Westinghouse WGR080LP076 Instructions / Assembly

High Efficiency
Water Heater
INSTALLATION
START-UP
MAINTENANCE
PARTS
Models*
WGR050NG076 / WGR060NG076 / WGR080NG076
WGR050LP076 / WGR060LP076 / WGR080LP076
This manual must only be used by a qualified heating installer/service technician. Read and understand all instructions in this manual
before installing. Perform steps in the order given. Failure to comply will result in substantial property damage, severe personal injury,
or death.
Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property damage, personal
injury, or death.
NOTICE: Westinghouse reserves the right to make product changes or updates without notice and will not be held liable for
typographical errors in literature.
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.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
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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 APPLIANCE.
WHAT TO DO IF YOU SMELL GAS





Do not try to light any appliance.
Do not touch any electrical switch.
Do not use any phone in your building.
Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the fire department. Installation and service must be provided by a qualified installer,
service agency, or the gas supplier.
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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.
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
NOTICE is used to address practices not related to personal injury.
FOREWORD
This manual is intended to be used in conjunction with other literature provided with the High Efficiency 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.
Installation should be made in accordance with the regulations of the Authority Having Jurisdiction, local code authorities, and utility
companies which pertain to this type of water heating equipment.
Authority Having Jurisdiction (AHJ) – The Authority Having Jurisdiction may be a federal, state, local government, or individual such
as a fire chief, fire marshal, chief of a fire prevention bureau, labor 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.
FOR THE INSTALLER
This manual must only be used by a qualified heating installer/service technician. Read and understand all instructions in this manual
before installing. Perform steps in the order given. Failure to comply will result in substantial property damage, severe personal injury,
or death.
This water heater must be installed by qualified and licensed personnel. The installer should be guided by the instructions furnished
with the heater, and with local codes and utility company requirements. In the absence of local codes, preference should be given to the
National Fuel Gas Code, ANSI Z223.1-2002.
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.
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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 22.1, from Canadian Standards Association, 5060 Spectrum Way, Suite 100,
Mississauga, Ontario, Canada L4W 5N6.
Code for the installation of Heat Producing Appliances (latest version), from American Insurance Association, 85 John Street, New
York, NY 11038.
The latest version of the National Electrical Code, NFPA No. 70.
NOTE: The gas manifold and controls met safe lighting and other performance criteria when undergoing tests specified in ANSI
Z21.10.3 – latest edition.
TABLE OF CONTENTS
PART 1 – GENERAL SAFETY INFORMATION ..........................................................................................................................6
A. PRECAUTIONS ................................................................................................................................................................................................ 6
B. IMPROPER COMBUSTION.............................................................................................................................................................................. 6
C. GAS ................................................................................................................................................................................................................. 7
D. WHEN SERVICING THE HEATER ................................................................................................................................................................... 7
E. HEATER WATER ............................................................................................................................................................................................. 7
PART 2 – BEFORE YOU START ................................................................................................................................................7
A. WHAT’S IN THE BOX ....................................................................................................................................................................................... 7
B. HOW THE HEATER OPERATES ..................................................................................................................................................................... 7
C. OPTIONAL EQUIPMENT ................................................................................................................................................................................. 8
PART 3 – PREPARE WATER HEATER LOCATION ..................................................................................................................9
A. BEFORE LOCATING THE HEATER................................................................................................................................................................. 9
B. LEVELING ...................................................................................................................................................................................................... 10
C. CLEARANCES FOR SERVICE ACCESS ....................................................................................................................................................... 10
D. RESIDENTIAL GARAGE INSTALLATION ...................................................................................................................................................... 10
E. EXHAUST VENT AND INTAKE PIPE ............................................................................................................................................................. 11
1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE ............................................................................................................................ 11
2. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE ................................................................................ 11
F. PREVENT COMBUSTION AIR CONTAMINATION ......................................................................................................................................... 12
G. REMOVING A HEATER FROM A COMMON VENT SYSTEM ....................................................................................................................... 12
H. WATER CHEMISTRY..................................................................................................................................................................................... 13
PART 4 – HEATER PIPING ....................................................................................................................................................... 16
A. GENERAL PIPING INFORMATION ................................................................................................................................................................ 16
B. SCALDING ..................................................................................................................................................................................................... 17
C. TEMPERATURE AND PRESSURE RELIEF VALVE ...................................................................................................................................... 17
D. BACKFLOW PREVENTER ............................................................................................................................................................................. 17
E. POTABLE EXPANSION TANK ....................................................................................................................................................................... 17
F. WATER PIPING .............................................................................................................................................................................................. 18
G. AUXILIARY CONNECTIONS ......................................................................................................................................................................... 18
H. FILLING THE HEATER .................................................................................................................................................................................. 18
I. IMPORTANT NOTICE...................................................................................................................................................................................... 19
J. PIPING DIAGRAMS ........................................................................................................................................................................................ 20
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PART 5 – VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL............................................................................ 23
A. GENERAL ...................................................................................................................................................................................................... 23
B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE ........................................................................................................... 24
C. REQUIREMENTS FOR INSTALLATION IN CANADA .................................................................................................................................... 24
D. EXHAUST VENT AND INTAKE PIPE LOCATION .......................................................................................................................................... 25
E. EXHAUST VENT AND INTAKE PIPE SIZING................................................................................................................................................. 26
F. LONGER VENT RUNS ................................................................................................................................................................................... 26
G. EXHAUST VENT AND INTAKE PIPE INSTALLATION ................................................................................................................................... 27
H. VENTING DRAWINGS ................................................................................................................................................................................... 27
1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE ............................................................................................................................ 27
2. VENTING THROUGH AN EXISTING SYSTEM .................................................................................................................................................. 31
3. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE ................................................................................ 33
I. CONDENSATE REMOVAL SYSTEM............................................................................................................................................................... 35
PART 6 – WIRING ..................................................................................................................................................................... 37
A. LINE VOLTAGE INPUT .................................................................................................................................................................................. 37
B. LINE VOLTAGE CONDENSATE OUTPUT ..................................................................................................................................................... 37
C. LOW VOLTAGE OUTDOOR SENSOR INPUT ............................................................................................................................................... 37
D. INTERNAL WIRING DIAGRAM ...................................................................................................................................................................... 38
PART 7 – GAS CONNECTIONS ............................................................................................................................................... 38
A. GAS PIPING ................................................................................................................................................................................................... 39
B. GAS TABLE.................................................................................................................................................................................................... 39
C. GAS VALVE ................................................................................................................................................................................................... 40
PART 8 – CONTROLS............................................................................................................................................................... 41
A. CONTROL AND DISPLAY OVERVIEW .......................................................................................................................................................... 41
B. BASIC CONTROL FUNCTIONS ..................................................................................................................................................................... 42
1. TURNING WATER HEATER ON / OFF .............................................................................................................................................................. 42
2. RESETTING THE WATER HEATER .................................................................................................................................................................. 42
3. PUTTING THE WATER HEATER IN ECO MODE .............................................................................................................................................. 42
4. CHANGING USER SETPOINT ........................................................................................................................................................................... 43
C. ADVANCED CONTROL FUNCTIONS ............................................................................................................................................................ 43
1. UPPER LEVEL INSTALLER MODE MENU NAVIGATION.................................................................................................................................. 43
2. TECHNICAL SERVICE AND NAVIGATION ........................................................................................................................................................ 43
D. OUTDOOR RESET ........................................................................................................................................................................................ 44
1. INQUIRY MODE AND NAVIGATION .................................................................................................................................................................. 45
2. HISTORY MODE AND NAVIGATION ................................................................................................................................................................. 45
3. RESET MODE AND NAVIGATION ..................................................................................................................................................................... 46
PART 9 – START-UP PROCEDURE ......................................................................................................................................... 47
A. OPERATING INSTRUCTIONS ....................................................................................................................................................................... 47
B. TEST MODE................................................................................................................................................................................................... 47
C. MAINTENANCE ............................................................................................................................................................................................. 48
PART 10 – SHUTDOWN............................................................................................................................................................ 49
A. SHUTDOWN PROCEDURE ........................................................................................................................................................................... 49
B. VACATION PROCEDURE .............................................................................................................................................................................. 49
C. FAILURE TO OPERATE ................................................................................................................................................................................ 49
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D. IMPORTANT NOTICE .................................................................................................................................................................................... 49
PART 11 – TROUBLESHOOTING ............................................................................................................................................ 49
A. ERROR CODE ............................................................................................................................................................................................... 49
B. HEATER ERROR ........................................................................................................................................................................................... 49
C. LOCKOUT ...................................................................................................................................................................................................... 49
PART 12 - MAINTENANCE ....................................................................................................................................................... 55
MAINTENANCE NOTES ........................................................................................................................................................................................ 59
CUSTOMER INSTALLATION RECORD FORM ..................................................................................................................................................... 60
PART 1 – GENERAL SAFETY INFORMATION
A. PRECAUTIONS
This water heater is for indoor installations only. Clearance to combustible materials: 0” top, bottom, sides, front, and back. Unit must
have room for service: 24” front, 3” left, 3” right, 6” top, and 0” back are minimum recommended service clearances. (A combustible
door or removable panel is acceptable front clearance.) This water heater has been approved for closet installation, and installation on
combustible flooring. Do not install this water heater directly on carpeting. Use only Category IV vent systems.
INSTALLER – Read all instructions in this manual before installing. Perform steps in the order given.
USER – This manual is for use only by a qualified heating installer/service technician. Have this heater serviced/inspected by a
qualified service technician annually.
FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE AND HAVE THIS HEATER SERVICED/INSPECTED ANNUALLY
CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.
If the heater is exposed to the following, do not operate until all corrective steps have been made by a qualified service technician:
1. FIRE
2. DAMAGE
3. WATER
Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualified service technician.
The appliance MUST BE replaced if it has been submerged. Attempting to operate an appliance that has been submerged could create
numerous harmful conditions, such as a potential gas leakage causing a fire and/or explosion, or the release of mold, bacteria, or other
harmful particulates into the air. Operating a previously submerged appliance could result in property damage, severe personal injury,
or death.
NOTE: Appliance damage due to flood or submersion is considered an Act of God, and IS NOT covered under product warranty.
Altering any Westinghouse appliance with parts not manufactured and/or approved by Westinghouse. WILL INSTANTLY VOID the
appliance warranty and could result in property damage, serious personal injury, or death.
This water heater has been designed to heat potable water ONLY. Using this water heater to heat non-potable fluid WILL VOID product
warranty, and could result in property damage, personal injury, or death.
B. IMPROPER COMBUSTION
Do not obstruct the flow of combustion and ventilating air. Adequate air is necessary for safe operation. Failure to keep the exhaust
vent and combustion air intake clear of ice, snow, or other debris could result in property damage, serious personal injury, or death.
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C. GAS
Should overheating or gas supply fail to shut off, turn off the manual gas control valve to the water heater.
D. WHEN SERVICING THE HEATER


To avoid electric shock, disconnect electrical supply before performing maintenance.
To avoid severe burns, allow heater to cool.
E. HEATER WATER


Do not use petroleum-based cleaning or sealing compounds in a heater system. Gaskets and seals in the system may be
damaged. This can result in substantial property damage.
Do not use “homemade cures” or “patent medicines”. Substantial property damage, damage to heater, and/or serious personal
injury may result.
PART 2 – BEFORE YOU START
A. WHAT’S IN THE BOX
Also included with the heater:

Intake PVC Tee with Screens

Exhaust PVC Coupling with Screens

Temperature and Pressure Relief Valve (Ships Installed)

High Output Cold Water Dip Tube

Installation Manual

Warranty
B. HOW THE HEATER OPERATES
Modulation Condensing Technology is an intelligent system that delivers highly efficient water heating, while maximizing efficiency
by measuring the data parameters of your water heating system. Some of its features are:
Stainless Steel Water Storage Tank
The stainless steel water storage tank has a combustion chamber submerged into the tank water. When the water heater is fired,
combustion gases heat the combustion chamber walls, transferring heat directly into the surrounding water. These hot gases are blown
into secondary heat exchanger coils, where more heat is transferred into the water, removing even more heat from the gases.
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Modulating Combustion System
Modulation during water heating operation is based on tank temperature. The control monitors the system to regulate burner output
during operation to match system demand. This increase in efficiency allows for substantial fuel savings.
High Output Cold Water Dip Tube (Optional – Supplied with Water Heater)
Increases hot water draw by 20% when installed. The High Output Cold Water Dip Tube also increases recovery time by 20%, and
decreases thermal efficiency by a small amount.
Gas Valve
The gas valve senses suction from the blower, allowing gas to flow only if the gas valve is energized and combustion air is flowing.
Tank Sensor
This sensor monitors system water temperature. The control module adjusts the burner firing rate so the outlet water temperature
meets the set point.
Control
The integrated control system monitors water temperature and regulates fan speed to regulate the unit’s energy output. This allows the
unit to deliver the required amount of heated energy and nothing more.
Burner
Constructed of high grade stainless steel, the burner uses pre-mixed air and gas and provides a wide range of firing rates.
Condensate System with Built-In Neutralizing Cartridge
This is a condensing high efficiency water heater, and therefore has a condensate removal system. Condensate is nothing more than
water vapor, derived from combustion products and similar to an automobile when it is initially started. It is very important that the
condensate line slopes away from the water heater and down to a suitable inside drain.
The Built-In Neutralizing Cartridge is filled with marble chips that neutralize the condensate before it flows into a local drain. The marble
chips dissolve over time. The cartridge is designed to be easily removed, refilled with marble chips, and reinstalled,
If the condensate outlet on the heater is lower than the drain, you must use a condensate removal pump. In addition, local authorities
may require a condensate neutralizer to neutralize the condensate.
It is also very important not to expose the condensate line to freezing temperatures or any type of blockage. Plastic tubing must be the
only material used for the condensate line. Steel, brass, copper or other materials will be subject to corrosion or deterioration. A second
vent may be necessary to prevent condensate line vacuum lock on a long horizontal run. Also, an increase in pipe size may be
necessary to allow condensate to drain properly. Support of the condensation line may be necessary to avoid blockage of the
condensate flow.
Spark Ignition
The burner flame is ignited by applying high voltage to the system spark electrode. This causes a spark from electrode to ground.
C. OPTIONAL EQUIPMENT
Below is a list of optional equipment available from Westinghouse:

2” PVC Concentric Vent Kit (Part # KGAVT0501CVT)

3" PVC Concentric Vent Kit (Part # KGAVT0601CVT)

Outdoor Sensor (Part # 7250P-319)

Condensate Neutralizer Replacement (Part # 7700P-026)
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PART 3 – PREPARE WATER HEATER LOCATION
Carefully consider installation when determining heater location. Please read the entire manual before attempting installation. Failure to
properly take factors such as heater venting, piping, condensate removal, and wiring into account before installation could result in
wasted time, money, and possible property damage and personal injury.
A. BEFORE LOCATING THE HEATER
Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk. Ensure that the 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 heater or components due to incorrect operating conditions IS NOT covered by product warranty.
1. Installation Area (Mechanical Room) Operating Conditions
o
o
o
o

Ensure ambient temperatures are higher than 32 F/0 C and lower than 104 F/40 C.

Prevent the air from becoming contaminated by the products, places, and conditions listed in this manual, Part 3, Section F.

Avoid continuously high levels of humidity

Never close existing ventilation openings

Ensure a minimum 1” clearance around hot water and exhaust vent pipes
o

NOTE: To prevent condensing in the fan, it is recommended to avoid prolonged exposure to temperatures below 45 F.
o
This water heater has a condensate disposal system that may freeze if exposed to sustained temperatures below 32 F. Precautions
should be taken to protect the condensate trap and drain lines from sustained freezing conditions. Failure to take precautions could
result in property damage, severe personal injury, or death.
The service life of the heater’s exposed metallic surfaces, such as the casing, as well as internal surfaces, such as the heat exchanger,
are directly influenced by proximity to damp and salty marine environments. In such areas, higher concentration levels of chlorides from
sea spray coupled with relative humidity can lead to degradation of the heat exchanger and other heater components. In these
environments, heaters must not be installed using direct vent systems which draw outdoor air for combustion. Such heaters must be
installed using room air for combustion. Indoor air will have a much lower relative humidity and, hence, potential corrosion will be
minimized.
This heater is certified for indoor installations only. Do not install the heater outdoors. Failure to install this 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
3. Check area around heater. Remove any combustible materials, gasoline, and other flammable liquids.
Failure to keep heater area clear and free of combustible materials, liquids, and vapors can result in substantial property damage,
severe personal injury, or death.
4. Gas control system components must be protected from dripping water during operation and service.
5. If the heater is to replace an existing heater, check for and correct any existing system problems, such as:

System leaks
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

Location that could cause the system and heater to freeze and leak.
Incorrectly-sized expansion tank
6. Clean and flush system when reinstalling a 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 heater model and serial number.
B. LEVELING
In order for the condensate to properly flow out of the collection system, the area where you locate the heater must be level. Location
must also fully support the weight of the filled water heater.
C. CLEARANCES FOR SERVICE ACCESS
All water heaters eventually leak. It is recommended to install a catch pan beneath the water heater. This catch pan should be sized
with a maximum depth of 2”, and a minimum diameter 2” greater than the diameter of the water heater. The catch pan should empty
into an open drain line. This drain line should be ¾” ID minimum, piped to an open drain. Failure to follow these instructions could result
in property damage. Such damages ARE NOT covered by product warranty.
Figure 1 – Recommended Service Clearances
NOTE: In addition, it is recommended to provide a minimum service clearance of 6” from the top of the water heater to allow for piping
of the T&P relief valve and top ports. Depending on the installation, this clearance may need to be substantially greater than 6”.
NOTE: If you do not provide the minimum clearances shown in Figure 1, it might not be possible to service the heater without removing
it from the space.
The space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space
as the heater. The heater cover must be securely fastened to prevent the heater from drawing air form the heater room. This is
particularly important if the heater is in a room with other appliances. Failure to comply with the above warnings could result in
substantial property damage, severe personal injury, or death.
D. RESIDENTIAL GARAGE INSTALLATION
PRECAUTIONS
If the heater is located in a residential garage, per ANSI Z223.1:

Mount the bottom of the heater a minimum of 18” above the floor of the garage, to ensure the burner and ignition devices are
well off the floor.
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

When raising the heater, fully support the entire bottom of the water heater.
Locate or protect the heater so it cannot be damaged by a moving vehicle.
E. EXHAUST VENT AND INTAKE PIPE
The heater is rated ANSI Z21.10.3 Category IV (pressurized vent, likely to form condensate in the vent) and requires a special vent
system designed for pressurized venting.
NOTE: The venting options described here (and further detailed in Venting, Part 5 in this manual) are the lone venting options
approved for this water heater. Failure to vent the water heater in accordance with the provided venting instructions will void
the warranty.
Failure to vent the water heater properly will result in serious personal injury or death.
Do not attempt to vent this water heater by any means other than those described in this manual. Doing so will void the warranty, and
may result in severe personal injury or death.
Vents must be properly supported. Heater exhaust and intake connections are not designed to carry heavy weight. Vent support
brackets must be within 1’ of the heater and the balance at 4’ intervals. Heater must be readily accessible for visual inspection for the
first 3’ from the heater.
The exhaust discharged by this water heater may be very hot. Avoid touching or other direct contact with the exhaust gases or the vent
termination assembly. Doing so may result in product damage, severe personal injury, or death.
1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE
If installing a direct vent option, combustion air must be drawn from the outdoors directly into the water heater intake, and exhaust must
terminate outside. There are three basic direct vent options detailed in this manual: 1. Side Wall Venting, 2. Roof Venting, and 3.
Unbalanced Venting.
Be sure to locate the heater such that the exhaust vent and intake piping can be routed through the building and properly terminated.
Different vent terminals can be used to simplify and eliminate multiple penetrations in the building structure (see Optional Equipment in
Venting Section). The exhaust vent and intake piping lengths, routing and termination methods must all comply with the methods and
limits given in the Venting section, Part 5 of this manual.
When installing a combustion air intake from outdoors, care must be taken to utilize uncontaminated combustion air. To prevent
combustion air contamination, see Table 1 – Contaminant Table.
2. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE
This heater requires fresh, uncontaminated air for safe operation and must be installed in a mechanical room where there is adequate
combustion and ventilating air. NOTE: To prevent combustion air contamination, see Table 1 – Contaminant Table.
Combustion air from the indoor space can be used if the space has adequate area or when air is provided through a duct or louver to
supply sufficient combustion air based on the water heater input. Never obstruct the supply of combustion air to the water heater.
If the water heater is installed in areas where indoor air is contaminated (see Table 1) it is imperative that the water heater be installed
as direct vent so that all combustion air is taken directly from the outdoors into the water heater intake connection.
Unconfined space is space with volume greater than 50 cubic feet per 1,000 Btu/hour (4.8 cubic meters per kW) of the total 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. See Figure 14, p. 34 for details.
Confined space is space with volume less than 50 cubic feet per 1,000 Btu/hour (4.8 cubic meters per kW) of the total 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.
When drawing combustion air from inside a conventionally constructed building to a confined space, such space should be provided
with two permanent openings: one located 6” (15 cm) below the space ceiling, the other 6” (15cm) above the space floor. Each opening
2
should have a free area of one square inch per 1,000 Btu/hr (22cm /kW) of the total input of all appliances in the space, but not less
2
than 100 square inches (645cm ).
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If the confined space is within a building of tight construction, air for combustion must be obtained from the outdoors as outlined in the
Venting section, Part 5 of this manual.
When drawing combustion air from the outside into the mechanical room, care must be taken to provide adequate freeze protection.
Do not attempt to vent this water heater by any means other than those described in this manual. Doing so will void the warranty, and
may result in severe personal injury or death.
Failure to provide an adequate supply of fresh combustion air can cause poisonous flue gases to enter living space, resulting in severe
personal injury or death. To prevent combustion air contamination, see Table 1.
F. PREVENT COMBUSTION AIR CONTAMINATION
Install intake air piping for the heater as described in the Venting Section. Do not terminate exhaust in locations that can allow
contamination of intake air.
Ensure that the intake air will not contain any of the contaminants below. Contaminated air will damage the heater, resulting in possible
substantial property damage, severe personal injury, or death. For example, do not pipe intake air near a swimming pool. Also, avoid
areas subject to exhaust fumes from laundry facilities. These areas always contain contaminants.
PRODUCTS TO AVOID
Spray cans containing fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric or Muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, laundry detergents, and cleaning solvents
Adhesives used to fasten building products
AREAS LIKELY TO HAVE CONTAMINANTS
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages and workshops
Table 1 – Contaminant Table
NOTE: DAMAGE TO THE HEATER CAUSED BY EXPOSURE TO
CORROSIVE VAPORS IS NOT COVERED BY WARRANTY. (Refer to
the limited warranty for complete terms and conditions).
G. REMOVING A HEATER FROM A COMMON VENT SYSTEM
Do not install the heater into a common vent with any other appliance.
This will cause flue gas spillage or appliance malfunction, resulting in
possible substantial property damage, severe personal injury, or death.
Failure to follow all instructions can result in flue gas spillage and
carbon monoxide emissions, causing severe personal injury or death.
When removing an existing heater, follow the steps below.
1. Seal any unused openings in the common venting system.
Figure 2 - CO Warning Label
2. Visually inspect the venting system for proper size and horizontal pitch to
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determine if there is blockage, leakage, corrosion or other deficiencies that could cause an unsafe condition.
3. If practical, close all building doors, windows and doors between the space in which the water heater remains connected to the
common venting system and other spaces in the building. Turn on clothes dryers and any appliances not connected to the common
venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, at maximum speed. Do not operate a summer
exhaust fan. Close all fireplace dampers.
4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust the thermostat so the appliance will operate
continuously.
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. Any improper operation of the common venting system should be corrected to conform to the National Fuel Gas Code, ANSI Z223.1.
When resizing any portion of the common venting system, the system should approach the minimum size as determined using the
appropriate tables in Appendix G in the National Fuel Gas Code, ANSI Z 223.1.
H. WATER CHEMISTRY
Chemical imbalance of the water supply may affect efficiency and cause severe damage to the water heater and associated equipment.
Westinghouse recommends having water quality professionally analyzed to determine whether it is necessary to install a water
softener. It is important that the water chemistry on both the domestic hot water and central heating sides are checked before installing
the water heater, as water quality will affect the reliability of the system. Failure of a heat exchanger due to lime scale build-up on the
heating surface, low pH, or other chemical imbalance IS NOT covered by the warranty.
o
Operating temperatures above 135 F will further accelerate the build-up of lime scale on the heating surface and may shorten the
service life of the water heater. Failure of a heat exchanger due to lime scale build-up on the heating surface, low pH, or other chemical
imbalance IS NOT covered by the warranty.
Outlined below are water quality parameters which need to be met in order for the system to operate efficiently for many years.
Water Hardness
Water hardness is mainly due to the presence of calcium and magnesium salts dissolved in water. The concentration of these salts is
expressed in mg/L, ppm, or grains per gallon as a measure of relative water hardness. Grains per gallon is the common reference
measurement used in the U.S. water heater industry. Hardness expressed as mg/L or ppm may be divided by 17.1 to convert to grains
per gallon. Water may be classified as very soft, slightly hard, moderately hard, or hard based on its hardness number. The minerals in
the water precipitate out as the water is heated and cause accelerated lime scale accumulation on a heat transfer surface. This lime
o
scale build-up may result in premature failure of the heat exchanger. Operating temperatures above 135 F will further accelerate the
build-up of lime scale on the heating surface and may shorten the service life of the water heater.
Water that is classified as hard and very hard must be softened to avoid heat exchanger failure. See below for further information about
water hardness.
CLASSIFICATION
Soft
Slightly Hard
Moderately Hard
Hard
Very Hard
MG/L OR PPM
0 – 17.1
17.1 – 60
60 – 120
120 – 180
180 and over
GRAINS/GAL
0-1
1 – 3.5
3.5 – 7.0
7.0 – 10.5
10.5 and over
If the hardness of the water exceeds the maximum level of 7 grains per gallon, water should be softened to a hardness level no lower
than 5 grains per gallon. Water softened as low as 0 to 1 grain per gallon may be under-saturated with respect to calcium carbonate,
resulting in water that is aggressive and corrosive.
pH of Water
pH is a measure of relative acidity, neutrality or alkalinity. Dissolved minerals and gases affect water pH. The pH scale ranges from 0 to
14. Water with a pH of 7.0 is considered neutral. Water with a pH lower than 7 is considered acidic. Water pH higher than 7 is
considered alkaline. A neutral pH (around 7) is desirable for most potable water applications. Corrosion damage and heater failures
resulting from water pH levels of lower than 6 or higher than 8 ARE NOT covered by the warranty. The ideal pH range for water
used in a storage tank or a water heater system is 7.2 to 7.8.
WHL-001 REV. 9.3.14
14
Total Dissolved Solids
Total Dissolved Solids (TDS) is a measurement of all minerals and solids dissolved in a water sample. The concentration of total
dissolved solids is usually expressed in parts per million (ppm).
Water with a high TDS concentration will greatly accelerate lime and scale formation in the hot water system. Most high TDS
concentrations precipitate out of the water when heated. This can generate a scale accumulation on the heat transfer surface that will
greatly reduce the service life of a water heater. This scale accumulation can also impede the ability of the heat exchanger to transfer
heat into the water. A heat exchanger damaged or blocked by lime/scale accumulation must be replaced.
The manufacturer of the water heater has no control of water quality, especially TDS levels in your system. Total dissolved solids in
excess of 2,000 ppm will accelerate lime and scale formation in the heat exchanger. Heat exchanger failure due to total dissolved solids
in excess of 2,000 ppm is a non-warrantable condition. Failure of a water heater due to lime scale build up on the heating surface
IS NOT covered by the warranty.
Hardness: 7 grains
Chloride levels: 100 ppm
pH levels: 6-8
TDS: 2000 ppm
Sodium: 20 mGL
WHL-001 REV. 9.3.14
15
Figure 3 – *ALL DIMENSIONS ARE APPROXIMATE
UNCRATING HEATER – Any claims for damage or shortage in shipment must be filed immediately against the transportation company
by the consignee.
o
COLD WEATHER HANDLING – If the heater has been stored in a very cold location (BELOW 0 F) before installation, handle with care
until the plastic components come to room temperature.
Remove all sides of the shipping crate to allow the heater to be lifted into its installation location.
WHL-001 REV. 9.3.14
16
BTUH
76,000
PERFORMANCE SPECIFICATIONS FOR HIGH EFFICIENCY WATER HEATER MODELS
Temperature Rise in Degrees Fahrenheit
Efficiency
(°F)
40
50
60
70
80
90
100
110
120
(°C)
22
28
33
39
44
50
56
61
67
GPH
231
187
158
135
119
107
97
86
79
97%
LPH
874
708
598
511
450
405
367
326
299
130
72
73
276
140
78
69
261
Table 2 – Recovery on rating plate is based at 97% thermal efficiency at 70o Fahrenheit rise, as required by ANSI
PART 4 – HEATER PIPING
Failure to follow the instructions in this section WILL VOID the warranty and may result in property damage, serious injury, or death.
Never use dielectric unions or galvanized steel fittings when connecting to a stainless steel storage tank or heater. Use only copper or
brass fittings. Teflon thread sealant must be used on all connections.
DO NOT pipe this water heater with black iron, galvanized steel, steel, or lead pipe. Doing so will result in premature product failure and
property damage, and WILL VOID the product warranty.
Do not apply heat to the Hot or Cold water heater connections. If sweat connections are used, sweat tubing to the adapter before fitting
adapter to the water connections on the heater. Any heat applied to the water heater connections will permanently damage the dip tube
and/or heat traps. Damages due to improper installation practices ARE NOT covered by warranty.
A. GENERAL PIPING INFORMATION
Use two wrenches when tightening water piping at heater. Use one wrench to prevent the heater return or supply line from turning.
Failure to prevent piping connections from turning could cause damage to heater components.
The heater control module uses temperature sensors to provide both high limit protection and modulating temperature control. The
control module also provides low water protection by sensing the water level in the tank. Some codes/jurisdictions may require
additional external controls.
NOTICE
Installing the Optional High Output Cold Water Dip Tube – For longer hot water draw, remove the factory installed dip tube from the
cold water inlet and replace with the Optional High Output Cold Water Dip Tube. This can be done by hand.
WHL-001 REV. 9.3.14
17
B. SCALDING
APPROXIMATE TIME / TEMPERATURE RELATIONSHIPS IN SCALDS
o
120 F
More than 5 minutes
o
125 F
1 ½ to 2 minutes
o
130 F
About 30 seconds
o
135 F
About 10 seconds
o
140 F
Less than 5 seconds
o
145 F
Less than 3 seconds
o
150 F
About 1 ½ seconds
o
155 F
About 1 second
Table 3
This heater can deliver scalding water. Be careful whenever using hot water to avoid scalding
injury. Certain appliances, such as dishwashers and automatic clothes washers may require
increased water temperature. By setting the thermostat on this heater to obtain the increased
water temperature required by these appliances, you may create the potential for scald injury.
To protect against injury, you should install a mixing valve in the water system. This valve will
reduce point of discharge temperature by mixing cold and hot water in branch supply lines.
Such valves are available from your local plumbing supplier.
Table 3 details the relationship of water temperature and time with regard to scald injury and
may be used as a guide in determining the safest water temperature for your applications.
C. TEMPERATURE AND PRESSURE RELIEF VALVE
Overheated water and high pressures can cause water tank explosion. A properly sized temperature and pressure relief valve must be
installed in the opening provided on the water heater. Failure to install a properly sized temperature and pressure relief valve could
result in explosion and property damage, serious injury, or death.
To avoid water damage or scalding due to relief valve operation:

Discharge line must be connected to relief valve outlet and run to a safe place of disposal. Terminate the discharge line in a
manner that will prevent possibility of severe burns or property damage should the relief valve discharge.

Discharge line must be as short as possible and the same size as the valve discharge connection throughout its entire length.

Discharge line must pitch downward from the valve and terminate at least 6” above the floor drain, making discharge clearly
visible.
o

The discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of 375 F or greater.

Do not pipe discharge to any location where freezing could occur.

No shutoff valve may be installed between the relief valve and heater or in the discharge line. Do not plug or place any
obstruction in the discharge line.

Test the operation of the relief valve after filling and pressurizing the system by lifting the lever. Make sure the valve
discharges freely. If the valve fails to operate correctly, immediately replace with a new properly rated relief valve.

Test T&P valve at least once annually to ensure the waterway is clear. If valve does not operate, turn the heater “off” and call
a plumber immediately.

Take care whenever operating relief valve to avoid scalding injury or property damage.
FAILURE TO COMPLY WITH THE ABOVE GUIDELINES COULD RESULT IN FAILURE OF RELIEF VALVE OPERATION,
RESULTING IN POSSIBILITY OF SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.
Do not thread a cap or plug into the relief valve under any circumstances! Explosion and property damage, serious injury, or death may
result.
D. BACKFLOW PREVENTER
Use a backflow preventer specifically designed for water heater installations. This valve should be installed on the cold water fill supply
line per local codes.
E. POTABLE EXPANSION TANK
A potable hot water expansion tank is required to offset heated water expansion. In most city plumbing systems, the water meter has a
no return or back flow device built into the system to prevent back flowing of water into city mains. Some local codes require back flow
WHL-001 REV. 9.3.14
18
preventers on all incoming water supplies. The hot water expansion tank must be listed for potable water use. The expansion tank
should be located on the cold inlet piping close to the water heater.
EXPANSION TANK AND MAKE-UP WATER
1. Ensure that the expansion tank is sized to correctly handle heater and system water volume and temperature.
Undersized expansion tanks cause system water to be lost from the relief valve, causing make-up water to be added. Eventual heater
failure can result due to excessive make-up water addition. SUCH FAILURE IS NOT COVERED BY WARRANTY.
2. The expansion tank must be located as shown in the Heater Piping Details, or following recognized design methods. See expansion
tank manufacturer’s instructions for details.
The expansion tank must be suitable for hot potable water.
F. WATER PIPING
Never use dielectric unions or galvanized steel fittings on any domestic water or auxiliary connections. Use only copper or brass fittings.
Thread sealant must be used on all connections.
Do not apply heat to the water heater connections. If sweat connections are used, sweat tubing to the adapter before fitting adapter to
the water connections on the heater. Any heat applied to the water heater connections will permanently damage the dip tube and/or
heat traps. Damages due to improper installation practices ARE NOT covered by warranty.
The domestic water connections must be installed in accordance to all local and national plumbing codes, or any applicable standard
which prevails. The inlet (cold) and outlet (hot) ports are ¾” on all models.
It is recommended to install a sweat shut off valve and a union in the cold inlet piping and hot outlet to ease future servicing. If there is a
back flow preventer or any type of a no return valve in the system, you must install an additional tee here, suitable for a potable hot
water expansion tank.
In the hot outlet, install a suitable adapter to match the copper tubing of the plumbing system. A thermal trap or heat trap loop may be
installed here to provide additional energy savings and prevent the thermal siphoning of domestic hot water.
G. AUXILIARY CONNECTIONS
The auxiliary connections are additional connections for a recirculation connection, air handlers, plate exchangers, or other devices that
supply hot water. These connections must be installed in accordance with all local and national codes or any applicable standard that
prevails. Auxiliary connections are ¾” on all models. Never use dielectric unions or galvanized steel fittings. Use only copper or brass
fittings. Sealant must be used on all connections.
Never connect auxiliary connections to any system that uses glycol or other solutions formulated for hydronic systems. These auxiliary
connections are to be used only in a potable water system. Failure to follow this warning could result in serious injury or death.
H. FILLING THE HEATER
When filling the water heater, open a hot water tap to release air in the tank and piping. The tank must be full of water before the heater
is turned on. Failure to ensure the water heater is full before turning it on will result in damage to the water heater, and could result in
property damage, serious personal injury, or death. Such damages ARE NOT covered by water heater warranty.




Make certain that the field installed drain valve is completely closed.
Open the shut-off valve in the cold water supply line.
Open the hot water faucets to allow air to vent from the heater and piping.
Allow sufficient time for the heater to completely fill with water.
WHL-001 REV. 9.3.14
19
The water heater must be full of water and the system fully purged BEFORE powering the water heater. Applying power to the water
heater when it is not full of water could result in a condition referred to as “dry-firing”. Dry-firing the water heater will damage the heat
exchanger, and could result in property damage, serious personal injury, or death. Such damages ARE NOT covered by water heater
warranty.
I. IMPORTANT NOTICE
NOTICE
It is extremely important that whenever work is performed on the plumbing system that either:

The water heater is powered off, or,

The water heater is valved off and isolated from the plumbing system.
Failure to take these measures could result in a dry-firing condition.
The water heater must be full of water and the system fully purged BEFORE powering the water heater. Performing any work in the
plumbing system without either powering off the water heater or isolating the water heater through the use of shut-off valves could
result in a condition referred to as “dry-firing”. Dry-firing the water heater will damage the heat exchanger, and could result in property
damage, serious personal injury, or death. Such damages ARE NOT covered by water heater warranty.
WHL-001 REV. 9.3.14
20
J. PIPING DIAGRAMS
Figure 4 – High Efficiency Water Heater with Recirculation Line and Thermostatic Mixing Valve Piping
NOTES:
1. Minimum pipe size should match unit connection size. Upsize pipe accordingly if greater flow is required.
2. A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold
water inlet.
3. Gas line must be rated to the unit maximum input capacity. Unit must have 10 feet of pipe after gas regulator.
4. All circulators should have an integral flow check.
5. Drains and check valve between unit and storage tank will assist in purging air from system.
6. This drawing is meant to demonstrate system piping only. The installer is responsible for all equipment and detailing required by local codes. In
Massachusetts, you must install a vacuum relief valve per 248 CMR.
7. Always shut off power to the water heater or isolate the heater from the system if ANY plumbing work is to be done. Running the water heater without
water will result in dry firing.
An ASSE 1017 thermostatic mixing valve MUST be installed when using outdoor reset. Failure to do so could result in substantial
property damage, serious injury, or death.
The piping will not support the weight of the water heater circulator pump. Refer to the pump manufacturer’s installation instructions to
properly support the circulator pump. Failure to comply with these instructions could result in substantial property damage, severe
personal injury, or death.
WHL-001 REV. 9.3.14
21
Figure 5 – High Efficiency Water Heater with Air Handler on Side
NOTES:
1. Minimum pipe size should match unit connection size. Upsize pipe accordingly if greater flow is required.
2. A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold
water inlet.
3. Gas line must be rated to the unit maximum input capacity. Unit must have 10 feet of pipe after gas regulator.
4. All circulators should have an integral flow check.
5. Check with air handler manufacturer for proper sizing.
6. This drawing is meant to demonstrate system piping only. The installer is responsible for all equipment and detailing required by local codes. In
Massachusetts, you must install a vacuum relief valve per 248 CMR. With air handlers, outdoor reset is available with an outdoor sensor. See Part 8,
Section D.
7. Always shut off power to the water heater or isolate the heater from the system if ANY plumbing work is to be done. Running the water heater without
water will result in dry firing.
NOTES FOR AIR HANDLER APPLICATION:
1. MASSACHUSETTS STATE PLUMBING CODE REQUIRES A DISTANCE NO GREATER THAN 50 FEET FROM THE WATER HEATER TO THE
FAN COIL IN THE AIR HANDLER.
2. MASSACHUSETTS STATE PLUMBING CODE REQUIRES AN ELECTRONICALLY TIMED CIRCULATOR PUMP TO ACTIVATE EVERY SIX
HOURS FOR 60 SECONDS. THIS CIRCULATOR IS REQUIRED TO BE BRONZE OR STAINLESS.
3. ALL WATER PIPING MUST BE INSULATED.
4. YOU MUST INSTALL A VACUUM RELIEF VALVE PER 248 CMR.
NOTE: THIS DRAWING IS MEANT TO DEMONSTRATE SYSTEM PIPING ONLY. THE INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND
DETAILING REQUIRED BY LOCAL CODES.
An ASSE 1017 thermostatic mixing valve MUST be installed when using outdoor reset. Failure to do so could result in substantial
property damage, serious injury, or death.
The piping will not support the weight of the water heater circulator pump. Refer to the pump manufacturer’s installation instructions to
properly support the circulator pump. Failure to comply with these instructions could result in substantial property damage, severe
personal injury, or death.
WHL-001 REV. 9.3.14
22
Figure 6 – High Efficiency Water Heater with Air Handler on Side
NOTES:
1. Minimum pipe size should match unit connection size. Upsize pipe accordingly if greater flow is required.
2. A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold
water inlet.
3. Gas line must be rated to the unit maximum input capacity. Unit must have 10 feet of pipe after gas regulator.
4. All circulators should have an integral flow check.
5. Check with air handler manufacturer for proper sizing.
6. This drawing is meant to demonstrate system piping only. The installer is responsible for all equipment and detailing required by local codes. In
Massachusetts, you must install a vacuum relief valve per 248 CMR. With air handlers, outdoor reset is available with an outdoor sensor. See Part 8,
Section D.
7. Always shut off power to the water heater or isolate the heater from the system if ANY plumbing work is to be done. Running the water heater without
water will result in dry firing.
NOTES FOR AIR HANDLER APPLICATION:
1. MASSACHUSETTS STATE PLUMBING CODE REQUIRES A DISTANCE NO GREATER THAN 50 FEET FROM THE WATER HEATER TO THE
FAN COIL IN THE AIR HANDLER.
2. MASSACHUSETTS STATE PLUMBING CODE REQUIRES AN ELECTRONICALLY TIMED CIRCULATOR PUMP TO ACTIVATE EVERY SIX
HOURS FOR 60 SECONDS. THIS CIRCULATOR IS REQUIRED TO BE BRONZE OR STAINLESS.
3. ALL WATER PIPING MUST BE INSULATED.
4. YOU MUST INSTALL A VACUUM RELIEF VALVE PER 248 CMR.
NOTE: THIS DRAWING IS MEANT TO DEMONSTRATE SYSTEM PIPING ONLY. THE INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND
DETAILING REQUIRED BY LOCAL CODES.
An ASSE 1017 thermostatic mixing valve MUST be installed when using outdoor reset. Failure to do so could result in substantial
property damage, serious injury, or death.
The piping will not support the weight of the water heater circulator pump. Refer to the pump manufacturer’s installation instructions to
properly support the circulator pump. Failure to comply with these instructions could result in substantial property damage, severe
personal injury, or death.
WHL-001 REV. 9.3.14
23
PART 5 – VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL
The heater must be vented as detailed in this Venting Section. Ensure
exhaust vent and intake piping complies with these instructions
regarding vent system. Inspect finished exhaust vent and intake piping
thoroughly to ensure all joints are well secured, airtight, and comply with
all applicable code requirements, as well as with the instructions
provided in this manual. Failure to properly install the vent system will
result in severe personal injury or death.
A. GENERAL
This heater is certified as a “Category IV” appliance, and requires a
special venting system. The vent system will operate with a positive
pressure in the pipe. Exhaust gases must be piped directly outdoors
using the vent materials and rules outlined in these instructions. Do not
connect vent connectors serving appliances vented by natural draft into
any portion of mechanical draft systems operating under positive
pressure. Follow the venting instructions carefully. Failure to do so will
result in substantial property damage, severe personal injury, or death.
1. Installation should be made in accordance with the regulations of the Authority Having Jurisdiction, local code authorities, and utility
companies which pertain to this type of water heating equipment.
2. Install the venting system in accordance with these instructions and with the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
CAN/CGA B149, and/or applicable provisions of local building codes.
3. This water heater must be vented with materials, components, and systems listed and approved for Category IV appliances.
Exhaust and intake are to be piped separately. This heater cannot share a common exhaust or intake with multiple appliances. Failure
to follow this instruction will result in substantial property damage, severe personal injury, or death.
NOTE: To avoid contamination often contained in indoor air, it is best to pipe all intake combustion air directly to the outdoors.
NOTE: If exhaust vent pipe system passes through an unheated space, such as an alcove or attic, the space must be heated or the
pipe must be insulated. The insulation must have an R value sufficient to prevent freezing of the condensate.
Improper seating of vent pipe gaskets can cause eventual gasket failure and exhaust gas leakage. Ensure the exhaust vent pipe is
properly beveled and seated before insertion into the flue adapter. Failure to do so could result in property damage, severe personal
injury, or death.
Due to the extreme flammability of most glues, cements, solvents, and primers used to join plastic exhaust vent and intake pipes,
explosive solvent vapors must be cleared from all vent piping before start-up. Avoid using excess cement or primer, as this may pool in
the vent pipes. Vent assemblies should be allowed to cure for a period of at least 8 hours before powering a connected appliance.
Failure to follow these instructions will result in substantial property damage, severe personal injury, or death. It is the installers’
responsibility to understand the hazards associated with explosive solvents and take the necessary precautions to avoid these risks.
DO NOT insulate the first 3 feet of the Exhaust Vent. CPVC, Polypropylene, or Stainless Steel pipe material MUST be used for the first
3 feet of the vent run if the Exhaust Vent is insulated or passes through an enclosed space greater than 6”, such as a wall. The balance
of the vent run can be installed with standard Schedule 40 PVC pipe. Failure to comply with this warning could result in substantial
property damage, severe personal injury, or death.
WHL-001 REV. 9.3.14
24
B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE
Item
Exhaust vent or Intake
pipe and fittings
Pipe cement/primer
APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL
Standards for Installation in:
Material
United States
Canada
PVC schedule 40/80
ANSI/ASTM D1785
PP, CPVC, and PVC venting must be
PVC-DWV*
ANSI/ASTM D2665
ULC-S636 Certified. IPEX is an approved
manufacturer in Canada, supplying vent
CPVC schedule 40/80
ANSI/ASTM F441
material listed to ULC-S636.
Polypropylene
ULCS636
Certified for Category IV and
Certified for Category IV and direct vent
Stainless Steel AL29-4C
direct vent appliance venting
appliance venting
PVC
ANSI/ASTM D2564
IPEX System 636 Cements & Primers
CPVC
ANSI/ASTM F493
Table 4








The exhaust and intake components installed with this heater must be used for near heater piping BEFORE transitioning to the
approved materials listed above. DO NOT REMOVE these installed components. Doing so WILL VOID heater warranty.
PVC/CPVC pipe and fittings of the same diameter are considered interchangeable.
DO NOT use Foam Core Pipe in any portion of the exhaust piping from this water heater.
DO NOT connect PVC/CPVC to PP without an approved vent connector.
When installing AL29-4C vent piping, install a PVC-to-stainless adapter at the heater vent connection, and at the termination
when using a PVC termination kit. DO NOT mix AL-29-4C piping from different manufacturers unless using adapters
specifically designed for the purpose by the manufacturer.
A double wall vent may be used when using stainless steel vent material in a freezing climate.
*PVC-DWV for air intake applications ONLY.
Contact the venting material manufacturer if there is any question about the applicability of the proposed venting material.
Failure to follow these directions will result in substantial property damage, severe personal injury, or death.
DO NOT mix components from different venting systems. The vent system could fail, causing leakage of flue products into the living
space. Use only the approved pipe and fitting materials, and primer and cement specifically designed for the material used, as listed in
Table 4. Failure to do so could result in property damage, severe personal injury, or death.
Exhaust vent adaptors are not designed as load-bearing devices, and must not be used to support exhaust vent piping. All vent pipes
must be properly connected, supported, and the exhaust vent must be pitched a minimum of ¼” per foot back to the heater to allow
drainage of condensate. Failure to properly support vent piping and follow the information in this statement could result in product
damage, severe personal injury, or death.
NOTE: The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent
the condensation of airborne moisture in the incoming combustion air.
o
o
High heat sources (sources generating heat 100 F / 37 C or greater, such as stove pipes, space heaters, etc.) may damage plastic
components of the water heater as well as plastic vent pipe materials. Such damages ARE NOT covered by warranty. It is
recommended to keep a minimum clearance of 8” from high heat sources. Observe heat source manufacturer instructions, as well as
local, state, provincial, and national codes, laws, regulations and ordinances when installing this water heater and related components
near high heat sources.
C. REQUIREMENTS FOR INSTALLATION IN CANADA
1. Installations must be made with a vent pipe system certified to ULC-S636. IPEX is an approved vent manufacturer in Canada
supplying vent material listed to ULC-S636. Additionally you may use AL29-4C stainless steel venting to comply with Canadian
requirements.
2. The first three (3) feet of vent pipe from the water heater flue outlet must be readily accessible for visual inspection.
3. The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe / fittings.
Cellular foam core piping may be used on air inlet piping only.
WHL-001 REV. 9.3.14
25
You must not use “B” vent in an exhaust application. “B” vent is for intake applications ONLY. Using “B” vent in an exhaust application
will result in serious injury or death.
D. EXHAUST VENT AND INTAKE PIPE LOCATION
Figure 7 – ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada – Exit Terminals for Direct-Vent Venting Systems
DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION – FIGURE 7 NOTES:
INSTALLATIONS IN THE UNITED STATES
A. Provide a minimum of 1 foot clearance from the bottom of the exhaust vent and intake pipe above the expected snow accumulation
level. Snow removal may be necessary to maintain clearance.
B. Provide a minimum of 1 foot distance from exhaust vent termination to any door, operable window, or gravity intake into any building.
C. Provide a minimum of 1 foot distance from exhaust vent termination to any permanently closed door or window.
D. Provide a minimum of 4 feet vertical clearance from the exhaust vent to all roof overhangs.
E. Locating exhaust vent termination near roof overhangs will result in the formation of icicles in freezing weather, and could result in
blockage of the exhaust vent. To prevent icicles from forming, maintain 4 feet vertical clearance from the exhaust vent to all roof
overhangs.
F. Provide 4 feet clearance from the outside corner of vertical walls, chimneys, etc., as well as horizontal corners created by roof
overhangs.
G. Provide 6 feet clearance from the inside corner of vertical walls, chimneys, etc., as well as horizontal corners created by roof
overhangs.
H. Provide 4 feet clearance from center line within a height of 15 feet above electrical meters, gas meters, gas regulators, relief
equipment, exhaust fans and inlets.
I. Provide 4 feet horizontal clearance from electrical meters, gas meters, gas regulators, relief equipment, exhaust fans and inlets. In no
case shall the exit terminal be above or below the aforementioned equipment unless the 4 foot horizontal distance is maintained.
J. This water heater vent system shall terminate at least 3 feet (0.9 m) above any forced air intake located within 10 ft (3 m).
NOTE: This does not apply to the combustion air intake of a direct-vent appliance.
K. When venting with a two pipe system, maximum distance between exhaust vent and intake pipe is 6 feet (1.8 m). Minimum distance
between exhaust vent and intake pipe on single direct vented appliance is 10” (0.255 m) center-to-center. Minimum distance between
exhaust vents and intake pipes on multiple water heaters is 10” (0.255 m) center-to-center.
L. When adjacent to a public walkway, locate exit terminal at least 7 feet above grade.
In addition:

Total length of vent piping shall not exceed the limits specified in this manual.

The vent piping for this direct vented appliance is approved for zero clearance to combustible construction.

The flue products coming from the exhaust vent will create a large plume when the boiler is in operation. Avoid venting in
areas that will affect neighboring buildings or be considered objectionable.

DO NOT locate exhaust vent or intake pipe in a parking area where machinery may damage the pipe.

DO NOT locate the exhaust vent or intake pipe terminals under a porch, balcony, or veranda.

Avoid terminating exhaust vents near shrubs, air conditioners, or other objects that will obstruct the exhaust stream.

DO NOT vent over a public walkway. Condensate could drip or freeze and create a nuisance or hazard.

NOTE: Due to potential moisture build-up, sidewall venting may not be the preferred venting option. Carefully consider venting
installation and location to save time and cost.
INSTALLATIONS IN CANADA
NOTE: Canadian installation must comply with the CAN/CSA B149.1 code and applicable local codes and supersede the restrictions
for the United States outlined in this section.
WHL-001 REV. 9.3.14
26
The building owner is responsible for keeping the exhaust and intake terminations free of snow, ice, or other potential blockages, as
well as scheduling routine maintenance. Failure to keep the vent piping terminations clear and properly maintain the heater could result
in property damage, severe personal injury, or death.
For each floor containing bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedrooms,
as well as in the room that houses the heater. Detectors and alarms shall comply with NFPA 720 (latest edition). Failure to comply with
requirements for detectors and alarms could result in property damage, severe personal injury, or death.
E. EXHAUST VENT AND INTAKE PIPE SIZING
1. The exhaust vent and intake pipe size is 2".
2. The total equivalent length of exhaust vent and intake pipe should not exceed 150 feet.
a. The equivalent length of elbows, tees, and other fittings are listed in the Friction Loss Table, Table 5:
FRICTION LOSS EQUIVALENT IN PIPING AND FITTINGS
EQUIVALENT FEET
FITTINGS OR PIPING
2”
90 DEGREE ELBOW*
5’
45 DEGREE ELBOW
3’
COUPLING
0’
AIR INLET TEE
0’
STRAIGHT PIPE
1’
CONCENTRIC VENT KIT
3’
V500 2” VENT KIT
1’
V1000 3” VENT KIT
N/A
V2000 4” VENT KIT
N/A
3”
5’
3’
0’
0’
1’
3’
N/A
1’
1’
Table 5 - *Friction loss for long radius elbow is 1 foot less. NOTE: Consult Polypropylene venting instructions for friction loss and pressure
drop equivalents.
b. For example: If the exhaust vent has two 90° elbows and 10 feet of PVC pipe we will calculate:
Exhaust Vent Equivalent Length = (2x5) + 10 = 20 feet.
Further, if the intake pipe has two 90° elbows, one 45° elbow and 10 feet of PVC pipe, the following calculation applies:
Intake Pipe Equivalent Length = (2x5) + 3 + 10 = 23 feet.
Finally, if a concentric vent kit is used we find:
Total Equivalent Length = 20 + 23 + 3 = 46 feet.
The total equivalent length is 46 feet which is well below the maximum of 150 feet.
c. The exhaust vent and intake pipe are intended to penetrate the same wall or roof of the building.
d. Effort should be made to keep a minimum difference in equivalent length between the exhaust vent and intake pipe.
3. The minimum total equivalent length is 16 feet.
F. LONGER VENT RUNS
1. The maximum total equivalent length can be extended by increasing the diameter of both the exhaust vent and intake pipes.
However, the transitions should begin a minimum of 15 equivalent feet from the water heater.
a. The maximum total equivalent length for increased diameter vent pipes is 200 feet.
b. Transitions should always be made in vertical sections of pipe to prevent the condensate from pooling in the vent pipe.
VENT CONNECTION
2”
REDUCING COUPLING
3” X 2”
VENT TRANSITION
3”
Table 6 – Vent Run Transition
c. Transition from 2” to 3” pipe should be made at the water heater.
Do not exceed the maximum lengths for vent pipes. Excessive length could result in appliance shutdown and property damage.
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G. EXHAUST VENT AND INTAKE PIPE INSTALLATION
All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into living space.
1. Use only solid PVC or CPVC pipe or a Polypropylene vent system approved for use with Category IV appliances.
FOAM CORE PIPING IS NOT APPROVED FOR EXHAUST VENT APPLICATIONS. Foam core piping may be used on air inlet piping
only.
2. Remove all burrs and debris from joints and fittings.
3. When using PVC or CPVC pipe, all joints must be properly cleaned, primed, and cemented. Use only cement and primer approved
for use with the pipe material. Cement must conform to ASTM D2564 for PVC and ASTM F493 for CPVC pipe. NOTE: DO NOT
CEMENT POLYPROPYLENE PIPE.
4. Ensure the vent is located where it will not be exposed to prevailing winds.
5. In all roof venting applications, exhaust discharge must point away from the pitch of the roof.
6. To prevent water leakage, install adequate roof flashing where the pipe enters the roof.
7. Do not locate vent over public walkways, driveways, or parking lots. Condensate could drip and freeze, resulting in a slip hazard or
damage to vehicles and machinery.
8. Due to potential moisture build-up, sidewall venting may not be the preferred venting option. To save time and cost, carefully
consider venting installation and location.
9. Horizontal lengths of exhaust vent must slope back towards the water heater not less than ¼" per foot to allow condensate to drain
from the vent pipe.
10. The exhaust vent must terminate where vapors cannot make accidental contact with people or pets, or damage shrubs or plants.
11. In vacant chimney applications, install and seal a rain cap over existing chimney openings.
12. All piping must be fully supported. Use pipe hangers at a minimum of 4 foot intervals to prevent sagging of the pipe where
condensate may form.
13. Do not use the heater to support any piping.
14. A screened straight coupling is provided with the heater for use as an outside exhaust termination.
15. A screened inlet air tee is provided with the heater to be used as an outside intake termination.
Table 7 lists optional exhaust/intake terminations available from Westinghouse:
DESCRIPTION
2” PVC CONCENTRIC VENT TERMINATION KIT
3” PVC CONCENTRIC VENT TERMINATION KIT
2” STAINLESS STEEL VENT TERMINATION KIT
3” STAINLESS STEEL VENT TERMINATION KIT
STOCK CODE
KGAVT0501CVT
KGAVT0601CVT
V500
V1000
Table 7
H. VENTING DRAWINGS
1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE
If installing a direct vent option, combustion air must be drawn from the outdoors directly into the water heater intake, and exhaust must
terminate outside. There are three basic direct vent options detailed in this manual: 1. Side Wall Venting, 2. Roof Venting, and 3.
Unbalanced Venting.
Be sure to locate the heater such that the exhaust vent and intake pipe can be routed through the building and properly terminated.
Different vent terminals can be used to simplify and eliminate multiple penetrations in the building structure (see Optional Equipment in
Venting Section). The exhaust vent and intake pipe lengths, routing and termination methods must all comply with the methods and
limits given in the Venting section, Part 5 of this manual.
WHL-001 REV. 9.3.14
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When installing a combustion air intake from outdoors, care must be taken to utilize uncontaminated combustion air. NOTE: To
prevent combustion air contamination, see Table 1 – Contaminant Table.
Take extra precaution to adequately support the weight of vent pipes terminating through the roof. Failure to properly support roof
terminated vent piping could result in property damage, serious personal injury, or death due to flue gas leakage.
Figure 8 – Sidewall Venting with Tee (Intake) and Coupling (Exhaust) - NOTE: This drawing is meant to demonstrate system
venting only. The installer is responsible for all equipment and detailing required by local codes.
All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the heater to allow
drainage of condensate. When placing support brackets on vent piping, the first bracket must be within 1 foot of the water heater and
the balance at 4 foot intervals on the vent pipe. Heater venting must be readily accessible for visual inspection for the first three feet
from the heater.
WHL-001 REV. 9.3.14
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Figure 9 – Venting with Optional Kits (NOT INCLUDED WITH THE WATER HEATER) NOTE: These drawings are meant to
demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.
All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the heater to allow
drainage of condensate. When placing support brackets on vent piping, the first bracket must be within 1 foot of the water heater and
the balance at 4 foot intervals on the vent pipe. Heater venting must be readily accessible for visual inspection for the first three feet
from the heater.
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Figure 10 – NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing
required by local codes.
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Figure 11 – Horizontal Venting - NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all
equipment and detailing required by local codes.
NOTES:
A. For every 1” of overhang, the exhaust vent must be located 1” vertical below overhang (overhang means top of building structure and not two
adjacent walls [corner of building]).
B. Typical installations require 12” minimum separation between bottom of exhaust outlet and top of air intake.
C. Maintain 12” minimum clearance above highest anticipated snow level or grade (whichever is greater).
D. Minimum 12” between vents when installing multiple vents.
E. 12” minimum beyond air intake.
All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the heater to allow
drainage of condensate. When placing support brackets on vent piping, the first bracket must be within 1 foot of the water heater and
the balance at 4 foot intervals on the vent pipe. Heater venting must be readily accessible for visual inspection for the first three feet
from the heater.
2. VENTING THROUGH AN EXISTING SYSTEM
This heater may be vented through an existing unused vent system. The inner diameter of the existing vent system is utilized for the
combustion air source. Two methods have been approved for such venting: Concentric Venting Through an Existing System and
Venting as a Chase.
VENT / AIR INLET SIZE
2”
3”
4”
MINIMUM EXISTING VENT / CHASE SIZE
4”
5”
7”
Table 8 – Minimum Existing Vent / Chase Sizing
WHL-001 REV. 9.3.14
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Do not install the heater into a common existing vent with any other appliance. This will cause flue gas spillage or heater malfunction,
resulting in substantial property damage, severe personal injury, or death.
Contractors must check state and local codes before installing through an existing vent opening. State and local codes always take
precedence over manufacturer’s instructions. Failure to check state and local codes before installing through an existing opening could
result in property damage and add significantly to installation costs.
If an existing venting system is converted for use with this heater, the installer must ensure that the existing venting system is clean and
free from particulate contamination that could damage the heater. Failure to do so could result in property damage and heater failure.
Such failure IS NOT covered under warranty.
CONCENTRIC VENTING THROUGH AN EXISTING SYSTEM
NOTE: The following instructions refer only to venting through an existing vent system, and not to venting with HTP’s optional
concentric vent kits. Refer to Concentric Vent Kit installation manual (LP-166) for further information on venting with the optional
concentric vent kits.
Concentric venting through an existing system must run vertically through the roof. See Table 5 for proper minimum vent sizing. Use
only the approved venting materials specified in Table 4 for piping the system. All instructions listed in Part 5 - Venting apply. See
Figures 12-1 and 12-2 for venting demonstrations.
The upper and lower vent terminations as well as all joints in the venting system must be properly sealed to ensure that all combustion
air is drawn properly and exhaust does not leak from the system. Failure to properly seal the venting system will result in property
damage, severe personal injury, or death.
CHASE VENTING THROUGH AN EXISTING SYSTEM
When venting as a chase, follow all instructions included in Part 5 – Venting of this manual, as well as the previous Concentric Venting
section. See Figure 12-3 for chase venting demonstration.
Figures 12 – 1, 12 – 2 Concentric Venting Through an Existing System, 12 – 3 Chase Venting Through an Existing System NOTE: This drawing
is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.
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3. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE
This heater requires fresh, uncontaminated air for safe operation and must be installed in a mechanical room where there is adequate
combustion and ventilating air. NOTE: To prevent combustion air contamination, see Table 1 – Contaminant Table on page 12.
Combustion air from the indoor space can be used if the space has adequate area or when air is provided through a duct or louver to
supply sufficient combustion air based on the water heater input. Never obstruct the supply of combustion air to the water heater.
If the water heater is installed in areas where indoor air is contaminated (see Figure 13) it is imperative that the water heater be
installed as direct vent so that all combustion air is taken directly from the outdoors into the water heater intake connection.
Unconfined space is space with volume greater than 50 cubic feet per 1,000 Btu/hour (4.8 cubic meters per kW) of the total 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 is space with volume less than 50 cubic feet per 1,000 Btu/hour (4.8 cubic meters per kW) of the total 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.
When drawing combustion air from inside a conventionally constructed building to a confined space, such space should be provided
with two permanent openings: one located 6” (15 cm) below the space ceiling, the other 6” (15cm) above the space floor. Each opening
2
should have a free area of one square inch per 1,000 Btu/hr (22cm /kW) of the total input of all appliances in the space, but not less
2
than 100 square inches (645cm ).
If the confined space is within a building of tight construction, air for
combustion must be obtained from the outdoors as outlined in the Venting
section of this manual. See Figure 14.
Figure 13 – LP-325-X
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Figure 14
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I. CONDENSATE REMOVAL SYSTEM
NOTE: Check with your local gas company to determine if combustion condensate disposal is permitted in your area. In the state of
Massachusetts, condensate must be neutralized before entering a drain.
This condensing high efficiency water heater has a condensate removal system. Condensate is water vapor derived from combustion
products, similar to that produced by an automobile when it is initially started. It is very important that the condensate line is sloped
down away from the heater and to a suitable drain.
If the heater condensate outlet is lower than the drain, you must use a condensate removal. If required by local authorities, a
condensate filter of lime crystals, marble, or phosphate chips will neutralize slightly acidic condensate.
The condensate line must remain unobstructed. If allowed to freeze in the line or obstructed in any other manner, condensate can exit
from the water heater tee, resulting in potential water damage to property. When installing a condensate pump, select one approved for
use with condensing heaters and furnaces. The condensate pump should have an overflow switch to prevent property damage from
spillage. Condensate from the heater will be slightly acidic (pH from 3.2 to 4.5). Install a neutralizing filter if required by local codes.
Figure 15 – Condensate Piping
NOTES:
1. Condensate line must be pitched at least ¼” per foot to properly drain. If this cannot be done, or a very long length of condensate hose is used,
increase the condensate line to a minimum of 1” ID and place a tee in the line after the condensate neutralizer to properly reduce vacuum lock in the
drain line.
2. PVC or CPVC pipe should be the only material used for condensate line. Steel, brass, copper, and other metals will be subject to corrosion or
deterioration.
3. A frozen condensate line could result in a blocked vent condition. It is very important to protect the condensate line from freezing temperatures or any
type of blockage. In installations that may encounter sustained freezing conditions, the use of heat tape is recommended to avoid freezing of the
condensate line. It is also recommended to bush up the condensate line size to 1” and terminate condensate discharge as close to the unit as possible.
Longer condensate runs are more prone to freezing. Damages due to frozen or blocked condensate lines ARE NOT covered by warranty.
4. Support of the condensate line may be necessary to avoid blockage of the condensate flow.
Power to the optional condensate pump is continuous. When the water heater is powered off the condensate pump will remain on. It is
important to remember to turn off the condensate pump when powering down the water heater. Failure to do so could result in property
damage, severe personal injury, or death.
WHL-001 REV. 9.3.14
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Figure 16 – Removing and Installing the Condensate Neutralizer
NOTICE
To ensure proper condensate neutralization it is recommended to check the condensate neutralizer cartridge every two years. Gently
shake the cartridge to ensure it is still filled with neutralization media. Replace the condensate neutralizer cartridge if it is empty. Failure
to do so could result in improper condensate neutralization. Please note that if not properly neutralized the slightly acidic condensate
could corrode materials subject to corrosion (metals, concrete, stonework, etc.)
WHL-001 REV. 9.3.14
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PART 6 – WIRING
To avoid electrical shock, turn off all power to the heater prior to opening an electrical box within the unit. Ensure the power remains off
while any wiring connections are being made. Failure to follow these instructions could result in component or product failure, serious
injury, or death. Such product failure IS NOT covered by warranty.
Jumping out control circuits or components WILL VOID product warranty and can result in property damage, personal injury, or death.
A. LINE VOLTAGE INPUT
The heater must be wired to a 115 volt circuit by a qualified electrician. It is recommended that the heater be wired on its own circuit to
minimize the possibility of circuit failure due to outside causes. The heater requires a maximum of 8 amps at 120 volts in use.
Figure 17 – Line Voltage Wiring
B. LINE VOLTAGE CONDENSATE OUTPUT
The heater has the capability of supplying power to a condensate pump. The connection is 115 VAC + 10% / - 15% at a max of 2 amps.
Power is supplied to the pump only when the heater is connected to power, and the power switch is in the on position.
C. LOW VOLTAGE OUTDOOR SENSOR INPUT
The heater has the capability of an outdoor reset. Connecting an outdoor sensor allows the heater to operate at optimum efficiency.
Westinghouse offers an outdoor sensor.
The outdoor sensor must be a 12K NTC sensor. Use a minimum 22 AWG wire for runs of 100 feet or less and minimum 18 AWG wire
for runs up to 150 feet. Instructions are included with the outdoor sensor to correctly mount the sensor on the exterior surface of the
building. It is preferable to mount the sensor on the north side in an area that will not be affected by direct sunlight but will be exposed
to varying weather conditions. Connect the outdoor sensor to terminals marked “Outdoor”.
It is of extreme importance that this unit be properly grounded. It is very important that the building system ground is inspected by a
qualified electrician prior to making this connection. Electrical power must only be turned on when the heater is completely filled with
cold water.
Figure 18 – Low Voltage Wiring
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Label all wires prior to disconnecting them when servicing the heater. Wiring errors can cause improper and dangerous operation.
Failure to follow these instructions may result in property damage or personal injury.
D. INTERNAL WIRING DIAGRAM
Figure 19 – Wiring Diagram
PART 7 – GAS CONNECTIONS
Failure to follow all precautions could result in fire, explosion, severe injury or death!
Ensure the gas on which the water heater will operate is the same type specified on the rating plate. Failure to do so could result in
water heater malfunction, property damage, serious personal injury, or death.
WHL-001 REV. 9.3.14
39
The gas supply shall have a maximum inlet pressure of less than 14" water
column (350 mm), ½ pound pressure (3.5 kPa), and a minimum of 3.5" water
column. The entire piping system, gas meter and regulator must be sized
properly to prevent pressure drop greater than 0.5" WC as stated in the
National Fuel Gas Code. This information is listed on the rating plate.
It is very important that you are connected to the type of gas as noted on the
rating plate: "LP" for liquefied petroleum, propane gas, or "Nat" for natural or
city gas. All gas connections must be approved by the local gas supplier or
utility, in addition to the governing authority, prior to turning the gas supply
on.
Do not remove the adaptor in Figure 20! It is mandatory that this fitting is used
for connection to a field fabricated drip leg per the National Fuel Gas Code.
You must ensure that the entire gas line to the connection at the water heater
is no smaller than ½”.
Once all inspections have been performed, the piping must be leak tested. If
the leak test requirement is a higher test pressure than the maximum gas
inlet pressure, you must isolate the heater from the gas line to continue leak
testing. To do this, you must turn off the factory and field-installed gas cocks.
This will minimize the possibility of damaging the gas valve. Failure to do so
Figure 20 –Gas Connection
may damage the gas valve. In the event the gas valve is exposed to a
pressure greater than ½ PSI, 14" water column, the gas valve must be replaced. Never use an open flame (match, lighter, etc.) to
check gas connections.
UL recognized fuel gas detectors are recommended in all enclosed propane and natural gas applications where there is a potential for
an explosive mixture of fuel gas to accumulate. The installation of these detectors should be made in accordance with the detector
manufacturer’s recommendations, and/or local laws. Failure to install fuel gas detectors in these applications could result in fire,
explosion, property damage, severe personal injury, or death.
A. GAS PIPING
Run the gas supply line in accordance with all applicable codes. Locate and install manual shutoff valves in accordance with local and
state requirements.
Support gas supply piping with hangers, not by the heater or its accessories. The heater gas valve and blower will not support the
weight of the piping. Make sure the gas piping is protected from physical damage and freezing, where required. Failure to follow these
instructions could result in gas leakage, and result in fire, explosion, property damage, severe personal injury, or death.
Do not use Teflon tape on gas line pipe thread. Use a pipe compound rated for use with natural and propane gases. Apply sparingly on
male pipe ends, leaving the two end threads bare. Failure to follow these instructions could result in gas leakage, and result in fire,
explosion, property damage, severe personal injury, or death.
B. GAS TABLE
Refer to the table below to size the supply piping to minimize pressure drop between meter or regulator and unit.
Maximum capacity of pipe in cubic feet of gas per hour for gas pressures of .5 psi or less and a pressure drop of .3 inch water column.
Nominal Iron
Pipe Size (In.)
Internal
Dia. (In.)
½
¾
1
1¼
.824
1.049
1.380
Length of Pipe (Feet)
10
278
520
1,050
Table 9 – Source – ANSI Z223.1
20
30
40
50
60
70
80
90
100
125
150
175
200
190
350
730
152
285
590
130
245
500
115
215
440
105
195
400
96
180
370
90
170
350
84
160
320
79
150
305
72
130
275
64
120
250
59
110
225
55
100
210
BTU’s
Per Hour
x
1,000
WHL-001 REV. 9.3.14
40
It is recommended that a soapy solution be used to detect leaks.
Bubbles will appear on the pipe to indicate a leak is present. The gas
piping must be sized for proper flow and length of pipe to avoid
excessive pressure drop. Both the gas meter and the gas regulator
must be properly sized for the total gas load. If you experience a
pressure drop greater than 1" WC, the meter, regulator or gas line is
undersized or in need of service. You can attach a manometer to the
incoming gas drip leg by removing the cap. The gas pressure must
remain between 3.5" WC and 14" WC during stand-by (static) mode
and while in operating (dynamic) mode at full output.
If an in-line regulator is used, it must be a minimum of 10 feet from
the heater. It is very important that the gas line is properly purged
by the gas supplier or utility. Failure to properly purge the lines or
improper line sizing will result in ignition failure. This problem is
especially noticeable in NEW LP installations and also in empty tank
situations. This can also occur when a utility company shuts off service
to an area to provide maintenance to their lines. The gas valve must
not be replaced with a conventional gas valve under any
circumstances. As an additional safety feature, the gas valve in this
water heater has a flanged connection to the swirl plate and blower.
C. GAS VALVE
Figure 21 – Gas Valve LP-441-S
Strain on the gas valve and fittings may result in vibration, premature component failure and gas leakage, and result in fire, explosion,
property damage, severe personal injury, or death.
Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated combustion analyzer
capable of measuring CO2 and CO. Failure to follow this instruction could result in fire, explosion, property damage, severe personal
injury, or death.
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PART 8 – CONTROLS
A. CONTROL AND DISPLAY OVERVIEW
Detailed Description of Button
Functions
1. Setting Adjust Down
2. Setting Adjust Up
3. Decreases the User Setpoint
4. Increases the User Setpoint
5. ECO Mode
6. RESET
7. OFF / Mode Enable
Figure 22 – Control Detail
Detailed Description of Control Functions
MODES OF OPERATION
MODE
SCREENSHOT
DESCRIPTION
Off Mode
The water heater will ignore heat demands while in Off Mode.
To put the water heater into Off Mode, press
Stand-By
Mode
RANGE (DEFAULT)
Off / On (Off)
.
In Stand-By Mode, the fan is off, the gas valve is closed, and
the water inlet shut-off valve is opened.
On Winter / On
Summer / Off (Off)
The water heater goes into Stand-By Mode when it is powered
but not firing.
User
Setpoint
The User Setpoint is used to set the temperature for the water
heater.
70 – 160 (120)
Press either
or
once to change the User Setpoint.
The normal operation screen will clear and be replaced by a
flashing number. This is the User Setpoint.
Outdoor
Reset Curve
Press
to decrease or
to increase the setpoint in
increments of two degrees. After choosing the setpoint, wait
five seconds. The screen will return to normal operation and
the setpoint will be stored.
Enabling Outdoor Reset Curve allows the user to set
additional parameters to increase water heater efficiency.
0 = Enabled, 1 =
Disabled (0)
An Outdoor Sensor is required to set Outdoor Reset Curve.
See Advanced Control Functions to set the Outdoor Reset
Curve.
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ECO Mode
Putting the water heater into ECO Mode reduces maximum
firing rate to 80% of the rated maximum firing rate. This
increases water heater efficiency in times of low hot water
demand.
Press
to put the water heater into ECO mode. Press
again to return to normal operation.
Test Mode allows the installer to test water heater operation
by running the fan at different speeds.
Test Mode
To enter Test Mode, press
seconds.
and
Push
to decrease or push
50 RPM increments.
Push
Push
Test Mode On / Off
(Off)
together for 5
to increase fan speed by
to operate at maximum fan speed.
to operate at minimum fan speed.
Test Mode will exit automatically after 15 minutes. Press
to leave Test Mode manually.
Lockout codes refer to a temporary condition that must be
cleared to resume operation. If code persists, the heater
should be serviced by a qualified service technician.
Lockout
Fault Codes
ECO On / Off (Off)
Press
to clear
the code. Observe
operation to ensure
code does not
reoccur.
Blocking
Error Codes
Blocking codes temporarily stop water heater operation until
the error condition clears. Once the condition clears, the error
will disappear and the water heater will resume operation. The
error will also be written into the water heater’s history data.
Water heater
operation resumes
when conditions
return to normal.
Installer
Mode
The Installer Mode allows installers to view history hidden
from the user.
Installer Mode On /
Off (Off)
See Advanced Control Functions for information on how to
enter
o
NOTE:
is a high temperature warning, and appears on the display if setpoint or actual water temperature is above 125 F.
o
Water temperature over 125 F can instantly cause severe burns or death from scalds. Children, disabled, and elderly are at
the highest risk of being scalded.
Table 10 – Water Heater Modes of Operation
B. BASIC CONTROL FUNCTIONS
There are a number of parameters accessible from the water heater main screen. These parameters are especially useful for the main
user of the water heater.
NOTE: These parameters ARE NOT ACCESSIBLE when the control is in a blocking or lockout state.
1. TURNING WATER HEATER ON / OFF
Press
to turn the water heater on / off.
2. RESETTING THE WATER HEATER
Press
to clear a fault code lockout and resume water heater operation.
3. PUTTING THE WATER HEATER IN ECO MODE
Press
to put the water heater into ECO Mode. Press
to resume normal operation.
WHL-001 REV. 9.3.14
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4. CHANGING USER SETPOINT
Press either
or
once to change the User Setpoint. The normal operation screen will clear and be replaced by a flashing
number. This is the User Setpoint.
o
o
Press
to decrease or
to increase the setpoint. The default setpoint is 120 F. The setpoint range is 70 – 160 F. After choosing
the setpoint, wait five seconds. The screen will return to normal operation and the setpoint will be stored.
C. ADVANCED CONTROL FUNCTIONS
The water heater control Installer Mode includes numerous parameters for system customization. These parameters should only be
accessed and changed by a qualified service technician.
Installer Mode Parameters should only be accessed and changed by a qualified service technician. Failure to follow this warning could
result in improper water heater operation, premature water heater or component failure, and/or excessively high temperatures that
could result in scalding, property damage, severe personal injury, or death.
NOTE: Water heater failures caused by improper Installer Mode Parameter sets WILL VOID product warranty.
To enter Installer Mode, press and hold
for five seconds. When the following screen appears, Installer Mode is active.
1. UPPER LEVEL INSTALLER MODE MENU NAVIGATION
See Figure 24 for information on how to navigate the Installer Menu Upper Level.
Figure 23 – Upper Level Navigation
2. TECHNICAL SERVICE AND NAVIGATION
The Technical Service Menu (
) is the initial menu to appear when entering Installer Mode. Technical Service Parameters allow the
installer to fully customize water heater settings to the system. The control is ready to access the Technical Service Parameter Menu
when the following screen appears on the display.
WHL-001 REV. 9.3.14
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To enter Installer Mode, press and hold
for five seconds. When the (
) screen appears, Installer Mode is active. Press
this screen to access the Technical Service Parameters codes (P00, P01, etc.).
To change parameter value, press
or
once. The value will appear. Press
to decrease or
Press
at this screen to accept the changed value and return to the Technical Service Parameters.
Press
to advance through the parameters. Press
Press
at any Technical Service Parameter code screens to return to the upper level menu.
at
to increase the value.
to return to the previous parameter.
Table 11 details the Technical Service Parameters in sequential order.
CODE
P00
SHORT DESCRIPTION
o
User Setpoint ( F)
LONG DESCRIPTION
RANGE (DEFAULT)
70 – 160 (120)
Minimum Tank Temperature
Difference Between Actual Tank Temperature and
o
o
4 – 20 (8)
P01
Temperature Differential ( C/ F)
User Setpoint that will Initiate Demand
50 – 100 (80)
P02
Maximum Power Percentage (%)
Maximum Combustion System Power
o
o
0 = C / 1 = F (1)
P03
Temperature Unit Displayed
Fahrenheit or Celsius
0
=
Off
/
1
=
On
(0)
P04
ECO Mode
Economy Mode
Turns on the Outdoor Reset Curve
NOTE: The following parameters are applicable only
0 = Off / 1 = On (0)
P05
Outdoor Reset Curve
if the Outdoor Reset Curve is turned on.
o
o
10 – 70 (10)
P06
Minimum Outdoor Temperature ( C/ F)
Minimum outdoor design conditions for reset curve
o
o
10 – 70 (68)
P07
Maximum Outdoor Temperature ( C/ F)
Maximum outdoor design conditions for reset curve
o
o
70 – 160 (120)
P08
Minimum Storage Temperature ( C/ F)
Minimum tank temperature for reset curve
o
o
70 – 160 (140)
P09
Maximum Storage Temperature ( C/ F)
Maximum tank temperature for reset curve
Warm Weather Shutdown Temperature
Outdoor temperatures greater than this value return
50 – 100 (68)
P10
o
o
( C/ F)
the tank target temperature to the User Setpoint
Table 11 – Technical Service Parameters - NOTE: Temperature Readings Depend on Temperature Unit Selection
Figure 24 – Outdoor Reset Curve
D. OUTDOOR RESET
This unit is supplied with outdoor reset wire connection terminals. When an outdoor sensor is connected, operation of the unit
immediately changes. Refer to the following steps to properly set up the unit with an outdoor sensor.
An ASSE 1017 thermostatic mixing valve MUST be installed when using outdoor reset. Failure to do so could result in substantial
property damage, serious injury, or death.
WHL-001 REV. 9.3.14
45
1.
Connect the outdoor sensor to the terminals marked “outdoor”.
2.
Press
at this screen to access the Technical Service Parameters codes (P00, P01, etc.).
3.
Press
to advance through the parameters. Press
4.
5.
Go to P06
Enter desired MIN Outdoor Temp value
6.
Press
7.
To change parameter value, press
or
value.
Enter desired MAX Outdoor Temp value
8.
to return to the previous parameter.
to advance to the next parameter.
once. The value will appear. Press
to decrease or
to increase the
9. Press
to advance to the next parameter.
10. Enter desired MIN Storage Temp value
11. Press
to advance to the next parameter.
12. Enter desired MAX Storage Temp value
13. Press
at this screen to accept the changed value and return to the Installer Parameters.
14. Press
at any Installer Parameter code screens to return to the upper level menu.
1. INQUIRY MODE AND NAVIGATION
Inquiry Mode (
) allows the installer to access water heater operating specifics, including temperature sensor and flame sensor
readings. These readings aid the installer in troubleshooting the water heater.
To enter Installer Mode, press and hold
for five seconds. When the (
) screen appears, Installer Mode is active. Press
once to find Inquiry Mode. The control is ready to access the Inquiry Mode when the following screen appears on the display.
Press
at this screen to access the Inquiry Mode codes (i00, i01, etc.).
To view code value, press
or
once. The value will appear. Press
Press
to advance through the codes. Press
Press
at any Inquiry Mode code screens to return to the upper level menu.
at this screen to return to the code screen.
to return to the previous code.
Table 12 details the Inquiry Mode codes in sequential order.
CODE
DESCRIPTION
RANGE
o
o
o
i00
UPPER (HL NTC1) SENSOR TEMPERATURE ( C/ F)
Between 32 and 257 F
i01
(--*)
--*
o
o
o
i02
Ventilation Sensor Temperature ( C/ F)
Between 32 and 257 F
o
o
o
i03
Outdoor Sensor Temperature ( C/ F)
Between 32 and 257 F
i04
Actual Flame Current (uA x 10)
Between 00 and 99
i05
Firmware Version
Custom Version C_x.xx
i06
Actual Fan Speed
Table 12 – History Mode Codes – NOTE: Temperature Readings Depend on Temperature Unit Selection – *NOTE: -- Means
option is not available or in use.
2. HISTORY MODE AND NAVIGATION
History Mode (
) aids the installer in troubleshooting by allowing access to the last eight (8) error or fault codes that have occurred.
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To enter Installer Mode, press and hold
for five seconds. When the (
) screen appears, Installer Mode is active. Press
twice to find History Mode. The control is ready to access the History Mode when the following screen appears on the display.
Press
at this screen to access the History Mode codes (H01, H02, etc.).
Press
to advance through the codes. Press
To view code value, press
Press
or
to return to the previous code.
once. The value will appear. Press
at this screen to return to the code screen.
at any History Mode code screens to return to the upper level menu.
Table 13 details the History Mode codes in sequential order.
CODE
DESCRIPTION
H01
Most Recent Error or Fault Code
H02
Second Most Recent Error or Fault Code
H03
Third Most Recent Error or Fault Code
H04
Fourth Most Recent Error or Fault Code
H05
Fifth Most Recent Error or Fault Code
H06
Sixth Most Recent Error or Fault Code
H07
Seventh Most Recent Error or Fault Code
H08
Eighth Most Recent Error or Fault Code
Table 13 – History Mode Codes – NOTE: Temperature Readings Depend on Temperature Unit Selection
3. RESET MODE AND NAVIGATION
Reset Mode (
) allows the installer to reset and clear water heater history. This is especially helpful after troubleshooting or repairs
have concluded.
To enter Installer Mode, press and hold
for five seconds. When the (
) screen appears, Installer Mode is active. Press
three times to find Reset Mode. The control is ready to access Reset Mode when the following screen appears on the display.
Press and hold
at this screen for five seconds to reset the water heater history.
Press
to return to History Mode. View History Mode to ensure history has been cleared.
Press
at any History Mode code screens to return to the upper level menu.
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PART 9 – START-UP PROCEDURE
FOR YOUR OWN SAFETY READ BEFORE OPERATING
1. This water heater does not have pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light
the burner by hand.
2. BEFORE OPERATING: smell all around the water heater area for gas. Be sure to smell next to the floor because some gas is
heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS





Do not try to light any water heater.
Do not touch any electric switch; do not use any phone in your building.
Immediately call your gas supplier from a neighbor's phone. Follow the gas suppliers' instructions.
If you cannot reach your gas supplier, call the fire department.
Turn off gas shutoff valve (located outside of the water heater) so that the handle is crosswise to the gas pipe. If the handle will
not turn by hand, don't try to force or repair it, call a qualified service technician. Force or attempted repair may result in a fire
or explosion.
4. Do not use this water heater if any part has been under water. Immediately call a qualified service technician to inspect the water
heater and to replace any part of the control system and any gas control that has been damaged.
5. The water heater shall be installed so the gas ignition system components are protected from water (dripping, spraying, rain, etc.)
during water heater operation and service (circulator replacement, condensate trap, control replacement, etc.)
Failure to follow these instructions could result in property damage, serious personal injury, or death.
A. OPERATING INSTRUCTIONS
If you smell gas, STOP. Follow listed safety instructions above. If you do not smell gas, follow the next steps.
1. Make sure tank is full with cold water and purge all piping. To assure adequate purging, open all hot water faucets.
Ensure the water heater is full of water before firing the burner. Failure to do so will damage the heater. Such damage IS NOT covered
by warranty, and could result in property damage, serious personal injury, or death.
2. Turn on all electric power to water heater.
3. Remove the Front Panel WARNING label.
4. Adjust the temperature set point of the heater to the desired level. The factory default setting is
120oF. If changes are necessary, follow “Overall Water Heater and Control Operation” in this
section.
5. If the water heater fails to start, refer to the Troubleshooting section in the back of this manual.
B. TEST MODE
Test mode is enabled by pressing
and
together for 5 seconds. In this mode the water
heater operates without modulation, and the combustion system initially runs at the maximum fan
speed. The SERVICE symbol is displayed on the LCD when Test mode is active.
RESISTANCE TABLE FOR
SUPPLY TEMPERATURE SENSOR
HIGH/LOW TEMP.
RESISTANCE
SENSOR TEMP.
(ohms)
(oF)
32
32550
41
25340
50
19870
59
15700
68
12490
77
10000
86
8059
95
6535
104
5330
113
4372
122
3605
131
2989
140
2490
149
2084
158
1753
167
1481
176
1256
185
1070
194
915
202
786
212
667
Table 14
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Test mode can be used to incrementally increase and decrease fan
speed to test the combustion system. See Tables 15 and 16 for
Combustion Settings and Fan Speeds.
1. Use the
and
push buttons to change the fan speed
(steps of 50 rpm) between the range maximum fan speed and
minimum fan speed
2. Use the
to go directly to the maximum fan speed
3. Use the
to go directly to the minimum fan speed
Range between minimum fan speed and maximum fan speed is
taken as absolute power value (0 - 100%).
During Test mode, the LCD flame symbols are enabled as follows:
Flame ON and power < 30% then one third of the flame symbol will
display
Flame ON and power > 30% or < 75% then two thirds of the flame
symbol will display
Flame ON and power > 75% then the full flame symbol will display
Burner ON and OFF conditions are:
Burner ON: UPPER temperature < 185°C
Burner OFF: UPPER temperature ≥ 194°C
The function is enabled for a maximum of 15 minutes.
Test mode can be disabled by pressing
button.
COMBUSTION SETTINGS ON ALL MODELS
Natural Gas
Fan Speed
Low
Ignition
High
Low
Carbon Monoxide PPM
1 – 10
2 - 15
2 – 20
1 – 10
Carbon Dioxide (CO2)
8 - 10%
8 – 10%
8 - 10%
8 ½ - 10 ½%
Table 15 – Combustion Settings on All Models
BTU (FUEL)
76000 (NATURAL)
76000 (LP)
Table 16 – Fan Speeds
IGNITION
5000
3800
FAN SPEEDS
MIN
2150
2100
Propane LP
Ignition
2 - 15
8 ½ - 10 ½%
High
2 – 20
9 - 11%
MAX
6300
6300
C. MAINTENANCE
The control system requires no periodic maintenance under normal conditions. However, in unusually dirty or dusty conditions, periodic
vacuuming of the cover to maintain visibility of the display and indicators is recommended. In dirty environments, such as construction
sites, care must be taken to keep the water heater burner cover in place and drywall or saw dust away from water heater.
In unusually dirty or dusty conditions, care must be taken to keep water heater burner door in place. Failure to do so VOIDS
WARRANTY!
Allowing the 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 heater failure, property damage, personal injury, or death. Such product failures ARE NOT
covered under warranty.
WHL-001 REV. 9.3.14
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PART 10 – SHUTDOWN
A. SHUTDOWN PROCEDURE
o
If the burner is not operating, lower the set point value to 70 F and wait for the burner to shut off. Continue to wait for the combustion
blower to stop, so all latent combustion gases are purged from the system. This should take a maximum of 300 seconds (5 minutes).
B. VACATION PROCEDURE
o
If there is danger of freezing, change the set point to 70 F. DO NOT turn off electrical power. If there is no danger of freezing, follow
“Shutdown Procedure”.
C. FAILURE TO OPERATE
Should the burner fail to light, the control will perform two more ignition trials prior to entering a lockout state. Note that each
subsequent ignition trial will not occur immediately. After a failed ignition trial, the blower must run for approximately 10 seconds to
purge the system. Therefore, a time period of approximately 40 to 90 seconds will expire between each ignition trial.
If the burner lights during any one of these three ignition trails, normal operation will resume. If the burner lights, but goes off in about 4
seconds, check the polarity of the wiring. See electrical connection section.
If the burner does not light after the third ignition trial, the control will enter a lockout state. This lockout state indicates that a problem
exists with the water heater, the controls, or the gas supply. Under such circumstances, a qualified service technician should be
contacted immediately to properly service the water heater and correct the problem. If a technician is not available, pressing the
button will remove the lockout state so additional trials for ignition can be performed.
D. IMPORTANT NOTICE
NOTICE
It is extremely important that whenever work is performed on the plumbing system that either:

The water heater is powered off, or,

The water heater is valved off and isolated from the plumbing system.
Failure to take these measures could result in a dry-firing condition.
The water heater must be full of water and the system fully purged BEFORE powering the water heater. Performing any work in the
plumbing system without either powering off the water heater or isolating the water heater through the use of shut-off valves could
result in a condition referred to as “dry-firing”. Dry-firing the water heater will damage the heat exchanger, and could result in property
damage, serious personal injury, or death. Such damages ARE NOT covered by water heater warranty.
PART 11 – TROUBLESHOOTING
A. ERROR CODE
An error code may occur during installation of the heater. This condition may lead to a lock out condition of the controller, which will
need to be manually reset by pressing the
button.
B. HEATER ERROR
1. When an error condition occurs the controller will display an error code on the display module.
2. These error codes and several suggested corrective actions are included in Table 17.
3. In the case of |E07|, and |E13|, this error, if uncorrected, will go into a fault condition as described in Paragraph C.
C. LOCKOUT
1. When a fault condition occurs the controller display a fault code (Example: |F00|) on the display module.
2. Note the fault code and refer to Table 18 for an explanation of the fault code along with several suggestions for corrective actions.
WHL-001 REV. 9.3.14
50
3. Press the
key to clear the fault and resume operation. Be sure to observe the operation of the unit to prevent a recurrence of
the fault. NOTE: You are allowed up to 5 “resets” to clear a Fault or Error code. After that, the controller will enter an |E13| Lockout
state.
When servicing or replacing any components of this water heater be certain that:

The gas is off.

All electrical power is disconnected.
When servicing or replacing components that are in direct contact with heater water, be certain that:

There is no pressure in the heater. Pull the release on the relief valve to relieve pressure in the heater.

Heater water is not hot.

The electrical power is off.
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualified service technician.
The appliance MUST BE replaced if it has been submerged. Attempting to operate an appliance that has been submerged could create
numerous harmful conditions, such as a potential gas leakage causing a fire and/or explosion, or the release of mold, bacteria, or other
harmful particulates into the air. Operating a previously submerged appliance could result in property damage, severe personal injury,
or death.
NOTE: Appliance damage due to flood or submersion is considered an Act of God, and IS NOT covered under product warranty.
The water heater has wire function labels on all internal wiring. Observe the position of each wire before removing it. Wiring errors may
cause improper and dangerous operation. Verify proper operation after servicing.
CODE
SHORT DESCRIPTION
E07
Flue Temperature Too High
E13
Remote Reset Volatile
Lockout
E34
Low Main Power Supply
E39
Outdoor Temperature Sensor
Error (When Enabled)
E53
Flue Temperature Sensor
Error
E64
Blocked Flue
CONTROL BOARD BLOCKING ERRORS
LONG DESCRIPTION
CORRECTIVE ACTION
1. Is the tank full of water? This error code will appear if the tank is
dry-fired.
2. Measure actual Flue temperature.
The Flue temperature has met /
3. Use an ohmmeter to check resistance on flue temperature sensor.
surpassed the maximum limit.
4. Replace sensor if it does not pass the resistance test.
This is first an E07 blocking error
5. If Flue temperature does not return to normal within 15 minutes,
code.
E07 shall become an F07 fault code.
6. Error will clear automatically if Flue temperature returns to normal
within 15 minutes.
FIVE RESET attempts counter
Service and repair unit per displayed error code. Turn the main
has been exhausted
power supply to the unit off and back on to clear out the error code.
The main power supply is too low
1. When main power is brought back to a normal state (over 75 VAC),
(below 75 VAC) to properly
water heater will resume normal operation.
power the water heater.
2. Measure AC Mains.
1. Check the Outdoor Temperature Sensor. Ensure it is properly
The Outdoor Temperature
wired and connected, and that there are no breaks, cuts, or other
Sensor is out of normal operating
visible issues with the sensor wire.
range, meaning the sensor is
2. Use an ohmmeter to check resistance on the outdoor temperature
either open or shorted.
sensor.
3. Replace Outdoor Temperature Sensor if it fails the resistance test.
1. Check the Flue Temperature Sensor. Ensure it is properly wired to
The Flue Temperature Sensor is
the control, and that there are no breaks, cuts, or other visible issues
out of normal operating range,
with the sensor wire.
meaning the sensor is either
2. Use an ohmmeter to check resistance on flue temperature sensor.
open or shorted.
3. Replace Flue Temperature Sensor if it does not pass the
resistance test.
1. Check the Flue termination. Ensure there are no blockages or
obstructions in the Flue.
The control detects a blocked
2. Check APS switch. Ensure it is properly wired to the control, and
Flue condition.
that there are no breaks, cuts, or other visible issues with the wiring.
3. Replace APS switch.
Table 17 – Blocking Error Codes
WHL-001 REV. 9.3.14
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CODE
SHORT DESCRIPTION
F01
Ignition Lockout Indication
F02
False Flame Indication
F03
High Limit Temperature
Protection
CONTROL BOARD LOCKOUT FAULTS
LONG DESCRIPTION
CORRECTIVE ACTION
The control senses no flame after
1. Is the gas turned on to the water heater?
three ignition attempts.
2. Manually reset the water heater.
3. Observe water heater operation. If fault code occurs
again
4. Check for stable gas pressure.
5. Check Ignitor cable connections.
6. Check Ignitor cable gound.
7. Replace cable.
8. Check spark gap between spark electrode and burner.
9. Replace ignitor.
The control senses a flame signal
1. Visually check for flame through sight glass.
when there is no heat demand.
2. Manually reset the water heater.
3. Observe water heater operation. If fault code occurs
again
4. Check Ignitor cable connections
5. Check Ignitor cable gound
6. Replace cable
7. Replace ignitor
The control shuts down the water
1. Manually reset the water heater.
heater after it has met / surpassed
2. Observe water heater operation. If fault code occurs
the high temperature limit.
again
3. Check the Dual Temperature Sensor. Ensure it is
properly wired to the control, and that there are no
breaks, cuts, or other visible issues with the sensor wire.
4. Use an ohmmeter to check resistance on first Sensor A,
then Sensor B of the Dual Temperature Sensor.
5. Replace Dual Temperature Sensor if either Sensor A or
Sensor B fails the resistance test.
The control detects incorrect fan
speed.
F05
F07
F08
Incorrect Fan Speed
Vent Temperature Too High
The vent temperature has met /
surpassed the maximum limit. This is
first an E07 blocking error code. If
vent temperature has not returned to
normal levels within 15 minutes, this
becomes an F07 lockout fault code.
The control detects an incorrect
flame level.
Flame Circuit Failure
The gas valve does not respond to
controller demands.
1.
2.
3.
4.
5.
1.
2.
3.
4.
1.
2.
3.
4.
5.
6.
7.
1.
2.
3.
F09
Valve Feedback Error
4.
F12
EEPROM Integrity Lockout
The EEPROM check fails. EEPROM
data is corrupted.
1.
2.
3.
Manually reset the water heater.
Observe water heater operation. If fault code occurs
again
Check condition of wiring
Check Fan PWM connections at control board and fan
Replace fan
Manually reset the water heater.
Observe water heater operation. If fault code occurs
again
Replace sensor
Measure actual vent temperature.
Manually reset the water heater.
Observe water heater operation. If fault code occurs
again
Check Ignitor cable connections
Check Ignitor cable gound
Replace cable
Check spark gap between spark electrode and burner.
Replace ignitor
Manually reset the water heater.
Observe water heater operation. If fault code occurs
again, reset the water heater and:
When water heater attempts to fire, check voltage at the
gas valve connector. If there is voltage, but no gas
pressure on the outlet side of the valve, the valve is stuck
closed. Replace the gas valve.
If there is no voltage at the ignition phase, replace the
control board.
Manually reset the water heater.
Observe water heater operation.
If fault code occurs again, replace controller.
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The data received from the tank
sensors exceeds the difference
allowed by the control.
1.
2.
3.
4.
5.
F14
Tank Sensor Data Not Consistent
F21
ADC Failure
The ADC test has detected a major
fault in the electronic components.
Dual Temperature Sensor B is out of
normal operating range, meaning the
sensor is either open or shorted.
1.
2.
3.
1.
2.
3.
4.
5.
F31
Dual Temperature Sensor B Error
Dual Temperature Sensor A is out of
normal operating range, meaning the
sensor is either open or shorted.
1.
2.
3.
4.
5.
F35
Dual Temperature Sensor A Error
Manually reset the water heater.
Observe water heater operation. If fault code occurs
again
Check the Dual Temperature Sensor. Ensure it is
properly wired to the control, and that there are no
breaks, cuts, or other visible issues with the sensor wire.
Use an ohmmeter to check resistance on first Sensor A,
then Sensor B of the Dual Temperature Sensor.
Replace Dual Temperature Sensor if either Sensor A or
Sensor B fails the resistance test
Manually reset the water heater.
Observe water heater operation.
If fault code occurs again, replace the controller.
Manually reset the water heater.
Observe water heater operation.
Check the Dual Temperature Sensor. Ensure it is
properly wired to the control, and that there are no
breaks, cuts, or other visible issues with the sensor wire.
Use an ohmmeter to check resistance on first Sensor B
of the Dual Temperature Sensor. Values should be close
to those given in Table 14
Replace Dual Temperature Sensor if either Sensor B
fails the resistance test.
Manually reset the water heater.
Observe water heater operation.
Check the Dual Temperature Sensor. Ensure it is
properly wired to the control, and that there are no
breaks, cuts, or other visible issues with the sensor wire.
Use an ohmmeter to check resistance on first Sensor A
of the Dual Temperature Sensor. Values should be close
to those given in Table 14
Replace Dual Temperature Sensor if either Sensor A
fails the resistance test.
The control detects an unstable
flame.
1. Manually reset the water heater.
2. Observe water heater operation.
3. If fault code occurs again check for stable gas pressure.
F82
Unstable Flame Lockout
4. check Ignitor cable connections
5. Check Ignitor cable ground
6. Replace cable
7. Replace ignitor
Table 18 – Lockout Fault Codes – NOTE: If you replace a part to remedy a fault, it is recommended that you cycle the unit at least three
or four times to assure the fault has been resolved.
WHL-001 REV. 9.3.14
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Figure 25 – Replacement Parts
WHL-001 REV. 9.3.14
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Figure 26 – Replacement Parts
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PART 12 - MAINTENANCE
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.
Hydrogen gas can build up in a hot water system served by this water heater that has not been used for a long period of time (generally
two weeks or more). When opening a hot water faucet in a system that has been out of use for a time, keep all ignition sources
(electrical appliances, open flame, etc.) away from the faucet. If hydrogen is present, there will be a sound of air escaping as water
begins to flow. Allow the water to run for a few minutes to dissipate built up hydrogen from the system. Failure to follow these
instructions can result in property damage, personal injury, or death.
The water heater requires minimal periodic maintenance under normal conditions. However, in unusually dirty or dusty conditions,
periodic vacuuming of the cover to maintain visibility of the display and indicators is recommended.
Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is operating
safely and efficiently. The owner should make necessary arrangements with a qualified heating contractor for periodic maintenance of
the heater. Installer must also inform the owner that the lack of proper care and maintenance of the heater may result in a hazardous
condition.
NOTICE
It is extremely important that whenever work is performed on the plumbing system that either:

The water heater is powered off, or,

The water heater is valved off and isolated from the plumbing system.
Failure to take these measures could result in a dry-firing condition.
The water heater must be full of water and the system fully purged BEFORE powering the water heater. Performing any work in the
plumbing system without either powering off the water heater or isolating the water heater through the use of shut-off valves could
result in a condition referred to as “dry-firing”. Dry-firing the water heater will damage the heat exchanger, and could result in property
damage, serious personal injury, or death. Such damages ARE NOT covered by water heater warranty.
INSPECTION ACTIVITIES
PIPING
Near heater piping
Vent
Gas
SYSTEM
Visual
Functional
Temperatures
Temperatures
ELECTRICAL
Connections
Smoke and CO
detector
Circuit Breakers
CHAMBER/BURNER
Combustion Chamber
DATE LAST COMPLETED
1st YEAR
2nd YEAR
3rd YEAR
4th YEAR*
Check heater and system piping for any sign of leakage;
make sure they are properly supported.
Check condition of all vent pipes and joints. Ensure the
vent piping terminations are free of obstructions and
blockages.
Check Gas piping, test for leaks and signs of aging. Make
sure all pipes are properly supported.
Do a full visual inspection of all system components.
Test all functions of the system (Heat, Safeties)
Verify safe settings on heater or Anti-Scald Valve
Verify programmed temperature settings
Check wire connections. Make sure they are tight.
Verify devices are installed and working properly. Change
batteries if necessary.
Check to see that the circuit breaker is clearly labeled.
Exercise circuit breaker.
Check burner tube and combustion chamber coils. Clean
according to maintenance section of manual. Vacuum
combustion chamber. Replace any gaskets that show
signs of damage.
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Spark Electrode
Combination Ignitor
and Flame Probe
CONDENSATE
Neutralizer
Condensate hose
GAS
Pressure
Pressure Drop
Check gas pipe for
leaks
COMBUSTION
CO/CO2 Levels
SAFETIES
ECO (Energy Cut
Out)
Sensors
FINAL INSPECTION
Check list
Clean. Set gap at ¼”. Clean probe with plumbers cloth to
remove oxides.
Check ionization in uA (i04 in the Inquiry Mode menu).
Record high fire and low fire. Clean probe with plumbers
cloth to remove oxides.
Check condensate neutralizer. Replace if necessary.
Disconnect condensate hose. Clean out dirt. Fill with
water to level of outlet and re-install. (NOTE: Verify the
flow of condensate, making sure that the hose is properly
connected during final inspection.)
Measure incoming gas pressure (3.5” to 10” W.C. Natural
Gas, 8” to 14” W.C. LP)
Measure drop in pressure on light off (no more than 1”
W.C.)
Check piping for leaks. Verify that all are properly
supported.
Check CO and CO2 levels in Exhaust (See Start-up
Procedures for ranges). Record at high and low fire.
Check continuity on Flue and Water ECO. Replace if
corroded.
Check wiring. Verify through ohms reading per Table 14.
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.
Table 19 - *Continue annual maintenance beyond the 4th year as required.
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MAINTENANCE NOTES
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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.
Customer’s Name:
Installation Address:
Date of Installation:
Installer’s Code/Name:
Product Serial Number(s):
Comments:
Installer’s Phone Number:
Signed by Installer:
Signed by Customer:
IMPORTANT:
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 are unable to make contact, please
contact your Westinghouse Sales Representative.
Distributor/Dealer: Please insert contact details.
WHL-001 REV. 9.3.14