VFS-I-O_Rev D_100161775_2000019057 (Vent Cat.).

VFS-I-O_100161775_2000019057_Rev D
Installation & Operation Manual
Models: 500 - 2000
Up To 4:1 Turndown
 WARNING:
This manual supplies information for the
installation, operation, and servicing of the
appliance. It is strongly recommended that this
manual and the VF Series Service Manual be
reviewed completely before proceeding with an
installation. Perform steps in the order given.
Failure to comply could result in severe personal
injury, death, or substantial property damage.
Save this manual for future reference.
Contents
HAZARD DEFINITIONS .................................................... 2
PLEASE READ BEFORE PROCEEDING ..................... 3-4
RATINGS ........................................................................... 5
THE VF SERIES -- HOW IT WORKS............................. 6-8
1. DETERMINE UNIT LOCATION
Location of Unit .................................................................. 9
Recommended Service Clearances ............................. 9
Combustion and Ventilation Air Requirements .......... 10-12
2. VENTING
Before You Begin ............................................................. 13
Venting Category Definitions ....................................... 13
Vent Materials ............................................................. 14
Condensing Vent Options: CAT II & IV ................ 15-18
Common Venting CAT II & IV Venting Information 19-20
Vertical Vent Options .................................................. 21
Horizontal Vent Options .............................................. 22
All Categories ........................................................ 23-28
3. GAS CONNECTIONS
Gas Supply ....................................................................... 29
Gas Pressure Test ............................................................ 29
Checking Manifold Gas Pressure ..................................... 29
Gas Connection ............................................................... 29
Gas Piping ........................................................................ 30
Checking Gas Supply Pressure ....................................... 31
High and Low Gas Pressure Switches ............................ 32
4. WATER CONNECTIONS
Inlet and Outlet Connections ............................................ 33
Water Heater Installations ........................................... 34-36
5. ELECTRICAL CONNECTIONS
Water Heater Operating Control Module ......................... 37
Line and Low Voltage Connections ............................ 37-38
EMS or Remote Thermostat Connection ......................... 38
Louver Proving Switch ................................................ 39
Water Heater Management System (BMS) ................ 39
Runtime Contacts ....................................................... 39
Alarm Contacts ............................................................ 39
Low Voltage Field Wiring Connections .................. 40
6. CONDENSATE DISPOSAL......................................... 41
7. START-UP
Check / Control Water Chemistry .................................... 42
Filling Hot Water Heater ................................................... 42
Check for Gas Leaks ........................................................ 42
Inspect / Fill Condensate System ..................................... 42
Check Vent and Air Piping ................................................ 42
Placing the Water Heater in Operation ............................. 43
Operating Instructions ....................................................... 44
8. OPERATING INFORMATION
General............................................................................. 45
How the Appliance Operates ............................................ 45
How the Control Module Operates.................................... 45
Control Inputs and Outputs ............................................... 45
Temperature Control ......................................................... 45
Protection Features ......................................................45-46
Water Heater Temperature Regulation ............................. 46
Sequence of Operation ..................................................... 47
VF Series Control Module ................................................. 48
Status Display Screens ................................................49-50
9. DOMESTIC WATER HEATERS
Initial Setup of Maximum Water Flow ............................... 51
Water Chemistry................................................................ 52
Pump Operation ................................................................ 57
Heat Exchanger ................................................................ 57
Thermostat Adjustment Procedure ................................... 58
Minimum Water Temperatures.......................................... 58
Adjustable High Water Temperature Limit Control ........... 59
Optional Relief Valve......................................................... 59
Thermal Expansion ........................................................... 59
Cathodic Protection ........................................................... 59
10. MAINTENANCE
Maintenance and Annual Startup ................................ 60-65
11. CONNECTION DIAGRAM .......................................... 66
12. LADDER DIAGRAM ................................................... 67
13. WARRANTY ............................................................... 69
Revision Notes .................................................. Back Cover
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels
or to important information concerning the life of the product.
 DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
 WARNING injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
 CAUTION injury.
CAUTION
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
2
Installation & Operation Manual
Please read before proceeding
NOTICE
This is a gas appliance and should be installed
by a licensed electrician and/or certified gas
supplier. Service must be performed by a
qualified service installer, service agency or the
gas supplier.
 WARNING If the information in these instructions is not
followed exactly, a fire or explosion may result
causing property damage, personal injury, or
death.
This appliance MUST NOT be installed in any
location where gasoline or flammable vapors
are likely to be present, unless the installation
is such to eliminate the probable ignition of
gasoline or flammable vapors.
What to do if you smell gas –
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any
phone in your building.
• Immediately call your gas supplier from a neighbors phone.
Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire
department.
 WARNING
Checking equipment –
Upon receiving equipment, check for signs of shipping
damage. Pay particular attention to parts accompanying the
appliances which may show signs of being hit or otherwise
being mishandled. Verify total number of pieces shown on
packing slip with those actually received. In case there is
damage or a shortage, immediately notify the carrier.
Do not use this appliance if any part has been under
water. The possible damage to a flooded appliance can
be extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced.
 Owner warning –
The information contained in this manual is intended for use
by qualified professional installers, service technicians, or gas
suppliers. Consult your local expert for proper installation
or service procedures.
NOTICE
Installation and service must be performed by a qualified installer,
service agency, or the gas supplier.
Warranty –
Factory warranty (shipped with unit) does not apply to units
improperly installed or improperly operated.
Experience has shown that improper installation or system
design, rather than faulty equipment, is the cause of most
operating problems.
1.
2.
Excessive water hardness causing a lime/scale build-up in
the copper tube is not the fault of the equipment and is
not covered under the manufacturer’s warranty (see
Water Treatment and Water Chemistry).
Excessive pitting and erosion on the inside of the copper
tube may be caused by too much water velocity through
the tubes and is not covered by the manufacturer’s
warranty (see Flow Rates and Temperature Rise for
flow requirements).
Improper installation, adjustment,
alteration, service or maintenance can
cause injury or property damage. Refer to
this manual for assistance or additional
information, consult a qualified installer,
service agency or the gas supplier.
Consult and follow all local Building and
Fire Regulations and other Safety Codes
that apply to this installation. Consult
local gas utility company to authorize and
inspect all gas and flue connections.
A gas appliance that draws combustion air from the
equipment room where it is installed must have a supply of
fresh air circulating around it during burner operation for
proper gas combustion and proper venting.
 WARNING
Should overheating occur or the gas
supply fail to shut off, do not turn off
or disconnect the electrical supply to the
pump. Instead, shut off the gas supply at
a location external to the appliance.
Prevention of freezing –
Heat exchangers and headers damaged by freezing are not
covered by warranty.
See Section 7, Startup - Freeze Protection for more information.
3
Installation & Operation Manual
Please read before proceeding
 WARNING
To minimize the possibility of serious
personal injury, fire, or damage to your
appliance, never violate the following safety
rules:
1. Water heaters are heat producing
appliances. To avoid damage or injury,
do not store materials against the
appliance or the vent-air intake system.
Use proper care to avoid unnecessary
contact (especially children) with the
appliance
and
vent-air
intake
components.
2. Never cover your appliance, lean
anything against it, store trash or debris
near it, stand on it or in any way block
the flow of fresh air to your appliance.
3. UNDER NO CIRCUMSTANCES must
flammable materials such as gasoline or
paint thinner be used or stored in the
vicinity of this appliance, vent-air intake
system or any location from which fumes
could reach the appliance or vent-air
intake system.
Codes –
The equipment shall be installed in accordance with those
installation regulations in force in the local area where the
installation is to be made. These shall be carefully followed in all
cases. Authorities having jurisdiction shall be consulted before
installations are made. In the absence of such requirements, the
installation shall conform to the latest edition of the National
Fuel Gas Code, ANSI Z223.1. All water heaters conform to
the latest edition of the ASME Boiler and Pressure Vessel Code,
Section IV. Where required by the authority having jurisdiction,
the installation must comply with the Canadian Gas Association
Code, CAN/CGA-B149.1 and/or B149.2 and/or local codes.
This appliance meets the safe lighting performance criteria with
the gas manifold and control assembly provided, as specified in
the ANSI standards for gas water heaters, ANSI Z21.10.3.
4
Installation & Operation Manual
Ratings
HLW
VF Series
Water Heater Rating
Input
MBH
Model Number
Other Specifications
GPH at 100°F
Rise
(Note 3)
Note: Change “N” to
“L” for L.P. gas models.
LOW LEAD CONTENT
(Note 1)
Appliance
Water
Water
Gas
Content Connections Connections
Gallons
Air / Vent
Sizes
(Note 2)
Min
Max
VWH0500N
125
500
515
3.60
2.5"
1"
5" - 4"
VWH0750N
188
750
773
4.00
2.5"
1 1/4"
5" - 5"
VWH1000N
250
1000
1030
4.30
2.5"
1 1/4"
6" - 6"
VWH1500N
375
1500
1545
5.50
2.5"
1 1/2"
6" - 6"
VWH2000N
500
2000
2061
6.20
2.5"
1 1/2"
8" - 8"
NOTICE
Maximum allowed working pressure is located on the rating plate.
Notes:
1. The ratings are based on standard test procedures
prescribed by the United States Department of Energy.
2. The VF Series requires special gas venting. Use only the
vent materials and methods specified in the VF Series
Installation and Operation Manual.
3. The VF Series is equipped for operation up to 2000 feet, and
including up to 4000 feet, with no field adjustments. The
appliance output ratings up to 4000 feet shall be reduced by
4% for each 1000 feet above sea level. For operation above
4000 feet, consult the factory.
5
Installation & Operation Manual
The VF Series - How it works...
1.
2.
3.
4.
Heat exchanger
The heat exchanger allows system water to flow through specially
designed tubes for maximum heat transfer. The glass lined
headers and copper finned tubing are encased in a jacket that
contains the combustion process.
Heat exchanger access cover
The heat exchanger access cover is a stainless steel door which
allows access for service, maintenance, and removal of the heat
exchanger from inside the combustion chamber.
Blower
The blower pulls in air and gas through the venturi (see item 5)
and injects the fuel/air mixture into the burner, where they burn
inside the combustion chamber.
Gas valve
The gas valve allows the proper amount of gas to pass into the
burner for combustion. The gas valve on the VF Series works
under a negative pressure so gas should only be pulled through the
valve when the blower is in operation.
The control module is the main control for the appliance. This
module contains the programming that operates the blower, gas
valve, and pumps in addition to other programmable features.
15. Air intake
The air intake pipe allows fresh air to flow directly to the
appliance. The air inlet is part of the filter box assembly where air
filtration is accomplished with a standard filter.
16. Line voltage terminal strip
The line voltage terminal strip provides a location to connect all of
the line voltage (120 VAC) contact points to the unit.
17. Low voltage connection board
The low voltage connection board provides a location to tie in
all of the low voltage contacts to the appliance. This is where most
of the external safety devices are connected to the unit such as the
louver proving switch.
18. Condensate trap
The condensate trap is designed to prevent flue gases from
escaping the appliance through the combustion chamber drain.
5.
Venturi
The venturi attaches to the inlet (or suction) side of the blower
and generates the negative pressure needed by the gas valve.
19. Access cover - front
The front access cover provides access to the gas train as well as the
blower and other key components for service and maintenance.
6.
Flue sensor (not shown)
The flue sensor is mounted in the exhaust collar of the unit and
monitors the flue gas temperature. If the temperature in the stack
exceeds the maximum temperature the unit will shut down to
prevent a hazardous condition.
20. Hot surface igniter (HSI)
The hot surface igniter is a device that is used to ignite the air/
gas mixture as well as monitor the performance of the flame
during operation. This device acts as a flame sense electrode.
7.
Outlet temperature sensor
This sensor monitors the outlet water temperature. If selected
as the controlling sensor, the appliance will maintain set point by
adjusting the firing rate of the unit according to this sensor.
21. Flame inspection window (sight glass)
(not shown on Models 500 - 1000)
The flame inspection window is a quartz glass window that
allows a visual inspection of the burner and flame during
operation.
8.
Inlet temperature sensor
This sensor monitors inlet water temperature. If selected as the
controlling sensor, the appliance will maintain set point by
adjusting the firing rate of the unit according to this sensor.
22. Gas shut off valve (downstream test cock)
The downstream test cock is provided in the gas train to ensure
complete shut off of the gas to the burner in case of
maintenance, inspection, or testing of the valve.
9.
Electronic display
The electronic display consists of 7 buttons and a dual line
32-character liquid crystal display used to monitor the operation
of the heater as well as enter and view the programming of the
main control board.
23. Manual reset high limit sensor
Device that monitors the outlet water temperature to ensure
safe operation. If the temperature exceeds its setting (field
adjustable), it will break the control circuit, shutting the
appliance down.
10. Burner (not shown)
The burner is made of a woven fabric over steel screen construction.
The burner uses pre-mixed air and gas and provides a wide range
of firing rates.
24. Relief valve
The relief valve is a safety device that ensures the maximum
pressure of the appliance is not exceeded. Water heaters operate
on temperature and pressure and are shipped standard as 125 PSI
and 210°F (98.9°C).
11. Water outlet (system supply)
The water outlet is a 2 1/2" pipe connection that supplies water to
the system with connections for a flow switch (see #28) and a relief
valve (see #25).
12. Water inlet (system return)
The water inlet is a 2 1/2" pipe connection that receives water from
the system and delivers it to the heat exchanger.
13. Gas connection pipe
The gas pipe connection on this appliance is 1", 1 1/4", or 1 1/2"
NPT. To deliver the correct amount of gas volume to the appliance
it may be necessary to have a larger gas line reduced to 1 1/4" at the
appliance. Please reference the National Fuel Gas Code charts for
more details.
14. Control module
6
25. Power switch
The power switch is used to engage and disengage power to the
appliance on the 120 VAC circuit.
26. Air pressure switch
The air pressure switch is a safety device which ensures proper
blower operation. The air pressure switch is wired in series with
the low voltage control circuit in such a way that if the fan does not
engage or shuts down prematurely the device will break the
control circuit and the unit will shut down.
27. Flow switch
The flow switch is a safety device that ensures flow through the
heat exchanger during operation. This appliance is low mass and
should never be operated without flow. The flow switch makes
contact when flow is detected and allows the unit to operate. If
flow is discontinued during operation for any reason the flow
switch will break the control circuit and the unit will shut down.
Installation & Operation Manual
The VF Series - How it works...
(continued)
28. Drain port(s)
Location from which the heat exchanger can be drained.
30. Ventilation fan
Provides air circulation around the controls inside the unit.
29. Auto reset high limit switch
The auto reset high limit is fixed at 200°F (93°C) preventing the
outlet water temperature from exceeding 210°F (98.9°C).
31. Manual shutoff valve
Manual valve used to isolate the unit from the gas supply.
30
16
19
13
31
9
17
15
12
25
24
11
18
27
IMG00611
IMG00612
28
Models 500 - 1000 Rear View
Models 500 - 1000 Front View
8
22
4
5
7
14
26
23
29
3
20
2
1
IMG00613
Models 500 - 1000 Right Side (inside unit)
IMG00614
Models 500 - 1000 Left Side (inside unit)
7
Installation & Operation Manual
The VF Series - How it works...
30
16
19
13
31
9
17
15
12
25
24
11
27
18
IMG00616
IMG00615
28
Models 1500 - 2000 Rear View
Models 1500 - 2000 Front View
5
22
8
4
26
7
14
23
3
29
20
21
1
2
IMG00617
Models 1500 - 2000 Right Side (inside unit)
8
IMG00618
Models 1500 - 2000 Left Side (inside unit)
Installation & Operation Manual
1
Determine unit location
Location of unit
Recommended service clearances
1. Locate the appliance so that if water connections
should leak, water damage will not occur. When
such locations cannot be avoided, it is recommended
that a suitable drain pan, adequately drained, be
installed under the unit. The pan must not restrict
combustion airflow. Under no circumstances is
the manufacturer to be held responsible for water
damage in connection with this unit, or any of its
components.
2. The appliance must be installed so that the ignition
system components are protected from water
(dripping, spraying, rain, etc.,) during appliance
operation and service (circulator replacement,
control replacement, etc.,).
3. Appliances located in a residential garage and in
adjacent spaces that open to the garage and are not
part of the living space of a dwelling unit must be
installed so that all burners and burner ignition
devices have a minimum clearance of not less than
18" (46 cm) above the floor. The appliance must
be located or protected so that it is not subject to
physical damage by a moving vehicle.
24"
MIN
TOP
24"
MIN
FRONT
0"
LEFT
SIDE
24"
MIN
REAR
FROM
PIPING
IMG00619
0"
RIGHT
SIDE
Figure 1-1_Recommended Service Clearances
4. DO NOT install this appliance in any location
where gasoline or flammable vapors are likely to be
present.
TABLE - 1A
CLEARANCES FROM COMBUSTIBLE CONSTRUCTION
5. The appliance must be installed on a level floor.
Combustible floor locations may be used. Maintain
required clearances from combustible surfaces.
6. The appliance must not be installed on carpet.
7. The appliance must be installed indoors where it is
protected from exposure to wind, rain, and weather.
8. This appliance may condense the products of
combustion when operating at water temperatures
below 140°F (60°C). Ensure that the appliance is
located near an acceptable drain where condensate
that may form in the venting system may be properly
collected and disposed.
Location
Right Side
Rear
Left Side
Clearances
0"
6" (15cm) (Minimum 24" (0.61m) suggested
for service to pump and components)
0"
Front - Alcove* (Minimum 24" (0.61m) suggested for service)
Top
6" (15cm) (Minimum 24" (0.61m) suggested
for service)
Flue
2" (51mm)
Hot Water Pipes 1" (25.4mm)
*An Alcove is a closet without a door.
9. Access to rear of appliance MUST be maintained.
NOTICE
Clearances from combustible construction are
noted on the appliance rating plate.
9
Installation & Operation Manual
1
Determine unit location
Maintain minimum specified clearances for adequate operation.
All installations must allow sufficient space for servicing the
vent connections, water pipe connections, piping and other
auxiliary equipment, as well as the appliance. The clearance
labels on each appliance note the same service and combustible
clearance requirements as shown above.
Multiple appliances may be installed in a modular water heater
installation. Multiple appliances may be installed side by side
with no clearance between adjacent appliances because this
appliance is approved for zero clearance from combustible
surfaces and no service access is required from the sides.
Consult the Venting section of this manual for specific
installation instructions for the appropriate type of venting
system that you will be using. Direct Vent and Vent/Air
venting systems require installation with Category IV flue pipe,
sealed air inlet pipe, and air inlet caps, which must meet the
manufacturer’s specifications.
Combustion
and
ventilation
air
requirements for appliances drawing air
from the equipment room
Provisions for combustion and ventilation air must be in
accordance with Air for Combustion and Ventilation, of the
latest edition of the National Fuel Gas Code, ANSI Z223.1, in
Canada, the latest edition of CGA Standard B149 Installation
Code for Gas Burning Appliances and Equipment, or applicable
provisions of the local building codes.
The equipment room MUST be provided with properly sized
openings to assure adequate combustion air and proper
ventilation.
IMG00620
Figure 1-2_Combustion Air Direct from Outside
1.
If air is taken directly from outside the building with no
duct, provide two permanent openings to the equipment
room (see FIG. 1-2):
(a) Combustion air opening, with a minimum free area of
one square inch per 4000 Btu/hr input (5.5 cm2 per
kW). This opening must be located within 12" (30 cm)
of the bottom of the enclosure.
(b) Ventilation air opening, with a minimum free area of
one square inch per 4000 Btu/hr input (5.5 cm2 per
kW). This opening must be located within 12" (30 cm)
of the top of the enclosure.
IMG00621
Figure 1-3_Combustion Air Through Ducts
10
Installation & Operation Manual
1
2.
Determine unit location
(continued)
If combustion and ventilation air is taken from the
outdoors using a duct to deliver the air to the
equipment room, each of the two openings should be
sized based on a minimum free area of one square inch
per 2000 Btu/hr (11 cm2 per kW) of input (see FIG. 1-3).
IMG00623
Figure 1-5_Combustion Air from Outside - Single
Opening
4.
IMG00622
Figure 1-4_Combustion Air from Interior Space
3.
If air is taken from another interior space, each of the
two openings specified above should have a net free
area of one square inch for each 1000 Btu/hr (22 cm2
per kW) of input, but not less than 100 square inches
(645 cm2) (see FIG. 1-4).
If a single combustion air opening is provided to bring
combustion air in directly from the outdoors, the opening
must be sized based on a minimum free area of one square
inch per 3000 Btu/hr (7 cm2 per kW). This opening must
be located within 12" (30 cm) of the top of the enclosure
(see FIG. 1-5).
TABLE - 1B
MINIMUM RECOMMENDED COMBUSTION
AIR SUPPLY TO EQUIPMENT ROOM
*Outside Air from
Inside Air from
2 Openings Directly from *Outside Air from
2 Ducts Delivered from
Model
1 Opening Directly
Outdoors
Outdoors
Number
Bottom
Top
Bottom
Top
from Outdoors, in2
Opening, in2 Opening, in2
Opening, in2 Opening, in2
125
125
167
250
250
500
(807 cm2)
(807 cm2)
(1077 cm2)
(1613 cm2)
(1613 cm2)
188
188
250
375
375
750
(1213 cm2)
(1213 cm2)
(1613 cm2)
(2420 cm2)
(2420 cm2)
250
333
500
500
250
1000
(1613 cm2)
(2149 cm2)
(3226 cm2)
(3226 cm2)
(1613 cm2)
375
375
750
750
500
1500
(2420 cm2)
(2420 cm2)
(4839 cm2)
(4839 cm2)
(3226 cm2)
500
500
667
1000
1000
2000
(3226 cm2)
(3226 cm2)
(4303 cm2)
(6452 cm2)
(6452 cm2)
Inside Air from
2 Ducts Delivered from
Interior Space
Top
Bottom
Opening, in2 Opening, in2
500
500
(3226 cm2)
(3226 cm2)
750
750
(4839 cm2)
(4839 cm2)
1000
1000
(6452 cm2)
(6452 cm2)
1500
1500
(9678 cm2)
(9678 cm2)
2000
2000
(12904 cm2)
(12904 cm2)
*Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a
duct, the net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Openings. The
above requirements are for the water heater only; additional gas fired appliances in the equipment room will require an increase in
the net free area to supply adequate combustion air for all appliances.
11
Installation & Operation Manual
1
Determine unit location
Combustion air requirements are based on the latest edition
of the National Fuel Gas Code, ANSI Z223.1; in Canada refer
to the latest edition of CGA Standard CAN B149.1 or B149.2.
Check all local code requirements for combustion air.
500 - 1000
All dimensions based on net free area in square inches. Metal
louvers or screens reduce the free area of a combustion air
opening a minimum of approximately 25%. Check with louver
manufacturers for exact net free area of louvers. Where two
openings are provided, one must be within 12" (30cm) of the
ceiling and one must be within 12" (30cm) of the floor of the
equipment room. Each opening must have net free area as
specified in the chart on page 11 (Table 1B). Single openings
shall commence within 12" (30cm) of the ceiling.
 CAUTION
1500 - 2000
Under no circumstances should the
equipment room ever be under negative
pressure. Particular care should be taken
where exhaust fans, attic fans, clothes dryers,
compressors, air handling units, etc., may
take away air from the unit.
The combustion air supply must be
completely free of any flammable vapors
that may ignite or chemical fumes which
may be corrosive to the appliance. Common
corrosive chemical fumes which must be
avoided are fluorocarbons and other
halogenated compounds, most commonly
present as refrigerants or solvents, such as
Freon, trichlorethylene, perchlorethylene,
chlorine, etc. These chemicals, when burned,
form acids which quickly attack the heat
exchanger finned tubes, headers, flue
collectors, and the vent system.
The result is improper combustion and a non-warrantable,
premature appliance failure.
EXHAUST FANS: Any fan or equipment which exhausts
air from the equipment room may deplete the combustion
air supply and/or cause a downdraft in the venting system.
Spillage of flue products from the venting system into an
occupied living space can cause a very hazardous condition
that must be immediately corrected. If a fan is used to supply
combustion air to the equipment room, the installer must make
sure that it does not cause drafts which could lead to nuisance
operational problems with the appliance.
Figure 1-6_Filter Access
Combustion air filter
This unit has a standard air filter located at the combustion air
inlet as shown above in FIG. 1-6. This air filter is provided to
help ensure clean air is used for the combustion process. Check
this filter every month and replace when it becomes dirty. The
filter size on Models 500 -1000 is 16" x 12" x 1" (40.6cm x 30.5cm
x 2.5cm) and for Models 1500 - 2000 it is 16" x 16" x 1" (40.6cm
x 40.6cm x 2.5cm). You can find these commercially available
filters at any home center or HVAC supply store. Follow the
steps below when replacing the combustion air filter:
1.
Locate the combustion air filter box mounted on the rear of
the appliance.
2.
Locate the flat thumb bolt at the top of the air filter box and
turn it a 1/4 turn counterclockwise to align it with the slot
in the air filter box.
3.
Lift and remove the air filter box cover to gain access to the
air filter.
4.
Slide the air filter out the top of the air filter box.
5.
Inspect the air filter for dirt and debris, replace if necessary.
6.
Replace the air filter and the air filter box cover. Turn the
thumb bolt clockwise a 1/4 turn to secure the air filter box
cover to the air filter box.
NOTICE
CAUTION
12
During construction the air filter should be
checked more frequently to ensure it does
not become clogged with combustion dirt
and debris.
Sustained operation of an appliance with
a clogged burner may result in nuisance
operational problems, bad combustion, and
non-warrantable component failures.
Installation & Operation Manual
2
Venting
BEFORE YOU BEGIN
Identify your appliance’s vent system:
This manual covers venting requirements for CAT II/IV models. Be sure to correctly identify the type of vent system your
appliance requires before proceeding.
Category II/IV Models: See page 15
Venting options:
VWH0500
VWH0750
VWH1000
VWH1500
VWH2000
A B C
D E F
NOTICE
 DANGER
CAT II requires vent
increaser kit.
Category II venting is required when common
venting multiple units .
Failure to use correct venting materials can result in loss of life from flue gas spillage into working or
living space.
Venting Category Definitions: (Reference National Fuel Gas Code ANSI Z223.1)
CAT IV: Positive pressure condensing
An appliance that operates with a positive vent static pressure with a vent gas temperature that may cause excessive condensate
production in the vent.
CAT II: Negative pressure condensing
An appliance that operates with a non-positive vent static pressure with a vent gas temperature that may cause excessive
condensate production in the vent.
13
Installation & Operation Manual
2
Venting
Vent Materials:
Category II/IV Vent Material Suppliers:
Category II/IV flue pipe materials and vent adapters (see FIG. 2-1) can be obtained from the following manufacturers:
Heat-Fab Inc., Saf-T CI Vent with AL29-4C stainless steel
Protech Systems Inc., Fas N Seal Vent with AL29-4C stainless steel
Flex-L International Inc., StaR 34 Vent with AL29-4C stainless steel
Metal-Fab Inc., Corr/Guard Vent with AL29-4C stainless steel
Z-Flex, Z-Vent with AL29-4C stainless steel
Or other listed Category IV vent systems suitable for a condensing, positive pressure, gas fired appliance.
A Category IV flue MUST have all vent joints and seams sealed gastight and have provisions for a drain to properly collect and
dispose of condensate that may occur in the venting system.
*
Increaser
Connector
Figure 2-1_Category IV Vent Adapter
Figure 2-2_Category IV to II Conversion Kit
TABLE - 2A
FLUE ADAPTER SIZES
MODEL
FLUE ADAPTER SIZE
VWH0500
4"
VWH0750
5"
VWH1000
6"
VWH1500
6"
VWH2000
8"
TABLE - 2B
CATEGORY IV TO CATEGORY II
CONVERSION KITS
MODEL
FLUE SIZE
KIT NUMBER
VWH0500
4" to 7"
100131418
VWH0750
5" to 9"
100131419
VWH1000
6" to 10"
100131420
VWH1500
6" to 8"
100131421
VWH2000
8" to 10"
100131422
*Note: The manufacturer of the selected vent material can also provide a vent adapter to connect the vent material to the VF Series
vent connection.
14
Installation & Operation Manual
2
Venting
(continued)
Condensing Vent Options: CAT II & IV
(CAT II vent options A, B, & C requires an adapter kit - see page 14)
A
Vertical vent with combustion air from
equipment room - see page 16.
CAT II/
IV
D
Sidewall termination with combustion air from
equipment room - see page 17.
CAT IV
CAT II
requires an
adapter kit.
See page 14.
B
Vertical Direct Vent installation with rooftop
combustion air inlet - see page 16.
E
Horizontal Direct Vent installation with sidewall
combustion air inlet - see page 18.
CAT IV
CAT II/
IV
CAT II
requires an
adapter kit.
See page 14.
C
CAT II/
IV
Vertical Vent/Air installation with sidewall
combustion air inlet - see page 17.
F
Horizontal Vent/Air installation with vertical
combustion air inlet - see page 18.
CAT IV
CAT II
requires an
adapter kit.
See page 14.
15
Installation & Operation Manual
2
Venting
Condensing vent options: CAT II & IV
(CAT II vent options A, B, & C requires an adapter kit - see page 14)
A
CAT II/IV
Vertical vent with combustion air from equipment room - see page 15.
The flue outlet terminates on the rooftop.
The termination point for the flue products must follow the vertical vent termination clearance requirements
on pages 24 and 25. These units can be identified by the Category IV as noted on the unit’s rating plate.
The flue from this Category IV appliance must have all vent joints and seams sealed gastight. A Category IV
vent system has specific vent material and installation requirements.
CAT II
requires an
adapter kit.
See page 14.
The flue products in the vent system may be cooled below their dew point and form condensate in the flue.
The materials used for a Category IV vent must be resistant to any corrosive damage from flue gas condensate.
The flue from a Category IV vent system must have a condensate drain with provisions to properly collect and
dispose of any condensate that may occur in the venting system.
Follow all requirements in the General Venting and Category IV General Venting sections for proper installation
and for venting flue products to the outdoors with a vertical termination (see pages 19 and 20).
TABLE - 2C
VENT TERMINATION SIZES
MODEL
CAT II
VENT SIZE
CAT IV
VENT SIZE
MODEL
VWH0500
7"
4"
VWH1500
8"
6"
VWH0750
9"
5"
VWH2000
10"
8"
VWH1000
10"
6"
--
--
--
B
CAT II/IV
CAT II
VENT SIZE
CAT IV
VENT SIZE
Vertical direct vent installation with rooftop combustion air inlet - see
page 15.
The Vertical Direct Vent system is installed with a Category IV flue and a separate combustion air pipe to the
outdoors. The flue outlet and combustion air intake must both terminate on the rooftop.
The termination point for the flue products must follow the vertical vent termination clearance requirements
on pages 24 and 25. These units can be identified by the Category IV as noted on the unit’s rating plate.
The optional Direct Vent system requires the installation of specific venting materials that are purchased
locally.
CAT II
requires an
adapter kit.
See page 14.
Follow all requirements in the General Venting and Category IV General Venting sections for proper installation
and for venting flue products to the outdoors with a vertical termination (see pages 19 and 20).
The Vertical Direct Vent system requires the installation of an additional pipe to supply combustion air from
outdoors directly to the appliance. Follow all requirements under the Combustion Air Inlet section on pages
22 and 23.
TABLE - 2D
AIR & VENT TERMINATION SIZES
CAT II
MODEL
CAT IV
CAT II
AIR
SIZE
VENT
SIZE
AIR
SIZE
VENT
SIZE
VWH0500
5"
7"
5"
4"
VWH0750
5"
9"
5"
VWH1000
6"
10"
6"
16
MODEL
CAT IV
AIR
SIZE
VENT
SIZE
AIR
SIZE
VENT
SIZE
VWH1500
6"
8"
6"
6"
5"
VWH2000
8"
10"
8"
8"
6"
--
--
--
--
--
Installation & Operation Manual
2
Venting
Condensing vent options:
(continued)
CAT II & IV
(CAT II vent options A, B, & C requires an adapter kit - see page 14)
C
CAT II/IV
Vent/Air Vertical installation with sidewall combustion air inlet - see page
15.
The Vent/Air Vertical with a Sidewall Combustion Air Vent system terminates the flue at the rooftop and air inlet
at the sidewall. The flue outlet and combustion air intake terminate in different pressure zones.
The optional Vent/Air vent system requires the installation of specific venting materials that are purchased locally.
The termination point for the flue products must follow the vertical vent termination clearance requirements on
pages 24 and 25. These units can be identified by the Category IV as noted on the unit’s rating plate.
CAT II
requires an
adapter kit.
See page 14.
Follow all requirements in the General Venting and Category IV General Venting sections for proper installation
and for venting flue products to the outdoors with a vertical termination (see pages 19 and 20).
The Vent/Air Vertical system requires the installation of an additional pipe to supply combustion air from outdoors
directly to the appliance. Follow all requirements under the Combustion Air Inlet section on pages 22 and 23.
Sidewall combustion air inlet: The air inlet cap for the sidewall air inlet must be purchased from the appliance
manufacturer.
Air Inlet Cap
MODEL
VWH0500
VWH0750
VWH1000
D
CAT IV
The part numbers for the required sidewall air inlet cap kit are listed by model. Each kit includes the special
combustion air inlet cap for installation on an exterior sidewall. The sidewall air inlet cap supplied in the kit is
sized to provide combustion air for a single appliance only.
CAT II
AIR
SIZE
5"
5"
6"
VENT
SIZE
7"
9"
10"
TABLE - 2E
AIR INLET CAP TERMINATIONS
CAT IV
CAT IV
CAT II
KIT
MODEL
AIR
VENT
AIR
VENT
NUMBER
SIZE
SIZE
SIZE
SIZE
5"
5"
6"
4"
5"
6"
100131423
100131423
100131425
VWH1500
VWH2000
--
6"
8"
--
8"
10"
--
CAT IV
AIR
SIZE
6"
8"
--
VENT
SIZE
6"
8"
--
CAT
IV KIT
NUMBER
100131425
100131427
--
Sidewall termination with combustion air from equipment room - see page
15.
The connection from the appliance flue outlet to the sidewall vent cap MUST be made with listed Category IV
vent materials and accessories. The installer must supply suitable vent pipe material. The sidewall vent cap must
be purchased from the appliance manufacturer.
The sidewall vent cap kit includes the wall penetration assembly and the discharge screen assembly. All required
Category IV vent pipe and fittings must be purchased locally.
The termination point for the flue products must follow the sidewall vent termination clearance requirements on
pages 25 and 26. These units can be identified by the Category IV as noted on the unit’s rating plate.
Follow all requirements in the General Venting and Category IV General Venting sections for proper installation
and for venting flue products to the outdoors with a sidewall termination (see pages 19 and 20).
Vent Cap
TABLE - 2F
FLUE VENT TERMINATION SIZES
VENT SIZE
CAT IV
CAT IV
KIT
MODEL
VWH0500
4"
100131428
VWH0750
5"
100131429
VWH1000
6"
100131430
MODEL
VENT SIZE
CAT IV
CAT IV
KIT
VWH1500
6"
100131430
VWH2000
8"
100131432
--
--
--
17
Installation & Operation Manual
2
Venting
Condensing vent options: CAT IV
E
CAT IV
Horizontal direct vent installation with sidewall combustion air inlet - see
page 15.
The horizontal direct vent system is installed with a Category IV flue and a separate combustion air pipe to the outdoors.
The flue outlet and combustion air intake must both terminate on the same sidewall.
The connection from the appliance flue outlet to the sidewall vent cap MUST be made with listed Category IV vent
materials and accessories. The installer must supply suitable vent pipe material. The horizontal direct vent must be
purchased from the appliance manufacturer.
The termination point for the flue products must follow the sidewall vent termination clearance requirements on pages
25 - 28. These units can be identified by the Category IV as noted on the unit’s rating plate.
The horizontal direct vent kit includes the wall penetration assembly and the discharge screen assembly for the flue and
a combustion air inlet cap. All required vent pipe and fittings must be purchased locally.
Follow all requirements in the General Venting and Category IV General Venting sections for proper installation and for
venting flue products to the outdoors with a sidewall termination (see pages 19 and 20).
Air Inlet Cap
Vent Cap
F
CAT IV
The horizontal direct vent system requires the installation of an additional pipe to supply combustion air from outdoors
directly to the appliance. Follow all requirements under the Combustion Air Inlet section on pages 22 and 23.
TABLE - 2G
SIDEWALL AIR AND VENT TERMINATION SIZES
CAT IV
CAT IV
CAT IV
MODEL
MODEL
AIR
VENT
AIR
VENT
KIT
CAT IV
KIT
VWH0500
VWH0750
VWH1000
100131435
100131439
--
SIZE
5"
5"
6"
SIZE
4"
5"
6"
100131433
100131434
100131435
VWH1500
VWH2000
--
SIZE
6"
8"
--
SIZE
6"
8"
--
Horizontal vent/air installation with vertical or sidewall combustion air page 15.
The Horizontal Vent/Air vent system terminates the flue at the sidewall and air inlet at either the rooftop or a sidewall
opposite the vent termination. The flue outlet and combustion air intake terminate in different pressure zones.
The connection from the appliance flue outlet to the sidewall vent cap MUST be made with listed Category IV vent
materials and accessories. The installer must supply suitable vent pipe material. The Horizontal Vent/Air vent cap must
be purchased from the appliance manufacturer.
The termination point for the flue products must follow the sidewall vent termination clearance requirements on pages
25 - 28. These units can be identified by the Category IV as noted on the unit’s rating plate.
The Horizontal Vent/Air vent system with a vertical air inlet requires a sidewall vent kit. The Horizontal Vent/Air vent
system with a sidewall air inlet requires a horizontal direct vent kit. All required vent pipe and fittings must be purchased
locally.
Follow all requirements in the General Venting and Category IV General Venting sections for proper installation and for
venting flue products to the outdoors with a sidewall termination (see pages 19 and 20).
The Horizontal Vent/Air vent system requires the installation of an additional pipe to supply combustion air from
outdoors directly to the appliance. Follow all requirements under the Combustion Air Inlet section on pages 21 and 22.
Vent Cap
MODEL
VWH0500
VWH0750
VWH1000
18
TABLE - 2H
SIDEWALL VENT TERMINATION SIZES
CAT IV
CAT IV
CAT IV
MODEL
AIR
VENT
AIR
VENT
KIT
SIZE
SIZE
5"
5"
6"
4"
5"
6"
100131428
100131429
100131430
VWH1500
VWH2000
--
SIZE
SIZE
6"
8"
--
6"
8"
--
CAT IV
KIT
100131430
100131432
--
Installation & Operation Manual
2
Venting
(continued)
Common Venting CAT II:
Flues of multiple VF Series water heaters may be combined by incorporating a vent increaser to change the Category IV appliance to
a Category II vent system which can be common vented using an engineered vent system. The increaser kit must be provided by the
manufacturer and the combined engineered vent system must be designed to ensure that flue products will be properly exhausted
from the building at all times. Failure to use the correct vent increaser or a properly sized vent system may result in a hazardous
condition where flue gases spill into an occupied living space. Consult a vent designer to determine the diameter of the common
vent pipe required for combined vent installation. It is recommended that all vent joints and seams are sealed gastight. This vent
system has specific vent material and installation requirements. The negative draft in a conventional vent installation must be
within the range of 0.02 to 0.08 inches w.c. to ensure proper operation. Make all draft readings while the unit is in stable operation
(approximately 2 to 5 minutes).
CAT II & IV General venting information - Vent options: All Categories
Vent installation for connection to gas vents or chimneys must be in accordance with “Venting of Equipment”, of the latest edition
of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA Standard B149 Installation Code for Gas
Burning Appliances and Equipment or applicable provisions of the local building codes.
All venting applications where combustion air is drawn from the equipment room must have adequate combustion and ventilation air
supplied to the equipment room in accordance with the latest edition of CAN/CGA Standard B149 Installation Code for Gas Burning
Appliances and Equipment or applicable provisions of the local building codes.
The distance of the vent terminal from adjacent buildings, windows that open and building openings MUST comply with the
minimum clearances stated in this manual and the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest
edition of CAN/CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment.
The vent connection is made directly to the flue outlet opening on the rear of the unit. The connection from the appliance vent to
the stack must be made as direct as possible with no reduction in diameter. A water heater shall not be connected to a chimney flue
serving a separate appliance designed to burn solid fuel.
Do not locate the terminations over public walkways. Do not locate the terminations near soffit vents, crawl space vents, or other
areas where condensate or vapor could create a nuisance, hazard, or cause property damage. Do not locate the terminations where
condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment.
Examine the venting system at least once a year. Check all joints and vent pipe connections for tightness. Also
NOTICE
check for corrosion or deterioration. Immediately correct any problems observed in the venting system.
CAT IV Specific venting information: Vent Options A, B, C, D, E, & F
A Category IV venting system operates with a positive pressure in the vent. This positive pressure is generated by the internal
combustion air blower which operates the combustion process and also exhausts the flue products from the building. The Category
IV flue from this appliance cannot be combined with the vent from any other appliance. The Category IV flue from this appliance
must be a dedicated stack, there is one exception however. The Category IV flues from multiple VF Series appliances may only
be combined when using an engineered vent system incorporating an induced draft fan to ensure that flue products will be
properly exhausted from the building at all times. Failure to use a properly sized induced draft fan on a combined Category IV
vent installation may result in a hazardous condition where flue gases spill into an occupied living space. Consult the induced draft
fan manufacturer to size the induced draft fan and to determine the diameter of the common vent pipe required for a combined vent
installation. The flue from this Category IV appliance must have all vent joints and seams sealed gastight. A Category IV vent system
has specific vent material and installation requirements.
The flue products in the vent system may be cooled below their dew point and form condensate in the flue. The flue materials used
for a Category IV vent must be resistant to any corrosive damage from flue gas condensate. The flue from a Category IV vent system
must have a condensate drain with provisions to properly collect and dispose of any condensate that may occur in the venting system.
The connection from the appliance vent to the stack or vent termination outside the building must be made with listed Category IV
vent material and must be as direct as possible. The Category IV vent and accessories such as firestop spacers, thimbles, caps, etc., must
be installed in accordance with the vent manufacturer’s instructions. The vent connector and firestop must provide correct spacing
to combustible surfaces and seal to the vent connector on the upper and lower sides of each floor or ceiling through which the vent
connector passes.
Any vent materials specified must be listed by a nationally recognized test agency for use as a Category IV vent material.
The venting system must be planned so as to avoid possible contact with concealed plumbing or electrical wiring inside walls, floors,
or ceilings. Locate the appliance as close as possible to a chimney or gas vent.
Horizontal portions of the venting system shall be supported to prevent sagging. Horizontal runs should slope upwards not less than
a 1/4 inch per foot from the drain tee installed in the flue to the vertical portion of the flue or to the vent terminal on sidewall venting
installations. This ensures proper removal of any condensate that may form in the flue. Follow the installation instructions from the
vent material manufacturer.
19
Installation & Operation Manual
2
Venting
CAT IV Specific venting information (continued): Vent options A, B, C, D, E, & F
Do not use an existing chimney as a raceway if another appliance or fireplace is vented through the chimney. The weight of the
venting system must not rest on the unit. Adequate support of the venting system must be provided in compliance with local codes
and other applicable codes. All connections should be secured and sealed per the vent manufacturer’s specifications.
Vent connectors serving appliances vented by natural draft shall not be connected to any portion of the Category IV positive
pressure vent system used by this appliance. Connection of a negative draft flue into the positive pressure stack from this appliance
may cause flue products to be discharged into an occupied living space causing serious health injury.
When a Category IV vent system is disconnected for any reason, the flue must be reassembled and resealed according to the vent
manufacturer’s instructions.
The flue may terminate either vertically at the rooftop or horizontally on a sidewall. Refer to the specific vent termination sections
for information about recommended vent termination location and clearances.
Length of flue pipe
The installed length of the Category IV flue from the appliance to the point of termination, outside of the building, must not exceed
a maximum of 50 equivalent feet (15.2m) in length. Subtract 5 feet (1.5m) of equivalent length for each 90° elbow installed in the
vent. Subtract 2 1/2 feet (0.7m) of equivalent length for each 45° elbow installed in the vent.
CAT II/IV Drain Tee Requirements: Vent options A, B, C, D, E, & F
Drain tee installation
A drain tee must be installed in the Category II & IV vent pipe to collect and dispose of any condensate that may occur in the vent
system. The drain tee should be installed at the point where the flue turns vertical for a rooftop termination or as one of the first
fittings in a horizontal flue connector that will terminate on a sidewall. Ensure that horizontal portions of the vent are properly
sloped to allow condensate to be evacuated at the drain tee. Plastic drain tubing, sized per the vent manufacturer’s instructions,
shall be provided as a drain line from the tee. The drain tubing must have a trap provided by a 10” (25.4cm) diameter circular
trap loop in the drain tubing. Prime the trap loop by pouring a small quantity of water into the drain hose before assembly to the
vent. Secure the trap loop in position with nylon wire ties. Use caution not to collapse or restrict the condensate neutralization
system or a suitable drain for disposal of condensate that may occur in the Category IV vent system. Ensure that the drain from
the condensate tee is not exposed to freezing temperatures. See Section 7, Startup - Freeze Protection for more information.
Figure 2-3_Drain Tee Installation
20
Installation & Operation Manual
2
Venting
(continued)
Vertical Air Inlet: Vent options B & F
Vertical combustion air inlet
The air inlet cap for the vertical rooftop air inlet is assembled from components purchased locally. The air inlet cap consists of two
90° elbows installed at the point of termination for the air inlet pipe. The first 90° elbow is installed on the rooftop at the highest
vertical point of the air inlet pipe and turned horizontal, the second 90° elbow is installed on the horizontal outlet of the first elbow
and turned down.
A 90° elbow and a 90° street elbow may be used to make this assembly. If a straight piece of pipe is used between the two elbows,
it should not exceed 6 inches (152mm) in length. The termination elbow on the air inlet must be located a minimum of 12 inches
(0.30m) above the roof or above normal levels of snow accumulation.
Location of a vertical air inlet cap
Incorrect installation and/or location of the air inlet cap can allow the discharge of flue products to be drawn into the combustion
process on the heater. This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue
products. This will cause operational problems with the heater and possible spillage of flue products that can cause personal injury,
death, or property damage.
The point of termination for the combustion air inlet cap MUST be at least 3 feet (0.91m) below the point of flue gas termination
(vent cap) if it is located within a 10 foot (3.05m) radius of the flue outlet. Use care to ensure that the 90° elbow assembly is properly
installed on the air inlet pipe.
The combustion air inlet cap must not be installed closer than 10 feet (3.05m) from an inside corner of an L-shaped structure.
The termination point of the combustion air inlet cap must be installed at least one foot (0.30m) above the rooftop and above
normal snow levels.
The combustion air cap assembly used MUST adequately protect the combustion air inlet from wind and weather.
Combustion air supplied from outdoors must be free of contaminants (see Combustion and Ventilation Air, page 10). To prevent
recirculation of flue products into the combustion air inlet, follow all instructions in this section.
The combustion air inlet caps for multiple appliance installations must maintain the minimum 3 foot (0.91m) clearance below the
closest vertical flue outlet if within 10 feet (3.05m).
Figure 2-4_Vertical Air Inlet Clearances
21
Installation & Operation Manual
2
Venting
Horizontal Air Inlet: Vent options C, E, & F
Sidewall combustion air inlet
The sidewall termination caps for both the flue products and combustion air must be purchased from the appliance
manufacturer.
The part numbers for the required sidewall termination kit are listed under each designated table. Each kit includes both the
special combustion air inlet cap and the sidewall flue cap for installation on an exterior sidewall. The sidewall air inlet cap
supplied in the kit is sized to provide combustion air for a single appliance only.
Location of a sidewall air inlet cap
Incorrect installation and/or location of the air inlet cap can allow the discharge of flue products to be drawn into the
combustion process on the heater. This can result in incomplete combustion and potentially hazardous levels of carbon
monoxide in the flue products. This will cause operational problems with the heater and possible spillage of flue products that
can cause personal injury, death, or property damage.
The termination point of the sidewall air inlet must be installed a minimum of 12 inches (0.30m) above ground level and above
normal levels of snow accumulation.
The point of termination for the sidewall combustion air inlet cap MUST be located a minimum of 3 feet (0.91m) horizontally
and 12 inches (0.30m) below the point of flue gas termination (vent cap) if it is located within a 10 foot (3.05m) radius of the
flue outlet.
The combustion air inlet caps for multiple appliance installations must maintain the same minimum clearance from the closest
vent cap installed within a 10 foot radius of the point of flue gas termination as specified in single appliance installations.
The combustion air inlet cap must not be installed closer
than 10 feet (3.05m) from an inside corner of an L-shaped
structure.
The combustion air cap assembly used MUST adequately
protect the combustion air inlet from wind and weather.
Combustion air supplied from outdoors must be free of
contaminants (see Combustion and Ventilation Air, page
10). To prevent recirculation of flue products into the
combustion air inlet, follow all instructions in this section.
Figure 2-5_Horizontal Air Inlet Clearances
Multiple horizontal or vertical direct vent installations
The combustion air inlet caps for multiple appliance installations must maintain the same minimum clearance from the closest
vent cap installed within a 10 foot radius of the point of flue gas termination as specified in single appliance installations.
Multiple flue outlet caps may be installed side by side and multiple air inlet caps may be installed side by side, but the minimum
clearance of a 3 foot (0.91m) horizontal radius and 12 inches (0.30m) below the closest flue outlet to the air inlet cap must be
maintained. All clearance and installation requirements in this section and the applicable portions of the Category IV General
Venting section must be maintained on multiple appliance installations.
22
Installation & Operation Manual
2
Venting
(continued)
Length of air inlet pipe for both vertical and horizontal - Vent options:
All Categories
The maximum installed length of the air inlet pipe from the appliance to the air inlet cap is 50 equivalent feet (15.2m) in length.
Subtract 5 feet (1.52m) of equivalent length for each 90° elbow installed in the air inlet pipe. Subtract 2 1/2 feet (0.7m) of equivalent
length for each 45° elbow installed in the air inlet pipe.
Air inlet pipe materials:
The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list:
PVC, CPVC or ABS
Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet)
Galvanized steel vent pipe with joints and seams sealed as specified in this section.
Type “B” double-wall vent with joints and seams sealed as specified in this section.
*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic
air inlet pipe.
 WARNING Using vent or air intake materials other than those specified, failure to properly seal all seams and joints or
failure to follow vent pipe manufacturer’s instructions can result in personal injury, death or property damage.
Mixing of venting materials will void the warranty and certification of the appliance.
NOTICE
The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold
climates to prevent the condensation of airborne moisture in the incoming combustion air.
Sealing of Type “B” double-wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical
rooftop Combustion Air Supply System:
a.
a
Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or
high quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric.
b.
Do not install seams of vent pipe on the bottom of horizontal runs.
c.
Secure all joints with a minimum of three sheet metal screws or pop rivets. Apply Aluminum Foil Duct Tape or silicone sealant
to all screws or rivets installed in the vent pipe.
d.
Ensure that the air inlet pipes are properly supported.
The PVC, CPVC, or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer’s recommended solvents and
standard commercial pipe cement for the material used. The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe should use a
silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent or flex duct should
use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures
that combustion air will be free of contaminants and supplied in proper volume.
When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed
to ensure that combustion air will be free of contaminants and supplied in proper volume.
 DANGER
Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation,
spillage of flue products and carbon monoxide emissions causing severe personal injury or death.
Combined combustion air inlet points - Category II & IV
The air inlet pipes from multiple appliances can be combined to a single common connection if the common air inlet pipe has a
cross sectional area equal to or larger than the total area of all air inlet pipes connected to the common air inlet pipe. [Example:
two 8" (20.3cm) air inlet pipes (50.3 in2(324.5cm2) area each) have a total area of 100.6 in2 (645.2cm2) requires a 12 inch (30.5cm)
(113.1in2 area) (729.7cm2) common air inlet pipe.] The air inlet point for multiple water heater air inlets must be provided with
an exterior opening which has a free area equal to or greater than the total area of all air inlet pipes connected to the common air
inlet. This exterior opening for combustion air must connect directly to the outdoors. The total length of the combined air inlet
pipe must not exceed a maximum of 50 equivalent feet (15.2m). You must deduct the restriction in area provided by any screens,
grills, or louvers installed in the common air inlet point. These (screens, grills, or louvers) are common on the sidewall air inlet
openings and some rooftop terminations. Screens, grills, or louvers installed in the common air inlet can reduce the free area of
the opening from 25% to 75% based on the materials used.
23
Installation & Operation Manual
2
Venting
Vertical Vent Termination Clearances - Venting options: A, B, & C
Figure 2-6_Vent Termination from Peaked Roof - 10 ft.
or Less From Ridge
Figure 2-8_Vent Termination from Flat Roof - 10 ft.
or Less From Parapet Wall
Figure 2-7_Vent Termination from Peaked Roof - 10 ft.
or More From Ridge
Figure 2-9_Vent Termination from Flat Roof - 10 ft. or
More From Parapet Wall
The vent terminal should be vertical and exhaust outside the building at least 2 feet (0.61m) above the highest point of the roof
within a 10 foot (3.05m) radius of the termination.
The vertical termination must be a minimum of 3 feet (0.91m) above the point of exit.
A vertical termination less than 10 feet (3.05m) from a parapet wall must be a minimum of 2 feet (0.61m) higher than the parapet
wall.
The vent cap should have a minimum clearance of 4 feet (1.22m) horizontally from and in no case above or below, unless a 4 foot
(1.22m) horizontal distance is maintained from electric meters, gas meters, regulators, and relief equipment.
The venting system shall terminate at least 3 feet (0.9m) above any forced air inlet within 10 feet (3.05m).
The venting system shall terminate at least 4 feet (1.2m) below, 4 feet (1.2m) horizontally from, or 1 foot (30cm) above any door,
window, or gravity air inlet into any building.
Do not terminate the vent in a window well, stairwell, alcove, courtyard, or other recessed area. The vent cannot terminate below
grade. The bottom of the vent terminal shall be located at least 12 inches (30cm) above the roof or above normal snow levels.
To avoid a blocked flue condition, keep the vent cap clear of snow, ice, leaves, debris, etc.
24
Installation & Operation Manual
2
Venting
(continued)
Vertical Vent Termination Clearances - Venting options: A, B, & C
Flue gases from this appliance may contain large amounts of water vapor that will form a white plume in winter. Plume could
obstruct window view.
Flue gas condensate can freeze on exterior surfaces or on the vent cap. Frozen condensate on the vent cap can result in a blocked
flue condition. Flue gas condensate can cause discoloration of exterior building surfaces. Adjacent brick or masonry surfaces
should be protected with a rust resistant sheet metal plate.
The manufacturer shall NOT be held liable for any personal injury or property damage due to ice formation or dislodging of ice
from the vent system or vent termination.
Masonry chimney installations
A standard masonry chimney must NOT be used to vent the products of combustion from the flue of a Category IV, positive
pressure appliance. If a masonry chimney is to be used, the chimney MUST use a sealed, metallic, corrosion resistant liner system
to vent flue products from this high efficiency appliance. Sealed, metallic, corrosion resistant liner systems (single-wall, doublewall, flexible or rigid metallic lines) must be rated for use with a high efficiency, Category IV, positive pressure vent system.
Corrosion resistant chimney liner systems are typically made from a high grade of corrosion resistant stainless steel such as AL294C. The corrosion resistant liner must be properly sized and fully sealed throughout the entire length if the flue is contained within
the masonry chimney. Both the top and the bottom of the masonry chimney must be capped and sealed to provide a dead air
space around the sealed corrosion resistant metallic liner. Consult with local code officials to determine code requirements or the
advisability of using a masonry chimney with a sealed corrosion resistant liner system.
 CAUTION
Venting of a high efficiency Category IV appliance into a masonry chimney without a sealed stainless steel liner
can result in operational and safety problems. Any breaks, leaks, or damage to the masonry flue/tile will allow
spillage of the positive pressure flue products from the chimney. These flue products can easily escape into an
occupied living space causing a health hazard. If there is any doubt about the condition of a masonry chimney,
or its acceptability for use after insertion of a corrosion resistant liner system, consult with local code officials.
Location of a sidewall vent termination - Venting options: D, E, & F
The vent cap shall terminate at least 3 feet (0.91m) above any forced air inlet within 10 feet (3.05m).
The vent shall terminate at least 4 feet (1.22m) below, 4 feet (1.22m) horizontally from or 1 foot (0.30m) above and 2 feet (0.60m)
horizontally from any door, window, or gravity air inlet to the building.
The sidewall vent termination must be at least 8 feet (2.4m) horizontally from any combustion air intake located above the sidewall
termination cap.
Do not terminate the vent in a window well, stairwell, alcove, courtyard, or other recessed area. The vent cap cannot terminate
below grade.
The vent shall not terminate directly above a public walkway due to the normal formation of water vapor in the combustion
process. Horizontal terminations must not be located over areas of pedestrian or vehicular traffic.
The vent system shall terminate at least 1 foot (0.30m) above grade, above normal snow levels and at least 7 feet (2.13m) above
grade when located adjacent to public walkways.
The vent terminal shall not be installed closer than 3 feet (0.91m) from an inside corner of an L-shaped structure.
The vent cap should have a minimum clearance of 4 feet (1.22m) horizontally from and in no case above or below, unless a 4 foot
(1.22m) horizontal distance is maintained from electric meters, gas meters, regulators, and relief equipment.
Flue gas condensate can freeze on exterior walls or on the vent cap. Frozen condensate on the vent cap can result in a blocked
flue condition. Some discoloration to exterior building surfaces can be expected. Adjacent brick or masonry surfaces should be
protected with a rust resistant sheet metal plate.
The sidewall vent system MUST use the sidewall vent cap kit provided by the appliance manufacturer for installation on a sidewall
termination.
The sidewall vent cap MUST be purchased as a kit from the appliance manufacturer to ensure proper operation. Locally purchased
or fabricated sidewall vent caps should not be used.
25
Installation & Operation Manual
2
Venting
Figure 2-10A Direct Vent Terminal Clearances
Table 2I Direct Vent Terminal Clearances
Canadian Installations¹
US Installations²
A=
Clearance above grade, veranda, porch,
deck, or balcony
12 in (30 cm)
12 in (30 cm)
B=
Clearance to window or door that may
be opened
6 in (15 cm) for appliances < 10,000 Btuh
(3 kW), 12 in (30 cm) for appliances >
10,000 Btuh (3 kW) and < 100,000 Btuh
(30 kW), 36 in (91 cm) for appliances >
100,000 Btuh (30 kW)
6 in (15 cm) for appliances < 10,000 Btuh
(3 kW), 9 in (23 cm) for appliances >
10,000 Btuh (3 kW) and < 50,000 Btuh (15
kW), 12 in (30 cm) for appliances > 50,000
Btuh (15 kW)
C=
Clearance to permanently closed
window
*
*
*
*
D=
Vertical clearance to ventilated soffit
located above the terminal within a
horizontal distance of 2 ft (61 cm) from
the center line of the terminal.
E=
Clearance to unventilated soffit
*
*
F=
Clearance to outside corner
*
*
G=
Clearance to inside corner
*
*
Clearance to each side of center line
extended above meter / regulator
assembly
*
*
H=
I=
Above a regulator within 3 ft (91 cm)
horizontally of the vertical center line of the
regulator vent outlet to a maximum vertical
distance of 15 ft (4.5 m)
*
Clearance to service regulator vent
outlet
26
Installation & Operation Manual
2
Venting
(continued)
Table 2I Direct Vent Terminal Clearances (continued)
*
†
‡
J=
Clearance to nonmechanical air supply
inlet to building or the combustion air
inlet to any other appliance
6 in (15 cm) for appliances < 10,000 Btuh
(3kW), 12 in (30 cm) for appliances >
10,000 Btuh (3 kW) and < 100,000 Btuh
(30 kW), 36 in (91 cm) for appliances >
100,000 Btuh (30 kW)
6 in (15 cm) for appliances < 10,000 Btuh
(3kW), 9 in (23 cm) for appliances > 10,000
Btuh (3 kW) and < 50,000 Btuh (15 kW),
12 in (30 cm) for appliances > 50,000 Btuh
(15 kW)
K=
Clearance to a mechanical air supply
inlet
6 ft (1.83 m)
3 ft (91 cm) above if within 10 ft (3 m)
horizontally
L=
Clearance above paved sidewalk or
paved driveway located on public
property
7 ft (2.13 m)†
*
M=
Clearance under veranda, porch, deck,
or balcony
12 in (30 cm)‡
*
Clearance in accordance with local installation codes and the requirements of the gas supplier.
A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings
and serves both dwellings.
Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath he floor.
NOTES:
1)
In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code
2)
In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code
Figure 2-10B Other than Direct Vent Terminal Clearances
27
Installation & Operation Manual
2
Venting
Table 2J Other than Direct Vent Terminal Clearances
Canadian Installations¹
US Installations²
A=
Clearance above grade, veranda, porch,
deck, or balcony
12 in (30 cm)
12 in (30 cm)
B=
Clearance to window or door that may
be opened
6 in (15 cm) for appliances < 10,000 Btuh
(3 kW), 12 in (30 cm) for appliances >
10,000 Btuh (3 kW) and < 100,000 Btuh
(30 kW), 36 in (91 cm) for appliances >
100,000 Btuh (30 kW)
4 ft (1.2 m) below or to side of opening; 1 ft
(300 mm) above opening
C=
Clearance to permanently closed
window
*
*
*
*
D=
Vertical clearance to ventilated soffit
located above the terminal within a
horizontal distance of 2 ft (61 cm) from
the center line of the terminal.
E=
Clearance to unventilated soffit
*
*
F=
Clearance to outside corner
*
*
G=
Clearance to inside corner
*
*
Clearance to each side of center line
extended above meter / regulator
assembly
*
*
H=
I=
Above a regulator within 3 ft (91 cm)
horizontally of the vertical center line of the
regulator vent outlet to a maximum vertical
distance of 15 ft (4.5 m)
*
Clearance to service regulator vent
outlet
6 in (15 cm) for appliances < 10,000 Btuh
(3kW), 12 in (30 cm) for appliances >
10,000 Btuh (3 kW) and < 100,000 Btuh
(30 kW), 36 in (91 cm) for appliances >
100,000 Btuh (30 kW)
4 ft (1.2 m) below or to side of opening; 1 ft
(300 mm) above opening
J=
Clearance to nonmechanical air supply
inlet to building or the combustion air
inlet to any other appliance
K=
Clearance to a mechanical air supply
inlet
6 ft (1.83 m)
3 ft (91 cm) above if within 10 ft (3 m)
horizontally
Clearance above paved sidewalk or
paved driveway located on public
property
7 ft (2.13 m)†
7 ft (2.13 m)
L=
M=
Clearance under veranda, porch, deck,
or balcony
12 in (30 cm)‡
*
*
†
Clearance in accordance with local installation codes and the requirements of the gas supplier.
A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings
and serves both dwellings.
Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath he floor.
‡
NOTES:
1)
In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code
2)
In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code
28
Installation & Operation Manual
3
Gas connections
Gas supply
Gas connection
Verify that the appliance is supplied with the type of gas specified
on the rating plate. This appliance is configured for operation
up to 4000 feet altitude. Consult factory for installations above
4000 feet elevation.
Safe operation of the appliance requires properly sized gas
supply piping. See gas line sizing data:
1.
Gas pipe size may be larger than appliance connection.
Inlet gas pressure: Measured at the inlet pressure tap on the
appliance gas manifold. The pressure tap is located upstream of
the redundant gas valve and downstream of the field installed
gas cock.
2.
Installation of a union at the appliance gas line
connection is required for ease of service and removal of
the gas train.
3.
If an additional manual shutoff valve is required by local
codes, install the valve on the outside at the gas supply to the
appliance as shown in FIG. 3-1.
4.
A sediment trap (drip leg) MUST be provided in the inlet of
the gas connection to the appliance, see FIG. 3-1.
5.
Optional gas controls may require routing of bleeds and
vents to the atmosphere, outside the building when
required by local codes.
TABLE 3A
INLET GAS PRESSURE
NATURAL
LP
MODEL
Max.
w.c.
Min.
w.c.
Max.
w.c.
Min.
w.c.
500 -1000
14.0
4.0
13.0
11.0
1500 - 2000
14.0
4.0
14.0
8.0
Maximum inlet gas pressure must not exceed the value specified.
Minimum value listed is for the purposes of input adjustment.
Gas pressure test
1.
2.
The appliance must be disconnected from the gas
supply piping system during any pressure testing of that
system at a test pressure in excess of 1/2 PSIG (3.5 kPa).
The appliance must be isolated from the gas supply
piping system by closing a manual shutoff valve during
any pressure testing of the gas supply piping system at
test pressures equal to or less than 1/2 PSIG (3.5 kPa).
TABLE - 3B
FITTINGS TO EQUIVALENT STRAIGHT PIPE
Diameter Pipe
(inches)
1 1/2
2
3
4
5
Equivalent
length of
Straight Pipe
(feet)
4
5
10
14
20
NOTICE
3.
The appliance and its gas connection must be leak
tested before placing it in operation.
Checking manifold gas pressure
If an inline high gas pressure regulator is
used, it MUST BE of the lockup type and
be located a minimum of 10 feet from the
appliance. Failure to do so may result in
insufficient gas volume supplied to the
appliance.
Reference the VF Series Service Manual for information
regarding manifold gas pressure.
29
Installation & Operation Manual
3
Gas connections
TABLE - 3C
GAS PIPING SIZE CHART
Nominal
Iron Pipe
Size
Inches
Length of Pipe in Straight Feet
10
20
30
40
50
60
70
80
90
100
125
150
175
3/4
369
256
205
174
155
141
128
121
113
106
95
86
79
1
697
477
384
328
292
267
246
256
210
200
179
164
149
1 1/4
1,400
974
789
677
595
543
502
472
441
410
369
333
308
1 1/2
2,150
1,500
1,210
1,020
923
830
769
707
666
636
564
513
472
2
4,100
2,820
2,260
1,950
1,720
1,560 1,440 1,330
1,250
1,180
1,100
974
871
2 1/2
6,460
4,460
3,610
3,100
2,720
2,460 2,310 2,100
2,000
1,900
1,700 1,540 1,400
3
11,200
7,900
6,400
5,400
4,870
4,410 4,000 3,800
3,540
3,300
3,000 2,720 2,500
Maximum
Capacity of Pipe
in Thousands of
200
Btu/hr per hour
for gas pressures
74
of 14 Inches
138
Water Column
(0.5 PSIG) or less
287
and a pressure
drop of 0.5 Inch
441
Water Column
(Based on NAT
820
GAS, 1025 Btu/hr
1,300 per Cubic Foot
of Gas and 0.60
2,340 Specific Gravity)
4
23,500 16,100 13,100 11,100 10,000 9,000 8,300 7,690
7,380
6,870
6,150 5,640 5,130
4,720
Gas piping
Install piping to control
1.
The gas line should be a separate line direct from the meter
unless the existing gas line is of sufficient capacity. Verify
pipe size with your gas supplier.
2.
Use new, properly threaded black iron pipe free from chips.
If tubing is used, make sure the ends are square, deburred
and clean. All tubing bends must be smooth and without
deformation. Avoid flexible gas connections. Internal
diameter of flexible gas lines may not provide appliance
with proper volume of gas.
3.
Run pipe or tubing to the unit’s gas inlet. If tubing is used,
obtain a tube to pipe coupling in order to connect the
tubing to the unit’s gas inlet.
4.
Install a sediment trap in the supply line to the unit’s gas
inlet (see FIG. 3-1).
5.
Remove seal over gas inlet to the appliance.
6.
Apply a moderate amount of good quality pipe compound
(DO NOT use Teflon tape) to pipe only, leaving two end
threads bare.
7.
Connect gas pipe to inlet of appliance. Use a wrench to
support the gas manifold on the appliance.
8.
For LP gas, consult your LP gas supplier for expert
installation.
Figure 3-1_Gas Line Connection with Sediment Trap
(Drip Leg) and Manual Main Gas Shutoff Valve
All gas connections must be made with pipe joint compound
resistant to the action of liquefied petroleum and natural
gas. All piping must comply with local codes and ordinances.
Tubing installations must comply with approved standards and
practices.
30
Installation & Operation Manual
3
Gas connections
(continued)
Checking gas supply pressure
14. Turn on the gas supply at the manual valve, turn on LP gas
at the tank if required.
15. Turn the power switch to the “ON” position.
16. Adjust the temperature set point on the display of the control
module to the desired water temperature so the appliance
will call for heat.
17. Check burner performance by cycling the system while you
observe burner response. The burner should ignite
promptly. Flame pattern should be stable, see “Maintenance
- Normal Flame Pattern” in the VF Series Service Manual.
Turn system off and allow burner to cool, then cycle burner
again to ensure proper ignition and flame characteristics.
NOTICE
Figure 3-2_Gas Supply Pressure Measurement
1.
Turn the main power switch to the “OFF” position.
2.
Shut off the gas supply at the manual gas cock in the gas
piping to the appliance. If fuel supply is LP gas, shut off gas
supply at the tank.
3.
Remove the 1/8" hex plug from the gas pressure test port
located on the manual shutoff valve at the rear of the
appliance. Install a fitting in the inlet pressure tapping
suitable to connect to a manometer or magnahelic gauge.
Range of scale should be 14 inches water column or greater
to check inlet pressure.
4.
Turn on gas supply at the field installed manual gas cock,
turn on LP gas at tank if required.
5.
Turn the power switch to the “ON” position.
6.
Adjust the temperature set point on the display to call for
heat.
7.
Observe the gas supply pressure as the burner fires at 100%
of rated input. Percent of burner input will be shown on the
display of the control module.
8.
Ensure inlet pressure is within specified range. Minimum
and maximum gas supply pressures are specified in the Gas
Supply section of this manual.
9.
If gas pressure is out of range, contact the gas utility, gas
supplier, qualified installer or service agency to determine
necessary steps to provide proper gas pressure to the
control.
If a pressure drop of more than 2" w.c.
occurs between Standby (Static) Mode and
Operating (Dynamic) Mode, a gas volume
problem exists. Contact the gas utility, gas
supplier, qualified installer, or service agency
to determine the necessary steps to provide
the proper gas volume to the appliance.
High and low gas pressure switches
1.
Manual reset high and low gas pressure switches are
supplied to meet Factory Mutual, GE GAP, and CSD-1
requirements.
2.
In the Commonwealth of Massachusetts, gas appliances
over 1,000,000 BTU must be equipped with manual reset
high and low gas pressure switches when required to meet
the Massachusetts requirements.
NOTE: Massachusetts code requires a pressure regulator to be
installed upstream of the low gas pressure switch. A.O. Smith
requires any inline regulator used MUST BE of the lockup
type and be located a minimum of 10 feet from the appliance.
Failure to do so may result in insufficient gas volume supplied
to the appliance. Massachusetts also requires a shutoff valve
be installed ahead of the regulator for replacement or service.
When required, both regulator and shutoff valve are to be “field
provided”.
3.
Figures 3-3A and 3-3B on page 32 show piping connections
for high and low gas pressure switches for respective VF
Series models.
10. If gas supply pressure is within normal range, proceed to
remove gas manometer and replace pressure tap fittings in
the gas piping to the appliance.
11. Turn the power switch to the “OFF” position.
12. Shut off gas supply at the manual gas cock in the gas piping
to the appliance. If fuel supply is LP gas, shut off gas supply
at the tank.
13. Remove the manometer and related fittings from the gas
pressure test port at the inlet gas supply connection to the
appliance. Replace the 1/8" plug in the gas pressure test port
and tighten.
31
Installation & Operation Manual
3
Gas connections
High and low gas pressure switches
VF Series gas train
TYPICAL PRESSURE REGULATOR
STYLE MAY VARY FROM SHOWN
“FIELD PROVIDED”
(IF REQUIRED BY LOCAL CODES)
TYPICAL SHUTOFF
VALVE
“FIELD PROVIDED”
(IF REQUIRED BY LOCAL CODES)
(continued)
GAS
VALVE
GAS COCK
LOW
PRESSURE
SWITCH
BALL VALVE
W/PRESSURE TAP
The ratio gas valve on this appliance uses line (120 VAC)
voltage for operation. The valve contains the safety shutoff
and operating valves required on water heaters. The ratio
valve uses the negative pressure signal generated by the
venturi to modulate the amount of gas, so that the proper
mixture of air and gas is delivered to the burner throughout
the full range of burner operation. The ratio gas valve does not
require installation of a vent line - see the Venting of Gas Train
Components section below.
There are no serviceable parts on the combination gas valve.
*SEE REGULATOR
INSTALLATION
NOTE ON PAGE 33
ALUMINUM
TUBING
.25 X .03
ROUTING MAY VARY
HIGH
PRESSURE
SWITCH
MANUAL SHUTOFF VALVE
VENTURI
Figure 3-3A_VF 500 - 1000 High & Low Gas Pressure
Switches
TYPICAL PRESSURE REGULATOR
STYLE MAY VARY FROM SHOWN
“FIELD PROVIDED”
(IF REQUIRED BY LOCAL CODES)
RATIO VALVE
TYPICAL SHUTOFF
VALVE
“FIELD PROVIDED”
(IF REQUIRED BY LOCAL CODES)
GAS VALVE
BALL VALVE
W/PRESSURE TAP
BALL VALVE
LOW
PRESSURE
SWITCH
DOWNSTREAM
TEST VALVE
Figure 3-4_Gas Train Assembly VF 1500 - 2000
Venting of gas train components - and optional
gas train components
*SEE REGULATOR
INSTALLATION
NOTE ON PAGE 33
ALUMINUM
TUBING
.25 X .03
ROUTING MAY VARY
HIGH
PRESSURE
SWITCH
Figure 3-3B_VF 1500 - 2000 High & Low Gas Pressure
Switches
NOTICE
32
The gas train and controls assembly
provided on this unit have been tested under
the applicable American National Standard
to meet minimum safety and performance
criteria such as safe lighting, combustion,
and safety shutdown operation.
Local codes may require the routing component bleeds and
vents to the atmosphere outside the building. Components
(valves, pressure switches) having vents which would require
external vent lines are provided with threaded vent line
connections. These vent line connection points may be
accessed by removing the top jacket panels. Proper routing
of vent lines to the atmosphere from the factory supplied
termination points is the responsibility of the installing
contractor.
Installation & Operation Manual
4
Water connections
Inlet and outlet connections
Initial set-up of maximum water flow
For ease of service, install unions on the inlet and outlet
of the appliance. The connection to the appliance marked
“Water Inlet” on the header should be used for return from
the system. The connection on the header marked “Hot
Water Outlet” is to be connected to the supply side of the
system. Minimum water pipe connections to this appliance
are 2 1/2 inches (63.5mm) pipe. See the piping requirements
in the water heater section of this manual for multiple
appliance installations.
On initial start-up of the VF water heater, the maximum water
flow to the heat exchanger must be checked and manually
limited with a valve or bypass before normal operation begins.
Minimum water temperatures
A minimum return water temperature of 140°F (60°C) has
been established to control condensate formation based on
the Btu/hr output at rated burner input. Maintaining inlet
water temperatures to the appliance equal to or higher than
the specified minimum temperature ensures proper operation
of the appliance and prevents condensate formation on the
heat exchanger. An appliance allowed to sustain operation
at water temperatures lower than the specified minimum
temperature may not provide enough heat from the burner
to maintain water temperature in the heat exchanger above
the 140°F (60°C) dew point of flue products. Operation of the
appliance at a temperature below the specified minimum set
point will result in non-warrantable operational problems from
the condensate formation on the primary heat exchanger (see
the Low Temperature Bypass Requirements section on page 35
of this manual).
 CAUTION
Figure 4-1_Water Connections
An appliance allowed to operate at return
temperatures below the specified minimum
setting may experience problems with
the operating controls, safety switches,
obstruction of the flue gas passages on the
heat exchanger, incomplete combustion and
possible flue gas spillage. Sustained operation
at lower than specified water temperatures
may cause hazardous conditions that may
result in personal injury or non-warrantable
damage to the appliance.
Water flow switch
A water flow switch is factory installed in the outlet piping
on all water heaters. The flow switch must prove water flow
before a trial for ignition can begin. The flow switch requires
a minimum flow of 26 GPM to make the flow switch and
start burner operation. A water flow switch meets most code
requirements for a low water cutoff device on water heaters
requiring forced circulation for operation. A fault message,
Flow Sw/LWCO will be indicated in the Operator Interface on
a low water flow condition as sensed by the flow switch.
33
Installation & Operation Manual
4
Water connections
Low water cutoff
If this water heater is installed above radiation level, a low
water cutoff device must be installed at the time of installation.
An electronic low water cutoff is available as a factory supplied
option on all models. The low water cutoff should be inspected
every 6 months. A fault message, Flow Sw/LWCO will be
indicated in the Operator Interface on a low water condition
as sensed by the low water cutoff.
Relief valve
This unit is supplied with a safety relief valve(s) sized in
accordance with ASME Boiler and Pressure Vessel Code,
Section IV (“Rules of Construction of Heating Boilers”). The
relief valve(s) is installed in the vertical position and mounted
in the hot water outlet. No valve is to be placed between
the relief valve and the unit. To prevent water damage, the
discharge from the relief valve shall be piped to a suitable floor
drain for disposal when relief occurs. No reducing couplings
or other restrictions shall be installed in the discharge line. The
discharge line shall allow complete drainage of the valve and
line. Relief valves should be manually operated at least once a
year.
 CAUTION
Avoid contact with hot discharge water.
Water heater installations
Piping of the water heater system
The drawings in this section show typical water heater piping
installations, see FIG.’s 9-1 through 9-4. Before beginning
the installation, consult local codes for specific plumbing
requirements. The installation should provide unions and
valves at the inlet and outlet of the appliance so it can be
isolated for service. An air separation device must be supplied
in the installation piping to eliminate trapped air in the
system. Locate a system air vent at the highest point in the
system. The system must also have a properly sized expansion
tank installed. Typically, an air charged diaphragm-type
expansion tank is used. The expansion tank must be installed
close to the appliance and on the suction side of the system
pump to ensure proper operation.
NOTICE
34
*Please note that these illustrations are
meant to show system piping concept only,
the installer is responsible for all equipment
and detailing required by local codes.
 CAUTION
The water heater system should not be
operated at less than 12 PSIG.
Hot water piping must be supported by suitable hangers or floor
stands, NOT by the water heater. Copper pipe systems will be
subject to considerable expansion and contraction. Rigid pipe
hangers could allow the pipe to slide in the hanger resulting in
noise transmitted into the system. Padding is recommended
on rigid hangers installed with a copper system. The pressure
relief valve must be piped to a suitable floor drain. See the Relief
Valve section on this page.
Water connections
All water heaters have 2 1/2 inch copper pipe inlet and outlet
connections. Installed piping to and from the appliance must
be a minimum of 2 1/2 inch diameter.
 CAUTION
Field installed reducing bushings must not
be used.
Any reduction in pipe size may decrease flow resulting in high
water temperatures, water heater noise, flashing to steam, and
non-warrantable heat exchanger damage.
It is important to guarantee that adequate flow is provided
to properly dissipate heat from the water heater and also
ensure that flow through the water heater does not exceed the
maximum recommended flow rate of 75 GPM for Models 500
- 1000 and 90 GPM for Models 1500 - 2000 for a water heater
equipped with a copper heat exchanger.
Water heater circulator requirements
This is a low mass, high efficiency hot water heater which
must have adequate flow for quiet, efficient operation. Pump
selection is critical to achieve proper operation. A pump should
be selected to achieve proper system design water temperature
rise. Pipe diameter and length are critical to ensure proper
flow through the water heater. A Temperature Rise Chart
(Table 4D on page 36) is provided to assist in proper pump
selection. This table provides GPM and water heater head-loss
at various temperature rises for each model based on Btu/hr
input. Temperature rise is the difference in water heater inlet
temperature and water heater outlet temperature while the
water heater is firing at full rate.
Example: The water heater inlet temperature is 160°F (71.1°C)
and the water heater outlet temperature is 180°F (82.2°C). This
means that there is a 20°F (11.1°C) temperature rise across the
water heater. The water heater temperature rise is visible in the
Operator Interface on the water heater’s front control panel.
Installation & Operation Manual
4
Water connections
(continued)
Circulator pump specifications
1.
Maximum operating pressure for the pump must exceed
system operating pressure.
2.
Maximum water temperature should not exceed the
nameplate rating.
3.
A properly sized expansion tank must be installed (reference
Section 9 - Domestic Water Heaters).
Intermittent pump operation
An intermittent pump operation feature is provided. The water
heater’s circulating pump will cycle on at each call for heat,
before the burner fires. The pump will continue to operate
while the burner is firing. The pump will run for a minimum
30 second period after the temperature set point is satisfied.
This timing is selectable from the Operator Interface. This
timing will remove any of the residual heat from the combustion
chamber before turning the pump off. See the wiring diagram
in Section 11 of this manual.
Pump Maintenance: Inspect the pump every six (6) months
and oil as necessary. Use SAE 30 non-detergent oil or lubricant
specified by the pump manufacturer.
 CAUTION
At no time should the system pressure be
less than 12 PSIG.
Low system water volume
System run time is very important to the overall operating
efficiency of the water heater. Short cycling of the water
heater creates problems with condensation in the vent stack,
condensation on the heat exchanger, system temperature spikes,
and mechanical component failures. To prevent short cycling of
the water heater, it is important to limit the water heater cycles
to six or fewer per hour.
Low temperature bypass requirements
To prevent condensation problems, a water heater MUST NOT
be operated (other than for brief periods during initial system
startup) with an inlet water temperature of less than 140°F
(60°C). If normal system return temperatures are less than
the required 140°F (60°C) water heater inlet requirement, a
method of low return water temperature protection MUST BE
provided to protect the water heater.
 CAUTION
A water heater allowed to operate at set
point temperatures below the specified
minimum settings may experience
operational problems with the operating
controls and safety switches, obstruction of
the flue gas passages on the heat exchanger,
incomplete combustion and possible flue gas
spillage. Operation at lower than specified
water temperatures may cause hazardous
conditions that result in non-warrantable
damage to the appliance.
TABLE - 4A
MAXIMUM FLOW FOR HEATING WATER HEATER
The maximum flow rate through the water heater with a
copper heat exchanger must not exceed the following:
Model
Maximum Flow
500 - 1000
75 GPM
1500 - 2000
90 GPM
If higher flow rates are required through the water heater, an
optional Cupro-Nickel heat exchanger is available. Consult the
factory for specific application requirements.
Minimum water heater inlet temperatures
Inlet water temperatures below the specified minimum of
140°F (60°C) can excessively cool the products of combustion
resulting in condensation on the heat exchanger. Condensation
on the heat exchanger can cause operational problems, bad
combustion, sooting, flue gas spillage and reduced service life
of the related components. See the Low Temperature Bypass
Requirements section for water heater system applications
below the minimum specified temperature.
35
Installation & Operation Manual
4
Water connections
TABLE - 4B
TABLE - 4C
Pressure Drop Chart
Models 500-1000
Pressure Drop Chart
Models 1500-2000
25
Press Drop in Feet Head
Press Drop in Feet Head
20
15
10
5
20
15
10
5
0
0
50
60
70
80
90
70
100
90
100
110
120
Flow in Gallons Per Minute
Flow in Gallons Per Minute
Typical water heating installations
TABLE - 4D
ACCEPTABLE TEMPERATURE RISE
Model
Min ∆ °F
Max ∆ °F
500
750
1000
1500
2000
11
17
23
28
38
18
25
30
35
41
Water heater requirements
The installer must ensure that the water heater is supplied
with adequate flow without excessive temperature rise. Flow
rates exceeding the maximum recommended flow will result in
erosion of the water heater tubes.
36
80
General plumbing rules:
1.
Check all local codes.
2.
For serviceability of water heater, always install unions.
3.
Always pipe pressure relief valve to an open drain.
4.
Locate system air vents at highest point of system.
5.
Expansion tank must be installed near the water heater and
on the suction side of the system pump.
6.
Support all water piping.
Installation & Operation Manual
5
Electrical connections
Water heater operating control module
The operating temperature control for the appliance is the
control module. It is located on the inside of the control panel,
behind the front access door. Access to adjust the temperature
set point and other user adjustable points is made through the
Operator Interface located on the right front access door. The
outlet sensor is placed in a bulbwell installed in the outlet side
of the heat exchanger top header. The inlet sensor is located in
a bulbwell on the inlet side of the heat exchanger top header.
The operating sensor, inlet or outlet, is selectable from the
screen in the Operator Interface.
TABLE - 5A
AMP DRAW DATA
Blower &
Approximate Total
Pump FLA*
Controls
Amps @ 120 VAC
500
6.7
8.8
15.5
750
6.7
8.8
15.5
1000
6.7
8.8
15.5
1500
6.5
8.8
15.3
2000
6.5
8.8
15.3
*Standard Pump Supplied with Water Heaters Only
Model
NOTICE
Wiring must be N.E.C. Class 1.
The exact temperature set point is based on your system’s
requirements. Set the control set point(s) to the desired
operating water temperature.
If original wiring as supplied with the
appliance must be replaced, use only type
105°C wire or equivalent.
The maximum temperature set point for a water heater is 190°F
(88°C). The auto reset high limit is fixed at 200°F (93°C), and
the adjustable manual reset high limit has a maximum setting
of 210°F (98.9°C).
Appliance must be electrically grounded as
required by National Electrical Code ANSI/
NFPA 70 – latest edition.
A 120 VAC, 15 Amp, 1 ph, 60 Hz circuit is required for
operation of the appliance controls.
The appliance, when installed, must be electrically grounded
in accordance with the requirements of the authority having
jurisdiction or in the absence of such requirements, with the
latest edition of the National Electrical Code ANSI/NFPA No.
70. When the unit is installed in Canada, it must conform to
the CAE C22.1, Canadian Electrical Code, Part I and/or local
Electrical Codes. Multiple units connected in a Cascade must
be grounded to the same ground connection.
1.
All wiring between the appliance and field installed devices
shall be made with type T wire [63°F (35°C) rise].
2.
All line voltage wire exterior to the appliance must be
enclosed in approved conduit or approved metal clad
cable.
3.
The circulating pump must run continuously when the
appliance is being fired.
4.
To avoid serious damage, DO NOT energize the appliance
until the system is full of water. Ensure that all air is
removed from the heat exchanger and piping before
beginning initial operation. Serious damage may result if
the appliance is operated without proper flow.
5.
 CAUTION
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.
Installation must comply with:
1. National Electrical Code and any other national, state,
provincial, local codes, or regulations.
2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and
any local codes.
Line voltage connections
1. Connect 120 VAC power wiring to the line voltage terminal
strip in the junction box, as shown in FIG. 5-1.
2. Provide and install a fused disconnect or service switch
(15 AMP recommended) as required by the code (see
FIG. 5-1).
3. To activate a system pump, wire as shown in FIG. 5-1. If the
motor is larger than 1 HP, you must install a contactor.
4. When connecting power to units which are to be cascaded,
each unit must be connected to the same ground connection.
Provide the appliance with proper overload protection.
 WARNING
ELECTRICAL SHOCK HAZARD – For your
safety, turn off electrical power supply before
making any electrical connections to avoid
possible electric shock hazard. Failure to do
so can cause severe personal injury or death.
37
Installation & Operation Manual
5
Electrical connections
LOUVER
SUPPLY
G
N
CONTROL
SUPPLY
N
L
UNIT PUMP
SUPPLY
L
G
D
I
S
C
O
N
N
E
C
T
N
EMS or remote thermostat connection
120VAC UNIT
SUPPLY
L
N
L
D
I
S
C
O
N
N
E
C
T
G
An EMS, remote thermostat or other remote
temperature control may be connected to the water
heater (see FIG. 5-3). Follow the manufacturer’s
instructions supplied with the remote temperature
control for proper installation and adjustment.
Connection of a set of dry switching contacts or
a remote on/off thermostat to the low voltage
connection board will allow the unit to be switched
on and off by making or breaking a 24 VAC control
circuit.
D
I
S
C
O
N
N
E
C
T
UNIT
PUMP
LOUVERS
A
L
A
R
M
Ensure that all wiring used to connect the switching
contacts of the remote temperature controller to the
connection board are a minimum of 18 gauge and
have a maximum installed length of 300 feet (91.4m).
Set the control to a set point temperature slightly
higher than the setting of the remote temperature
control. This will ensure that the remote temperature
controller functions as the operating control for the
heater.
R
U
N
N
/
A
N
/
A
N
/
A
N
/
A
TO UNIT
OUT
IN OUT
3/4HP
MAX
LOUVER
CONTACTS
IN OUT
2A
MAX
ALARM
CONTACTS
IN OUT
2A
MAX
RUN-TIME
CONTACTS
IN
1HP
MAX
PUMP
CONTACTS
N
L
GND
120V/IPH
50/60HZ
POWER
IMG00624
Figure 5-1_Line Voltage Field Wiring Connections
Low voltage connections
1. Route all low voltage wires through the knockouts in the
rear of the heater, as shown in FIG. 5-2.
2. Connect low voltage wiring to the low voltage connection
board as shown in FIG. 5-4 on page 40 of this manual and
the heater wiring diagram.
Figure 5-3_Remote ON/OFF Wire Connection
Figure 5-2_Routing Field Wiring
38
Installation & Operation Manual
5
Electrical connections
(continued)
Louver proving switch
1. When the operation of a louver proving switch needs
to be verified before the water heater fires, remove the
jumper wire from these terminals and connect them to the
normally open contacts on its proving switch (FIG. 5-4).
Water heater Management System (BMS)
1. An external control may be connected to control either the
firing rate or the set point of the appliance. Connect the 0 10 VDC terminals to the 0 - 10 VDC output of the external
control. The control can be programmed to use the enable
output of the Boiler Management System, or use the voltage
signal to enable the heater. Connect the enable terminals to
the enable output of the BMS, when used.
2. Make sure the ground terminal is connected to the ground
output terminal of the external control, and the 0 - 10 VDC
terminal is connected to the 0 - 10 VDC terminal of the
external control.
Runtime contacts
The control closes a set of dry contacts whenever the burner
is running. This is typically used by Building Management
Systems to verify that the water heater is responding to a call
for heat.
Alarm contacts
The control closes another set of contacts whenever the heater is
locked out or the power is turned off. This can be used to turn
on an alarm, or signal a Building Management System that the
water heater is down.
39
40
IMG00625
0-10V INPUT
28
27
26
25
24
23
22 SENSOR
21 TANK
20 (-)
19 (+)
18
17
16
15
14
13
12
11
10 PROVING
9
8
7
6
LOUVER
THERMOSTAT
4
5
TANK
3
2
0-10 V
COM
TANK SENSOR
EXTERNAL
SEQUENCER /
BUILDING
AUTOMATION
CONTROL
LOUVER
PROVING
SWITCH
DHW TANK
THERMOSTAT
5
1
Installation & Operation Manual
Electrical connections
Figure 5-4_Low Voltage Field Wiring Connections
Installation & Operation Manual
6
Condensate disposal
Condensate trap installation
1.
Locate the condensate trap kit shipped loose with the
appliance. The kit includes a sheet metal mounting
base, two (2) nuts and the condensate trap.
2.
Install the condensate trap mounting base on the rear
of the appliance in the lower left-hand corner as
depicted in FIG. 6-1. Use the pre-drilled holes on the
appliance to secure the mounting base to the appliance.
3.
Secure the condensate trap to the base using the two (2)
nuts supplied with the kit. The trap should be oriented
so that the barb connections are pointing toward the
appliance (FIG. 6-1).
4.
Use a level to ensure that the condensate trap is level on
its base. Failure to keep the condensate trap level can
result in the spillage of flue products from the
condensate trap.
5.
Locate the two hoses exiting the back of the appliance.
Attach the larger hose on the appliance to the lower
barb connection on the condensate trap. Secure the
hose to the barb with a field supplied hose clamp
(FIG. 6-1).
6.
7.
Figure 6-1_Install Condensate Trap
 WARNING
Attach the smaller hose on the unit to the upper barb
connection on the condensate trap. Secure the hose to
the barb connection with a field supplied hose clamp
(FIG. 6-1).
Route the 3-pin wiring harness from the condensate
trap to the matching connector on the lower back of
the appliance as shown in FIG. 6-1. This is the blocked
drain safety switch. This switch will shut the appliance
off if the condensate trap becomes too full of liquid.
Use a level to ensure that the condensate
trap is level on its base. Failure to keep
the condensate trap level can result in the
spillage of flue products from the condensate
trap.
Failure to follow this warning could result
in product damage or improper operation,
personal injury, or death.
8.
Remove the four (4) screws securing the top cover to
the condensate trap and remove the cover (FIG. 6-1).
Use materials approved by the authority
having jurisdiction. In the absence of other
authority, PVC and CPVC pipe must comply
with ASTM D1785 or D2845. Cement and
primer must comply with ASME D2564 or
F493. For Canada use CSA or ULC certified
PVC or CPVC pipe, fittings, and cement.
9.
Locate the plastic ball inside the float tube. Verify there
is nothing under the ball causing it to not seat properly
(FIG. 6-1).
14. Slope the condensate line down and away from the appliance
into a drain or condensate neutralizing filter. Do not expose
the condensate line to freezing temperatures.
10. Fill with fresh water until the water begins to pour out
of the drain.
11. Replace the cover.
12. Replace the four (4) screws removed in Step 8.
NOTICE
NOTICE
The condensate line must remain
unobstructed, allowing free flow of
condensate. If condensate is allowed to
freeze in the line or if the line is obstructed in
any other manner, the blocked drain safety
switch will prevent the appliance from firing.
13. A 1/2" pipe connection is supplied on the condensate
trap. Connect a suitable pipe or tube to this connection
(see FIG. 6-1).
41
Installation & Operation Manual
7
Start-up
Check/control water chemistry
 CAUTION
Do not use petroleum-based cleaning or
sealing compounds in the water heater
system. Damage to elastomer seals and
gaskets in the system could occur, resulting
in substantial property damage.
Inspect/fill condensate system
Inspect/check condensate lines and fittings
1. Inspect the condensate drain line, condensate PVC fittings
and condensate trap.
Fill condensate trap with water
Filling hot water heater
1. Remove the four (4) screws securing the top cover to the
condensate trap and remove the cover (FIG. 7-1).
1. Close the system’s drain valve by turning the handle
clockwise.
2. Locate the plastic ball inside the float tube. Verify there is
nothing under the ball causing it to not seat properly.
2. Open a nearby hot water faucet to permit the air to escape.
3. Fill with fresh water until the water begins to pour out of the
drain.
3. Fully open the cold water inlet pipe valve allowing the
water heater and piping to be filled.
4. Close the hot water faucet as water starts to flow.
4. Replace the cover.
5. Replace the four (4) screws removed in Step 1.
5. The water heater is ready for operation.
 WARNING Eliminate all system leaks. Continual fresh
makeup water will reduce water heater life.
Minerals can build up in the heat exchanger,
reducing heat transfer, overheating the heat
exchanger, and causing heat exchanger
failure.
Check for gas leaks
 WARNING
Before starting the water heater, and during
initial operation, smell near the floor and
around the water heater for gas odorant or
any unusual odor. Remove the front access
panel and smell the interior of the water
heater enclosure. Do not proceed with
startup if there is any indication of a gas leak.
Use an approved leak detection solution.
Repair any leaks at once.
Propane water heaters only – Your propane
 WARNING
supplier mixes an odorant with the propane
to make its presence detectable. In some
instances, the odorant can fade, and the gas
may no longer have an odor. Before startup
(and periodically thereafter), have the
propane supplier verify the correct odorant
level in the gas.
Figure 7-1_Condensate Trap
 WARNING
Check vent and air piping
1.
42
The condensate trap (FIG. 7-1) must be
filled with water during all times of water
heater operation to avoid flue gas emission
from the condensate drain line. Failure to
fill the trap could result in severe personal
injury or death.
Inspect vent piping and air piping for signs of
deterioration from corrosion, physical damage or
sagging. Verify air piping and vent piping are intact
and correctly installed per this manual.
Installation & Operation Manual
7
Start-up
(continued)
Placing the water heater in operation
Water heater operational checks
2.
Turn the water heater main power switch to the “ON”
position.
3.
Verify operation of the control module and Operator
Interface.
4.
Program the adjustable points from the Operator
Interface.
5.
Push the reset for the low water cutoff (if equipped).
6.
Ensure that maximum flow to the water heater does not
exceed 75 GPM on Models 500 - 1000 and 90 GPM on Models
1500- 2000. Verify by checking temperature rise while
burner is firing at 100% of rated input.
7.
Install a manometer on the gas supply to the water heater
and verify minimum gas supply pressure as the burner fires at
100% of rated input.
8.
Verify operation of safeties as necessary (low water
cutoff, high limit, gas pressure, etc.,).
9.
Verify that all adjustable points in the Operator
Interface are set as required.
 WARNING The venting system must be installed so that
it will prevent flue gas spillage and carbon
monoxide emissions, which will result in
severe personal injury or death.
Set clock
The control has a built-in clock that it uses for its night setback
feature and for logging events. This clock must be set when
the appliance is installed, and anytime the appliance has been
powered off for more than one month. Use the following
procedure to set the clock:
1.
Press and hold the SETUP/RETURN button (FIG. 8-1) for
at least 5 seconds.
2.
The display changes to ready “ENTER MENU CODE”,
with four (4) zeros below it.
3.
Change the zeros to match the user code (factory set at
“0704”). Use the (+) and (-) buttons to increment or
decrement the flashing digit, and the FORWARD and
BACK buttons to select which digit flashes.
4.
Press the SAVE/CLEAR button.
5.
The display changes to read USER CODE for a few
seconds, then displays a menu.
6.
Press the SAVE/CLEAR button.
7.
Press the (+) button twice to display “A3 DATE AND
TIME”.
8.
Press the SAVE/CLEAR button once.
9.
The date and time are displayed as “YY:MM:DD W
hh:mm”, where:
Water heater operation
10. Water heater should begin the start-up process for the
sequence of operation.
11. The water heater will ignite at the proper ignition speed and
will then modulate to meet the system demand.
12. Ensure that inlet water temperature does not fall below
the specified minimum for the water heater.
13. Based on system demand, water heaters may run for an
extended period of time at a reduced rate of input to
maximize efficiency.
14. As system demand is satisfied, the burner will cycle off
and the combustion air blower will run for a post
purge operation before the water heater shuts down.
Start the water heater
1. Read and follow the Operating instructions in FIG. 7-2, on
page 44.
If water heater does not start correctly
1. Check for loose connections, blown fuse or service switch
off?
mm:
hh:
W:
minutes
hour (24 hour time; e.g., 2:00 PM = 14:00)
day of the week (1 = Sunday, 2 = Monday,
3 = Tuesday, etc.,)
YY: year
MM: month
DD: date
NOTICE
The internal clock does not adjust for
Daylight Savings Time and therefore, will
require a manual adjustment.
Use the (+) and (-) buttons to increment or decrement the
flashing number, and the FORWARD and BACK buttons to
select which number flashes.
2. Is external limit control (if used) open? Is water temperature
above 200°F (93.3°C)?
10. Press the SAVE/CLEAR button to save the setting.
3. Is thermostat set below tank temperature?
11. Press the SETUP/RETURN button twice to exit the
Programming Mode.
4. Is gas turned on at meter or water heater?
5. Is incoming gas pressure less than 4 inches water column?
If none of the above corrects the problem, refer to the
Troubleshooting section of the VF Series Service Manual.
43
Installation & Operation Manual
7
Start-up
Figure 7-2_Operating Instructions
44
Installation & Operation Manual
8
Operating information
General
0 - 10V input (set point or power)
How the appliance operates
The VF Series uses a copper finned tube heat exchanger to
transfer heat from the flue products to the water. An electronic
control module monitors various inputs to initiate a call for
heat. The blower provides both primary and secondary air to
the burner and forces the flue products out of the combustion
chamber and into the vent system. The control module
regulates the blower speed to control the firing rate of the unit.
The modulating gas valve monitors the amount of combustion
air being pulled into the blower and regulates the amount of
gas supplied, which then mixes with the combustion air and is
supplied to the burner.
NOTICE
NOTICE
If an inline high gas pressure regulator is
used, it MUST BE of the lockup type and
be located a minimum of 10 feet from the
appliance. Failure to do so may result
in insufficient gas volume supplied to the
appliance.
If a pressure drop of more than 2” water
column occurs between Standby (static)
Mode and Operating (dynamic) Mode, a
gas volume problem exists. Contact the gas
utility, gas supplier, qualified installer, or
service agency to determine the necessary
steps to provide the proper gas volume to
the appliance.
How the control module operates
The control module receives input from appliance sensors and
external devices. The control module activates and controls the
blower and gas valve to regulate heat input and switches the
system pumps on and off as needed. The user programs the
module to meet system needs by adjusting control parameters.
These parameters set operating temperatures and appliance
operating modes. Water heater operation can be based on a
tank sensor or a tank thermostat.
Control inputs and outputs
Tank thermostat (field provided)
This input tells the water heater to provide water for heating
a domestic hot water tank (see FIG. 5-4 on page 40 of this
manual).
The VF Series can be controlled by a Building Management
System (BMS) using a 0 - 10 VDC signal. The control can be
configured by the installer to use this signal to either control set
point or firing rate.
Temperature control
Modulation
The VF Series is capable of modulating its firing rate from
a minimum of 25% to a maximum of 100%. The firing rate
is dictated by the call for heat (i.e., domestic hot water), the
heating load, ramp delay (if enabled), and various other
temperature limitations.
Gradient limiting
If during operation of the heater the outlet water temperature
is rising too quickly, the control will reduce the firing rate to its
lowest setting.
Night setback
The controller may be programmed to reduce the tank (water
heaters) set points during a certain time each day. A start and
stop time can be programmed for each day of the week.
Flame current support
To prevent nuisance shutdowns when the water heater is firing
at minimum rates, the control will increase fan speed when the
flame signal drops too low.
Protection features
Outlet temperature, flue temperature, and temperature
rise limiting
The outlet temperature is monitored by the water heater outlet
temperature sensor. When the outlet temperature exceeds
185°F (85°C), the unit will reduce the fan speed. If the outlet
water temperature exceeds 195° (90.6°C) the control will shut
the unit down until it cools off.
The control module monitors the flue temperature by a sensor
located in the flue exhaust. If the flue temperature exceeds
400°F (204°C) the control will reduce the maximum fan speed.
If the flue temperature exceeds 450°F (232°C) the control will
shut the unit down. The unit will restart automatically once the
flue temperature drops 100°F (56°C) and the minimum off time
has expired.
The control monitors the temperature difference between
the inlet and the outlet sensor. If this difference exceeds 55°F
(31°C) the control will reduce the fan speed. If the temperature
difference exceeds 65°F (36°C) the control will shut the unit
down. The unit will restart automatically once the temperature
difference has dropped 10°F (6°C) and the minimum off time
has expired.
45
Installation & Operation Manual
8
Operating information
Freeze protection
Run-time and alarm outputs
DO NOT install the appliance in a room likely to freeze.
The appliance provides dry contacts for indicating when the
appliance is running, and when it is unable to operate.
The following integral feature of the control module provides
some protection for the appliance only -- not for the system.
• The control module provides freeze-up protection as
follows when the appliance water temperature drops
below 45°F (7.2°C):
• Below 45°F (7.2°C), the appliance and system pumps
operate constantly.
• Below 37°F (2.7°C), the appliance turns on.
• Appliance and pumps turn off if appliance water
temperature rises above 45°F (7.2°C).
 CAUTION
This feature of the control module does not
eliminate the possibility of freezing. The
installer must still use recognized design,
installation and maintenance practice to
prevent freeze potential for the appliance
and system.
High limit operations
When outlet temperature exceeds 200°F (93°C), high limit
action occurs. The appliance shuts down until the outlet water
cools down and the RESET button on the Operator Interface is
pressed.
Low water cutoff protection
1.
2.
Run-time and cycle counting
The control uses two timers to monitor the total hours of
burner operation. One timer monitors the time the appliance is
firing under 50% of rate. The other timer monitors the time the
appliance is firing over 50% rate.
The control uses four (4) ignition counters to monitor the
amount of appliance cycles. The first counter counts all
ignitions of the control. The second counter counts only
ignition attempts that have failed. The third and fourth counters
are the same as the first and second respectively, but can be reset
by the installer.
Service reminder
The control can be programmed for service reminder
notification. This notification will become active when either a
set time frame has expired, or a set amount of running hours or
cycles has expired (all adjustable by the installer). The display
will alternate the standard text on the display screen with
Service Due every 5 seconds. The service reminder notification
can be reset by the installer.
Error logging
The control module uses temperature sensing of both inlet The control will hold in memory the last 10 error codes as
and outlet areas of the heat exchanger. If the flow rate is too well as the last 10 turn-off functions. The date and time of the
low or the outlet temperature too high, the control module occurrence will be recorded as well. Only the 10 most current
modulates and shuts the appliance down. This along with occurrences will be held in memory.
the flow switch, ensures appliance shutdown in the event of Water heater temperature regulation
low water or low flow conditions.
Operating temperature (target)
Some codes and jurisdiction may accept these integral
The control module senses water temperature and regulates
features of the control in lieu of requiring an additional
appliance firing and firing rate to achieve a target temperature.
limit control or low water cutoff. Consult local jurisdiction
The target temperature can be set between 60°F (16°C) and
to determine. Contact manufacturer for low water cutoff kit
190°F (88°C).
availability.
Monitor external limits
Connections are provided on the connection board for external
limits such as a louver proving switch. The will shut off the
burner and inhibit relighting whenever any of these external
limits open.
46
Installation & Operation Manual
8
Operating information
(continued)
Sequence of operation
OPERATION
DISPLAY
1. The manual reset high limit must be closed before any action will take HTR: Standby
place.
OUT: 123.8F(129)
2. Upon a call for heat the control turns on the appropriate pumps. The flow
switch and low water cutoff (if equipped) must close.
HTR: Standby
OUT: 123.8F(129)
3. • If the unit is equipped with a proof of closure valve, the proof of closure
switch must be closed. The proof of closure valve is then energized.
The gas pressure switch(es) (if equipped) must close.
• If the contact for the louvers is closed, the louver proving, blocked drain
switch, and auto reset high limit (water heater only) inputs must close.
• If the air pressure switch is open, the prepurge cycle then begins by
starting the combustion blower. Once started, the air pressure switch
must close.
HTR: Standby
OUT: 123.8F(129)
4. After prepurge, the blower slows down and the hot surface igniter (HSI) is
energized.
HTR: PREPURGE
OUT: 123.9F(129)
5. Once the HSI is hot, the trial for ignition begins with the opening of the gas
valve.
HTR: IGNITION
OUT: 123.9F(129)
6. If the control does not sense flame, it will lock out.
HTR: POSTPURGE, LOCKOUT
OUT: 123.9F(129)
7. If the control senses flame at the end of the trial for
ignition period, it will fire the burner to maintain the set point. The firing
rate will modulate as required to hold the actual temperature at the set
point.
HTR: SH 20% RATE
OUT: 124.8F(129)
8. Once both calls for heat are satisfied, the control will turn off the burner.
The blower will remain on for the postpurge cycle. The pump will continue
to run for its respective pump delay times and then turn off.
HTR: POSTPURGE
OUT: 127.4F(129)
9. System pump continues its delay if longer.
10. Pump off.
HTR:
OUT:
HTR:
OUT:
Standby
124.7F(129)
Standby
122.9F(129)
47
Installation & Operation Manual
8
Operating information
VF Series control module
Use the control panel (FIG. 8-1) to set temperatures, operating conditions, and monitor appliance operation.
Access modes
Figure 8-1_Control Panel - Operator Interface
User
SAVE/CLEAR
RUN/STOP
SETUP/RETURN
The user can adjust the space heating target
temperature and the tank target temperature
(if a tank sensor is used) by using the (+) and (-)
buttons (FIG. 8-1) at any time during normal
operation. By entering the USER code (0704),
the user can also change temperature units,
time and date, and night setback settings. In
User Mode, the following parameters can be
viewed but not changed:
•
•
•
•
Appliance model number
Software version
Total operating hours
Total cycles
Installer
Most parameters are available only to the
installer, accessible only by entering the
installer access code, see the VF Series Service
Manual.
Saving parameters (reference the
Parameter Table in the VF Series Service
Manual)
To save parameters and exit programming:
Press the SAVE/CLEAR button, then the
SETUP/RETURN button 3 times.
To keep parameter settings only for a current
operating cycle:
Press the SETUP/RETURN button 3 times
after making all desired parameter changes.
To enter a parameter and continue
programming:
+
BACK
FORWARD
Press the SETUP/RETURN button 1 time to
return to the parameter listings; press again
to return to the menu listings. Remember to
press the SAVE/CLEAR button when finished
programming in order to save the changes
made.
See the VF Series Service Manual for a detailed
description of parameters and access modes.
48
Installation & Operation Manual
8
Operating information
(continued)
Status display screens
Status Display Screens
By using the Back/Forward (, ) arrow keys on the display panel, you can navigate through the nine (9) display screens. Each
screen will contain two (2) viewable items. The following is a description of the individual items and what they can display:
Screen
Display shows:
Description
HTR: OFF
The unit has been turned OFF by the Enter/Reset button on the
display panel.
Standby
The unit has not received a call for heat from a remote thermostat.
Set Point Met
The unit has met the water temperature set point, but is still receiving
a call for heat from either a remote thermostat or a BMS.
Prepurge
The unit has initiated the prepurge and HSI warm-up periods on a
call for heat.
Ignition
The unit has begun a trial for ignition.
DHW***% Rate
#1
The unit has fired and is running at the displayed percentage.
Postpurge
The call for heat has been satisfied and the unit runs the fan for an
additional postpurge period to clear the combustion chamber and vent
system of residual flue products.
Service
The unit has been placed in a temporary mode that will allow the unit
to fire for the purpose of combustion analysis.
OUT: ***F(***)
When the outlet sensor has been selected as the control sensor
(default), the control will display the outlet temperature as well as the
set point in parenthesis.
***F
If the outlet sensor has not been selected as the control sensor or a
system supply sensor is connected, only the outlet temperature will
be displayed.
Open
The control does not detect the outlet sensor.
Shorted
The outlet sensor wires or the sensor itself has become shorted.
Press the Forward  arrow key on the display to access Screen #2.
IN: ***F
If the inlet sensor has not been selected as the control sensor or a
system return sensor is installed, only the inlet temperature will be
displayed.
***F (***)
When the inlet sensor has been selected as the control sensor, the
control will display the inlet temperature as well as the set point in
parenthesis.
#2
Open
Shorted
RISE: ***F
The control does not detect the inlet sensor.
The inlet sensor wires or the sensor itself has become shorted.
The difference between the inlet temperature and the outlet
temperature.
49
Installation & Operation Manual
8
Operating information
Status Display Screens (cont’d)
By using the Back/Forward (, ) arrow keys on the display panel, you can navigate through the nine (9) display screens. Each
screen will contain two (2) viewable items. The following is a description of the individual items and what they can display:
Screen
Display shows:
Description
Press the Forward  arrow key on the display to access Screen #3.
FLUE: ***F
Open
Shorted
#3
TANK: ***F
Open
Shorted
The control will display the flue temperature.
The control does not detect the flue sensor.
The flue sensor wires or the sensor itself has become grounded.
The control will display the temperature.
The control does not detect the auxiliary sensor.
The auxiliary sensor wires or the sensor itself has become grounded.
Press the Forward  arrow key on the display to access Screen #4.
#4
FAN SPD: ****RPM
The control will display the actual fan motor RPM.
FLAME SIG: **.*uA
The control will display the flame signal in dc microamps.
Press the Forward  arrow key on the display to access Screen #5.
DHW CFH: OFF
The control has not received a call for heat from a tank sensor or tank
thermostat.
ON
The control has received a call for heat from a tank sensor or tank
thermostat.
#5
Press the Forward  arrow key on the display to access Screen #6.
#6
DHW PUMP: OFF
The control has not received a DHW call for heat and has not powered
the DHW pump.
ON
The control has received a DHW call for heat and has powered the
DHW pump.
Delay
The DHW call for heat has been satisfied and the DHW pump is
running for a fixed time to remove any residual heat.
0-10V IN: **.VDC
The control will display a 0-10 VDC signal received from a Building
Management System (BMS) connected to the unit.
Press the Forward  arrow key on the display to roll back to Screen #1. At any point if you wish to access an earlier screen, press
the Back  arrow key on the display.
50
Installation & Operation Manual
9
Domestic water heaters
This section applies only to those appliances used to supply
domestic hot water, installed with a storage tank(s). A
circulating pump MUST be installed in the piping assembly
to the storage tank and valves used to control water velocity
through the appliance. Proper water velocity is important for
correct operation of your water heater.
This section contains specific instructions for those appliances
used to supply domestic hot water. All warnings, cautions,
notes and instructions in the general installation and operation
sections apply to these instructions. Water heaters are designed
for installation with a storage tank. The operation of the
circulating pump, proper sizing of the piping between the tank
and heater and the control of water velocity, as explained in
this section, are important for correct operation of your water
heater.
NOTICE
To ensure proper velocity through the heat
exchanger, it is necessary to regulate the
temperature rise across the heat exchanger
from inlet to outlet. This must be done
on initial installation and periodically
rechecked. With the correct temperature
rise across the heat exchanger when the
water heater is firing at 100% of rated input,
you may be assured of the proper velocity
in the tubes. This will yield long life and
economical operation from your water
heater.
Excessive lime/scale build-up in the heat
exchanger tubes is a result of restricted flow
and too little velocity in the tubes. Excessive
pitting or erosion in the tube is caused by
high water flow and too much velocity
through the tubes. Care should be taken
to measure temperature rise and maintain
velocity as follows:
Initial set-up of maximum water flow
On initial start-up of the VF water heater the maximum water
flow through the heat exchanger must be manually set before
normal operation begins.
TABLE 9A
MAXIMUM WATER FLOW
 CAUTION: The maximum flow rate through a VF water
heater with a copper heat exchanger must be set to provide
and not exceed the following flow:
Model
Maximum Flow
500 - 1000
75 GPM
1500 - 2000
90 GPM
If higher flow rates are required through the water heater, an
optional Cupro Nickel heat exchanger is available. Consult the
factory for specific application requirements.
The heat exchanger is capable of operating within the design
flow rates required for the water heater, storage tank(s), and
connecting piping. Erosion of the finned copper tubes may
occur if the flow rate exceeds the maximum allowable flow rate
through the water heater. The maximum flow rate through the
water heater must be adjusted. Maximum flow on Models 500 1000 is 75 GPM and 90 GPM on Models 1500 - 2000. Flow rate
can be determined by measuring the temperature rise through
the water heater when it is firing at full rate input.
TABLE - 9B
TEMPERATURE RISE AT FULL RATE FIRE
75 AND 90 GPM FLOW
Model
Temperature Rise
500
11°F (6.1°C) @ 75 GPM
750
17°F (9.4°C) @ 75 GPM
1000
23°F (12.8°C) @ 75 GPM
1500
28°F (15.6°C) @ 90 GPM
2000
38°F (21.1°C) @ 90 GPM
1. The pump must run continuously when the burner is
firing.
2. With the pump running and the burner in the water heater
in the off cycle, the inlet water temperature and outlet water
temperature readings on the Operator Interface should read
approximately the same temperatures. Water Temperature
Rise on the Operator Interface should read near zero.
3. Turn the water heater on and allow time for the temperature
to stabilize. The Service Mode can be used to force the water
heater to run at full fire. See the VF Series Service Manual
for a detailed explanation of the Service Mode. Check the
water temperature rise in the Operator Interface when the
burner is firing at 100% of rated input.
4. Compare the water temperature rise in the Operator
Interface with the required temperature rise. Should
adjustment be needed, proceed as follows.
51
Installation & Operation Manual
9
Domestic water heaters
If the temperature rise is too high, the water velocity is
too low, adjust as follows:
Water chemistry
NOTICE
1. Check for restrictions in the outlet of the water heater.
2. Be sure all valves are open between the water heater and
the storage tank. Ensure that all ball valves are fully
ported.
3. Check the pump to be sure it is running properly and
that the pump motor is running in the proper
direction.
4. Check diameter and length of the piping between the
storage tank and water heater against the head capacity
of the circulating pump.
5. Be sure the pipes between the water heater and storage
tank are not less than 2 1/2 inch (63.5mm) diameter.
To increase flow and decrease temperature rise, increase
the piping to 3 inch (76.2mm) diameter to decrease
head loss in the piping to the storage tank.
6. Common manifold piping for multiple unit
installations will require larger minimum pipe sizes
and tank circulating tappings to ensure proper flow.
If the temperature rise is too low, the water velocity is too
high, adjust as follows:
1. Temperature rise can be increased by slowly closing the
field-installed ball valve in the outlet piping from the
water heater to the storage tank to achieve the proper
temperature rise.
2. Sustained high water velocity and low temperature rise
may result in pitting or erosion of the copper tubes in
the heat exchanger. This is a non-warrantable failure.
Temperature rise must be properly adjusted to achieve
the specified flow rate.
3. Once temperature rise has been properly set, return to
normal operation.
 CAUTION
52
Temperature rise cannot be adjusted
when the burner is firing at less than
100% of rated input.
Water temperature rise and maximum flow
data is based on heating potable water with
a hardness of 5 to 25 grains per gallon and
total dissolved solids not exceeding 350
ppm.
The required temperature rise and the standard circulating
pump are sized based on the heating of potable water with
a hardness of 5 to 25 grains per gallon and a total dissolved
solids not exceeding 350 ppm. Consult the manufacturer when
heating potable water exceeding these specifications. Heating
of high hardness and/or high total dissolved solids water may
require a larger circulating pump, an optional Cupro Nickel
heat exchanger and a revised temperature rise specification
based on the water chemistry of the water to be heated. Water
with a hardness of less than 5 grains per gallon will usually
have a pH which can be aggressive and corrosive causing nonwarrantable damage to the heater, pump, and associated piping.
Corrosion due to water chemistry generally shows up first in
the hot water system because heated water increases the rate of
corrosive chemical reactions.
Installation & Operation Manual
NOTES:
Number of Units
75
GPM
Diameter
(in.)
2 1/2
COMMON MANIFOLD SIZE (Min.)
Models: 500 - 1000
1
1. PREFERRED PIPING LAYOUT.
90
COMMON MANIFOLD SIZE (Min.)
Models: 1500 - 2000
Diameter
Number of Units GPM
(in.)
2 1/2
1
2. THE TEMPERATURE AND PRESSURE RELIEF VALVE SETTING SHALL NOT EXCEED PRESSURE RATING OF ANY
COMPONENT IN THE SYSTEM.
3. SERVICE VALVES ARE SHOWN FOR SERVICING WATER HEATER. HOWEVER, LOCAL CODES SHALL GOVERN
THEIR USAGE.
4. MAXIMUM PIPING LENGTH BETWEEN TANK AND WATER HEATER SHOULD NOT EXCEED A TOTAL OF 50 EQUIVALENT
FEET CONSTRUCTED OF 2-1/2 INCH PIPE SIZE OR LARGER.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
(continued)
Domestic water heaters
9
Figure 9-1_Typical Water Heater Piping with Storage Tank
53
Installation & Operation Manual
Domestic water heaters
9
Figure 9-2_Single Water Heater Piping with Two Storage Tanks
Number of Units
75
GPM
Diameter
(in.)
2 1/2
COMMON MANIFOLD SIZE (Min.)
Models: 500 - 1000
1
NOTES:
1. PREFERRED PIPING LAYOUT.
1
90
COMMON MANIFOLD SIZE (Min.)
Models: 1500 - 2000
Diameter
Number of Units GPM
(in.)
2 1/2
2. THE TEMPERATURE AND PRESSURE RELIEF VALVE SETTING SHALL NOT EXCEED PRESSURE RATING OF ANY
COMPONENT IN THE SYSTEM.
3. SERVICE VALVES ARE SHOWN FOR SERVICING WATER HEATER. HOWEVER, LOCAL CODES SHALL GOVERN
THEIR USAGE.
4. MAXIMUM PIPING LENGTH BETWEEN TANK AND WATER HEATER SHOULD NOT EXCEED A TOTAL OF 50 EQUIVALENT
FEET CONSTRUCTED OF 2-1/2 INCH PIPE SIZE OR LARGER.
54
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
Installation & Operation Manual
NOTES:
4
3
2
Number of Units
450
375
300
225
150
GPM
8
6
6
6
5
4
Diameter
(in.)
3 1/2
8
7
6
5
4
3
2
Number of Units
720
630
540
450
360
270
180
GPM
8
8
6
6
6
5
Diameter
(in.)
4
COMMON MANIFOLD SIZE (Min.)
Models: 1500 - 2000
5
525
COMMON MANIFOLD SIZE (Min.)
Models: 500 - 1000
6
600
EXPANSION
TANK
COLD WATER
SUPPLY
7
HOT WATER
TO FIXTURES
ALTERNATE COLD WATER
CONNECTION FOR
“OLD-STYLE” TANK
8
1. PREFERRED PIPING LAYOUT.
COMPONENT IN THE SYSTEM.
2. THE TEMPERATURE AND PRESSURE RELIEF VALVE SETTING SHALL NOT EXCEED PRESSURE RATING OF ANY
THEIR USAGE.
3. SERVICE VALVES ARE SHOWN FOR SERVICING WATER HEATER. HOWEVER, LOCAL CODES SHALL GOVERN
4. A.O. SMITH PIPING METHOD IS BASED ON 50 EQUIVALENT FEET OF PIPING. WATER HEATER PLACEMENT SHALL BE
SHALL REQUIRE A LICENSED ENGINEER FOR DESIGN ASSISTANCE.
AS CLOSE AS PRACTICAL TO THE STORAGE TANK. APPLICATIONS IN EXCESS OF THESE RECOMMENDATIONS
AND CONNECTED TO EACH WATER HEATER.
5. TEMPERATURE CONTROL PROBE (QUAD THERMISTOR PROBE, P/N 9006905005 MUST BE INSTALLED ONTO THE TANK,
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
(continued)
Domestic water heaters
9
Figure 9-3_Multiple Water Heater Piping with a Single Storage Tank
55
Installation & Operation Manual
Domestic water heaters
9
Figure 9-4_Multiple Water Heater Piping with Multiple Storage Tanks
5
4
3
2
Number of Units
525
450
375
300
225
150
GPM
8
6
6
6
5
4
Diameter
(in.)
3 1/2
8
7
6
5
4
3
2
Number of Units
720
630
540
450
360
270
180
GPM
8
8
6
6
6
5
Diameter
(in.)
4
COMMON MANIFOLD SIZE (Min.)
Models: 1500 - 2000
6
600
COMMON MANIFOLD SIZE (Min.)
Models: 500 - 1000
7
HOT WATER
TO FIXTURES
EXPANSION
TANK
COLD WATER
SUPPLY
8
Finished Floor
NOTES:
1. PREFERRED PIPING LAYOUT.
2. THE TEMPERATURE AND PRESSURE RELIEF VALVE SETTING SHALL NOT EXCEED PRESSURE RATING OF ANY
COMPONENT IN THE SYSTEM.
3. SERVICE VALVES ARE SHOWN FOR SERVICING WATER HEATER. HOWEVER, LOCAL CODES SHALL GOVERN
THEIR USAGE.
4. A.O. SMITH PIPING METHOD IS BASED ON 50 EQUIVALENT FEET OF PIPING. WATER HEATER PLACEMENT SHALL BE
AS CLOSE AS PRACTICAL TO THE STORAGE TANK. APPLICATIONS IN EXCESS OF THESE RECOMMENDATIONS
SHALL REQUIRE A LICENSED ENGINEER FOR DESIGN ASSISTANCE.
5. TEMPERATURE CONTROL PROBE (QUAD THERMISTOR PROBE, P/N 9006905005 MUST BE INSTALLED ONTO THE TANK,
AND CONNECTED TO EACH WATER HEATER.
56
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
Installation & Operation Manual
9
Domestic water heaters
(continued)
TABLE 9C
COMMON WATER MANIFOLD SIZE FOR
MULTIPLE WATER HEATER INSTALLATIONS
Pipe sizing chart provides minimum pipe size for common
manifold piping to ensure adequate flow.
Common Manifold Size (Min.)
Models
Number of Water Heaters
500 - 1000
1500 - 2000
1
2 1/2"
2 1/2"
2
3 1/2"
4"
3
4"
5"
4
5"
6"
5
6"
6"
6
6"
6"
7
8
6"
8"
8"
8"
Pump operation
1. The water heater must have a properly sized circulating
pump. This pump is sized to circulate water between
the heater and the storage tank only.
2. The pump is sized to the heater input and water
chemistry specifications noted in the Water Chemistry
section on page 52.
3. The diameter and length of the piping installed between
the storage tank(s) and water heater must be properly
sized based on the capacity of the circulating pump.
4. The pump must run continuously when the water
heater is energized. This is the standard operating
system for a water heater.
An intermittent pump control function with an all bronze
pump is installed as standard equipment on all water heater
systems. The pump will operate only while there is a “Call
for Heat” and for a timed period after the water temperature
set point is satisfied to remove any residual heat from the
combustion chamber.
The standard circulating pump on this water heater is sized
based on installation of a single storage tank and heater in close
proximity. If the number of fittings and straight pipe exceeds
the specified maximum equivalent number of straight feet
for a specified diameter of pipe, non-warrantable operational
problems may be experienced.
500,000 - 1,000,000 Btu/hr Models
1/2 HP, 120 VAC, 9.8 Amps
1,500,000 - 2,000,000 Btu/hr Models
3/4 HP, 120 VAC, 8.8 Amp
The standard pump selection is based on the following pipe and
fittings from the water heater to the storage tank:
6 - 90° elbows
2 - unions
2 - ball valves
1 - cold water tee
Not more than 45 feet of straight pipe.
For every elbow and tee in excess of those shown above,
DEDUCT 6.5 FEET from the maximum allowable straight pipe
in the heater to tank circulating loop.
TABLE 9D
MINIMUM PUMP PERFORMANCE
Based on heating potable water with a hardness of 5 to 25
grains per gallon and total dissolved solids not exceeding
350 ppm. See Water Chemistry section on page 52 .
Model
GPM Ft. Hd.
500 - 1000
75
15
1500 - 2000
90
15
When installing multiple water heaters and/or multiple storage
tanks, the diameter of the inter-connecting pipe and all fittings
must be increased. An increase in pipe diameter will decrease
head loss in the system piping and ensure proper flow. Proper
pipe size between the heater and storage tank MUST be
maintained to ensure that the standard pump supplied on the
water heater will maintain desired flow.
Heat exchanger
On all models, header inspection plugs in the heat exchanger
can be removed for field inspection and cleaning of copper
tubes. The heat exchanger may be removed from the unit.
5. Lubricate pump to manufacturer’s recommendations.
Pump damage due to inadequate lubrication is
non-warrantable.
The tank sensor must be installed in the tapping provided in
the lower 25% of the storage tank to achieve proper operation.
As shipped from the factory, the tank sensor is in the literature
package shipped with the unit. Placing the sensor in the tapping
provided on the storage tank will improve temperature response
and prevent short cycles of operation.
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Installation & Operation Manual
9
Domestic water heaters
Thermostat adjustment procedure
1. Press the (+) or (-) button to view the set point
setting.
 CAUTION
2. Press either the (+) or (-) button to increase or
decrease the displayed set point value.
3. Press the SAVE/CLEAR button to permanently store
the new set point into the control module’s memory.
Failure to press the SAVE/CLEAR key after changing the
display value will result in the set point reverting back to its
previous value after the current heat demand ends.
The control may be adjusted any time regardless of call for
heat status. When pressing the (+) or (-) key to enter any
new set points, the control module will immediately begin
controlling based on the new set point.
Minimum water temperatures (domestic
hot water use)
Domestic water temperatures:
This high efficiency water heater should be operated at a
temperature setting high enough to prevent condensing of
the products of combustion on the unit’s heat exchanger or
in the attached venting system. Use extreme caution when
storing water at elevated temperatures. A water temperature
setting maintained above the dew point of the products of
gas combustion should prevent condensate formation and
ensure proper performance of the venting system. The
manufacturer recommends the use of a properly sized
thermostatic mixing valve to supply domestic hot water at
temperatures less than 140°F (60°C). Storing the water at a
higher temperature and thermostatically mixing the water
will increase the available quantity of mixed hot water,
greatly reducing the possibility of condensate formation
on the heat exchanger or in the venting system and help
prevent the growth of water borne bacteria.
NOTICE
An appliance allowed to operate at return
temperatures below the specified minimum
setting may experience problems with
the operating controls, safety switches,
obstruction of the flue gas passages on the
heat exchanger, incomplete combustion,
and possible flue gas spillage. Sustained
operation at lower than specified water
temperatures may cause hazardous
conditions that may result in personal
injury or non-warrantable damage to the
appliance.
The maximum temperature set point that can be programmed
into the control module from the Operator Interface for water
heater operation is 190°F (88°C). The control is factory pre-set
at approximately 120°F (49°C). Facilities with small children
or invalids may require 120°F (49°C) or a lower temperature
setting to reduce risk of scald injury. Some states may require a
lower temperature setting. Check with your gas supplier for local
requirements governing the temperature setting. Remember, no
water heating system will provide exact temperature at all times.
Allow a few days of operation at this setting to determine the
correct temperature setting consistent with your needs.
NOTICE
1. This water heater, when set at the
lower temperature setting, is not capable of
producing hot water of sufficient temperature
for sanitizing purposes.
2. Higher stored water temperature
increases the ability of the water heater
to supply desired quantities of hot water,
however remember --
 CAUTION
Hotter water increases the risk of scald injury.
Adequate care MUST be taken to
prevent a potential scald injury when
storing water at elevated temperatures
for domestic use.
Inlet water temperatures below the specified minimum
recommendations can excessively cool the products
of combustion resulting in condensation on the heat
exchanger. Condensation on the heat exchanger can cause
operational problems, bad combustion, sooting, flue gas
spillage and reduced service life of the related components.
Figure 9-5_Danger Warning
58
Installation & Operation Manual
9
Domestic water heaters
(continued)
The following chart (Table 9E) details the relationship of water
temperature and time with regard to scald injury and may be
used as a guide in determining the safest water temperature for
your applications.
TABLE 9E
APPROXIMATE TIME / TEMPERATURE
RELATIONSHIPS IN SCALDS
120°F
More than 5 minutes
125°F
1 1/2 to 2 minutes
130°F
About 30 seconds
135°F
About 10 seconds
140°F
Less than 5 seconds
145°F
Less than 3 seconds
150°F
About 1 1/2 seconds
155°F
About 1 second
 CAUTION
Setting the temperature selector to higher
settings provides hotter water, which
increases the risk of scald injury.
Location of Cold Water Supply Piping Connections
Incorrect piping of the cold water supply to the system may result
in excessive low temperature operation causing condensate
formation on the primary heat exchanger and operational
problems. The cold water supply piping must be installed in
the discharge piping from the heater to the storage tank. This
allows the cold water to be tempered in the storage tank before
entering the heater. See typical installation drawings provided
in this manual for correct piping (FIG.’s 9-1 thru 9-4). Higher
water temperatures reduce the volume of condensate formed.
 WARNING
Should overheating occur or the gas supply
fail to shut off, do not turn off or disconnect
the electrical supply to the pump. Instead,
shut off the gas supply at a location external
to the appliance.
Adjustable high water temperature limit
control
A high limit control is located on the inside of the left front
panel, as shown in FIG. 9-6. The setting of this control knob
limits maximum discharge water temperature. The water heater
temperature limit control is adjustable up to a maximum
setting of 210°F (99°C). This water heater also includes a fixed
high water temperature limit control set to 200° (93.3°C).
The RESET key on the display must be pushed whenever
water temperature has exceeded the set point of the limit. The
temperature of the water in the heat exchanger must drop a
minimum of 15°F (8.3°C) below the setting of the high limit
control before the reset function can be activated. A high limit
message will be shown in the Operator Interface when water
temperature exceeds the high water temperature limit control
set point.
NOTICE
The high limit control will not reset until the
water temperature has dropped below the set
point of the high limit.
Optional relief valve
This water heater is normally supplied with a temperature and
pressure relief valve sized in accordance with applicable codes.
Units may be supplied with an optional pressure only relief
valve. When a water heater is equipped with this optional relief
valve and is piped to a separate storage vessel, the storage vessel
must have a properly installed temperature and pressure relief
valve which complies with local codes.
Thermal expansion
A relief valve that discharges periodically may be due to thermal
expansion in a closed system. A water heater installed in a
closed system, such as one with a backflow preventer or check
valve installed in the cold water supply, shall be provided with
means to control expansion. Contact the water supplier or local
plumbing inspector on how to correct this situation. Do not
plug or cap the relief valve discharge.
Cathodic protection
Hydrogen gas can be produced in a hot water system that has
not been used for a long period of time (generally two weeks
or more). Hydrogen gas is extremely flammable. To prevent
the possibility of injury under these conditions, we recommend
the hot water faucet be open for several minutes at the kitchen
sink before you use any electrical appliance which is connected
to the hot water system. If hydrogen is present, there will be
an unusual sound such as air escaping through the pipe as the
hot water begins to flow. There should be no smoking or open
flames near the faucet at the time it is open.
ADJUSTABLE
HIGH WATER
TEMPERATURE
LIMIT CONTROL
IMG00627
Figure 9-6_Adjustable High Water Temperature Limit Control
59
Installation & Operation Manual
10
Maintenance
Maintenance and annual startup
Table 10A_Service and Maintenance Schedules
Owner maintenance
Service technician
(see the following pages for instructions)
(see the VF Series User’s Information Manual for
instructions)
General:
• Address reported problems
• Check appliance area
• Inspect interior; clean and vacuum if
necessary;
Daily
• Check pressure/temperature
gauge
• Inspect condensate system and flush with
fresh water
ANNUAL START-UP
• Check for leaks
condensate)
(water,
gas,
flue,
• Examine venting system
• Check vent piping
• Check system water pressure/system
piping/expansion tank
Monthly
• Check control settings
• Check air piping
• Check relief valve
• Check igniter
• Check condensate drain system
• Check wiring and connections
• Check flue gas passageways
Periodically
• Flame inspection (stable, uniform)
• Test low water cutoff (if used)
• Reset button (low water cutoff)
• Inspect and clean the burner
• Perform
start-up
checkout
and
performance verification per Section 7 Start-up.
If combustion
indicate need:
or
performance
• Clean heat exchanger
• Remove and clean
compressed air only
• Clean the blower wheel
60
burner
using
Every
6 months
• Check appliance piping (gas and
water) for leaks
• Operate relief valve
Installation & Operation Manual
10
Maintenance
(continued)
 WARNING
Follow the service and maintenance procedures given throughout this manual and in component literature
shipped with the appliance. Failure to perform the service and maintenance could result in damage to the
appliance or system. Failure to follow the directions in this manual and component literature could result in
severe personal injury, death, or substantial property damage.
 WARNING
The appliance should be inspected annually only by a qualified service technician. In addition, the maintenance
and care of the appliance designated in Table 10A and explained on the following pages must be performed to
assure maximum appliance efficiency and reliability. Failure to service and maintain the appliance and system
could result in equipment failure.
 WARNING
Electrical shock hazard – Turn off power to the appliance before any service operation on the appliance except
as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical
shock, causing severe personal injury or death.
Address reported problems
Figure 10-1_Condensate Trap
1. Inspect any problems reported by the owner and correct
before proceeding.
Inspect appliance area
1. Verify that appliance area is free of any combustible
materials, gasoline and other flammable vapors and liquids.
Inspect appliance interior
1. Remove the outer access panels and inspect the interior of
the appliance.
2. Vacuum any sediment from inside the appliance and
components. Remove any obstructions.
Inspect condensate system
1. Inspect the condensate drain line, condensate PVC fittings,
and condensate trap on an annual basis.
Flush condensate trap with water
1. Remove the four (4) screws securing the top cover to the
condensate trap and remove the cover (reference FIG.
10-1).
Check all piping for leaks
 WARNING
Eliminate all system or appliance leaks.
Continual fresh makeup water will reduce
appliance life. Minerals can build up in
sections, reducing heat transfer, overheating
heat exchanger, and causing heat exchanger
failure. Leaking water may also cause severe
property damage.
1. Inspect all water and gas piping and verify to be leak free.
2. Locate the plastic ball inside the float tube. Verify there is
nothing under the ball causing it to not seat properly.
2. Look for signs of leaking lines and correct any problems
found.
3. If necessary, flush with fresh water until the water begins to
pour out of the drain.
3. Check gas line using the procedure found in Section 3 - Gas
Connections.
4. Replace the top cover on the condensate trap.
5. Replace the four (4) screws removed in Step 1.
61
Installation & Operation Manual
10
Maintenance
Flue vent system and air piping
 WARNING
Safety relief valves should be re-inspected
AT LEAST ONCE EVERY THREE YEARS,
by a licensed plumbing contractor or
authorized inspection agency, to ensure
that the product has not been affected by
corrosive water conditions and to ensure
that the valve and discharge line have not
been altered or tampered with illegally.
Certain naturally occurring conditions may
corrode the valve or its components over
time, rendering the valve inoperative. Such
conditions are not detectable unless the
valve and its components are physically
removed and inspected. This inspection
must only be conducted by a plumbing
contractor or authorized inspection agency
– not by the owner. Failure to re-inspect the
water heater relief valve as directed could
result in unsafe pressure buildup, which can
result in severe personal injury, death, or
substantial property damage.
 WARNING
Following installation, the valve lever must
be operated AT LEAST ONCE A YEAR to
ensure that waterways are clear. Certain
naturally occurring mineral deposits may
adhere to the valve, rendering it inoperative.
When manually operating the lever, water
will discharge and precautions must be taken
to avoid contact with hot water and to avoid
water damage. Before operating lever, check
to see that a discharge line is connected to
this valve directing the flow of hot water
from the valve to a proper place of disposal.
Otherwise severe personal injury may result.
If no water flows, valve is inoperative. Shut
down the appliance until a new relief valve
has been installed.
1. Check for gastight seal at every connection, seam of air
piping, and vent piping periodically inspected by a qualified
service agency.
 WARNING Venting system must be sealed gastight
to prevent flue gas spillage and carbon
monoxide emissions, which will result in
severe personal injury or death.
Check water system
1. Verify all system components are correctly installed and
operational.
2. Watch the system pressure as the water heater heats up
(during testing) to ensure pressure does not rise too high.
Excessive pressure rise indicates expansion tank sizing or
performance problem.
3. Inspect automatic air vents and air separators. Remove air
vent caps and briefly press push valve to flush vent. Replace
caps. Make sure vents do not leak. Replace any leaking
vents.
Check expansion tank
1. Expansion tanks provide space for water to move in and
out as the heating system water expands due to temperature
increase or contracts as the water cools. Tanks may be
open, closed, diaphragm or bladder type. See Section 4 Water Connections for suggested best location of expansion
tanks and air eliminators.
Check relief valve
1.
Inspect the relief valve and lift the lever to verify flow.
Before operating any relief valve, ensure that it is piped with
its discharge in a safe area to avoid severe scald potential.
Read Section 4 - Water Connections before proceeding
further.
62
2. After following the above warning directions, if the relief
valve weeps or will not seat properly, replace the relief valve.
Ensure that the reason for relief valve weeping is the valve
and not over-pressurization of the system due to expansion
tank waterlogging or undersizing.
Installation & Operation Manual
10
Maintenance
(continued)
Inspect/replace hot surface igniter
Perform start-up and checks
1. Turn off main electrical power to the appliance.
1.
Start appliance and perform checks and tests specified in
Section 7 - Start-up.
2.
Verify cold fill pressure is correct and that operating
pressure does not go too high.
2. Turn off main manual gas shutoff to the appliance.
3. Carefully pull back the insulation flaps to expose the burner
mounting flange.
4. Locate the hot surface igniter. Disconnect the two power
leads to the hot surface igniter.
5. Loosen and remove the two wing nuts that mount the
igniter.
6. Lift the igniter vertically out of the burner mounting flange.
Use care, do not hit or break the silicon carbide igniter. Do
not contaminate the igniter by handling with oily or dirty
hands.
Check burner flame
Visually check main burner flames at each start-up after long
shutdown periods or at least every six months. A burner
viewport is located on the burner mounting flange.
 WARNING The area around the burner viewport is hot
and direct contact could result in burns.
Figure 10-2_Flame Pattern Illustration
7. Check the replacement igniter for cracks or damage before
installing.
8. Ensure that the fiber gasket used to seal the base of the
igniter to the burner flange is reinstalled to seal the base of
the replacement igniter.
9. Carefully insert the igniter into the mounting point on the
burner flange and position on the mounting studs.
10. Reinstall the two wing nuts and tighten by hand only. Over
tightening the wing nuts may break the ceramic mounting
flange.
11. Ensure that the igniter gasket is properly installed and
seals the point of contact between the igniter and burner
mounting flange.
12. Reconnect the power leads to the igniter.
13. Replace the insulation blanket flaps.
14. Turn on main gas supply and main power.
15. Test fire the appliance to ensure proper operation.
Check all wiring
1. Inspect all wiring, making sure wires are in good condition
and securely attached.
Check control settings
1. Set the control module display to Parameter Mode and
check all settings. See Section 1 of the VF Series Service
Manual. Adjust settings if necessary. See Section 1 of the
VF Series Service Manual for adjustment procedures.
Normal Flame: A normal flame at 100% of burner input is blue,
with slight yellow tips, a well defined flame and no flame lifting.
Yellow Tip: Yellow tipping can be caused by blockage or partial
obstruction of air flow to the burner.
Yellow Flames: Yellow flames can be caused by blockage of
primary air flow to the burner or excessive gas input. This
condition MUST be corrected immediately.
Lifting Flames: Lifting flames can be caused by over firing the
burner, excessive primary air or high draft.
If improper flame is observed, examine the venting system,
ensure proper gas supply and adequate supply of combustion
and ventilation air.
2. Check settings of external limit controls (if any) and adjust
if necessary.
63
Installation & Operation Manual
10
Maintenance
Check flue gas passageways
Any sign of soot around the inner jacket, outer jacket, flue
pipe connections, burner or in the areas between the fins on
the copper heat exchanger indicates a need for cleaning. The
following cleaning procedure must only be performed by a
qualified serviceman or installer. Proper service is required to
maintain safe operation. Properly installed and adjusted units
seldom need flue cleaning.
NOTICE
 CAUTION
All gaskets/sealants on disassembled
components or jacket panels must be
replaced with new gaskets/sealants on
reassembly. Gasket and sealant kits are
available from your distributor.
When a Category IV vent system is
disconnected for any reason, the flue must
be reassembled and resealed according to the
vent manufacturer’s instructions.
Inspect and clean burner
The burner should be removed for inspection and cleaned
on an annual basis. An appliance installed in a dust or dirt
contaminated environment may require cleaning of the burner
on a 3 to 6 month schedule or more often, based on severity of
the contamination. The fan assisted combustion process may
force airborne dust and dirt contaminants, contained in the
combustion air, into the burner. With sustained operation,
non-combustible contaminants may reduce burner port area,
reduce burner input or cause non-warrantable damage to the
burner.
Use extreme care when operating an appliance for temporary
heat during new construction. Airborne contaminants such
as dust, dirt, concrete dust or drywall dust can be drawn into
the burner with the combustion air and block the burner port
area. An external combustion air filter is provided with the
appliance. This filter helps ensure clean air is used for the
combustion process. Check this filter every month and replace
when it becomes dirty. The burner of an appliance used for
temporary heat without a combustion air filter installed will
probably require a thorough cleaning before the unit is placed
into normal service.
Access to the burner will require the following steps:
1.
Turn off main electrical power to the appliance.
2.
Turn off main manual gas shutoff to the appliance.
3.
Remove the front outer control panel covers. Slide out the
inner control panel to increase service clearances and
carefully remove the multi-pin wiring connectors on the
back of the control panel. Remove the screws along the
front and rear edge of the top outer jacket panel to remove
top. Remove the control panel to allow access to
the components in the top of the appliance.
4.
Remove the sensing tubes from the low air pressure switch
to the combustion air blower.
5.
Disconnect the wiring connections on the top of the
combustion air blower.
6.
Remove the six (6) hex head bolts attaching the gas/air
venturi to the inlet of the combustion air blower.
7.
Remove the four (4) nuts holding the combustion air
blower to the top of the burner and remove the combustion
air blower assembly.
8.
Use care when removing the combustion air blower
assembly to prevent damage to the venturi and burner
gaskets.
9.
Disconnect the power wires to the hot surface igniter.
10. Remove the hot surface igniter. The hot surface igniter is
fragile. Use care to prevent impact damage to the silicone
carbide igniter surface when removing the igniter.
11. Remove the eight (8) nuts holding the burner to the
heat exchanger.
12. The burner can now be lifted vertically out of the heat
exchanger chamber.
13. Use care when removing the burner to prevent damage
to the woven burner port surface or gaskets on removal.
14. Remove any visible dust or dirt blockage from the
surface of the burner with a vacuum. Compressed air
may also be blown across the burner surface to clean
the “pores” of the woven burner port material.
15. Reassemble in reverse order.
64
Installation & Operation Manual
10
Maintenance
(continued)
Inspect and clean the heat exchanger
1.
Turn off all power to the appliance.
2.
Turn off main gas to appliance.
3.
Remove the front outer jacket panel.
4.
Remove the inner jacket panel (see FIG. 10-3).
5.
Check the heat exchanger surface for soot. If soot is
present, the heat exchanger must be cleaned and the
problem corrected.
6.
Remove the burner as described in the Inspect and
Clean Burner section of the VF Series Service Manual.
7.
Check the “V” baffles on the heat exchanger. Remove
and clean if necessary.
8.
Remove soot from the heat exchanger with a stiff bristle
brush. Use a vacuum to remove loose soot from
surfaces and inner chamber.
9.
The heat exchanger can be removed by disconnecting
all water piping to the heat exchanger, removing the
screws holding the heat exchanger to the top of the
inner jacket and sliding the heat exchanger towards the
front of the appliance. Once the heat exchanger is
removed, a garden hose can be used to wash the tubes
to ensure that all soot is removed from the heat
exchanger surfaces. Note: Do not wet the insulation
blankets on the inside of the outer jacket panels.
10. Ensure that any soot present on the burner is removed.
See Inspect and Clean Burner section of the VF Series
Service Manual.
11. Carefully reinstall the heat exchanger and “V” baffles if
removed from the appliance.
12. Reinstall the inner jacket panel, burner, manifolds,
wires, and hoses. Use new gasket material to ensure a
proper air seal.
Figure 10-3_Location of the Heat Exchanger Inside
Jacket
Review with owner
1. Review the VF Series User’s Information Manual with the
owner.
2. Emphasize the need to perform the maintenance schedule
specified in the VF Series User’s Information Manual (and
in this manual as well).
3. Remind the owner of the need to call a licensed contractor
should the appliance or system exhibit any unusual behavior.
13. Reassemble all gas and water piping. Test for gas leaks.
NOTICE
Upon completion of any testing on the gas
system, leak test all gas connections with a
soap and water solution while main burners
are operating. Do not spray soap and water
solution on the control module housing.
The use of an excessive amount of soap
and water solution can damage the control.
Immediately repair any leak found in the gas
train or related components. Do not operate
an appliance with a leak in the gas train,
valves, or related piping.
4. Remind the owner to follow the proper shutdown procedure
and to schedule an annual start-up at the beginning of the
next heating season.
Oiled bearing circulators
Inspect the pump every six (6) months and oil as necessary. Use
SAE 30 non-detergent oil or lubricant specified by the pump
manufacturer.
14. Reassemble outer jacket panels.
15. Cycle unit and check for proper operation.
65
Installation & Operation Manual
11
Connection diagram
LO-GAS PRESSURE SWITCH
BR
1
1
PR
2
2
P
3
BR
1
1
2
2
3
3
3
O/R
PR /
BK
BR/W
HI-GAS PRESSURE SWITCH
BR
1
BL
1
PR
2
2
PK
3
3
T
BL
P
BL/
BK
T/
W
R
GY GY
2
2
1
1
P
W
BK/R
G
T
O
W
4
1
1 4
O/ BK
5
2
2 5
O/BK
6
3
3 6
O/BR
O/PR
W
W
SILENC E
SWITCH
O/
BR
O /P R
O/
BK
ALARM RELAY
4
O/BK
6 3
O
BR = BROWN
BL = BLUE
R/BK
6
5
1
O
4
13 14 15
15 14 13
10 11 12
12 11 10
7
8 9
9
8
7
4
5
6
6
5
4
1
2
3
3
2
1
R/BK
BK/R
O/BK
6
3
T
5
2
Y
4
1
BK
O
R/O
7
8 9
9 8
7
4
5 6
6
4
W
5
2 3
3 2
1
G
1
TE S T
R
T
GY
T
1
2
3
5
2
4
1
3
Y
6
2
5
1
4
10 11 12
BL/BK
BL
O
3
BR/W
7
8 9
4
5 6
1
LOW WATER CUTOFF – 24V
ON/OFF
POWER
SWITCH
X1
2 3
W
BK/R
BK
X8
BK/R
O
W
BL/W
BK
GY
7 8
9
4
5 6
1
2 3
X2
GY
X6
O/BK
BR
X7
W/BK
BL/W
VF
O
4
3
R/BK
2
R/O
1
X3
W
BR/W
BL/W
1
1
2
3
2
3
2
8
4
3
11
16
14
13
1
12
15
5
18
17
7
6
19
20
10
9
R
Notes:
1. All wiring must be installed in accordance with: local, state, provincial and national code
requirements per either N
.E.C. in USA or C.S.A. in Canada.
2. If any original equipment wire as supplied with the appliance must be r eplace,dit must be
r eplaced with wir e having same wir e gauge(AWG) and rated for a minimum of105°C
3. Actual connector block locations may vary from those shown on diagr am
. sRefer to actual
components for proper connector block locations when using diagr ams to tr ouble shoot un.it
X5
"X5"
BLOCK'S
WIRING IS
MODEL
DEPENDENT
1
2
3
4
8
9
17
18
4
13
6
14
5
10
16
7
11
2
1
15
12
3
1
5
2
6
3
7
4
8
BLOCKED
DRAIN
SWITCH
OUTLET
SENSOR
FLUE
SENSOR
INLET
SENSOR
W
Y
O
Y
W
BL
O
BL
R/W
PR
Y
Y
2
O/R
4
1
BK/W
BK
BLOWER
RELAY
UNIT
PUMP
RELAY
BL/W
CHASSIS
GROUND
BL
6
AUTO-RESET HIGH -LIMIT
WATER HEATER ONLY
INTEGRATED CONTROL
G
BOILER
SUPPLY
R
CHASSIS
GROUND
O/BK
GROUND
This appliance may be
connected to one or
more branch circuits.
To prevent electrical
shock, ensure all branch
circuits are de-energized
before attempting to
service this equipment.
BK/R
12 11 10
W
LINE
WARNING:
O
R/BK
10 11 12
R/O
G
PR
NEUTRAL 120 VAC
G
BK
O
UNIT
PUMP
LINE
GY
BL/R
PR
PUMP
BK
O/BK
BR
G
MANUAL RE S E T
RUN-TIME
CONTACTS
W/BK
BR
W/BK
O
O/ BK
OUT
LINE
BL
2
ALARM
CONTACTS
LINE
Y
BK/W
BK/W
GY = GRAY
R = RED
3
OUT
W
O
LOUVER
CONTACTS
LINE
O/BR
GY
EXAMPLE OF STRIPED WIRE
R/O = RED WITH ORANGE TRACER
LWCO
JUMPER
OUT
O
R
G = GREEN
P = PINK
O = ORANGE
BK BL
GY
Y = YELLOW
LOUVER
RELAY O/BK
PR/
BK
Y
R/O
GY
PR = PURPLE
PR
O/R
G
To avoid possible
shock hazard,
disconnect power
before servicing.
COLOR DESIGNATIONS
W = WHITE
T = TAN
BK = BLACK
PR
O/R
Y
2
GAS
VALVE
COMBUSTION
BLOWER
WARNING:
1
5 2
1
1
1
O/PR
IGNITER
ALARM JUMPER
DOTTED BOX DEPICTS
OPTIONAL OR FIELD
SUPPLIED ITEMS
2
P ROOF
CLOS E
V ALV E
V ALV E RE LAY
O/ BK
CONNECTIONS FOR FIELD INSTALLED
ITEMS. SEE I &O MANUAL FOR DETAILS.
LWCO
PROBE
BK/R
O/R
W
O
W
O
NOTE
3 2 1
120V
W
O
2
3
W
~~~~~
~~~~~
~~~~~
120VAC ALARM
PROOF OF CLOSURE
2
HI-LIMIT
AIR SWITCH
W
BK/R
1
3
Y/
BL
1 2 34 5
VENTILATION
FAN
PR
O/R
Y
26
25
9
24
23
Y
R/W
O/R
PR
3
10
11
12
13
14
15
5
16
8
7
6
22
21
20
19
18
17
16
15
14
13
12
11
BL/R
8
9
10
10
9
8
7
6
5
4
3
2
1
n /a
n /a
n /a
n /a
Y/BL
P
T/W
R
BL/BK
PR
28
27
PR/BK
BL/W
BL/R
PR /BK
Y
W/BK
W/BK
BL
BL
GY
T
O
OPERATOR
INTERFACE
11
12
6
5
4
3
7
2
1
TANK
SENSOR
(-)
(+) 0-10 VDC
LOUVER
PROVING
HEATER
ENABLE
FACTORY
JUMPER
CONNECTION
BOARD
FLOW
SWITCH
WIRING LEGEND
LOW VOLTAGE
BL
O/BK
120 VAC
GROUNDING
X4
~~~~~
~~~~~
~~~~~
LBL20320 REV B
66
Installation & Operation Manual
Ladder diagram
BOILER
SUPPLY
BOILER
SUPPLY
LOUVER
CONTACTS
L
ALARM
CONTACTS
N
TERMINAL
STRIP
G
PUMP
SUPPLY
PUMP
SUPPLY
L
N
IN
BLOWER
BLOWER
RELAY
LOUVER
RELAY
ALARM
RELAY
1
OUT
2
1
IN
UNIT
PUMP
UNIT
PUMP
RELAY
OUT
3
PROOF OF
PROOF OF
CLOSURE RELAY CLOSURE VALVE
2
VENTILATION FAN
CHASSIS
IN
OUT
ON/OFF
SWITCH
ALARM RELAY
SILENCE
SWITCH
1
ALARM
4
3
2
X3-3
X1-6
ALARM
CONTACTS
X3-4
F5
X1-4
UNIT PUMP RELAY
X2-7
BLOWER RELAY
5A
F3
3.15A
X1-3
INTERGRATED
CONTROL
BOARD
BOX DEPICTS
OPTIONAL ITEMS
LOW VOLTAGE
120 VAC
X1-12
HSI
X2-2
X2-1
F2
X3-1
5A
RUN-TIME
CONTACTS
F1
1.6A
GAS VALVE
X3-2
X2-3
X2-6
F4
X6-18
1.6A
BLOWER
X6-17
X1-7
X1-8
X1-5
1
2
X6-9
X1-10
4
5
X6-8
1.6A
X6-1
F6
X6-10
24VAC
1.6A
FLOW
SWITCH
CONNECTION
BOARD
6
J3-6
J3-2
2
4
J3-4
J3-3
TEST
5
J3-5
J2-3
RESET
LWCO
PROBE
J2-2
X8-5
CN1-12
19
X8-15
CN1-11
20
((
(
((
LOW WATER
CUTOFF
3
J2-1
CHASSIS
0-10VDC
X6-3
LOW PRESSURE
AIR SWITCH
15
X6-12
16
MANUAL RESET
HIGH LIMIT
X6-4
17
18
X6-13
PROOF OF
CLOSURE RELAY
1
PROOF OF
CLOSURE
SWITCH
3
LOW GAS
PRESSURE SWITCH
2
HIGH GAS
PRESSURE SWITCH
1
LOUVER
RELAY
3
11
X6-5
CONNECTION LOUVER CONNECTION
BOARD
BOARD
PROVING
SWITCH
CN2-9
CN2-8
X6-14
14
10
9
BLOCKED
DRAIN
SWITCH
AUTO-RESET
HIGH LIMIT
X6-15
X6-6
CN2-4
12
13
CONNECTION
BOARD
X5-1
X5-2
HEATER
ENABLE
4
3
CN2-6
X6-11
X5-6
X5-3
7
FACTORY
JUMPER
X5-7
5
X5-4
6
X5-8
21
TANK
SENSOR
CN1-10
X8-12
22
X8-2
23
OUTLET
SENSOR
24
X8-3
25
25
INLET
SENSOR
26
26
LBL20321 REV B
X8-4
27
27
28
CONNECTION
BOARD
CN1-3
X8-1
FLUE
SENSOR
WHERE POSSIBLE, SWITCHES ARE SHOWN WITHOUT UTILITIES (GAS,
WATER OR ELECTRICITY) CONNECTED TO THE UNIT. AS SUCH, ACTUAL
SWITCH STATES MAY VARY FROM THOSE SHOWN ON DIAGRAMS
DEPENDING UPON WHETHER UTILITIES ARE CONNECTED OR A FAULT
CONDITION IS PRESENT. SEE WIRING DIAGRAM FOR ADDITIONAL NOTES.
1
8
X5-5
2
MODEL DPENDENT
12
67
Installation & Operation Manual
Notes
68
Installation & Operation Manual
Notes
69
Installation & Operation Manual
Notes
70
Installation & Operation Manual
13
Warranty
LIMITED WARRANTY
A. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this hot water supply boiler:
1.
If within FIVE years after initial installation of the hot water supply boiler, a heat exchanger or gas burner shall prove upon examination by the warrantor to be
defective in material or workmanship, the warrantor, at his option will exchange or repair such part or portion.
a. This warranty is extended to the owner for all other parts or portion during the FIRST year following initial installation of this hot water supply boiler.
b. The warranty on the repair or replacement of the part or portion will be limited to the unexpired term of the original warranty.
2. CONDITIONS AND EXCEPTIONS
This warranty shall apply only when the h o t water supply boiler is installed in accordance with local plumbing and building codes, ordinances and
regulations, the printed instructions provided with it and good industry practices. In addition, a pressure relief valve, certified by C.S.A. and approved
by the American Society of Mechanical Engineers, must have been installed and fresh water used for filling and make-up purposes.
a. This warranty shall apply only when the hot water supply boiler is used:
(1) with inlet water temperature 140°F (60°C) and above and outlet water temperatures not exceeding the maximum setting of its operative and/
or high limit control;
(2) at water pressure not exceeding the working pressure shown on the hot water supply boiler;
(3) when filled with water, free to circulate at all times and with the heat exchanger free of damaging scale deposits;
(4) in a non-corrosive and non-contaminated atmosphere;
(5) in the United States, its territories or possessions, and Canada;
(6) at a water velocity flow rate not exceeding or below the hot water supply boiler’s designed rates;
b. Any accident to the hot water supply boiler, any misuse, abuse (including freezing) or alteration of it, any operation of it in a modified form, or any attempt
to repair leaks in the heat exchanger will void this warranty.
3. SERVICE AND REPAIR EXPENSE
Under this limited warranty the warrantor will provide only a replacement part. The owner is responsible for all other costs. Such costs may include but are
not limited to:
a. Labor charges for service, removal, repair, or reinstallation of the component part;
b. Shipping, delivery, handling, and administrative charges for forwarding the replacement part from the nearest distributor and returning the claimed defective
part to such distributor.
c. All cost necessary or incidental for any material and/or permits required for installation of the replacement.
4. LIMITATIONS ON IMPLIED WARRANTIES
Implied warranties, including any warranty of merchantability imposed on the sale of this hot water supply boiler under state or provincial law are limited to one
(1) year duration for the hot water supply boiler or any of its parts. Some states and provinces do not allow limitations on how long an implied warranty lasts,
so the above limitation may not apply to you.
5. CLAIM PROCEDURE
Any claim under this warranty should be initiated with the dealer who sold the hot water supply boiler, or with any other dealer handling the warrantor’s
products. If this is not practicable, the owner should contact:
U.S. Customers
Canadian Customers
A. O. Smith Corporation
A. O. Smith Enterprises Ltd.
500Tennessee Waltz Parkway
P. O. Box, 310 - 768 Erie Street
Ashland City, TN
Stratford, Ontario N5A 6T3
Telephone: 800 527-1953
Telephone: 800-265-8520
a. The warrantor will only honor replacement with identical or similar parts thereof which are manufactured or distributed by the warrantor.
b. Dealer replacements are made subject to in-warranty validation by warrantor.
6. DISCLAIMERS
NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE ON BEHALF OF THE WARRANTOR WITH RESPECT TO THE MERCHANTABILITY OF
THE HOT WATER SUPPLY BOILER OR THE INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF THE HOT WATER SUPPLY BOILER. THE
WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL
PROPERTY, OR OTHER CONSEQUENTIAL DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE
FOR DAMAGE TO ANY PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR TORT.
a. Some states and provinces do not allow the exclusion or limitation of the incidental or consequential damage, so the above limitations or exclusions may
not apply to you.
b. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or province to province.
Fill in the following for your own reference. Keep it. Registration is not a condition of warranty. The model and serial number are found on the hot water supply boiler’s rating plate.
Owner
Installation Address
City and State
Date Installed
Dealer’s Name
Zip Code
Model No.
Serial No.
Phone No.
Dealer’s Address
FILL IN WARRANTY AND KEEP FOR FUTURE REFERENCE
71
Revision Notes:
release.
Revision A (ECO #C12846) initial
Revision B (ECO #C14970) reflects wiring and ladder
diagram updates.
Revision C (Change # 500001030) reflects the update
of Table 4-D on page 34 as well as the addition of the
factory startup logo on the manual cover.
Revision D (PCP# 3000006581 / CN# 500006679)
reflects the addition of new clearance information on
pages 26-28. SAP material numbers have been updated.
VFS-I-O_MM# 100161775_DIR# 2000019057_Rev D
02/17
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