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Westinghouse WGRTCLP199, Nstallation & Maintenance Manual

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Westinghouse WGRTCLP199 Nstallation & Maintenance Manual Download Page 5

5 

 

 

                                                                                  WHL-004 REV. 12.17.14 

3. Screen Installation ..................................................................................................................................................................... 20

 

PART 6 

– INSTALL THE CONDENSATE DRAIN ..................................................................................................................... 21

 

PART 7 

– GAS PIPING .............................................................................................................................................................. 21

 

A. GAS PIPE SIZING TABLES ..................................................................................................................................................... 21

 

1. Gas Pipe Sizing .......................................................................................................................................................................... 21

 

2. Natural Gas Pipe Sizing ............................................................................................................................................................ 21

 

3. LP (Liquid Propane) Gas Pipe Sizing ....................................................................................................................................... 22

 

B. GAS CONNECTION REQUIREMENTS ................................................................................................................................... 22

 

C. ADJUSTING GAS PRESSURE AT THE WATER HEATER ..................................................................................................... 24

 

PART 8 

– WATER PIPING ........................................................................................................................................................ 24

 

A. GENERAL PLUMBING CONNECTION GUIDELINES ............................................................................................................. 24

 

B. INSTALL A BACKFLOW PREVENTER .................................................................................................................................... 24

 

C. PIPING THE WATER HEATER ................................................................................................................................................ 24

 

D. PIPING DIAGRAM.................................................................................................................................................................... 25

 

E. PRESSURE RELIEF VALVE .................................................................................................................................................... 25

 

PART 9 

– CONNECT ELECTRICAL POWER / INITIAL STARTUP ......................................................................................... 26

 

A. WIRING INFORMATION .......................................................................................................................................................... 26

 

B. DIP SWITCHES ........................................................................................................................................................................ 27

 

PART 10 

– OPERATING SYSTEM INSTRUCTIONS ................................................................................................................ 32

 

A. CONTROL PANEL ................................................................................................................................................................... 32

 

B. LCD DISPLAY DESCRIPTIONS .............................................................................................................................................. 32

 

C. START-UP SEQUENCE .......................................................................................................................................................... 32

 

D. CHANGING THE DHW SET-POINT ........................................................................................................................................ 33

 

E. CHANGING THE TEMPERATURE INDICATOR ..................................................................................................................... 33

 

G. STATUS DISPLAY MODE ....................................................................................................................................................... 33

 

H. INSTALLER MODE .................................................................................................................................................................. 34

 

F. ERROR MODE ......................................................................................................................................................................... 35

 

G. ERROR TREE ANALYSIS ....................................................................................................................................................... 38

 

1. FLAME DETECTION ................................................................................................................................................................... 38

 

2. GAS DETECTION ....................................................................................................................................................................... 39

 

3. AIR PRESSURE SWITCH ........................................................................................................................................................... 39

 

4. Inlet / DHW / Operating Temperature SENSORS ..................................................................................................................... 39

 

PART 11 

– FINAL INSTALLATION CHECKLIST ..................................................................................................................... 40

 

PART 12 

– TROUBLESHOOTING ............................................................................................................................................ 41

 

PART 13 

– MAINTENANCE PROCEDURES ............................................................................................................................ 42

 

REPLACEMENT PARTS ................................................................................................................................................................ 47

 

Limited Warranty for Residential Tankless Water Heaters ........................................................................................................ 49

 

MAINTENANCE REPORT .............................................................................................................................................................. 51

 

MAINTENANCE NOTES ................................................................................................................................................................. 55

 

CUSTOMER INSTALLATION RECORD FORM ............................................................................................................................. 56

 

 

Summary of Contents for WGRTCLP199

Page 1: ... 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 NOT STORE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER WATER HEATER WHAT TO DO IF YOU SMELL GAS Do not try to light any water heater Do not touch any electrical switch Do not use any phone ...

Page 2: ... not 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 symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTICE SAFETY INSTRUCTIONS NOTICE is used to address practices not related to personal injury S...

Page 3: ...or department or health department building official or 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 departmental official may be the AHJ NOTE Westinghouse reserves the right to modify product technical specifications and components without prior notice ...

Page 4: ...ter heater underwent tests specified in ANSI Z21 10 3 latest edition TABLE OF CONTENTS PART 1 ITEMS SHIPPED WITH THE WATER HEATER 6 PART 2 SAFETY REGULATIONS 6 A OPERATION AND INSTALLATION WARNINGS 6 C IMPROPER COMBUSTION 8 D GAS 8 E WHEN SERVICING THE WATER HEATER 8 F WATER QUALITY 8 G FREEZE PROTECTION 8 PART 3 TECHNICAL SPECIFICATIONS 9 PART 4 PREPARE WATER HEATER LOCATION 11 A BEFORE LOCATING ...

Page 5: ... POWER INITIAL STARTUP 26 A WIRING INFORMATION 26 B DIP SWITCHES 27 PART 10 OPERATING SYSTEM INSTRUCTIONS 32 A CONTROL PANEL 32 B LCD DISPLAY DESCRIPTIONS 32 C START UP SEQUENCE 32 D CHANGING THE DHW SET POINT 33 E CHANGING THE TEMPERATURE INDICATOR 33 G STATUS DISPLAY MODE 33 H INSTALLER MODE 34 F ERROR MODE 35 G ERROR TREE ANALYSIS 38 1 FLAME DETECTION 38 2 GAS DETECTION 39 3 AIR PRESSURE SWITCH...

Page 6: ...se 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 PART 2 SAFETY REGULATIONS A OPERATION AND INSTALLATION WARNINGS To avoid serious injury or death read understand and follow all the p...

Page 7: ...ginal professional service technician if the water heater needs repair or maintenance If the original technician is unavailable ask your gas supplier for a list of qualified service providers Keep the area around the water heater clean and free of all materials that can burn DO NOT store or place gasoline oils spray paint or other flammable products near the water heater DO NOT use spray paint hai...

Page 8: ... not turn off or disconnect electrical supply to the circulator Instead shut off the gas supply at a location external to the appliance E WHEN SERVICING THE WATER HEATER To avoid electric shock disconnect electrical supply before performing maintenance To avoid severe burns allow water heater to cool Do not use petroleum based cleaning or sealing compounds in a water heater system Gaskets and seal...

Page 9: ...er Supply and Communication CN4 14V DC Product Approvals and Requirements EMC 89 336 EEC LVD 73 23 EEC Ignition System Direct Electronic Ignition Automatic Flame Sensing Burner System Single Orifice Premixed Fuel Modulation Metal Fiber Infrared Gas Valve System Air Ratio Valve Minimum Flow Rate 0 5 GPM Internal Pipe Material Stainless Steel Dimensions W 17 3 H 27 6 D 14 8 Sub Heat Exchanger Water ...

Page 10: ...Figure 1 Specifications and Dimensions DESCRIPTION DIAMETER A Exhaust Outlet Pipe 3 B Air Intake 3 C Gas Inlet D DHW Outlet Adapter E DHW Inlet Adapter F Condensate Adapter G DHW Inlet Filter N A Table 4 Adapter Specifications ...

Page 11: ... Filter 12 Manual Power Switch 30 Control Panel 13 Water Adjustment Valve 31 Operating Temperature Sensor 14 Main Controller 32 High Limit Overheat Switch 15 Secondary Heat Exchanger Assembly 33 Ceramic Heater 16 Gas Inlet Pipe 1 34 DHW Sensor 17 Flame Sight Glass 35 Condensate Trap Hose 18 Burner Case 36 Burner Overheat Switch Table 5 Component List PART 4 PREPARE WATER HEATER LOCATION Carefully ...

Page 12: ...o not install the water heater outdoors Failure to install this water heater indoors could result in substantial property damage severe personal injury or death 2 Check for nearby connections to System water piping Venting connections Gas supply piping Electrical power Condensate drain Locate the water heater where any leakage from the relief valve related piping tank or connections will not resul...

Page 13: ...3 in 76 2 mm Left Side Bottom 12 in 304 8 mm 12 in 304 8 mm Table 6 Minimum Installation and Service Clearances NOTE The exhaust vent piping for this direct vented appliance is approved for zero clearance to combustible construction NOTE If the water heater is installed in a narrow space or corner ensure that there is sufficient space for service and maintenance access There should be easy access ...

Page 14: ...ic or Muriatic acid Furniture refinishing areas and establishments Cements and glues New building construction Antistatic fabric softeners used in clothes dryers Remodeling areas Chlorine type bleaches laundry detergents and cleaning solvents Garages and workshops Adhesives used to fasten building products Table 7 NOTE DAMAGE TO THE WATER HEATER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERE...

Page 15: ...g the water heater on a wall which cannot support its weight could result in property damage personal injury or death The water heater may be installed on any suitable internal wall suitable sound proofing may be required when installing onto a stud partition wall This water heater is too heavy for one person to lift It is highly recommended to install the water heater with two people Use caution ...

Page 16: ...rectly from the outdoors to the burner and the flue exhaust gases should be vented directly to the outdoors through the wall or roof 4 This water heater uses 2 or 3 diameter pipe for exhaust vent and intake pipe It is important to ensure an airtight seal from the water heater collar to the vent terminations It is EXTREMELY IMPORTANT that the maximum allowed combined venting lengths are not exceede...

Page 17: ...where condensate may form Do not use the water heater to support any piping Figure 5 Vent Termination Detail DESCRIPTION US CANADA A Clearance above grade veranda porch deck or balcony 1 foot 1 foot B Clearance to window or door that may be opened 1 foot 3 feet C Clearance to permanently closed window D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance...

Page 18: ...using adapters specifically designed for the purpose by the manufacturer DO NOT insulate non metallic exhaust vent pipe or fittings DO NOT obstruct the flow of combustion or ventilation air When using Pipe Cement Primer follow the instructions included with the Cement Primer closely Clean and dry all applicable surfaces before applying Failure to follow these directions will result in substantial ...

Page 19: ...rewdriver 4 Ensure the pipe is secure before continuing installation 5 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 Two Pipe Roof and Sidewall Vent Terminations Figure 8 Direct Vent Roof and Sidewall Vent Terminations All vent pi...

Page 20: ...ance at 4 foot intervals on the vent pipe Appliance venting 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 the included screens into the exhaust vent and intake pipe terminations to prevent damages to the unit due to blockages See Figure 10 for instal...

Page 21: ...er display if condensate line is blocked The water heater will not operate with a blocked condensate line It is extremely important to have this condition repaired by a qualified service technician PART 7 GAS PIPING FIRE AND OR EXPLOSION HAZARD To avoid serious injury or death the gas line installation and the gas line inlet pressure test must be done by a licensed professional Always match the wa...

Page 22: ... WC Pressure Drop 10 20 30 40 50 60 80 100 150 200 129 91 74 64 58 53 45 41 31 28 303 216 177 153 137 126 109 98 75 69 1 605 425 344 297 265 241 208 186 143 129 1 971 661 528 449 397 359 307 270 217 183 1 1990 1400 1140 988 884 805 696 621 506 438 2 4640 3290 2680 2330 2080 1900 1650 1480 1210 1050 Table 13 Liquid Propane Delivery Capacity Corrugated Stainless Steel Pipe Refer to ANSI Z223 1 Natio...

Page 23: ...d 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 Figure 13 Natural Gas Piping Installation NOTE Capacity to be not Less than T...

Page 24: ...ions 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 Isolation shutoff valves should be used to ease future servicing All piping should be insulated B INSTALL A BACKFLOW PREVENTER It may be recommended to use a back flow preventer check local codes If a back flow preventer or a no return v...

Page 25: ...built in as a standard safety feature Therefore a pressure only relief valve is required DO NOT operate this water heater before the supplied pressure relief valve is installed with sufficient relieving capacity in accordance with the ASME rating plate on the water heater Pressure relief valves must be installed as close to the water heater as possible No other valves should be placed between the ...

Page 26: ... call a plumber immediately Take care whenever operating relief valve to avoid scalding injury or property damage For water heaters installed with only a pressure relief valve the separate storage vessel must have a temperature and pressure relief valve installed This relief valve shall comply with Relief Valves for Hot Water Supply Systems ANSI Z21 22 CSA4 4 FAILURE TO COMPLY WITH THE ABOVE GUIDE...

Page 27: ...em B DIP SWITCHES There is one DIP switch DIP switches 6 and 7 need to be set to OFF for the water heater to operate normally Figure 20 Dip Switch Detail DIP SWITCH GROUP DIP SWITCH OFF ON 1 3 NOT USED NOT USED 4 NOT USED NOT USED 5 Gas Type LP NG 6 High Fire Normal High Fire 7 Low Fire Normal Low Fire Table 16 DIP Switch Group SYSTEM CONTROL SETTINGS MAXIMUM FLAME DETECTING VOLTAGE 2 5V PRE PURGE...

Page 28: ...28 WHL 004 REV 12 17 14 Figure 21 Electrical Wiring Diagram ...

Page 29: ...29 WHL 004 REV 12 17 14 Figure 22 Ladder Diagram ...

Page 30: ... 03 1 RS 485 RS485 SELV 5V 2 GND 3 RS485 CN4 LWD1140 06 1 FAN Unused 2 GND SELV 30V 3 VDD SELV 14V 4 Fan power start coil SELV 30V 5 Fan power end coil 6 Fan speed feedback signal SELV 14V CN8 SMW250 04 1 MCU ISP GND SELV 5V 2 ISP Reset Port 3 ISP TOOL0 Data Port 4 VCC CN11 1 HWL Unused 8 2 LWL Unused 10 3 HD Unused 11 4 TH Connect to the Display Control Thermostat SELV 14V 12 5 APS Air Pressure S...

Page 31: ...pper Motor Coil X Phase 4 5 GND 6 AGM Stepper Motor Position SELV 14V 7 VDD SELV 24V CN10 SMW250 08 1 DHM DHM Stepper Motor Coil Y Phase SELV 14V 2 3 DHM Stepper Motor Coil X Phase 4 5 GND 6 DHM Stepper Motor Position 7 Unused 8 VDD CN14 SMW250 09 1 IWM GND 2 IWM Stepper Motor Position 3 VDD 4 IWM Stepper Motor Coil X Phase 5 IWM Stepper Motor Coil Y Phase 6 VDD 7 IWM Stepper Motor Coil X Phase 8 ...

Page 32: ...ected 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 icons will flash followed by various indicators that describe the appliance controller and software versions It will take the appliance roughly 15 seconds to cycle through the Start Up Sequence After start up the d...

Page 33: ... 49 o C press and hold the button for five seconds when the display panel is powered ON The current DHW set point will display The DHW icon will flash And the scald warning letter H high temperature will display High temperature DHW Set Point range is 121 140 o F 49 4 60 o C Turn the dial counterclockwise to lower and clockwise to raise the DHW set point After changing the temperature press the bu...

Page 34: ...unit displayed 5 IH Ignition Attempts Number Ignition Attempts Number 10 000 times unit displayed J AG N A N A Table 20 Status Mode Display Screen Descriptions NOTE Shaded Parameters Not Used on This Software Version Turn the dial counterclockwise and clockwise to scroll through the displayed parameters To view parameter details press the button at the appropriate screen Press the or buttons to le...

Page 35: ...rsion Toggle through displayed items by turning the dial To change an item press the Dial button Displayed items can be changed by turning the dial counterclockwise to lower and clockwise to raise the displayed value To save settings press the Dial button again To leave Installer Mode press button B again The water heater will return to power off mode F ERROR MODE When the water heater encounters ...

Page 36: ...problem persists replace the main control Er 29 APS Condensate Closed is Normal Open is Fault Condensate Drain Trap Press the Power button to clear the Error Code 1 Check APS Condensate and main controller connections Ensure all are secure 2 Check APS Condensate resistance If resistance is zero replace the switch 3 Check APS Condensate hose Ensure it is connected and in good condition 4 Check cond...

Page 37: ... Error happens again 1 Turn power OFF and ON at the main power switch internal to the water heater 2 Check wiring connections to supply water valve Ensure all are secure 3 Replace supply water valve 4 If the problem persists replace the main control Er 66 Mixing Valve Error Press the Power button to clear the Error Code If Error happens again 1 Turn power OFF and ON at the main power switch intern...

Page 38: ...lem persists replace the control 6 If the problem persists replace the heat exchanger Table 22 Diagnostics and Suggested Corrective Actions This water heater is equipped with a blocked vent shutoff system If Error Codes Er 29 Er 41 or Er 94 occur turn off the gas valve at the manual shutoff Check the vent terminations for obstructions If no obstructions are found reset the water heater by pressing...

Page 39: ...DETECTION Figure 31 Gas Detection Error Analysis Tree 3 AIR PRESSURE SWITCH Figure 32 Air Pressure Switch Analysis Tree 4 Inlet DHW Operating Temperature SENSORS Figure 33 Inlet DHW Operating Temperature Sensors Error Analysis Tree ...

Page 40: ...ent and 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 heater been installed Is the condensate line piped with the approved materials listed in this manual Has the condensate line been routed to a laundry tub or other drain INSTALL GAS PIPING Is the gas...

Page 41: ... do other gas devices work 1 Restore electrical power to the unit 2 Press and hold the Power button to turn the unit ON 3 Refer to the Diagnostic and Error Codes section in this manual 4 Open the gas supply valve The water temperature is not hot enough or turns cold during use 1 Is the faucet open enough to draw at least 0 6 gallons 2 3L per minute through the water heater 2 Is an error code flash...

Page 42: ...n the installation manual Inspect the fuse Replace as necessary Replace the fuse with the proper part found in the replacement part section of this manual If fuse blows again recheck the wiring per diagram Nothing appears on the display control panel but the water heater is operating Occurs when communications is lost from the control to the display Check for loose connections and proper pin align...

Page 43: ... and in good condition Notify a qualified service technician immediately if any problems are found Failure to inspect the venting system and have it repaired by a qualified service technician can result in vent system failure causing severe personal injury or death Visually inspect the intake piping for any signs of blockage Inspect the entire length of the intake pipe to ensure piping is intact a...

Page 44: ...arge avoiding any possibility of scalding from hot water Shut power off to the water heater To avoid scalding wait for water heater to cool before operating the relief valve To avoid water damage or scalding due to relief valve operation a discharge line must be connected to the valve outlet and directed to a safe place of disposal This discharge line must be installed by a qualified service techn...

Page 45: ...ice to the water heater by opening the isolation valves or turning on the main water valve 8 Turn on the gas valve Turn on electrical power to the water heater and press the Power button to turn the water heater on Flushing the Water Heater Flushing the heat exchanger is a complicated procedure that should only be performed by a qualified service technician NOTE Improper maintenance WILL VOID wate...

Page 46: ...of drain hose D1 from the bucket b Close service valve V4 and open shutoff valve V2 c Do not open shutoff valve V1 d Allow water to flow through the water heater for 5 minutes e Close shutoff valve V2 8 Disconnect all hoses 9 Remove the cold water inlet filter from the water heater and clean out any residues 10 Reinsert the filter and ensure the filter cap is securely tightened 11 Connect electric...

Page 47: ...3 16 ROCKER SWITCH 7850P 059 4 IGNITION TRANSFORMER 7850P 045 17 FLOW CONTROL VALVE 7850P 053 5 GAS INLET NIPPLE 7850P 043 18 WATER INLET VALVE ASSY 7850P 018 6 OVERHEAT SENSOR 7850P 050 18 1 WATER INLET VALVE BODY 7850P 067 7 DHW SUPPLY PIPE ASSY 7850P 020 18 2 WATER INLET SENSOR 7850P 015 7 1 DHW SUPPLY PIPE 7850P 063 18 3 WATER INLET FILTER 7850P 017 7 2 WATER OUTLET SENSOR 7850P 019 18 4 WATER...

Page 48: ...CLIP 7850P 055 32 FAN ASSEMBLY 7850P 006 42 DHW INLET PIPE 7850P 048 32 1 FAN 7850P 002 43 CERAMIC HEATER 7850P 076 32 2 O RING 7850P 003 44 GAS VALVE PIPE 7850P 039 32 3 AGM ACTUATOR 7850P 004 45 GAS VALVE PIPE 7850P 040 33 SILENCER ELBOW 7850P 036 46 GAS VALVE ADAPTER STRAIGHT 7850P 077 34 SILENCER BODY 7850P 035 47 GAS VALVE ASSY W PLUG 7850P 078 35 BURNER ASSY 7850P 011 47 1 GAS VALVE 7850P 01...

Page 49: ... in this 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 any unnecessary breakdown of your water heater and keep it running at optimum efficiency 2 Maintain all related system components in good operating condition 3 If the cold water supply line ha...

Page 50: ... 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 repairing or replacing the water heater or part s This warranty does not extend to labor costs beyond the coverage specified in this warranty document All such expenses are the owner s responsibility LIM...

Page 51: ...ent 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 are properly supported SYSTEM Visual Do a full visual inspection of all system components Functional Test all functions of the system Heat Safeties Temperatures Verify safe settings on water heater ...

Page 52: ... Verify 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 28 Continue annual maintenance beyond the 4 th year as required ...

Page 53: ...53 WHL 004 REV 12 17 14 ...

Page 54: ...54 WHL 004 REV 12 17 14 ...

Page 55: ...55 WHL 004 REV 12 17 14 MAINTENANCE NOTES ...

Page 56: ...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 Customer Please only sign after the installer has reviewed the installation safety proper operation and maintenance of the system In the case that the system has any problems please call the installer If you a...

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