HTP Premium WGRTC 199 Series Instructions Manual
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HTP Premium WGRTC 199 Series Instructions Manual

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Installation
Start-Up
Maintenance
Parts
Warranty
WGRTC**199 Models
** "NG" Denotes Natural Gas; "LP" Denotes Propane Gas
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.
California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth
defects, or other reproductive harm.
The manufacturer 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.
www.westinghousewaterheating.com
High Temperature
Tankless Water Heaters
whl-042 Rev. 000 Rel. 020 Date 2.25.21

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  • Page 1 High Temperature Tankless Water Heaters Installation Start-Up Maintenance Parts Warranty WGRTC**199 Models ** “NG” Denotes Natural Gas; “LP” Denotes Propane Gas 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.
  • Page 2 WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. • Do not store or use 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 Foreword For the Installer This manual is intended to be used in conjunction with other This water heater must be installed by qualified and licensed personnel. literature provided with the water heater. This includes all related The installer should be guided by the instructions furnished with the control information.

  • Page 4: Table Of Contents

    E. Applications F. Circulator Sizing G. Pressure Relief Valve From the Uniform Plumbing Code 2000 - Section 510 - H. Filling the Heater Protection From Damage Part 5 - Venting 1. Water heaters generating a glow, spark or flame capable of igniting A.

  • Page 5: Part 1 - General Safety Information

    Part 1 - General Safety Information This water heater must be installed by a licensed plumber, licensed This water heater is approved for indoor installations only and is not gas fitter, and/or qualified installer / service technician. Improper intended for use as a pool heater. Clearance to combustible materials: installation and/or operation can cause a potentially hazardous 0”...

  • Page 6: Improper Combustion

    D. When Servicing the Water Heating System This water heater is equipped with a three prong plug. It should only be plugged directly into a properly grounded three prong Be sure to disconnect electrical power before opening water receptacle. DO NOT remove the ground plug from the plug. heater cabinet or performing service.

  • Page 7: Freeze Protection

    Contaminant Maximum Allowable Level Approximate Time / Temperature Relationships in Scalds Total Hardness More than 5 minutes 200 mg/l (Commercial Use - Below 140 F water (12 grains/gallon) 1 1/2 to 2 minutes temperature) About 30 seconds Total Hardness 120 mg/l (Commercial Use - Above 140 About 10 seconds (7 grains/gallon)

  • Page 8: Part 2 - Before You Start

    Part 2 - Before You Start Open the shipping crate of the water heater. UNCRATING THE WATER HEATER - Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. A. What’s in the Box Components included with the water heater: Item Description...

  • Page 9: Part 3 - Prepare The Water Heater Installation

    Part 3 - Prepare the Water Heater Installation The service life of the water heater’s exposed metallic surfaces, Remove all sides of the shipping crate to allow the heater to be such as the casing, as well as internal surfaces, such as the heat moved into its installation location.

  • Page 10: Clearances For Service Access

    C. Clearances for Service Access See Table 6 for recommended service clearances. If these minimum Always take future maintenance into consideration when locating clearances are not provided, it may not be possible to service the water the water heater. If the water heater is located in an installation heater without removing it from the space.

  • Page 11: Direct Vent Of Exhaust And Intake

    1. Direct Vent of Exhaust and Intake F. Carbon Monoxide Detectors If installing a direct vent option, combustion air must be drawn In the Commonwealth of Massachusetts and As Required by State from the outdoors directly into the water heater intake and exhaust and Local Codes: must terminate outdoors.

  • Page 12: Removing A Heater From A Common Vent System

    Products to Avoid Areas Likely to Have Contaminants Spray cans containing fluorocarbons Dry cleaning / laundry areas and establishments Permanent wave solutions Swimming pools Chlorinated waxes / cleaners Metal fabrication plants Chlorine-based swimming pool chemicals Beauty shops Calcium chloride used for thawing Refrigeration repair shops Sodium chloride used for water softening Photo processing plants...

  • Page 13: Technical Specifications

    I. Technical Specifications Model Installation Indoor, Wall Hung, Fully Condensing Minimum / Maximum Input (Btu/Hr) 19,900 / 199,000 F Rise 11 GPM Hot Water Capacity F Rise 8.5 GPM F Rise 5 GPM Flue System Sealed Combustion Direct Vent, Power Vent Vent Run 2”...
  • Page 14 Figure 2 - Dimensions Description Diameter Exhaust Outlet Adapter 3” Air Intake Adapter 3” Gas Inlet Adapter 3/4” NPT DHW Outlet Adapter 3/4” NPT DHW Inlet Adapter 3/4” NPT Condensate Adapter 1/2” NPT DHW Inlet Filter Table 9 - Adapter Specifications How the Water Heater Operates as the master and the other connected water heaters as followers.
  • Page 15 Figure 3 - Components Number Component Description Number Component Description Number Component Description Exhaust Vent Adapter Water Adjustment Valve Freeze Protector Air Inlet Pipe Main Controller DHW Outlet Adapter Secondary Heat Exchanger AGM (Air Gas Mixer) Condensate Trap Assembly Ignition Transformer Gas Inlet Pipe 1 Cold Water Inlet Adapter Igniter...

  • Page 16: Wall-Mounting

    connection to connect the incoming gas supply. Field Wiring and Power Switch – Each water heater is supplied with a power switch to cut off power. The water heater is also equipped with two front mounted terminal strips. These terminal strips are separated into low and line voltage to ease system wiring. Condensate Trap and Hose Assembly –...

  • Page 17: Part 4 - Water Piping

    Part 4 - Water Piping 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. Failure to follow the instructions in this section WILL VOID the Expansion Tank warranty and may result in property damage, severe personal 1.

  • Page 18: Applications

    E. Applications Figure 5 - Piping Symbol Legend DO NOT use this water heater for high temperature (over 140 F) central heating applications. Failure to comply will result in substantial overworking of the appliance and possibly lead to early appliance failure and property damage. Use of the water heater for high temperature central heating applications WILL VOID the warranty.
  • Page 19 Figure 6 - DHW Piping, Single Water Heater Figure 7 - DHW Piping, Single Water Heater with Recirculation Figure 8 - DHW Piping with Storage Tank Figure 9 - DHW Piping with Storage Tank and Recirculation NOTES: 1. Minimum pipe size should match connection size. Upsize pipe accordingly if greater flow is required. 2.
  • Page 20 Figure 10 - Cascaded Water Heaters Figure 11 - Cascade Water Heaters with Recirculation 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 21 Figure 12 - Cascaded Water Heaters with Storage Tank Figure 13 - Cascaded Water Heaters with Storage Tank and Recirculation 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 22: Circulator Sizing

    F. Circulator Sizing Figure 14 - Pressure Drop through the Heat Exchanger ∆T = 77 ∆T = 45 ∆T = 35 Number of Water Water Water Flow Rate Pipe Dia. Flow Rate Pipe Dia. Flow Rate Pipe Dia. Units Velocity Velocity Velocity (GPM)

  • Page 23: Filling The Heater

    DO NOT operate this water heater before the supplied pressure relief valve is installed with sufficient relieving capacity in accordance with the rating plate on the water heater. RE-INSPECTION OF RELIEF VALVES: Valves should be Pressure relief valves must be installed as close to the water heater as inspected AT LEAST ONCE EVERY THREE YEARS, and replaced possible.

  • Page 24: Approved Materials For Exhaust Vent And Intake Pipe

    NOTE: Care must be taken to prevent condensate freezing in the exhaust vent pipe system. See local, state, provincial, and national Exhaust and intake are to be piped separately. This heater cannot codes for best practices to prevent condensate freezing in the exhaust share a common exhaust or intake with multiple appliances.

  • Page 25: Additional Requirements For Installation In Canada

    C. Additional Requirements for Installation in Canada 1. Installations must be made with a vent pipe system certified Exhaust vent adaptors are not designed as load-bearing devices, to ULC-S636. IPEX is an approved vent manufacturer in Canada and must not be used to support exhaust vent piping. All vent pipes supplying vent material listed to ULC-S636.

  • Page 26: Exhaust Vent And Intake Pipe Location

    D. Exhaust Vent and Intake Pipe Location INSIDE CORNER DETAIL FIXED OPERABLE CLOSED FIXED CLOSED OPERABLE LP-179-CC 03/28/17 Exhaust Vent Terminal Intake Pipe Terminal Area Where Intake Terminal Is Not Permitted Figure 16 - Exit Terminals for Direct Vent Systems - ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada DESCRIPTION CANADA Clearance above grade, veranda, porch, deck, or balcony...

  • Page 27: Exhaust Vent And Intake Pipe Sizing

    NOTE: Clean and dry the appliance connection. DO NOT use primer E. Exhaust Vent and Intake Pipe Sizing or cement on the appliance connection. 1. The exhaust vent and intake pipe size is 3” for these models. Push the length of pipe into the connection until it touches 2.

  • Page 28: Applications

    existing chimney openings. Westinghouse: 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. Description Stock Code 13. Do not use the heater to support any piping. 2”...
  • Page 29 Two Pipe Sidewall Venting Two Pipe Roof Venting EXTERIOR WALL with Elbow (Intake) with Elbow (Intake) and Coupling (Exhaust) and Coupling (Exhaust) 1" MIN. 12" MIN. EXHAUST INSERT EXHAUST SCREEN MAINTAIN 12" MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER (TYP) LP-505-A 06/23/15...
  • Page 30 EXHAUST AIR INTAKE FRONT VIEW EXHAUST AIR INTAKE LP-325-PP 03/31/11 SIDE VIEW Figure 21 - Horizontal (Snorkel) Venting 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]).

  • Page 31: Venting Through An Existing System

    2. Venting Through an Existing System This heater may be vented through an existing unused vent system. concentric vent kits. The inner diameter of the existing vent system is utilized for the Concentric venting through an existing system must run vertically combustion air source.

  • Page 32: Power Venting, Indoor Combustion Air In Confined Or Unconfined Space

    3. Power Venting, Indoor Combustion Air in Confined or Unconfined Space This heater requires fresh, uncontaminated air for safe operation considered part of the space. Confined space is space with volume less than 50 cubic feet per and must be installed in a mechanical room where there is adequate combustion and ventilating air.

  • Page 33: Part 6 - Installing The Condensate Drain

    Part 6 - Installing the Condensate 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.

  • Page 34: Part 7 - Connecting Electrical Service

    Part 7 - Connecting Electrical Service 3. The wiring diagrams in this manual are to be used for reference purposes only. 4. Refer to these diagrams and the wiring diagrams of any external Install wiring and electrically ground water heater in accordance controls used with the installation when wiring the water heater.
  • Page 35 C. Wiring a Cascaded System When wiring the water heater for Cascade operation, select one as the Master water heater. The remaining water heaters will be designated Followers. See “Setting Up a Cascade System” for more When installing a cascaded system, it is important that the water details.
  • Page 36 Figure 33 - Electrical Wiring Diagram whl-042 Rev. 000 Rel. 020 Date 2.25.21...
  • Page 37 Figure 34 - Ladder Diagram whl-042 Rev. 000 Rel. 020 Date 2.25.21...
  • Page 38 Connector Description HT Selv No. of Location Board Silk UNUSED Power Supply Line UNUSED Ignitor Power Supply L/HT Ceramic Heater (Freeze Protection) 65001WS-12 HT (120V~) Gas Valve Power Supply GROUND Power Supply (Neutral) 9-12 AC Power COM Line RS-485 + RS-485 SELV (5V) SMW250-03...
  • Page 39 Connector Description HT SELV No. of Location Board Silk Flame Sensor OP.S Outlet Operating Water Temperature Sensor DH.S DHW Temperature Sensor Inlet Water Temperature Sensor SELV (5V) LWD1140-14 BG.S Exhaust Temperature Sensor ST.S UNUSED SP.S UNUSED AGM Stepper Motor Coil / Y Phase SELV (24V) AGM Stepper Motor Coil / X Phase CN12...

  • Page 40: Part 8 - Gas Connections

    Part 8 - Gas Connections FIRE AND/OR EXPLOSION HAZARD To avoid serious injury or death, the gas line installation and the gas line inlet pressure test must be done by a licensed professional. Ensure the gas on which the water heater will operate is the same type specified on the rating plate (natural gas or LP gas). This water heater must be converted into propane operation unless specifically manufactured for use with propane.

  • Page 41: Additional Precaution For Excess Flow Valve (Efv)

    calibrated combustion analyzer agree with those stated in Table 24. C. Additional Precaution for Excess Flow Valve (EFV) If an excess flow valve (EFV) is in the gas line, check the manufacturer’s minimum and maximum flow capacity ratings. An improperly sized EFV will not allow for a full flow of gas to the water heater and will It is required to use a calibrated combustion analyzer to verify final cause the water heater to malfunction.

  • Page 42: Part 9 - Controls

    Part 9 - Controls A. Control and Display Overviews Figure 38 - Control Panel Detail Figure 39 - LCD Display After start-up, the display appears as follows. LCD also features a backlit lamp that will illuminate: • When a user action is detected (a button is pressed) •...

  • Page 43: Changing The Dhw Set-Point

    C. Changing the DHW Set-Point D. Changing the Temperature Indicator NOTE: The setpoint cannot be changed if water is flowing through the To change the temperature indicator from Fahrenheit to Celsius, unit. Ensure there is no demand on the water heater when changing press and hold the button for more than five (5) seconds when the setpoint.

  • Page 44: Status Display

    E. Status Display Status Display will activate when button is pressed and held for five seconds at Standby Mode. Figure 42 - Status Display Screens Display Display Detail Description (Main Menu) (Sub Menu) A:GA or A:LI Flow Unit Current Flow Unit (LI: Liters/min, GA: Gallons/min) b:Fr Fan Speed (RPM) Current Fan Speed (RPM)

  • Page 45: Installer Mode

    F. Installer Mode Installer Mode will activate when button is pressed and held for five seconds while the water heater display is powered Off. Figure 43 - Installer Mode Screens Display Default Detail Description 1:EH E0.00 Error history up to 10 Check ten most recent Error Codes (H0 - H9) 2:cE Clear Error History...
  • Page 46 Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 G. Setting Up a Cascaded System Sequence Before CA 01 CA 02 CA 03 CA 04 CA 05 CA 06 Rotation A maximum of eighteen (18) units may be installed in a cascaded Sequence After system.

  • Page 47: Part 10 - Troubleshooting

    Part 10 - Troubleshooting A. Error Code When the water heater encounters an error, the display will flash “Er” followed by a numerical code. The water heater shall enter a soft lockout condition if the error is such that it can return to normal operation once the condition relieves itself (overheat conditions, NTC open or shorts, etc.).
  • Page 48 Error Code Error Code Description Possible Remedies This Error Code will go away when outlet water temperature decreases. If Error happens again: Water Outlet Sensor Open or Er:32 1. Check DHW outlet temperature sensor. Ensure connections are secure. Short 2. Check sensor resistance. If resistance is zero, replace the sensor. 3.
  • Page 49 Error Code Error Code Description Possible Remedies Press the Power button to clear the Error Code. If Error happens again: 1. Turn power OFF and ON at the main power switch internal to the water heater. 2. Ensure fan inlet hole is completely open after turning the power OFF and ON. Er:67 AGM Error 3.

  • Page 50: Error Tree Analysis

    B. Error Tree Analysis 1. Flame Detection Figure 45 - Flame Detection Error Analysis Tree 2. Air Pressure Switch Detection Figure 46 - Air Pressure Switch Analysis Tree whl-042 Rev. 000 Rel. 020 Date 2.25.21...

  • Page 51: Inlet / Dhw / Operating Temperature / Exhaust Sensors

    3. Inlet / DHW / Operating Temperature / Exhaust Sensors Figure 47 - Inlet / DHW / Operating Temperature Sensors Error Analysis Tree C. Suggested Corrective Actions Problem Possible Causes Possible Remedies 1. Is the plug on the power supply cord unplugged 1.
  • Page 52 DIAGNOSTICS AND SUGGESTED CORRECTIVE ACTIONS The water heater control is able to record information about the water heater’s condition at the time of the ten previous faults or errors. This information is available to view in the Installer Mode under the History screen. The following screens may be displayed when reviewing the water heater history.

  • Page 53: Part 11 - Installation Checklist

    DHW Inlet Temperature Sensor DHW Outlet Temperature Sensor (7850P-015) (7850P-019) Exhaust Temperature Sensor HX (OP) Temperature Sensor (7850P-070) (7850P-081) Temperature ( Resistance (Ω) Temperature ( Resistance (Ω) 62162 28409 48440 22152 38045 17408 30107 13782 23998 10990 19261 8824 15562 7131 12655 5800...
  • Page 54 Install Exhaust Vent and Intake Piping Is air supply sufficient for proper water heater operation? Is total vent piping length within the maximum vent length restriction listed in this manual? Have venting lengths been minimized? 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?

  • Page 55: Part 12 - Maintenance

    Part 12 - Maintenance The water heater must be inspected and serviced annually, Failure to inspect the venting system and have it repaired by a preferably at the start of the heating season, by a qualified installer qualified installer / service technician can result in vent system / service technician.
  • Page 56 7. Dry the filter completely. Then reinsert the filter into the plastic assembly. 8. Replace the front cover of the water heater cabinet. Reconnect power supply to the water heater. 9. Press the Power button on the control panel to turn on the water heater.
  • Page 57 Maintenance Report 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.
  • Page 58 INSPECTION ACTIVITIES DATE LAST COMPLETED 1 st YEAR 2 nd YEAR 4 th YEAR* 3 rd YEAR PIPING Near water heater Check water heater and system piping for any sign of leakage. piping Leaking pipes could cause property damage. Make sure all piping is properly supported.

  • Page 59: Part 13 - Replacement Parts

    Part 13 - Replacement Parts 17-2 17-1 17-3 17-4 Figure 52 - Cabinet Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER Exhaust Assembly 7850P-021 Display Bracket 7850P-065 Case 7850P-044 Display 7850P-057 Door Assembly PCB (Control Board) 7850P-104 7850P-256 Front Cover Control Board Bracket 7850P-066...
  • Page 60 Figure 53 - Heat Exchanger Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER Heat Exchanger Assembly 7850P-032 Mixing Valve 7850P-054 31-1 Exhaust Pipe Assembly (Upper) 7850P-033 HX Temperature Sensor 7850P-081 31-2 Exhaust Temperature Sensor 7850P-070 HX Overheat Switch 7850P-051 31-3 Exhaust Gasket 1...

  • Page 61: Limited Warranty For Tankless Water Heaters

    Limited Warranty for Tankless Water Heaters OWNER RESPONSIBILITIES The Owner or Qualified Installer / Service Technician must: 1. Have a relief valve bearing the listing marks of the American Society of Westinghouse warrants this instantaneous water heater and its Mechanical Engineers (ASME) installed with the water heater assembly in components to be free from defects in material and workmanship accordance with federal, state, and local codes.
  • Page 62 17. Damages, malfunctions, or failures caused by abuse, accident, fire, If the water heater is “in-warranty”, contact the retailer from whom the flood, freeze, lightning, electrochemical reaction, acts of God and the like. water heater was purchased (or the installer) for assistance. Be prepared 18.

  • Page 63: Notes

    Notes whl-042 Rev. 000 Rel. 020 Date 2.25.21...

  • Page 64: 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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