74
WHL-060 REV. 1.6.16
Page 1: ...equired by the Safe Drinking Water Act Section 1417 IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE DO...
Page 2: ...ot avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION used without the safety alert...
Page 3: ...r electrical inspector or others having statutory authority In some circumstances the property owner or his her agent assumes the role and at government installations the commanding officer or departm...
Page 4: ...TS PART 1 ITEMS SHIPPED WITH THE WATER HEATER 6 PART 2 SAFETY REGULATIONS 7 A OPERATION AND INSTALLATION WARNINGS 7 B IMPROPER COMBUSTION 8 C GAS 8 D WHEN SERVICING THE WATER HEATER 8 E WATER QUALITY...
Page 5: ...HEATER 30 D APPLICATIONS 30 E CIRCULATOR SIZING 37 F PRESSURE RELIEF VALVE 38 PART 9 CONNECT ELECTRICAL POWER INITIAL STARTUP 38 A WIRING INFORMATION 39 B DIP SWITCHES 39 PART 10 OPERATING SYSTEM INS...
Page 6: ...SHIPPED WITH THE WATER HEATER ITEM DESCRIPTION QUANTITY Hybrid Water Heater 1 User and Installation Manuals 1 Each Condensate Hose 7855P 089 1 Anchors and Wall Mounting Bracket 7850P 084 4 Spare Parts...
Page 7: ...tely close the gas shut off valve if the water heater is subjected to fire overheating flood physical damage or any other damaging condition that might affect the operation of the unit Have the water...
Page 8: ...e Label all wires while performing service to ensure proper re wiring of the water heater Wiring errors can cause improper or dangerous operation Failure to do so could result in an electrical shock i...
Page 9: ...water temperature of 104o F 40o C and above Stage 3 If control detects water temperature of 34o F 1o C and below Er 85 will appear on the display Table 3 Freeze Protection Detail G SCALDING This heate...
Page 10: ...EEC LVD 73 23 EEC Ignition System Direct Electronic Ignition Automatic Flame Sensing Burner System Single Orifice Premixed Fuel Modulation Ceramic Fiber Burner Gas Valve System Air Ratio Valve Minimum...
Page 11: ...cations and Dimensions DESCRIPTION DIAMETER A Air Intake Adapter 3 B Exhaust Outlet Adapter 3 C Gas Inlet Adapter D Condensate Adapter E DHW Outlet Adapter F DHW Inlet Adapter G Recirculation Return A...
Page 12: ...culation Return Water Sensor 8 Hot Water High Limit Switch 27 Control Panel 9 Heat Exchanger Water Thermistor 28 Heat Exchanger 10 Gas Inlet Pipe 29 Flame Detection Sensor 11 Hot Water Outlet Pipe 30...
Page 13: ...se environments water heaters must not be installed using direct vent systems which draw outdoor air for combustion Such water heaters must be installed using room air for combustion Indoor air will h...
Page 14: ...ame space as the water heater The water heater cover must be securely fastened to prevent it from drawing air from the water heater room This is particularly important if the water heater is in a room...
Page 15: ...ith methods and limits given in the venting section F PREVENT COMBUSTION AIR CONTAMINATION Install intake piping for the water heater as described in the Venting section Do not terminate exhaust in lo...
Page 16: ...ance to their previous condition of use 7 Any improper operation of the common venting system should be corrected so the installation conforms to the National Fuel Gas Code ANSI Z223 1 When resizing a...
Page 17: ...prevailing winds Moisture will be produced by the exhaust vent Take precautions when determining exhaust vent termination Moisture may fall from the vent termination to the ground and turn to ice in...
Page 18: ...arapet wall ensure the exhaust vent terminates a minimum of 10 from nearest wall and extends level with or above the top of the wall This will ensure flue gas does not get trapped and possibly recircu...
Page 19: ...sembly I Clearance to service regulator vent outlet 3 feet J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 1 foot 3 feet K Clearance to a...
Page 20: ...low these directions will result in substantial property damage severe personal injury or death Table 11 Approved Venting Materials High heat sources sources generating heat 100 o F 37 o C or greater...
Page 21: ...3 to 2 Vent Pipe E VENT TERMINATION 1 Direct Vent Two Pipe Roof and Sidewall Vent Terminations Figure 9 Direct Vent Roof and Sidewall Vent Terminations All vent pipes must be glued properly supported...
Page 22: ...ing must be readily accessible for visual inspection for the first three feet from the appliance 3 Screen Installation After connecting the intake air and exhaust vent pipes it is required to install...
Page 23: ...al input rating of all fuel burning appliances installed in that space Rooms connected directly to this space through openings not furnished with doors are considered part of the space Confined space...
Page 24: ...24 WHL 060 REV 1 6 16 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...
Page 25: ...est must be done by a licensed professional Always match the water heater with the type of gas supplied to the unit natural gas or LP gas This water heater must be converted into propane operation unl...
Page 26: ...SI Z223 1 National Fuel Gas Code Latest Edition Maximum Liquid Propane Delivery Capacity Length of Black Iron Pipe Sch 40 Metallic in Feet Pipe Size Cubic Feet per Hour 0 60 Specific Gravity 0 5 WC Pr...
Page 27: ...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...
Page 28: ...fired flip DIP switch seven 7 to the ON position low fire Proceed to check heater combustion values NOTE Use a combustion analyzer to ensure CO and CO2 values are within the range shown in Table 18 I...
Page 29: ...orch within 12 of the bottom connections of the water heater Doing so could damage the water heater Such damages ARE NOT covered by product warranty The size of the hot water pipe should be diameter I...
Page 30: ...the installation Failure to properly accommodate thermal expansion could result in property damage severe personal injury or death C PIPING THE WATER HEATER Use at least the MINIMUM pipe size for all...
Page 31: ...ater heater and piping will assist in purging air from system 5 These drawings are meant to demonstrate system piping only The installer is responsible for all equipment and detailing required by loca...
Page 32: ...en water heater and piping will assist in purging air from system 5 These drawings are meant to demonstrate system piping only The installer is responsible for all equipment and detailing required by...
Page 33: ...ater heater and piping will assist in purging air from system 5 These drawings are meant to demonstrate system piping only The installer is responsible for all equipment and detailing required by loca...
Page 34: ...valve between water heater and piping will assist in purging air from system 5 These drawings are meant to demonstrate system piping only The installer is responsible for all equipment and detailing...
Page 35: ...detailing required by local codes In Massachusetts you must install a vacuum relief valve per 248 CMR 6 Mixing valve application is optional but recommended to help prevent scalding 7 Always shut off...
Page 36: ...required to set the water heater Installer Mode parameter 0 RC to InRC Internal Recirculation Mode NOTE The Crossover Valve must only allow flow rates less than 0 4 GPM If the flow rate is greater th...
Page 37: ...NG Figure 29 This chart represents the internal recirculation pump performance curve taking into account valves and heat exchanger pressure losses Figure 30 This chart represents pressure drop through...
Page 38: ...its entire length Discharge line must pitch downward from the valve and terminate at least 6 above the floor drain making discharge clearly visible Discharge line shall terminate plain not threaded w...
Page 39: ...connect the power supply when the water heater is in normal operation NOTE For additional electrical protection the use of a whole house surge protector is recommended Damage caused by power surges is...
Page 40: ...2 seconds TEMPERATURE SENSOR FAULT DETECTION TIME 3 seconds OF IGNITION ATTEMPTS Ntl 5 DHW SET TEMPERATURE RANGE 100 o F 140 o F 35 o C 60 o C DHW OFF TEMPERATURE DHW Target Temperature DHW Different...
Page 41: ...41 WHL 060 REV 1 6 16 Figure 35 Electrical Wiring Diagram...
Page 42: ...42 WHL 060 REV 1 6 16 Figure 36 Ladder Diagram...
Page 43: ...CN4 LWD1140 06D 1 FAN Unused 2 3 VDD SELV 14V 4 Fan power start coil SELV 8 26V 5 Fan power end coil 6 Fan speed feedback signal SELV 14V CN8 LWD1140 16 1 MCU ISP GND SELV 14V 2 ISP Reset Port SELV 5V...
Page 44: ...t Temperature Sensor 14 CN10 SMW250 08D 1 IWM Flow Control Valve IWM Stepper Motor Coil Y Phase SELV 14V 2 3 IWM Stepper Motor Coil X Phase 4 5 GND 6 IWM Stepper Motor Position 7 VDD 8 CN14 SMW250 09D...
Page 45: ...l 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 sequ...
Page 46: ...nt Temperature Changing Time Error Mode Status Display Mode Installer Mode High Elevation Mode NOTE The Control System will not allow changes if Lock Mode is activated unless the B button is pressed f...
Page 47: ...vere burns or death from scalds Children disabled and elderly are at the highest risk of being scalded See instruction manual before setting temperature at appliance Feel water before bathing or showe...
Page 48: ...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...
Page 49: ...or externally maintain hot water temperature on selected days The burner will turn on during this period if the heat exchanger water temperature drops below the Recirculation Differential Temperature...
Page 50: ...button to set the time See Figure 47 A j Press the button to store the time setting See Figure 47 B NOTE If a mistake is made when setting the date or time it can be cleared or restored to the defaul...
Page 51: ...gnition Cycle Select YES to Reset Ignition Cycles Range YES or NO 8 Cn 0 Cascade Number N A 9 CP 1 Cascade Parameter 10 Eh OFF Common Vent 11 Cr Auto Auto Automatic rotation Cr Ct 48 Cascade Rotation...
Page 52: ...when using an Air Handler application The pump will operate once every 24 hours if there was not a call for heat firing and running pumps to sanitize recirculation water Range Cd AH Default Cd Table 2...
Page 53: ...ction 5 Clean the spark igniter with steel wool to remove oxides Ensure proper separation 3 4 mm 6 Replace the spark igniter if damaged 7 Assure that the flame is stable when lit 8 If the problem pers...
Page 54: ...eplace the main control Er 40 Gas Leakage is Detected in 10 Minutes or three times within One Hour Greater than 5 Seconds Each Time IMPORTANT If you smell gas STOP Follow the instructions on page 2 th...
Page 55: ...purged from the system 3 Check wiring connections to low water level sensor Ensure all are secure 4 Check low water level sensor resistance If resistance is zero replace the sensor 5 If the problem p...
Page 56: ...56 WHL 060 REV 1 6 16 K ERROR TREE ANALYSIS 1 FLAME DETECTION Figure 51 Flame Detection Error Analysis Tree 2 GAS DETECTION Figure 52 Gas Detection Error Analysis Tree...
Page 57: ...REV 1 6 16 3 AIR PRESSURE SWITCH Figure 53 Air Pressure Switch Analysis Tree 4 Recirculation Inlet DHW Operating Temperature Exhaust SENSORS Figure 54 Inlet DHW Operating Temperature Sensors Error Ana...
Page 58: ...intake pipes been properly installed into the connectors provided on the water heater INSTALL CONDENSATE PIPING TUBING AND COMPONENTS Have all condensate line components included with the water heate...
Page 59: ...4 28409 5 48440 5 22152 14 38045 14 17408 23 30107 23 13782 32 23998 32 10990 41 19261 41 8824 50 15562 50 7131 59 12655 59 5800 68 10353 68 4747 77 8520 77 3906 86 7051 86 3233 95 5867 95 2690 104 4...
Page 60: ...outlet water temperature refer to the procedure in this manual It takes a long time before hot water flows from the faucet Is the faucet some distance from the water heater a Allow time for the cold w...
Page 61: ...ce and care of the water heater as outlined in this manual must be performed by the user owner to assure maximum efficiency and reliability Follow the maintenance procedures given throughout this manu...
Page 62: ...opening this indicates a dry condensate drain trap If problem persists contact a qualified service technician to inspect the water heater and condensate line and refill the condensate trap If applicab...
Page 63: ...aid in draining the system 5 Remove the cold water inlet filter Then clean it with a toothbrush and clean running water See Figure 56 Figure 56 Draining the Water Heater 6 Reinstall the cold water inl...
Page 64: ...five minutes to ensure all cleaning solution is purged from the system Check for leaks and ensure the water heater is operating properly REPLACEMENT PARTS NUMBER DESCRIPTION PART NUMBER NUMBER DESCRI...
Page 65: ...266 4 2 Exhaust Intake Gaskets 7850P 210 14 Display Panel Cover Plastic Washers 7850P 267 4 3 Exhaust Duct 7855P 333 15 Front Cover 7850P 272 4 4 Exhaust Duct Inner Adapter 7855P 004 16 Display Panel...
Page 66: ...t Switch 7855P 066 25 Exhaust Pipe Gasket 7855P 418 27 8 Burner Body 7855P 606 26 Heat Exchanger Assy 7850P 274 27 9 Burner Refractory 7855P 612 27 Burner Body Assy 7855P 417 28 Flame Sensor 7855P 031...
Page 67: ...P 425 LP Gas Orifice 6 3 mm 7855P 435 38 Fan 7855P 025 46 Gas Valve Assy 7855P 380 39 Mixer Assy 7850P 275 46 1 Gas Valve Outlet Adapter 7855P 232 39 1 Air Gas Mixer Outer Part 7855P 608 46 2 Gas Valv...
Page 68: ...ck 7855P 251 53 Pipe Clip 7855P 246 66 Recirculation Pipe 7850P 277 54 Mixing Valve 7855P 043 67 Pump Block Hybrid 7855P 616 55 DHW Temperature Sensor 7855P 617 68 Recirculation Block 7855P 604 56 DHW...
Page 69: ...warranty the owner or installer must 1 Maintain the water heater in accordance with the maintenance procedure listed in the manufacturer s provided instructions Preventive maintenance can help avoid...
Page 70: ...one number stated below 1 774 417 6000 SERVICE LABOR AND SHIPPING COSTS This limited warranty does not extend to any shipping charges delivery expenses or administrative fees incurred by the owner in...
Page 71: ...t pipes and joints Ensure all vent piping is properly supported Check for obstructions exhaust and intake termination points Gas Check Gas piping test for leaks and signs of aging Make sure all pipes...
Page 72: ...erify that you have completed entire check list WARNING FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH Homeowner Review what you have done with the homeowner TECH SIGN OFF Table 39 Continue...
Page 73: ...73 WHL 060 REV 1 6 16...
Page 74: ...74 WHL 060 REV 1 6 16...
Page 75: ...75 WHL 060 REV 1 6 16 MAINTENANCE NOTES...
Page 76: ...of Installation Installer s Code Name Product Serial Number s Combustion Setting at Time of Installation Comments Installer s Phone Number Signed by Installer Signed by Customer IMPORTANT NOTES Custo...
