Residential Gas Hybrid Water Heater INSTALLATION START-UP MAINTENANCE PARTS WGRGH**199 Models* **A suffix of “NG” denotes natural gas A suffix of “LP” denotes propane gas NOTICE: Westinghouse reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature. NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE. The surfaces of these products contacted by consumable water contain less than 0.
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.
FOREWORD This manual is intended to be used in conjunction with other literature provided with the water heater. This includes all related control information. It is important that this manual, all other documents included with this system, and additional publications including the National Fuel Gas Code, ANSI Z223.1-2002, be reviewed in their entirety before beginning any work.
The latest version of the National Fuel Gas Code, ANSI Z223.1, from American Gas Association Laboratories, 8501 East Pleasant Valley Road, Cleveland, OH 44131. 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.
3. Screen Installation ..................................................................................................................................................................... 22 4. Power Vent, Indoor Combustion Air Installation in Confined or Unconfined Space ........................................................... 23 PART 6 – INSTALL THE CONDENSATE DRAIN .....................................................................................................................
PART 12 – TROUBLESHOOTING ............................................................................................................................................ 63 PART 13 – MAINTENANCE PROCEDURES ............................................................................................................................ 64 REPLACEMENT PARTS ................................................................................................................................................................
PART 2 – SAFETY REGULATIONS A. OPERATION AND INSTALLATION WARNINGS To avoid serious injury or death, read, understand, and follow all the precautions listed here. Vapors from flammable liquids will explode and can cause a fire, resulting in personal injury or death. The water heater has a burner that can come on at any time and ignite vapors. DO NOT use or store flammable liquids around the water heater. Improper venting can cause a build-up of carbon monoxide.
NOTICE Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. This water heater provides a overheat shutdown limit. In the event the water heater water exceeds the set point of the control limit, the cutoff will trip and the water heater will shut down. Certain local codes require additional temperature limits.
The water heater control is equipped with freeze protection that activates based on internal water temperature. See the table below for details on freeze protection operation. NOTE: Freeze protection will not be active if the water heater loses power. System Freeze Protection (Activates Based on Internal Water Temperature) Freeze Protection Operation Stage 1 – If control detects water temperature of 46oF (8oC) and below, it turns the internal and external pumps On for 600s and Off for 30s.
PART 3 – TECHNICAL SPECIFICATIONS MODEL Installation Minimum / Maximum Input (Btu/Hr) o 35 F Rise o Hot Water Capacity 45 F Rise o 77 F Rise Flue System Vent Run Weight (lbs) NG Orifice Size LP NG Gas Supply Pressure LP Min (3”) Manifold Pressure Max (3”) Main Supply Power Supply Maximum Power Consumption General Operating Conditions Ignition System Burner System Gas Valve System Minimum Flow Rate Internal Pipe Material Dimensions Heat Exchanger Water Capacity (DHW) Control Panel / Main Controller Wat
Figure 1 – Specifications and Dimensions A B C D E F G Table 6 – Adapter Specifications DESCRIPTION Air Intake Adapter Exhaust Outlet Adapter Gas Inlet Adapter Condensate Adapter DHW Outlet Adapter DHW Inlet Adapter Recirculation Return Adapter DIAMETER 3” 3” ¾” ½” ¾” ¾” ¾” WHL-590 REV. 7.27.
Figure 2 – Components NUMBER COMPONENT DESCRIPTION 1 Air Intake Adapter 2 Flue Air Pressure Sensor 3 Air Inlet Orifice 4 Air Inlet Pipe 5 Gas Outlet Pipe 6 Burner High Limit Switch 7 Gas Valve 8 Hot Water High Limit Switch 9 Heat Exchanger Water Thermistor 10 Gas Inlet Pipe 11 Hot Water Outlet Pipe 12 Manual Power Switch 13 Condensate Air Pressure Switch 14 Condensate Trap 15 Gas Pipe Adapter 16 Condensate Adapter 17 Hot Water Adapter 18 Hot Water Thermistor 19 Cold Water Inlet Adapter Table 7 – Compone
PART 4 – PREPARE WATER HEATER LOCATION Carefully consider installation when determining water heater location. Please read the entire manual before attempting installation. Failure to properly take factors such as water 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 water heater to freeze and leak. Incorrectly-sized expansion tank Do not connect the water heater to any heating systems or components that have been previously used for non-potable applications. Do not introduce toxic chemicals, such as antifreeze or water heater treatments, into the water heater or any piping meant for potable water purposes. Ensure that all piping and components connected to the water heater are suitable for potable water applications.
D. RESIDENTIAL GARAGE AND CLOSET INSTALLATIONS Check with your local Authority Having Jurisdiction for requirements when installing water heater in a garage or closet. Please read the entire manual before attempting installation. Failure to properly take factors such as venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.
G. REMOVING A WATER HEATER FROM A COMMON VENT SYSTEM Do not install the water heater into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible substantial property damage, severe personal injury, or death. 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 water heater, the following steps must be followed. 1.
This wall mounting system is not seismic rated and should not be applied as such. Failure to comply with the above and properly mount the water heater could result in substantial property damage, severe personal injury, or death. POSITIONING THE WATER HEATER ON THE WALL 1. Attach the wall bracket on the location where you want to install the water heater. Ensure it is level and on stud (16” centers) before proceeding. 2. Mark the four drill holes with a pencil or marker. Remove the wall bracket. 3.
A. INTAKE PIPE AND EXHAUST VENT GUIDELINES 1. Vent system must be installed in accordance with local codes, or, in absence of local codes, the National Fuel Gas Code, ANSI Z223.1 / NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Code. 2. For installation in Canada, installer supplied plastic vent piping must comply with CAN/CGA B149.1 and be certified to the Standard for Type BH Gas Venting Systems, ULC-S636.
Do not use the water heater to support any piping.
Item Exhaust vent or Intake pipe and fittings Pipe Cement Pipe Primer APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL Standards for Installation in: Material United States Canada PP, CPVC, and PVC venting must be CPVC schedule 40 ASTM-D2846 ULC-S636 Certified. IPEX is an approved PVC schedule 40 ANSI/ASTM D1785 manufacturer in Canada, supplying vent Polypropylene ULC-S636, UL-1738 material listed to ULC-S636.
3. 4. 5. Tighten the clamps using a screwdriver. Ensure the pipe is secure before continuing installation. For 2” installations, install the reducing coupling in a vertical section of pipe. At least a 6” length of 3” pipe MUST BE INSTALLED before reducing to 2”. See Figure 8. Figure 7 – Correct Installation into the Water Heater Collar Figure 8 – Transitioning from 3” to 2” Vent Pipe E. VENT TERMINATION 1.
2. Direct Vent, Optional Horizontal and Vertical Vent Kits Figure 10 – Direct Vent, Vent Terminations (With Optional Kits) All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the appliance to allow drainage of condensate. When placing support brackets on vent piping, the first bracket must be within 1 foot of the appliance and the balance at 4 foot intervals on the vent pipe.
4. Power Vent, 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 9. 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 heater input.
Figure 13 – Power Vent - NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. WHL-590 REV. 7.27.
PART 6 – INSTALL THE CONDENSATE DRAIN 1. Due to its efficient design, the water heater produces condensate (water) as a normal by-product. This condensate is acidic, with a pH level between 3 and 4. This condensate must be drained away from the water heater and disposed in accordance with all local regulations. 2. Use corrosion-resistant materials to drain condensate. Use the included flexible plastic hose or ½” PVC and CPVC drain pipe complying with ASTM D1785, F441, or D2665 may be used.
Maximum Natural Gas Delivery Capacity – Length of Black Iron Pipe (Sch. 40 Metallic) in Feet Cubic Feet per Hour (0.60 Specific Gravity, 0.
Figure 15 – Gas Line With Shut-Off Valve Detail 6. Test the gas pressure to make sure it meets the minimum standards and does not exceed the maximum standards of the water heater. 7. Leak test the gas line pipe before placing the water heater in operation. Only use approved leak detector liquid solutions to check for leaks. 8. Do not operate the water heater until all connections have been completed and the heat exchanger is filled with water.
C. ADDITIONAL PRECAUTION FOR EXCESS FLOW VALVE (EFV) If an excess flow valve (EFV) is in the gas line, check the manufacturer’s minimum and maximum flow capacity ratings. An improperly sized EFV will not allow for a full flow of gas to the water heater and will cause the water heater to malfunction. See Figure 18. D. ADJUSTING GAS PRESSURE AT THE WATER HEATER NOTE: Refer Figure 19 when adjusting gas pressure. Loosen the bolts before checking the gas inlet pressure. 1.
2. When low fire settings have been obtained, flip DIP switch seven (7) to its original (OFF) position. This will return the heater to normal operation. 3. Flip DIP switch six (6) to ON (high fire). Again check combustion readings with a combustion analyzer. NOTE: DO NOT adjust the gas valve offset screw at high fire. The offset screw is only used to adjust combustion values at low fire. 4. When complete, flip DIP switch six (6) to its original (OFF) position.
External Recirculation Mode – This mode keeps an external recirculation loop warm to make hot water production more efficient and also aid in freeze protection. An external recirculation line must be installed in order to recirculate water externally. The installer may program specific recirculation functions by day and time to circulate and heat water when the user most needs hot water. See Recirculation Functions, this manual, for details. B.
Figure 23 – DHW Piping, Single Water Heater – NOTE: There is a Built-In Flow Check in the Internal Pump Loop NOTES: 1. Minimum pipe size should match 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. All circulators should have an integral flow check. 4.
Figure 24 – Piping with Recirculation – NOTE: There is a Built-In Flow Check in the Internal Recirculation Pump Loop NOTE: For installations where internal pump is not adequate for the recirculation loop, an additional pump can be installed and powered by the water heater (2A Max). See Pressure Drop and Pump Curves, this manual. NOTES: 1. Minimum pipe size should match connection size. Upsize pipe accordingly if greater flow is required. 2.
Figure 25 – Water Heater with Storage Tank – NOTE: There is a Built-In Flow Check in the Internal Pump Loop NOTES: 1. Minimum pipe size should match 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. All circulators should have an integral flow check. 4.
Figure 26 – Water Heater with Storage Tank and Recirculation – NOTE: There is a Built-In Flow Check in the Internal Recirculation Pump Loop NOTES: 1. Minimum pipe size should match 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. All circulators should have an integral flow check. 4.
Figure 27 – Water Heater with Air Handler – NOTE: There is a Built-In Flow Check in the Internal Recirculation Pump Loop NOTE: If Preheat, Internal, or External Recirculation is active when using an Air Handler, a solenoid valve must be used to isolate air handler loop when central heating is not needed. NOTES: 1. Minimum pipe size should match connection size. Upsize pipe accordingly if greater flow is required. 2.
Figure 28 – Water Heater with Air Handler and Recirculation – NOTE: There is a Built-In Flow Check in the Internal Recirculation Pump Loop NOTE: If Preheat, Internal, or External Recirculation is active when using Air Handler, a solenoid valve must be used to isolate air handler loop when central heating is not needed. NOTES: 1. Minimum pipe size should match connection size. Upsize pipe accordingly if greater flow is required. 2.
Figure 29 – Water Heater with Thermal Bypass Valve – NOTE: There is a Built-In Flow Check in the Internal Recirculation Pump Loop Using the Optional Crossover (Thermal Bypass) Valve In piping applications where a dedicated recirculation line is not available or too costly to install, the water heater can use a crossover (thermal bypass) valve as a method of recirculation.
Figure 30 – Water Heater Installed with Combi Boiler – NOTE: There is a Built-In Flow Check in the Internal Recirculation Pump Loop – LP-569-M NOTE: The solenoid valve is powered by the water heater. The solenoid valve must be normally closed, energize when the water heater is over 90% of capacity, and deactivate when water heater is less than 50% of capacity. NOTE: When a water heater is installed with a combi boiler, ensure Installer Parameter 19:SU is set to Cd – Comfort Mode.
E. CIRCULATOR SIZING Figure 31 – This chart represents the internal recirculation pump performance curve taking into account valves and heat exchanger pressure losses. Figure 32 – This chart represents pressure drop through the heat exchanger and internal valves. WHL-590 REV. 7.27.
F. PRESSURE RELIEF VALVE An external pressure relief valve must be installed on this water heater. When installing, observe the following guidelines. Failure to comply with these guidelines can result in substantial property damage, personal injury, or death. This water heater must be provided with an approved 150 psi, ¾” ASME HV Valve that must be installed on the DHW outlet line (See Figure 32).
A. WIRING INFORMATION 1. This water heater must be properly grounded. Ensure the electrical receptacle that the water heater will be plugged into is properly grounded. 2. Do not attach the ground wire to either the gas or water piping. Figure 34 – Proper Grounding – Internal Manual Power Switch 3. The wiring diagrams contained in this manual are to be used for reference purposes only. 4.
SYSTEM CONTROL SETTINGS MAXIMUM FLAME DETECTING VOLTAGE PRE-PURGE TIME (Tp) SAFETY TIME (IGNITING TIME) (Ts) IGNITING INTERVAL TIME POST-PURGE TIME (Tip) OVER-HEATING 1,2,3 PROTECTION DETECTION TIME TEMPERATURE SENSOR FAULT DETECTION TIME # OF IGNITION ATTEMPTS (Ntl) DHW SET TEMPERATURE RANGE 2.
Figure 37 – Electrical Wiring Diagram WHL-590 REV. 7.27.
Figure 38 – Ladder Diagram WHL-590 REV. 7.27.
CONNECTOR PIN 1 2 3 4 CN9 5 65001WS-12 6 7 8 9-12 CN6 1 LW6A4-03 3 1 2 CN1 3 SMW250-05D 4 5 1 2 CN4 3 LWD1140-06D 4 5 6 1 CN8 2 LWD1140-16 3 4 1 8 2 10 3 11 4 CN11 12 LWD1140-16 5 13 6 14 7 15 8 16 Table 21 – Water Heater Wiring 1 NO.
CONNECTOR NO. OF LOCATION PIN 1 8 2 9 3 10 CN7 4 LWD1140-14 11 5 12 6 13 7 14 1 2 3 CN10 4 SMW250-08D 5 6 7 8 1 2 3 4 CN14 5 SMW250-09D 6 7 8 9 1 2 CN3 3 SMW250-06D 4 5 6 Table 22 – Water Heater Wiring 2 BOARD SILK DESCRIPTION F.S Flame Sensor OP.S Operating Water Temperature Sensor DH.S DHW Temperature Sensor I.S Inlet Water Temperature Sensor BG.S Exhaust Temperature Sensor ST.S Return Water Temperature Sensor SP.
PART 10 – OPERATING SYSTEM INSTRUCTIONS A. CONTROL PANEL Figure 39 – Water Heater Control Panel Detail B. LCD DISPLAY DESCRIPTIONS Figure 40 – LCD Display Detail LCD also features a backlit lamp that will illuminate: When a user action is detected (a button is pressed) The display has timed out for approximately 2 minutes C. START-UP SEQUENCE After the water heater is powered ON, the LCD display shows a sequence of information.
Display Items LCD Test Category: RGH-199 Software Version for Front Panel Software Version for Water Heater Hardware Version for Water Heater Time for Display 1 Sec 0.5 Sec 1 Sec 1 Sec 1 Sec 1 Sec 1 Sec 1 Sec 1 Sec 1 Sec Remarks All segments “ON” All segments “OFF” Pdn 0061 SPn 00.XX SFn XX.XX Hdn 00XX Table 23 – Start-Up Sequence After start-up, the display appears as follows.
Turn the dial counterclockwise to lower and clockwise to raise the DHW set-point. After changing the temperature, press the button to save the set-point. o o To change the DHW Set-Point above 121 F (49.5 C), press, then press and hold the button when the display panel is powered ON. The current DHW set-point will display. The DHW icon will flash. Then press and hold the warning symbol “ button for five seconds. The scald o o ” (high temperature) will display.
Display (Main Menu) Display (Sub Menu) Detail Description A: GA or A:LI Flow Unit Current Flow Unit (Li: Liters/min, GA: Gallons/min) b: dH DHW outlet water temperature Current DHW outlet water temperature C: In DHW inlet water temperature Current DHW inlet water temperature d: Rt Recirculation return water temperature Current recirculation return water temperature E: oP Heat exchanger outlet water temperature Current heat exchanger outlet water temperature F: Eh Exhaust temperature
Display Default Detail Description : Recirculation Pump is not used. (Recirculation and Preheat Modes are OFF.) 0: RC Recirculation Pump Operation : Preheat Mode is used. The water heater automatically turns on and meets the DHW setpoint temperature when the internal temperature falls below the differential setting (15: So). : Internal Recirculation Mode – Internal recirculation pump is used. : External Recirculation Mode – External recirculation pump is used.
Range: 0 – 2 minutes 18: dt 0 Delay time from DHW Mode Display Default Detail Description Solenoid Valve Operation Cd – Comfort Mode. When this mode is active the solenoid valve energizes when the water heater is over 90% of the capacity, and deactivate when water heater is less than 50% of the capacity. This can be used in combination with a combi boiler to increase the domestic hot water production of the system.
program specific recirculation functions by day and time to circulate and heat water when the user most needs hot water. See Recirculation Functions, this manual, for details. To set Recirculation Modes: 1. Installer Mode will activate when is pressed and held for five seconds while the water heater display is powered Off. 2. Turn the dial to O:RC. Press the Dial button 3. Turn the dial to select “ Recirculation, or “ .“ ” will flash when the O:RC setting is ready to be changed.
Figure 48 – Recirculation Programming Screen Setting Detail Smart Auto-Learn (Default Recirculation) Recirculation Program 1 Recirculation Program 2 Description When set in Smart Auto-Learn, the pump will run in the Pulse Function for the first seven (7) days. During this period the water heater will monitor and record hot water usage patterns. After the initial seven (7) day learning period, the water heater will use the preceding week’s usage pattern to cycle the pump and preheat the water.
Figure 50 – A – Selecting a Recirculation Function, B – Entering Day Setting e. The default day is displayed when the program function is selected. Press the other days. See Figure 51 A. f. Press the button to remove a day. Turn the dial to select button to set the time. See Figure 51 B. Figure 51 – A – Selecting the Day, Turning the Dial to Other Days, B – Setting the Time i. Turn the dial button to set the time. See Figure 52 A. Wait for the time to flash twice. j.
Figure 53 – A - Error Screen, B – Resetting an Error Code Error Code Error Code Description Er:10 Flame has Extinguished 5 (Five) Times Er:11 Ignition has Failed 5 (Five) Times Er:16 Operating Temperature Sensor Detects Water Temperature Greater o o than 199 F (93 C) Er:20 Temperature High Limit Overheat Switch – Closed is Normal, Open is Fault Er:28 Overheat Sensor Open or Short Er:29 APS/Condensate – Closed is Normal, Open is Fault (Condensate Drain Trap) Er:30 Recirculation Sensor Faul
Error Code Error Code Description Er:31 Water Inlet Sensor Open or Short Er:32 Water Outlet Sensor Open or Short Er:33 H/X Temperature Sensor Open or Short Er:35 Exhaust Sensor Open or Short Er:37 Abnormal Supply Frequency Er:38 Error Appears When Control Stores Data, but Data is not Saved Er:40 Gas Leakage is Detected in 10 Minutes, or three times within One Hour (Greater than 5 Seconds Each Time) Er:41 Fan Speed too High with Flame On Er:42 Jumped Wire Disconnected Er:43 Burner Ove
Error Code Error Code Description Er:61 Fan Speed Feedback Signal Abnormal Er:64 Flow Control Valve Operation Fault Er:65 Flow Control Valve Error Er:66 Mixing Valve Error Er:68 Mixing Valve Zero Position Fault Er:70 Register, Ram, Rom, I/O Port, AD Abnormal, Important EPROM Data or Safe Data Abnormal Er:72 Flame Signal Detected before Ignition Er:76 Poor Communication Er:80 Low Water Level Sensor (Low Water Level Detected Four (4) Consecutive times) Er:81 Low Water Level Circuit Er
K. ERROR TREE ANALYSIS 1. FLAME DETECTION Figure 54 – Flame Detection Error Analysis Tree 2. GAS DETECTION Figure 55 – Gas Detection Error Analysis Tree WHL-590 REV. 7.27.
3. AIR PRESSURE SWITCH Figure 56 – Air Pressure Switch Analysis Tree 4. Recirculation / Inlet / DHW / Operating Temperature / Exhaust SENSORS Figure 57 – Inlet / DHW / Operating Temperature Sensors Error Analysis Tree WHL-590 REV. 7.27.
PART 11 – FINAL INSTALLATION CHECKLIST YES BEFORE INSTALLING INSTALL WATER PIPING INSTALL EXHAUST VENT AND INTAKE PIPING INSTALL CONDENSATE PIPING / TUBING AND COMPONENTS INSTALL GAS PIPING PRESSURE RELIEF VALVES WIRE THE WATER HEATER START-UP, ADJUST, AND TEST BURNER FLAME NO Is there enough space to ensure proper installation? Does installation location allow for proper service clearances? Are water and gas lines properly sized and set at proper pressures for the installation? Is water heater
Figure 58 – Flame Sight Glass DHW Inlet Temperature Sensor (7850P-015) Exhaust Temperature Sensor (7850P-070) Temperature (◦F) Resistance (Ω) -4 62162 5 48440 14 38045 23 30107 32 23998 41 19261 50 15562 59 12655 68 10353 77 8520 86 7051 95 5867 104 4908 113 4125 122 3485 131 2957 140 2520 149 2157 158 1854 167 1600 176 1386 185 1205 194 1051 203 920 212 808 Table 30 – Temperature Sensor Resistance DHW Outlet Temperature Sensor (7850P-019) HX (OP) Temperature Sensor (7850P-081) Temperature (◦F) Resista
PART 12 – TROUBLESHOOTING PROBLEM No electrical power to the water heater No water available when a faucet is opened Hot water is not available when the faucet is opened. The water temperature is not hot enough or turns cold during use. It takes a long time before hot water flows from the faucet. TROUBLESHOOTING CHART POSSIBLE CAUSES POSSIBLE REMEDIES 1. Is the plug on the power supply cord unplugged 1. Reset the plug. from the electrical outlet? 2. Reset the circuit breaker. 2.
Display Nothing appears on the display control panel and no other water heater components are operating Condition Diagnostic Ensure service switch and/or circuit breaker to water heater is turned ON Is there 120V at the service switch Control is not receiving 120V power Is the ON/OFF switch inside the water heater cabinet is turned on Check for 120V at the line voltage terminal block located inside the water heater cabinet Inspect the fuse.
Check the Status of the Control Panel Observe the Control Panel to ensure the water heater is powered on, and to check for any error codes. Clear any debris from the panel. Check Exhaust Vent and Intake Pipe Terminations Verify that the water heater exhaust vent and intake pipe terminations are clean and free of obstructions. Remove any debris from the exhaust vent or intake pipe openings.
If relief valve seats properly, restore power to the water heater. Observe operation for five minutes and ensure it operates properly. Check the Burner Clean the exterior of the burner. Cleaning the Cold Water Inlet Filter (Draining the Water Heater) 1. Place a bucket under the water heater to collect the residual water inside the water heater. 2. Press the Power button on the control panel to turn off the electrical power to the water heater. Then turn off the gas valve. 3.
5. Open service valves (V3 and V4) on the hot water outlet and cold water inlet lines. 6. Turn on the circulation pump. Operate the pump and allow the cleaning solution to circulate through the water heater for at least 1 hour at a rate of 4 gallons per minute. This will remove any possible harmful scale deposits. 7. Rinse the cleaning solution from the water heater as follows: a. Remove the free end of drain hose D1 from the bucket. b. Close service valve V4 and open shutoff valve V2. c.
Figure 61 - Cabinet Replacement Parts NUMBER 1 2 3 4 4-1 DESCRIPTION Bottom Wall Mount Bracket Cabinet Assy Top Wall Mount Bracket Exhaust Duct Assy Exhaust / Intake Duct Clamps PART NUMBER 7850P-092 7850P-263 7850P-068 7855P-002 7855P-332 NUMBER 9 10 11 12 13 4-2 Exhaust / Intake Gaskets 7850P-210 14 4-3 4-4 4-5 5 5-1 6 7 8 Exhaust Duct Exhaust Duct Inner Adapter Combustion Analyzer Port Plug Air Intake Cap Assy Air Intake Cap Air Pressure Sensor Air Pressure Sensor Bracket Display Panel 7855
Figure 62 – Heat Exchanger Replacement Parts NUMBER DESCRIPTION PART NUMBER Exhaust Temperature Sensor 22 7855P-349 Clip 23 Exhaust Temperature Sensor 7855P-092 24 Exhaust Pipe Assy 7850P-273 25 Exhaust Pipe Gasket 7855P-418 26 Heat Exchanger Assy 7850P-274 27 Burner Body Assy 7855P-417 27-1 Burner Body Top Gasket 7855P-426 27-2 Burner Body 7855P-606 27-3 Burner Gasket 7855P-419 27-4 Ceramic Fiber Burner 7855P-420 Table 36 – Heat Exchanger Replacement Parts NUMBER DESCRIPTION PART NUMBER 27-5 Igni
Figure 63 – Heat Exchanger Replacement Parts NUMBER DESCRIPTION PART NUMBER 34 Burner Inlet Channel 7855P-424 35 Air Damper 7855P-618 36 Air Damper Guide 7855P-369 37 Fan Outlet Gasket 7855P-425 38 Fan 7855P-025 39 Mixer Assy 7850P-275 39-1 Air-Gas Mixer (Outer Part) 7855P-608 39-2 Air-Gas Mixer (Inner Part) 7855P-609 40 Air Intake Hose Clamp (Ø89) 7855P-429 41 Air Intake Hose 7855P-430 42 Barb Fitting 1 X 2 7855P-611 Table 37 – Heat Exchanger Replacement Parts NUMBER 43 44 45 46 46-1 46-2 46-3 46-4 47
Figure 64 – Heat Exchanger Replacement Parts NUMBER DESCRIPTION PART NUMBER Heat Exchanger Temperature 49 7850P-081 Sensor (OP) 50 ¾” Pipe Gasket 7855P-073 Overheat Switch (Heat 51 7850P-051 Exchanger) 52 Water Outlet Pipe 7850P-276 53 ½” Pipe Clip 7855P-246 54 Mixing Valve 7855P-043 55 DHW Temperature Sensor 7855P-617 56 DHW Inlet Block Cap 7855P-283 57 CH Return Block with Filter Clips 7855P-284 58 DHW Inlet Adapter 7855P-203 59 DHW Inlet Filter Block 7855P-279 60 DHW Flow Sensor 7855P-083 61 Mixing
Limited Warranty for WGRGH**199 Water Heaters Westinghouse warrants each instantaneous water heater and its parts to be free from defects in materials and workmanship according to the following terms, conditions, and time periods. 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.
14. Tank failures (leaks) caused by operating the water heater in a corrosive or contaminated atmosphere. 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 EPA DEFINITION OF POTABLE WATER deposits. Contaminant Level 17.
MAINTENANCE REPORT 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.
FINAL INSPECTION Check list Homeowner Verify that you have completed entire check list. WARNING: FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH. Review what you have done with the homeowner. TECH SIGN OFF th Table 39 - *Continue annual maintenance beyond the 4 year as required. WHL-590 REV. 7.27.
WHL-590 REV. 7.27.
WHL-590 REV. 7.27.
MAINTENANCE NOTES WHL-590 REV. 7.27.
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.
