Residential Tankless Water Heater INSTALLATION START-UP MAINTENANCE PARTS Models* WGRTNG199 WGRTLP199 NOTICE: Westionghouse 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 0.25% lead by weight, as required by the Safe Drinking Water Act, Section 1417.
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.
INSTALLATIONS MUST COMPLY WITH: Local, state, provincial, and national codes, laws, regulations and ordinances. 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.
3. Direct Vent, Optional Horizontal and Vertical Concentric Vent ............................................................................................. 21 4. Screen Installation ..................................................................................................................................................................... 22 PART 6 – INSTALL THE CONDENSATE DRAIN .....................................................................................................................
PART 1 – ITEMS SHIPPED WITH THE WATER HEATER ITEM DESCRIPTION QUANTITY Residential Tankless Water Heater WGRTNG199 WGRTLP199 1 Quick Reference Guide, User, and Installation Manuals 1 Each Condensate Hose 1 Anchors and Wall Mounting Bracket 4 Spare Parts Kit (Gaskets and O-Rings) 1 Vent Screens (3”) 2 Screens OPTIONAL PARTS (Not Included) 150 PSI Pressure Relief Valve 1 Tankless Isolation Valves 2 Vent Screens (2” Mesh) 2 Screens Table 1 – Items Included with the Water Heater WHL-00
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 This water heater is equipped with a three prong plug. It should only be plugged directly into a properly grounded three prong receptacle. DO NOT remove the ground plug from the plug. 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.
G. FREEZE PROTECTION Consider water heater piping and installation when determining water heater location. NOTE: Damages resulting from incorrect installation or from use of products not approved by Westinghouse ARE NOT covered by warranty.
Figure 1 – Specifications and Dimensions A B C D E F G Table 4 – Adapter Specifications DESCRIPTION Exhaust Outlet Pipe Air Intake Gas Inlet DHW Outlet Adapter DHW Inlet Adapter Condensate Adapter DHW Inlet Filter DIAMETER 3” 3” ¾” ¾” ¾” ½” N/A WHL-004 REV. 8.5.
Figure 2 – Components NUMBER COMPONENT DESCRIPTION 1 Exhaust Vent Adapter 2 Air Inlet Pipe 3 AGM (Air Gas Mixer) 4 Ignition Transformer 5 Igniter 6 Flame Detection Sensor 7 Primary Heat Exchanger Assembly 8 Hot Water Outlet 9 Mixing Valve 10 Air Pressure Switch 11 N/A 12 Manual Power Switch 13 Water Adjustment Valve 14 Main Controller 15 Secondary Heat Exchanger Assembly 16 Gas Inlet Pipe 1 17 Flame Sight Glass 18 Burner Case Table 5 – Component List NUMBER 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
A. BEFORE LOCATING THE WATER HEATER Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk. Ensure that the water 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 water heater or components due to incorrect operating conditions IS NOT covered by product warranty. 1.
Do not use this water heater for space heating applications. Circulators suitable for DHW applications must be used. 6. Clean and flush system when reinstalling a water 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 water heater model and serial number. B. LEVELING In order for the condensate to properly flow out of the collection system, the water heater must be installed level. C.
Exhaust vent and intake pipe may be vented vertically through the roof or out a side wall. Venting methods are detailed in the Venting Section. Do not attempt installation using any other means. Be sure to locate the water heater so exhaust vent and intake piping can be routed through the building and properly terminated. Exhaust vent and intake piping lengths, routing, and termination method must comply with methods and limits given in the venting section. F.
5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle or smoke from a cigarette. 6. After it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous condition of use. 7.
Figure 4 – Wall Mounting the Water Heater PART 5 – VENTING Vent this water heater in accordance with these instructions. Failure to do so will result in property damage, severe personal injury, or death. DO NOT mix vent systems or materials unless specifically told to do so in this manual. DO NOT thermally insulate the exhaust vent or intake pipes. DO NOT use an electric damper, vent damper, or draft hood with this water heater.
For sidewall venting, the minimum horizontal distance between adjacent exhaust vent terminations is 1 foot. It is recommended this distance be greater than 1 foot to better avoid frost damage to building surfaces. For roof venting, minimum horizontal distance between any adjacent exhaust vent termination is 1 foot. All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into living space.
Figure 5 – Vent Termination Detail A B C D E F G H I J K DESCRIPTION Clearance above grade, veranda, porch, deck, or balcony Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet from the center line of the terminal Clearance to unventilated soffit Clearance to outside corner Clearance to inside corner Clearance to each side of center line extended above meter / reg
Item Exhaust vent or Intake pipe and fittings APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL Standards for Installation in: Material United States Canada CPVC schedule 40 ASTM-D2846 PVC schedule 40 ANSI/ASTM D1785 Polypropylene ULCS636 Stainless Steel AL29-4C Pipe cement/primer PVC CPVC PP, CPVC, and PVC venting must be ULC-S636 Certified. IPEX is an approved manufacturer in Canada, supplying vent 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 a reducing coupling in a vertical section of pipe. See Figure 7. Figure 6 – Correct Installation into the Water heater Collar Figure 7 – Transitioning from 3” to 2” Vent Pipe E. VENT TERMINATION 1. Horizontal Vent Terminations Figure 8 – Direct Vent, Sidewall Vent Termination WHL-004 REV. 8.5.
2. Vertical Vent Termination Figure 9 – Direct Vent, Vertical Termination 3. Direct Vent, Optional Horizontal and Vertical Concentric Vent Figure 10 – Direct Vent, Concentric Vent Termination (With Optional Kit) WHL-004 REV. 8.5.
4. Screen Installation After connecting the intake air and exhaust vent pipes, it is required to install the included screens into the exhaust vent and intake pipe terminations to prevent damages to the unit due to blockages. See Figure 11 for installation detail. Figure 11 – Screen Installation - NOTE: Vent termination elbow is meant to be installed open end facing the ground. Orientation in Figure 11 is meant to demonstrate proper Vent Screen installation ONLY.
A. GAS PIPE SIZING TABLES 1. Gas Pipe Sizing This information is for reference use only. Refer to gas pipe manufacturer specifications for actual delivery capacity. The DOE standard 3 3 for Natural Gas is 1100 BTU/ft . Contact the local gas supplier for actual BTU/ft rating. 2. Natural Gas Pipe Sizing The following tables list maximum capacity of pipe in cubic feet of gas per hour for gas pressures of 14” or less and a pressure drop of 0.5 inches water column, based on a 0.
2. The supply line must be sized for the maximum output of the water heater being installed. If there are additional gas appliances from the main supply line, measure the size of the supply line according to the COMBINED total maximum BTUH draw for the appliances as if they were operating at the same time. 3. Measure the length of the gas supply line from the gas meter to the water heater. Water heater must be installed downstream of the gas meter to ensure adequate gas supply.
Figure 15 – LP Gas Piping Installation – NOTE: Capacity to be Not Less than Total Capacity of Connected Appliances C. ADJUSTING GAS PRESSURE AT THE WATER HEATER NOTE: Refer Figure 16 when adjusting gas pressure. Loosen the bolts before checking the gas inlet pressure. 1. The water heater and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of the system at test pressures greater than ½ psi (3.5 kPa). 2.
To control thermal expansion, a thermal expansion tank should be installed in systems with an installed backflow preventer. DO NOT use a closed type expansion tank. Follow expansion tank manufacturer’s specifications to properly size an expansion tank to the installation. Failure to properly accommodate thermal expansion could result in property damage, severe personal injury, or death. C.
E. 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 19).
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 20 – 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 DHW OFF TEMPERATURE DHW ON TEMPERATURE DHW WATER ON MINIMUM WATER FLOW DHW WATER OFF MINIMUM WATER FLOW Table 17 – System Control Settings 2.5V Maximum 10 seconds, minimum 1 second 3.
Figure 22 – Electrical Wiring Diagram WHL-004 REV. 8.5.
Figure 23 – Ladder Diagram WHL-004 REV. 8.5.
CONNECTOR PIN 1 2 3 4 CN9 5 65001WS-12 6 7 8 9-12 1 CN1 2 SMW250-03 3 1 2 3 CN4 LWD1140-06 4 5 6 1 2 CN8 SMW250-04 3 4 1 8 2 10 3 11 4 12 CN11 5 13 6 14 7 15 8 16 Table 18 – 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 CN12 4 SMW250-07 5 6 7 1 2 3 CN10 4 SMW250-08 5 6 7 8 1 2 3 4 CN14 5 SMW250-09 6 7 BOARD SILK F.S Flame Detect 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 Unused SP.
PART 10 – OPERATING SYSTEM INSTRUCTIONS A. CONTROL PANEL Figure 24 – Water heater Control Panel Detail B. LCD DISPLAY DESCRIPTIONS Figure 25 – 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 appliance is powered ON, the LCD display shows a sequence of information.
The Control System can operate through user and service modes that have specific LCD outputs and dedicated controls, including: Changing the Set-Point Temperature Error Mode Status Display Mode Installer Mode NOTE: The Control System will not allow changes if Lock Mode is activated unless the B button is pressed for more than 5 seconds. D. CHANGING THE DHW SET-POINT The display shows the icon when the DHW set-point can be changed.
Figure 28 – Status Mode Screens Parameter A: Li or A: GA b: Fr Description Current Flow Value (Li: Liters/min, GA: Gallons/min) Current Fan RPM Value Lock Mode is In Use (ON) or Unused (OFF) C: Lc Lock Mode Allows user to lock out any temperature change.
Figure 29 – Installer Mode Screens Index 1: EH 2: cE Default E0:00 OFF Parameter History Clear Error History Description Most Recent History Error Codes (H0 – H9) Clears Error History Restores System to Default Settings (Burner operation time, Ignition cycles, and Supply 3: In OFF System Reset power time will not be reset) Range: ON or OFF Displays Flow Rate in Liters/Minute or Gallons/Minute 4: Fu GA Flow Unit Range: GA or Li 5: FH 00 N/A N/A 6: FL 00 N/A N/A 7: dr NO Reset Burner Operation Time Res
Error Code Error Code Description Er:10 Flame has Extinguished 8 (Eight) Times Er:11 Ignition has Failed 10 (Ten) Times Er:16 Operating Temperature Sensor or DHW Sensor detects Water Temperature Greater than o o 199 F (93 C) Er:20 High Limit Overheat Switch – Closed is Normal, Open is Fault Er:29 APS/Condensate – Closed is Normal, Open is Fault (Condensate Drain Trap) Er:31 Inlet Water Sensor Open or Short Er:32 DHW Sensor Open or Short Er:33 Operating Temperature Sensor Open or Short E
Error Code Error Code Description 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 Overheat Switch Open Er:61 Fan Speed Feedback Signal Abnormal Er:65 Supply Water Valve Error Er:66 Mixing Valve Error Er:67 AGM Error Er:70 Register, Ram, Rom, I/O Port, AD Abnormal, Important EPROM Data or Safe Data Abnormal Er:72 Flame Signal Detected before
Error Code Er:94 Error Code Description Exhaust NTC detects Vent Temperature is Greater o o than 149 F (65 C) Possible Remedies This Error Code will go away when the condition is remedied. If Error happens again: 1. Check if dip switch High Fire setting is ON. Switches 6 and 7 should be OFF for normal operation. 2. Check exhaust temperature sensor. Ensure connections are secure. 3. Check sensor resistance. If resistance is zero, replace the sensor. 4. Check exhaust vent for blockage. 5.
2. GAS DETECTION Figure 32 – Gas Detection Error Analysis Tree 3. AIR PRESSURE SWITCH Figure 33 – Air Pressure Switch Analysis Tree 4. Inlet / DHW / Operating Temperature SENSORS Figure 34 – Inlet / DHW / Operating Temperature Sensors Error Analysis Tree WHL-004 REV. 8.5.
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 35 – Flame Sight Glass 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. The water is not hot enough. The water at the faucet is too hot. A fan can be heard even when the unit is not operating.
PROBLEM POSSIBLE CAUSES White “smoke” can be seen coming out Depending on the outside temperature, water vapor of the exterior can be produced as the exhaust is vented. exhaust gas vent. Table 24 – Troubleshooting Chart POSSIBLE REMEDIES This is normal operation – no action is required. DIAGNOSTICS AND SUGGESTED CORRECTIVE ACTIONS The water heater control is able to record information about the water heater’s condition at the time of the ten previous faults or errors.
Combustible/Flammable Materials Do not store combustible materials, gasoline, or other flammable vapors or liquids near the water heater. If found, remove these materials immediately. Air Contaminates If allowed to contaminate combustion air, products containing chlorine or fluorine will produce acidic condensate that will cause significant damage to the water heater. Read the list of potential contaminates and areas likely to have these contaminates in Error! eference source not found., Part 2.
Figure 36 – Cleaning the Air Intake Filter 7. Dry the filter completely. Then reinsert the filter into the plastic assembly. 8. Replace the front cover of the water heater cabinet. Reconnect power supply to the water heater. 9. Press the Power button on the control panel to turn on the water heater. Check Primary and Gas Piping Remove the water heater cover and perform a gas leak inspection following Operating Instructions, page 2, this manual.
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 appliance 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 combination 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.
REPLACEMENT PARTS Figure 39 – Cabinet Replacement Parts NUMBER 1 2 3 3-1 3-2 3-3 4 5 6 7 7-1 7-2 8 9 10 DESCRIPTION EXHAUST ASSY CASE DOOR ASSY FRONT COVER DISPLAY PANEL BRACKET DISPLAY PANEL IGNITION TRANSFORMER GAS INLET NIPPLE OVERHEAT SENSOR DHW SUPPLY PIPE ASSY DHW SUPPLY PIPE WATER OUTLET SENSOR N/A SIPHON ASSY SIPHON AIR PRESSURE HOSE PART NUMBER 7850P-021 7850P-044 7850P-025 7850P-062 7850P-024 7850P-023 7850P-045 7850P-043 7850P-050 7850P-020 7850P-063 7850P-019 N/A 7850P-014 7850P-064 NUMBE
Figure 40 – Heat Exchanger Replacement Parts NUMBER 31 31-1 31-2 DESCRIPTION HEAT EXCHANGER ASSY EXHAUST PIPE ASSY (UP) EXHAUST TEMPERATURE SENSOR 31-3 EXHAUST GASKET 1 31-4 EXHAUST PIPE ASSY (DOWN) 31-5 31-6 32 32-1 32-2 32-3 EXHAUST GASKET 2 CONDENSATE GUTTER FAN ASSEMBLY FAN O-RING AGM (ACTUATOR) 33 SILENCER ELBOW 34 35 35-1 SILENCER BODY BURNER ASSY BURNER HEAD 35-2 IGNITION ROD BRACKET 35-3 IGNITION ROD 35-4 BLOWER HEAD BRACKET 35-5 OVERHEAT SENSOR (BURNER) PART NUMBER 7850P-032
Limited Warranty for Residential Tankless 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. The replacement water heater will be warranted for the unexpired portion of the applicable warranty period of the original water heater. The number of replacement water heaters is limited to one (1) per original water heater purchased.
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, or heating anything other than potable water. DEFINITION OF POTABLE WATER - Potable water is defined as drinkable water supplied from utility or well water in compliance with EPA secondary maximum contaminant levels (40 CFR Part 143.3) as shown in the table. Westinghouse will warrant the heat exchanger coil for hardness up to 12 Grains per gallon. 18.
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 28 - *Continue annual maintenance beyond the 4 year as required. WHL-004 REV. 8.5.
WHL-004 REV. 8.5.
WHL-004 REV. 8.5.
MAINTENANCE NOTES WHL-004 REV. 8.5.
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.
