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Westinghouse WGC055NG100 Installation Manual

1. MULTI FIT WATER HEATER MODEL B D E E G H K L M 80 GALLON MODELS 27 55 46 7 1 4 17 18 1 4 8 3 38 1 4 7 1 4 9 1 2 100 GALLON MODELS 27 63 54 7 1 4 17 181 4 8 3 38 1 4 7 1 4 9 1 2 MULTI FIT WATER HEATER SPECIFICATION AIR INTAKE INLET GAS SYSTEM sHiPPING MAX MODEL INPUT MODULATION EXHAUST VENT OUTLET LINE RELIEF TEMPERATURE SIZE SIZE CONN CONN PIPE size WEIGHT LIMIT 80 GALLON 35 000 130 000 27 1 1 2 1 3 4 3 4 235 LBS 160 MODELS 40 000 199 000 3 1 1 2 NPT 1 FNPT 3 4 3 4 235 LBS 160 100 GALLON 35 000 130 000 2 1 1 2 NPT 1 3 4 3 4 405 LBS 160 MODELS 40 000 199 000 3 1 1 2 NPT 1 FNPT 3 4 3 4 405 LBS 160 ALL DIMENSIONS ARE APPROXIMATE LP DENOTES PROPANE GAS LP 179 B 08 25 14 Figure 4 Phoenix Multi Fit Specifications and Dimensions 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 sid
2. Rated Input x 9 Temp Rise F x 500 GPM x60 PART 4 HEATER PIPING 4 WARNING Failure to follow the instructions in this section WILL VOID the warranty and may result in property damage serious injury or death CAUTION 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 CAUTION 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 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 CAUTION The heater control module uses temperature sensors to provide both high limit protection and modulating temperature control The control module also provides low water protection by sensing the water level in the tank Some codes jurisdictions may require additional external controls WHL 019 REV 12 17 14 17 B SCALDING APPROXIMATE TIME TEMPERATURE RELATIONSHIPS IN SCALDS A D A G E
3. and or applicable provisions of local building codes local codes and manufacturers installation instructions Do not obstruct heater air 3 This water heater must be vented with materials components and exhaust Support all vent piping per systems listed and approved for Category IV appliances SaaS Seen Do not place chemical vapor emitting products near unit Py According to NFPA 720 carbon monoxide 2 detectors should be installed outside each sleeping area Exhaust vent and intake pipes are to be piped separately This heater Never operate the heater unless it is outdoors cannot share a common exhaust or intake with multiple appliances Failure vented to the to follow this instruction will result in substantial property damage severe li eem ee 1O MEO ice trapped in a section of vent and personal injury or death therefore reduce the open foes sectional area of the vent NOTE To avoid contamination often contained in indoor air itis best to pipe ip Bui Enel 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 ga
4. LP 179 L 08 25 10 Figure 5 Water Heater With Air Handler 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 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
5. 38 CIRCULATOR 2 5 4 VALVE ov HOT HOT WATER WATER OUTLET OUTLET LP 179 S 10 29 14 Figure 12 Reverse Manifold and Piping Diagram for Multi Fit Model 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 WHL 019 REV 12 17 14 27 PART 5 VENTING COMBUSTION AIR AND CONDENSATE REMOVAL A DANGER The heater must be vented as detailed in this Venting S
6. COLD WATER INLET AQUASTAT CONTROL SPRING CHECK LP 179 V VALVE DRAIN VALVE 10 17 14 Figure 11 Multi Fit Model with Storage Tank and Thermostatic Mixing Valve 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 required by local codes In Massachusetts you must install a vacuum relief valve per 248 CMR 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 019 12 17 14 SHUT OFF BALL VALVE BACKFLOW PREVENTER EXPANSION TANK 26 COLD WATER COLD WATER
7. A 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 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 INSPECTION ACTIVITIES DATE LAST COMPLETED PIPING 1 YEAR 27 YEAR 3 YEAR 4 YEAR Near heater piping 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 vent piping terminations are free of obstructions and blockages Gas Check Gas piping test for leaks and signs of aging Make sure all pipes are properly supported SYSTEM Visual Do a fu
8. If the burner is 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 40 to 90 seconds 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 problem If a technician is not available
9. 59 15 Damages malfunctions or failures caused by operating the water heater with an empty or partially empty tank dry firing or failures caused by operating the water heater when it is not supplied with potable water free to circulate at all times 16 Failure of the heater due to the accumulation of solid materials and lime deposits 17 Any damage or failure resulting from improper water chemistry WATER CHEMISTRY REQUIREMENTS Sodium less than 20mGL Water pH between 6 0 and 8 0 Hardness less than 7 grains Chlorine concentration less than 100 ppm 18 Any damages malfunctions or failures resulting from the use of dielectric unions 19 Components of the water heater that are not defective but must be replaced during the warranty period as a result of reasonable wear and tear 20 Damages malfunctions or failures caused by subjecting the tank to pressures or firing rates greater than those shown on the rating label 21 Damages malfunctions or failures resulting from the use of any attachment s not supplied by Westinghouse 22 Water heaters installed outside the fifty states and the District of Columbia of the United States of America and Canada 23 Water heaters moved from the original installation location 24 Water heaters that have had their rating labels removed PROCEDURES FOR WARRANTY SERVICE REQUESTS Any claim for warranty assistance must be made promptly Determine if the water heater is in warranty tha
10. and 200 maximum total equivalent feet for 3 transitioning to 4 pipe including the minimum 15 total equivalent feet necessary for transition b Transitions should always be made in vertical sections of pipe to prevent the condensate from pooling in the vent pipe kBTU MAXIMUM TOTAL EQUIVALENT LENGTH AT REDUCING MAXIMUM TOTAL EQUIVALENT LENGTH AT STANDARD VENT CONNECTION COUPLING MAXIMUM INCREASED VENT SIZE 100 A 25221 130 85 2 3 X2 125 at 3 160 ae 199 200 3 4X3 200 at 4 Table 6 Vent Sizing Diameter and Length c If the transition occurs at a distance greater than 15 equivalent feet from the water appliance the maximum equivalent length will be reduced WHL 019 12 17 14 31 DA R Total maximum equivalent length of increased diameter exhaust vent and intake pipe must not exceed the lengths defined in this manual 125 maximum total equivalent feet for 2 increased to 3 diameter vent pipe 200 maximum total equivalent feet for 3 increased to 4 diameter vent pipe Failure to keep the total equivalent length below the maximum lengths determined in this manual will result in faulty appliance operation substantial property damage serious personal injury or death TRANSITION POINT FT FROM WATER APPLIANCE TEL OF OVERSIZED VENT PIPE FT MAXIMUM TEL OF ALL VENT PIPE FT 15 95 125 20 77 1 2 117 1 2 25
11. Gas Fired e STS Commercial Water Heater INSTALLATION G al START UP 4 s MAINTENANCE PARTS WGC WGCM Water Heaters 100 199 kBTU 55 119 Gallon Capacities M denotes Multi Fit Model NG denotes natural gas LP denotes propane gas LEAD FREE Safe Drinking Water Act SDWA Section 1417 ENERGY STAR ULTRA Low NOx AHD CERTIFIED us Emissions www ahridirectory org ISTE SCAQMD Rule 1146 2 Py N 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 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 019 REV 12 17 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
12. accordance with local codes and manufacturers installation instructions Do not obstruct heater air intake or exhaust Support all vent piping per manufacturers installation instructions Do not pes chemical vapor emitting prod 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 s to make ree pr Mg trap section of vent pipe and therefore the area of th Breathing carbon monoxide can cause brain damage or death Always read and understand Instruction manual LP 304 4 28 09 Figure 2 CO Warning Label 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 Z223 1 When resizing any portion of the common venting system the system should approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code ANSI Z 223 1 WHL 019 REV 12 17 14 13 H WATER CHEMISTRY CAUTION Chemical imbalance of the water supply may affect efficiency and cause severe damage to the wa
13. depressing the button once will remove the lockout state so additional trials for ignition can be performed The unit will try to re light once every 6 minutes PART 10 TROUBLESHOOTING A ERROR CODE 48 RESISTANCE TABLE FOR SUPPLY TEMPERATURE SENSOR HIGH LOW TEMP RESISTANCE SENSOR ohms TEMP F 32 32550 41 25340 50 19870 59 15700 68 12490 77 10000 86 8059 95 6535 104 5330 113 4372 122 3605 131 2989 140 2490 149 2084 158 1753 167 1481 176 1256 185 1070 194 915 202 786 212 667 Table 13 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 These following will help the installer correct the problem before going into a lock out condition which will require a manual reset 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 14 3 In the case of TRI and this error if uncorrected will go into a fault condition as described in Paragraph C LOCKOUT 1 When a fault condition occurs the controller will illuminate the red fault indication light and display a fault code in the format Example on the display module
14. 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 I Provide 4 feet horizontal clearance from electrical meters gas meters gas regulators relief equipment exhaust 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 8 m NOTE This does not apply to the combustion air intake of a direct vent appliance K When v
15. uS Sa RAS RR isda Edaina da Cariddi eaan 7 IN THE BOX dE 7 B HOW THE HEATEFCOPERATES 2 bh ette ee b tee e e a a 7 C OPTIONAL EQUIPMENT eb o Rede eei Lec Se tei ie et a on Ee E eas 8 PART 3 PREPARE WATER HEATER 1 111 8 BEFORE LOGATING THE HEATER notet dte tete e LU ER nee i LEE HP et dd 9 M s 9 CLEARANCES FOR SERVICE 5 2 10 D RESIDENTIAL GARAGE 4444440000000000 cae 10 Sa tied Slee 10 1 DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE 11 2 INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED 6 11 F PREVENT COMBUSTION AIR 11 REMOVING A HEATER FROM COMMON VENT 5 5 12 te n Doe ees ee cis c re 13 PART 4 HEATER PIPING ci cina onm kn icc nnnc imr LR SR T X E n E LR EX ER RT RE UR ER UNS URNA ROG aA E 16 A GENERAL PIPING 2 16 B SCALDING eit rendre cett t tee
16. 12 17 14 37 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 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 19 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 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 s
17. 400 370 350 320 305 275 250 225 210 1 000 1 1 610 1 600 1 100 890 760 670 610 560 530 490 460 350 320 Table 10 Source ANSI 2223 1 It is recommended that a soapy solution be used to detect leaks Bubbles will appear on the pipe to indicate 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 operating dynamic mode at full output WHL 019 REV 12 17 14 44 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 und
18. GREATER PART 0501 CVT 2 cube KGAV0601CVT 3 VENT KIT PART 500 2 V1000 3 2000 4 EXHAUST MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER TYP NOTE EXTENDED VENT RUNS WHEN LP 505 A TRANSITIONING TO A LARGER DIAMETER 07 30 14 MUST ALWAYS TAKE PLACE IN A VERTICAL POSITION TO PREVENT CONDENSATE BLOCKAGE LP 505 C 11 24 14 SIDEWALL VENTING WITH CONCENTRIC VENT KIT IMPORTANT INTAKE LEG MUST BE FACING UP EXHAUST CONCENTRIC VENT KIT PART 5 2 INTAKE KGAVO0601CVT 3 MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER TYP Figure 15 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
19. R 120 F More than 5 minutes 125 F 1 to 2 minutes 130 F About 30 seconds 135 F About 10 seconds 140 F Less than 5 seconds 145 F Less than 3 seconds 150 F About 1 seconds 155 F About 1 second Table 3 This heater can deliver scalding water Be careful whenever using hot water to avoid scalding injury Certain appliances such as dishwashers and automatic clothes washers may require increased water temperature By setting the thermostat on this heater to obtain the increased water temperature required by these appliances you may create the potential for scald injury fat ics Water temperature over 125 F can cause To protect against injury you should install a mixing valve in the water system This severe burns instantly or death from scalds valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines Such valves are available from your local plumbing supplier Children disabled and elderly are at highest risk of being scalded Table 3 details the relationship of water temperature and time with regard to scald See instruction manual before setting injury and may be used as a guide in determining the safest water temperature for temperature at water heater your applications Feel water before bathing or showering Temperature limiting valves are available see manual C TEMPERATURE AND PRESSURE RELIEF VALVE A WARNING To avoid water damag
20. S636 Certified for Category IV and Certified for Category IV and direct vent direct vent appliance venting appliance venting PVC ANSI ASTM D2564 Pipe cement primer CPVG ANSI ASTM F493 IPEX System 636 Cements amp Primers DA R e 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 an PVC termination kit DO NOT mix AL 29 4C piping from different manufacturers unless using adapters specifically designed for the purpose by the manufacturer e PVC DWV for air intake applications ONLY Failure to follow these directions will result in substantial property damage severe personal injury or death Table 4 Approved Materials for Exhaust Vent and Intake Pipe 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 materi
21. 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 926 CONTROL BOARD ERROR CODES CODE DESCRIPTION DURATION CORRECTIVE ACTION Heater combustion air fan 1 Check the combustion air fan wiring speed less than 70 of 60 Sec 2 Replace the combustion air fan expected 3 Replace the control board Heater combustion air fan 1 Check the combustion air fan wiring az speed is more than 130 of 60 Sec 2 Replace the combustion air fan expected 3 Replace the control board 1 Be sure all air is bled from system Water ven Tankis ow 2 Inspect low level switch and wiring for damage and repair if necessary Blocked Vent Pressure Switch 1 Check the flue vent to be sure it is not blocked or damaged FLU open Condensate cup Full Until Corrected 2 Check the blocked vent pressure switch operation by applying a jumper Condensate Cup not present If the switch is not functioning properly replace it 1 Check line voltage Must be between 100 128 volts 2 If available connect a PC and using Westinghouse service software check the 24v supply display in the lower left corner of the screen The number displayed must be greater than 128 and should be greater than 250 Use this as a troubleshooting guide as you follow the steps below 3 Remo
22. VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE WHAT TO DO IF YOU SMELL GAS e Do nottry to light any appliance e Do not touch any electrical switch e Do not use any phone in your building e Immediately call your gas supplier from neighbor s phone Follow the gas supplier s instructions e f 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 If you cannot reach your gas supplier call the fire with an ignition device which automatically lights the department burner Do not try to light the burner by hand C Use only your hand to turn the gas control knob B BEFORE OPERATING smell all around the appliance Never use tools If the handle will not turn by hand area for gas Be sure to smell next to the floor don t try to repair it call a qualified service technician because some gas is heavier than air and will settle on Force or attempted repair may result in a fire or the floor explosion WHAT TO DO IF YOU SMELL GAS D Do not use this appliance if any part has been under water Immediately call a qualified service technician Do not try to
23. WATER HEATER AND SANITIZER BOOSTER DIMENSIONS euowewacm Jas 5 ss as se gt sve _ 2s rz sae ir wer rre sue seve on ws ar ze cue are heor s jer 2r WATER HEATER SPECIFICATIONS AIRINTAKE INLET GAS SYSTEM MAX INPUT MODULATION EXHAUST VENT OUTLET AT UNE RELER gt TEMPERATURE 7 we we 3 onon moons 9810 38000 190 7 rwr rmer we we vsus i okBTU 40000 16000 37 wrer 3e 175145 199kBTU 40000 199000 weet 3 4 3 4 175485 Coss ssoem woow 7 we we so Galton moos 13987 mom 7 ruzwe rer ae we meus Fus 0090 19000 s ruzer rrer we we 3 __ 199kBTU 40000 19000 37 uznet 3 6 3 6 235185 1600 35000 10000 7 wwzwr rmer we we esus 3 mones 139870 3502 109 z rvzwr rer se c Feu 199k8TU 40000 199 000 _ 3 2 3 4 3 4 405085 160 Figure 3 ALL DIMENSIONS ARE APPROXIMATE WHL 019 REV 12 17 14 15
24. 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 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 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 20 p 38 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 open
25. 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 NOTE 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 TWO PIPE ROOF VENTING WITH TEE INTAKE INSERT INLET EXHAUST TWO PIPE SIDEWALL VENTING WITH TEE INTAKE AND COUPLING EXHAUST SCREEN PROVIDED NON AND COUPLING EXHAUST STRAIGHT COUPLING s INSERT INLET EXHAUST SCREENS PROVIDED INTO EACH END OF TEE E INSERT INLET EXHAUST EX
26. clear and free of combustible materials liquids and vapors can result in substantial property damage severe personal injury or death 4 Gas control system components must be protected from dripping water during operation and service 5 If the heater is to replace an existing heater check for and correct any existing system problems such as e System leaks e Location that could cause the system and heater to freeze and leak Incorrectly sized 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 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 WHL 019 REV 12 17 14 10 CLEARANCES FOR SERVICE ACCESS ua M n o 12 MIN 12 MIN LEARANCE CLEARANCE FRONT VIEW LP 179 W DIAMETER OF WATER HEATER DEBE PLUS 27 MINIMUM TOP VIEW LP 179 T CLEARANCE Figure 1 Minimum Service Clearances 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 comb
27. 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 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 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 019 REV 12 17 14 14
28. gt GAS VALVE CABLE 926 CONTROL CONDENSATE CONNECTION J5 4 J5 5 o 45 6 LP 179 BB 11 18 10 Figure 23 Wiring Diagram WHL 019 REV 12 17 14 41 CON OPEN OPEN OPEN BLK VENT PRES SWITCH OPEN OPEN BOTTOM TEMP THERMISTOR TOP TEMP THERMISTOR OUTDOOR SENSOR COMBUSTION BLOWER COMBUSTION BLOWER ECO WATER ECO FLUE BLK VENT PRES SWITCH LWCO BLUE YELLOW LT GREEN BLUE OPEN OPEN COMBUSTION BLOWER hot COMBUSTION BLOWER neutral WHITE OPEN OPEN OPEN OPEN OPEN LINE VOLTAGE NEUTRAL OPEN GROUND BUS FLAME RECTIFICATION PROBE WHITE COMB BLOWER GROUND COMB BLOWER GROUND FLAME RECTIFICATION PROBE PHOENIX TROL BOARD YELLOW BLUE LT GREEN RED 42 TOP TEMP THERMISTOR BOTTOM TEMP THERMISTOR OPEN OPEN ECO FLUE OPEN OPEN OPEN OUTDOOR SENSOR COMBUSTION BLOWER COMBUSTION BLOWER ECO WATER GAS VALVE GAS VALVE OPEN UTILITY GROUND GROUND BUS EXTERNAL 10 PIN CONNECTOR RED LOW WATER CUT OFF ECO FLUE ECO WATER BOTTOM TEMP THERMISTOR TOP TEMP THERMISTOR YELLOW Figure 24 LP 179 L OPEN ECO FLUE ECO WATER BOTTOM TEMP SENSOR TOP TEMP SENSOR WHL 019 REV 12 17 14 PART 7 GAS CONNECTIONS A WARNING Failure to follow all precautions could result in fire explosion severe injury or death The gas supply shall have a maximum inlet pressure of less than 14 water column 3
29. in substantial property damage serious injury or death WHL 019 REV 12 17 14 20 SPARCO AQUAMIX cas MIXING VALVE SHOWN FOR OTHER VALVES CONSULT VALVE MANUFACTURER HOT WATER CIRCULATOR OUTLET REQUIRED IN LINE IF NOT ON AIR HANDLER UNIT SEE NOTE 4 HOT OUT 135 140 D 120 130 COLD IN E BALL 2 AUXILIARY VALVE BACKFLOW PREVENTER EXPANSION 05 25 10 p VALVE COLD WATER AIR HANDLER INLET E CHECKWITH AIR HANDLER MANUFACTURER FOR PROPER SIZING Figure 6 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 Massachusetts you must install a vacuum relief valve per 248 CMR With air handlers outdoor reset is availa
30. light any appliance to inspect the appliance and to replace any part of the control system and any gas control which has been Do not touch any electric switch under water do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions OPERATING INSTRUCTIONS 1 STOP Read the safety information above 5 Remove front cover Set the thermostat to lowest setting 6 Turn gas shutoff valve to off Handle will be across the piping do not force 3 Turn off all electric power to the appliance Wait five 5 minutes to clear out any gas If you then This appliance is equipped with an ignition device smell gas STOP Follow B in the safety which automatically lights the burner Do not try to information above on this label If you don t smell light the burner by hand gas go to next step Turn gas shutoff valve to on Handle will be GAS VALVE GAS VALVE in line with piping ON OFF 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 OFF GAS TO APPLIANCE 1 Set the thermostat to lowest setting 4 Turn gas shutoff valve to off Handle will be 2 Turn off all electric power to the appliance if service is across the pipin
31. 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 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 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 9 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 18 1 and 18 2 for venting d
32. responsible for all equipment and detaihng requited by local codes ROOM OPENING 1 352 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 detailing required by local codes Figure 20 WHL 019 REV 12 17 14 39 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 removal system Condensate is water vapor derived from combustion products similar to 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 pump kit p n 554200 available from Westinghouse If required by local authorities a condensate filter of lime crystals marble or phosphate chips will neutralize slightly acidic condensate This can be installed in the field and purchased from Westinghouse p n 7450P 212 CAUTION 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 prope
33. tete en stc e d aet e cce oda e e 17 C TEMPERATURE AND PRESSURE RELIEF 17 D BACKEEOWFCPREVENTER eth tte b d he to e cotum een d ctc 17 E POTABLE EXPANSION TANK Ru E eben BEP di 17 F WATER PIPING ettet ce e e ir e Re ede el ee Lec ete 18 G AUXILIARY CONNECTIONS tnnt reet eec ti hats hae t cea dee te t ga ctis deed 18 H PIPING DIAGRAMS m ete d Ba ee aec i d de abe reda dte eot cd 19 PART 5 VENTING COMBUSTION AIR AND CONDENSATE atn sain satanas tna 27 uns Seo RC edu ene m T E eU bae Ei EID ee ceca gens 27 B APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE 0 28 C REQUIREMENTS FOR INSTALLATION IN 28 D EXHAUST VENT AND INTAKE PIPE 2 4 04001040100 20 29 E EXHAUST VENT AND INTAKE PIPE 30 WHL 019 REV 12 17 14 dee ttt ov rr dec pc du te 30 G EXHAUST VENT AND INTAKE PIPE 1 5 31 H VENTING DRAWINGS 2 2 nee doe Dat ipei etit UR ed eee a e e e lei
34. the menu c Use to scroll to Function 8 to adjust minimum outdoor temperature Use and to adjust temperature to desired setting Range 49 F 32 F Default 5 F d Use to scroll to Function 9 to adjust maximum supply temperature Use and to adjust temperature to desired setting Range 77 F 160 F Default 119 F It is recommended that the Mff setting matches Function 9 e Use to scroll to Function 10 to adjust maximum outdoor temperature Use and to adjust temperature to desired setting Range 32 F 95 F Default 68 F f Use to scroll to Function 11 to adjust maximum supply temperature From the water heater use and to adjust temperature to desired setting It is recommended that this temperature is set to the maximum desired DHW temperature Range 32 F 160 F Default 159 F g Use to scroll to Function 12 to adjust desired DHW temperature minimum tank temperature Use and to adjust temperature to desired setting Range 32 F 160 F Default 95 F h Press and hold to exit the menu DANGER Water temperature over 125 degrees can cause severe burns IB instantly or death from scalds Children disabled and elderly are es to _ at highest risk of being scalded See instruction manual before 67 setting temperature at water heater Feel water before bathing __ Li 1 ver c C showering Temperature limiting valves are available
35. 2 Note the fault code and refer to Table 15 for an explanation of the fault code along with several suggestions for corrective actions 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 A WARNING When servicing or replacing any components of this water heater be certain that e The gas is off e All electrical power is disconnected WHL 019 12 17 14 49 DANGER When servicing or replacing components that 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 e The electrical power is off A 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 CAUTION
36. 32 1 DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE sessseesseeeeeeeeeeneee nennen nnne neret eren 2 VENTING THROUGH AN EXISTING SYSTEM t rti dente t E Re ERR genet tea ere ge i a 3 INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED 5 CONDENSATE REMOVA E SYSTEM retenir e UNDER IRR RPM Tota EAE NENAS 39 PART 6 MIRIN cce 39 ntt eda 39 LINE VOLTAGE idee ain eldest Pee aod e 40 GLOW VOLTAGE OUTDOOR SENSORINPU T nci or Medien cte eaa pee erai tnt hr 40 D INTERNAL WIRING DIAGRAM iss ruote ead ene n RED E DR DE 41 PART 7 GAS CONNECTIONS icici c E 43 ASGAS PIPING siehe vega uns Immun idu eR 43 B GAS TABLE ais ee eR RE ERU t ih e e ate ne ede HE Rd d te 43 CG GASNALV ttai cerni e en e se re Mien dh 44 PART 8 START UP PROCEDURE niece aene t reaeacet ic ee oorr ae came ede 45 A OPERATING INSTRUCTIONS s iis aede ce rete itte teret xr rr ri is Eb e vedi D Due RE aem 4
37. 5 B OVERALL WATER HEATER AND CONTROL 4 40 21 nnennneen nnne nnree triente trii tn nennen enne 45 G STATUS ede vei s he De ups a de ER CER tbe dece dI e A eese dn 45 eerte ir c gie dec en cp ien c c Ae 46 E TEST MODE ueniens EE Ren 47 d etri ei t tare e re eed Ue D ec De era 47 PARTO SHUTDOWN c uec a aa ete euer 48 A te cce E eU e ete Ud e Eee e ce ede E HEC ee uu e 48 B VAGATION PROGEDURE 3 RE LU E E ER eL d I REO EE EE Eua 48 C FAILURE TO OPERBATE isis nee eG Ime ERA BEIDE B 48 TROUBLESHOOTING 2 2 48 AV ERROR taste eut Senn ee tte m ee et QT ela oir eee Mee cd aei pue Dh 48 BUHEATER ERROR 52 3 iate ed dee ete 48 Led a etl ae m a aah oL te 6 48 PART 11 MAINTENANCE ricette nite ie ceu SD easet ice antec ap DL n sae rane cu 53 MAINTENANGE NOTES z tto rere e ettet aiite Eu CUST
38. 50 mm pound pressure 3 5 kPa and a minimum of 3 5 water column The entire piping system gas meter and regulator must be sized properly to prevent pressure drop greater than 0 5 WC as stated in the 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 25 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 94 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 PSI 14 water column the gas valve must be replaced Never use an open flame match lighter etc to
39. 60 1 2 110 1 2 30 43 103 35 26 96 40 8 1 2 88 1 2 NONE 0 85 Table 7 TEL Total Equivalent Length Oversized vent pipe diameter is 1 or greater than factory supplied connection G EXHAUST VENT AND INTAKE PIPE INSTALLATION WARNING All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into living space 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 pipe all joints must be properly cleaned primed and cemented Use only cement and primer approved for use with the pipe material Cement must conform to ASTM D2564 for PVC and ASTM F493 for CPVC pipe NOTE DO NOT CEMENT POLYPROPYLENE PIPE 4 Ensure the vent is located where it will not be exposed to prevailing winds 5 In all roof venting applications exhaust discharge must point away from the pitch of the roof 6 To prevent water leakage install adequate roof flashing where the pipe enters the roof 7 Do not locate vent over public walkways driveways or parking lots Condensate could drip and freeze resulting in a slip hazard or damage to vehicles and machinery 8 Due to potential moisture build up sidewall venting may not b
40. ER SINK SHUT OFF VALVE DRAIN PURGE VALVE SHUT OFF VALVE CHECK VALVE CIRCULATOR a PUMP W IFC EXPANSION LP 179 Z 08 25 10 PURGE DRAIN VALVE Figure 10 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 required by local codes In Massachusetts you must install a vacuum relief valve per 248 CMR 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 019 REV 12 17 14 25 EXPANSION TANK HOT WATER OUTLET COLD INLET BACKFLOW PREVENTER HOT OUTLET g bos EM
41. NT KIT 3 3 N A V500 2 VENT KIT 1 N A N A V1000 3 VENT KIT N A 1 1 V2000 4 VENT KIT N A 1 1 Table 5 Friction loss for long radius elbow is 1 foot less NOTE Consult Polypropylene venting instructions for friction loss and pressure drop equivalents 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 85 feet 3 The minimum total equivalent length is 16 equivalent feet CAUTION Failure to provide a minimum total vent length of 16 equivalent feet could result in property damage and improper product operation LONGER VENT RUNS The maximum total equivalent length can be extended by increasing the diameter of both exhaust vent and intake pipe equally However the transitions should begin a minimum of 15 total equivalent feet from the water heater a The maximum total equivalent length for increased diameter vent pipes is 125 feet for 2 transitioning to 3 pipe this number includes the minimum 15 total equivalent feet necessary for transition
42. OMER INSTALLATION RECORD FORM iirrainn eene e deed dne de ee ie iie e deed eee e C e Gas Fired Commercial Water Heater Limited PART 1 GENERAL SAFETY INFORMATION A PRECAUTIONS This water heater is for indoor installations only Clearance to combustible materials 0 top bottom sides and back Unit must have room for service 24 front and 12 sides are minimum recommended service clearances A combustible door or removable panel is WHL 019 REV 12 17 14 6 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 serviceman 1 FIRE 2 DAMAGE 3 WATER Any claims for damage or shortage in shipment must be f
43. OPERATION RESULTING IN POSSIBILITY OF SUBSTANTIAL PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH A 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 preventers on all incoming water 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 WHL 019 REV 12 17 14 18 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 follo
44. SKET Replacement Part 7100P 139 ADAPTER PLATE 7250P 644 7100P 007 FLAT HEAD SCREW ADAPTER PLATE 7100P 045 7100P 155 AIR INTAKE ADAPTER BLOWER SIDE 7500 185 7100 082 SWIRL PLATE BLACK 100 130 BTU 7100P 042 IGNITOR ELECTRODE w GASKET 7100P 124 SWIRL PLATE WHITE 160 199 BTU 10 32 X 3 8 SCREWS 10 LOCK WASHERS NUTS 5 16 18 GASKET BURNER MOUNTING FLANGE BURNER 100 130K BTU 7500 092 AIR INTAKE ADAPTER VALVE SIDE 7500 184 GAS VALVE 100 130 BTU 7000 862 7100 152 GAS VALVE 160 199 BTU 7000 863 7100 316 SCREWS GAS VALVE 7100P 046 BURNER 160 199K BTU 7100P 317 1 2 FLARE X 1 2 NPT FLEX HOSE GASKET BURNER OUTLET GASKET SIGHT GLASS SIGHT GLASS COMBUSTION BLOWER w GASKET SIGHT GLASS 7100P 140 7000P 361 TUBE AIR INLET 7500 189 7100 105 GAS VALVE ADAPTER w O RING 7250P 454 G2000 SCREWS M4 X 20MM GAS VALVE ADAPTER 7250P 717 7100P 015 GAS SHUT OFF VALVE 7250P 140 COMBUSTION BLOWER w GASKET SIGHT GLASS 199K BTU ONLY 1 4 20 BRASS NUTS 1 4 LOCK WASHERS 7100P 350 24VAC GAS VALVE COIL ONLY GREY 7350P 624 7100P 268 Figure 29 LP 179 H WHL 019 REV 12 17 14 PART 11 MAINTENANCE 53 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
45. STION SETTINGS ON ALL MODELS Natural Gas Propane LP Fan Speed Low Ignition High Low Ignition High Carbon Monoxide PPM 1 10 2 15 2 20 1 10 2 15 2 20 Carbon Dioxide CO2 8 10 8 1096 8 1096 8 1 10 596 8 Ve 10 9 1196 Table 11 FAN SPEEDS BTU IGNITION MIN MAX 100 000 3000 2000 5700 130 000 3000 2000 7300 160 000 3000 2000 7450 199 000 3000 2000 9100 Table 12 F 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 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 A 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 019 REV 12 17 14 PART 9 SHUTDOWN A SHUTDOWN PROCEDURE If the burner is not operating disconnect the electrical supply
46. See chart below showing temperature burn rate WHL 019 REV 12 17 14 47 Outdoor Reset Curve g 140 _ _ du setting Function9 135 130 Function 11 Function 12 2 _ _ cunction tT J 4 1 12 unctio 115 i 0 20 40 50 80 100 Outdoor Temperature Function 8 Function 107 Figure 27 NOTE The maximum tank temperature is 160 F independent of all settings described above TEST MODE This function is intended to simplify the gas valve adjustment if needed Listed below are the recommended limits on each heater and the combustion settings Automatic modulation does not take place when the controller is in Test mode only temperature limitation based on the heater set point The user will be allowed to increase or decrease the fan speed by pressing in either the or keys To activate the Test Mode simply press the and key together for 1 second Once activated you will see in the display and the actual fan speed The measurement of the combustion levels should always be taken at the highest and lowest fan speed When in Test Mode the heater s limit will shut down the burner if temperature limit is exceeded It is recommended to draw water out of the tank to lower temperature so tests can be performed After 10 minutes Test Mode stops automatically To exit Test Mode manually press amp and S key together for 1 second COMBU
47. TERIOR WALL A INSERT INLET EXHAUST SCREEN PROVIDED INTO STRAIGHT SCREENS PROVIDED INTO STRAIGHT COUPLING COUPLING EACH END OF TEE pre TEE 12 OVER MAXIMUM d Puy SNOW LEVEL OR 24 1 WHICHEVER IS GREATER EXHAUST 4 t An JJ IT Lt MAINTAIN 12 MINIMUM EXHAUST CLEARANCE ABOVE HIGHEST VENT ANTICIPATED SNOW LEVEL GRADE WHICHEVER IS GREATER TYP M Jet LP 505 A I d LP 445 G 30 bs 07 30 14 RIGHT SIDE VIEW INTAKE AIR VENT Figure 14 Two Pipe Roof and Sidewall Venting with Included Equipment Tee and Coupling NOTE These drawings are meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes 4 WARNING All vent pipes must be glued properly supported and the exhaust must be pitched 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 WHL 019 REV 12 17 14 SIDEWALL VENTING WITH KIT EXTERIOR WALL ROOF VENTING WITH CONCENTRIC VENT KIT CONCENTRIC VENT KIT 33 12 OVER MAXIMUM SNOW LEVEL OR 24 WHICHEVER IS
48. V2000 2 PVC Concentric Vent Kit Part KGAVT0501CVT 3 PVC Concentric Vent Kit Part KGAVT0601CVT 3 Polypro Vent Kit Part 8400P 001 3 Polypro Pipe 33 length Part 8400P 002 49 5 length Part 8400P 003 PC Connection Kit Part 7250P 320 Condensate Neutralizer Part 7450P 212 Outdoor Sensor Part 7250P 319 Sanitizer Booster Kit Part VSBK 1200 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 WHL 019 REV 12 17 14 A BEFORE LOCATING THE HEATER 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 e Ensure ambient temperatures are higher than 32 F 0 C and lower than 104 F 40 C Prevent the air from becomin
49. a fault it is recommended that you cycle the unit at least three or four times to assure the fault has been resolved WHL 019 12 17 14 51 LP 179 J 10 01 14 Description Replacement Part LOW WATER CUT OFF SENSOR 7000P 852 1 HIGH TEMP SAFETY SWITCH 7100 006 UPPER TEMPERATURE SENSOR 7100P 004 LOWER TEMPERATURE SENSOR 7100 005 TEMPERATURE AND PRESSURE RELIEF VALVE 100 BTU TP1900 TEMPERATURE AND PRESSURE RELIEF VALVE 130 160 199 BTU TP1400 BLOCKED VENT PRESSURE SWITCH 7250P 150 CONTROL BOARD 7450P 122 120 VOLT WIRE HARNESS LOCATION SHOWN 7100 272 LOW VOLTAGE WIRE HARNESS LOCATION SHOWN 7100P 273 CONTROL DISPLAY 7350P 009 5 5 HOSE BARB 7250P 154 HIGH FLUE TEMP SWITCH VS210 CONDENSATE HOSE 7100 121 HOSE CLAMP CONDENSATE HOSE 7250P 215 SENSOR WIRE HARNESS ATTACHES TO ITEM 9 7100 274 2 COUPLING AIR INLET 100 130 BTU 7100 114 3 COUPLING AIR INLET 160 199 BTU 7100 103 NUT AIR INLET COUPLING 7100 104 M MO D E L N LY OUTDOOR SENSOR NOT SHOWN 7250P 319 COLD WATER INLET DIP TUBE PHM MODELS ONLY 6070P 048 DRAIN VALVE PHM MODELS ONLY 6070P 009 Figure 28 LP 179 J WHL 019 REV 12 17 14 52 LP 179 H 02 07 14 Description Replacement Port Description GASKET MOUNTING PLATE MOUNTING PLATE GASKET PROBES FLAME RECTIFICATION PROBE w GA
50. actual fan speed 7 Actual ionization current read from flame rectification probe d8 9 Not used d9 Not used d10 Actual status of bus communication connected not connected 19111 Not used 4121 Power on hours in thousands display will not read until 100 hrs d13 Total water heating hours in thousands display will not read until 100 hrs 414 Not used d15 Passed ignition attempts in thousands D OUTDOOR RESET NOTE The outdoor reset function cannot be used if the 0 10 volt function is enabled This unit is supplied with outdoor reset wire connection terminals When an outdoor sensor p n 7250P 319 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 1 Connect the outdoor sensor to the terminals marked outdoor 2 Press and hold You will see a nashina and a temperature value Set to the maximum desired tank temperature default 119 F After you set the temperature press until you exit the menu 3 Setting the outdoor reset curve change only the functions in the descriptions below a Press and hold and together for 5 seconds b Use and to adjust flashing 8 to code Press until you enter
51. allation instructions OWNER RESPONSIBILITIES To avoid the exclusion list in this warranty the owner or installer must 1 Maintain the water heater in accordance with the maintenance procedure listed in the manufacturer s provided instructions Preventive maintenance can help avoid any unnecessary breakdown of your water heater and keep it running at optimum efficiency 2 Maintain all related heating components in good operating condition 3 Check all condensate lines to confirm that all condensate drains properly from the water heater 4 Use the water heater in an open system or in a closed system with a properly sized and installed thermal expansion tank 5 Use the water heater at water pressures not exceeding the working pressure shown on the rating plate WARRANTY EXCLUSIONS This limited warranty will not cover 1 Any water heater purchased from an unauthorized dealer or online retailer 2 Any water heater not installed by a qualified heating installer service technician 3 Service trips to teach you how to install use maintain or to bring the water heater installation into compliance with local building codes and regulations 4 Failure to locate the water heater in an area where leakage of the tank or water line connections and the combination temperature and relief valve will not result in damage to the area adjacent to the water heater or lower floors of the structure 5 Any failed components of the heat system not manufactured by We
52. als 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 must be pitched a minimum of 72 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 CAUTION 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 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 wit
53. and battery back up may be installed on the next adjacent floor level b 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 019 REV 12 17 14 55 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the 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 thr
54. 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 alll venting design instructions shall remain with the appliance or equipment at the completion of the installation LP 172 REV 02 16 06 WHL 019 REV 12 17 14 56 MAINTENANCE NOTES WHL 019 REV 12 17 14 57 CUSTOMER INSTALLATION RECORD FORM The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim After reading the important notes at the bottom of the page please also sign this document Customer s Name Installation Address Date of Installation Installers Code Name Product Serial Number s 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 Sales Representative Distributor Dealer Please insert contact detai
55. ble with an outdoor sensor See Part 8 Section D 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 4 DANGER property damage serious injury or death WHL 019 12 17 14 BACKFLOW PREVENTER SHUT OFF BALL VALVE COLD WATER gy COLD WATER HOT WATER HOT WATER HOT WATER QUEE VALVE CIRCULATOR SEE NOTE 4 EXPANSION TANK HOT WATER OUTLET N 21 AUXILIARY CONNECTION Figure 7 Reverse Manifold and 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 wate
56. check gas connections 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 B GAS TABLE Refer to the table below to size the supply piping to minimize pressure drop between meter or regulator and unit 43 GAS LINE DO NOT REMOVE THIS ADAPTER Do not operate heater if flood damaged Install vent system in accordance with local codes and manufacturers installation instructions Do not obstruct heater air intake or exhaust 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 the sectional Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual 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 Iron Internal Length of Pipe Feet Pipe Size In Dia In 20 30 40 50 60 70 80 90 100 125 150 175 200 BTU s A 824 278 190 152 130 115 105 96 90 84 79 72 64 59 55 PerHour 1 1 049 520 350 285 245 215 195 180 170 160 150 130 120 110 100 x 1 1 380 1 050 730 590 500 440
57. e or scalding due to relief valve operation e Discharge line must be connected to relief valve outlet and run to a safe place of disposal Terminate the discharge line manner that will prevent possibility of severe burns or property damage should the relief valve discharge e Discharge line must be as short as possible and the same size as the valve discharge connection throughout its entire length e Discharge line must pitch downward from the valve and terminate at least 6 above the floor drain making discharge clearly visible e discharge line shall terminate plain not threaded with a material serviceable for temperatures of 375 F or greater e Do not pipe discharge to any location where freezing could occur e shutoff valve may be installed between the relief valve and heater or in the discharge line Do not plug or place any obstruction in the discharge line e 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 e 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 e 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
58. e 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 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 coupling 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 8 lists optional intake air exhaust vent termination WHL 019 12 17 14 32 DESCRIPTION STOCK CODE 2 PVC CONCENTRIC VENT TERMINATION KIT KGAVT0501 CVT 3 PVC CONCENTRIC VENT TERMINATION KIT KGAVT0601CVT 2 STAINLESS STEEL VENT TERMINATION KIT V500 3 STAINLESS STEEL VENT TERMINATION KIT V1000 4 STAINLESS STEEL VENT TERMINATION KIT V2000 3 POLYPRO VENT KIT 8400P 001 Table 8 H VENTING DRAWINGS 1 DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE If installing a direct vent option combustion
59. ection Ensure exhaust vent and intake piping complies with these instructions regarding vent system Inspect finished exhaust vent and intake piping thoroughly to ensure all joints are well secured airtight and comply with all applicable code requirements as well as with the instructions provided in this manual Failure to properly install the vent system will result in severe personal injury or death A GENERAL Ny 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 below carefully Failure to do so will result in substantial property damage severe personal injury or death 1 Installation should be made in accordance with the regulations of the Authority Having Jurisdiction local code authorities and utility companies which pertain to this type of water heating equipment T i dam Breathing Hazard Carbon Monoxide Gas Install the venting system in accordance with these instructions and wit Do not operate heater flood the National Fuel Gas Code ANSI Z223 1 NFPA 54 CAN CGA 149
60. emonstrations DA 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 18 3 for chase venting demonstration Concentric Venting Through an Concentric Venting Through an Chase Venting Through an Existing Existing System Existing System System 1 EXHAUST EXHAUST 2 3 EXHAUST bu 24 i INTAKE COMBUSTION AIR COMBUSTION AIR EXISTING ae EXISTING VENT VENT N INTAKE w SCREEN EXHAUST NTAKE 12 MIN I INTAKE xp w SCREEN SEALED P poen CAP SEAL Jk EXHAUST EXHAUST S LP 325 LL LP 325 MM LP 325 NN 03 15 12 03 15 12 07 22 13 Figures 18 1 18 2 Concentric Venting Through an Existing System 18 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 019 REV
61. enting 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 vent piping for this direct vented appliance is approved for zero clearance to combustible construction e flue products coming from the exhaust vent will create a large plume when the water heater 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 objects 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 WARNING The building owne
62. eplace the defective or malfunctioning water heater with a replacement of the nearest comparable model available at the time of replacement B If Westinghouse is unable to repair or replace the water heater so as to conform to this warranty after a reasonable number of attempts Westinghouse will then provide at its option a replacement unit These remedies are the purchaser s exclusive remedies for breach of warranty C If government regulations industry certification or similar standards require the replacement water heater or part s to have features not found in the defective water heater or part s you will be charged the difference in price represented by those required features If you pay the price difference for those required features and or to upgrade the size and or other features available on a new replacement water heater or part s you will also receive a complete new limited warranty for that replacement water heater or part s D If at the time of a request for service the purchaser cannot provide a copy of the original sales receipt or the warranty card registration the warranty period for the water heater shall then be deemed to have commenced thirty 30 days after the date of manufacture of the water heater and NOT the date of installation of the water heater E This warranty extends only to water heaters utilized in heating applications that have been properly installed by qualified professionals based upon the manufacturer s inst
63. er een UM manufacturers installation instructions Do not use petroleum based cleaning or sealing compounds Do not place aid a heater system Gaskets and seals the system may be near unit damaged This can result in substantial property damage According 720 carton monoxide e Donot use homemade cures or heater patent medicines sleeping area Substantial property damage damage to heater and or Never operate the heater unless it is serious personal injury may result Analyze the entire vent to make sure that condensate will not area of th Breathing carbon monoxide can cause brain damage or death Always read and understand Instruction manual LP 304 4 28 09 WHL 019 REV 12 17 14 A DANGER WWE A Vapors from flammable liquids v will explode and catch fire causing death or severe burns Water temperature over 125 F can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded Do not install wator hoster 4 j See instruction manual before setting where flammable products will temperature at water heater be stored or used unless the i main bumer and pilot flames Feel water before bathing or showering Temperature limiting valves are available see Read and follow water heater warnings and instructions If owners manual is missing contact the retailer or man
64. er 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 GAS SHUT OFF VALVE PRESSURE TAP INLET GAS VALVE THROTILE ADJUSTER A 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 operstion Turn the adjuster to the to increase or to decrease gas supply This adjustment could affect CO levels Make sure the levels correspond to the chart in combustion settings 1 i j P d C b OFFSET ADJUSTMENT X CHE CAUTION Do not remove or attempt PRESSURE lt to make any adjustment to this screw TAP OUTLET without a COMBUSTION ANALYZER Figure 26 Gas Valve LP 179 P Do not do a gas conversion on this water heater without an officially approved conversion kit and instructions supplied by Westinghouse Failure to use a conversion kit when converting the heater to fire on Natural or LP gas will result in extremely dangerous burner operation leading to fire explosion severe injury or death A 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 qual
65. es of the shipping crate to allow the heater to be lifted into its installation location WHL 019 12 17 14 16 PERFORMANCE SPECIFICATIONS FOR ALL MODELS Temperature Rise BTUH Efficiency F 40 50 60 70 80 90 100 110 120 130 140 C 22 28 33 39 44 50 56 61 67 72 78 GPH 298 240 202 173 152 136 123 110 101 94 88 100 000 96 GPM 5 4 3 4 2 9 2 5 2 25 2 1 8 1 7 1 6 1 5 LPH 1128 908 765 655 575 515 466 416 382 356 333 LPM 18 8 15 1 12 75 10 9 9 6 8 6 7 8 6 9 6 4 5 9 5 6 GPH 384 309 260 222 195 175 158 141 130 120 112 GPM 6 4 5 2 4 3 3 7 3 25 2 9 2 6 2 4 2 2 2 1 9 50 000 96 LPH 1454 1170 984 840 738 662 598 534 492 454 424 LPM 2425 195 164 14 123 11 10 89 82 76 7 470 378 317 271 238 213 192 173 159 147 137 GPM 78 63 53 45 4 36 32 29 27 25 23 60 000 75 LPH 1779 1431 1200 1026 901 806 727 655 602 556 519 297 239 20 171 15 134 121 109 10 93 87 GPH 582 468 392 335 294 263 237 213 196 181 169 7 M GPM 97 78 65 56 49 44 4 86 33 3 28 LPH 2203 1772 1484 1268 1113 996 897 806 742 685 640 LPM 36 7 29 5 24 7 21 1 18 6 16 6 15 13 4 12 4 11 4 10 7 Table 2 Recovery on rating plate is based at 94 thermal efficiency at 70 Fahrenheit rise as required by ANSI PERFORMANCE EQUATIONS
66. event the thermal siphoning of domestic hot water G AUXILIARY CONNECTIONS The auxiliary connections are additional connections for 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 1 on all models Never use dielectric unions or galvanized steel fittings Use only copper or brass fittings Sealant must be used on all connections The top port is the supply outlet and the bottom port is the return inlet 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 WHL 019 REV 12 17 14 19 H PIPING DIAGRAMS AIR HANDLER UNITS MOUNTED TO CEILING x CIRCULATOR circulator required in line if not on air handler unit COLD IN See note 4 1 BALL VALVE BACKFLOW PREVENTER SPARCO AQUAMIX SHOWN HOT OUT FOR OTHER VALVES CONSULT VALVE MANUFACTURER HOT WATER OUTLET EXPANSION TANK AUXILIARY CONNECTION
67. g Do not force to be performed 5 Install Front C 3 Remove Front Cover TAY TRIN LP 175 Rev 4 3 11 08 WHL 019 REV 12 17 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 A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A 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 CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage FOREWORD This manual is intended to be used in conjunction with other literature provided with the Commercial Gas Fired 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 2223 1 2002 be reviewed in their entirety before beginning any work Installation should be made in accordance with the regulations of the Authority Having Jurisdiction local code authorities and
68. g 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 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 A WARNING Failure to keep heater area
69. h 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 A DANGER You must not use vent in an exhaust application vent is for intake applications ONLY Using vent an exhaust application will result in serious injury or death WHL 019 REV 12 17 14 29 D EXHAUST VENT AND INTAKE PIPE LOCATION ux m INSIDE CORNER DETAIL 1 179 08 12 13 EXHAUST VENT TERMINAL INTAKE PIPE TERMINAL DS TERMINAL IS NOT Figure 13 ANSI Z223 1 NFPA 54 for US and CAN CSA B149 1 for Canada Exit Terminals for Direct Vent Venting Systems DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION FIGURE 13 NOTES 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
70. 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 0 to 14 Water 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
71. ified gas technician using a calibrated combustion analyzer capable of measuring and CO Failure to follow this instruction could result in fire explosion property damage severe personal injury or death WHL 019 REV 12 17 14 45 PART 8 START UP PROCEDURE 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 co
72. iled immediately against the transportation company by the consignee A 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 B IMPROPER COMBUSTION WARNING Do not obstruct the flow of combustion and ventilating air Adequate air is necessary for safe operation Failure to keep the vent and combustion air intake clear of ice snow or other debris could result in property damage serious personal injury or death 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 e To avoid electric shock disconnect electrical supply before s performing maintenance LE im ME ufacturers e To avoid severe burns allow heater to cool local codes and mani heater E HEATER WATER ee exhaust Support all vent piping p
73. ill 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 completely filled with cold water dund Seep H 280833 Figure 22 Low Voltage Wiring 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 WHL 019 REV 12 17 14 D INTERNAL WIRING DIAGRAM EY PHOENIX INTERNAL CONNECTION DIAGRAM LINE GROUND wane NEUTRAL BLACK o 8886 ao0o o 8 8 8 8 DISPLAY BOARD ASSEMBLY LOWER TEMP SENSOR X6 1 X64 X62 X 2 PROTECTED BY AN INTERNAL 6 3 AMP FUSE HIGH TEMP SAFETY SWITCH 8 HIGH FLUE TEMPERATURE SENSOR Corp RED LOW WATER CUT OFF 50 ORANGE gt SPARK CABLE TO IGNITOR ELECTRODE BLACK lt FLAME RECTIFICATION PROBE BLOCKED VENT PRESSURE SWITCH RED COMBUSTION BLOWER gt gt BLACK gt
74. ings 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 Part 5 of this manual CAUTION When drawing combustion air from the outside into the mechanical room care must be taken to provide adequate freeze protection A 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 A WARNING 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 piping for the heater as described in the Venting Section Do not terminate exhaust in locations that can allow contamination of intake air A WARNING 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 F
75. ional Fuel Gas Code ANSI Z223 1 from American Gas Association Laboratories 8501 East Pleasant Valley Road Cleveland OH 44131 In Canada CGA No B149 latest version from Canadian Gas Association Laboratories 55 Scarsdale Road Don Mills Ontario Canada M3B 2R3 Also Canadian Electrical Code C 22 1 from Canadian Standards Association 5060 Spectrum Way Suite 100 Mississauga Ontario Canada LAW 5N6 Code for the installation of Heat Producing Appliances latest version from American Insurance Association 85 John Street New York NY 11038 WHL 019 REV 12 17 14 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 1 GENERAL SAFETY 5 A PREGCAUTIONS ttt de pte cie p tandem a ra ben n 5 B IMPROPER COMBUSTION waits ent pen Uaec e c eod oe cb R Do ete 6 ute EE e e E e De De I RB e I te eret b ad ad e et etd eed 6 D WHEN SERVICING THE HEATER Re i dc ende i E d nc ec 6 E HEATER WATEFEU eei teet T T cs bxc eterni tae 6 PART2 BEFORE YOU 2 n RES A RR Ra E
76. k draft 2 Revise 10 8 3 by adding the following additional requirements 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 gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas 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 a crawl space or an attic the hard wired carbon monoxide detector with alarm
77. ll visual inspection of all system components Functional Test all functions of the system Heat Safeties Temperatures Verify safe settings on heater or Anti Scald Valve Temperatures Verify programmed temperature settings ELECTRICAL Connections Check wire connections Make sure they are tight Smoke and CO detector Verify devices are installed and working properly Change batteries if necessary Circuit Breakers Check to see that the circuit breaker is clearly labeled Exercise circuit breaker CHAMBER BURNER Combustion Chamber Check burner tube and combustion chamber coils Clean according to maintenance section of manual Vacuum combustion chamber Replace any gaskets that show signs of damage Spark Electrode Clean Set gap at 4 Flame Probe Clean Check ionization in uA d7 on status menu in Start up Procedures Record high fire and low fire CONDENSATE Neutralizer Check condensate neutralizer Replace if necessary 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 GAS Pressure Measure incoming gas pressure 3 5 to 10 W C for Natural Gas 8 14 W C for LP Pressure Drop Measure drop in pressure on light off no more than 1 W C Check gas pipe for leaks Check piping fo
78. low the exclusion or limitation of incidental or consequential damages so this limitation or exclusion may not apply to you These are the only written warranties applicable to the Gas Fired Commercial Water Heater manufactured and sold by Westinghouse Westinghouse neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said Gas Fired Commercial Water Heater Westinghouse reserves the right to change specifications or discontinue models without notice WHL 019 REV 12 17 14
79. ls WHL 019 REV 12 17 14 58 Gas Fired Commercial Water Heater Limited Warranty For Residential and Commercial Use Westinghouse warrants each water heater and its parts to be free from defects in materials and workmanship according to the following terms conditions and time periods The replacement water heater will be warranted for the unexpired portion of the applicable warranty period of the original water heater Replacement parts will be warranted for 90 days UNLESS OTHERWISE NOTED THESE WARRANTIES COMMENCE ON THE DATE OF INSTALLATION This limited warranty is only available to the original owner of this water heater and is non transferable Residential Use Warranty One 1 year Parts Seven 7 years Tank Residential setting shall mean water heater usage in a single family dwelling or usage in a multiple family dwelling provided that the water heater services only one 1 dwelling in which the original consumer purchaser resides on a permanent basis and operating temperatures do not exceed 140 F Commercial Use Warranty One 1 year Parts Three 3 years Tank Water heaters used in a commercial setting shall mean any usage not falling within the definition of a residential setting COVERAGE A Should a defect or malfunction result in a leakage of water within the above stated warranty periods due to defective material or workmanship malfunction or failure to comply with the above warranty Westinghouse will r
80. ly 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 WHL 019 REV 12 17 14 11 1 DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE 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
81. must be readily accessible for visual inspection for the first three feet from the heater WHL 019 REV 12 17 14 34 EXHAUST UNBALANCED VENT WITH TEE INTAKE AND COUPLING EXHAUST SUPPORT BRACKETS MUST BE USED ON ALL HORIZONTAL AND VERTICAL PIPING INTAKE AIR INTAKE MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER LEFT SIDE VIEW Figure 16 LP 179 F 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 019 REV 12 17 14 35 FRONT VIEW EXHAUST EXHAUST R INTAKE ae INTAKE FRONT VIEW SIDE VIEW Figure 17 Horizontal Venting NOTE Drawing is meant to demonstrate system venting ONLY NOTES A For every 1 of overhang the exhaust vent must be l
82. ng 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 LP 179 U 07 13 10 WHL 019 REV 12 17 14 23 HOT OUT COLD IN SHUT OFF BACKFLOW VALVE PREVENTER EXPANSION TANK HOT WATER CIRCULATOR see note 4 AUXILIARY CONNECTION AQUASTAT CONTROL SPRING CHECK DRAIN VALVE VALVE COLD WATER INLET LP 179 O 01 21 13 Figure 9 Water Heater With Storage Tank 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 required by local codes In Massachusetts you must install a vacuum relief valve per 248 CMR WHL 019 12 17 14 24 TUB SHOW
83. ntrol 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 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 Turn on all electric power to water heater Make sure tank is full with cold water and purge all piping To assure adequate purging open all hot water faucets A 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 2 Adjust the temperature set point of the heater to the desired level The factory default setting is 119 F If changes are necessary follow Overall Water Heater and Control Operation in this section 3 If the water heater fails to start refer to the Troubleshooting section in the back of this manual OVERALL WATER HEATER AND CONTROL OPERATION To adjust the temperature of stored water press and hold for 2 seconds The first item is BJ Water Temperature Set Point factory set at 119 F Adjust down by pressing
84. ocated 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 A 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 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 2 4 3 5 4 7 Table 9 Minimum Existing Vent Chase Sizing WHL 019 REV 12 17 14 36 DA Do not install the heater into a common existing vent with any
85. ockout displaying 01 replace the flue switch using care to mount the new flue switch in the same position and mounting holes as the old one If the display flashes a code other than 01 follow the troubleshooting guide for that code 7 If the flue temperature increases to over 190 F consult Westinghouse for further assistance Interrupted or shorted 1 Check the electrical connection to the appropriate temperature sensor upper temperature 2 If connection is okay replace bad sensor sensor Interrupted or shorted lower temperature sensor Upper temperature sensor 1 If water in tank is not greater than 194 F check wiring Repair if faulty exceeds 194 F 2 If wiring is okay check appropriate sensor with ohmmeter and compare to reading in resistance chart above 06 Lower temperature sensor reading does not agree with water temperature replace bad sensor exceeds 194 F No flame detected 1 Watch the igniter through the observation window provided Heater will make three 2 If there is no spark check the spark electrode for the proper 74 gap FO9 attempts at ignition before 3 Remove any corrosion from the spark electrode and flame rectifier probe the control goes into this 4 If there is a spark but no flame check the gas supply to the heater lockout condition Will 5 If there is a flame check the flame sensor reset in 1 hour 6 Check any flue blockage or condensate blocks 1 Monitor the gas pressure to the unit
86. or example do not pipe intake near a swimming pool Also avoid areas subject to exhaust fumes from laundry facilities These areas always contain contaminants WHL 019 REV 12 17 14 12 PRODUCTS TO AVOID AREAS LIKELY TO HAVE CONTAMINANTS Spray cans containing fluorocarbons Dry cleaning laundry areas and establishments Permanent wave solutions Swimming pools Chlorinated waxes cleaners Metal fabrication plants Chlorine based swimming pool chemicals Beauty shops Calcium chloride used for thawing Refrigeration repair shops Sodium chloride used for water softening Photo processing plants Refrigerant leaks Auto body shops Paint or varnish removers Plastic manufacturing plants Hydrochloric or Muriatic acid Furniture refinishing areas and establishments Cements and glues New building construction Antistatic fabric softeners used in clothes dryers Remodeling areas Chlorine type bleaches laundry detergents and cleaning solvents Garages and workshops Adhesives used to fasten building products Table 1 Contaminant Table Refer to the limited warranty for complete terms and conditions NOTE DAMAGE TO THE HEATER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY G REMOVING A HEATER FROM A COMMON VENT SYSTEM A DANGER Do not install the heater into acommon vent with any other appliance This
87. osts beyond the coverage specified in this warranty document All such expenses are your responsibility LIMITATIONS OF YOUR WESTINGHOUSE WARRANTY AND REMEDIES THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ANY OBLIGATION LIABILITY RIGHT CLAIM OR REMEDY IN CONTRACT OR TORT WHETHER OR NOT ARISING FROM WESTINGHOUSE S NEGLIGENCE ACTUAL OR IMPUTED THE REMEDIES OF THE PURCHASER SHALL BE LIMITED TO THOSE PROVIDED HEREIN TO THE EXCLUSION OF ANY OTHER REMEDIES INCLUDING WITHOUT LIMITATION INCIDENTAL OR CONSE QUENTIAL DAMAGES SAID INCIDENTAL AND CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO PROPERTY DAMAGE LOST PROFIT OR DAMAGES ALLEGED TO HAVE BEEN CAUSED BY ANY FAILURE OF WESTINGHOUSE TO MEET ANY OBLIGATION UNDER THIS AGREEMENT INCLUDING THE OBLIGATION TO REPAIR AND REPLACE SET FORTH ABOVE NO AGREEMENT VARYING OR EXTENDING THE FOREGOING WARRANTIES REMEDIES OR THIS LIMITATION WILL BE BINDING UPON WESTINGHOUSE UNLESS IN WRITING AND SIGNED BY A DULY AUTHORIZED OFFICER OF WESTINGHOUSE THE WARRANTIES STATED HEREIN ARE NOT TRANSFERABLE AND SHALL BE FOR THE BENEFIT OF THE ORIGINAL PURCHASER ONLY NO OTHER WARRANTIES Your Westinghouse Warranty gives you specific legal rights and you may also have other rights that vary from state to state Some states do not al
88. ough 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required to be Vented in the most current edition of NFPA 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 instructions 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
89. ower temperature sensor If either reading displayed does not make sense check appropriate sensor with ohmmeter Refer to resistance chart this section Replace bad sensor Do an OHMs reading on both sensors to check continuity 1 Inspect all flue piping If the flue is damaged or shows signs of overheating repair or replace the flue parts as necessary before proceeding 2 If the flue piping system is intact not damaged and there is no sign of the flue overheating such as discoloration or melting push the red reset button on the flue switch 3 Be sure the heater is connected to a water supply and full of water 4 Push the RESET button on the heater control panel The water heater should light If the water heater lights proceed to step 5 If the water heater does not light and the display again begins to flash 01 inspect the Vent temperature limit wiring to the flue switch repairing or replacing as necessary If the wiring is intact replace the flue switch using F01 exceeded care to mount the new flue switch in the same position and mounting holes as the old one If the display flashes a code other than F01 follow the troubleshooting guide for that code 5 Observe operation for 5 minutes Place the probe of an exhaust analyzer into the flue system within 6 feet of the heater The exhaust temperature should not rise above 190 F after several minutes of operation 6 If the flue temperature is below 190 F and the heater again goes into l
90. pace 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 20 Do not operate heater if flood damaged Install vent system in accordance with local codes and manufacturers installation Instructions ox epar eL reme ee p ta B lace chemical vapor emitting oduc neer unit 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 s to make sure that condensate will not become appead in OF Vert pipo and 22 2 reduce th S crous DO NOT PLACE DRYER IN PROXIMITY TO WATER HEATER Figure 19 LP 325 X WHL 019 12 17 14 38 EXHAUST VENT INDOOR COMBUSTION AIR SINGLE PIPE ROOMOPENING NOTE This drawing is meant to demonstrate system venting only The installer is
91. r 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 WHL 019 REV 12 17 14 BACKFLOW PREVENTER PRESSURE REDUCING PRESSURE GAUGE BALL CIRCULATOR See note 4 AUXILIARY CONNECTION AUXILIARY CONNECTION Figure 8 Closed Loop with Radiant Heating NOTES AIR ELIMINATOR CIRCULATOR see note 4 L1 22 RADIANT HEAT EXPANSION TANK SYSTEM DRAIN 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 brazed plate manufacturer for correct plate connections and orientation 6 This drawi
92. r 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 WHL 019 REV 12 17 14 30 A 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 for the 100 and 130kKBTU models and 3 for the 160 and 199kBTU models 2 The maximum total equivalent length of 2 exhaust vent and intake pipe must not exceed 85 feet The total maximum equivalent length of 3 exhaust vent and intake pipe must not exceed 200 feet a The equivalent 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 2 EQUIVALENT FEET 4 90 DEGREE ELBOW 5 5 3 45 DEGREE ELBOW 3 3 1 COUPLING 0 0 0 AIR INLET TEE 0 0 0 STRAIGHT PIPE 1 1 1 CONCENTRIC VE
93. r leaks Verify that all are properly supported COMBUSTION CO CO2 Levels Check CO and CO2 levels in Exhaust See Start up Procedures for ranges Record at high and low fire SAFETIES ECO Energy Cut Out Check continuity on Flue and Water ECO Replace if corroded Upper Lower Sensors Check wiring Verify through ohms reading FINAL INSPECTION Check list Verify that you have completed entire check list WARNING FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH Homeowner Review what you have done with the homeowner Table 16 Continue annual maintenance beyond the 47 year as required WHL 019 REV 12 17 14 54 ADDITIONAL INSTALLATION REQUIREMENTS 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 to the burner in the event of a sustained bac
94. rn 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 A LINE VOLTAGE INPUT The heater must be wired to a 120 volt circuit by a qualified electrician It is recommended that the heater be wired on its own circuit to minimize the possibility of circuit failure due to outside causes The heater requires a maximum of 8 amps at 120 volts in use WHL 019 REV 12 17 14 40 LINE VOLTAGE CONDENSATE OUTPUT The heater has the capability of supplying power to a condensate pump The connection is 120 VAC 10 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 HTP offers an outdoor sensor p n 7250P 319 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 w
95. rty 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 NEUTRALZER __ PART 7450 212 CONDENSATE UNE CONDENSATE NEUTRALZER PART 7450 212 LITTLE GIANT CONDENSATEPUMP 554200 rtm x um CONDENSATE LINE WITH PUMP Figure 21 LP 179 K NOTES 1 Condensate line must be pitched at least 1 4 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 Plastic pipe should be the only material used for condensate line Steel brass copper and other metals will be subject to corrosion or deterioration 3 NEVER install condensate lines outside It is very important that the condensate line is not exposed to freezing temperatures or any type of blockage 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 PART 6 WIRING WARNING To avoid electrical shock tu
96. rystals marble or phosphate chips Neutralizers can be installed in the field by the installer and purchased from Westinghouse p n 7450P 212 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 DANGER Water temperature over 125 degrees can cause severe burns instantly or death from scalds Children disabled and elderly are af 29 _ at highest risk of being scalded See instruction manual before setting temperature at water heater Feel water before bathing or E T TA showering Temperature limiting valves are available See chart below showing temperature burn rate C OPTIONAL EQUIPMENT Below is a list of optional equipment available from Westinghouse e 3 Stainless Steel Outside Termination Vent Kit V1000 4 Stainless Steel Outside Termination Vent Kit
97. skets can cause eventual gasket failure and exhaust gas leakage Ensure the exhaust vent pipe is properly beveled and seated before insertion into the flue adapter Failure to do so could result in property damage severe personal injury or death 4 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 WHL 019 12 17 14 28 APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL Item Material Standards for Installation in United States Canada PVC schedule 40 80 ANSI ASTM D1785 PP CPVC and PVC venting must be ULC PVC DWV ANSI ASTM D2665 5636 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
98. stinghouse as part of the water heater 6 Water heaters repaired or altered without the prior written approval of Westinghouse 7 Damages malfunctions or failures resulting from failure to install the water heater in accordance with applicable building codes ordinances or good plumbing and electrical trade practices 8 Damages malfunctions or failures resulting from improper installation failure to operate the water heater at pressures not exceeding the working pressure shown on the rating plate or failure to operate and maintain the water heater in accordance with the manufacturer s provided instructions 9 Failure to operate the water heater in an open system or in a closed system with a properly sized and installed thermal expansion tank 10 Failure or performance problems caused by improper sizing of the water heater expansion device piping or the gas supply line the venting connection combustion air openings electric service voltage wiring or fusing 11 Damages malfunctions or failures caused by improper conversion from natural gas to LP gas or LP gas to natural gas 12 Damages malfunctions or failures caused by operating the water heater with modified altered or unapproved parts 13 Damages malfunctions or failures caused by abuse accident fire flood freeze lightning acts of God and the like 14 Tank failures leaks caused by operating the water heater in a corrosive or contaminated atmosphere WHL 019 REV 12 17 14
99. t is within the applicable warranty period by reviewing a copy of the original sales receipt You must present a copy of the original sales receipt for a warranty service request If your water heater is in warranty contact the retailer from whom the water heater was purchased or the installer for assistance Be prepared to provide the retailer or installer with a copy of your original receipt complete model and serial numbers and the date of installation of your water heater in addition to explanation of your water heater problem Warranty coverage is subject to validation of in warranty coverage by Westinghouse claims department personnel All alleged defective or malfunctioning parts must be returned to Westinghouse via the local distribution channels where original purchase was made NOTE Any parts or heaters returned to Westinghouse for warranty analysis will become the property of Westinghouse and will not be returned even if credit is denied If all warranty conditions are satisfied Westinghouse will provide replacement parts to the retailer If you have questions about the coverage of this warranty please contact Westinghouse at the phone number stated below 1 774 417 6000 SERVICE LABOR AND SHIPPING COSTS This limited warranty does not extend to any shipping charges delivery expenses or administrative fees incurred by the purchaser in repairing or replacing the water heater or part s This warranty does not extend to labor c
100. temperature system supply of the water heater The control module adjusts the burner firing rate so the outlet water temperature meets the set point WHL 019 REV 12 17 14 Lower Return Tank Sensor This sensor monitors the lower portion of the water heater inlet water temperature system return The control module reduces or increases input depending on how close the water temperature is to the outlet water temperature set point Control The integrated control system monitors upper and lower 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 Drain Connection 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 If the condensate outlet on the heater is lower than the drain you must use a condensate removal pump kit p n 554200 available from Westinghouse In addition local authorities may require a condensate neutralizer to neutralize the condensate Condensate neutralizers are made up of lime c
101. ter 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 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
102. to a temperature as low as 95 F Adjust up as high as 160 F by pressing the 1 Press again to display the differential which is factory set at 7 F and adjustable down to 1 F by pressing and up to 18 F by pressing Note Due to the highly advanced control on this water heater which compensates for varying inlet water temperature the actual differential temperature may vary slightly from your setting Press again to display the factory default temperature measurement in Fahrenheit Change the default to Celsius by pressing When finished press one final time to place unit back into operation The control automatically re starts if no key is pressed for 2 minutes C STATUS MENU Installers are also able to check the current status of the heater parameters by pressing for 3 seconds Once activated the display will show alternating value of the actual upper supply tank temperature Actual values are displayed for each function To view the next value simply press to go to the next displayed value Listed below are the values which can be displayed These values cannot be changed To exit this menu press to resume normal operation Function Value d1 Actual temperature from upper tank sensor 421 Actual temperature from lower sensor WHL 019 REV 12 17 14 46 d3 Not used 44 used d5 Outdoor sensor 46 Actual fan speed multiplied by 10 Example If fan speed displayed is RPM x 10 4100
103. ufacturer 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 Installation Manual Warranty LP Conversion Kit Natural Gas Models Only Two Threaded Caps WGCM Models Only 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 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 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 Upper Supply Tank Sensor This sensor monitors the upper portion water
104. ustion 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 Z223 1 e Mount the bottom of the heater a minimum of 18 above the floor of the garage to ensure the burner and ignition devices are well off the floor 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 A WARNING Vents must be proper
105. 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 AHJ NOTE Westinghouse reserves the right to modify product technical specifications and components without prior notice FOR THE INSTALLER DA 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 ordinances The latest version of the Nat
106. ve 10 pin Molex connector from customer connection board If LOU clears the problem is with external sensor wiring Examine external sensor LOU 24 Volt Low Until Corrected wiring for shorts to ground repairing as necessary If LOU code is still present and the heater is so equipped disconnect high gas pressure switch then low gas pressure switch then UL 353 low water cutoff in this order one at a time to see if LOU code clears Replace faulty part Check low voltage wire harness in heater for shorts to ground 4 If LOU only occurs when burner tries to light check gas valve for excessive current draw 5 If LOU is present with the low voltage harness disconnected from the 926 control board replace the 926 control board Table 14 Control Board Error Codes WHL 019 REV 12 17 14 50 926 CONTROL BOARD FAULT CODE DESCRIPTION REMEDY 1 Try reset If FOO repeats create a demand for hot water DANGER Use caution to prevent burn injury If water is above 194 F test upper and lower temperature sensor with an ohmmeter Refer to resistance chart this section Replace bad sensor If water is below 194 F test high temperature switch and wiring with FOO High temperature switch ohmmeter Switch should be closed at this point If not replace switch limit exceeded 194 F 2 If unit did reset successfully let the heater run and go into the status menu to check the upper and l
107. while in operation rod of flame signal The 5 Assure that the flame is stable when lit eater will relight 4 times 5 F10 before the control goes 3 Check to see if the green light on the display module is out while the heater is running us 4 If the green light doesn t come on or goes off during operation check the flame signal on the status menu IAG 5 If the signal reads less than 1 microampere clean the flame rectifier probe Will reset in 1 hour 9 6 If the flame rectifier probe continues to read low replace it False flame signal The 1 Turn the gas off to the unit at the service valve heater will lock out if it 2 If the flame signal is still present replace the igniter EI senses a flame signal 3 If the flame signal is not present after turning off the gas supply check the gas valve electrical connection when there should be 4 If there is no power to the gas valve remove the valve and check for obstruction in the valve seat or replace none present the gas valve 5 Turn the gas on at the service valve after corrective action is taken Combustion fan speed 1 Check the combustion air fan wiring incorrect The heater will 2 Replace the combustion air fan lock out if it senses that 3 Replace the control board the fan speed is less than 70 of expected rate for more than 60 seconds Table 15 NOTE If you replace a part to remedy
108. will cause flue gas spillage or appliance malfunction resulting in possible substantial property damage severe personal injury or death WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death When removing an existing heater follow the steps below 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch to determine if there is blockage leakage corrosion or other deficiencies that could cause an unsafe condition 3 If practical close all building doors windows and doors between the space in which the 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 Breathing Hazard Carbon Monoxide Gas Do not operate heater flood damaged Install vent system
109. wing recognized design methods See expansion tank manufacturer s instructions for details 4 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 The domestic water connections must be installed in accordance to all local and national plumbing codes or any applicable standard which prevails The inlet and outlet ports are 1 on 55 gallon models and 1 on 80 119 gallon models On the cold inlet install a 1 brass tee 55 gallon models or a 1 1 2 tee on 80 119 gallon models On the run of the 1 brass tee install a 1 brass drain cock or equivalent with pipe sealant compound In the branch of the 1 or a 1 brass tee install a copper male adapter to match your copper plumbing system For convenience you may install a sweat shut off valve and a union in the cold inlet piping 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 pr

Westinghouse WGC055NG100 Installation Manual

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