andrews Fastflo WHC56 Manual

CONDENSING GAS WATER HEATER
WHC56, LWHC56 (Internal)
INSTALLATION AND SERVICE MANUAL
Andrews. Built to perform.
Please read and understand these instructions before commencing installation and leave this manual with the customer for future reference.
Part number E890
SBA8198-3

Potential dangers from accidents during installation and use are divided into the following three
categories. Closely observe these warnings, they are critical to your safety.
Prohibited Disconnect
Power Earth Be sure to do
•Failures and damage caused by erroneous work or work not as instructed in this manual are not
covered by the warranty.
•Check that the installation was done properly in accordance with this Installation Manual upon
completion.
•After completion of installation, be sure to hand the Operation Manual to the customer upon filling
in all of the required items.
Requests to Installers
•In order to use the water heater safely, read this installation manual carefully,
and follow the installation instructions.
Caution
WARNING: If the information in this manual is not followed exactly, a fire or explosion may result
causing property damage, personal injury or death.
Warning
Caution
Danger Danger of serious injury or even death as well as danger of fire when the
product is misused by ignoring this symbol.
Possibility of serious injury or even death as well as possibility of fire when
the product is misused by ignoring this symbol.
Possibility of bodily injury or damage to property when the product is
misused by ignoring this symbol.
•The appliance must be installed in accordance with the Gas Safety (Installation and Use) Regulations
and the rules in force in the country of installation.
•The manufacturer's instructions supplied.
•The Gas Safety (Installation and Use) Regulations.
•The appropriate Buildings Regulations either The Building Regulations, The Building Regulations
(Scotland), The Building Regulations (Northern lreland).
•In IE, the installation must be carried out by a competent person and installed in accordance with the
current edition of I.S.813 "Domestic Gas Installations", the current Building Regulations and reference
should be made to the current ETCI rules for Electrical Installation.
SBA8198-3
Installation Manual
CONDENSING GAS WATER HEATER
5, Minamifutami, Futami-cho,
Akashi, Hyogo, Japan
NORITZ CORPORATION
PRODUCT :
AGENT :
ANDREWS WATER HEATERS
WHC56, LWHC56 (Internal)
Innovation House, 3, Oaklands
Business Centre, Oaklands Park,
Wokingham, Berkshire, RG41 2FD

2
2. Optional Accessories
The accessories listed below are not
included with the units, but may be necessary
for installation.
Q’tyShapePartPart Shape Q’ty
Quick Connect
Cord 1
1. Included Accessories
The following accessories are included with the unit.
Check for any missing items before starting installation.
Q’tyShapePart
Tapping Screw
1
Part Shape Q’ty
5
Installation Manual
(this document)
1
Owner's Guide
System Controller 1
Remote Controller 1
Horizontal
Flue Terminal (*1)
(Short)
Horizontal
Flue Terminal (*1)
(Long)
1
Vertical
Flue Terminal (*1) 1
1
Special Adapter
(For intake pipe) 1
(*1) Attach the seal ring included with the Flue Terminal (optional accessories) to the groove of exhaust
side of equipment securely following precautions.
Otherwise, a leakage of exhaust air is generated and it will cause CO poisoning.

3
WHC56
140W
G20 20mbar
55.8kW
(CONDENSING)
(CONDENSING)
Freeze Preventive Heater
55.8kW
2.98kW 2.98kW
54.0kW 54.0kW
3.20kW 3.20kW
GB&IEGB&IE
G31 30/37mbar
140W
170W 170W
LWHC56
3P
10.0mbar
2.7mbar 12.9mbar 3.0mbar

4
3.
Quick Connect Multi System Installation
• The Quick Connect Multi System allows the installation of two units together utilizing only the Quick
Connect Cord.
Typical Plumbing
The Quick Connect Cord is 2m. long. Install the two units 470mm-950mm apart at the center to
ensure the cord will be able to reach between the units. (See Typical Plumbing diagram).
(If the distance between the two units is too great, not only will the cord not be able to reach,
but the water temperature may also become unstable because of the difference in pipe length
between the two units.)
* When connecting 2 devices, use only a
single remote controller.
Note: Connect the remote
controller to only one
of the devices.
System Diagram
• Insulate the hot water piping to prevent heat loss. Insulate and apply heating materials to the cold
water supply piping to prevent heat loss and freezing of pipes when exposed to excessively cold
temperatures.
G
Quick Connect
Cord
Remote Controller Cord Gas Supply Piping
Cold Water Supply
Hot Water
Remote Controller
Terminal Block
Cord
Connector Cord Connector
Leave enough clearance around the plumbing
to apply insulation. It will be necessary to add
bends to the piping to ensure that this
clearance is available.
Size the piping to allow for the maximum
flow rates of the units.
Union
Distance at center: 470 - 950mm.
Quick Connect
Cord
Union
Shutoff
Valve Shutoff Valve Hot Water
Shutoff
Valve
Cold Water
Distance on sides
5 - 480mm.
Make this distance as short as possible.
* The hot water temperature will
become unstable as the pipe
length increases.
Union
Gas Valve

5
Check the Gas
•Check that the rating plate indicates the correct type of gas.
If the equipment is used with a gas other than displayed one, it will cause an explosion or a fire.
Check that the gas supply line is sized for 54.0 kW for this unit.
Check the Power
•The power supply required is 230V AC, at 50Hz. Using the incorrect voltage may result in fire or
electric shock.
Do Not Use Equipment for Purposes Other Than Those Specified
•Do not use for purposes other than increasing the temperature of the water supply,
it will cause an unexpected accident or a failure of equipment.
Check Water Supply Quality
•If the water supply is hard, acidic or otherwise impure, treat the water with approved methods in
order to ensure full warranty coverage.
Do not use hot spring water, well water or under ground water.
• The foreign material is attached to the piping in the equipment or the piping become eroded and
causes water leakage depending on the quality of water. In this case, the repair will be imple-
mented with charge even within the guarantee period.
Use Extreme Caution if Using With A Solar Pre-Heater
• Using this unit with a solar pre-heater can lead to unpredictable output temperatures and
possibly scalding. If absolutely necessary, use mixing valves to ensure output temperatures do
not get to scalding levels. Do not use a solar pre-heater with the quick-connect multi-system.
Checkup
• Check the fixing brackets and the flue pipe yearly for damage or wear. Replace if necessary.
4. Before Installation
Caution
Precautions on replacement of equipment
•Replace the intake and exhaust pipe, the flue terminal and the fixing bracket with new one as a
general rule. However, the material of intake and exhaust pipe, flue terminal or fixing bracket is
equivalent to SUS304 or more, these parts can be reused.
*Check there is no hole, crack, block on the intake and exhaust pipe and misalignment of connection
part and there is no problem before using these parts.
*Replace the flue terminal with the product specified by our company.
Confirmation of top of adapted flue terminal
•Use the flue terminal specified by our company, which is described in this construction manual.
If it is mismatching, it will cause a fire or other accident.
Precautions on accumulation of snow or fallen snow
•If an accumulation of snow is forecasted, undertake the construction of flue terminal so that it is not
blocked by surrounding accumulation of snow or fallen snow.
Warning

6
5.
Choosing Installation Site
* Locate the appliance in an area where leakage from the unit or connections will not result in damage
to the area adjacent to the appliance or to the lower floors of the structure. When such locations
cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed
under the appliance. The pan must not restrict combustion air flow.
The appliance must be installed in a
suitably ventilated room, in accordance
with the regulatins in force.
•Do not install the fence or the obstacle around the flue terminal.
It will cause carbon monoxide poisoning.
Danger
•The water heater is designed for internal installation only.
Never install it outdoors or in a bathroom, it may be dam-
aged or a fire may be caused.
Warning
Caution
•Consult with the customer concerning the location of installation.
• Avoid places where fires are common, such as those where petrol,
benzene and adhesives are handled, or places in which corrosive
gases (ammonia, chlorine, sulfur, ethylene compounds, acids) are
present.
This may cause incomplete combustion or failures.
• Locate the flue terminal so that there are no obstacles around the
termination and so that exhaust can't accumulate. Do not enclose the
termination with corrugated metal or other materials.
• Install the water heater in an area that allows for the proper clear-
ances to combustible and noncombustible construction.
• Do not install the water heater in a place where it may be threatened
by falling objects, such as under shelves.
•The water heater must be installed in a place where supply and
exhaust pipes can be installed as directed.

7
•Do not install the water heater where the exhaust will blow on outer
walls or material not resistant to heat. Also consider the surro-
unding trees and animals.
The heat and moisture from the water heater may cause discolo-
ration of walls and resinous materials, or corrosion of aluminum
materials.
As the heatproof temperature of wired sheet glass is approximately
half of that of general glass and it is breakable, the glass may break
because of exhaust gas if there is wired sheet glass in the exhaust
direction of equipment (approximately 1m or less). Be sure to avoid
the installation or change the exhaust direction.
•Avoid installation above gas ranges or stoves.
•Avoid installation between the kitchen fan and stove. If oily fumes or
a large amount of steam are present in the installation location, take
measures to prevent the fumes and steam from entering in the
equipment.
•Avoid installation in places where dust or debris will accumulate.
Dust may causing the performance of the fan motor to drop and
incomplete combustion to occur as a result.
• Install in a location where the exhaust gas flow will not be
affected by fans or range hoods.
• Take care that noise and exhaust gas will not affect neighbors.
•Avoid installation in places where special chemical agents
(e.g., hair spray or spray detergent) are used.
Ignition failures and malfunction may occur as a result.
•When you install the equipment, check the wall or ceiling around the
installation place is safe for fire protection or install the equipment
where the free space effective for fire protection can be ensured.

8
6. Installation Clearances
Before installing, check for the following:
The appliance must be installed in a suitably ventilated room, in accordance with the regulations
in force.
Install in accordance with relevant building and mechanical codes, as well as any local, state or
national regulations.
Item
Distance from both combustibles
and non combustible materials
• Maintain the following clearances
from both combustible and
non-combustible materials.
• There must be a clearance of 600mm
or more in front of the flue terminal.
•This restriction will not be applied
to an area where an effective
shield makes a clearance of
600mm or more in front of the
exhaust outlet.
Check Illustration
Caution
•If possible, leave 200mm or more
on either side of the unit to facilitate
inspection.
•If possible, leave 600mm or more
in front of the unit to facilitate main-
tenance and service if necessary.
Securing of space for
repair/inspection
600mm
or more
200mm
or more
Outdoor Clearances to Opening
into Any Building
Distance from
the top surface
Distance from
the side
45 mm
or more
45 mm
or more
Consult the flue
manufacturer for
clearances
300mm
or more
300mm
or more
300mm
or more
There must be no
building opening
within this area.
300mm
or more
Flue Terminal
200mm
or more
Distance from
the back surface
10 mm
or more

9
Illustration
7. Installation
Check
4. Drill holes for the remaining four screws.
5. Hang the unit again by the first screw, and then
insert and tighten the remaining four screws.
6. Take waterproofing measures so that water does
not enter the building from screws mounting the
device.
•Make sure the unit is installed securely so that it will
not fall or move due to vibrations or earth-quakes.
Securing to the wall
Mounting Bracket
(upper)
Tapping Screw
Location of Screw Hole
1. Drill a single screw hole, making sure to hit a stud.
2. Insert and tighten the screw and hang the unit by
the upper wall mounting bracket.
3. Determine the positions for the remaining four screws
(two for the top bracket and two for the bottom), and
remove the unit.
• The weight of the device will be applied to the wall. If the strength of the wall is not suffi-
cient, reinforcement must be done to prevent the transfer of vibration.
• Do not drop or apply unnecessary force to the device when installing. Internal parts may
be damaged and may become highly dangerous.
• Install the unit on a vertical wall and ensure that it is level.
Locating Screw Holes
Locating Screw Holes
Mounting
Structure
Caution
•When installing with bare hands,
take caution to not inflict injury.
•Be careful not to hit electrical
wiring, gas, or water piping while
drilling holes.
Item

10
Filling the drain trap unit with water
The drain trap unit can be filled before connecting the vent pipe.
Filling the drain trap unit before vent pipe installation.
DANGER
Prior to initial start up, make sure that you fill the drain trap unit with water.
This is to prevent dangerous exhaust gases from entering the building.
Failure to fill the drain trap unit could result in severe personal injury or death.
Please follow one of the procedures described below to ensure that the drain trap unit is filled with water.
700ml
Intake
Exhaust
1) Fill the drain trap unit by pouring approx. 700ml of water into the
exhaust accessory on the top of the appliance as illustrated below.
Or, if the vent pipe has already been installed:
2) After installing the drain pipe, make sure that the area around the
appliance is well ventilated; open a window or a door if necessary.
Then, operate the unit and verify that condensate is coming out of
the drain pipe.
(During normal use of the water heater, condensate will begin to discharge
from the drain pipe within 30 minutes of use. However, depending on the
season and/or installation site conditions, it may take longer.)

11
Flue Terminal Installation Precautions
Note the following flue terminal installation requirements
•Do not install the flue terminal indoors • Install the flue terminal with a upward slope
upward
slope
downward
slope
•Avoid storing hazardous
objects near the terminal
Petrol
Gas
Flue Terminal
Flue Terminal
Snow
drift Tree
•Avoid installing the terminal where obstacles will block it
•Clearance from the flue terminal.
If multiple units are installed,
terminals must be separated by
300mm or more in a plain view
regardless of the vertical clearance.
Flue Terminal Flue Terminal
300mm or more 300mm or
more
•In the case the discharge direction of the exhaust
is to the side as shown in the diagram below, do
not select the supply/exhaust tube top. Incomplete
combustion caused by short cycling of exhaust
gas may occur as a result.
(except terminal guard.)
8. Flue Pipe Installation
Flue Terminal Installation
•Follow the installation instructions included with the flue terminal and which are reproduced at the end
of this manual. This appliance must be the flue through the wall, not vertically to the roof.
1500mm or more
(terminal above
a terminal.)
Flue Terminal
Snow
drift

12
Detailed recommendations for the flue installations are given in BS 5440:1:2000. The following
notes are for general guidance only.
Note: An adapter is always required on top of the heater.
For the vertical flue set up, offset adapter will be supplied for the air intake.
a) The flue system must be constructed using only Andrews Water Heaters approved
components.
b) It is important that the position of the terminal allows free passage of air across it at all times.
c) It is ESSENTIAL TO ENSURE that products of combustion discharging from the terminal
cannot reenter the building, or any other adjacent building, through ventilators, windows, doors,
other sources of natural air infiltration, or forced ventilation / air conditioning.
d) The minimum acceptable dimensions from the flue terminal to obstructions and ventilation
openings are specified in the regulations.
e) If the flue terminal discharges into a pathway or passageway check that combustion products
will not cause nuisance and that the terminal will not obstruct the passageway.
a. Measure and cut the first pair of the flue pipes away from the appliance. Push pipes fully into
the sockets on top of the boiler whilst also fitting the flue duct prepared as above.
b. Measure and cut next pair of the air/flue pipes.
c. Prepare pipe support brackets as required before engaging pipes with the socket of preced-
ing pipes or bends.
d. Push pipes together as before taking care not to dislodge seals. When cutting and fitting the
flue pipes on extended the flue systems, allow approx. 5 mm clearance at the bottom of each
joint.
e. Repeat above procedure to reach terminal. Ensure that air inlet and the flue gas connections
are correctly made and are not inadvertently reversed.
f. Fix pipe supports to masonry or woodwork so that the flue/air pipes are held securely in
position.
g. Check especially that all joints within any duct or other void are correctly engaged and sealed
before fixing the ductwork.
The flue pipes must be assembled with the plain end of pipe or fitting nearest the boiler and the
female (socket) end furthest from the boiler. Check that a seal is fitted in every socket.
Always adjust length of pipes by cutting and de-burring plain end so that it does not damage or
disturb the seal. Remove burrs from inside and outside of pipe and ensure the pipe is clean and
free from oil and grease.
Assembling Air/Flue Pipes

13
720
720
Maximum length 1745
Maximum length 12000 with 1 x 90
°
bend
Maximum length 7000 with 4 x 90
°
bends
Maximum length 1745
Pitched roof
Straight roof
Air and flue
adapter
720
720
150
150
315
125
Special adapter
Pitched roof
Flat roof
Heater to flue adapter
Air and flue adapter
Maximum length 1745
Maximum length 12000 with 1 x 90 °bend
Maximum length
7000 with 4 x 90 °bends
Maximum length
860
Air and
flue adapter
• HORIZONTAL FLUE TERMINAL (LONG)
•VERTICAL FLUE TERMINAL
• HORIZONTAL FLUE TERMINAL (SHORT)
suit wall thickness
Standard length cut to
Maximum length 560

14
Main unit
Straight pipe
• Do not store hazardous or flammable sub-
stances near the flue terminal.
• Slope the intake and exhaust pipes at a 1/20
grade up towards the termination.
• Connect the flue pipe firmly so that it will prevent
exhaust gases from leaking.
• Steam or condensed water may drip out of the
flue terminal. Dispose of this condensed water
according to local codes and in order to prevent
injury or property damage.
• If this product will be installed in an area where
snow is known to accumulate,protect the flue ter-
mination from blockage by snow drifts or dam-
age from snow falling off of roofs.
• Support the flue pipe with hangers at intervals.
• Install the flue terminal so that it is easily acces-
sible for maintenance both from the indoors and
the outdoors.
Flue Precautions
• Use 100mm diameter exhaust pipe.
• Maximum flue length
4 elbow (90 degree) +
7m (exhaust pipe) + Flue Terminal
*Maximum flue length : 12m
• Minimum flue length
1 elbow (90 degree) + Flue Terminal
• Exceeding the maximum flue length is danger-
ous and may result in bad combustion.
• Maximum 90 degree bends not to exceed 4.
• Maximum length must be reduced by 2000mm
for each 90°bend used.
• Maximum length must be reduced by 1000mm
for each 45°bend used.
• If possible, don’t install the flue pipe through any
enclosed areas.If necessary,consult ANDREWS
WATER HEATER for clearances.
• Install the flue terminal so that all exhaust is di-
rected to and all intake air is taken from outdoors.
Elbows
Elbow
Flue Terminal
sloping up
Intake pipe
Exhaust
pipe
Flue system installation example
HORIZONTAL FLUE TERMINAL
• Use only the following models of the flue terminals with this unit.
• The M&G Horizontal Flue Terminal can be cut to suit the wall thickness.
Special
adapter

15
Main unit
Straight pipe
•Do not store hazardous or flammable sub-
stances near the flue terminal.
•Slope the intake and exhaust pipes at a 1/20
grade up towards the termination.
•Connect the flue pipe firmly so that it will prevent
exhaust gases from leaking.
•Steam or condensed water may drip out of the
flue terminal. Dispose of this condensed water
according to local codes and in order to prevent
injury or property damage.
•If this product will be installed in an area where
snow is known to accumulate,protect the flue ter-
mination from blockage by snow drifts or dam-
age from snow falling off of roofs.
• Support the flue pipe with hangers at intervals.
•Install the flue terminal so that it is easily acces-
sible for maintenance both from the indoors and
the outdoors.
Flue Precautions
•Use 100mm diameter exhaust pipe.
•Maximum flue length
4 elbow (90 degree) +
7m (exhaust pipe) + Flue Terminal
*Maximum flue length : 12m
•Minimum flue length
1 elbow (90 degree) + Flue Terminal
• Exceeding the maximum flue length is danger-
ous and may result in bad combustion.
•Maximum 90 degree bends not to exceed 4.
•Maximum length must be reduced by 2000mm
for each 90°bend used.
•Maximum length must be reduced by 1000mm
for each 45°bend used.
• If possible, don’t install the flue pipe through
any enclosed areas. If necessary, consult
ANDREWS WATER HEATER for clearances.
•Install the flue terminal so that all exhaust is
directed to and all intake air is taken from
outdoors.
Elbow
Elbow
Flue Terminal
sloping up
Intake pipe
Exhaust
pipe
Flue system installation example
VERTICAL FLUE TERMINAL
•Use only the following models of the flue terminals with this unit.
Special
adapter
Main unit
Straight pipe
Flue Terminal
Intake pipe
Exhaust pipe
hangers
hangers
•The M&G Vertical Flue Terminal can be cut to suit the roof.
Special adapter

16
(Combustible material)
Intake pipe
External wall,
combustible material
•If the ventilation of hidden part is not sufficient, install two or more
ventilation holes.
•If you install the exhaust pipe at the hidden part, install the access
hole for checking the full length of exhaust pipe with eye.
•If the partition wall goes right through the hidden part, be sure to
install the access hole near the wall.
Suggested inspection openings
When the intake/exhaust pipes pass through an enclosed space:
Ceiling
Sloping up toward flue terminal
Exhaust pipe

17
Measuring Gas Pressure
In order to check the gas supply pressure to the unit, a
pressure measurement port is provided on the gas inlet.
Remove the hex head screw from the pressure mea-
surement port, and connect a manometer using a silicon
tube.
Follow the instructions from the gas supplier.
9. Gas Piping
The appliance and its individual shutoff valve must be disconnected from the gas supply piping system
during any pressure testing of that system at test pressures in excess of 35 mbar.
The Appliance must be isolated from the gas supply piping system by closing its individual manual shutoff
valve during any pressure testing of the gas supply piping system at test pressures equal to or less than
35 mbar.
The appliance and its gas connections must be leak tested before placing the appliance in operation.
The inlet gas pressure must be within the range specified. This is for the purposes of input adjustment.

18
10. Water Piping
This appliance is suitable for potable water. Do not use this appliance if any part has been underwater. Immediately
call a qualified service technician to inspect the appliance and replace any part of the control system and gas control
which has been under water.
If the water heater is installed in a closed water supply system, such as one having a backflow preventer in the cold
water supply line, means shall be provided to control thermal expansion. Contact ANDREWS WATER HEATERS
TECHNICAL DEPARTMENT FOR ADVICE.
Piping and components connected to the water heater shall be suitable for use with potable water.
Toxic chemicals, such as those used for boiler treatment, shall not be introduced into the potable water.
A water heater used to supply potable water may not be connected to any heating system or components previously
used with a nonpotable water heating appliance.
When water is required in one part of the system at a higher temperature than in the rest of the system, means such
as a mixing valve shall be installed to temper the water to reduce the scalding hazard.
• Flush water through the pipe to clean out metal powder, sand and dirt before connecting it.
•Take appropriate heat insulation measures (e.g., wrapping with heat insulation materials, using electric heaters)
according to the climate of the region to prevent the pipe from freezing.
•
Use a union coupling or flexible pipe for connecting the pipes to reduce the force applied to the piping.
• Do not use piping with a diameter smaller than the coupling.
•When feed water pressure is too high, insert a depressurizing valve, or take water hammer prevention measures.
• Avoid using joints as much as possible to keep the piping simple.
• Avoid piping in which an air holdup can occur.
•Use approved piping materials.
•If installing the unit on a roof:
If the unit is installed on a roof to supply water to the levels below, make sure that the water pressure supplied to
the unit does not drop below 2000 mbar. It may be necessary to install a pump system to ensure that the water
pressure is maintained at this level.
Check the pressure before putting the unit into operation.
Failing to supply the proper pressure to the unit may result in noisy operation, shorter lifetime of the unit, and
may cause the unit to shut down frequently.
Supply water piping
•Do not use PVC piping.
•Mount a check valve and a shut off valve (near
the inlet).
•In order for the client to use the water heater
comfortably,1000 mbar to 5000 mbar of pres-
sure is needed from the water supply.
Be sure to check the water pressure. If the water
pressure is low, the water heater cannot perform
to its full capability, and may become a source of
trouble for the client.
Drain piping
•Expansion water may drop from the pressure
prevention device and wet the floor. If neces-
sary, provide drain piping or use a drain hose to
remove the water.
Hot water piping
•Do not use lead or PVC piping.
•The longer the piping, the greater the heat loss.
Try to make the piping as short as possible.
•Use a mixing valve with a low water resistance.
Use shower heads with low pressure loss.
•If necessary, use a pump or other means to en-
sure that the supply water pressure to the inlet
of the heater does not fall below 2000 mbar when
the maximum amount of water is being de-
manded. Also install a pressure meter on the in-
let. If this is not done, local boiling will occur in-
side the water heater causing abnormal sounds
and decreasing the durability of the heat ex-
changer.
Ask a qualified plumber to perform the installation
of the plumbing. Observe all applicable codes.