andrews Fastflo WHC56 Installation And Service Manual Download Page 26

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Wiring Diagram (WHC56, LWHC56)

RELAY 10

FLAME ROD

EARTH

GND

AIR INLET
THERMISTOR

HEAT EXCHANGER
THERMISTOR

<CN1>

RC-7508M

EARTH

V : Violet

BL : Blue

O : Orange

G : Green

BR : Brown
Y : Yellow

GY : Gray

COLOR CODING

R : Red
BK : Black

W : White

HEAT EXCANGE
HIGH-LIMIT SWITCH

ELECTRODE

IGNITER

REMOTE CONTROLLER

FAN MOTOR

FLAME ROD

THERMAL FUSE

HEAT
EXCHANGER
FLOW
CONTROL
VALVE

BYPASS
FLOW
CONTROL
VALVE

(VCC)

BR(Vs)

R(Vcc)

BL(GND)

Y(FG)

(Fully open)

(GND)

<CN27>

(VCC)

(Fully open)

(VCC)

(GND)

<CN78>

HEAT EXCHANGER
THERMISTOR

WATER OUTLET
THERMISTOR

WATER INLET
THERMISTOR

<CN38>

<CN89>

RELAY 9

IGNITER

<CN101>

DC15V

DC90V

FLOW CONTROL VALVE

15V POWER CIRCUIT

BYPASS FLOW CONTROL VALVE

HEAT EXCHANGER FLOW SENSOR

THERMAL FUSE

GND

EARTH

FAN
PULSE
CONTROL
CIRCUIT

CENTRAL
PROCESSING
UNIT

RELAY 5

RELAY 7

RELAY 3

RELAY 1

RELAY
DRIVING
CIRCUIT

CPU

Sub-CPU
SUB
CONTROL
UNIT

WATER INLET
THERMISTOR

WATER OUTLET
THERMISTOR

FAN CURRENT
VALUE INPUT

FAN ROTATION
SPEED INPUT

SOLENOID
VALVE Q3

SOLENOID
VALVE Q2

SOLENOID
VALVE Q1

SOLENOID
VALVE 0

SECONDARY

PRIMARY

DC12V

RELAY 10

SV3

SV2

RELAY 5

RELAY 4

SV0

SV1

RELAY 1

RELAY 3

FAN CONTROL
OUTPUT

COMBUTION FAN

HIGH LIMIT
SWITCH

DC90V

3
2

6
5

POWER
CIRCUIT
BOARD

<CN104>

W W O

<CN102>

<CN92>

BL W

<CN89A>

HOT

<CN10>

BKW

BKO

MAIN
CIRCUIT
BOARD

<CN184>

3
2

6
5

1 2 3 4 5 6

7 8 9

3
2

6
5

3
2

SECONDARY

PRIMARY

CIRCULATION PUMP

RELAY 7

AC100V

AC230V

10A(FUSE)

NEUTRAL

3
2

GAS VALVE
UNIT

Manifold Gas Pressure
Decrease Button

Manifold Gas Pressure
Increase Button

Maximum Manifold Pressure
Set Button

Minimum Manifold Pressure
Set Button

<CN102>

W Y

<CN63>

WW W

<CN75>

<CN70>

EXTERNAL POWER

<CN184>

MAIN CIRCUIT
BOARD

Other Unit in
Quick Connect
Multi System

Quick Connect Cord(Optional)

(For Quick Connect Multi System Only)

6
5

184

6
5

5
4

HEAT EXCHANGER
FLOW SENSOR

(GND)

(Vcc)

(Pulse)

RC TERMINAL

DC140V

GAS PROPORTION VALVE
POWER CONTROL CIRCUIT

FLAME DETECTING CIRCUIT

5V POWER CIRCUIT

EARTH

Y/G

CURRENT
LEAKAGE
SAFETY DEVICE
(GFCI)

TRANSFORMER

EARTH

Y/G

W W

FREEZE PROTECTION
THERMOSTAT

POWER CORD

EARTH

Y/G

W W

CHANGE GAS CATEGORY

FLUE BOX
HIGH-LIMIT SWITCH

BURNING LED

WATER LEVEL
ELECTRODE 1

(GND)

WATER LEVEL
ELECTRODE 2

(GND)

2
3

(OPTIONAL)

SYSTEM CONTROLLER
SC-201-6M INT

(OPTIONAL)

R
R

CHANGE 3P CONNECTOR
(OPTIONAL)

ANTI-FROST HEATER

FREEZE PROTECTION

VARISTOR

EARTH

VARISTOR

ARRESTER

WATER LEVEL
ELECTORODE 1

WATER LEVEL
ELECTORODE 2

THERMOSTAT

2
1

4
3

6
5

8
7

2
1

4
3

2
1

1
2
3

2
1

4
3

2
1

6
5

8
7

2
3

FAN

POWER
CONTROLLER

(G)BK

(BK)G
(R)W

(W)R

G(BK)

BK(G)
R(W)

W(R)

2
3

10
12 11
14 13
16 15
18 17
20 19
22 21
24 23
26 25
28 27
30 29
32 31

1 2 3 4
5 6 7 8

3
4

5
6

Summary of Contents for Fastflo WHC56

Page 1: ...WHC56 Internal INSTALLATION AND SERVICE MANUAL Andrews Built to perform Please read and understand these instructions before commencing installation and leave this manual with the customer for future reference Part number E890 SBA8198 3 ...

Page 2: ......

Page 3: ...sed by ignoring this symbol Possibility of serious injury or even death as well as possibility of fire when the product is misused by ignoring this symbol Possibility of bodily injury or damage to property when the product is misused by ignoring this symbol The appliance must be installed in accordance with the Gas Safety Installation and Use Regulations and the rules in force in the country of in...

Page 4: ...lation Q ty Shape Part Tapping Screw 1 Part Shape Q ty 5 Installation Manual this document 1 Owner s Guide System Controller 1 Remote Controller 1 Horizontal Flue Terminal 1 Short Horizontal Flue Terminal 1 Long 1 Vertical Flue Terminal 1 1 1 Special Adapter For intake pipe 1 1 Attach the seal ring included with the Flue Terminal optional accessories to the groove of exhaust side of equipment secu...

Page 5: ...56 140W G20 20mbar 55 8kW CONDENSING CONDENSING Freeze Preventive Heater 55 8kW 2 98kW 2 98kW 54 0kW 54 0kW 3 20kW 3 20kW GB IE GB IE G31 30 37mbar 140W 170W 170W LWHC56 3P 10 0mbar 2 7mbar 12 9mbar 3 0mbar ...

Page 6: ...ices System Diagram Insulate the hot water piping to prevent heat loss Insulate and apply heating materials to the cold water supply piping to prevent heat loss and freezing of pipes when exposed to excessively cold temperatures G Quick Connect Cord Remote Controller Cord Gas Supply Piping Cold Water Supply Hot Water Remote Controller Terminal Block Cord Connector Cord Connector Leave enough clear...

Page 7: ...th a solar pre heater can lead to unpredictable output temperatures and possibly scalding If absolutely necessary use mixing valves to ensure output temperatures do not get to scalding levels Do not use a solar pre heater with the quick connect multi system Checkup Check the fixing brackets and the flue pipe yearly for damage or wear Replace if necessary 4 Before Installation Caution Precautions o...

Page 8: ... bathroom it may be dam aged or a fire may be caused Warning Caution Consult with the customer concerning the location of installation Avoid places where fires are common such as those where petrol benzene and adhesives are handled or places in which corrosive gases ammonia chlorine sulfur ethylene compounds acids are present This may cause incomplete combustion or failures Locate the flue termina...

Page 9: ...between the kitchen fan and stove If oily fumes or a large amount of steam are present in the installation location take measures to prevent the fumes and steam from entering in the equipment Avoid installation in places where dust or debris will accumulate Dust may causing the performance of the fan motor to drop and incomplete combustion to occur as a result Install in a location where the exhau...

Page 10: ... applied to an area where an effective shield makes a clearance of 600mm or more in front of the exhaust outlet Check Illustration Caution If possible leave 200mm or more on either side of the unit to facilitate inspection If possible leave 600mm or more in front of the unit to facilitate main tenance and service if necessary Securing of space for repair inspection 600mm or more 200mm or more Outd...

Page 11: ...nd hang the unit by the upper wall mounting bracket 3 Determine the positions for the remaining four screws two for the top bracket and two for the bottom and remove the unit The weight of the device will be applied to the wall If the strength of the wall is not suffi cient reinforcement must be done to prevent the transfer of vibration Do not drop or apply unnecessary force to the device when ins...

Page 12: ... that the drain trap unit is filled with water 700ml Intake Exhaust 1 Fill the drain trap unit by pouring approx 700ml of water into the exhaust accessory on the top of the appliance as illustrated below Or if the vent pipe has already been installed 2 After installing the drain pipe make sure that the area around the appliance is well ventilated open a window or a door if necessary Then operate t...

Page 13: ...300mm or more in a plain view regardless of the vertical clearance Flue Terminal Flue Terminal 300mm or more 300mm or more In the case the discharge direction of the exhaust is to the side as shown in the diagram below do not select the supply exhaust tube top Incomplete combustion caused by short cycling of exhaust gas may occur as a result except terminal guard 8 Flue Pipe Installation Flue Term...

Page 14: ...way from the appliance Push pipes fully into the sockets on top of the boiler whilst also fitting the flue duct prepared as above b Measure and cut next pair of the air flue pipes c Prepare pipe support brackets as required before engaging pipes with the socket of preced ing pipes or bends d Push pipes together as before taking care not to dislodge seals When cutting and fitting the flue pipes on ...

Page 15: ...0 150 150 315 125 Special adapter Pitched roof Flat roof Heater to flue adapter Air and flue adapter Maximum length 1745 Maximum length 12000 with 1 x 90 bend Maximum length 7000 with 4 x 90 bends Maximum length 860 Air and flue adapter HORIZONTAL FLUE TERMINAL LONG VERTICAL FLUE TERMINAL HORIZONTAL FLUE TERMINAL SHORT suit wall thickness Standard length cut to Maximum length 560 ...

Page 16: ...he outdoors Flue Precautions Use 100mm diameter exhaust pipe Maximum flue length 4 elbow 90 degree 7m exhaust pipe Flue Terminal Maximum flue length 12m Minimum flue length 1 elbow 90 degree Flue Terminal Exceeding the maximum flue length is danger ous and may result in bad combustion Maximum 90 degree bends not to exceed 4 Maximum length must be reduced by 2000mm for each 90 bend used Maximum len...

Page 17: ...iameter exhaust pipe Maximum flue length 4 elbow 90 degree 7m exhaust pipe Flue Terminal Maximum flue length 12m Minimum flue length 1 elbow 90 degree Flue Terminal Exceeding the maximum flue length is danger ous and may result in bad combustion Maximum 90 degree bends not to exceed 4 Maximum length must be reduced by 2000mm for each 90 bend used Maximum length must be reduced by 1000mm for each 4...

Page 18: ...nstall the exhaust pipe at the hidden part install the access hole for checking the full length of exhaust pipe with eye If the partition wall goes right through the hidden part be sure to install the access hole near the wall Suggested inspection openings When the intake exhaust pipes pass through an enclosed space Ceiling Sloping up toward flue terminal Exhaust pipe ...

Page 19: ... be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 35 mbar The Appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 35 mbar The appliance and its gas connections must be l...

Page 20: ...to keep the piping simple Avoid piping in which an air holdup can occur Use approved piping materials If installing the unit on a roof If the unit is installed on a roof to supply water to the levels below make sure that the water pressure supplied to the unit does not drop below 2000 mbar It may be necessary to install a pump system to ensure that the water pressure is maintained at this level Ch...

Page 21: ...o the electrical supply must be through one common isolator and must be fused 10 Amp maximum Isolation should be by a double pole switched fused spur box with a minimum gap of 3 mm for both poles The fused spur box should be readily accessible and preferably adjacent to the appliance It should be identified as to its use Caution Label all wires prior to disconnection when servicing controls Wiring...

Page 22: ...it Keep the remote controller cord away from the freeze prevention heaters in the unit Tie the redundant cord outside the water heater Do not put the extra length inside the equipment The remote controller cord can be extended up to 100m with Remote controller cord Use a Y type terminal with a resin sleeve Without the sleeve the copper wire may corrode and cause problems Be sure to hand tighten wh...

Page 23: ...12 Commissioning The installer should test operate the unit explain to the customer how to use the unit and give the owner this manual before leaving the installation Preparation 1 Ensure all lines are purged flushed of debris prior to connection to appliance 2 Open the shut off valve on the water supply check that water passes through the valve and close the valve 3 Open the gas supply valve turn...

Page 24: ... when placed into contact with water Keep the drain pipe length to a minimum Install the pipe with a decline when horizontally pulling the pipe in the middle The end of the drain pipe must be released in to the air Be sure the pipe is not submerged in water In addition take measures to prevent clogging of the pipe After performing piping check to make sure drain water is properly drained In the ca...

Page 25: ...3 4 UPPER WALL MOUNT BRACKETS LOWER WALL MOUNT BRACKETS EXHAUST PIPE CONNECTION OPERATION LAMP 4 13 WATER DRAIN VALVE CONDENSATE DRAIN WATER FILTER HOT WATER OUTLET WATER DRAIN VALVE OVER WATER PRESSURE RELIEF VALVE WIRING THROUGHWAY WATER DRAIN VALVE COLD WATER INLET HOT WATER OUTLET R3 4 CONDENSATE DRAIN R1 2 WIRING THROUGHWAY POWER CORD COLD WATER INLET R3 4 VIEW FROM TOP HEIGHT OF EACH FITTING...

Page 26: ...ARY CIRCULATION PUMP RELAY 7 AC100V AC230V 10A FUSE NEUTRAL O SV O W 4 GY BL 3 5 BK 1 W 2 W 0 10 BL 7 8 6 R 3 2 1 4 BL R DU 11 12 13 GY GY O BK BK Q2 SV SV Q1 SV GAS VALVE UNIT 3 1 2 4 Manifold Gas Pressure Decrease Button Manifold Gas Pressure Increase Button Maximum Manifold Pressure Set Button Minimum Manifold Pressure Set Button BL CN102 W Y O R W CN63 WW W CN75 CN70 W Y R Y BL EXTERNAL POWER ...

Page 27: ...r 2 Position the holes diameter 6 mm X depth 25 30 mm to secure the remote controller for the kitchen and knock in all the wall anchors Next secure it using oval headed wood screws 3 Replace the decorative cover Oval headed wood screws The screws must be tightened manually and the remote controller secured properly without rattling Main remote controller body 15 Remote Controller Installation Manu...

Page 28: ...e boiler should be isolated from the electrical supply and water supply and the gas supply should be turned off at the gas service cock All routine servicing requirements can be achieved by the removal of the front panel only Remove the four screws on the front panel and lift off For access inside the appliances screwdriver can be used To remove chassis front Unless stated otherwise any part remov...

Page 29: ...igure and pull the bypass servo B B A 3 Unscrew two fixing screws A and B in the right figure and remove the transformers 2 How to remove the board 1 Unscrew two screws A and B that fix the board and the earth screw C and remove the board A B C B A ...

Page 30: ... two fixing screws of mounting plate for current leakage safety device in advance 1 Remove the quick fastener A in the right figure and slide the gas pipe B upward 2 Unscrew four screws that fix the manifold and pull out the manifold SET A B ...

Page 31: ...tfitting LWHC56 WHC56 18 Servicing parts lists 003 002 002 003 001 005 073 072 044 045 071 A 031 B 032 033 007 077 017 016 072 034 072 046 078 034 072 028 072 042 076 072 075 043 072 072 029 027 021 C H 041 I 037 036 ...

Page 32: ... 7287909 2 036 Wiring coupling 2 EHK EHKA014 1 037 Grommet ELE ELEA031 1 041 Mounting plate for terminal block DZT DZTA006 1 042 Current leakage safety device 240 EJS EJSJ022 1 043 Power supply cord ELE ELEJ006 1 044 Transformer EPJ EPJJ061 1 045 Transformer cover EJS EJSA021 1 046 Conduit 90 2 CCP CCPJ028 1 071 Cross recessed truss type3 EVERTIGHT tapping screw with PW 4X12 072 Cross recessed rou...

Page 33: ...ombustion unit and gas route LWHC56 WHC56 140 143 116 072 113 102 106 108 072 072 072 072 105 171 172 175 175 142 136 176 142 107 104 127 135 135 126 100 077 101 131 134 132 174 174 114 076 118 117 125 110 ...

Page 34: ...D7463 1 3P Gas mech manifold 23 ELV SET AS SKD7462 126 Manifold seal packing top ELV ELVL003 1 127 Manifold seal packing bottom ELV ELVL007 1 131 Solenoid SO9L EBT SET V SBP7501 2 132 Solenoid S16 CRU SET V SBB7213 1 134 Gas mech harness ELV ELVJ018 1 135 O ring JASO 2030 type 1 SAA6044 3 136 Quick fastener 16B 6340407 1 140 Gas fitting 20A SET EPJ EPJE021 1 142 O ring P18 2110903 2 143 Manifold p...

Page 35: ...BACK THERMAL FUSE LEFT SIDE FASTENER FASTENER 403 407 406 410 410 411 408 171 418 424 419 481 417 429 413 446 417 432 435 412 432 435 445 431 484 435 432 432 435 418 440 444 441 416 437 443 405 176 404 483 G F E 410 D 077 461 442 400 438 Thermal fuse rounding procedure 410 411 403 400 407 405 461 ...

Page 36: ...432 434 433 482 421 419 482 420 418 414 F G D C 472 072 072 473 474 466 432 475 452 466 432 442 463 466 465 457 432 442 477 459 464 441 077 E 464 455 416 458 477 456 451 467 453 460 441 416 468 176 467 460 462 404 478 477 479 B 072 469 454 176 485 480 485 487 459 476 489 471 072 486 488 ...

Page 37: ...lter cover DTJ DTJD006 1 427 Water filter SUS EGB EGBD032 1 428 QMF safety valve A S SAA2811 1 429 Conduit 86 DZT DZTJ008 1 431 O ring P22C 7573308 1 432 O ring P16C 3223302 9 433 O ring P12 5C 3359808 1 434 Quick fastener 12 7 6340202 1 435 Quick fastener 16A 6340300 5 437 Sensor fastener CRU CRUD055 1 438 Bypass pipe ENJ ENJD005 1 440 Hot water thermistor 300 BWC BWCD096 1 441 Hot water resistan...

Page 38: ... EMUJ001 1 477 Hose clamp NO 35 SAD6670 3 478 Remaining flame safety device 80 ENJ ENJH001 1 479 Thermostat BVU BVUH002 1 480 Neutralizer packing ENJ ENJL007 1 481 Cross recessed round head P TIGHT screw 4X10 482 Cross recessed round head P TIGHT screw 4X10 483 Cross straight recessed round head collar type3 S TIGHT tapping screw 4X8 484 Cross recessed round head machine screw M4X8 485 Cross reces...

Page 39: ...56 WHC56 Remote controller Kitchen remote controller RC 7508M Special part Special part no Special part Owner s guide 888 Installation manual 889 Electronic control unit Attached set 700 701 715 705 076 A 703 805 H 075 751 752 786 788 787 072 I 789 785 804 716 For 3P ...

Page 40: ...13 786 785 Oar plug 6X25 787 Cross recessed flat head screw M4X35 788 Cross recessed flat head wood screw All screw 4 1X20 789 Cross recessed bind machine screw M3 5X5 800 GQC3252WZFF AD packing set V SKF7138 804 Screw SET W SAB2753 805 Cross recessed round head type 1 tapping screw 5X35 888 Owner s guide GQC3252WZFFAD SBA8089 889 Installation manual GQ C3252WZFFAD SBA8198 1 1 1 1 1 716 gas type s...

Page 41: ...ntion Device Overheat Preven tion Device Freezing Prevention Device Fan Rotation Detector Anchoring Screws Performance Item Model Name Type Ignition Minimum Pressure for Maximum flow Minimum Flow Rate Dimensions Weight Water Holding Capacity Accessories Installation Air Supply Exhaust Connection Sizes Power Supply Materials Water Inlet Hot Water Outlet Gas Inlet Condensate Drain Supply Consumption...

Page 42: ...power level indoors L WA dB 57 57 57 57 57 57 57 57 Daily fuel consumption Q fuel kWh 30 452 30 452 30 332 30 332 27 73 27 46 33 57 33 01 Emissions of nitrogen oxides NO X mg kWh 70 70 70 70 52 52 60 60 Weekly fuel consumption with smart controls Qfuel week sm kWh Weekly electricity consumption with smart controls Qelec week sm kWh Weekly fuel consumption without smart controls Qfuel week kWh 213 ...

Page 43: ......

Page 44: ...wsWH 500403 Register now to activate your warranty www andrewswaterheaters co uk register a warranty Please make sure you attach proof of purchase for your warranty to be monitored All descriptions and illustrations provided in this document have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the Conditions of Sale which are avail...

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