Westinghouse WI050, WI030, WI060, WI080, WI100 Installation Manual

Installation

Start-Up

Maintenance

Parts

Indirect

Water Heaters

Warranty

For Residential and
Commercial Use

WI Models

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.

This manual must only be used by a qualied 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.

Westinghouse reserves the right to make product changes or updates without notice and will not be held liable for
typographical errors in literature.

NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

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2

The following dened terms are used throughout this manual
to bring attention to the presence of hazards of various risk
levels or to important product information.

DANGER indicates an imminently hazardous situation which,
if not avoided, will result in serious personal injury or death.

WARNING indicates a potentially hazardous situation which, if
not avoided, could result in personal injury or death.

CAUTION indicates a potentially hazardous situation which, if
not avoided, may result in moderate or minor personal injury.

CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided, may
result in property damage.

NOTICE is used to address practices not related to personal
injury.

Foreword

This manual is intended to be used in conjunction with other
literature provided with the water heater. This includes all
related control information. It is important that this manual,
all other documents included in this system, and additional
publications including the Code for the Installation of Heat
Producing Appliances (latest version), be reviewed in their
entirety before beginning any work.

Installation should be made in accordance with the regulations
of the Authority Having Jurisdiction, local code authorities, and
utility companies which pertain to this type of water heating
equipment.

Authority Having Jurisdiction (AHJ) – The AHJ may be a federal,
state, local government, or individual such as a re chief, re
marshal, chief of a re prevention bureau, labor department
or health department, building ocial or electrical inspector,
or others having statutory authority. In some circumstances,
the property owner or his/her agent assumes the role, and
at government installations, the commanding ocer or
departmental ocial may be the AHJ.

NOTE: Westinghouse reserves the right to modify product
technical specications and components without prior notice.

For the Installer

This water heater must be installed by qualied and licensed
personnel. The installer should be guided by the instructions
furnished with the water heater, and by local codes and utility
company requirements.

Installations Must Comply With:

Local, state, provincial, and national codes, laws, regulations,
and ordinances.

Table of Contents

Part 1 - General Safety Information 2
A. When Servicing the Water Heating System 3
B. Heater Water 3
C. Freeze Protection 3
D. Water Temperature Adjustment 3
Part 2 - Prepare the Water Heater 3
A. Locating the Water Heater 4
B. Water Chemistry Requirements 4
Part 3 - Piping 6
A. Plumbing 6
B. Boiler Connections 6
C. Domestic Piping Inlet 6
D. Auxiliary Connections 6
E. Temperature and Pressure Relief Valve 7
F. Scalding 7
G. Potable Expansion Tank 8
H. Pressure Drop Sizing For Circulator 8
I. Applications 9
Part 4 - Heater Control and Wiring 10
A. Control 10
B. Wiring 10
C. Wiring Diagrams 10
Part 5 - Start-Up and Operation 11
Part 6 - Maintenance and Troubleshooting 12
Limited Warranty 14
Customer Installation Record Form 16

Part 1 - General Safety Information

This water heater is approved for indoor installations only
and is not intended for use as a pool heater. Clearance to
combustible materials: 0” top, bottom, sides, and back. Heater
must have room for service: 24” front, 6” top, and 0” sides are
minimum recommended service clearances. (A combustible
door or removable panel is acceptable front clearance.) This
water heater has been approved for closet installation and
installation on combustible ooring. Do not install directly
on carpeting. Install the water heater in a location where
temperature and pressure relief valve discharge or a leak will
not result in damage to the surrounding area. If such a location
is not available, install an auxiliary catch pan.

Installer - Read all instructions in this manual before
installing. Perform steps in the given order.

User - This manual is for use only by a qualied heating
installer / service technician. Have this water heater serviced
/ inspected annually by a qualied service technician.

FAILURE TO ADHERE TO THESE GUIDELINES CAN
RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE
PERSONAL INJURY, OR DEATH.
NOTE: Obey all local codes. Obtain all applicable permits

before installing the water heater.

NOTE: Install all system components and piping in such a
manner that does not reduce the performance of any re
rated assembly.

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NOTE: If the water heater is exposed to the following, do not
operate. Immediately call a qualied service technician.

1. Fire

2. Damage

3. Water
Failure to follow this information could result in property
damage, severe personal injury, or death.

High heat sources (sources generating heat 100oF / 37oC or
greater, such as stove pipes, space heaters, etc.) may damage
plastic components of the water heater as well as plastic
vent pipe materials. Such damages ARE NOT covered by
warranty. It is recommended to keep a minimum clearance of
8” from high heat sources. Observe heat source manufacturer
instructions, as well as local, state, provincial, and national
codes, laws, regulations and ordinances when installing this
water heater and related components near high heat sources.

Do not use this water heater for anything other than its
intended purpose (as described in this manual). Doing so
could result in property damage and WILL VOID product
warranty.

UNCRATING THE WATER HEATER - Any claims for damage
or shortage in shipment must be led immediately against
the transportation company by the consignee.

A. When Servicing the Water Heating System

To avoid electric shock, disconnect electrical supply before
performing maintenance.

To avoid severe burns, allow water heater and associated
equipment to cool before servicing.

B. Heater Water

Do not use petroleum-based cleaning or sealing compounds in
a water heating system. Gaskets and seals in the system may
be damaged. This can result in substantial property damage.

Do not use “homemade cures” or “patent medicines”. Damage
to the water heater, substantial property damage, and/or
serious personal injury may result.

NOTICE FOR SINGLE-WALL HEAT EXCHANGER MODELS

Per the Uniform Plumbing Code:

Single-wall heat exchangers are permitted if they satisfy all of
the following requirements:

The heat exchanger medium is potable water or contains only
substances which are recognized as safe by the US Food and
Drug Administration (FDA).

The pressure of the heat exchanger medium is maintained
less than the normal minimum operating pressure of the
potable water system (steam systems must comply with this
statement).

The equipment is permanently labeled to indicate that only
additives recognized as safe by the FDA shall be used as the
heat transfer medium.

Other heat exchanger designs may be permitted where
approved by the AHJ.

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C. Freeze Protection

NOTE: Consider piping and installation when determining
heater location. Place the water heater as close to the boiler as
possible in a location not prone to freezing.

Failure of the water heater due to freeze related damage IS
NOT covered by product warranty.

In water heaters with single wall heat exchangers, the heat
transfer uid must be water or nontoxic food grade glycol,
FDA rated “generally recognized as safe” (GRAS) and having
a toxicity rating or class of 1, as listed in Clinical Toxicology
of Commercial Products, 5th edition. Ensure the system is
permanently labeled to indicate any additives used in the heat
transfer uid.

NEVER use any toxic chemical, including automotive, standard
glycol antifreeze, or ethylene glycol made for hydronic (non­potable) systems. These chemicals can attack gaskets and
seals in water systems, are poisonous if consumed, and can
cause personal injury or death.

D. Water Temperature Adjustment

If the water heater is going to have a set temperature above
120oF, you must use an ASSE 1017 rated mixing valve to avoid
severe burns or death from scalding temperatures.

Households with small children, disabled, or elderly persons
may require a 120oF or lower temperature setting to prevent
severe personal injury or death due to scalding.

Approximate Time / Temperature Relationships in Scalds

120oF More than 5 minutes

125oF 1 1/2 to 2 minutes

130oF About 30 seconds

135oF About 10 seconds

140oF Less than 5 seconds

145oF Less than 3 seconds

150oF About 1 1/2 seconds

155oF About 1 second

Table 1 - Approximate Time / Temperature Relationships in Scalds

Part 2 - Prepare the Water Heater

Remove all sides of the shipping crate to allow the heater to be
moved into its installation location.

COLD WEATHER HANDLING - If the water heater has been
stored in a very cold location (BELOW 0oF) before installation,
handle with care until the components come to room
temperature. Failure to do so could result in damage to the
water heater.

NOTE: A drain valve is included with the water heater.

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4

RECOMMENDED SERVICE CLEARANCES

CATCH PAN DIMENSIONS

A. Locating the Water Heater

High heat sources (generating heat 100oF / 37oC or greater, such
as boiler ue pipes, space heaters, etc.) may damage plastic
components of the water heater as well as plastic vent pipe
materials. Such damages ARE NOT covered by warranty. It is
recommended to keep a minimum clearance of 8” from high
heat sources. Observe heat source manufacturer instructions,
as well as local, state, provincial, and national codes, laws,
regulations, and ordinances when installing this water heater
and related components near high heat sources.

This water heater is certied for indoor use only. DO NOT
INSTALL OUTDOORS. Outdoor installations ARE NOT covered
by warranty.

Choose a location for the water heater as centralized to the
piping system as possible. Also, locate the water heater and
domestic water piping where it will not be exposed to freezing
temperatures. All piping should be insulated. Additionally,
place the water heater so that the drain, controls, and inlets/
outlets are easily accessible.

Locate the water heater where any leakage from the relief valve,
related piping, tank, or connections will not result in damage
to surrounding areas or lower oors of the building. The water
heater should be located near a oor drain or installed in a drain
pan. Leakage damages ARE NOT covered by warranty.

NOTE: To save on heating costs and improve energy eciency
keep the distance between the boiler and water heater to a
minimum to reduce heat loss from excess piping and keep
friction loss at a minimum. Ensure all piping between the boiler
and water heater is properly insulated to minimize heat loss.

The water heater may be located some distance from the boiler
provided the circulator meets ow requirements through the
coil. The greater the distance from the water heater to the boiler
the longer the response will be to a call for hot water.

This water heater must be installed vertical on a level surface.

NOTE: In the State of California, the water heater must be
braced, anchored, or strapped to avoid moving during an
earthquake. Contact local utilities for code requirements in your
area. Visit http://www.dsa.dgs.ca.gov or call 1-916-445-8100
and request instructions.

However, applicable local codes shall govern installation.
For residential water heaters of a capacity of greater than 52
gallons, consult the local building jurisdiction for acceptable
bracing procedures.

NOTE: If you do not provide the minimum clearances shown
in Figure 1, it might not be possible to service the water heater
without removing it from the space.

Ensure the location can support the entire lled weight of the
water heater. Failure to properly support the water heater could
result in property damage, severe personal injury, or death.

This water heater must not be located near ammable liquids
such as gasoline, butane, liqueed propane, adhesives,
solvents, paint thinners, etc., as the controls of this water
heater could ignite these vapors and cause an explosion
resulting in property damage, severe personal injury, or death.

Figure 1 - Recommended Service Clearances

B. Water Chemistry Requirements

Chemical imbalance of the water supply may aect eciency
and cause severe damage to the water heater and associated
equipment. Westinghouse recommends having water quality
professionally analyzed to determine whether it is necessary to
install a water softener. It is important that the water chemistry
on both the domestic hot water and central heating sides are
checked before installing the water heater, as water quality
will aect the reliability of the system. In addition, operating
temperatures above 135oF will further accelerate the build­up of lime scale and may shorten the service life of the water
heater. Failure of a water heater due to lime scale build-up,
low pH, or other chemical imbalance IS NOT covered by the
warranty.

The following are water quality parameters that need to be
met in order for the system to operate eciently for many
years.

Water Hardness

Water hardness is mainly due to the presence of calcium and
magnesium salts dissolved in water. The concentration of these
salts is expressed in mg/L, ppm, or grains per gallon as a measure

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VIEW

5

Figure 2 - Specications and Dimensions

of relative water hardness. Grains per gallon is the common
reference used in the US water heater industry. Hardness
expressed as mg/L or ppm may be divided by 17.1 to convert
to grains per gallon. Water may be classied as very soft,
slightly hard, moderately hard, or hard based on its hardness
number. The minerals in the water precipitate out as the water
is heated and cause accelerated lime scale accumulation on
a heat transfer surface. This lime scale build-up may result in
premature failure of the water heater. Operating temperatures
above 135oF will further accelerate the build-up of lime scale

and may shorten the service life of the water heater.
Water that is classied as hard and very hard must be softened to
avoid water heater failure.

CLASSIFICATION MG/L OR PPM GRAINS/GAL

Soft 0 - 17.1 0 - 1

Slightly Hard 17.1 - 60 1 - 3.5

Moderately Hard 60 - 120 3.5 - 7

Hard 120 - 180 7 - 10.5

Very Hard 180 and over 10.5 and over

whl-007 Rev. 1.14.15