sensor B of the Dual Temperature Sensor Replace Dual Temperature Sensor if either Sensor A or Sensor B fails the resistance test 5 r A SENSOR B The ADC test has detected a major Manually reset the water heater ADC Failure fault in the electronic components Observe water heater operation If fault code occurs again replace the controller Manually reset the water heater Observe water heater operation Check the Dua
13. WHICHEVER IS GREATER INTAKE EXHAUST SUPPORT BRACKETS MUST BE USE TTE 04 02 13 EXHAUST UNBALANCED VENTING WITH TEE INTAKE AND COUPLING EXHAUST INTAKE lt I MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER SUPPORT BRACKETS MUST BE USED ON LP 441 M ALL HORIZONTAL AND 04 02 13 VERTICAL PIPING Figure 10 NOTE This drawing is meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes WHL 001 REV 9 3 14 31 SIDE VIEW A A EXHAUST JN EXHAUST B E E I AIR INTAKE AIR INTAKE D C FRONT VIEW SIDE VIEW Figure 11 Horizontal Venting NOTE This drawing is meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes 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 WARNING All vent pipes must be glued properly supported and the exhaust must be pitched
14. properly beveled and seated before insertion into the flue adapter Failure to do so could result in property damage severe personal injury or death A 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 A WARNING DO NOT insulate the first 3 feet of the Exhaust Vent CPVC Polypropylene or Stainless Steel pipe material MUST be used for the first 3 feet of the vent run if the Exhaust Vent is insulated or passes through an enclosed space greater than 6 such as a wall The balance of the vent run can be installed with standard Schedule 40 PVC pipe Failure to comply with this warning could result in substantial property damage severe personal injury or death WHL 001 REV 9 3 14 24 B APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL Wem for Installa
15. 26 27 8 8 4 5 5 7 Figure 25 Replacement Parts Cei EA EX EE EN hls EM zz WHL 001 REV 9 3 14 54 1 CODINETDPTRE SOGALON aros 7 77008 mmuwDPWBE GALON UXUAYDFTBE SOGALON ooe s COMBNAIONIEMPERAURESEOR 7 007 5 10 COLD INLET DIP TUBE 50 GAL 7 008 INLET DIP TUBE w VENTUR 60 GAL not shown 77005088 eo INLET DIP TUBE w VENTUR 80 GAL trot shown ITEM 10 IS OPTIONAL Figure 26 Replacement Parts WHL 001 REV 9 3 14 55 PART 12 MAINTENANCE CAUTION In unusually dirty or dusty conditions care must be taken to keep water heater cabinet door in place at all times Failure to do so VOIDS WARRANTY WARNING Allowing the water heater 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 water heater failure property damage personal injury or death Such product failures ARE NOT covered under warranty WARNING Hydrogen gas can build up in a hot water system served by this water heater that has not been used for a long period of time generally two weeks or m
16. LEVEL MENU PRESS FROM THESE SCREENS TO ADVANCE TO CHANGEABLE PARAMETERS PRESS AT ANY TIME FROM CHANGEABLE PARAMETERS TO RETURN TO UPPER LEVEL MENU PRESS AT ANY TIME FROM THESE SCREENS TO RETURN TO NORMAL OPERATION CONTROL WILL AUTOMATICALLY RETURN TO NORMAL OPERATION AFTER 15 SECONDS OF NO ACTION Figure 23 Upper Level Navigation 2 TECHNICAL SERVICE AND NAVIGATION The Technical Service Menu is the initial menu to appear when entering Installer Mode Technical Service Parameters allow the installer to fully customize water heater settings to the system The control is ready to access the Technical Service Parameter Menu when the following screen appears on the display WHL 001 REV 9 3 14 44 To enter Installer Mode press and hold reset for five seconds When the screen appears Installer Mode is active Press at this screen to access the Technical Service Parameters codes POO etc To change parameter value press or once The value will appear Press to decrease or to increase the value Press at this screen to accept the changed value and return to the Technical Service Parameters Press to advance through the parameters Press to return to the previous parameter Press 9 at any Technical Service Parameter code screens to return to the upper level menu Table 11 details the Technical Service Parameters in sequential order CODE SHORT DESCRIPTION LONG DESCRIPTION RANGE DE
17. 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 FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS D Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions f you cannot reach your gas supplier call the fire department Use only your hand to turn the gas control knob Never use tools If the handle will not turn by hand don t try to repair it ca
18. To prevent combustion air contamination see Table 1 Contaminant Table WARNING Take extra precaution to adequately support the weight of vent pipes terminating through the roof Failure to properly support roof terminated vent piping could result in property damage serious personal injury or death due to flue gas leakage SIDEWALL VENTING WITH TEE INTAKE AND COUPLING EXHAUST ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER TYP MAINTAIN 12 MINIMUM CLEARANCE SUPPORT BRACKETS MUST BE USED ON ALL HORIZONTAL LP 441 G AND VERTICAL PIPING 04 02 13 Figure 8 Sidewall Venting with Tee Intake and Coupling Exhaust NOTE This drawing is meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes WARNING All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of 74 per foot back to the heater to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the water heater and the balance at 4 foot intervals on the vent pipe Heater venting must be readily accessible for visual inspection for the first three feet from the heater WHL 001 REV 9 3 14 29 SIDEWALL VENTING SIDEWALL VENTING WITH WITH KIT CONCENTRIC VENT VENT KIT PART V500 2 V 1000 IMPORTANT INTAKE LEG MUST BE FACING UP CON
19. a minimum of per foot back to the heater to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the water heater and the balance at 4 foot intervals on the vent pipe Heater venting must be readily accessible for visual inspection for the first three feet from the heater 2 VENTING THROUGH AN EXISTING SYSTEM This heater 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 VENT AIR INLET SIZE MINIMUM EXISTING VENT CHASE SIZE Ze 4 3 5 4 Table 8 Minimum Existing Vent Chase Sizing WHL 001 REV 9 3 14 32 Do not install the heater into a common existing vent with any other appliance This will cause flue gas spillage or heater malfunction resulting in substantial property damage severe 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 CAUTION If an existing venting system is converted for use with this heater
20. and heater 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 immediately replace with a new properly rated relief valve Test T amp P valve at least once annually to ensure the waterway is clear If valve does not operate turn the heater off and call a plumber immediately Take care whenever operating relief valve to avoid scalding injury or property damage 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 WARNING Do not thread a cap or plug into the relief valve under any circumstances Explosion and property damage serious injury or death may result D BACKFLOW PREVENTER Use a backflow preventer specifically designed for water heater installations This valve should be installed on the cold water fill supply line per local codes E POTABLE EXPANSION TANK A potable hot water expansion tank is required to offset heated water expansion In most city plumbing systems the water meter has a no return or back flow device built into the system to prevent back flowing of water into city mains Some local codes require back flow WHL 001 REV 9 3 14 preventers on all incoming water
21. failure due to outside causes The heater requires a maximum of 8 amps at 120 volts in use z x ir a 65 Z 1 A Figure 17 Line Voltage Wiring B LINE VOLTAGE CONDENSATE OUTPUT The heater has the capability of supplying power to a condensate pump The connection is 115 10 15 at a max of 2 amps Power is supplied to the pump only when the heater is connected to power and the power switch is in the on position C LOW VOLTAGE OUTDOOR SENSOR INPUT The heater has the capability of an outdoor reset Connecting an outdoor sensor allows the heater to operate at optimum efficiency Westinghouse offers an outdoor sensor The outdoor sensor must be a 12K NTC sensor Use a minimum 22 AWG wire for runs of 100 feet or less and minimum 18 AWG wire for runs up to 150 feet Instructions are included with the outdoor sensor to correctly mount the sensor on the exterior surface of the building It is preferable to mount the sensor on the north side in an area that will not be affected by direct sunlight but will be exposed to varying weather conditions Connect the outdoor sensor to terminals marked Outdoor WARNING 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 heater is complet
22. fire explosion property damage severe personal injury or death B GAS TABLE Refer to the table below to size the supply piping to minimize pressure drop between meter or regulator and unit Maximum capacity of pipe in cubic feet of gas per hour for gas pressures of 5 psi or less and a pressure drop of 3 inch water column Nominal Internal Length of Pipe Feet Pipe Size in Dia n 19 20 p 30 60 70 80 90 100 125 150 175 200 BTU s LL 5 lo 4 1 824 278 190 152 130 115 105 96 90 84 79 72 64 59 55 1 1 049 520 350 285 245 215 195 180 170 160 150 130 120 110 100 1 000 1 1 380 1 050 730 590 500 440 400 370 350 320 305 275 250 225 210 Table 9 Source ANSI Z223 1 WHL 001 REV 9 3 14 It is recommended that a soapy solution be used to detect leaks Bubbles will appear on the pipe to indicate a leak is present The gas piping must be sized for proper flow and length of pipe to avoid excessive pressure drop Both the gas meter and the gas regulator must be properly sized for the total gas load If you experience a pressure drop greater than 1 WC the meter regulator or gas line is undersized or in need of service You can attach a manometer to the incoming gas drip leg by removing the cap The gas pressure must remain between 3 5 WC and 14 WC during stand by static mode and while in
23. manual PART 2 BEFORE YOU START A WHAT S IN THE BOX Also included with the heater e Intake PVC Tee with Screens Exhaust PVC Coupling with Screens Temperature and Pressure Relief Valve Ships Installed High Output Cold Water Dip Tube Installation Manual Warranty B HOW THE HEATER OPERATES Modulation Condensing Technology is an intelligent system that delivers highly efficient water heating while maximizing efficiency by measuring the data parameters of your water heating system Some of its features are Stainless Steel Water Storage Tank The stainless steel water storage tank has a combustion chamber submerged into the tank water When the water heater is fired combustion gases heat the combustion chamber walls transferring heat directly into the surrounding water These hot gases are blown into secondary heat exchanger coils where more heat is transferred into the water removing even more heat from the gases WHL 001 REV 9 3 14 Modulating Combustion System Modulation during water heating operation is based on tank temperature The control monitors the system to regulate burner output during operation to match system demand This increase in efficiency allows for substantial fuel savings High Output Cold Water Dip Tube Optional Supplied with Water Heater Increases hot water draw by 20 when installed The High Output Cold Water Dip Tube also increases recovery time by 20 and decreases thermal efficiency by a small
24. 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 heater is to replace an existing heater check for and correct any existing system problems such as e System leaks WHL 001 REV 9 3 14 e Location that could cause the system and heater to freeze and leak expansion tank 6 Clean and flush system when reinstalling a heater 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 heater model and serial number B LEVELING CAUTION In order for the condensate to properly flow out of the collection system the area where you locate the heater must be level Location must also fully support the weight of the filled water heater C CLEARANCES FOR SERVICE ACCESS CAUTION All water heaters eventually leak It is recommended to install a catch pan beneath the water heater This catch pan should be sized with a maximum depth of 2 and a minimum diameter 2 greater than the diameter of the water heater The catch pan should empty into an open line This drain line should be 7 ID minimum piped to an open drain Failure to follow these instructions could result in property damage Such damages ARE NOT covered by
25. product warranty O MIN CLEARANCE MIN YS 3 MIN 2 MIN CLEARANCE CLEARANCE MAXIMUM 2 TO OPEN DRAIN LINE SHOULD BE AT LEAST 3 4 ID AND PITCHED FOR PROPER WHL 001 B DIAMETER OF WATER HEATER DRAINAGE 06 19 14 PLUS 2 MINIMUM 24 MIN CLEARANCE WHL 001 C 06 19 14 Figure 1 Recommended Service Clearances NOTE In addition it is recommended to provide a minimum service clearance of 6 from the top of the water heater to allow for piping of the T amp P relief valve and top ports Depending on the installation this clearance may need to be substantially greater than 6 NOTE If you do not provide the minimum clearances shown in Figure 1 it might not be possible to service the heater without removing it from the space A WARNING The space must be provided with combustion ventilation air openings correctly sized for all other appliances located in the same space as the heater The heater cover must be securely fastened to prevent the heater from drawing air form the heater room This is particularly important if the heater is in a room with other appliances Failure to comply with the above warnings could result in substantial property damage severe personal injury or death D RESIDENTIAL GARAGE INSTALLATION PRECAUTIONS If the heater is located in a residential garage per ANSI 2223 1 e Mount the bottom of the heater a minimum of 18 above the floor of the ga
26. 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 water heater and related components near high heat sources C 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 water heater 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 Cellular foam core piping may be used on air inlet piping only WHL 001 REV 9 3 14 25 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 D EXHAUST VENT AND INTAKE PIPE LOCATION E FTH I Lo wince Eu ES Jaen 08 12 13 E EXHAUST VENT TERMINAL T INTAKE PIPE TERMINAL 22 TERMINAL 15 NOT Figure 7 ANSI Z223 1 NFPA 54 for US and CAN CSA B149 1 for Canada Exit Terminals for Direct Vent Venting Systems DETERMINE EXH
27. reference measurement used in the U S water heater industry Hardness expressed as mg L or ppm may be divided by 17 1 to convert to grains per gallon Water may be classified as very soft slightly hard moderately hard or hard based on its hardness number The minerals in the water precipitate out as the water is heated and cause accelerated lime scale accumulation on a heat transfer surface This lime scale build up may result in premature failure of the heat exchanger Operating temperatures above 135 F will further accelerate the build up of lime scale on the heating surface and may shorten the service life of the water heater Water that is classified as hard and very hard must be softened to avoid heat exchanger failure See below for further information about water hardness CLASSIFICATION MG L OR PPM GRAINS GAL Soft 0 17 1 0 1 Slightly Hard 17 1 60 1 3 5 Moderately Hard 60 120 3 5 7 0 Hard 120 180 7 0 10 5 Very Hard 180 and over 10 5 and over If the hardness of the water exceeds the maximum level of 7 grains per gallon water should be softened to a hardness level no lower than 5 grains per gallon Water softened as low as 0 to 1 grain per gallon may be under saturated with respect to calcium carbonate resulting in water that is aggressive and corrosive pH of Water pH is a measure of relative acidity neutrality or alkalinity Dissolved minerals and gases affect water pH The pH scale ranges from O to 14 Wat
28. warrantable condition Failure of a water heater due to lime scale build up on the heating surface IS NOT covered by the warranty Hardness 7 grains Chloride levels 100 ppm PH levels 6 8 TDS 2000 ppm Sodium 20 mGL WHL 001 REV 9 3 14 15 T amp P AUXILIARY RETURN HOT OUTLET 4 00 COLD INLET noone s 9 WGRO5ONGO76 46 3 4 WGRO amp ONGO76 60 543 4 36 1 4 33 1 4 7 1 4 23 32 174 WGRO80NGO76 80 71 3 4 AIR SYSTEM SHIPPING INPUT INLET OUTLET AUXILIARY MODEL MODULATION INTAKE EXHAUST S RELIEF VENT SIZE PIPE SIZE WGRO50NG076 WGRO60NGO76_ 25 000 76 000 2 3 4 3 4 1 2 3 4 160 TEES WGRO080NGO076 09 03 14 Figure 3 ALL DIMENSIONS ARE APPROXIMATE A WARNING UNCRATING HEATER Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee CAUTION COLD WEATHER HANDLING If the heater has been stored in a very cold location BELOW 0 F before installation handle with care until the plastic components come to room temperature Remove all sides of the shipping crate to allow the heater to be lifted into its installation location WHL 001 REV 9 3 14 PERFORMANCE SPECIFICATIONS FOR HIGH EFFICIENCY WATER HEATER MODELS BTUH Efficiency Temperature Rise in Degrees Fahrenheit 40 50 60 70 80 90 100 110 120 130 140 C GPH LPH 22 231
29. water will result in dry firing NOTES FOR AIR HANDLER APPLICATION 1 MASSACHUSETTS STATE PLUMBING CODE REQUIRES A DISTANCE NO GREATER THAN 50 FEET FROM THE WATER HEATER TO THE FAN COIL IN THE AIR HANDLER 2 MASSACHUSETTS STATE PLUMBING CODE REQUIRES AN ELECTRONICALLY TIMED CIRCULATOR PUMP TO ACTIVATE EVERY SIX HOURS FOR 60 SECONDS THIS CIRCULATOR IS REQUIRED TO BE BRONZE OR STAINLESS 3 ALL WATER PIPING MUST BE INSULATED 4 YOU MUST INSTALL A VACUUM RELIEF VALVE PER 248 CMR NOTE THIS DRAWING IS MEANT TO DEMONSTRATE SYSTEM PIPING ONLY THE INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES An ASSE 1017 thermostatic mixing valve MUST be installed when using outdoor reset Failure to do so could result in substantial property damage serious injury or death WARNING The piping will not support the weight of the water heater circulator pump Refer to the pump manufacturer s installation instructions to properly support the circulator pump Failure to comply with these instructions could result in substantial property damage severe personal injury or death WHL 001 REV 9 3 14 23 PART 5 VENTING COMBUSTION AIR AND CONDENSATE REMOVAL A DANGER The heater must be vented as detailed in this Venting Section Ensure exhaust vent and intake piping complies with these instructions Breathing Hazard Carbon Monoxide Gas Do not operate heater if flood damaged Install vent system in
30. 4 PART 3 PREPARE WATER HEATER LOCATION CAUTION Carefully consider installation when determining heater location Please read the entire manual before attempting installation Failure to properly take factors such as heater venting piping condensate removal and wiring into account before installation could result in wasted time money and possible property damage and personal injury A BEFORE LOCATING THE HEATER A WARNING Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk Ensure that the heater installation location adheres to the information included in this manual Failure to do so could result in property damage serious personal injury or death CAUTION Failure of heater or components due to incorrect operating conditions IS NOT covered by product warranty 1 Installation Area Mechanical Room Operating Conditions Ensure ambient temperatures are higher than 32 F 0 C and lower than 104 F 40 C Prevent the air from becoming contaminated by the products places and conditions listed in this manual Part 3 Section F 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 F WARNING This water heater has a condensate disposal system that may free
31. 874 33 158 598 39 135 511 44 119 450 50 107 405 56 97 61 86 326 67 19 299 72 73 2 6 78 69 Table 2 Recovery rating plate is based at 97 thermal efficiency at 70 Fahrenheit rise as required by ANSI PART 4 HEATER PIPING Never use dielectric unions or galvanized steel fittings when connecting to a stainless steel storage tank or heater Use only copper or brass fittings Teflon thread sealant must be used on all connections DO NOT pipe this water heater with black iron galvanized steel steel or lead pipe Doing so will result in premature product failure and property damage and WILL VOID the product warranty CAUTION Do not apply heat to the Hot or Cold water heater connections If sweat connections are used sweat tubing to the adapter before fitting adapter to the water connections on the heater Any heat applied to the water heater connections will permanently damage the dip tube and or heat traps Damages due to improper installation practices ARE NOT covered by warranty A GENERAL PIPING INFORMATION CAUTION Use two wrenches when tightening water piping at heater Use one wrench to prevent the heater return or supply line from turning Failure to prevent piping connections from turning could cause damage to heater components The heater control module uses temperature sensors to provide both high limit protection and modulating temperature contro
32. ART UP PROCEDURE A WARNING FOR YOUR OWN SAFETY READ BEFORE OPERATING 1 This water heater does not have pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 2 BEFORE OPERATING smell all around the water heater area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any water heater Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions If you cannot reach your gas supplier call the fire department Turn off gas shutoff valve located outside of the water heater so that the handle is crosswise to the gas pipe If the handle will not turn by hand don t try to force or repair it call a qualified service technician Force or attempted repair may result in a fire or explosion 4 Do not use this water heater if any part has been under water Immediately call a qualified service technician to inspect the water heater and to replace any part of the control system and any gas control that has been damaged 5 The water heater shall be installed so the gas ignition system components are protected from water dripping spraying rain etc during water heater operation and service circulator replacement condensate trap control replacement etc
33. AUST VENT AND INTAKE PIPE LOCATION FIGURE 7 NOTES INSTALLATIONS IN THE UNITED STATES A Provide a minimum of 1 foot clearance from the bottom of the exhaust vent and intake pipe above the expected snow accumulation level Snow removal may be necessary to maintain clearance B Provide a minimum of 1 foot distance from exhaust vent termination to any door operable window or gravity intake into any building C Provide a minimum of 1 foot distance from exhaust vent termination to any permanently closed door or window D Provide a minimum of 4 feet vertical clearance from the exhaust vent to all roof overhangs E Locating exhaust vent termination near roof overhangs will result in the formation of icicles in freezing weather and could result in blockage of the exhaust vent To prevent icicles from forming maintain 4 feet vertical clearance from the exhaust vent to all roof overhangs F Provide 4 feet clearance from the outside corner of vertical walls chimneys etc as well as horizontal corners created by roof overhangs G Provide 6 feet clearance from the inside corner of vertical walls chimneys etc as well as horizontal corners created by roof overhangs H Provide 4 feet clearance from center line within a height of 15 feet above electrical meters gas meters gas regulators relief equipment exhaust fans and inlets l Provide 4 feet horizontal clearance from electrical meters gas meters gas regulators relief equipment exhaust
34. CENTRIC VENT KIT PART KGAV0501CVT 2 KGAV0601CVT MAINTAIN 12 MINIMUM MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST CLEARANCE ABOVE Ro uae Y SNOW LEVEL HIGHEST ANTICIPATED ADE WHICHEVER IS SNOW LEVEL OR GREATER TYP GRADE WHICHEVER IS GREATER TYP LP 505 A 07 30 14 ROOF VENTING WITH xcavos0i CVI 7 CONCENTRIC VENT KIT ER 10 0 MIN Im 12 OVER MAXIMUM SNOW LEVEL OR 24 WHICHEVER IS GREATER NOTE EXTENDED VENT RUNS WHEN TRANSITIONING TO A LARGER DIAMETER MUST ALWAYS TAKE PLACE IN A VERTICAL POSITION TO PREVENT CONDENSATE BLOCKAGE LP 505 C 01 17 14 Figure 9 Venting with Optional Kits NOT INCLUDED WITH THE WATER HEATER NOTE These drawings are meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes WARNING All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of 74 per foot back to the heater to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the water heater and the balance at 4 foot intervals on the vent pipe Heater venting must be readily accessible for visual inspection for the first three feet from the heater WHL 001 REV 9 3 14 30 EXHAUST 24 MIN f i ROOF VENT WITH TEE INTAKE AND COUPLING EXHAUST 10 0 MIN 12 OVER MAXIMUM SNOW LEVEL OR 24
35. E 2 DAMAGE 3 WATER Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee WARNING 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 WARNING Altering any Westinghouse appliance with parts not manufactured and or approved by Westinghouse WILL INSTANTLY VOID the appliance warranty and could result in property damage serious personal injury or death WARNING This water heater has been designed to heat potable water ONLY Using this water heater to heat non potable fluid WILL VOID product warranty and could result in property damage personal injury or death B IMPROPER COMBUSTION A 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
36. ENTS FOR THE COMMONWEALTH OF MASSACHUSETTS In the Commonwealth of Massachusetts the installer or service agent shall be a plumber or gas fitter licensed by the Commonwealth When installed in the Commonwealth of Massachusetts or where applicable state codes may apply the unit shall be installed with a CO detector per the requirements listed below 5 08 Modifications to NFPA 54 Chapter 10 1 Revise NFPA 54 section 10 5 4 2 by adding a second exception as follows Existing chimneys shall be permitted to have their use continued when a gas conversion burner is installed and shall be equipped with a manually reset device that will automatically shut off the gas the burner in the event of a sustained back draft 2 Revise 10 8 3 by adding the following additional requirements a For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gastitter shall observe that a hard wired carbon monoxide detector with an
37. FAULT POO User Setpoint F Minimum Tank Temperature 70 160 120 TT Difference Between Actual Tank Temperature and Temperature Differential User Setpoint that will Initiate Demand tige i Maximum Power Percentage 96 Maximum Combustion System Power 0 100 80 Temperature Unit Displayed Fahrenheit or Celsius 1 1 0 Off 1 0 Minimum Outdoor Temperature C F Minimum outdoor design conditions for reset curve 10 70 10 Maximum Outdoor Temperature C F Maximum outdoor design conditions for reset curve 10 70 68 Minimum Storage Temperature C F Minimum tank temperature for reset curve 70 160 120 09 Maximum Storage Temperature C F Maximum tank temperature for reset curve 70 160 140 10 Warm Weather Shutdown Temperature Outdoor temperatures greater than this value return 0 100 68 C F the tank target temperature to the User Setpoint Table 11 Technical Service Parameters NOTE Temperature Readings Depend on Temperature Unit Selection 5 Turns on the Outdoor Reset Curve PO5 Outdoor Reset Curve NOTE The following parameters are applicable only 0 Off 1 On 0 if the Outdoor Reset Curve is turned on 5 OUTDOOR RESET CURVE OUTDOOR RESET CURVE emu Laemexesesmemsd TANK TEMPERATURE 20 40 60 OUTDOOR TEMPERATURE P06 VALUE P07 VALUE P10 VALUE Figure 24 Outdoor Reset Curve
38. High Efficiency Water Heater Ww Westinghouse INSTALLATION START UP MAINTENANCE PARTS Models WGHRO050NG076 WGRO60NG076 WGRO80NG076 WGRO50LP076 WGRO60LP076 WGRO80LP076 ULTRA 6 Low NOx Emissions SCAQMD Rule 1146 2 LEAD FREE Safe Drinking Water Act SDWA Section 1417 Fu FA CERTIFIED This manual must only be used by a qualified heating installer service technician Read and understand all instructions in this manual before installing Perform steps in the order given Failure to comply will result in substantial property damage severe personal injury or death Listed WARNING Improper installation adjustment alteration service or maintenance could void product warranty and cause property damage personal injury or death 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 NOTE TO CONSUMER PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE WHL 001 REV 9 3 14 WARNING 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
39. SURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY Refer to Breathing Hazard Carbon Monoxide Gas the limited warranty for complete terms and conditions Do not operate heater if flood darnaged G REMOVING A HEATER FROM A COMMON VENT SYSTEM local codes and manufacturers TEE installation Instructions DANGER Do not obstruct heater air intake or exhaust Support all vent piping per R22229977 7 PP PPPPPPPPPPPPPPPPPPP nstructions Do not install the heater into a common vent with any other appliance This will cause flue gas spillage or appliance malfunction resulting in manufacturers installation i ed chemical vapor emitting possible substantial property damage severe personal injury or death near unit According to NFPA 720 carbon monoxide detectors should be installed outside each sleeping area Never operate the heater unless it is vented to the outdoors Analyze the entire vent m to make sure that condensate will not become trapped in a section of vent pipe and therefore reduce the open cross prod 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 heater follow the steps below Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual 1 Seal any unused openings in the common venting system
40. TDOWN A SHUTDOWN PROCEDURE If the burner is not operating lower the set point value to 70 F and wait for the burner to shut off Continue to wait for the combustion blower to stop so all latent combustion gases are purged from the system This should take a maximum of 300 seconds 5 minutes B VACATION PROCEDURE If there is danger of freezing change the set point to 70 F DO NOT turn off electrical power If there is no danger of freezing follow Shutdown Procedure C FAILURE TO OPERATE Should the burner fail to light the control will perform two more ignition trials prior to entering a lockout state Note that each subsequent ignition trial will not occur immediately After a failed ignition trial the blower must run for approximately 10 seconds to purge the system Therefore a time period of approximately 40 to 90 seconds will expire between each ignition trial If the burner lights during any one of these three ignition trails normal operation will resume If the burner lights but goes off in about 4 seconds check the polarity of the wiring See electrical connection section If the burner does not light after the third ignition trial the control will enter a lockout state This lockout state indicates that a problem exists with the water heater the controls or the gas supply Under such circumstances a qualified service technician should be contacted immediately to properly service the water heater and correct the probl
41. WARNING When filling the water heater open a hot water tap to release air in the tank and piping The tank must be full of water before the heater is turned on Failure to ensure the water heater is full before turning it on will result in damage to the water heater and could result in property damage serious personal injury or death Such damages ARE NOT covered by water heater warranty Make certain that the field installed drain valve is completely closed Open the shut off valve in the cold water supply line Open the hot water faucets to allow air to vent from the heater and piping Allow sufficient time for the heater to completely fill with water WHL 001 REV 9 3 14 WARNING The water heater must be full of water and the system fully purged BEFORE powering the water heater Applying power to the water heater when it is not full of water could result in a condition referred to as dry firing Dry firing the water heater will damage the heat exchanger and could result in property damage serious personal injury or death Such damages ARE NOT covered by water heater warranty I IMPORTANT NOTICE NOTICE It is extremely important that whenever work is performed on the plumbing system that either e The water heater is powered off or e The water heater is valved off and isolated from the plumbing system Failure to take these measures could result in a dry firing condition WARNING The water heater mus
42. accordance with local codes and manufacturers installation instructions Do not obstruct heater air intake or exhaust Support all vent piping per manufacturers installation 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 with the instructions provided in this manual Failure to properly install the vent system will result in severe personal injury or death A GENERAL Do not place chemical vapor emitting products near unit According to NFPA 720 carbon monoxide detectors should be installed outside each sleeping area Never operate the heater unless it is vented to the outdoors Analyze the entire vent system to make sure that condensate will not become trapped in a section of vent pipe and th reduce the open cross sectional area of the vent DANGER This heater 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
43. accordance with local codes and manufacturers installation instructions Do not obstruct heater air intake or exhaust all vent piping per manufacturers installation instructions lt lt not pue chemical vapor emitting near unit According to NFPA 720 carbon monoxide detectors should be installed outside each sleeping area Never operate the heater unless it is vented to the outdoors Analyze the entire vent to make trapped in sect n cue an na on of ve reduce Open CORE sectional area of the vent DO NOT PLACE DRYER IN PROXIMI TO WATER HEATER x Figure 13 LP 325 X WHL 001 REV 9 3 14 34 EXHAUST VENT INDOOR COMBUSTION AIR SINGLE PIPE ROOM OPENING NOTE This drawing is meant to demonstrate system venting only The installer 1 responsible for all equipment and detailing required by local codes ROOM OPENING x ou m 1 3 52 5 8 5 2010 OUTDOOR COMBUSTION AIR SINGLE PIPE NOTE This drawing is meant to demonstrate system venting only The installer is responsible for all equipment and detaihng required by local codes Figure 14 WHL 001 REV 9 3 14 35 I CONDENSATE REMOVAL SYSTEM NOTE Check with your local gas company to determine if combustion condensate disposal is permitted in your area In the state of Massachusetts condensate must be neutralized before entering a drain This condensing high efficiency water heater has a condensate re
44. ace has adequate area or when air is provided through a duct or louver to supply sufficient combustion air based on the water heater input Never obstruct the supply of combustion air to the water heater If the water heater is installed in areas where indoor air is contaminated see Table 1 it is imperative that the water heater be installed as direct vent so that all combustion air is taken directly from the outdoors into the water heater 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 with doors are considered part of the space See Figure 14 p 34 for details 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 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 22cm kW of the total input of all appliances
45. alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the service of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level In the event that the requirements of this subdivision 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 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified LP 172 REV 02 16 06 WHL 001 REV 9 3 14 58 3 SIGNAGE metal or plastic identification plate shall be permanently mounted to t
46. allation Instructions Do not obstruct heater air intake or exhaust Support all vent piping manufacturers inatallalion inetuctions 7 near unit to NFPA 720 carbon monoxide detectors EIU be installed outside each sleeping area Never operate tho heater unless i vented to the outdoors Analyze the entire vent m to make sure that condensate will not become a i in a section o E ana reduce the open cross area of the vent 4 28 09 LP 441 S 05 02 13 4 WARNING Strain on the gas valve and fittings may result in vibration premature component failure and gas leakage and result in fire explosion property damage severe personal injury or death WARNING Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated combustion analyzer capable of measuring CO and CO Failure to follow this instruction could result in fire explosion property damage severe personal injury or death WHL 001 REV 9 3 14 PART 8 CONTROLS A CONTROL AND DISPLAY OVERVIEW Detailed Description of Button Functions 1 Setting Adjust Down 2 Setting Adjust Up 41 T Burner Power Indicator 3 Digit Display Economy Mode 3 Decreases the User Setpoint 4 Increases the User Setpoint Test Mode or Time for Service Temp in Fahrenheit F or Celsius C XB Warning Icon 5 ECO Mode 6 RESET DHW Mode R
47. aller Mode Putting the water heater into ECO Mode reduces maximum firing rate to 80 of the rated maximum firing rate This increases water heater efficiency in times of low hot water demand Press to put the water heater into ECO mode Press again to return to normal operation Test Mode allows the installer to test water heater operation by running the fan at different speeds To enter Test Mode press and together for 5 seconds Push to decrease or push to increase fan speed by 50 RPM increments Push to operate at maximum fan speed Push to operate at minimum fan speed Test Mode will exit automatically after 15 minutes Press c3 to leave Test Mode manually Lockout codes refer to a temporary condition that must be cleared to resume operation If code persists the heater should be serviced by a qualified service technician Blocking codes temporarily stop water heater operation until the error condition clears Once the condition clears the error will disappear and the water heater will resume operation The error will also be written into the water heater s history data The Installer Mode allows installers to view history hidden from the user See Advanced Control Functions for information on how to enter 42 Off Test Mode On Off Off Press ES to clear the code Observe operation to ensure code does not reoccur Water heater operation resumes when condi
48. also sign this document Customer s Name Installation Address Date of Installation Installers Code Name MEM Comments Installers Phone Number Signed by Installer Signed by Customer IMPORTANT Customer Please only sign after the installer has reviewed the installation safety proper operation and maintenance of the system In the case that the system has any problems please call the installer If you are unable to make contact please contact your Westinghouse Sales Representative Distributor Dealer Please insert contact details w WESTINGHOUSE are trademarks of Westinghouse Electric Corporation Used under license by Inc All Rights Reserved WHL 001 REV 9 3 14
49. amount Gas Valve The gas valve senses suction from the blower allowing gas to flow only if the gas valve is energized and combustion air is flowing Tank Sensor This sensor monitors system water temperature The control module adjusts the burner firing rate so the outlet water temperature meets the set point Control The integrated control system monitors water temperature and regulates fan speed to regulate the unit s energy output This allows the unit to deliver the required amount of heated energy and nothing more Burner Constructed of high grade stainless steel the burner uses pre mixed air and gas and provides a wide range of firing rates Condensate System with Built In Neutralizing Cartridge This is a condensing high efficiency water heater and therefore has a condensate removal system Condensate is nothing more than water vapor derived from combustion products and similar to an automobile when it is initially started It is very important that the condensate line slopes away from the water heater and down to a suitable inside drain The Built In Neutralizing Cartridge is filled with marble chips that neutralize the condensate before it flows into a local drain The marble chips dissolve over time The cartridge is designed to be easily removed refilled with marble chips and reinstalled If the condensate outlet on the heater is lower than the drain you must use a condensate removal pump In addition local authorities may
50. ances 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 WHL 001 REV 9 3 14 In Canada CGA No B149 latest version from Canadian Gas Association Laboratories 55 Scarsdale Road Don Mills Ontario Canada 2R3 Also Canadian Electrical Code C 22 1 from Canadian Standards Association 5060 Spectrum Way Suite 100 Mississauga Ontario Canada LAW 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 undergoing tests specified in ANSI Z21 10 3 latest edition TABLE OF CONTENTS PART I GENERAL SAFETY INFORMA TION toe eee ta tee uen ut s eerte tenu tr cte dede 6 A PRECAUTIONS erri 6 6 Ci GINS EE PR 7 De WHEN SERVICING HE HEATER tite 7 E HEATER WATER S Seid at ae ad bru acc Raa MU M ea MENU dM ELE M LM 7 PART 2 BEFORE YOU START a CoE act 7 AWRA TSIN THE BOX X M
51. as determined using the appropriate tables in Appendix G in the National Fuel Gas Code ANSI Z 223 1 H WATER CHEMISTRY CAUTION Chemical imbalance of the water supply may affect efficiency and cause severe damage to the water heater and associated equipment Westinghouse recommends having water quality professionally analyzed to determine whether it is necessary to install a water softener It is important that the water chemistry on both the domestic hot water and central heating sides are checked before installing the water heater as water quality will affect the reliability of the system Failure of a heat exchanger due to lime scale build up on the heating surface low pH or other chemical imbalance IS NOT covered by the warranty CAUTION Operating temperatures above 135 F will further accelerate the build up of lime scale on the heating surface and may shorten the service life of the water heater Failure of a heat exchanger due to lime scale build up on the heating surface low pH or other chemical imbalance IS NOT covered by the warranty Outlined below are water quality parameters which need to be met in order for the system to operate efficiently for many years Water Hardness Water hardness is mainly due to the presence of calcium and magnesium salts dissolved in water The concentration of these salts is expressed in mg L ppm or grains per gallon as a measure of relative water hardness Grains per gallon is the common
52. at show signs of damage WHL 001 REV 9 3 14 remove oxides Combination Ignitor Check ionization in uA i04 in the Inquiry Mode menu and Flame Probe Record high fire and low fire Clean probe with plumbers cloth to remove oxides CONDENSATE Neutralizer Check condensate neutralizer Replace if necessary 171777 Condensate hose Disconnect condensate hose Clean out dirt Fill with water to level of outlet and re install NOTE Verify the flow of condensate making sure that the hose is properly connected during final inspection Pressure Measure incoming gas pressure 3 5 to 10 W C Natural OO ee ee Gas 8 to 14 W C LP Misc NN aola cod W C 0 l1 leaks supported COMBUSTION gt O COMBUSTION Levels Check CO and 2 levels in Exhaust See Start up Procedures for ranges Record at high and low fire SAFETIES SAFETIES ECO Energy Cut Check continuity on Flue and Water ECO Replace if pf LLL Out corroded Check wiring Verify through ohms reading per Table 14 FINAL INSPECTION RR Check list Verify that you have completed entire check list SERIOUS INJURY OR DEATH Homeowner Review what you have done withthe homeowner o Tlo o Table 19 Continue annual maintenance beyond the 4 year as required WHL 001 REV 9 3 14 57 ADDITIONAL INSTALLATION REQUIREM
53. aving 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 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 NOTE Westinghouse reserves the right to modify product technical specifications and components without prior notice FOR THE INSTALLER A DANGER This manual must only be used by a qualified heating installer service technician Read and understand all instructions in this manual before installing Perform steps in the order given Failure to comply will result in substantial property damage severe personal injury or death This water heater must be installed by qualified and licensed personnel The installer should be guided by the instructions furnished with the heater 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 ordin
54. bustion air is taken directly from the outdoors into the water heater 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 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 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 22cm kW of the total input of all appliances in the space but not less than 100 square inches 645cm 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 14 A X A E d d 1 3 Breathing Hazard Carbon Monoxide Gas Do not operate heater if flood damaged Install vent system in
55. e 14 WHL 001 REV 9 3 14 48 Test mode can be used to incrementally increase and decrease fan speed to test the combustion system See Tables 15 and 16 for A WARNING Combustion Settings and Fan Speeds m VUE LEENA Breathing Hazard Carbon Monoxide Gas 1 Use the and push buttons to change the fan speed Do not operate heater if flood damaged steps of 50 rom between the range maximum fan speed and Install vent system in accordance with minimum fan speed cbc Do not obstruct heater intake or 2 Use the to go directly to the maximum fan speed exhaust Support all vent piping per C3 X manufacturers installation instructions 3 Use the to go directly to the minimum fan speed not place chemical vapor emitting prod near unit Range between minimum fan speed and maximum fan speed is vi yer ede Nt es taken as absolute power value 0 100 sleeping area Never operate the heater unless it is During Test mode the LCD flame symbols are enabled as follows vented to the outdoors Flame ON and power 3096 then one third of the flame symbol will sure that condensate wil not become gt trapped in a section of vent pipe and display therefore red Flame ON and power gt 30 or lt 75 then two thirds of the flame 6 Breathing carbon monoxide can cause brain damage or death symbol will display Always read and understand Instruction manual Flame ON and power gt 75 t
56. e 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 WARNING 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 Table 4 Failure to do so could result in property damage severe personal injury or death WARNING 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 74 per foot back to the heater 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 NOTE The use of double wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air High heat sources sources generating heat 100 F 37 C or greater such as stove pipes space heaters etc may damage plastic components of the water heater as well as plastic vent pipe materials Such damages ARE NOT covered by warranty It is
57. e water heater Observe water heater operation If fault code occurs again Check the Dual Temperature Sensor Ensure it is properly wired to the control and that there are no breaks cuts or other visible issues with the sensor wire Use an ohmmeter to check resistance on first Sensor A then Sensor B of the Dual Temperature Sensor Replace Dual Temperature Sensor if either Sensor A or Sensor B fails the resistance test MEN TE UNA SENSOR Manually reset the water heater Observe water heater operation If fault code occurs again Check condition of wiring Check Fan PWM connections at control board and fan Replace fan Manually reset the water heater Observe water heater operation If fault code occurs again Replace sensor Measure actual vent temperature Manually reset the water heater Observe water heater operation If fault code occurs again Check Ignitor cable connections Check Ignitor cable gound Replace cable Check spark gap between spark electrode and burner Replace ignitor Manually reset the water heater Observe water heater operation If fault code occurs again reset the water heater and When water heater attempts to fire check voltage at the gas valve connector If there is voltage but no gas pressure on the outlet side of the valve the valve is stuck closed Replace the gas valve If there is no voltage at the ignition phase replace the control board Manually reset the water heater
58. ects that will obstruct the exhaust stream DO NOT vent over a public walkway Condensate could drip or freeze and create a nuisance or hazard NOTE Due to potential moisture build up sidewall venting may not be the preferred venting option Carefully consider venting installation and location to save time and cost INSTALLATIONS IN CANADA NOTE Canadian installation must comply with the CAN CSA B149 1 code and applicable local codes and supersede the restrictions for the United States outlined in this section WHL 001 REV 9 3 14 26 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 routine maintenance Failure to keep the vent piping terminations clear and properly maintain the heater could result in property damage severe personal injury or death WARNING For each floor containing bedroom s a carbon monoxide detector and alarm shall be placed in the living area outside the bedrooms as well as in the room that houses the heater Detectors and alarms shall comply with NFPA 720 latest edition Failure to comply with requirements for detectors and alarms could result in property damage severe personal injury or death E EXHAUST VENT AND INTAKE PIPE SIZING 1 The exhaust vent and intake pipe size is 2 2 The total equivalent length of exhaust vent and intake pipe should not exceed 150 feet a The equivale
59. efore bathing or showering Table 3 details the relationship of water temperature and time with regard to scald injury and Temperature limiting valves are available see may be used as a guide in determining the safest water temperature for your applications manual C TEMPERATURE AND PRESSURE RELIEF VALVE A WARNING Overheated water and high pressures can cause water tank explosion A properly sized temperature and pressure relief valve must be installed in the opening provided on the water heater Failure to install a properly sized temperature and pressure relief valve could result in explosion and property damage serious injury or death 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 The discharge line shall terminate plain not threaded with a material serviceable for temperatures of 375 F or greater Do not pipe discharge to any location where freezing could occur No shutoff valve may be installed between the relief valve
60. ely filled with cold water k i L12005 ital ap Out 2 PLACK ow BLACK id Figure 18 Low Voltage Wiring WHL 001 REV 9 3 14 38 CAUTION Label all wires prior to disconnecting them when servicing the heater Wiring errors can cause improper and dangerous operation Failure to follow these instructions may result in property damage or personal injury D INTERNAL WIRING DIAGRAM INTERNAL CONNECTION DIAGRAM 4 1 GROUND 4 2 PINK BLOWER TACH X4 3 RED BLOWER24VDC X4 4 ORANGE BLOWER PWM X4 5 GAS VALVE X4A 6 _PINK X4 7 BLACK UPPER TEMP SENSOR 1 1 GREY x5 2 GREY AWHITE x X5 3 veuow UPPER TEMP SENSOR 2 x54 YELLOW WHITE HIGH FLUE TEMPERATURE SWITCH X5 7 _GREEN _GREENWHITE BLOCKED VENT PRESSURE SWITCH GREY X3 1 oT 3 2 GREYAVHITE X3 7 _ BLACK OUTDOOR SENSOR OPT X3 8 2 120V NEUTRAL WHITE 120V LINE BLACK L1203 4 17 2013 Figure 19 Wiring Diagram PART 7 GAS CONNECTIONS WARNING Failure to follow all precautions could result in fire explosion severe injury or death WARNING Ensure the gas on which the water heater will operate is the same type specified on the rating plate Failure to do so could result in water heater malfunction property damage serious personal injury or death WHL 001 REV 9 3 14 39 The gas supply shall have a maxim
61. em If a technician is not available pressing the button will remove the lockout state so additional trials for ignition can be performed D IMPORTANT NOTICE NOTICE It is extremely important that whenever work is performed on the plumbing system that either e The water heater is powered off or e The water heater is valved off and isolated from the plumbing system Failure to take these measures could result in a dry firing condition WARNING The water heater must be full of water and the system fully purged BEFORE powering the water heater Performing any work in the plumbing system without either powering off the water heater or isolating the water heater through the use of shut off valves could result a condition referred to as dry firing Dry firing the water heater will damage the heat exchanger and could result in property damage serious personal injury or death Such damages ARE NOT covered by water heater warranty PART 11 TROUBLESHOOTING A ERROR CODE An error code may occur during installation of the heater This condition may lead to a lock out condition of the controller which will need to be manually reset by pressing the button B HEATER ERROR 1 When an error condition occurs the controller will display an error code on the display module 2 These error codes and several suggested corrective actions are included in Table 17 In the case of 4 and 2858 this error if uncorrected will
62. emperature over 125 degrees F can cause severe burns ger trrra d instantly or death from scalds Children disabled and elderly are 25 _ at highest risk of being scalded See instruction manual before a 77 setting temperature at water heater Feel water before bathing or ad 2A showering Temperature limiting valves are available See chart below showing temperature burn rate C ADVANCED CONTROL FUNCTIONS The water heater control Installer Mode includes numerous parameters for system customization These parameters should only be accessed and changed by a qualified service technician WARNING Installer Mode Parameters should only be accessed and changed by a qualified service technician Failure to follow this warning could result in improper water heater operation premature water heater or component failure and or excessively high temperatures that could result in scalding property damage severe personal injury or death NOTE Water heater failures caused by improper Installer Mode Parameter sets WILL VOID product warranty To enter Installer Mode press and hold for five seconds When the following screen appears Installer Mode is active ES 1 UPPER LEVEL INSTALLER MODE MENU NAVIGATION See Figure 24 for information on how to navigate the Installer Menu Upper Level gt gt EG Lg in ee H E5 gt press or AT THESE SCREENS TO NAVIGATE THROUGHOUT THE UPPER
63. er with a pH of 7 0 is considered neutral Water with a pH lower than 7 is considered acidic Water pH higher than 7 is considered alkaline A neutral pH around 7 is desirable for most potable water applications Corrosion damage and heater failures resulting from water pH levels of lower than 6 or higher than 8 ARE NOT covered by the warranty The ideal pH range for water used in a storage tank or a water heater system is 7 2 to 7 8 WHL 001 REV 9 3 14 Total Dissolved Solids Total Dissolved Solids TDS is a measurement of all minerals and solids dissolved in a water sample The concentration of total dissolved solids is usually expressed in parts per million ppm Water with a high TDS concentration will greatly accelerate lime and scale formation in the hot water system Most high TDS concentrations precipitate out of the water when heated This can generate a scale accumulation on the heat transfer surface that will greatly reduce the service life of a water heater This scale accumulation can also impede the ability of the heat exchanger to transfer heat into the water A heat exchanger damaged or blocked by lime scale accumulation must be replaced The manufacturer of the water heater has no control of water quality especially TDS levels in your system Total dissolved solids in excess of 2 000 ppm will accelerate lime and scale formation in the heat exchanger Heat exchanger failure due to total dissolved solids in excess of 2 000 ppm is a non
64. erature sensor and flame sensor readings These readings aid the installer in troubleshooting the water heater To enter Installer Mode press and hold 9 for five seconds When the screen appears Installer Mode is active Press once to find Inquiry Mode The control is ready to access the Inquiry Mode when the following screen appears on the display in Press 0 at this screen to access the Inquiry Mode codes i00 i01 etc To view code value press or once The value will appear Press 09 at this screen to return to the code screen Press to advance through the codes Press to return to the previous code Press 0 at any Inquiry Mode code screens to return to the upper level menu Table 12 details the Inquiry Mode codes in sequential order CODE DESCRIPTION po UPPER HL NTC1 SENSOR TEMPERATURE C F Between 32 and 257 F 01 102 Ventilation Sensor Temperature Between 32 and 257 F i03 i04 i05 Firmware Version 222 AcudFanSpeed X Jj J Table 12 History Mode Codes NOTE Temperature Readings Depend on Temperature Unit Selection NOTE Means option is not available or in use 2 HISTORY MODE AND NAVIGATION History Mode Hi aids the installer in troubleshooting by allowing access to the last eight 8 error or fault codes that have occurred WHL 001 REV 9 3 14 46 To enter Installer Mode press and hold reset for five seconds When the
65. eset Icon Outdoor Reset Curve 7 OFF Mode Enable Figure 22 Control Detail Detailed Description of Control Functions MODES OF OPERATION MODE SCREENSHOT Off Mode Stand By Mode User Setpoint DESCRIPTION The water heater will ignore heat demands while in Off Mode RANGE DEFAULT Off On Off On Winter On Summer Off Off To put the water heater into Off Mode press In Stand By Mode the fan is off the gas valve is closed and the water inlet shut off valve is opened The water heater goes into Stand By Mode when it is powered but not firing The User Setpoint is used to set the temperature for the water 70 160 120 heater Press either or once to change the User Setpoint The normal operation screen will clear and be replaced by a flashing number This is the User Setpoint to decrease or 6 to increase the setpoint increments of two degrees After choosing the setpoint wait five seconds The screen will return to normal operation and the setpoint will be stored Enabling Outdoor Reset Curve allows the user to set additional parameters to increase water heater efficiency Press Outdoor Reset Curve 0 Enabled 1 Disabled 0 An Outdoor Sensor is required to set Outdoor Reset Curve See Advanced Control Functions to set the Outdoor Reset Curve WHL 001 REV 9 3 14 ECO Mode Test Mode Lockout Fault Codes Blocking Error Codes Inst
66. fans and inlets In no case shall the exit terminal be above or below the aforementioned equipment unless the 4 foot horizontal distance is maintained J This water heater vent system shall terminate at least 3 feet 0 9 m above any forced air intake located within 10 ft 3 m NOTE This does not apply to the combustion air intake of a direct vent appliance K When venting with a two pipe system maximum distance between exhaust vent and intake pipe is 6 feet 1 8 m Minimum distance between exhaust vent and intake pipe on single direct vented appliance is 10 0 255 m center to center Minimum distance between exhaust vents and intake pipes on multiple water heaters is 10 0 255 m center to center L When adjacent to a public walkway locate exit terminal at least 7 feet above grade In addition e Total length of vent piping shall not exceed the limits specified in this manual e The vent piping for this direct vented appliance is approved for zero clearance to combustible construction e 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 locate the exhaust vent or intake pipe terminals under a porch balcony or veranda Avoid terminating exhaust vents near shrubs air conditioners or other obj
67. go into a fault condition as described in Paragraph C C LOCKOUT 1 When a fault condition occurs the controller display a fault code Example 4 on the display module 2 Note the fault code and refer to Table 18 for an explanation of the fault code along with several suggestions for corrective actions WHL 001 REV 9 3 14 50 3 Press the reset key to clear the fault and resume operation Be sure to observe the operation of the unit to prevent a recurrence of the fault NOTE You are allowed up to 5 resets to clear a Fault or Error code After that the controller will enter an Lockout state WARNING When servicing or replacing any components of this water heater be certain that The gas is off e electrical power is disconnected A DANGER When servicing or replacing components that are in direct contact with heater water be certain that e There is no pressure in the heater Pull the release on the relief valve to relieve pressure in the heater e Heater water is not hot electrical power is off WARNING 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
68. he exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 b EXEMPTIONS the following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required to be Vented in the most current edition of 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes C MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed i
69. hen the full flame symbol will display Burner ON and OFF conditions are Burner ON UPPER temperature lt 185 C Burner OFF UPPER temperature 2 194 C The function is enabled for a maximum of 15 minutes Test mode can be disabled by pressing button COMBUSTION SETTINGS ON ALL MODELS 1 High 2 20 8 10 8 10 87 10 72 9 11 Table 15 Combustion Settings on All Models FAN SPEEDS 0 O BTU FUEL IGNITION 76000 NATURAL 5000 2150 6300 76000 LP 3800 2100 6300 Table 16 Fan Speeds C MAINTENANCE The control system requires no 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 In dirty environments such as construction sites care must be taken to keep the water heater burner cover in place and drywall or saw dust away from water heater A CAUTION In unusually dirty or dusty conditions care must be taken to keep water heater burner door in place Failure to do so VOIDS WARRANTY WARNING Allowing the heater 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 heater failure property damage personal injury or death Such product failures ARE NOT covered under warranty WHL 001 REV 9 3 14 49 PART 10 SHU
70. ice snow or other debris could result in property damage serious personal injury or death WHL 001 REV 9 3 14 C GAS Should overheating or gas supply fail to shut off turn off the manual gas control valve to the water heater D WHEN SERVICING THE HEATER To avoid electric shock disconnect electrical supply before performing maintenance To avoid severe burns allow heater to cool E HEATER WATER e Do not use petroleum based cleaning or sealing compounds in a heater system Gaskets and seals in the system may be damaged This can result in substantial property damage not use homemade cures or patent medicines Substantial property damage damage to heater and or serious personal injury may result A DANGER ADANGER Ma tnt Vapors from flammable inii will explode and 1 catch fire causing death or severe burns 2 are heavior than air 3 way on the Water temperature over 125 F can cause 4 can be carried from severe burns instantly or death from scalds meine mire Children disabled and elderly are at highest risk of being scalded are at least 18 above the floor This will reduce but not See instruction manual before setting eliminate the risk of vapors temperature at water heater or used being ignited by the main bumer and pilot flames bumer or Feel water before bathing showering Temperature limiting valves are available see
71. in the space but not less than 100 square inches 645cm WHL 001 REV 9 3 14 12 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 Part 5 of this manual When drawing combustion air from the outside into the mechanical room care must be taken to provide adequate freeze protection Do not attempt to vent this water heater 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 Failure to provide an adequate supply of fresh combustion air can cause poisonous flue gases to enter living space resulting in severe personal injury or death To prevent combustion air contamination see Table 1 F PREVENT COMBUSTION AIR CONTAMINATION Install intake air piping for the heater as described in the Venting Section Do not terminate exhaust in locations that can allow contamination of intake air Ensure that the intake air will not contain any of the contaminants below Contaminated air will damage the heater resulting in possible substantial property damage severe personal injury or death For example do not pipe intake air near a swimming pool Also avoid areas subject to exhaust fumes from laundry facilities These areas always contain contaminants Garages and workshops Table 1 Contaminant Table NOTE DAMAGE TO THE HEATER CAUSED BY EXPO
72. ing is provided with the heater for use as an outside exhaust termination 15 A screened inlet air tee is provided with the heater to be used as an outside intake termination Table 7 lists optional exhaust intake terminations available from Westinghouse DESCRIPTION STOCK CODE 2 PVC CONCENTRIC VENT TERMINATION KIT KGAVT0501CVT 3 PVC CONCENTRIC VENT TERMINATION KIT KGAVT0601CVT 2 STAINLESS STEEL VENT TERMINATION KIT V500 3 STAINLESS STEEL VENT TERMINATION KIT V1000 Table 7 H VENTING DRAWINGS 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 water heater 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 heater 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 Part 5 of this manual WHL 001 REV 9 3 14 28 When installing a combustion air intake from outdoors care must be taken to utilize uncontaminated combustion air NOTE
73. io ea eh uui Eu D M EM LIEU 55 MAINTENANCE NOTES tu e d UI LI E mE M 59 CUSTOMERINSTALLANON RECORD FORM 1 e eher ore Ene re Re e Ee Stir Roe tte Ye hoe nte e vete 60 PART 1 GENERAL SAFETY INFORMATION A PRECAUTIONS This water heater is for indoor installations only Clearance to combustible materials O top bottom sides front and back Unit must have room for service 24 front 3 left 3 right 6 top and 0 back are minimum recommended service clearances A combustible door or removable panel is acceptable front clearance This water heater has been approved for closet installation and installation on combustible flooring Do not install this water heater directly on carpeting Use only Category IV vent systems WARNING INSTALLER Read all instructions in this manual before installing Perform steps in the order given USER This manual is for use only by a qualified heating installer service technician Have this heater serviced inspected by a qualified service technician annually FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE AND HAVE THIS HEATER SERVICED INSPECTED ANNUALLY CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH WARNING If the heater is exposed to the following do not operate until all corrective steps have been made by a qualified service technician 1 FIR
74. ional plumbing codes or any applicable standard which prevails The inlet cold and outlet hot ports are 74 on all models It is recommended to install a sweat shut off valve and a union in the cold inlet piping and hot outlet to ease future servicing If there is a back flow preventer or any type of a no return valve in the system you must install an additional tee here suitable for a potable hot water expansion tank In the hot outlet install a suitable adapter to match the copper tubing of the plumbing system A thermal trap or heat trap loop may be installed here to provide additional energy savings and prevent the thermal siphoning of domestic hot water G AUXILIARY CONNECTIONS The auxiliary connections are additional connections for a recirculation connection air handlers plate exchangers or other devices that supply hot water These connections must be installed in accordance with all local and national codes or any applicable standard that prevails Auxiliary connections are 34 on all models Never use dielectric unions or galvanized steel fittings Use only copper or brass fittings Sealant must be used on all connections WARNING Never connect auxiliary connections to any system that uses glycol or other solutions formulated for hydronic systems These auxiliary connections are to be used only in a potable water system Failure to follow this warning could result in serious injury or death H FILLING THE HEATER A
75. ipe 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 water heater not less than 1 4 per foot to allow condensate to drain from 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 heater to support any piping 14 A screened straight coupl
76. l The control module also provides low water protection by sensing the water level in the tank Some codes jurisdictions may require additional external controls NOTICE Installing the Optional High Output Cold Water Dip Tube For longer hot water draw remove the factory installed dip tube from the cold water inlet and replace with the Optional High Output Cold Water Dip Tube This can be done by hand WHL 001 REV 9 3 14 B SCALDING ADANGER 140 F Less than 5 seconds un 145 F Less than 3 seconds HOT 150 F About 1 1 2 seconds 155 F About 1 second 1 HUN Table 3 A This heater can deliver scalding water Be careful whenever using hot water to avoid scalding BURN 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 over 125 F can cause water temperature required by these appliances you may create the potential for scald injury severe burns instantly or death from scalds Children disabled and elderly are at highest To protect against injury you should install a mixing valve in the water system This valve will risk of being scalded reduce point of discharge temperature by mixing cold and hot water in branch supply lines See instruction manual before setting Such valves are available from your local plumbing supplier temperature at water heater Feel water b
77. l Temperature Sensor Ensure it is properly wired to the control and that there are no breaks cuts or other visible issues with the sensor wire Use an ohmmeter to check resistance on first Sensor B of the Dual Temperature Sensor Values should be close to those given in Table 14 Replace Dual Temperature Sensor if either Sensor B fails the resistance test A SENSOR Manually reset the water heater Observe water heater operation Check the Dual Temperature Sensor Ensure it is properly wired to the control and that there are no breaks cuts or other visible issues with the sensor wire Use an ohmmeter to check resistance on first Sensor A of the Dual Temperature Sensor Values should be close to those given in Table 14 Replace Dual Temperature Sensor if either Sensor A fails the resistance test was ell SENSOR Manually reset the water heater Observe water heater operation If fault code occurs again check for stable gas pressure check Ignitor cable connections Check Ignitor cable ground Replace cable Replace ignitor Table 18 Lockout Fault Codes NOTE If you replace a part to remedy a fault it is recommended that you cycle the unit at least three or four times to assure the fault has been resolved WHL 001 REV 9 3 14 53 WHL 001 Q 06 19 14 7500P 189 CONTROL BOARD LP GAS CAP 1 2 NPT WASHER NEUTRALIZER ADAPTER 1 2 NPT FEM X BARB z 36 37 z 2 2 1 23 24 25
78. ll a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above 5 2 Set the thermostat to lowest setting 6 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand GAS VALVE GAS VALVE OFF 10 11 12 Remove front cover Turn gas shutoff valve to off Handle will be across the piping do not force Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to next step Turn gas shutoff valve to Handle will be in line with piping Install Front Cover Turn on all electric power to appliance Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier TURN OFF GAS APPLIANCE NENNEN 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be
79. moval 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 heater and to a suitable drain If the heater condensate outlet is lower than the drain you must use a condensate removal If required by local authorities a condensate filter of lime crystals marble or phosphate chips will neutralize slightly acidic condensate The condensate line must remain unobstructed If allowed to freeze in the line or obstructed in any other manner condensate can exit from the water heater tee resulting in potential water damage to property When installing a condensate pump select one approved for use with condensing heaters and furnaces The condensate pump should have an overflow switch to prevent property damage from spillage Condensate from the heater will be slightly acidic pH from 3 2 to 4 5 Install a neutralizing filter if required by local codes CONDENSATE PUMP 3 4 PVC FITTINGS Figure 15 Condensate Piping NOTES 1 Condensate line must be pitched at least 74 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 2 PVC or CPVC pipe should be the only material used for c
80. nstructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all installation instructions for all Product Approval side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the installation LP 172 REV 02 16 06 WHL 001 REV 9 3 14 59 MAINTENANCE NOTES WHL 001 REV 9 3 14 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
81. nt termination assembly Doing so may result in product damage severe personal injury or death 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 water heater 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 heater 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 Part 5 of 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 1 Contaminant Table 2 INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE This heater requires fresh uncontaminated air for safe operation and must be installed in a mechanical room where there is adequate combustion and ventilating air NOTE To prevent combustion air contamination see Table 1 Contaminant Table Combustion air from the indoor space can be used if the sp
82. nt length of elbows tees and other fittings are listed in the Friction Loss Table Table 5 FRICTION LOSS EQUIVALENT IN PIPING AND FITTINGS FITTINGS OR PIPING 90 DEGREE ELBOW 45 DEGREE ELBOW COUPLING AIR INLET TEE STRAIGHT PIPE CONCENTRIC VENT KIT V500 2 VENT KIT V1000 3 VENT KIT V2000 4 VENT KIT Table 5 Friction loss for long radius elbow is 1 foot less NOTE Consult Polypropylene venting instructions for friction loss and pressure drop equivalents N A SSS Ss 1 1 Q90DEGREEELBOW 5 O 45DEGREE ELBOW 239 COUPLING 1 STRAIGHTPIPE 4 7 CONCENTRCVENTKT 2 9 O Ve002ZVNTKT 7 Vf003 VENTKT 1 2 V20004VENTKT b For example If the exhaust vent has two 90 elbows and 10 feet of PVC pipe we will calculate Exhaust Vent Equivalent Length 2x5 10 20 feet Further if the intake pipe has two 90 elbows one 45 elbow and 10 feet of PVC pipe the following calculation applies Intake Pipe Equivalent Length 2x5 3 10 23 feet Finally if a concentric vent kit is used we find Total Equivalent Length 20 23 3 46 feet The total equivalent length is 46 feet which is well below the maximum of 150 feet c The exhaust vent and intake pipe are intended to penetrate the same wall or roof
83. of the building d Effort should be made to keep a minimum difference in equivalent length between the exhaust vent and intake pipe 3 The minimum total equivalent length is 16 feet F LONGER VENT RUNS 1 The maximum total equivalent length can be extended by increasing the diameter of both the exhaust vent and intake pipes However the transitions should begin a minimum of 15 equivalent feet from the water heater a The maximum total equivalent length for increased diameter vent pipes is 200 feet b Transitions should always be made in vertical sections of pipe to prevent the condensate from pooling in the vent pipe VENT CONNECTION REDUCING COUPLING VENT TRANSITION 2 3 Table 6 Vent Run Transition c Transition from 2 to 3 pipe should be made at the water heater CAUTION Do not exceed the maximum lengths for vent pipes Excessive length could result in appliance shutdown and property damage WHL 001 REV 9 3 14 27 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 living 1 Use only solid PVC or CPVC pipe or a Polypropylene vent system approved for use with Category IV appliances FOAM CORE PIPING IS NOT APPROVED FOR EXHAUST VENT APPLICATIONS Foam core piping may be used on air inlet piping only 2 Remove all burrs and debris from joints and fittings 3 When using PVC or CPVC p
84. ondensate line Steel brass copper and other metals will be subject to corrosion or deterioration 3 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 4 Support of the condensate line may be necessary to avoid blockage of the condensate flow WARNING Power to the optional condensate pump is continuous When the water heater is powered off the condensate pump will remain on It is important to remember to turn off the condensate pump when powering down the water heater Failure to do so could result in property damage severe personal injury or death WHL 001 REV 9 3 14 SIDE VIEW NEUTRALIZER BODY HOSE BARB NEUTRALIZER CARTRIDGE REMOVE CONDENSATE HOSE BY UNSCREWING HOSE BARB FROM NEUTRALIZER CARTRIDGE BODY OF UNIT INSTALL THE NEW NEUTRALIZER CARTRIDGE BY SLIDING IT INTO THE GROOVES ON THE NEUTRALIZER BODY BE SURE IT IS PUSHED IN UNTIL IT TOUCHES BODY OF UNIT LP 44 U 05 17 13 36
85. operating dynamic mode at full output If an in line regulator is used it must be a minimum of 10 feet from the heater It is very important that the gas line is properly purged by the gas supplier or utility Failure to properly purge the lines or improper line sizing will result in ignition failure This problem is especially noticeable in NEW LP installations and also in empty tank situations This can also occur when a utility company shuts off service to an area to provide maintenance to their lines The gas valve must not be replaced with a conventional gas valve under any circumstances As an additional safety feature the gas valve in this water heater has a flanged connection to the swirl plate and blower C GAS VALVE PRESSURE TAP INLET OFFSET ADJUSTMENT CAUTION Do not remove or attempt to make any adjustmen to this screw without a COMBUSTION ANALYZER THROTTLE 77 NOTE If for any reason the throttle needs to be adjusted it is very important that a COMBUSTION ANALYZER be used to ensure safe and proper operation Turn the adjuster clockwise to increase counterclockwise to decrease gas supply PRESSURE TAP OUTLET Figure 21 Gas Valve LP 441 S 40 4 ty 1 u E 1 sy n 5 1 i f 7 i Do not operate heater if flood damaged Install vent system in accordance with local codes and manufacturers inst
86. ore When opening a hot water faucet in a system that has been out of use for a time keep all ignition sources electrical appliances open flame etc away from the faucet If hydrogen is present there will be a sound of air escaping as water begins to flow Allow the water to run for a few minutes to dissipate built up hydrogen from the system Failure to follow these instructions can result in property damage personal injury or death The water heater 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 heater Installer must also inform the owner that the lack of proper care and maintenance of the heater may result in a hazardous condition NOTICE It is extremely important that whenever work is performed on the plumbing system that either e The water heater is powered off or e The water heater is valved off and isolated from the plumbing system Failure to take these measures could result in a dry firing condition WARNING The water heater must be full of water and the system fully purged BEFORE powering
87. ough an Concentric Venting Through an Chase Venting Through an Existing Existing System Existing System 1 2 EXHAUST COMBUSTION AIR EXISTING ae VENT VENT N w SCREEN 12 MIN NTAKE EXHAUST INTAKE w SCREEN 3 eee CAP EXHAUST EXHAUST LP 325 LL LP 325 MM 2 LP 325 NN 03 15 12 03 15 12 07 22 13 Figures 12 1 12 2 Concentric Venting Through Existing System 12 3 Chase Venting Through an Existing System NOTE This drawing is meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes WHL 001 REV 9 3 14 33 3 INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE This heater requires fresh uncontaminated air for safe operation and must be installed in a mechanical room where there is adequate combustion and ventilating air NOTE To prevent combustion air contamination see Table 1 Contaminant Table on page 12 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 water heater input Never obstruct the supply of combustion air to the water heater If the water heater is installed in areas where indoor air is contaminated see Figure 13 it is imperative that the water heater be installed as direct vent so that all com
88. 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 A CAUTION The water heater has wire function labels on all internal wiring Observe the position of each wire before removing it Wiring errors may cause improper and dangerous operation Verify proper operation after servicing CONTROL BOARD BLOCKING ERRORS CODE SHORT DESCRIPTION LONG DESCRIPTION CORRECTIVE ACTION 1 Is the tank full of water This error code will appear if the tank is dry fired 2 Measure actual Flue temperature 2 3 Use ohmmeter to check resistance on flue temperature sensor Flue Temperature Too High This is first an E07 ng eriei 4 Replace sensor if it does not pass the resistance test cod 5 If Flue temperature does not return to normal within 15 minutes i E07 shall become an F07 fault code 6 Error will clear automatically if Flue temperature returns to normal within 15 minutes Lockout has been exhausted power supply to the unit off and back on to clear out the error code The main power supply is too low 1 When main power is brought back to a normal state over 75 4 Low Main Power Supply below 75 VAC to properly water heater will resume normal operation power the water heater 2 Measure AC Mains 1 Check the O
89. performed 3 Remove Front Cover 4 Turn gas shutoff valve to off Handle will be across the piping Do not force 5 Install Front Cover LP 175 Rev 4 3 11 08 WHL 001 REV 9 3 14 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 indicates an imminently hazardous situation which if not avoided will result in death or serious injury 4 WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION 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 FOREWORD This manual is intended to be used in conjunction with other literature provided with the High Efficiency Water Heater 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 H
90. rage to ensure the burner and ignition devices are well off the floor WHL 001 REV 9 3 14 e When raising the heater fully support the entire bottom of the water heater e Locate or protect the heater so it cannot be damaged by a moving vehicle E EXHAUST VENT AND INTAKE PIPE The heater is rated ANSI Z21 10 3 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 Venting Part 5 in this manual are the lone venting options approved for this water heater Failure to vent the water heater in accordance with the provided venting instructions will void the warranty Failure to vent the water heater properly will result in serious personal injury or death WARNING Do not attempt to vent this water heater 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 WARNING Vents must be properly supported Heater exhaust and intake connections are not designed to carry heavy weight Vent support brackets must be within 1 of the heater and the balance at 4 intervals Heater must be readily accessible for visual inspection for the first 3 from the heater WARNING The exhaust discharged by this water heater may be very hot Avoid touching or other direct contact with the exhaust gases or the ve
91. rature Protection je Incorrect Fan Speed EN Vent Temperature Too High Flame Circuit Failure Valve Feedback Error F The control senses no flame after three ignition attempts The control senses a flame signal when there is no heat demand The control shuts down the water heater after it has met surpassed the high temperature limit The control detects incorrect fan speed The vent temperature has met surpassed the maximum limit This is first an E07 blocking error code If vent temperature has not returned to normal levels within 15 minutes this becomes an F07 lockout fault code The control detects an incorrect flame level The gas valve does not respond to controller demands 59 19 The EEPROM check fails EEPROM 1 EEPROM Integrity Lockout data is corrupted 2 3 Is the gas turned to the water heater Manually reset the water heater Observe water heater operation If fault code occurs again Check for stable gas pressure Check Ignitor cable connections Check Ignitor cable gound Replace cable Check spark gap between spark electrode and burner Replace ignitor Visually check for flame through sight glass Manually reset the water heater Observe water heater operation If fault code occurs again Check Ignitor cable connections Check Ignitor cable gound Replace cable Replace ignitor Manually reset th
92. replaced Never use an open flame match lighter etc to check gas connections LP 441 O 4 _ 04 03 13 Figure 20 Gas Connection WARNING UL recognized fuel gas detectors are recommended in all enclosed propane and natural gas applications where there is a potential for an explosive mixture of fuel gas to accumulate The installation of these detectors should be made in accordance with the detector manufacturer s recommendations and or local laws Failure to install fuel gas detectors in these applications could result in fire explosion property damage severe personal injury or death A GAS PIPING Run the gas supply line in accordance with all applicable codes Locate and install manual shutoff valves in accordance with local and state requirements 4 WARNING Support gas supply piping with hangers not by the heater or its accessories The heater gas valve and blower will not support the weight of the piping Make sure the gas piping is protected from physical damage and freezing where required Failure to follow these instructions could result in gas leakage and result in fire explosion property damage severe personal injury or death WARNING Do not use Teflon tape on gas line pipe thread Use a pipe compound rated for use with natural and propane gases Apply sparingly on male pipe ends leaving the two end threads bare Failure to follow these instructions could result in gas leakage and result in
93. require a condensate neutralizer to neutralize the condensate It is also very important not to expose the condensate line to freezing temperatures or any type of blockage Plastic tubing must be the only material used for the condensate line Steel brass copper or other materials will be subject to corrosion or deterioration A second vent may be necessary to prevent condensate line vacuum lock on a long horizontal run Also an increase in pipe size may be necessary to allow condensate to drain properly Support of the condensation line may be necessary to avoid blockage of the condensate flow Spark Ignition The burner flame is ignited by applying high voltage to the system spark electrode This causes a spark from electrode to ground FETON Water temperature over 125 degrees can cause severe burns instantly or death from scalds Children disabled and elderly are LEX E at highest risk of being scalded See instruction manual before 4 Qm _ setting temperature at water heater Feel water before bathing or TA TA showering Temperature limiting valves are available See chart TA below showing temperature burn rate C OPTIONAL EQUIPMENT Below is a list of optional equipment available from Westinghouse 2 PVC Concentric Vent Kit Part KGAVT0501CVT PVC Concentric Vent Kit Part KGAVT0601CVT Outdoor Sensor Part 7250P 319 e Condensate Neutralizer Replacement Part 7700P 026 WHL 001 REV 9 3 1
94. required by local codes In Massachusetts you must install a vacuum relief valve per 248 CMR 7 Always shut off power to the water heater or isolate the heater from the system if ANY plumbing work is to be done Running the water heater without water will result in dry firing 4 DANGER An ASSE 1017 thermostatic mixing valve MUST be installed when using outdoor reset Failure to do so could result in substantial property damage serious injury or death WARNING The piping will not support the weight of the water heater circulator pump Refer to the pump manufacturer s installation instructions to properly support the circulator pump Failure to comply with these instructions could result in substantial property damage severe personal injury or death WHL 001 REV 9 3 14 21 r DRAIN VALVE j BALL VALVE BACKFLOW PREVENTER Cale AUXILARY CONNECTION EXPANSION TANK WHL 001 E 06 18 14 Figure 5 High Efficiency Water Heater with Air Handler on Side NOTES 1 Minimum pipe size should match unit connection size Upsize pipe accordingly if greater flow is required 2 A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold water inlet 3 Gas line must be rated to the unit maximum input capacity Unit must have 10 feet of pipe after gas regulator 4 All circulators should have an integral flow check
95. substantial property damage severe personal injury or death Breathing carbon moncxide can cause brain damage or death Always read and understand instruction manual LP 304 4 28 09 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 2223 1 54 CAN CGA B149 and or applicable provisions of local building codes 3 This water heater must be vented with materials components and systems listed and approved for Category IV appliances Exhaust and intake are to be piped separately This heater cannot share a common exhaust or intake with multiple appliances Failure to follow this instruction will result in substantial property damage severe personal injury or death NOTE To avoid contamination often contained in indoor air it is best to pipe all intake combustion air directly to the outdoors NOTE If exhaust vent pipe system passes through an unheated space such as an alcove or attic the space must be heated or the pipe must be insulated The insulation must have an R value sufficient to prevent freezing of the condensate WARNING Improper seating of vent pipe gaskets can cause eventual gasket failure and exhaust gas leakage Ensure the exhaust vent pipe is
96. supplies The hot water expansion tank must be listed for potable water use The expansion tank should be located on the cold inlet piping close to the water heater EXPANSION TANK AND MAKE UP WATER 1 Ensure that the expansion tank is sized to correctly handle heater and system water volume and temperature CAUTION Undersized expansion tanks cause system water to be lost from the relief valve causing make up water to be added Eventual heater 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 the Heater Piping Details or following recognized design methods See expansion tank manufacturer s instructions for details CAUTION The expansion tank must be suitable for hot potable water F WATER PIPING CAUTION Never use dielectric unions or galvanized steel fittings on any domestic water or auxiliary connections Use only copper or brass fittings Thread sealant must be used on all connections Do not apply heat to the water heater connections If sweat connections are used sweat tubing to the adapter before fitting adapter to the water connections on the heater Any heat applied to the water heater connections will permanently damage the dip tube and or heat traps Damages due to improper installation practices ARE NOT covered by warranty The domestic water connections must be installed in accordance to all local and nat
97. t be full of water and the system fully purged BEFORE powering the water heater Performing any work in the plumbing system without either powering off the water heater or isolating the water heater through the use of shut off valves could result a condition referred to as dry firing Dry firing the water heater will damage the heat exchanger and could result in property damage serious personal injury or death Such damages ARE NOT covered by water heater warranty WHL 001 REV 9 3 14 20 J PIPING DIAGRAMS SHOWER SINK SHUT OFF VALVE CIRCULATOR PUMP W CHECK VALVE AUXILIARY LINE EXPANSION TANK T amp P LINE WHL 001 F 06 18 14 Figure 4 High Efficiency Water Heater with Recirculation Line and Thermostatic Mixing Valve Piping NOTES 1 Minimum pipe size should match unit connection size Upsize pipe accordingly if greater flow is required 2 A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold water inlet 3 Gas line must be rated to the unit maximum input capacity Unit must have 10 feet of pipe after gas regulator 4 All circulators should have an integral flow check 5 Drains and check valve between unit and storage tank will assist in purging air from system 6 This drawing is meant to demonstrate system piping only The installer is responsible for all equipment and detailing
98. the installer must ensure that the existing venting system is clean and free from particulate contamination that could damage the heater Failure to do so could result in property damage and heater 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 HTP 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 5 for proper minimum vent sizing Use only the approved venting materials specified in Table 4 for piping the system All instructions listed in Part 5 Venting apply See Figures 12 1 and 12 2 for venting demonstrations 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 severe personal injury or death CHASE VENTING THROUGH AN EXISTING SYSTEM When venting as a chase follow all instructions included in Part 5 Venting of this manual as well as the previous Concentric Venting section See Figure 12 3 for chase venting demonstration Concentric Venting Thr
99. the water heater Performing any work in the plumbing system without either powering off the water heater or isolating the water heater through the use of shut off valves could result in a condition referred to as dry firing Dry firing the water heater will damage the heat exchanger and could result in property damage serious personal injury or death Such damages ARE NOT covered by water heater warranty INSPECTION ACTIVITIES DATE LAST COMPLETED Check heater and system piping for any sign of leakage make sure they are properly supported Vent Check condition of all vent pipes and joints Ensure the blockages mu aurem TT sure all pipes are properly supported SYSTEM Visual Dov full visual inspection of all system components Functional Test all functions of the system Heat Safeties y Temperatures 7 Verify safe settings on heater or Anti Scald Valve 7 Temperatures 7 Verify programmed temperature settings d 1 ELECTRICAL Connections Check wire connections Make sure they are tight Boe pada detector batteries if necessary Circuit Breakers Check to see that the circuit breaker is clearly labeled 1 1 eo eee CHAMBER BURNER Combustion Chamber Check burner tube and combustion chamber coils Clean according to maintenance section of manual Vacuum combustion chamber Replace any gaskets th
100. tion ine Canada PP CPVC and PVC venting must be ULC S636 Certified IPEX is an approved Exhaust vent or Intake CPVC schedule 40 80 ANSI ASTM F441 manufacturer in Canada supplying vent pipe and fittings Polypropylene ULCS636 material listed to ULC S636 Stainless Steel AL29 4C Certified for Category IV and Certified for Category IV and direct vent direct vent appliance venting appliance venting ANSI ASTM D2564 Pipe cement primer ANSI ASTM F493 IPEX System 636 Cements 8 Primers Table 4 e The exhaust and intake components installed with this heater must be used for near heater piping BEFORE transitioning to the approved materials listed above DO NOT REMOVE these installed components Doing so WILL VOID heater warranty PVC CPVC pipe and fittings of the same diameter are considered interchangeable DO NOT use Foam Core Pipe in any portion of the exhaust piping from this water heater 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 heater vent connection and at the termination when using a PVC termination kit DO NOT mix AL 29 4C piping from different manufacturers unless using adapters specifically designed for the purpose by the manufacturer A double wall vent may be used when using stainless steel vent material in a freezing climate PVC DWYV for air intake applications ONLY Contact the venting material manufacturer if ther
101. tions return to normal Installer Mode On Off Off NOTE is a high temperature warning and appears display if setpoint actual water temperature is above 125 F Water temperature over 125 F can instantly cause severe burns or death from scalds Children disabled and elderly are at the highest risk of being scalded Table 10 Water Heater Modes of Operation B BASIC CONTROL FUNCTIONS There are a number of parameters accessible from the water heater main screen These parameters are especially useful for the main user of the water heater NOTE These parameters ARE NOT ACCESSIBLE when the control is in a blocking or lockout state 1 TURNING WATER HEATER ON OFF Press to turn the water heater on off 2 RESETTING THE WATER HEATER Press eset to clear a fault code lockout and resume water heater operation 3 PUTTING THE WATER HEATER IN ECO MODE Press CA to put the water heater into ECO Mode Press CA to resume normal operation WHL 001 REV 9 3 14 43 4 CHANGING USER SETPOINT Press either or once to change the User Setpoint The normal operation screen will clear and be replaced by a flashing number This is the User Setpoint Press qa to decrease or to increase the setpoint The default setpoint is 120 F The setpoint range is 70 160 F After choosing the setpoint wait five seconds The screen will return to normal operation and the setpoint will be stored FETCH Water t
102. uctions to properly support the circulator pump Failure to comply with these instructions could result in substantial property damage severe personal injury or death WHL 001 REV 9 3 14 22 BALL VALVE i CIRCULATOR BACKFLOW i m amp PUMP w CHECK PREVENTER GAS pom M lie TANK LINE aoe CIRCULATOR PUMP w CHECK WHL 001 07 01 14 Figure 6 High Efficiency Water Heater with Air Handler on Side NOTES 1 Minimum pipe size should match unit connection size Upsize pipe accordingly if greater flow is required 2 A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold water inlet 3 Gas line must be rated to the unit maximum input capacity Unit must have 10 feet of pipe after gas regulator 4 All circulators should have an integral flow check 5 Check with air handler manufacturer for proper sizing 6 This drawing is meant to demonstrate system piping only The installer is responsible for all equipment and detailing required by local codes In Massachusetts you must install a vacuum relief valve per 248 CMR With air handlers outdoor reset is available with an outdoor sensor See Part 8 Section D 7 Always shut off power to the water heater or isolate the heater from the system if ANY plumbing work is to be done Running the water heater without
103. um inlet pressure of less than 14 water column 350 mm gt pound pressure 3 5 kPa and a minimum of 3 5 water column The entire piping system gas meter and regulator must be sized p properly to prevent pressure drop greater than 0 5 WC as stated in the GAS LINE National Fuel Gas Code This information is listed on the rating plate It is very important that you are connected to the type of gas as noted on the rating plate LP for liquefied petroleum propane gas or Nat for natural or city gas All gas connections must be approved by the local gas supplier or utility in addition to the governing authority prior to turning the gas supply on Do not remove the adaptor in Figure 20 It is mandatory that this fitting is used for connection to a field fabricated drip leg per the National Fuel Gas Code You must ensure that the entire gas line to the connection at the water heater is no smaller than 72 DRIP LEG Once all inspections have been performed the piping must be leak tested If the leak test requirement is a higher test pressure than the maximum gas inlet pressure you must isolate the heater from the gas line to continue leak testing To do this you must turn off the factory and field installed gas cocks This will minimize the possibility of damaging the gas valve Failure to do so may damage the gas valve In the event the gas valve is exposed to a pressure greater than 12 PSI 14 water column the gas valve must be
104. utdoor Temperature Sensor Ensure it is properly The Outdoor Temperature wired and connected and that there are no breaks cuts or other E39 Outdoor Temperature Sensor Sensor is out of normal operating visible issues with the sensor wire Error When Enabled range meaning the sensor is 2 Use an ohmmeter to check resistance on the outdoor temperature either open or shorted sensor 3 Replace Outdoor Temperature Sensor if it fails the resistance test 1 Check the Flue Temperature Sensor Ensure it is properly wired to The Flue Temperature Sensor is the control and that there are no breaks cuts or other visible issues Flue Temperature Sensor out of normal operating range with the sensor wire Error meaning the sensor is either 2 Use an ohmmeter to check resistance on flue temperature sensor open or shorted 3 Replace Flue Temperature Sensor if it does not pass the resistance test 1 Check the Flue termination Ensure there are no blockages or obstructions in the Flue E64 Blocked Flue 98058510555 2 Check APS switch Ensure it is properly wired to the control and Flue condition that there are no breaks cuts or other visible issues with the wiring 3 Replace APS switch Table 17 Blocking Error Codes WHL 001 REV 9 3 14 o1 CONTROL BOARD LOCKOUT FAULTS CODE SHORT DESCRIPTION LONG DESCRIPTION CORRECTIVE ACTION Ignition Lockout Indication False Flame Indication 2 3 KE E High Limit Tempe
105. ze if exposed to sustained temperatures below 32 F Precautions should be taken to protect the condensate trap and drain lines from sustained freezing conditions Failure to take precautions could result in property damage severe personal injury or death CAUTION The service life of the heater 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 heater components In these environments heaters must not be installed using direct vent systems which draw outdoor air for combustion Such heaters must be installed using room air for combustion Indoor air will have a much lower relative humidity and hence potential corrosion will be minimized WARNING This heater is certified for indoor installations only Do not install the heater outdoors Failure to install this heater indoors could result in substantial property damage severe personal injury or death 2 Check for nearby connections to e System water piping Venting connections Gas supply piping Electrical power Condensate drain 3 Check area around heater Remove any combustible materials gasoline and other flammable liquids WARNING Failure to keep heater area clear and free

Westinghouse WGR080LP076 Instructions / Assembly

Contents

Download Pdf Manuals

Related Search

Related Contents