Westinghouse WGR-076 Series Installation, Start-Up, Maintenance, Parts, Warranty
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Westinghouse WGR-076 Series Installation, Start-Up, Maintenance, Parts, Warranty

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Installation
Start-Up
Maintenance
Parts
Warranty
WGR-----076* Models
* "LP" Denotes Propane Gas Operation
"NG" Denotes Natural Gas Operation
This manual must only be used by a qualified installer / service technician. Read all instructions in this manual before
installing. Perform steps in the given order. Failure to do so could 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, severe personal injury, or death.
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 potable (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.
High Efficiency

Water Heaters

WHL-001 Rev. 3.16.15

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Summary of Contents for Westinghouse WGR-076 Series

  • Page 1: Water Heaters

    Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property damage, severe personal injury, or death. Westinghouse reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.
  • Page 2 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 •...
  • Page 3 AHJ. levels or to important product information. NOTE: Westinghouse reserves the right to modify product technical specifications and components without prior notice. DANGER indicates an imminently hazardous situation...

  • Page 4: Table Of Contents

    Table of Contents 1. Inquiry Mode and Navigation 2. History Mode and Navigation Part 1 - General Safety Information 3. Reset Mode and Navigation A. Improper Combustion Part 9 - Start-Up Procedure B. Gas C. When Servicing the Water Heating System A.

  • Page 5: Improper Combustion

    Do not use “homemade cures” or “patent medicines”. Damage rated assembly. to the water heater, substantial property damage, and/or Altering any Westinghouse water heater with parts not serious personal injury may result. manufactured by Westinghouse WILL INSTANTLY VOID the E. Freeze Protection...

  • Page 6: Part 2 - Before You Start

    A. What’s in the Box us a condensate removal pump (Part # 554200, available Components included with the water heater: from Westinghouse). In addition, local authorities may • Intake PVC Tee with Screens require an additional condensate neutralizer to neutralize the •...

  • Page 7: Locating The Water Heater

    The service life of the water heater’s exposed metallic surfaces, Carefully consider installation when determining heater such as the casing, as well as internal surfaces, such as the heat location. Please read the entire manual before attempting exchanger, are directly influenced by proximity to damp and installation.

  • Page 8: Clearances For Service Access

    C. Clearances for Service Access D. Residential Garage Installation Precautions If the heater is located in a residential garage, per ANSI Z223.1: All water heaters eventually leak. It is recommended to install • Install the water heater burner and ignition devices a a catch pan beneath the water heater.

  • Page 9: Indoor Combustion Air In Confined Or Unconfined Space

    2. Indoor Combustion Air in Confined or Unconfined Space Areas Likely Have Products to Avoid This heater requires fresh, uncontaminated air for safe Contaminants operation and must be installed in a mechanical room where Spray cans containing Dry cleaning / laundry areas and there is adequate combustion and ventilating air.

  • Page 10: Water Chemistry Requirements

    Most high equipment. Westinghouse recommends having water quality TDS concentrations precipitate out of the water when heated. professionally analyzed to determine whether it is necessary to This can generate a scale accumulation that will greatly reduce install a water softener.

  • Page 11: Part 4 - Piping

    Figure 3 - Water Heater Dimensions - NOTE: All Dimensions Are Approximate Performance Specifications for High Efficiency Water Heater Models Temperature Rise in Degrees Fahrenheit (F) and Celsius (C) BTU/Hr Efficiency (°F) (°C) 76,000 Table 3 - Recovery on Rating Plate is based at 97% Thermal Efficiency at 70 Fahrenheit rise, as required by ANSI Part 4 - Piping Dielectric unions or galvanized steel fittings must not be used...

  • Page 12: Heater Plumbing

    supply line per local codes. D. Potable Expansion Tank Do not apply heat to the Hot or Cold water heater connections. If A potable hot water expansion tank is required to offset sweat connections are used, sweat tubing to the adapter before heated water expansion.

  • Page 13: Scalding

    time with regard to scald injury and may be used as a guide in correctly, immediately replace with a new properly determining the safest water temperature for your applications. rated relief valve. • Test T&P valve at least once annually to ensure the waterway is clear.

  • Page 14: Applications

    H. Applications Figure 4 - Piping with Recirculation Line and Thermostatic Mixing Valve Piping NOTES: 1. Minimum pipe size should match 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.
  • Page 15 Figure 5 - Piping with Air Handler on Side Figure 6 - Additional View with Air Handler on Side NOTES: 1. Minimum pipe size should match 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.

  • Page 16: Part 5 - Venting And Condensate Removal

    Part 5 - Venting and Condensate Removal The heater must be vented as detailed in this 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 the instructions provided in this manual.

  • Page 17: Approved Materials For Exhaust Vent And Intake Pipe

    B. Approved Materials for Exhaust Vent and Intake Pipe Standards for Installation In: Item Material United States Canada PVC Schedule 40/80 ANSI / ASTM D1785 PVC, CPVC, and PP Venting Must PVC-DWV* ANSI / ASTM D2665 be ULC-S636 Certified. IPEX is Exhaust Vent or Intake an approved manufacturer in CPVC Schedule 40/80...

  • Page 18: Exhaust Vent And Intake Pipe Location

    D. Exhaust Vent and Intake Pipe Location Area Where Terminal Is Not Permitted Exhaust Vent Terminal Intake Pipe Terminal Figure 7 - Exit Terminals for Direct Vent Systems - ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION –...

  • Page 19: Longer Vent Runs

    However, the transitions should begin a minimum of 15 The following table lists optional exhaust/intake terminations equivalent feet from the water heater. available from Westinghouse: a. The maximum total equivalent length for increased diameter vent pipes is 200 feet.

  • Page 20: Applications

    H. Applications SIDEWALL VENTING WITH KIT 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.

  • Page 21: Venting Through An Existing System

    UNBALANCED VENTING WITH TEE (INTAKE) AND COUPLING (EXHAUST) SIDE VIEW FRONT VIEW Figure 11 - Unbalanced Venting - Roof Exhaust and Sidewall Intake NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.

  • Page 22: Indoor Combustion Air In Confined Or Unconfined Space

    NOTE: The following instructions refer only to venting through feet per 1,000 Btu/hour (4.8 cubic meters per kW) of the an existing vent system, and not to venting with Westinghouse’s total input rating of all fuel-burning appliances installed in optional concentric vent kits. Refer to Concentric Vent Kit that space.

  • Page 23: Condensate Removal System

    If the heater condensate outlet is lower than the drain, you must use a condensate removal pump (kit p/n 554200 available from Westinghouse). If required by local authorities, a condensate filter of lime crystals, marble, or phosphate chips will neutralize slightly acidic condensate.
  • Page 24 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”...

  • Page 25: Part 6 - Wiring

    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, p/n 7250P- 319. 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.

  • Page 26: Internal Wiring Diagram

    INTERNAL CONNECTION DIAGRAM D. Internal Wiring Diagram X4-1 GROUND WHITE X4-2 BLOWER TACH PINK X4-3 BLOWER 24VDC ORANGE BLOWER PWM X4-4 GAS VALVE X4-5 X4-6 PINK BLACK WHITE X4-7 BLACK GREEN COMBUSTION BLOWER UPPER TEMP SENSOR 1 X5-1 GREY X5-2 GREY/WHITE UPPER TEMP SENSOR 2 X5-3...

  • Page 27: Gas Piping

    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 UL recognized fuel gas detectors are recommended in column. all enclosed propane and natural gas applications where It is recommended that a soapy solution be used to detect leaks.

  • Page 28: Gas Valve

    C. Gas Valve 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.

  • Page 29: Basic Control Functions

    The User Setpoint is used to set the temperature for the water heater. Press either once to change the User Setpoint. The normal operation screen will clear and be replaced by a flashing User Setpoint number. This is the User Setpoint. 70 - 160 (120) Press to decrease or...

  • Page 30: Advanced Control Functions

    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.

  • Page 31: Outdoor Reset

    D. Outdoor Reset This unit is supplied with outdoor reset wire connection terminals. When an outdoor sensor (p/n 7250P-319) is connected, operation of the unit immediately changes. Refer to the following steps to properly set up the unit with an outdoor sensor.

  • Page 32: Reset Mode And Navigation

    replacement, condensate trap, control replacement, etc.) Code Description Failure to follow these instructions could result in property Most Recent Error or Fault Code damage, serious personal injury, or death. Second Most Recent Error or Fault Code A. Operating Instructions Third Most Recent Error or Fault Code If you smell gas, STOP.

  • Page 33: Maintenance

    Test Mode can be used to incrementally increase and decrease fan speed to test the combustion system. See the tables below for Combustion Settings and Fan Speeds. 1. Use the buttons to decrease or increase the fan speed in increments of 50 rpm. 2.

  • Page 34: Important Notice

    If a technician is not available, pressing the button will remove the lockout state so additional trials for ignition can be When servicing or replacing any components of this water performed. heater be certain that: D. Important Notice • The gas is off. •...
  • Page 35 Control Board Blocking Errors Code Short Description 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. 3. Use an ohmmeter to check resistance on flue temperature The flue temperature has met / sensor.
  • Page 36 Code Short Description Long Description Corrective Action 1. Manually reset the water heater. 2. Observe water heater operation. If fault code occurs 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.
  • Page 37 Code Short Description Long Description Corrective Action 1. Manually reset the water heater. 2. Observe water heater operation. If fault code occurs again: 3. Check the Dual Temperature Sensor. Ensure it is properly Dual Temperature Sensor B is wired to the control, and that there are no breaks, cuts, or other Dual Temperature Sensor B out of normal operating range, visible issues with the sensor wire.

  • Page 38: Part 12 - Installation Checklist

    Figure 27 - Replacement Parts Part 12 - Installation Checklist Before Installing Is there enough space to ensure proper installation? Does installation location allow for proper service clearances? Are water and gas lines properly sized and set at proper pressures for the installation? Is water heater location as near the exhaust vent / intake pipe terminations as possible? Have combustible materials been cleared from the installation location? Is there a drain close to the water heater?

  • Page 39: Part 13 - Maintenance

    Are terminations properly spaced from windows, doors, and other intake vents? Have all vent terminations been installed at least one foot above exterior grade and one foot above normal snow accumulation level? Is vent piping properly supported? Has vent piping been checked for leaks? Has the exhaust vent line been pitched back to the water heater at a rate of 1/4”...
  • Page 40 of the display and indicators is recommended. Periodic maintenance should be performed once a year by a The water heater must be full of water and the system fully qualified service technician to assure that all the equipment purged BEFORE powering the water heater. Performing any is operating safely and efficiently.
  • Page 41 Combustion 1st Year 2nd Year 3rd Year 4th Year* CO / CO2 Levels Check CO and CO2 levels in exhaust. See Start-Up Procedures for ranges. Record at high and low fire. Safeties 1st Year 2nd Year 3rd Year 4th Year* ECO (Energy Cut Check continuity on flue and water ECO.
  • Page 42 ADDITIONAL INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS In the Commonwealth of Massachusetts, the installer or service agent shall be a plumber or gas fitter licensed by the Commonwealth. When installed in the Commonwealth of Massachusetts or where applicable state codes may apply;...
  • Page 43 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.

  • Page 44: Limited Warranty

    9. Failure to operate the water heater in an open system, or in a B. If Westinghouse is unable to repair or replace the water heater closed system with a properly sized and installed thermal expansion so as to conform to this warranty after a reasonable number tank.
  • Page 45 To be valid, proof of purchase must also BENEFIT OF THE ORIGINAL PURCHASER ONLY. include the unit serial number. Proof of purchase may be typed or hand written. Submit the proof of purchase to Westinghouse via the NO OTHER WARRANTIES directions provided on the website.

  • Page 46: Maintenance Notes

    Maintenance Notes WHL-001 Rev. 3.16.15...

  • Page 47: Customer Installation Record Form

    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 Date of Installation Installation Address...

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