andrews LWH42 Installation Manual, Operation And Maintenance Manual Download

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Andrews Water Heaters
Wednesbury One
Black Country New Road
Wednesbury
West Midlands WS10 7NZ
Tel: +44 (0)121 506 7400
Fax: +44 (0)121 506 7401
Email: [email protected]
Website: www.andrewswaterheaters.co.uk

12814 182x257 Internal 30/11/05 14:34 Page 7

Summary of Contents for LWH42

Page 1: ...H42 WH56 LWH42 LWH56 Internal FASTTflo CONTINUOUS FLOW WALL HUNG BALANCED FLUE HEATERS FOR NATURAL GAS AND LPG November 2005 Part No E791 T H I S M A N U A L M U S T B E K E P T W I T H T H E A P P L I A N C E 12814 182x257 Internal 30 11 05 14 34 Page 1 ...

Page 2: ...1993 All installation and service on the Andrews Water Heater must be carried out by properly qualified personnel and therefore no liability can be accepted for any damage or malfunction caused as a result of intervention by unauthorised personnel The Andrews Water Heaters policy is one of continuous product improvement and therefore the information in this manual whilst completely up to date at t...

Page 3: ...allation 8 8 Flue Pipe Installation 9 15 9 Gas Piping 16 10 Water Piping 17 11 Electrical Wiring 18 19 12 Commissioning 20 21 13 Dimensions 22 23 14 Remote Controller Installation Manual 24 15 Optional Accessories Guide 25 38 16 Servicing 39 17 Disassembly of each part 39 44 18 Servicing parts lists 45 55 Specifications 56 57 CONTENTS PAGE 12814 182x257 Internal 30 11 05 14 34 Page 3 ...

Page 4: ...12814 182x257 Internal 30 11 05 14 34 Page 4 ...

Page 5: ...th as well as danger of fire when the product is misused 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 Re...

Page 6: ...ories are included with the unit Check for any missing items before starting installation Q ty Shape Part Tapping Screw 1 Part Shape Q ty 5 Installation Manual this document 1 Remote Controller 1 Flue Terminal FF 100A 1 1 Owner s Guide Crescent clamp 1 Drain hose Condensate trap M G Horizontal Flue Terminal 1 M G Vertical Flue Terminal 1 1 Special Adapter 1 System Controller 1 L WH42 56 01 08 E 05...

Page 7: ...3 L WH42 56 01 08 E 05 9 26 7 40 PM Page 3 Adobe PageMaker 6 5J PPC ...

Page 8: ...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 clearance around the plumbing to apply...

Page 9: ...upply Quality If the water supply is hard acidic or otherwise impure treat the water with approved methods in order to ensure full warranty coverage Use Extreme Caution if Using With A Solar Pre Heater Using this unit with 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 scal...

Page 10: ... the water heater may cause discolo ration of walls and resinous materials or corrosion of aluminum materials Avoid installation above gas ranges or stoves Avoid installation 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 wher...

Page 11: ... 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 maintenance and service if necessary Securing of space for repair inspection 600mm or more 200mm or more Outdoor Clearances to Opening int...

Page 12: ...l 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 installing Internal parts may be dam...

Page 13: ...units are installed terminals must be separated by 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 excep...

Page 14: ...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 extended the flue systems allow approx 5 mm clearance at the bottom of each joint see Fig 8 e Repe...

Page 15: ...rted with the rim on the inside 3 Fit the liner through the hole and make good internal and external rendering The latter may be done with arm extended through liner 4 Push the flue terminal assembly into liner Ensure terminal protrudes by 110mm from the wall Important The grille must be totally exposed to air Fit the closure plate around the pipes and secure to the wall 5 The flue pipe MUST be su...

Page 16: ...145 150 Minimum length 845 175 150 Special adapter Special adapter Pitched roof Flat roof Heater to flue adapter Air and flue adapter 300 Minimum Minimum length 750 suit wall thickness Maximum length 12000 with 1 x 90 bend Maximum length 7000 with 4 x 90 bends Standard length 565 160 Service clearance Standard length cut to Air and flue adapter AdjustIble plate M G HORIZONTAL FLUE TERMINAL M G VER...

Page 17: ...ction begins Make the vertical pipe as short as possible Flue Precautions Use 100mm diameter flue pipe Maximum flue length 4 elbow 90 degree 7m flue pipe Flue Terminal 1 elbow 90 degree 12m flue pipe Flue Terminal 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 lengt...

Page 18: ...00mm diameter flue pipe Maximum flue length 4 elbow 90 degree 7m flue pipe Flue Terminal 1 elbow 90 degree 12m flue pipe Flue Terminal 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 reduce...

Page 19: ... to switch the airflow amount Extending conditions for the exhaust flues 4 bends within 7 m Extending limits for the exhaust flues Pulling out Connector Connector to switch the airflow amount Connector to switch the airflow amount ＵＰＤＯＷＮ small large b u t t o n 1234567890123 1234567890123 1234567890123 1234567890123 1234567890123 1234567890123 1234567890123 1234567890123 1234567890123 1234567 123...

Page 20: ...ore placing the appliance in operation The inlet gas pressure must be within the range specified This is for the purposes of input adjustment Manifold Gas Pressure Adjustment NOTE Use the following procedure to adjust the manifold gas pressure only if it can be done with a high flow rate through the unit 1 With a manometer or pressure guage connected to the manifold pressure tap press and hold the...

Page 21: ...ping 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 Check the pressure before putting th...

Page 22: ...ating controls to 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...

Page 23: ...y 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 when screwing to the terminal block Powe...

Page 24: ...ressure Adjustment on page 16 9 Check the gas pressure at checking point Refer to Specification on page 3 If the water heater does not operate normally refer to Troubleshooting in the Operation Manual After the trial operation clean the filter in the cold water inlet 12 Commissioning The installer should test operate the unit explain to the customer how to use the unit and give the owner this manu...

Page 25: ...mell of gas remains stop and follow the instructions on page 3 of owner s guide 6 Turn the gas control manual valve counterclockwise to the on position 7 Turn on electric power to the unit 8 The unit will now operate whenever hot water is called for If the unit will not operate follow the shutdown instructions and call a service technician Shutdown Instructions 1 Stop any water demand 2 Turn off e...

Page 26: ...NG THROUGHWAYS 450 10 87 170 140 100 70 36 70 170 140 100 36 150 226 100 AIR INLET WATER DRAIN VALVE WATER FILTER 464 450 361 89 FLUE COLLAR LED 173 HOT WATER OUTLET GAS INLET COLD WATER INLET WATER DRAIN VALVES WIRING THROUGHWAYS WATER DRAIN VALVES 79 615 BOTTOM OF CASE 44 51 55 BOTTOM OF CASE 10 240 94 100 140 61 244 VIEW FROM TOP L WH42 56 16 24 E 05 9 26 7 41 PM Page 22 Adobe PageMaker 6 5J PP...

Page 27: ...K V W BL R O Y BK V BL Y O R V BK G G BK W VCC SM LS SM LS GND VCC Fully open HEAT EXCHANGER THERMISTOR OUTLET WATER THERMISTOR MAIN WATER FLOW CONTROL VALVE OPERATING LED R Y G O BL BL R O G Y BL BL BL R BL VCC GND Fully open BL BL BL BL REMOTE CONTROLLER THERMAL FUSE BYPASS WATER FLOW CONTROL VALVE VCC W W INLET WATER THERMISTOR RELAY 9 RELAY 1 RELAY 5 RELAY 2 RELAY 4 RELAY 10 RELAY 3 DC90V SECO...

Page 28: ...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 14 Remote Controller Installation Manual RC 7508M Model Number Included ...

Page 29: ... 4 Prohibited Be sure to do The following accessories are included with the unit Check for any missing items before starting installation They are all attached to the product body To operate the water heater properly and safely comply with this installa tion manual and the installation manuals of any other equipment The flue terminal must be installed in accordance with regulation in force Directi...

Page 30: ...ance from both the indoors and the outdoors Install the flue terminal so that all exhaust is directed to and all intake air is taken from the outdoors Steam or condensed water may drip out of the flue terminal Dispose of this condensed water according to local codes and in order to prevent injury or property damage Check Wall Thickness This flue terminal model has four different sizes Choose the c...

Page 31: ...s sloping up sloping down The red line is not visible Flue Terminal Flue Terminal 300 mm or more 300 mm or more 300 mm or more Flue Terminal 300mm or more Sides Below Flue terminal 300 mm or more Flue Terminal 600 mm or more Front Flue Terminal Flue Terminal 300 or more 300 mm or more 300 mm or more 300 mm or more 300 mm or more There must be no building opening within this area Flue Terminal Flue...

Page 32: ...h a high temperature sealant Rounded wood screw short Sleeve Wall anchor Waterproof the clearance with a high temperature sealant Rounded wood screw long 2 4 3 Up Down Up Down Top Bottom Correct Correct Incorrect Incorrect Intake Exhaust Intake Exhaust Up Down Up Down Intake Exhaust Intake Exhaust 174 mm 210 mm 174 mm 210 mm 174 mm 210 mm The proper flange orientation depends on the desired orient...

Page 33: ... clearance between the flue terminal and the wall surface Fill this clearance with a high temperature sealant Wall flange Flue Terminal Wing nut The following figure shows installation pattern 1 External wall surface Standard projection length 75 mm The red line should be visible The red rectangle should not be visible from the outdoor Screwing position for installation pattern 2 Fill in clearance...

Page 34: ... the flue terminal until red line is identical with the edge of the socket B In case of the flue pipe without line mark the flue pipe has a swelling part formed around on it to fix the inserted length or lock in position Insert the flue pipe into the other side surely until locking position C In case of the flue pipes with other colored line mark insert the flue pipe into the socket up to the line...

Page 35: ...er for 100 mm diameter type in case of necessity Refer to the flue pipe manufacture s installation instructions for the proper interval Steam or condensed water may drip out of the flue terminal Dispose of this condensed water according to local codes and in order to prevent injury or property damage Protection from condensed water accumulation Slope the intake and exhaust pipes at a 1 50 grade do...

Page 36: ...om Exhaust Supply Exhaust Supply Exhaust Supply Installation orientation options 130 to 210 210 to 370 370 to 690 130 to 210 210 to 370 370 to 690 216 to 296 296 to 456 456 to 776 Dimension Table Model Numbers wall thickness L1 L2 FF 100 200 FF 100 400 FF 100 700 Note L1 and L2 can be adjusted in increments of 10 mm mm 300 270 60 150 192 140 20 20 5 174 234 108 40 10 5 14 5 L2 10 External dia 102 ...

Page 37: ...ING The flue terminal must be installed in accordance with the rules in force Failures and damage caused by erroneous work or work not as instructed in this manual are not covered by the warranty Be sure to do Flue Terminal Q ty Part Shape Q ty Part Shape 1 Tapping Screw Sleeve 1 1 4 Wing Nut Packing only for products for wall thicknesses of 370 mm to 690 mm 1 Rounded Wood Screw Wall Anchor 4 15 2...

Page 38: ...nd the outdoors Install the flue terminal so that all exhaust is directed to and all intake air is taken from the outdoors Steam or condensed water may drip out of the flue terminal Dispose of this condensed water according to local codes and in order to prevent injury or property damage Check Wall Thickness This flue terminal model has four different sizes Choose the correct model to fit the thic...

Page 39: ...line is not visible Flue Terminal Flue Terminal 300 mm or more 300 mm or more 300 mm or more Flue Terminal 300mmormore Sides Below Flue Terminal 300 mm or more Flue Terminal 600 mm or more Front Flue Terminal Flue Terminal 300 mm or more 300 mm or more 300 mm or more 300 mm or more 300 mm or more There must be no building opening within this area Flue Terminal Flue Terminal Clearance Requirements ...

Page 40: ... cylinder until it is flush with the external wall and replace the screw 2 Adjust the sleeve length to fit the wall thickness Install the sleeve with the symbol on the top side Rounded wood screw Sleeve Wall anchor 160 mm dia Waterproof the clearance with a high temperature sealant 3 Waterproof the clearance between the sleeve and wall with a high temperature sealant Sleeve Waterproof the clearanc...

Page 41: ...leak 3 Screw the exhaust slide pipe of the flue terminal to the flue collar of the water heater using the included tapping screw 4 Cover all of the connections between the water heater and the flue terminal with the included aluminum tape Note that the aluminum tape by itself is not sufficient to make the connection gas tight and prevent the terminal from becoming disconnected from the water heate...

Page 42: ...105 180 40 14 5 10 5 2 L2 200 to 265 103 to168 10 External diameter 102 External diameter 102 Extern al diame ter 122 Exte rnal diam eter 140 130 to 210 210 to 370 370 to 690 mm 130 to 210 210 to 370 370 to 690 216 to 296 296 to 456 456 to 776 Dimension Table Model Numbers wall thickness L 2 L 1 FF 100A 200 FF 100A 400 FF 100A 700 Note L1 and L2 can be adjusted in increments of 10 mm 15 2 5 Dimens...

Page 43: ...ORITZ Before commencing with a service or replacement of parts the 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 us...

Page 44: ...moving the manifold Remove the electric board and fixing plate of the ground fault circuit interrupter in advance 1 Remove the locking screw of the gas electromagnetic valve and the manifold pipe 2 Remove the 2 locking screws of the transformer then pull out L WH42 56 39 44 E 05 9 26 7 48 PM Page 40 Adobe PageMaker 6 5J PPC ...

Page 45: ...he 4 manifold locking screws 4 Removing the hot water supply fan Remove the electric board manifold and intake gas pipe in advance 1 Remove the 3 fan locking screws then pull out 3 Pull up and remove the manifold L WH42 56 39 44 E 05 9 26 7 48 PM Page 41 Adobe PageMaker 6 5J PPC ...

Page 46: ...e electric board and manifold in advance 1 Remove the gas electromagnetic valve locking screw 2 Pull out the fan motor 2 Pull up the gas electromagnetic valve to the upper section and remove it L WH42 56 39 44 E 05 9 26 7 48 PM Page 42 Adobe PageMaker 6 5J PPC ...

Page 47: ...e locking screw of the intake water pipe and the locking quick fastener of water flow sensor set 3 of the heat exchanger then pull out the intake water pipe 2 Remove the quick fastener of the water flow sensor set 1 and the discharge hot water pipe locking screw 3 Remove the connecting quick fasteners of the water flow sensor set 3 adjustment valve and the water flow servo set 2 and the mixing bod...

Page 48: ... the 3 locking screws at the bottom of the burner case 2 Remove the 2 case top plate locking screws 4 Pull up the mixing tube block to the upper section and remove it 3 Remove the 3 locking screws at the flue collar and adapter pull out the heat exchanger L WH42 56 39 44 E 05 9 26 7 48 PM Page 44 Adobe PageMaker 6 5J PPC ...

Page 49: ...AD WH56AD 001 003 003 023 004 015 025 070 071 006 007 013 009 010 012 072 072 072 070 039 022 070 730 002 002 014 024 028 075 070 050 005 029 18 Servicing parts lists WH42AD 56AD印刷 05 9 26 7 48 PM Page 45 Adobe PageMaker 6 5J PPC ...

Page 50: ... ELE ELEK077 1 023 Plug insulation sheet CRU CRUK002 1 024 Intake Exhaust label EJM EJMK031 1 025 Case FF AD ELE ELEA016 1 028 Wiring coupling BXK BXKA022 1 029 EHKA348 1 039 Connection diagram label AD ELE ELEK063 1 050 Connecting cord 2 DMB DMBJ010 1 070 Cross recessed round head collar N tapping screw 4X8 SAD6181 071 Cross recessed truss type3 EVERTIGHT tapping screw with PW 4X12 SAB6510 072 Cr...

Page 51: ... 119 125 070 173 122 123 121 120 172 172 075 124 171 121 110 116 117 117 118 171 172 175 175 112 111 115 114 127 070 073 070 132 131 129 128 072 103 104 101 102 105 070 141 070 133 For WH42AD 3P For WH56AD 3P WH42AD 56AD印刷 05 9 26 7 48 PM Page 47 Adobe PageMaker 6 5J PPC ...

Page 52: ... DHN DHNE015 1 121 O ring P25 5 SAB1512 2 122 Gas mech S24DQ CRP SET V SAQ7708 1 123 O ring JASO 2028A 8590109 1 124 Gas fitting 20ASET ELE ELEE001 1 125 Mounting plate for burner case DLT DLTC001 1 126 Main damper 11 CRP CRPC052 1 127 Conduit R10 DEK DEKJ014 1 128 Igniter AGV AGVJ007 1 129 High voltage cord 470 SAC1229 1 131 Mounting plate for igniter EAC EACC011 1 132 Mounting plate for igniter ...

Page 53: ...43 445 509 418 434 456 456 434 431 468 468 456 412 417 456 B B 438 439 440 434 172 509 418 075 446 472 471 434 456 A A C C D D 435 412 463 507 508 413 458 423 412 510 402 413 418 172 509 442 441 075 414 454 428 456 434 400 412 511 413 435 421 422 434 437 444 447 452 412 425 413 508 427 507 WH42AD 56AD印刷 05 9 26 7 48 PM Page 49 Adobe PageMaker 6 5J PPC ...

Page 54: ...xchanger SET Thermal fuse fastener Rear side view Left side view Right side view Front side view Thermal fuse rounding procedure Freeze preventive heater 1 Beginning of roll Thermal fuse fastener WH42AD 56AD印刷 05 9 26 7 48 PM Page 50 Adobe PageMaker 6 5J PPC ...

Page 55: ...t EAC EACD006 1 438 Water filter SUS EGB EGBD032 1 439 O ring 16DF BRQ BRQL008 1 440 Water filter cover DTJ DTJD006 1 441 Drain cock CRU CRUD003 1 442 Hot water resistant O ring P3 SAD6633 1 443 Mixing coupling EAC EACD007 1 444 Mixing body EAC EACD013 1 445 Mixing cylinder BWC BWCD035 1 446 QMF safety valve A S SAA2811 1 447 Hot water resistant O ring P9 SAD6635 1 452 Hot water outlet fitting HGH...

Page 56: ...tronic control unit WH42AD WH56AD 703 705 700 073 710 732 070 070 714 715 717 722 070 073 721 721 733 730 731 713 711 070 070 F G H 701 H F G 712 WH42AD 56AD印刷 05 9 26 7 48 PM Page 52 Adobe PageMaker 6 5J PPC ...

Page 57: ...el ELE ELEK068 1 713 Power supply cord ELE ELEJ006 1 714 Nylon clamp HP 4N NK 4N 7287909 1 715 Nylon clamp HP 6N NK 6N 5164702 1 717 Conduit 90 2 CCP CCPJ028 1 721 Cross recessed bind machine screw M3 5X6 SAC6564 722 Cross recessed round head N tapping screw 4X12 6347801 730 Transformer EJX EJXJ021 1 731 Transformer cover EJS EJSA021 1 732 Connecting cord 1 DEM DEMJ009 1 733 Conduit R92 250 EJS EJ...

Page 58: ...ched set Remote controller and Attached set WH42AD WH56AD 803 751 752 786 788 787 805 804 Special part Special part no Special part Owner s Guide 888 installation manual 889 WH42AD 56AD印刷 05 9 26 7 48 PM Page 54 Adobe PageMaker 6 5J PPC ...

Page 59: ...ssed flat head wood screw All screw 4 1X20 SHC6365 800 GQ3211WZFF2AD packing set V SKA7265 1 803 Cross recessed round head type 1 tapping screw 5X35 SAC6208 804 Crescent clamp 18 5 1230701 1 805 Drain hose ID17XT1 5 AHE AHED061 1 888 Owner s Guide GQ 3211WZ 2AD SAR8227 1 889 Installation Manual GQ 3211WZ FF 2AD SAR8286 1 Part Nos Part Names Order Nos Q ty unit WH42AD 56AD印刷 05 9 27 9 01 AM Page 55...

Page 60: ...essure Relief Valve Lightning Protection Device ZNR Electric Leakage Prevention Device Overheat Prevention Device Freezing Prevention Device Fan Rotation Detector Remote Controller Anchoring Screws Specifications Performance Item Model Name Type Ignition Minimum Pressure for Maximum flow Minimum Flow Rate Dimensions Weight Water Holding Capacity Accessories Installation Air Supply Exhaust Connecti...

Page 61: ...ention Device Overheat Prevention Device Freezing Prevention Device Fan Rotation Detector Remote Controller Anchoring Screws Specifications 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 Su...

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Page 64: ... Black Country New Road Wednesbury West Midlands WS10 7NZ Tel 44 0 121 506 7400 Fax 44 0 121 506 7401 Email andrews andrews waterheaters co uk Website www andrewswaterheaters co uk WTC WX 00404 12814 182x257 Internal 30 11 05 14 34 Page 7 ...

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