andrews WH42 User manual

Installation
Guide,
Operation and
Maintenance
Manual
WH42
WH56
LWH42
LWH56
Internal
FASTTflo
CONTINUOUS FLOW WALL HUNG
BALANCED FLUE HEATERS FOR
NATURAL GAS AND LPG
November 2005 Part No. E791
THIS MANUAL MUST BE KEPT WITH THE APPLIANCE
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Copyright Andrews Water Heaters 2005
Reproduction of any information in this publication by any method is not permitted
unless prior written approval has been obtained from Andrews Water Heaters.
Andrews Storage Water Heaters have been designed and manufactured to comply
with current International standards of safety. In the interests of the Health and
Safety of personnel and the continued safe, reliable operation of the equipment,
safe working practices must be emplyed at all times. The attention of U.K. users is
drawn to their responsibilities under the Health and Safety Regulations 1993.
All installation and service on the Andrews Water Heater must be carried out by
properly qualified personnel, and therefore no liability can be accepted for any
damage or malfunction caused as a result of intervention by unauthorised
personnel.
The Andrews Water Heaters policy is one of continuous product improvement, and
therefore the information in this manual, whilst completely up to date at the time of
publication, may be subject to revision without prior notice.
Further information and assistance can be obtained from:
Andrews Water Heaters
Wednesday One, Black Country New Road
Wednesbury, West Midlands WS10 7NZ
Tel: [phone] Fax: [phone]
Email: [e-mail]
Website: www.andrewswaterheaters.co.uk
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1) Included Accessories 2
2) Optional Accessories 2-3
3) Quick Connect Multi System Installation 4
4) Before Installation 5
5) Choosing Installation Site 6
6) Installation Clearances 7
7) Installation 8
8) Flue Pipe Installation 9-15
9) Gas Piping 16
10) Water Piping 17
11) Electrical Wiring 18-19
12) Commissioning 20-21
13) Dimensions 22-23
14) Remote Controller Installation Manual 24
15) Optional Accessories Guide 25-38
16) Servicing 39
17) Disassembly of each part 39-44
18) Servicing parts lists 45-55
Specifications 56-57
CONTENTS PAGE
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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.
SAR8286q
*SAR8286C*
Installation Manual
GAS WATER HEATER
WH42, LWH42 (Internal)
WH56, LWH56 (Internal)
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2. Optional Accessories
The accessories listed below are not
included with the units, but may be necessary
for installation.
Q’tyShapePartPart Shape Q’ty
Flue Terminal
FF-100 1
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
Remote Controller 1
Flue Terminal
FF-100A 1
1
Owner's Guide
Crescent clamp 1Drain hose
Condensate trap
M&G Horizontal
Flue Terminal 1
M&G Vertical
Flue Terminal 1
1
Special Adapter 1
System Controller 1
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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
Gas Valve
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.
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Check the Gas
•Check that the rating plate indicates the correct type of gas.
Check that the gas supply line is sized
for 62.3 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,
as unexpected accidents may occur as a result.
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.
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
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Caution
•The water heater is designed for internal installation only. Never
install it outdoors or in a bathroom, it may be damaged or a fire may
be caused.
•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. Consult the
rating plate on the appliance for proper clearances.
• 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.
•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.
•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 block the air-supply opening, 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.
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.
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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 combustibles
• 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 maintenance 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
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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
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Flue Terminal Installation Precautions
Note the following flue terminal installation requirements
•Do not install the flue terminal indoors • Install the flue terminal with a downward slope
upward
slope
downward
slope
• Install with the proper length protruding through the wall (FF-100A only)
•Avoid storing hazardous
objects near the terminal
Petrol
Gas
Proper installation. The
red line can be seen,but
the red rectangle cannot
be seen from the outside.
Flue Terminal
Flue Terminal
not far
enough too far
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 (Internal Installation Only)
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
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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 Powermax 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 Figs. 4& 5 opposite.
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 - see Fig. 8.
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.
Any generally "horizontal" run of the flue pipe MUST NOT FORM A LOW POINT at which
condensate could accumulate.
Assembling Air/Flue Pipes
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Important: The flue terminal must be installed horizontally.
1. Mark the centre of the 152mm diameter hole and core drill.
Note:If the wall is clad with a combustible material an additional 25mm wide area must be
removed around liner.
2. Measure the wall thickness and cut the liner to this length.
Note:Cut opposite end to rim and allow some material to be used as tabs on the inside of the
wall to ensure a secure fixing.
Note:If the terminal has to be fitted from inside the property, the liner can be inserted with the
rim on the inside.
3. Fit the liner through the hole and make good internal and external rendering.
The latter may be done with arm extended through liner.
4. Push the flue terminal assembly into liner. Ensure terminal protrudes by 110mm from the wall.
Important:The grille must be totally exposed to air. Fit the closure plate around the pipes and
secure to the wall.
5. The flue pipe MUST be supported by a pipe clamp before the first joint.
Note:The flue pipe ends with a female socket designed for use with the optional 3° Bend.
If not using the bend, the socket should be cut off the flue pipe.
Installing Horizontal Extended Terminal
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Standard length 1145
720
720
Maximum length 845
Maximum length 12000 with 1 x 90
°
bend
Maximum length 7000 with 4 x 90
°
bends
160
Pitched roof Straight roof
To drain
Fit condensate trap E746
and siphon E211 to flues
over 2m high.
Air and flue adapter
720
720
150
362
Standard length 1145
150
Minimum length 845
175
150
Special adapterSpecial adapter
Pitched roof
Flat roof
Heater to flue adapter
Air and flue adapter
300 Minimum
Minimum length 750
suit wall thickness
Maximum length 12000 with 1 x 90 °bend
Maximum length
7000 with 4 x 90 °bends
Standard length 565
160
Service clearance
Standard length cut
to
Air and flue adapter
AdjustIble plate
•M&G HORIZONTAL FLUE TERMINAL
•M&G VERTICAL FLUE TERMINAL
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Main unit
Straight pipe
•Do not store hazardous or flammable sub-
stances near the flue terminal.
•Slope the intake and exhaust pipes at a 1/50
grade down 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.
•If the flue terminal will be installed higher than
the water heater, make the vertical section di-
rectly above the water heater as short as
possible,and slope down to the terminal. Do not
have another vertical section after the horizontal
section begins.
• Make the vertical pipe as short as possible.
Flue Precautions
•Use 100mm diameter flue pipe.
•Maximum flue length
4 elbow (90 degree) +
7m (flue pipe) + Flue Terminal
1 elbow (90 degree) +
12m (flue pipe) + Flue Terminal
•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 out-
doors.
Elbows
Elbow
Flue Terminal
sloping down
Intake pipe
Exhaust
pipe
Flue system installation example
M&G 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.
Seal any connections that
are not gas tight using a
high temperature silicone
sealant.
Special
adapter
Wall thickness
50 mm to 500 mm
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Main unit
Straight pipe
•Do not store hazardous or flammable sub-
stances near the flue terminal.
•Slope the intake and exhaust pipes at a 1/50
grade down 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.
• Fit condensate trap and siphon to flues over 2m high.
•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.
•If the flue terminal will be installed higher than
the water heater,make the vertical section di-
rectly above the water heater as short as
possible,and slope down to the terminal. Do not
have another vertical section after the horizontal
section begins.
• Make the vertical pipe as short as possible.
Flue Precautions
•Use 100mm diameter flue pipe.
•Maximum flue length
4 elbow (90 degree) +
7m (flue pipe) + Flue Terminal
1 elbow (90 degree) +
12m (flue pipe) + Flue Terminal
•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 down
Intake pipe
Exhaust
pipe
Flue system installation example
M&G VERTICAL FLUE TERMINAL
•Use only the following models of the flue terminals with this unit.
Seal any connections that
are not gas tight using a
high temperature silicone
sealant.
Special
adapter Main unit
Straight pipe
Flue Terminal
Intake pipe Exhaust pipe
Flue system installation example
Seal any connections that
are not gas tight using a
high temperature silicone
sealant.
Special adapter
hangers hangers
•The M&G Vertical Flue Terminal can be cut to suit the roof.
Special adapter
Roof thickness
50 mm to 500 mm
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1234567890123456789
1
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9
1
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9
1
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9
1
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9
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9
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(Combustible material)
Intake pipe
External wall,
combustible material
• Inspection openings are suggested for the flue pipe if they are
installed in an enclosure. These openings should be near the
entrance and exit of the flue into the enclosure.
• These openings should be 450mm x 450mm.
Suggested inspection openings (450mm x 450mm)
When the intake/exhaust pipes pass through an enclosed space:
Ceiling
Sloping down toward flue terminal
Exhaust pipe
Under the exhaust conditions indicated by the shaded portion of the table
below, the connector for switching the airflow rate shown in the illustration
below is pulled out. (Changes the speed of fan rotation.)
Connecter for switching airflow rate depending on exhaust conditions
The power must be unplugged when
adjusting (pulling in or out) the connector
to switch the airflow amount.
<Extending conditions for the exhaust flues>
4 bends within 7 m
[Extending limits for the exhaust flues]
Pulling out
Connector
Connector to switch
the airflow amount
Connector to switch
the airflow amount
ＵＰ
ＤＯＷＮ
small
large
b
u
t
t
o
n
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1 m 1
Bends
Length
2 m
3 m
4 m
5 m
6 m
7 m
234
Controller
Description:Flue Outlet Guard
Andrews Part Number:E105
Manufactured by:H.Docherty Limited
Red Shute Hill Industrial Estate
Red Shute Hill
Hermtage, Newbury
Berkshire, RG18 9QL
United Kingdom
Terminal Guard
A terminal guard is required if persons could come into contact with the terminal or the terminal
could be subject to damage.
If a terminal guard is required, it must be positioned to provide minimum of 50 mm clearance from
any part of the terminal and be central over the terminal.
le
8 m
9 m
10 m
11 m
12 m
1 bend within 12 m
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16
Measuring Gas Pressure
In order to check the gas supply pressure to the unit, a
tap is provided on the gas inlet. Remove the hex head
philips screw from the tap, 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.
Manifold Gas Pressure Adjustment
NOTE:
*
Use the following procedure to adjust the manifold gas pressure
only if it can be done with a high flow rate through the unit.
(1) With a manometer or pressure guage connected to the manifold pressure
tap, press and hold the maximum pressure set button. Use the manifold
pressure increase and decrease buttons to adjust to the correct pressure.
(2) Press and hold the minimum pressure set button. Use the
manifold pressure increase and decrease buttons to
adjust to the correct pressure.
(3) Repeat steps (1) and (2) until both are at the correct pressure.
Manifold Pressure
Increase Button
Manifold Pressure
Decrease Button
Minimum Pressure
Set Button
Maximum Pressure
Set Button
Circuit Board
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