2814 182x257 Internal 30/11/05 14:34 Page 1 Installation Guide, Operation and Maintenance Manual Internal FASTTflo CONTINUOUS FLOW WALL HUNG BALANCED FLUE HEATERS FOR NATURAL GAS AND LPG WH42 WH56 LWH42 LWH56 THIS MANUAL MUST BE KEPT WITH THE APPLIANCE November 2005 Part No.
12814 182x257 Internal 30/11/05 14:34 Page 2 Copyright Andrews Water Heaters 2005 Reproduction of any information in this publication by any method is not permitted unless prior written approval has been obtained from Andrews Water Heaters. Andrews Storage Water Heaters have been designed and manufactured to comply with current International standards of safety.
12814 182x257 Internal 30/11/05 14:34 Page 3 CONTENTS PAGE 1) Included Accessories 2 2) Optional Accessories 2-3 3) Quick Connect Multi System Installation 4 4) Before Installation 5 5) Choosing Installation Site 6 6) Installation Clearances 7 7) Installation 8 8) Flue Pipe Installation 9) Gas Piping 16 10) Water Piping 17 11) Electrical Wiring 18-19 12) Commissioning 20-21 13) Dimensions 22-23 14) Remote Controller Installation Manual 15) Optional Accessories
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Installation Manual GAS WATER HEATER WH42, LWH42 WH56, LWH56 (Internal) (Internal) WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. Potential dangers from accidents during installation and use are divided into the following three categories. Closely observe these warnings, they are critical to your safety.
1. Included Accessories Part Shape The following accessories are included with the unit. Check for any missing items before starting installation. Q’ty Part Owner's Guide 1 Installation Manual (this document) 1 Crescent clamp 1 Drain hose 1 Tapping Screw 5 Remote Controller 1 2. Optional Accessories Part Shape Shape Q’ty The accessories listed below are not included with the units, but may be necessary for installation.
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3. Quick Connect Multi System Installation • The Quick Connect Multi System allows the installation of two units together utilizing only the Quick Connect Cord. The Quick Connect Cord is 2m. long. Install the two units 470mm-950mm apart at the center to ensure the cord will be able to reach between the units. (See Typical Plumbing diagram).
4. Before Installation Caution Check the Gas • Check that the rating plate indicates the correct type of gas. Check that the gas supply line is sized for 62.3 kW for this unit. Check the Power • The power supply required is 230V AC, at 50Hz. Using the incorrect voltage may result in fire or electric shock. Do Not Use Equipment for Purposes Other Than Those Specified • Do not use for purposes other than increasing the temperature of the water supply, as unexpected accidents may occur as a result.
5. Choosing Installation Site The appliance must be installed in a suitably ventilated room, in accordance with the regulatins in force. * Locate the appliance in an area where leakage from the unit or connections will not result in damage to the area adjacent to the appliance or to the lower floors of the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow.
6. Installation Clearances Caution Before installing, check for the following: The appliance must be installed in a suitably ventilated room, in accordance with the regulations in force. Install in accordance with relevant building and mechanical codes, as well as any local, state or national regulations. Distance from combustibles Item Check Illustration • Maintain the following clearances from both combustible and non-combustible materials.
7. Installation Securing to the wall • The weight of the device will be applied to the wall. If the strength of the wall is not sufficient, reinforcement must be done to prevent the transfer of vibration. • Do not drop or apply unnecessary force to the device when installing. Internal parts may be damaged and may become highly dangerous. • Install the unit on a vertical wall and ensure that it is level.
8. Flue Pipe Installation (Internal Installation Only) Flue Terminal Installation • Follow the installation instructions included with the flue terminal and which are reproduced at the end of this manual. This appliance must be the flue through the wall, not vertically to the roof.
Detailed recommendations for the flue installations are given in BS 5440:1:2000. The following notes are for general guidance only. Note: An adapter is always required on top of the heater. For the vertical flue set up, offset adapter will be supplied for the air intake. a) The flue system must be constructed using only Powermax approved components. b) It is important that the position of the terminal allows free passage of air across it at all times.
Installing Horizontal Extended Terminal Important: The flue terminal must be installed horizontally. 1. Mark the centre of the 152mm diameter hole and core drill. Note: If the wall is clad with a combustible material an additional 25mm wide area must be removed around liner. 2. Measure the wall thickness and cut the liner to this length. Note: Cut opposite end to rim and allow some material to be used as tabs on the inside of the wall to ensure a secure fixing.
• M&G HORIZONTAL FLUE TERMINAL Maximum length 7000 with 4 x 90° bends Maximum length 12000 with 1 x 90° bend Standard length 565 160 Air and flue adapter AdjustIble plate Minimum length 750 Standard length cut to suit wall thickness 300 Minimum Service clearance 720 720 Minimum length 845 Straight roof Standard length 1145 Pitched roof Maximum length 845 720 720 Standard length 1145 Flat roof Pitched roof 362 Air and flue adapter 150 Air and flue adapter 175 Maximum length 7000 with 4
M&G HORIZONTAL FLUE TERMINAL • Use only the following models of the flue terminals with this unit. • The M&G Horizontal Flue Terminal can be cut to suit the wall thickness. Wall thickness 50 mm to 500 mm Flue system installation example Elbows Straight pipe Intake pipe slo g pin Flue Terminal dow n Exhaust pipe Elbow Main unit Special adapter Seal any connections that are not gas tight using a high temperature silicone sealant. Flue Precautions • Use 100mm diameter flue pipe.
M&G VERTICAL FLUE TERMINAL • Use only the following models of the flue terminals with this unit. • The M&G Vertical Flue Terminal can be cut to suit the roof.
Under the exhaust conditions indicated by the shaded portion of the table below, the connector for switching the airflow rate shown in the illustration below is pulled out. (Changes the speed of fan rotation.
9. Gas Piping Follow the instructions from the gas supplier. The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 35 mbar. The Appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 35 mbar.
10. Water Piping Ask a qualified plumber to perform the installation of the plumbing. Observe all applicable codes. This appliance is suitable for potable water. Do not use this appliance if any part has been underwater. Immediately call a qualified service technician to inspect the appliance and replace any part of the control system and gas control which has been under water.
11. Electrical Wiring Consult a qualified electrician for the electrical work. Do not connect electrical power to the unit until all electrical wiring has been completed. i) "A means of disconnection from the supply mains having a contact separation in all poles must be provided to allow for full disconnection". ii) Under voltage Cat III conditions should be incorporated in the fixed wiring in accordance with the wiring regulations.
Remote Controller • Applicable Model WH42, LWH42, WH56, LWH56 Remote controller • Main RC-7508M The remote controller must be installed in accordance with the installation manual enclosed in the package. Connecting Remote Controller Cord to Unit • • • • Keep the remote controller cord away from the freeze prevention heaters in the unit. Tie the redundant cord outside the water heater. Do not put the extra length inside the equipment.
12. Commissioning The installer should test operate the unit, explain to the customer how to use the unit, and give the owner this manual before leaving the installation NOTE: The appliance has been factory set and no adjustment is necessary. • Preparation ... (1) Ensure all lines are purged / flushed of debris prior to connection to appliance. (2) Open the shut off valve on the water supply, check that water passes through the valve and close the valve.
Lighting Instructions This water heater does not have a pilot. It is equipped with an ignition device that automatically lights the burner. 1. Read the safety information in the installation manual or on the front of the water heater. 2. Turn off all electrical power to the unit. 3. Do not attempt to light the burner by hand. 4. Turn the gas control manual valve (external to the unit) clockwise to the off position. 5. Wait five minutes to clear out any gas.
13. Dimensions (unit: mm) WH42, LWH42, WH56, LWH56 (VIEW FROM TOP) 361 244 GAS INLET (3/4) 450 140 87 71 173 89 61 COLD WATER INLET (3/4") HOT WATER OUTLET (3/4) 給気 排気 WIRING THROUGHWAYS 464 170 140 100 10 450 240 150 94 AIR INLET 39.
Wiring Diagram ( WH42, LWH42, WH56, LWH56) BR BR W 1 2 3 (UN-USED) AIRFLOW CHANGE -OVER CONNECTOR R W O 1 2 3 4 5 6 7 BL 1 2 3 4 5 6 BL BL 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 MAIN CIRCUIT BOARD INLET WATER THERMISTOR W 3 W 2 W 1 W HEAT EXCHANGER THERMISTOR W W 4 W 3 2 W 1 W W W 2 W W 1 W 2 1 BK W MAIN WATER FLOW CONTROL VALVE SM (VCC) LS (VCC) (Fully open) (GND) 2 1 4 3 6 5 8 7 10 9 12 11 14 13 16 15 18 17 20 19 22 21 24 23 26 25 28 27
14. Remote Controller Installation Manual Model Number: For Installers: Read this installation guide carefully before carrying out installation. RC-7508M Note Do not connect power to the water heater before the remote controller has been properly installed. Included Accessories Part Shape Q’ty Part Shape Remote Controller 1 Cross recessed flat-head screw 2 Cross recessed flathead wood screw 2 Wall anchor 2 Q’ty Remote Controller Installation Procedure (1) Remove the decorative cover.
15. Optional Accessories Guide For Installers: Read this installation guide carefully before carrying out installation. 15-1. Flue Terminal Installation Manual FF-100-200 FF-100-400 FF-100-700 Model Numbers: Icons warning of risk level: WARNING Denotes content that may result in personal injury or property damage if ignored. Prohibited CAUTION This symbol warns of hazards which have the immediate potential to result in severe or lethal personal injury or fire.
15-1-2. Before Installation Caution Compatibility Check • Make sure that the flue terminal is compatible with the product it will be installed with. If an improper terminal is used, a fire hazard will be created. Choosing the Installation Site • Maintain the proper clearances to combustibles The heat and moisture from the water heater may cause corrosion of aluminum materials. • Install the flue terminal so that it is easily accessible for maintenance from both the indoors and the outdoors.
15-1-3. Installation Requirements 300 mm or more 300 mm or more 300 mm or more Above Flue Terminal Clearance Requirements Clearances from obstacles Clearances from combustibles Flue Terminal Caution Flue terminal installation precautions Note the following flue terminal installation requirements.
15-1-4. Flue Terminal Installation Procedure 1) Determine the flue terminal installation location and make a 160 mm diameter hole. Install the sleeve into the hole with the triangular mark ( ) pointing up. Use the wall anchors and rounded wood screws. Before installing the sleeve, adjust its length to fit the wall thickness. (The length can be adjusted in increments of 10 mm.) Remove this screw Slide out the external cylinder and slide out the until it is flush with the external external cylinder.
3) Adjusting the flue terminal length Make sure the flue terminal has been set to the appropriate length and the outlet is oriented properly to prevent combustion and operation problems. The length of the flue terminal must be adjusted to fit with the wall thickness before the installation is completed. Note: If the flue terminal will be installed in orientations (2) or (3) from the table on the previous page, the outlet cylinder will have to be rotated so that it is oriented properly.
5) Connect the heater and the flue terminal using 100 diameter supply and exhaust pipes. Flue Terminal Intake pipe Make sure the connections are secure and take measures to prevent exhaust gas from leaking. Seal any connections that are not gas tight using a high temperature silicone sealant. Exhaust pipe Water heater Connect the flue pipe to the flue terminal as follows: Flue pipe Connecting: following procedure A to C.
15-1-5. Installation Overview Exhaust pipe connection Flue Terminal Intake pipe connection Intake pipe connection Exhaust pipe connection Water heater Flue pipe installation precautions • Do not extend the flue pipe longer than the maximum limits as stated in the installation manual. The flue lengths longer than the stated maximum are dangerous and may cause a fire or explosion. • Avoid installing the flue pipe in an enclosure if possible. • Do not install a damper on the intake or exhaust pipe.
15-1-6. Dimensions (Unit : mm) After installation (2) Wall hole dia.:160 (1) (3) Installation orientation options Top 13 Supply 121 Top Top Exhaust Exhaust Wall thickness Exhaust Supply Bottom (2) Wall flange (1) Sleeve 174 162 174 162 142 le . ho dia 8 14 4 14 192 210 (3) Flue Terminal 108 L2 External dia.: 140 External dia.:102 140 60 300 270 150 28 174 234 External dia.: 122 40 10 20 20.5 192 14.5 10.
15-2. Flue Terminal Installation Manual FF-100A-200 FF-100A-400 FF-100A-700 Model Numbers: Icons warning of risk level: WARNING Denotes content that may result in personal injury or property damage if ignored. Prohibited CAUTION This symbol warns of hazards which have the immediate potential to result in severe or lethal personal injury or fire.
15-2-2. Before Installation Caution Compatibility Check • Make sure that the flue terminal is compatible with the product it will be installed with. If an improper terminal is used, a fire hazard will be created. Choosing the Installation Site • Maintain the proper clearances to combustibles The heat and moisture from the water heater may cause corrosion of aluminum materials. • Install the flue terminal so that it is easily accessible for maintenance from both the indoors and the outdoors.
15-2-3. Installation Requirements Flue Terminal Clearance Requirements 300 mm or more Clearances from combustibles 300 mm or more 300 mm or more Above Clearances from obstacles Flue Terminal Caution Flue terminal installation precautions Note the following flue terminal installation requirements.
15-2-4. Flue Terminal Installation Procedure * When drilling, take care not to damage electric wiring, or gas or water piping in walls. 1) Determine the flue terminal installation location and make a 160 mm diameter hole in the wall for the sleeve and 7.2 mm diameter holes for the screws to hold the sleeve. 160 mm diameter hole for the flue terminal sleeve Center line of the flue terminal 200 to 245 142 142 Screw holes (4) (7.2 mm diameter and 35 to 40 mm depth).
4) Adjusting the flue terminal length Combustion and operation problems my result if the flue terminal isn't set to the appropriate length. Remove this screw and slide out the external cylinder. The length of the flue terminal must be adjusted to fit the wall thickness before the installation is completed. External wall surface Intake slide pipe Exhaust slide pipe The red line should be visible. The red rectangle should not be visible from the outdoors.
15-2-5. Dimensions (1) Sleeve After installation External diameter: 151 de Instier: 146 e m a di 140 Wall hole dia.:160 (2) 2 210 192 142 174 142 (1) Wall thickness 180 8 L1 105 Min. projection: 75 (Max. projection: 105) (2) Flue Terminal 330 290 180 70 20 140 105 14.
16. Servicing Important Notes To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a year should be enough. It is the Law that any servicing is carried out by a competent person.
(2) Remove the 2 locking screws of the transformer, then pull out. 2. Removing the electric board (1) Remove the locking screws at the top and bottom and ground screw, then pull board out. 3. Removing the manifold • Remove the electric board and fixing plate of the ground-fault circuit interrupter in advance. (1) Remove the locking screw of the gas electromagnetic valve and the manifold pipe. 40 (L)WH42_56(39_44)_E Page 40 05.9.26, 7:48 PM Adobe PageMaker 6.
(2) Remove the fasten terminal of the gas electromagnetic valve, then remove the 4 manifold locking screws. (3) Pull up and remove the manifold. 4. Removing the hot-water supply fan • Remove the electric board, manifold and intake gas pipe in advance. (1) Remove the 3 fan locking screws, then pull out. 41 (L)WH42_56(39_44)_E Page 41 05.9.26, 7:48 PM Adobe PageMaker 6.
(2) Pull out the fan motor. 5. Removing the gas electromagnetic valve block • Remove the electric board and manifold in advance. (1) Remove the gas electromagnetic valve locking screw. (2) Pull up the gas electromagnetic valve to the upper section and remove it. 42 (L)WH42_56(39_44)_E Page 42 05.9.26, 7:48 PM Adobe PageMaker 6.
6. Removing the mixing tube block • Remove the electric board and connectors in advance. (1) Remove the locking screw of the intake water pipe and the locking quick fastener of water flow sensor set 3 of the heat exchanger, then pull out the intake water pipe. For Quick-discharge type Remove the intake water pipe locking screw and 2 locking fasteners of the non-return valve, then remove the intake water pipe and pull out the pump discharge pipe.
(4) Pull up the mixing tube block to the upper section and remove it. 7. Removing the heat exchanger • Remove the electric board, manifold, mixing tube block and connectors in advance. (1) Remove the 3 locking screws at the bottom of the burner case. (2) Remove the 2 case top plate locking screws. (3) Remove the 3 locking screws at the flue collar and adapter, pull out the heat exchanger. 44 (L)WH42_56(39_44)_E Page 44 05.9.26, 7:48 PM Adobe PageMaker 6.
18. Servicing parts lists External outfitting WH42AD,WH56AD 072 072 006 007 010 013 072 009 014 024 070 025 012 070 001 003 050 002 015 071 023 028 003 029 022 070 075 039 070 005 002 004 730 45 WH42AD,56AD印刷 Page 45 05.9.26, 7:48 PM Adobe PageMaker 6.
External outfitting WH42AD,WH56AD Part Nos.
Combustion unit and gas route WH42AD,WH56AD 100 109 102 101 105 110 117 103 126 116 131 070 104 072 117 070 132 070 118 129 173 128 073 171 172 170 111 112 114 070 119 125 141 115 070 070 173 133 175 175 122 For WH42AD 3P For WH56AD 3P 121 121 120 123 172 171 124 127 172 075 47 WH42AD,56AD印刷 Page 47 05.9.26, 7:48 PM Adobe PageMaker 6.
Combustion unit and gas route WH42AD,WH56AD Part Nos. Order Nos.
Hot-water feed route WH42AD,WH56AD 412 425 456 424 413 402 A 434 428 401 508 507 427 456 421 D 433 412 434 423 468 406 B 413 484 510 402 483 407 400 470 417 402 402 C 173 471 408 412 472 406 435 452 414 409 471 172 413 456 410 511 418 412 509 434 413 441 411 075 511 422 A 456 413 508 435 412 458 434 444 442 507 B 420 073 463 428 454 D 453 172 431 434 468 456 437 434 172 445 434 446 440 455 439 456 C 443 418 509 447 438 172 509 4
Hot-water feed route WH42AD,WH56AD (Thermal fuse rounding procedure) (Left side view) (Front side view) (Right side view) (Rear side view) Freeze preventive heater 1.Beginning of roll Thermal fuse fastener Heat exchanger SET Thermal fuse Thermal fuse fastener 50 WH42AD,56AD印刷 Page 50 05.9.26, 7:48 PM Adobe PageMaker 6.
Hot-water feed route WH42AD,WH56AD Part Nos.
Electronic control unit WH42AD,WH56AD 705 701 F G 700 H 073 703 732 070 714 710 715 070 717 711 722 H 070 712 070 070 730 731 721 733 073 721 713 G F 52 WH42AD,56AD印刷 Page 52 05.9.26, 7:48 PM Adobe PageMaker 6.
Electronic control unit WH42AD,WH56AD Part Nos. Part Names Order Nos.
Remote controller and Attached set WH42AD,WH56AD Remote controller (RC-7508M) 751 787 788 786 752 Attached set 803 804 805 Special part Special part no. Owner's Guide 888 installation manual 889 54 WH42AD,56AD印刷 Page 54 05.9.26, 7:48 PM Adobe PageMaker 6.
Remote controller and Attached set WH42AD,WH56AD Part Nos. Part Names Order Nos. Q'ty/unit QPAJ013 QPAA013 1 1 751 752 RC-7508M Body AD(SE) QPA M Dressed frame body AD(SE) 786 787 788 Oar plug 6X25 Cross recessed flat-head screw M4X35 Cross recessed flat-head wood screw (All screw)4.1X20 6339000 SHB6879 SHC6365 800 803 804 805 888 889 GQ3211WZFF2AD packing set V Cross recessed round-head type 1 tapping screw 5X35 Crescent clamp 18.5 Drain hose ID17XT1.
Specifications Specifications Specification Item Model Name Type WH42 Installation Air Supply/Exhaust Ignition Minimum Pressure for Maximum flow Minimum Flow Rate Dimensions Weight Water Holding Capacity Connection Sizes Water Inlet Power Supply Materials Hot Water Outlet Gas Inlet Supply Consumption Casing Flue Collar Heat Exchanger LWH42 Internal, Wall Hanging Power Flue Direct Ignition 2.0 bar 3.5 L/min. 61.5 cm(Height) x 46.4 cm(Width) x 24 cm(Depth) 29 kg 1.
• Specifications may be changed without prior notice. • The capacity may differ slightly, depending on the water pressure, water supply, piping conditions, and water temperature.
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12814 182x257 Internal 30/11/05 14:34 Page 7 Andrews Water Heaters Wednesbury One Black Country New Road Wednesbury West Midlands WS10 7NZ Tel: +44 (0)121 506 7400 Fax: +44 (0)121 506 7401 Email: andrews@andrews-waterheaters.co.uk Website: www.andrewswaterheaters.co.
