Gas Fired Commercial Water Heater INSTALLATION START-UP 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 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.
IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electrical switch. Do not use any phone in your building. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important product information. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
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 INFORMATION ..........................................................................................................................5 A. PRECAUTIONS ...................................................................................................
F. LONGER VENT RUNS ............................................................................................................................................................. 30 G. EXHAUST VENT AND INTAKE PIPE INSTALLATION ............................................................................................................ 31 H. VENTING DRAWINGS ........................................................................................................................................................
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. 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.
PART 2 – BEFORE YOU START A. WHAT’S IN THE BOX Also included with the heater: 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) B.
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.
A. BEFORE LOCATING THE HEATER 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. Failure of heater or components due to incorrect operating conditions IS NOT covered by product warranty. 1.
C. CLEARANCES FOR SERVICE ACCESS 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. The space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the heater. The heater cover must be securely fastened to prevent the heater from drawing air form the heater room.
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.
PRODUCTS TO AVOID Spray cans containing fluorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric or Muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine-type bleaches, laundry detergents, and cleaning solvents Adhesives used to fasten building products AREAS LIKELY TO HAVE CONTAMINANTS D
H. WATER CHEMISTRY Chemical imbalance of the water supply may affect efficiency and cause severe damage to the water heater and associated equipment. Westinghouse recommends having water quality professionally analyzed to determine whether it is necessary to install a water softener. It is important that the water chemistry on both the domestic hot water and central heating sides are checked before installing the water heater, as water quality will affect the reliability of the system.
Figure 3 – *ALL DIMENSIONS ARE APPROXIMATE WHL-019 REV. 12.17.
Figure 4 - Phoenix Multi Fit Specifications and Dimensions UNCRATING HEATER – Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. o COLD WEATHER HANDLING – If the heater has been stored in a very cold location (BELOW 0 F) before installation, handle with care until the plastic components come to room temperature. Remove all sides of the shipping crate to allow the heater to be lifted into its installation location. WHL-019 REV.
PERFORMANCE SPECIFICATIONS FOR ALL MODELS BTUH Efficiency 100,000 96% 130,000 96% 160,000 96% 199,000 96% (°F) (°C) GPH GPM LPH LPM GPH GPM LPH LPM GPH GPM LPH LPM GPH GPM LPH LPM 40 22 298 5 1128 18.8 384 6.4 1454 24.25 470 7.8 1779 29.7 582 9.7 2203 36.7 50 28 240 4 908 15.1 309 5.2 1170 19.5 378 6.3 1431 23.9 468 7.8 1772 29.5 60 33 202 3.4 765 12.75 260 4.3 984 16.4 317 5.3 1200 20 392 6.5 1484 24.7 Temperature Rise 70 80 90 39 44 50 173 152 136 2.9 2.5 2.25 655 575 515 10.9 9.6 8.
B. SCALDING APPROXIMATE TIME / TEMPERATURE RELATIONSHIPS IN SCALDS o 120 F More than 5 minutes o 125 F 1 ½ to 2 minutes o 130 F About 30 seconds o 135 F About 10 seconds o 140 F Less than 5 seconds o 145 F Less than 3 seconds o 150 F About 1 ½ seconds o 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.
EXPANSION TANK AND MAKE-UP WATER 1. Ensure that the expansion tank is sized to correctly handle heater and system water volume and temperature. Undersized expansion tanks cause system water to be lost from the relief valve, causing make-up water to be added. Eventual heater failure can result due to excessive make-up water addition. SUCH FAILURE IS NOT COVERED BY WARRANTY. 2. The expansion tank must be located as shown in the Heater Piping Details, or following recognized design methods.
H. PIPING DIAGRAMS 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.
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.
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 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.
Figure 8 –Closed Loop with Radiant Heating 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.
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.
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.
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.
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.
PART 5 – VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL The heater must be vented as detailed in this Venting Section. 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.
B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE Item Exhaust vent or Intake pipe and fittings Pipe cement/primer APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL Standards for Installation in: Material United States Canada PVC schedule 40/80 ANSI/ASTM D1785 PP, CPVC, and PVC venting must be ULCPVC-DWV* ANSI/ASTM D2665 S636 Certified. IPEX is an approved manufacturer in Canada, supplying vent CPVC schedule 40/80 ANSI/ASTM F441 material listed to ULC-S636.
D. EXHAUST VENT AND INTAKE PIPE LOCATION 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.
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.
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.
DESCRIPTION 2” PVC CONCENTRIC VENT TERMINATION KIT 3” PVC CONCENTRIC VENT TERMINATION KIT 2” STAINLESS STEEL VENT TERMINATION KIT 3” STAINLESS STEEL VENT TERMINATION KIT 4” STAINLESS STEEL VENT TERMINATION KIT 3” POLYPRO VENT KIT STOCK CODE KGAVT0501CVT KGAVT0601CVT V500 V1000 V2000 8400P-001 Table 8 H. VENTING DRAWINGS 1.
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. All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the heater to allow drainage of condensate.
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. All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” 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.
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 located 1” vertical below overhang (overhang means top of building structure and not two adjacent walls [corner of building]). B. Typical installations require 12” minimum separation between bottom of exhaust outlet and top of air intake. C. Maintain 12” minimum clearance above highest anticipated snow level or grade (whichever is greater). D.
Do not install the heater into a common existing vent with any other appliance. This will cause flue gas spillage or heater malfunction, resulting in substantial property damage, severe personal injury, or death. 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.
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.
Figure 20 WHL-019 REV. 12.17.
I. CONDENSATE REMOVAL SYSTEM NOTE: Check with your local gas company to determine if combustion condensate disposal is permitted in your area. In the state of Massachusetts, condensate must be neutralized before entering a drain. This condensing high efficiency water heater has a condensate removal system. Condensate is water vapor derived from combustion products, similar to an automobile when it is initially started.
B. 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.
D. INTERNAL WIRING DIAGRAM Figure 23 – Wiring Diagram WHL-019 REV. 12.17.
Figure 24 – LP-179-L WHL-019 REV. 12.17.
PART 7 – GAS CONNECTIONS 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 (350 mm), ½ 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.
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.
PART 8 – START-UP PROCEDURE 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.
|d3| — |0| (Not used) |d4| — |308| (Not used) |d5| — Outdoor sensor |d6| — Actual fan speed multiplied by 10 (Example: If fan speed displayed is |410| RPM x 10 = 4100 actual fan speed) |d7| — Actual ionization current read from flame rectification probe |d8| — |0| (Not used) |d9| — |1| (Not used) |d10| — Actual status of bus communication |co| = connected, |nc| = not connected |d11| — |32| (Not used) |d12| — Power on hours in thousands (display will not read until 100 hrs.
du setting / Function 9 Function 11 Function 8 Function 10 Function 12 Figure 27 - NOTE: The maximum tank temperature is 160oF, independent of all settings described above. E. 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.
PART 9 – SHUTDOWN A. SHUTDOWN PROCEDURE If the burner is not operating, disconnect the electrical supply. o 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 o If there is danger of freezing, change the set point to 70 F. DO NOT turn off electrical power.
When servicing or replacing components that are in direct contact with heater water, be certain that: There is no pressure in the heater. Pull the release on the relief valve to relieve pressure in the heater. Heater water is not hot. The electrical power is off. 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.
CODE DESCRIPTION F00 High temperature switch limit exceeded 194oF. F01 Vent temperature limit exceeded. F02 F03 F05 F06 F09 F10 F11F Interrupted or shorted upper temperature sensor. Interrupted or shorted lower temperature sensor. Upper temperature sensor exceeds 194oF. Lower temperature sensor exceeds 194oF. No flame detected – Heater will make three attempts at ignition before the control goes into this lockout condition. Will reset in 1 hour.
Figure 28 – LP-179-J WHL-019 REV. 12.17.
Figure 29 – LP-179-H WHL-019 REV. 12.17.
PART 11 - MAINTENANCE 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! 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.
WHL-019 REV. 12.17.
WHL-019 REV. 12.17.
MAINTENANCE NOTES WHL-019 REV. 12.17.
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.
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.
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.
