High Efficiency Water Heater INSTALLATION START-UP MAINTENANCE PARTS Models* WGR050NG076 / WGR060NG076 / WGR080NG076 WGR050LP076 / WGR060LP076 / WGR080LP076 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.
In Canada – CGA No. B149 (latest version), from Canadian Gas Association Laboratories, 55 Scarsdale Road, Don Mills, Ontario, Canada M3B 2R3. Also, Canadian Electrical Code C 22.1, from Canadian Standards Association, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6. Code for the installation of Heat Producing Appliances (latest version), from American Insurance Association, 85 John Street, New York, NY 11038. The latest version of the National Electrical Code, NFPA No. 70.
PART 5 – VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL............................................................................ 23 A. GENERAL ...................................................................................................................................................................................................... 23 B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE ...........................................................................................................
D. IMPORTANT NOTICE .................................................................................................................................................................................... 49 PART 11 – TROUBLESHOOTING ............................................................................................................................................ 49 A. ERROR CODE .........................................................................................................................
C. GAS Should overheating or gas supply fail to shut off, turn off the manual gas control valve to the water heater. D. WHEN SERVICING THE HEATER To avoid electric shock, disconnect electrical supply before performing maintenance. To avoid severe burns, allow heater to cool. E. HEATER WATER Do not use petroleum-based cleaning or sealing compounds in a heater system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.
Modulating Combustion System Modulation during water heating operation is based on tank temperature. The control monitors the system to regulate burner output during operation to match system demand. This increase in efficiency allows for substantial fuel savings. High Output Cold Water Dip Tube (Optional – Supplied with Water Heater) Increases hot water draw by 20% when installed. The High Output Cold Water Dip Tube also increases recovery time by 20%, and decreases thermal efficiency by a small amount.
PART 3 – PREPARE WATER HEATER LOCATION Carefully consider installation when determining heater location. Please read the entire manual before attempting installation. Failure to properly take factors such as heater venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury. A.
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. B. LEVELING In order for the condensate to properly flow out of the collection system, the area where you locate the heater must be level.
When raising the heater, fully support the entire bottom of the water heater. 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.
If the confined space is within a building of tight construction, air for combustion must be obtained from the outdoors as outlined in the Venting section, Part 5 of this manual. When drawing combustion air from the outside into the mechanical room, care must be taken to provide adequate freeze protection. Do not attempt to vent this water heater by any means other than those described in this manual. Doing so will void the warranty, and may result in severe personal injury or death.
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.
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.
Figure 3 – *ALL DIMENSIONS ARE APPROXIMATE 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-001 REV. 9.3.
BTUH 76,000 PERFORMANCE SPECIFICATIONS FOR HIGH EFFICIENCY WATER HEATER MODELS Temperature Rise in Degrees Fahrenheit Efficiency (°F) 40 50 60 70 80 90 100 110 120 (°C) 22 28 33 39 44 50 56 61 67 GPH 231 187 158 135 119 107 97 86 79 97% LPH 874 708 598 511 450 405 367 326 299 130 72 73 276 140 78 69 261 Table 2 – Recovery on rating plate is based at 97% thermal efficiency at 70o Fahrenheit rise, as required by ANSI PART 4 – HEATER PIPING Failure to follow the instructions in this section WILL VOID
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.
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. 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.
The water heater must be full of water and the system fully purged BEFORE powering the water heater. Applying power to the water heater when it is not full of water could result in a condition referred to as “dry-firing”. Dry-firing the water heater will damage the heat exchanger, and could result in property damage, serious personal injury, or death. Such damages ARE NOT covered by water heater warranty. I.
J. PIPING DIAGRAMS Figure 4 – High Efficiency Water Heater with Recirculation Line and Thermostatic Mixing Valve Piping NOTES: 1. Minimum pipe size should match unit connection size. Upsize pipe accordingly if greater flow is required. 2. A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold water inlet. 3. Gas line must be rated to the unit maximum input capacity.
Figure 5 – High Efficiency Water Heater with Air Handler on Side NOTES: 1. Minimum pipe size should match unit connection size. Upsize pipe accordingly if greater flow is required. 2. A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold water inlet. 3. Gas line must be rated to the unit maximum input capacity. Unit must have 10 feet of pipe after gas regulator. 4.
Figure 6 – High Efficiency Water Heater with Air Handler on Side NOTES: 1. Minimum pipe size should match unit connection size. Upsize pipe accordingly if greater flow is required. 2. A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold water inlet. 3. Gas line must be rated to the unit maximum input capacity. Unit must have 10 feet of pipe after gas regulator. 4.
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 PVC-DWV* ANSI/ASTM D2665 ULC-S636 Certified. IPEX is an approved manufacturer in Canada, supplying vent CPVC schedule 40/80 ANSI/ASTM F441 material listed to ULC-S636.
You must not use “B” vent in an exhaust application. “B” vent is for intake applications ONLY. Using “B” vent in an exhaust application will result in serious injury or death. D. EXHAUST VENT AND INTAKE PIPE LOCATION Figure 7 – 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 7 NOTES: INSTALLATIONS IN THE UNITED STATES A.
The building owner is responsible for keeping the exhaust and intake terminations free of snow, ice, or other potential blockages, as well as scheduling routine maintenance. Failure to keep the vent piping terminations clear and properly maintain the heater could result in property damage, severe personal injury, or death. 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.
G. EXHAUST VENT AND INTAKE PIPE INSTALLATION 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 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. 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.
Figure 9 – Venting with Optional Kits (NOT INCLUDED WITH THE WATER HEATER) NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. 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 10 – NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. WHL-001 REV. 9.3.
Figure 11 – Horizontal Venting - NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. NOTES: A. For every 1” of overhang, the exhaust vent must be located 1” vertical below overhang (overhang means top of building structure and not two adjacent walls [corner of building]). B. Typical installations require 12” minimum separation between bottom of exhaust outlet and top of air intake. C.
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 on page 12.
Figure 14 WHL-001 REV. 9.3.
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 that produced by an automobile when it is initially started.
Figure 16 – Removing and Installing the Condensate Neutralizer NOTICE To ensure proper condensate neutralization it is recommended to check the condensate neutralizer cartridge every two years. Gently shake the cartridge to ensure it is still filled with neutralization media. Replace the condensate neutralizer cartridge if it is empty. Failure to do so could result in improper condensate neutralization.
PART 6 – WIRING To avoid electrical shock, turn off all power to the heater prior to opening an electrical box within the unit. Ensure the power remains off while any wiring connections are being made. Failure to follow these instructions could result in component or product failure, serious injury, or death. Such product failure IS NOT covered by warranty. Jumping out control circuits or components WILL VOID product warranty and can result in property damage, personal injury, or death. A.
Label all wires prior to disconnecting them when servicing the heater. Wiring errors can cause improper and dangerous operation. Failure to follow these instructions may result in property damage or personal injury. D. INTERNAL WIRING DIAGRAM Figure 19 – Wiring Diagram PART 7 – GAS CONNECTIONS Failure to follow all precautions could result in fire, explosion, severe injury or death! Ensure the gas on which the water heater will operate is the same type specified on the rating plate.
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.
It is recommended that a soapy solution be used to detect leaks. Bubbles will appear on the pipe to indicate a leak is present. The gas piping must be sized for proper flow and length of pipe to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load. If you experience a pressure drop greater than 1" WC, the meter, regulator or gas line is undersized or in need of service.
PART 8 – CONTROLS A. CONTROL AND DISPLAY OVERVIEW Detailed Description of Button Functions 1. Setting Adjust Down 2. Setting Adjust Up 3. Decreases the User Setpoint 4. Increases the User Setpoint 5. ECO Mode 6. RESET 7. OFF / Mode Enable Figure 22 – Control Detail Detailed Description of Control Functions MODES OF OPERATION MODE SCREENSHOT DESCRIPTION Off Mode The water heater will ignore heat demands while in Off Mode.
ECO Mode Putting the water heater into ECO Mode reduces maximum firing rate to 80% of the rated maximum firing rate. This increases water heater efficiency in times of low hot water demand. Press to put the water heater into ECO mode. Press again to return to normal operation. Test Mode allows the installer to test water heater operation by running the fan at different speeds. Test Mode To enter Test Mode, press seconds. and Push to decrease or push 50 RPM increments.
4. CHANGING USER SETPOINT Press either or once to change the User Setpoint. The normal operation screen will clear and be replaced by a flashing number. This is the User Setpoint. o o Press to decrease or to increase the setpoint. The default setpoint is 120 F. The setpoint range is 70 – 160 F. After choosing the setpoint, wait five seconds. The screen will return to normal operation and the setpoint will be stored. C.
To enter Installer Mode, press and hold for five seconds. When the ( ) screen appears, Installer Mode is active. Press this screen to access the Technical Service Parameters codes (P00, P01, etc.). To change parameter value, press or once. The value will appear. Press to decrease or Press at this screen to accept the changed value and return to the Technical Service Parameters. Press to advance through the parameters.
1. Connect the outdoor sensor to the terminals marked “outdoor”. 2. Press at this screen to access the Technical Service Parameters codes (P00, P01, etc.). 3. Press to advance through the parameters. Press 4. 5. Go to P06 Enter desired MIN Outdoor Temp value 6. Press 7. To change parameter value, press or value. Enter desired MAX Outdoor Temp value 8. to return to the previous parameter. to advance to the next parameter. once. The value will appear.
To enter Installer Mode, press and hold for five seconds. When the ( ) screen appears, Installer Mode is active. Press twice to find History Mode. The control is ready to access the History Mode when the following screen appears on the display. Press at this screen to access the History Mode codes (H01, H02, etc.). Press to advance through the codes. Press To view code value, press Press or to return to the previous code. once. The value will appear.
PART 9 – 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.
Test mode can be used to incrementally increase and decrease fan speed to test the combustion system. See Tables 15 and 16 for Combustion Settings and Fan Speeds. 1. Use the and push buttons to change the fan speed (steps of 50 rpm) between the range maximum fan speed and minimum fan speed 2. Use the to go directly to the maximum fan speed 3. Use the to go directly to the minimum fan speed Range between minimum fan speed and maximum fan speed is taken as absolute power value (0 - 100%).
PART 10 – SHUTDOWN A. SHUTDOWN PROCEDURE o If the burner is not operating, lower the set point value to 70 F and wait for the burner to shut off. Continue to wait for the combustion blower to stop, so all latent combustion gases are purged from the system. This should take a maximum of 300 seconds (5 minutes). B. VACATION PROCEDURE o 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.
3. Press the key to clear the fault and resume operation. Be sure to observe the operation of the unit to prevent a recurrence of the fault. NOTE: You are allowed up to 5 “resets” to clear a Fault or Error code. After that, the controller will enter an |E13| Lockout state. When servicing or replacing any components of this water heater be certain that: The gas is off. All electrical power is disconnected.
CODE SHORT DESCRIPTION F01 Ignition Lockout Indication F02 False Flame Indication F03 High Limit Temperature Protection CONTROL BOARD LOCKOUT FAULTS LONG DESCRIPTION CORRECTIVE ACTION The control senses no flame after 1. Is the gas turned on to the water heater? three ignition attempts. 2. Manually reset the water heater. 3. Observe water heater operation. If fault code occurs again 4. Check for stable gas pressure. 5. Check Ignitor cable connections. 6. Check Ignitor cable gound. 7.
The data received from the tank sensors exceeds the difference allowed by the control. 1. 2. 3. 4. 5. F14 Tank Sensor Data Not Consistent F21 ADC Failure The ADC test has detected a major fault in the electronic components. Dual Temperature Sensor B is out of normal operating range, meaning the sensor is either open or shorted. 1. 2. 3. 1. 2. 3. 4. 5. F31 Dual Temperature Sensor B Error Dual Temperature Sensor A is out of normal operating range, meaning the sensor is either open or shorted.
Figure 25 – Replacement Parts WHL-001 REV. 9.3.
Figure 26 – Replacement Parts WHL-001 REV. 9.3.
PART 12 - 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.
Spark Electrode Combination Ignitor and Flame Probe CONDENSATE Neutralizer Condensate hose GAS Pressure Pressure Drop Check gas pipe for leaks COMBUSTION CO/CO2 Levels SAFETIES ECO (Energy Cut Out) Sensors FINAL INSPECTION Check list Clean. Set gap at ¼”. Clean probe with plumbers cloth to remove oxides. Check ionization in uA (i04 in the Inquiry Mode menu). Record high fire and low fire. Clean probe with plumbers cloth to remove oxides. Check condensate neutralizer. Replace if necessary.
WHL-001 REV. 9.3.
WHL-001 REV. 9.3.
MAINTENANCE NOTES WHL-001 REV. 9.3.
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.
