American Water Heater | DCG | Use & care guide | American Water Heater DCG Use & care guide

Commercial Gas
Water Heater
Installation
Instructions and
Use & Care Guide
for models with prefix DCG and ADCG
To obtain technical, warranty or service assistance during
or after the installation of this water heater, call toll free:
1-800-456-9805
When calling for assistance, please have the following
information ready:
1. Model number
2. 7 digit product number
3. Serial number
4. Date of installation
5. Place of purchase
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PART NO. 60375 REV. A (07-10)
GSW Water Heating is a division of
A. O. Smith Enterprises Ltd.
Your safety and the safety of others is very important.
We have provided many important safety messages in this manual and on your appliance.
Always read and obey all safety messages.
This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word
“DANGER” or “WARNING”.
DANGER You can be killed or seriously injured if you don’t immediately follow
instructions.
WARNING You can be killed or seriously injured if you don’t follow instructions.
All safety messages will tell you what the potential hazard is, tell you how to reduce the
chance of injury, and tell you what can happen if the instructions are not followed.
• Do not use this appliance if any part has been under water. Immediately call a qualified service
technician. Water heaters subjected to flood conditions or any time the gas controls, main burner
or electrical components have been submerged in water require replacement of the entire water
heater.
• 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 and can ignite when
exposed to a spark or flame. To prevent the possibility of injury under these conditions, we recommend the hot water faucet be opened for several minutes at the kitchen sink before using any
electrical appliance which is connected to the hot water system. If hydrogen is present there will
probably be an unusual sound such as air escaping through the faucet as water begins to flow.
Do not smoke or have an open flame near the faucet at the time it is open.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to
publish a list of substances known to the State of California to cause cancer, birth defects, or other
reproductive harm, and requires businesses to warn of potential exposure to such substances.
WARNING: This product contains a chemical known to the State of California to cause cancer, birth
defects, or other reproductive harm.
This appliance can cause low-level exposure to some of the substances listed, including formaldehyde, carbon monoxide, and soot.
Table of Contents
Water Heater Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
I) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
II) Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5
III) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unpacking The Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearances And Accessibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IV) Lighting & Operating Instructions . . . . . . . . . . . . . . . . . . . . . . 18
V) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
VI) Integrated Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
VII) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
VIII) Combination Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
IX) Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
X) Parts Reference Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
–2–
I) INTRODUCTION
Thank you for purchasing a Commercial Water Heater.
Properly installed and maintained, it will provide years of
trouble free service.
This gas-fired water heater has been developed to produce
potable hot water for commercial demands and may also be
used in combination with space heating applications. Any
deviation from these applications could affect your warranty.
User Responsibilities
This manual has been prepared to acquaint you with the
installation, operation and maintenance of your gas fired
water heater and provide important safety information in
these areas. It is your responsibility to ensure that your
water heater is properly installed and cared for.
FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS
MANUAL MAY RESULT IN SERIOUS BODILY INJURY
AND/OR PROPERTY DAMAGE. THOROUGHLY READ
AND UNDERSTAND ALL INSTRUCTIONS BEFORE YOU
ATTEMPT TO INSTALL, OPERATE OR MAINTAIN THIS
HEATER.
Installation and service requires trade knowledge in the
areas of plumbing, electricity, venting, air supply and gas
supply. If you lack these skills or have difficulty understanding these instructions, you should not proceed. Enlist the
help of a qualified service technician to install this water
heater.
Service to the Power Vent System should only be performed by a qualified service technician.
The manufacturer and seller of this water heater will not
assume any liability for any property damage, personal
injury or death resulting from improper sizing, installation or
failure to comply with these instructions.
The warranty on this water heater is in effect only when the
water heater is installed and operated in accordance with
these instructions. A data plate identifying your water heater
can be found at the front of the water heater near the integrated control. When referring to your water heater, always
have the information listed on the data plate readily available.
Protect your warranty: Regularly service your water
heater as directed in the "Maintenance" section of this manual.
Retain your original receipt as proof of purchase.
Do not discard this manual. You or future users of this
water heater will need it for reference.
Examples of qualified service technicians include those
trained in the plumbing and heating industry, local gas utility personnel or an authorized service person.
–3–
II) SAFETY
WARNING
This water heater is design-certified by CSA International as
a Category I, non-direct vented water heater which takes its
combustion air either from the installation area or from air
ducted to the unit from the outside.
In addition to the installation instructions found in this manual, the water heater must be installed in accordance with
all local or state codes and with the latest editions of:
“National Fuel Gas Code” ANSI Z223.1 (NFPA 54) and
“National Electrical Code” (NFPA 70)” available from:
American National Standards Institute,
25 West 43rd Street,
New York, NY 10036
Massachusetts code requires this water heater to be
installed in accordance with Massachusetts Plumbing and
Fuel Gas Code 248 CMR Section 2.00 and 5.00.
Check your phone listings for the local authorities having
jurisdiction over your installation.
Safety Warning (Flammable Vapours)
W ARNI NG
FLAMMABLES
FLAMMABLES
FLAMMABLE VAPOURS
Vapours from flammable liquids will
explode and catch fire causing death or
severe burns.
Do not use or store flammable products
such as gasoline, solvents or adhesives in
the same room or area near the water heater.
Keep flammable products:
1. far away from heater;
2. in approved containers;
3. tightly closed; and
4. out of children’s reach.
This water heater has a main burner and an
automatic ignition system. The ignition system:
1. can come on at any time; and
2. will ignite flammable vapours.
Flammable Vapours
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
Do not store or use gasoline or other flammable vapours and liquids
in the vicinity of this or any other appliance. Storage of or use of gasoline
or other flammable vapours or liquids in the vicinity of this or any other
appliance can result in serious injury or death.
There is a risk of property damage, personal injury or death
from the by-products of combustion (e.g., flue gases), in
using fuel-burning appliances such as water heaters. Areas
that may not be suitable for water heater installation include
those where flammable liquids, gasoline, solvents, adhesives etc. are stored, or where engine-driven equipment or
vehicles are stored, operated or repaired. These, and similar products, should not be stored or used near the water
heater or air intake. Due to the nature of air movement,
flammable vapours can be carried some distance from the
point of storage. The gas-fired water heater igniter or burner flame can ignite these vapours causing a flashback, fire
or explosion, which may result in severe property damage,
serious personal injury or death. If flammable liquids or
vapours have spilled or leaked in the area of the water
heater, leave the area immediately and call the fire department from a neighbor’s home. Do not attempt to clean the
spill until all ignition sources have been extinguished.
Vapours:
1. cannot be seen;
2. are heavier than air;
3. go a long way on the floor; and
4. can be carried from other rooms to the
water heater by air currents.
Do not install this water heater where flammable products will be stored.
–4–
Safety Warning (Scalding)
Relief Valve Requirements (T&P)
All water heaters must be fitted with a proper temperature
and pressure relief valve. These valves must be certified as
meeting the requirements of the “Standard For Relief
Valves For Hot Water Supply Systems, ANSI
Z21.22/CSA 4.4”.
DANGER
CAUTION
Hot water produced by this appliance can cause severe
burns due to scalding. The hazard is increased for young
children, the aged or the disabled when water temperatures
exceed 52°C (125°F). Use tempering valves, also known as
mixing valves, in the hot water system to reduce the risk of
scalding at point-of-use such as lavatories, sinks and
bathing facilities. Such precautions must be followed when
this heater is operated in combination with dishwashing or
space heating applications.
Safety Warning (Carbon Monoxide)
DANGER
Hydrogen gas can be produced in a hot water system
served by this heater that has not been used for a long
period of time (generally two (2) weeks or more).
Hydrogen gas is extremely flammable and can ignite
when exposed to a spark or flame. To reduce the risk of
injury under these conditions, it is recommended that the
hot water faucet be opened for several minutes at the
kitchen sink before using any electrical appliance connected to the hot water system. Use caution in opening
faucets. If hydrogen is present, there will probably be an
unusual sound such as air escaping through the pipe as
the water begins to flow. There should be no smoking or
open flame near the faucet at the time it is open.
If this water heater has been exposed to flooding, freezing,
fire or any unusual condition, do not put it into operation until
it has been inspected and approved by a qualified service
technician.
THESE CONDITIONS CAN RESULT IN UNSEEN INTERNAL DAMAGE and are not subject to warranty coverage.
Carbon Monoxide Warning
• Follow all vent system requirements by
the local authorities having jurisdiction
over your installation.
• Failure to do so can result in death, explosion or carbon monoxide poisoning.
As with all fuel burning equipment, this heater requires an
adequate supply of air for combustion and ventilation. An
insufficient air supply can result in poor combustion or the
re-circulation of the flue gases. Such a condition can cause
soot build-up and present a fire hazard. Flow reversal of flue
gases can cause an increase of carbon monoxide inside of
the dwelling that could result in serious bodily harm or death
from asphyxiation.
MAKE SURE THE FLOW OF COMBUSTION AND VENTILATION AIR IS NOT RESTRICTED.
–5–
III) INSTALLATION
Unpacking the Water Heater
WARNING
Excessive Weight Hazard
Use two or more people to move and install
water heater. Failure to do so can result in
back or other injury.
Important: Do not remove any permanent instructions,
labels, or the data label from outside of the water heater or
on the inside of panels.
• Remove exterior packaging and place installation components aside.
• Inspect all parts for damage prior to installation and startup.
• Completely read all instructions before attempting to
assemble and install this product.
If you observe damage to the water heater or any of its components, DO NOT ASSEMBLE OR INSTALL IT OR MAKE
ANY ATTEMPT TO FIX THE DAMAGED PART(S). Contact
the place of purchase for further instructions.
• After installation, dispose of packaging material in the
proper manner.
IMPORTANT:
This water heater must be installed strictly in accordance
with the instructions enclosed, and local electrical, fuel
and building codes. It is possible that connections to the
water heater, or the water heater itself, may develop
leaks. IT IS THEREFORE IMPERATIVE that the water
heater be installed so that any leakage of the tank or related water piping is directed to an adequate drain in such a
manner that it cannot damage the building, furniture, floor
covering, adjacent areas, lower floors of the structure or
other property subject to water damage. This is particularly important if the water heater is installed in a multi-story
building, on finished flooring or carpeted surfaces. GSW
WILL NOT ASSUME ANY LIABILITY for damage caused
by water leaking from the water heater, pressure relief
valve, or related fittings. Select a location as centralized
within the piping system as possible. In any location
selected, it is recommended that a suitable drain pan be
installed under the water heater. This pan must limit the
water level to a MAXIMUM depth of 45mm (1 3/4 in.) and
have a diameter that is a minimum of 50mm (2 in.) greater
than the diameter of the water heater. Suitable piping shall
connect the drain pan to a properly operating floor drain.
When used with a fuel-fired heater, this drain pan must not
restrict combustion air flow.
Location Requirements
• Select a location near the center of the water piping system. The water heater must be installed indoors and in a
vertical position on a level surface. DO NOT install in
bathrooms, bedrooms, or any occupied room normally
kept closed.
• Locate the water heater as close to the gas vent as practical. Consider the vent system piping and combustion air
supply requirements when selecting the water heater
location. The venting system must be able to run from the
water heater to termination with minimal length and
elbows.
• Locate the water heater near the existing gas piping. If
installing a new gas line, locate the water heater to minimize the pipe length and elbows.
• The water heater should be located in an area not subject
to freezing temperatures. Water heaters located in
unconditioned spaces (i.e. attics, basements, etc.) may
require insulation of the water piping and drain piping to
protect against freezing. The drain and controls must be
easily accessible for operation and service. Maintain
proper clearances as specified on the data plate.
• The operation of air-moving devices such as exhaust
fans, ventilation systems, clothes-dryers, fire-places, etc.,
can affect the proper operation of the water heater. Note:
Special attention must be given to the location of these
devices and the conditions they may create. Flow reversal of flue gases may cause an increase of carbon
monoxide inside of the dwelling.
Pipe to
adequate
drain
45mm max.
(1¾ in.)
At least 50mm (2 in.) greater than
the diameter of the water heater.
Figure 1 Drain Pan Installation
strapped to avoid moving during an earthquake. Contact
local utilities for code requirements in your area.
Important: If installing over carpeting, the carpeting must
be protected by a metal or wood panel beneath the water
heater. The protective panel must extend beyond the full
width and depth of the water heater by at least 76mm (3 in.)
in any direction, or if in an alcove the entire floor must be
covered by the panel. The panel must be strong enough to
carry the weight of the water heater when full of water.
Figure 2 may be used as a reference guide to locate the
specific clearance locations. A minimum of 610mm (24 in.)
of front clearance and 102mm (4 in.) on each side should be
provided for inspection and service.
Clearances and Accessibility
Notice: Minimum clearances from combustible materials
are stated on the data plate located on the front of the water
In Earthquake Zones
Note: The water heater must be braced, anchored, or heater.
–6–
• If the water heater is installed in a restaurant or food service location where the floor is cleaned frequently, NSF
International requires the water heater to maintain
152mm (6 in.) of clearance above the floor. To comply
with the NSF International requirement, install leg extension kit. For availability contact 1-800-456-9805
• The water heater is certified for installation on a combustible floor.
GAS SUPPLY
DANGER
Back
Sides
•
•
•
Front 610mm (24 in.)
min. for service
Top View
•
•
Vent
Top to
ceiling
Explosion Hazard
Use a new CSA or AGA approved gas supply line.
Install a gas supply shut-off valve.
Do not connect a natural gas water heater
to a L.P. gas supply.
Do not connect a L.P. gas water heater to
a natural gas supply
Failure to follow these instructions can
result in death, an explosion or carbon
monoxide poisoning.
Read the data plate to be sure the water heater is made
for the type of gas you will be using in your application.
This information will be found on the data plate located near
the integrated control. If the information does not agree with
the type of gas available, do not install or attempt to start.
Call your dealer.
Note: An odourant is added by the gas supplier to the gas
used by this water heater. This odourant may fade over an
extended period of time. Do not depend upon this odourant
as an indication of leaking gas.
Gas Piping
This gas piping must be installed in accordance with all local
and provincial or state codes or, in the absence of such, the
latest edition of “National Fuel Gas Code” ANSI Z223.1
(NFPA 54).
Manual Gas
Shut-off
Valve
Sides
Ground
Joint
Union
Check with
local utility for
min. height
Drip Leg
Front View
Figure 2 Minimum Clearance Locations
Figure 3 Gas Piping
–7–
Note: If using a flexible gas connector, make sure its rating
tag matches or exceeds the input of the water heater.
Tables 1, 2, and 3 provide a sizing reference for commonly
used gas pipe materials. Consult the “National Fuel Gas
Code” for the recommended gas pipe size of other materials. Follow the instructions below and reference Figure 3 for
gas piping installation.
Note: When installing gas piping, apply sealing compounds
approved for use with natural and propane gas.
1. Install a readily accessible manual shut-off valve in the
gas supply line as recommended by the local utility. The
owner/operator must be shown the location of this valve
and be given instructions on how to use it to shut off the
gas to the heater.
2. Install a drip leg (if not already incorporated as part of
the water heater) as shown (see Figure 3). The drip leg
must be no less than 76mm (3 in.) long for the accumulation of dirt, foreign material, and water droplets.
3. Install a ground joint union between the gas valve and
the manual shut-off valve. This is to allow easy removal
of the gas valve.
4. Turn the gas supply on and check for leaks. Use a chloride-free soap and water solution (bubbles forming indicate a leak) or other approved method.
Gas Pressure
Important: The gas supply pressure must not exceed the
maximum supply pressure as stated on the water heater’s
data plate. Minimum supply pressure should also be maintained per the data plate.
Natural Gas Pipe Capacity (Cu. ft./hr)
Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific
gravity of 0.60 (natural gas).
Nominal Iron Pipe
Length of Pipe, Feet
Size, in.
10
20
30
40
50
60
70
80
90
100
125
150
175
200
1/2
132
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
3/4
278
190
152
130
115
105
96
n/a
n/a
n/a
n/a
n/a
n/a
n/a
1
520
350
285
245
215
195
180
170
160
150
130
120
110
100
1-1/4 1050
730
590
500
440
400
370
350
320
305
275
250
225
210
1-1/2 1600 1100
890
760
670
610
560
530
490
460
410
380
350
320
After the length of pipe has been determined, select the pipe size which will provide the maximum cubic feet per hour
required for the gas input rating of the water heater. By formula:
Gas Input of Water Heater (BTU/HR)
Cu. Ft. Per Hr. Required =
Heating Value of Gas (BTU/FT 3)
The gas input of the water heater is marked on the water heater data plate. The heating value of the gas (BTU/ft3) may
be determined by consulting the local natural gas utility.
Table 1
L.P. Gas Capacity
Maximum capacity of gas pipe in thousands of BTU per hour of undiluted liquified petroleum gasses (at 11 inches
water column pressure). Based on a Pressure Drop of 0.5 Inch Water Column.
Nominal Iron Pipe
Length of pipe, Feet
Size, (in)
10
20
30
40
50
60
70
80
90
100
125
150
1/2
275
189
152
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
3/4
576
393
315
267
237
217
196
185
173
162
146
132
1
1071
732
590
504
448
409
378
346
322
307
275
252
1-1/4
2205
1496
1212
1039
913
834
771
724
677
630
567
511
Example: Input BTU requirements of the water heater, 199,000 BTUH
Total pipe length, 80 feet - 1" IPS required.
Table 2
L.P. Gas Capacity
Maximum capacity of gas pipe in thousands of BTU per hour of undiluted liquified petroleum gasses (at 11 inches
water column pressure). Based on a Pressure Drop of 0.5 Inch Water Column.
Copper Tubing OD
Length of pipe, Feet
Size, (in)
10
20
30
40
50
60
80
100
125
5/8
206
141
n/a
n/a
n/a
n/a
n/a
n/a
n/a
3/4
348
239
192
164
146
132
n/a
n/a
n/a
7/8
536
368
296
253
224
203
174
154
137
Example: Input BTU requirements of the water heater, 199,000 BTUH
Total pipe length, 50 feet = 7/8" IPS required.
Table 3
–8–
Air Requirements
Gas Leak Testing
WARNING
Exposure to a higher gas supply pressure
may cause damage to the gas valve, resulting in explosion or fire. Consult your local
gas supplier and gas authorities. DO NOT
PUT INTO SERVICE IF OVER-PRESSURIZATION HAS OCCURRED.
Important: This water heater and its gas connection must
be leak tested before placing the appliance in operation.
• If the code requires the gas lines to be tested at a pressure exceeding 14 in. w.c. (3.5 kPa), the water heater and
its manual shut-off valve must be disconnected from the
gas supply piping system and the line capped.
• If the gas lines are to be tested at a pressure less than 14
in. w.c. (3.5 kPa), the water heater must be isolated from
the gas supply piping system by closing its manual shutoff valve.
U.L. recognized fuel gas and (CO) detectors are recommended in all applications and should be installed using the
manufacturer’s instructions and local codes, rules, or regulations.
Note: Air may be present in the gas lines and could prevent
the burner from lighting on initial start-up. The gas lines
should be purged of air by a qualified service technician
after installation of the gas piping system.
WARNING
Explosion Hazard
Have a qualified service technician make
sure L.P. gas pressure does not exceed 13
in. w.c. (3.24 kPa). Failure to do so can result
in death, explosion, or fire.
WARNING
An adequate air supply shall be provided for
combustion and ventilation of this water
heater.
An insufficient supply can result in poor
combustion and possible sooting of the
burner, combustion chamber, or flue passageway. This may present a potential fire
hazard or create a serious health hazard by
producing carbon monoxide.
Important: Air for combustion and ventilation must not
come from a corrosive atmosphere. Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage.
Installations in or for certain places including, but not limited
to, those listed below will require outdoor air for combustion
to reduce the risk of chemical exposure:
• Beauty shops
• Photo processing labs
• Buildings with indoor pools
• Water heaters installed in laundry, hobby or craft rooms
• Water heaters installed near chemical storage areas
Combustion air must be free of acid-forming chemicals.
These chemicals are found in aerosol sprays, detergents,
bleaches, cleaning solvents, air freshener, paint and varnish
removers, refrigerant, and many other commercial products. When burned, vapours from these products form highly corrosive acid compounds. These products should not be
stored or used near the water heater or air inlet.
The area in which the heater is located is classified as either
“an unconfined space” or “a confined space”.
An unconfined space is defined as a space having a volume not less than 50 cubic feet per 1000 BTU/hour (4.8
cubic meters per kilowatt) of combined input rating of all
appliances using the space. Adjacent open rooms may be
included as part of the unconfined space provided there
are no closeable doors between these rooms. An example of this is an open basement.
A confined space is one smaller than described above. Air
shall be supplied through permanent openings as described
in Figure 4. At no time shall an air opening have a dimension of less than 76mm (3 in.) and at no time shall any top
opening be lower than the top of the water heater.
For buildings that are not well sealed (do not have tight fitting doors and windows) natural air infiltration may provide
sufficient air required for combustion and ventilation. For
buildings using tight construction (newer and renovated
structures), the air supply shall be introduced from the outdoors, regardless of whether the space is confined or
unconfined.
Where an exhaust fan or any other air consuming appliance
(e.g. clothes dryer, furnace, etc.) is installed in the same
space as the water heater, sufficient air openings must be
available to provide fresh air when all appliances are operating simultaneously.
Combustion Air “Supply” Ducts
Air supply ducts shall be of galvanized steel or equivalent
corrosion resistant material. A single air duct may not be
substituted when required for upper and lower air openings.
Horizontal upper combustion air ducts shall not slope downward toward the air inlet.
–9–
Louvers and Grilles
Openings for air supply ducts must provide free unobstructed air movement. Louver and grille openings must be sized
to ensure that the FREE OPEN AREA is never less than the
area of the air duct.
LOCATION:
The locations for top and bottom openings are as follows:
The top opening shall commence within 305mm (12 in.) of
the top of space and the bottom opening shall commence
within 305mm (12 in.) of the bottom of the enclosure.
Air Opening Requirements
(a) Equipment located in confined spaces; all air
from inside the building.
Two permanent openings (top and bottom) shall be provided connecting the confined space (e.g., closet/small
room) with the unconfined space. Each opening shall
have a free area of one square inch per 1,000 BTU/hour
(22 cm²/kW) input of all appliances in the confined
space, but not less than 100 square inches (645 cm²).
(a)
Permanent
Ventilation
Air
(b) Basement installation, equipment located in
confined spaces; all air from outdoors.
Outside air inlets shall be a minimum of 305mm (12 in.)
above the grade (snow) line. When supplying air directly from the outdoors:
Two openings (top and bottom) shall be provided with
each opening having a minimum free area of one
square inch per 4,000 BTU/hour input (5.5 cm²/kW) of
total input rating of all appliances in the confined space.
Combustion
Air Duct
305mm
(12 in.)
12” Grade
305mm
(12 in.)
12”
(b)
(c) Equipment located in confined spaces; all air
from outdoors.
When supplying air directly from the outdoors using horizontal ducting, each opening shall have a free minimum area of one square inch per 2,000 BTU/hour (11
cm²/kW) of total input rating of all appliances in the confined space.
Venting
Outdoor
Air Ducts
Combustion
(c)
(d) Equipment located in confined spaces; all air
from outdoors through ventilated attic.
When supplying air directly through vertical ducting,
each opening shall have a free minimum area of one
square inch per 4,000 BTU/hour (5.5 cm²/kW) of total
input rating of all appliances in the confined space.
Outlet Air
Inlet
Air Ducts
(d)
*U.S. installations require a dual duct system.
Figure 4 Equipment Location and
Combustion/Ventilation Air Requirements
– 10 –
Com bined input of
all appliances in
confined space
Required
free area of
duct
Acceptable equivalent duct
diam eter
A1
B2
BTU/h (kW)
mm2 (in2)
mm (in)
mm (in)
75,000 (23)
7,000 (11)
100 (4)
125 (5)
100,000 (30)
9,000 (14)
100 (4)
125 (5)
125,000 (37)
12,000 (18)
125 (5)
150 (6)
150,000 (45)
14,000 (22)
125 (5)
150 (6)
175,000 (53)
16,000 (25)
150 (6)
175 (7)
200,000 (60)
19,000 (29)
150 (6)
175 (7)
225,000 (68)
21,000 (32)
150 (6)
175 (7)
250,000 (75)
23,000 (36)
175 (7)
200 (8)
275,000 (83)
26,000 (40)
175 (7)
200 (8)
300,000 (90)
28,000 (43)
175 (7)
200 (8)
325,000 (98)
30,000 (47)
200 (8)
225 (9)
350,000 (105)
32,000 (50)
200 (8)
225 (9)
375,000 (113)
35,000 (54)
200 (8)
225 (9)
400,000 (120)
37,000 (58)
225 (9)
250 (10)
Notes:
1. Maximum length of ducts in column A is 6.1 equivalent metres (20
ft).
2. Maximum length of ducts in column B is 15.2 equivalent metres
(50 ft).
Table 4
• Some models are shipped with a vent reducer. The vent
reducer can be installed directly to the drafthood if the
existing vent system is adequately sized to support the
exhaust gases.
• Vertical gas vents must terminate with a listed cap or
other roof assembly and be installed according to their
manufacturer’s instructions.
• Horizontal vent connections must have an upward slope
of at least 21mm per metre (1/4 in per foot).
• Gas vents must be supported to prevent damage, joint
separation, and maintain clearances to combustible
materials.
• Vent connection joints should be fastened by sheet metal
screws or by other approved methods.
• Vent and vent connectors should have adequate support
to keep weight off the drafthood.
All pipe, fittings, and procedures must conform to American
National Standard Institute and American Society for Testing
and Materials (ANSI/ASTM) standards in the United States.
Important: If you lack the necessary skills required to properly install this venting system, you should not proceed, but
get help from a qualified service technician.
Drafthood/Damper Installation
Venting
WARNING
It is the responsibility of the installing contractor to provide a
vent adequate in capacity and in good usable condition.
Btu/hr capacity limitations are governed by the style and
height of the vent/chimney. Vent piping must be installed in
accordance with all local and state codes or, in the absence
of such, the latest edition of “National Fuel Gas Code”
ANSI Z223.1 (NFPA 54).
U.L. recognized fuel gas and carbon monoxide (CO) detectors are recommended in all applications and should be
installed using the manufacturer’s instructions and local
codes, rules, or regulations.
Important: Check to make sure the vent pipe is not blocked
in any way.
• Venting should be as direct as possible with a minimum
number of pipe fittings.
• Exhaust gas vents must be installed with U.L. listed type
B vent pipe according to the vent manufacturer’s instructions and the terms of its listing.
• Single wall vent connectors must have 152mm (6 in.) of
clearance from unprotected combustible surfaces.
• If sidewall venting is necessary, a power vent kit is
required. For availability contact 1-800-456-9805.
• Vents that run through unconditioned spaces where
below freezing temperatures are expected should be
properly insulated to prevent freezing.
• Existing vent systems must be inspected for obstructions,
corrosion and proper installation.
• Vents must be connected to the water heater’s drafthood
by a certified vent connector or by directly originating at
the drafthood opening.
Do not operate heater with damper in closed
position, it must be in the open position during water heater operation. Do not negate the
action of any existing safety or operational
controls.
Install the supplied drafthood and damper on the flue outlet
collar. Use only the supplied drafthood and damper, DO
NOT use any substitute or alter the components in any way.
Place the damper on the water heater (see Figure 5). Align
the four pilot holes on top of the water heater with the 4 corresponding holes on the damper bracket and secure with
the supplied screws. Next, align the drafthood legs with the
4 corresponding pilot holes on top of the water heater and
attach securely with the supplied screws. Locate the wiring
from the ECO, and attach it to the wiring harness on the
damper (see Figure 5). Once damper is installed, ensure
that the damper position indicator is visible (See Figure 5).
Flue Outlet Reducer
Some units are shipped with a flue outlet reducer (See
Figure 6). Use only the flue outlet reducer supplied with this
unit. The flue outlet reducer should be connected to the top
of the flue damper and sealed by high temperature silicon.
The vent piping must be installed in accordance with all
local and state codes or, in the absence of such, the latest
edition of “National Fuel Gas Code” ANSI Z223.1 (NFPA
54).
– 11 –
Water Heater
Model Base #
Drafthood
Bracket screws
Drafthood
screws
Damper
motor
Damper wiring
harness
Damper
motor
Damper wiring
harness
Damper in
OPEN position
75-125
80-199
80-250
100-199
100-270
75-300
75-360
75-399
75-300NOx
60238
60053
60053
71325
71325
60053
N/A
N/A
60239
60057
60057
75085
75085
60057
60194
60194
60239
60057
60057
75086
60023
60057
60195
60195
N/A
60194
60195
75-350NOx
N/A
60194
60195
Table 5
ECO wiring
harness
Damper position
indicator
Figure 5 Flue Damper Assembly
WATER SUPPLY
Piping Installation
Piping, fittings, and valves should be installed according to
the installation drawing (Figure 7). If the indoor installation
Inlet Tube
Inlet Tube
(Optional Front) (Optional Back)
Dip Tube
Dip Tube Usage
area is subject to freezing temperatures, the water piping
must be protected by insulation. Water supply pressure
should not exceed 80% of the working pressure of the water
heater. The working pressure is stated on the water heater’s
data plate. If this occurs, a pressure reducing valve with a
bypass should be installed in the cold water inlet line to the
entire system. This should be placed on the supply to the
entire structure in order to maintain equal hot and cold water
pressures.
Note: Water supplied to the unit that exceeds 12 grains
(205 mg/l) total hardness may reduce the life and performance of the water heater. Depending on the degree of hardness, it is recommended that either a water pre-treatment
system or a water softener be installed and properly maintained.
Important: Heat cannot be applied to the water fittings on
the water heater as they may contain nonmetallic parts. If
solder connections are used, solder the pipe to the adapter
before attaching the adapter to the hot and cold water fittings.
1. The water heater may have three water piping connection points. The top and front are 1-1/2” NPT and the
connections on the back of some heaters are 2” NPT.
When using front or back connections a combination
nipple inlet tube is required (top entry uses a dip tube).
Any one of the options listed in Table 5 may be used.
For availability contact 1-800-456-9805.
Note: Inlet and outlet piping connections cannot be mixed.
In a closed system use a
Thermal Expansion Tank
Hot Water
Outlet
High
temperature
silicon sealant
Flue outlet reducer
Unions
Main Water
Supply
Cold Water
Inlet Valve
Temperature and
Pressure Relief Valve
Metal drain
pan 45mm
(1-3/4 in.)
depth max.
Drain line 19mm
(3/4 in.) ID min.
Floor Drain
Damper in OPEN position
Figure 6 Flue Outlet Reducer
Pressure Reducing
Valve with Bypass
Discharge line
152mm (6 in.)
max. above
drain
Damper motor
Damper wiring harness
Cold Water
Supply to Fixtures
Figure 7 Water Piping Installation
– 12 –
Massachusetts:
Install a vacuum relief
in cold water line per
section 19MGL 142
For example, a top inlet connection must use a top outlet
connection.
2. The installation of unions in both the hot and cold water
supply lines is recommended for ease of removing the
water heater for service or replacement.
3. Since most commercial installations utilize higher temperatures, the use of a tempering valve is strongly
recommended in all domestic hot water lines (i.e.
public restroom sinks, etc).
4. If installing the water heater in a closed water system,
install an expansion tank in the cold water line as specified under “Closed System/Thermal Expansion”.
5. Install a shut-off valve in the cold water inlet line. It
should be located close to the water heater and be easily accessible. The owner/operator must be shown the
location of this valve and be given instructions on how
to use it to shut off the water to the heater.
6. The water heater is shipped with a factory-installed
Temperature and Pressure Relief Valve. Install a discharge line in the opening in the T&P valve.
7. After piping has been properly connected to the water
heater, remove the aerator at the nearest hot water
faucet. Open the hot water faucet and allow the tank to
completely fill with water. To purge the lines of any
excess air, keep the hot water faucet open for 3 minutes
after a constant flow of water is obtained. Close the
faucet and check all connections for leaks.
DO NOT tamper with the integrated control, gas valve, igniter or temperature and pressure relief valve. Tampering
voids all warranties. Only qualified service technicians
should service these components.
DO NOT use with piping that has been treated with chromates, boiler seal, or other chemicals.
DO NOT add any chemicals to the system piping which will
contaminate the potable water supply.
Tempering Valve Installation
Temperature and Pressure (T&P) Relief Valve
For protection against excessive pressures and temperatures, a temperature and pressure relief valve must be
installed in the opening marked “T&P RELIEF VALVE” (see
Figure 9). This valve must be design certified by a nationally recognized testing laboratory that maintains periodic
inspection of the production of listed equipment or materials
as meeting the requirements of the “Standard For Relief
Valves For Hot Water Supply Systems”, ANSI
Z21.22/CSA 4.4”. The function of the temperature and pressure relief valve is to discharge water in large quantities in
the event of excessive temperature or pressure developing
in the water heater. The valve’s relief pressure must not
exceed the working pressure of the water heater as stated
on the data plate.
Cold
Water
Inlet
Follow the tempering
valve manufacturer’s
instructions.
Hot
Water
Outlet
Tempered water
to fixtures
Figure 8 Tempering Valve
Closed System/Thermal Expansion
Periodic discharge of the temperature and pressure relief
valve may be due to thermal expansion in a closed water
supply system. The water utility supply meter may contain a
check valve, backflow preventer or water pressure reducing
valve. This will create a closed water system. During the
heating cycle of the water heater, the water expands causing pressure inside the water heater to increase. This may
cause the temperature and pressure relief valve to discharge small quantities of hot water. To prevent this, it is
recommended that a diaphragm-type expansion tank (suitable for potable water) be installed on the cold water supply
line. The expansion tank must be properly sized for the
application. Contact the local water supplier or plumbing
inspector for information on other methods to control this situation.
Important: Do not plug or remove the temperature and
pressure relief valve.
Tempering valve
(Set to 120°F)
A Tempering Valve should be installed per the manufacturer’s instructions in the hot water line. See Figure 8 for sample tempering valve installation.
Please note the following:
DO NOT install this water heater with iron piping. The system should be installed only with piping that is suitable for
potable (drinkable) water such as copper, CPVC, or polybutylene. DO NOT use PVC water piping.
DO NOT use any pumps, valves, or fittings that are not
compatible with potable water.
DO NOT use valves that may cause excessive restriction to
water flow. Use full flow ball or gate valves only.
DO NOT use any lead based solder on potable water lines.
Use appropriate tin-antimony or other equivalent material.
WARNING
•
•
•
•
– 13 –
Explosion Hazard
If the temperature and pressure relief
valve is dripping or leaking, have a
licensed plumber repair it.
Do not plug valve.
Do not remove valve.
Failure to follow these instructions can
result in death or an explosion.
The Discharge Line:
• Must not be smaller than the pipe size of the relief valve
or have any reducing coupling installed in the discharge
line.
• Must not be capped, blocked, plugged or contain any
valve between the relief valve and the end of the discharge line.
• Must terminate a maximum of 152mm (6 in.) above a
floor drain or external to the building.
• Must be capable of withstanding 121°C (250°F) without
distortion.
• Must be installed to allow complete drainage of both the
valve and discharge line.
Temperature
and Pressure
Relief Valve
Discharge line
152mm (6 in.)
above drain.
Drain line 19mm
(3/4 in.) min.
Drain
Figure 9 T&P Relief Valve
Important: Only a new temperature and pressure relief
valve should be used with your water heater. Do not use an
old or existing valve as it may be damaged or not adequate
for the working pressure of the new water heater. Do not
place any valve between the relief valve and the tank.
The Temperature & Pressure Relief Valve:
• Must not be in contact with any electrical part.
• Must be connected to an adequate discharge line.
• Must not be rated higher than the working pressure
shown on the data plate of the water heater.
• The BTUH rating of the T&P valve must be greater than,
or equal to, the input rating of the water heater.
Hot Water
Outlet
Shut-off Valve
Shut-off Valve
Thermometer
Storage Tank
Temperature and
Pressure Relief Valve
Temperature
and Pressure
Relief Valve
Pressure
Reducing
Valve
Heater
Thermal
Expansion
Tank
45mm (1 1/2 in.)
Cold water supply
Plug
Cock
Circulating
Pump
Shut-off Valve
Check
Valve
Note: Install a vacuum
relief valve if required
by local codes.
Figure 10 Commercial Unit with Auxiliary Storage Heater - Forced Circulation With or Without Building Recirculation Front Inlet/Outlet Connections
– 14 –
Outlet Boosted
Temperature
Hot Water
to Fixtures
Shut-off Valve
Shut-off Valve
Temperature
and Pressure
Relief Valve
Temperature
and Pressure
Relief Valve
Thermometer
Thermometer
Pre-Heater
Typical
Booster
Heater
Thermal
Expansion
Tank
Pressure
Reducing
Valve
Check Valve
Shut-off Valve
Pre-Heated
Water to
the Booster
45mm (1 1/2 in.)
Cold water supply
Note: Install a vacuum
relief valve if required
by local codes.
Figure 11 Commercial Unit with Auxiliary Booster Heater - Two Temperature (With or Without Building Recirculation)
Thermometer
Outlet Boosted
Temperature
Thermometer
Pre-Heated
Water to
the Booster
Hot Water
to Fixtures
Shut-off Valve
Pressure
Reducing Valve
Shut-off Valve
45mm (1 1/2 in.)
Cold water supply
Check Valve
Temperature
and Pressure
Relief Valve
Typical
Booster
Heater
Thermal
Expansion Tank
Pre-Heater
Temperature
and Pressure
Relief Valve
Note: Install a vacuum
relief valve if required
by local codes.
Figure 12 Commercial Unit with Auxiliary Storage Heater - Forced Circulation With or Without Building Recirculation Top Inlet/Outlet Connections
– 15 –
ELECTRICAL SUPPLY
WARNING
•
Electrical Shock Hazard
• Disconnect power before
servicing.
• Replace all parts and panels
before operating.
• Failure to do so can result in
death or electrical shock.
•
•
•
•
breaker protection. The water heater draws less than 7
amps.
Wire sizes and connections comply with all applicable
codes.
Wiring is enclosed in approved conduit (if required by
local codes).
The water heater and electrical supply are properly
grounded.
The water heater must be connected to a branch circuit
that is dedicated to the water heater only.
This water heater must be connected directly to a dedicated branch circuit outlet. Do not use an extension cord
to supply electrical power to this water heater.
If you lack the necessary skills required to properly install
the electrical wiring to this water heater, do not proceed but
have a qualified service technician perform the installation.
Wiring Diagram
When making the electrical connections, always make sure:
• The voltage and frequency correspond to that specified
on the water heater data plate on the front of the water
heater.
• The electrical supply has the proper overload fuse or
The wiring diagrams can be found in Figure 13. Always reference the wiring diagram(s) for the correct electrical connections.
Caution: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
GND
120 VAC
Honeywell Integrated Water Heater
Control S9631B for Commercial Gas
Water Heaters.
Spark
igniter
N
primary:
120 VAC
L1
Vent
M
damper
transformer
secondary:
24 VAC
External communication device
Gas valve
Upper sensor
& ECO
Lower sensor
Integrated control
Electrical Ratings:
Line Voltage: 120 Vac, 60 Hz.
Transformer: 24 Vac Nom. (30 Vac Max., 8 Vac Min.)
5.0 VA plus external loads (gas valve,
vent damper, etc.)
Main Valve: Full Load 2A at 24 Vac (0.5 to 0.6 PF).
In Rush 6A at 24 Vac (0.5 to 0.6 PF)
Vent Damper (Optional)
Full Load:
0.5A at 24 Vac.
In Rush:
1A at 24 Vac.
Pilot Valve (Optional)
Full Load:
2A at 24 Vac (0.5 to 0.6 PF).
In Rush:
6A at 24 Vac (0.5 to 0.6 PF).
Schematic Diagram
Integrated control
ORN
WHT
Spark igniter
BLK
GRN
BLK
BLK
WHT
Power cord
PRP
ORN
WHT
BRN
BLK - Black
WHT - White
GRN - Green
YEL - Yellow
BRN - Brown
ORN - Orange
PNK - Pink
PRP - Purple
24 VAC
transformer
External communication device
BRN
PNK
ORN
BRN
YEL
BLK
BLK
BLK
BLK
BLK
Vent damper
Gas valve
Upper sensor
ECO
Lower sensor
Wiring Diagram
Figure 13 Wiring Diagrams
– 16 –
INSTALLATION CHECKLIST
Check Here
Water Heater Location
1. Centrally located with the water piping system.
Located as close to the gas piping and vent pipe
system as possible.
2. Located indoors and in a vertical position.
Protected from freezing temperatures.
3. Proper clearances from combustible surfaces
maintained and not installed directly on a carpeted floor.
4. Sufficient room to service the water heater.
5. Provisions made to protect the area from water
damage. Properly sized drain pan installed and
piped to an adequate drain.
6. Installation area free of corrosive elements and
flammable materials.
Gas Supply and Piping
1. Gas supply is the same type as listed on the
water heater data plate.
2. Gas line equipped with full opening shut-off
valve, union and drip leg.
3. Approved pipe joint compound used.
4. Adequate pipe size and of approved material.
5. Chloride-free soap and water solution or other
approved means used to check all connections
and fittings for possible gas leaks.
6. Rating tag of flexible gas connector (if used),
matches or exceeds the input of the water heater.
Check Here
Vent Termination
Vertical
1. Vertical gas vents terminated with a listed cap or
other roof assembly and installed according to
their manufacturer’s instructions.
Water System Piping
1. Temperature and pressure relief valve properly
installed with a discharge line run to an open
drain and protected from freezing.
2. All piping properly installed and free of leaks.
3. Water heater completely filled with water.
4. A properly sized expansion tank installed on
closed system.
5. A tempering valve installed as per the manufacturer’s instructions.
Electrical Connections
1. Unit “hard-wired” to a dedicated 120V power supply.
2. Proper polarity.
3. Water heater properly grounded.
4. Installed in accordance with prevailing provisions
of local codes, or in the absence of such, the latest edition of “National Electrical Code” (NFPA
70).
If the answer to all of the questions
above is “Yes”, proceed with lighting
the heater.
Vent Pipe System
1. Vent pipe and fittings of approved material.
2. Acceptable size, length, and number of elbows
on exhaust outlet pipe.
3. Installed in accordance with prevailing provisions
of local codes, or in the absence of such, the latest edition of “National Fuel Gas Code” ANSI
Z223.1 (NFPA 54).
4. Vent connectors securely fastened with screws
and supported properly to maintain 152mm (6 in.)
clearance.
5. Drafthood and damper properly installed.
6. Drafthood or vent pipe not obstructed in any way.
– 17 –
IV) LIGHTING & OPERATING INSTRUCTIONS
WARNING: If you do not follow these instructions
exactly, a fire or explosion may result causing property
damage, personal injury or loss of life.
A. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the
pilot by hand.
B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because
some gases are heavier than air and will settle on the floor.
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 neighbour’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call fire department.
C. Use only your hand to press the integrated control buttons. Never use tools. If the control buttons will not push
in by hand, don’t try to repair them, call a qualified service technician. Force or attempted repair may result in
a fire or explosion.
D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to
inspect the appliance and to replace any part of the control system and any gas control which has been under
water.
Gas Control
Knob
“OFF” Position
Honeywell Gas Valve
“ON” Position
– 18 –
V) OPERATION
Safety Shut-off
water heater until proper adjustments or repairs are made to
the vent pipe system.
This water heater is designed to automatically shut-off in the
event of the following:
1. The pilot flame is extinguished for any reason.
2. The water temperature exceeds 96°C (205°F).
Water Temperature Regulation
Read and understand these directions thoroughly before
attempting to operate the water heater (“Lighting &
Operating Instructions”). Check the data plate on the front of
the water heater for the correct gas. Do not use this water
heater with any gas other than the one listed on the data
plate. If you have any questions or doubts, consult your gas
supplier or gas utility company.
L.P. (Propane) Models
Propane gas is heavier than air and in the occurrence of a
leak in the system, the gas will settle on the floor level.
Basements, crawl spaces, skirted areas under mobile
homes (even when ventilated), closets and areas below
ground level will serve as pockets for the accumulation of
gas. Before lighting a propane gas water heater, smell all
around the appliance at floor level. If you smell gas, follow
the instructions as given in the warning on the front page.
When your propane tank runs out of fuel, turn off the gas at
all gas appliances including pilot lights. After the tank is
refilled, all appliances must be re-lit according to their manufacturer’s instructions.
WARNING:
Risk of scalding
Hot water can produce third degree burns
in 6 seconds at . . . . . . . .60°C (140°F)
in 30 seconds at . . . . . . .54°C (130°F)
in 5 minutes at . . . . . . . . .49°C (120°F)
The integrated control is adjusted to a temperature setting
of 49°C (120°F) when it is shipped from the factory. To make
a change to this setting, use the buttons on the front of the
integrated control to select the desired water temperature.
Important: Since most commercial installations utilize higher temperatures, the use of a tempering valve is strongly
recommended in all domestic hot water lines (i.e. public
restroom sinks, etc). Auxiliary commercial equipment (i.e.
dishwashers, laundry equipment, etc.) may require higher
temperature settings. Refer to instruction manuals supplied
with this type equipment for recommended temperature settings.
Important: Adjusting the integrated control past the 49°C
(120°F) setting will increase the risk of scald injury.
DANGER
Checking the Draft
Burn Hazard
Do not touch vent.
Doing so can result in
burns.
After successfully lighting the water heater, allow the unit to
operate for 15 minutes and check the drafthood relief opening for proper draft. Pass a match flame around the relief
opening of the drafthood (See Figure 14). A steady flame
drawn into the opening indicates proper draft. If the flame
flutters or is blown out, combustion products are escaping
from the relief opening. If this occurs, do not operate the
Water temperature over 52°C (125°F) can cause
severe burns instantly or death from scalds.
Children, disabled and elderly are at highest risk of
being scalded.
Feel water before bathing or showering.
Temperature limiting valves are recommended.
Water Heater Operation
When the integrated control calls for heat, it will signal the
damper to open. Once the damper fully opens, it will signal
the igniter to light the pilot. The pilot will then ignite the main
burners. The water heater will operate until the call for heat
ends. At this time the main burners and pilot will shut-off and
the damper will close. See Figure 22 for a sequence of
operation flowchart.
Figure 14 Vent Draft Test
– 19 –
Burner Flames
Inspect the burner flames through the viewport and compare them to the drawings in Figure 15. A properly operating burner should produce a soft blue flame and be about
50mm (2 in.) to 64mm (2 -1/2 in.) in height. Blue tips with
yellow inner cones are satisfactory. The tips of the flame
may have a slight yellow tint. The flame should not be all
yellow or have a sharp blue-orange colour. Contaminated
air may cause an orange coloured flame. Contact a qualified
service technician if the flame is not satisfactory.
50 - 64mm
- 2 1/2 in.)
2 - 2(21/2”
Figure 15 Pilot/Burner Flame
Stacking
Stacking occurs when a series of short draws of hot water
are taken from the water heater tank. This causes increased
cycling of the burner and can result in increased water temperatures at the hot water outlet. A tempering valve should
be installed in the hot water supply line to reduce the risk of
scald injury.
1. Normal expansion and contraction of metal parts during
periods of heat-up and cool-down.
2. Condensation causes sizzling and popping within the
burner area and should be considered normal.
3. Sediment buildup in the tank bottom will create varying
amounts of noise and may cause premature tank failure. Drain and flush the tank as directed under
“Draining and Flushing”.
Smoke/Odour
The water heater may give off a small amount of smoke and
odour during the initial start-up of the unit. This is due to the
burning off of oil from metal parts of a new unit and will disappear after a few minutes of operation.
VI) INTEGRATED CONTROL
High Humidity or Dripping Water
Over time, dripping water or high ambient humidity can create unwanted electrical paths on the circuit board, causing
the integrated control to fail. Never install an appliance
where water can drip on the controls. In addition, high ambient humidity can cause the gas valve to corrode and finally
fail. Where the appliance may be installed in a humid
WARNING
Emergency Shut Down
Important: If overheating occurs or the gas supply fails to
shut off, close the manual gas supply shut-off valve and turn
the gas valve knob to the “OFF” position. Turn off the electrical supply to the unit and close the cold water supply
valve. Do not operate the water heater again until it has
been thoroughly checked by a qualified service technician.
Operational Conditions
Condensation
Moisture from the products of combustion condenses on the
tank surface and the outside jacket of the water heater and
forms drops of water which may fall onto the burner or other
hot surfaces. This will produce a “sizzling” or “frying” noise.
This condensation is normal and should not be confused with a leaking tank. Condensation may increase or
decrease at different times of the year.
High efficient energy saver water heaters will produce larger amounts of condensation on initial start up or when a
large amount of hot water is being used. Do not confuse
this with a “tank leak”. Once the water reaches a temperature of 49°C (120°F) and the tank warms up (usually 1-2
hours), the condensation will stop.
Important: It is always recommended that a suitable drain
pan be installed under the water heater to protect the area
from water damage resulting from normal condensation production, a leaking tank or piping connections. Under no circumstances is the manufacturer to be held responsible for
any water damage in connection with this water heater.
Water Heater Sounds
1.
2.
3.
4.
During the normal operation of the water heater sounds or
noises may be heard. These noises are common and may
result from the following:
– 20 –
Fire or Explosion Hazard
Can cause severe injury, death or
property damage.
The integrated control can malfunction if
it gets wet, leading to accumulation of
explosive gas.
. Never install where water can flood, drip
or condense on the integrated control.
. Never try to use an integrated control
that has been wet - replace it.
Liquefied petroleum (LP) gas is heavier
than air and will not vent upward naturally.
. Do not light pilot or operate electric
switches, lights, or appliances until you
are sure the appliance area is free of
gas.
If a new gas valve is to be installed, turn
off gas supply before starting installation.
Conduct Gas Leak Test according to gas
valve manufacturer’s instructions after
the gas valve is installed.
If the integrated control must be mounted
near moisture or water, provide suitable
waterproof enclosure.
atmosphere, make sure air circulation around the integrated
control and the gas valve is adequate to prevent condensation. It is also important to regularly check out the system. A
NEMA 4 enclosure may be needed.
Water or Steam Cleaning
Once an integrated control or gas valve has been wet, it
may operate unreliably and must be replaced. If the appli-
ance is likely to be cleaned with water or steam, the controls
and associated wiring should be covered so that water or
steam cannot reach them. The controls should be high
enough above the bottom of the cabinet so they will not be
subjected to flooding or splashing during normal cleaning
procedures. If necessary, shield the controls to protect them
from splashing water. A NEMA 4 enclosure is recommended for the ignition module.
Operating Instructions
The on-board user interface consists of three push-button
switches (“HOTTER”, “COOLER” and “MODE”) and a threedigit, 7-segment LED display (see Figures 16 & 17).
Together these controls can be used to view system settings and status as well as set some control parameters.
The integrated control is active only while power is applied
and can be set to one of three different modes: "Reading",
"Installer" or "Error” (explained below).
(View as installed)
Display
“HOTTER“
Button
“MODE”
Button
“COOLER”
Button
(View with cover removed)
Figure 16 Integrated Control
Figure 17 Integrated Control (Details)
Operational status codes
This mode is used to display the operational status of the
integrated control. If an “Err” code is being displayed, press
and hold the “COOLER” button for 3 seconds to reset. To
reset temperature set point, make sure the heater is not
fired on. Press and hold the “HOTTER”, “COOLER” and
“MODE” buttons simultaneously for 5 seconds until
Description
“SP” is displayed. Press the (HOTTER) button to increase
and
(COOLER) button to decrease the temperature set
point. When the set point is reached, press and hold the
“HOTTER”, “COOLER” and “MODE” buttons again for 5
seconds. The display should now be back to normal showing “StA” and “SP”.
Display Shows
Description
Display Shows
Calling for heat
Valve control disconnect
Opening damper
Damper quick connector
disconnect
Pilot igniting (90 seconds)
Primary disconnect
no display
Waiting for ignite (60 seconds)
Secondary disconnect
no display
Ignition failed lock out (after 3
trials)
Line disconnect
no display
Successful sense igniting
Sensor 2 disconnected
Open gas valve
Sensor 1 disconnected
ECO cut off
Main gas valve disconnected
Thermostat satisfied
Pilot gas valve disconnected
Figure 18 Display readout definitions (Operational Status codes)
– 21 –
Reading mode
The integrated control defaults to Reading mode after a
reset. This mode is for information display only and no
adjustments can be made to parameter settings. The display characters for each parameter and their definitions are
shown in Figure 19. Use the “MODE” button to cycle
Text
Description
Display Shows
through the available parameters. Once a parameter is
selected, the
(HOTTER) and
(COOLER) buttons are
used to view the value of the selected parameter. If no button is pressed, the display will cycle through the parameter's
name, value and unit at one (1) second intervals.
Text
sta
Current State
°F
fla
Flame Current (Measured)
°C
sp
Current Setpoint
uA
s1t
s2t
hr
Current Sensor 1
Temperature (Limit)
Current Sensor 2
Temperature (2-wire)*
Description
Temp. Displayed is in
Degrees Fahrenheit
Temp. Displayed is in
Degrees Celsius
Units Displayed are in
Micro Amps
off
Input or Output is Off
on
Input or Output is On
Display Shows
Heat Request Status
Figure 19 Display readout definitions (Reading mode)
Installer mode
The integrated control must be in installer mode in order for
the parameters (see Figure 20) to be adjusted. This mode is
entered by pressing and holding all three buttons simultaneously for about three (3) seconds. Repeating this action,
or if no key is pressed for 60 seconds, will set the integrated control back to Reading mode. Use the “MODE”
Text
Description
Display Shows
Reset the Hard Lockout
loc
Flag
Reset the Soft Lockout
rst
Timer
button to cycle through the available parameters. Once a
parameter is selected, use the (HOTTER) and (COOLER) buttons to adjust the value of the selected parameter. If
no key is pressed, the display cycles through parameter
name, value and unit at 1 second interval for 60 seconds
before returning to Reading mode.
Text
Description
Display Shows
F-C
Set mode to °F or °C
sp_
Set the Setpoint mode
Figure 20 Display readout definitions (Installer mode)
Error mode
When the integrated control detects a failure condition it
enters Error mode. In this mode the display alternates
between showing “Err” and an error code number, displaying each for one (1) second. The display characters for each
Description
Flame was sensed out of normal
sequence
Flame was sensed during prepurge
Flame was sensed during postpurge
Temp. sensor(2), interface or A/D
conversion failure
Temp. sensor(1), interface or A/D
conversion failure
Atmospheric Damper End Switch
failed to close
Atmospheric Damper End Switch
failed to open
Flame Rod shorted to burner
ground
error and their definitions are shown in Figure 21. While in
Error mode the functions of the buttons are disabled. The
integrated control returns to Reading mode only if all error
conditions are cleared.
Display Shows
Description
AC line frequency error
AC line voltage error
Line volage unstable
Soft Lockout - Max number of
retries exceeded
Soft Lockout - Max number of
recycles exceeded
Soft Lockout - Electronics failure
Over Temperature error - ECO
limit exceeded
Figure 21 Display readout definitions (Error mode)
– 22 –
Display Shows
START
STAGE 1
PREPURGE
STAGE 2
1
CALL FOR
HEAT ACTIVE
(Temperature low)
2
Damper energized.
3
SPARK GENERATOR
POWERED
Pilot valve opens.
TRIAL FOR IGNITION
PILOT BURNER OPERATION
Pilot burner does not light. After retry delay system
retries. If retries exceed maximum, timed lockout is entered.
OR
Pilot burner lights. Ignition module senses flame current
and continues.
4
5
STAGE 3
6
MAIN BURNER OPERATION
FLAME CURRENT
SENSED
Spark generator off,
Main Valve opens.
MAIN BURNER
OPERATION
Ignition module monitors pilot
flame current.
CALL FOR HEAT
INACTIVE
(Temperature at setpoint) Valves
close
7
STAGE 4
POSTPURGE
8
Damper de-energized.
END
Figure 22 Sequence of Operation
– 23 –
POWER INTERRUPTION System
shuts off
OR
PILOT FLAME FAILURE Valves close,
after recycle delay system recycles. If
recycles exceed maximum, timed
lockout is entered.
Temperature and Pressure Relief Valve
VII) MAINTENANCE
Draining and Flushing
WARNING
It is recommended that the tank be drained and flushed
every 6 months to remove sediment which may buildup during operation.
Note: Warranty is null and void in the event lime & scale
deposits are allowed to exceed two inches in depth.
The water heater should be drained if being shut down during freezing temperatures. To drain the tank, perform the following steps:
1. Turn off the gas to the water heater at the manual gas
shut-off valve and turn off electricity.
2. Close the cold water inlet valve.
3. Open a nearby hot water faucet.
4. Connect a hose to the drain valve and terminate it to an
adequate drain.
Note: The drain hose should be rated for at least 93°C
(200°F). If the drain hose does not have this rating, open the
cold water inlet valve and a nearby hot faucet until the water
is no longer hot.
5. Open the water heater drain valve and allow all the
water to drain from the tank.
6. Remove the screws holding the cleanout plate, then
remove the plate for access.
7. Remove any lime, sediment, or scale from the tank. Be
careful not to damage the glass lining.
8. Flush the tank with water as needed to remove any
remaining sediment.
9. Check gasket on cleanout plate, replace if necessary.
10. Replace the cleanout plate and screws, tighten sufficiently.
11. Close the drain valve, refill the tank, and restart the
water heater as directed under “Lighting & Operating
Instructions”.
If the water heater is going to be shut down for an extended
period, the drain valve should be left open.
Important: Condensation may occur when refilling the tank
and should not be confused with a tank leak.
•
•
•
•
Manually operate the temperature and pressure relief valve
at least once a year to make sure it is working properly (See
Figure 23). To prevent water damage, the valve must be
properly connected to a discharge line which terminates at
an adequate drain. Standing clear of the outlet (discharged
water may be hot), slowly lift and release the lever handle
on the temperature and pressure relief valve to allow the
valve to operate freely and return to its closed position. If the
valve fails to completely reset and continues to release
water, immediately turn off the gas at the manual gas shutoff valve, the electric power and the cold water inlet valve
and call a qualified service technician.
Temperature and Pressure
Relief Valve
Manual Relief Valve
Routine Preventative Maintenance
At least annually, a visual inspection should be made of the
venting and air supply system, piping systems, main burner,
and pilot burner. Check the water heater for the following:
• Obstructions, damage, or deterioration in the venting system. Make sure the ventilation and combustion air supplies are not obstructed.
• Build-up of soot and carbon on the main burner and pilot
burner. Check for a soft blue flame.
• Leaking or damaged water and gas piping.
• Presence of flammable or corrosive materials in the
installation area.
• Presence of combustible materials near the water heater.
• Verify proper operation after servicing this water heater.
Important: If you lack the necessary skills required to properly perform this visual inspection, you should not proceed,
but get help from a qualified service technician.
Explosion Hazard
If the temperature and pressure relief
valve is dripping or leaking, have a
licensed plumber repair it.
Do not plug valve.
Do not remove valve.
Failure to follow these instructions can
result in death or an explosion.
Discharge line to drain
Figure 23 T&P Valve Test
Pilot Burner and Main Burner Assembly
Inspection
To access the pilot burner and main burner for inspection:
1. Turn off gas at main shutoff valve and turn off electrical
power.
2. Disconnect the gas supply line from the gas valve.
3. Remove the 2 screws holding the Pilot & Main Burner
Assembly in place. See Figure 24 for location of screws.
4. Carefully slide the assembly out of the water heater.
5. If needed, use a brush or vacuum to clean any soot or
debris from the burners.
6. Check for correct alignment of burners before sliding
assembly back into the water heater.
7. Carefully slide Pilot/Burner Assembly back into the
water heater.
– 24 –
Figure 24 Pilot/Burner Assembly Removal
8. Replace and sufficiently tighten the two screws holding
the Pilot/Burner Assembly in place.
9. Reconnect the gas supply line to the gas valve.
10. Turn on gas at main shutoff valve.
11. Check for gas leaks and proper operation on the unit
after servicing.
Gas Valve Removal and Replacement
It is recommended that this maintenance be performed by a
qualified service technician.
1. Turn the integrated control to its lowest setting.
2. Turn off gas at manual gas shut-off valve (see Figure 3
for reference) and disconnect electrical power from
water heater.
3. Unplug the 4 wires located on the gas valve. Label wire
position for correct reattachment.
4. Disconnect pilot tube from the gas valve.
5. Disconnect the main gas line from the gas valve. Use
care not to crack the gas valve housing.
6. Carefully unscrew the gas valve from the burner assembly.
Important: When removing gas valve do not use a pipe
wrench or vise to grip the body.
7. When replacing the gas valve, use an approved Teflon®
or pipe joint compound on the pipe threads.
8. Screw the new gas valve onto the burner assembly.
9. Reconnect the pilot tube to the gas valve.
10. Reconnect the main gas line to the gas valve.
11. Turn the gas supply on and check for leaks. Use a chlorine-free soap and water solution (bubbles forming indicate a leak) or other approved method.
12. Reconnect the 4 wires to their proper location and
restore electrical power to the unit.
13. Verify proper operation after servicing this water heater.
14. If additional information is required, contact the Product
Service and Support Group at 1-800-456-9805.
Anode Rod Inspection
Each water heater contains at least one anode rod, which
will slowly deplete while protecting the glass-lined tank from
corrosion and prolonging the life of the water heater. Certain
water conditions will cause a reaction between the rods and
the water. Once the anodes are depleted, the tank will start
to corrode, eventually developing a leak. The most common
complaint associated with the anode rod is a "rotten egg
smell" produced from the presence of hydrogen sulfide gas
dissolved in the water. Do not remove this rod permanently
as it will void any warranties, stated or implied. A special
anode is available for this complaint. This rod may reduce
but not eliminate water odour problems. The water supply
system may require special filtration equipment from a
water conditioning company to successfully eliminate all
water odour problems. Artificially softened water is exceedingly corrosive because the process substitutes sodium ions
for magnesium and calcium ions. The use of a water softener may decrease the life of the water heater tank. The
anode rods should be removed from the water heater tank
every 3 years for inspection. If the rods are more than 50%
depleted, the anode rods should be replaced.
To replace the anodes:
1. Turn off gas supply and electrical power to the water
heater.
2. Shut off the water supply and open a nearby hot water
faucet to depressurize the water tank.
3. Drain approximately 20l (5 gal) of water from tank
(Refer to “Draining and Flushing” for proper procedures). Close drain valve.
4. Remove old anode rods.
5. Use Teflon® tape or approved pipe sealant on threads
and install new anode rods.
6. Turn on water supply and open nearby hot water faucet
to purge air from water system.
7. Restart the water heater as directed under “Lighting &
Operating Instructions”. See the "Parts Reference
Illustration" for anode rod location.
Replacement Parts
Replacement parts may be ordered through your plumber or
the local distributor. When ordering replacement parts,
always have the following information ready:
1. model, serial and product number
2. type of gas
3. item number
4. parts description
See “Parts Reference Illustration” for a list of available
repair parts.
VIII) COMBO HEATING
Space Heating
If this unit is to be used to supply both space heating and
domestic potable (drinking) water then the following instructions must be followed:
1. All piping and components used must be suitable for
use with domestic (potable) drinking water.
2. Do not use piping or components that have been connected to a non-potable system or treated with chromates or other toxic chemicals. Do not add any chemicals to the water heater piping.
3. If system requires temperatures in excess of 49°C
(120°F) install a tempering valve, per the manufacturer’s instructions, in the domestic (potable) hot water line
to limit the risk of scalding (See Figure 8).
4. Be sure to follow the manual(s) shipped with the heating system. Also follow any state or local codes.
– 25 –
IX) TROUBLESHOOTING GUIDE
Detect Conditions
Flame current lower
than threshold.
Damper END SW
failed to close
(stuck open).
Damper END SW
failed to open (stuck
closed).
Flame rod to ground
leakage resistance
< ~200K (AC
voltage dependent).
Alarm (ERROR) Name
Control Action
FLAME_CURRENT
Normal.
DAMPER_SW_CLOSE
Wait until closed.
DAMPER_SW_OPEN
Wait until open.
Check END SW.
In an IGN
cycle.
DamperEndSwit
chOpen
ROD_SHORT
Check flame rod.
Flame drive
inactive.
alarm #
Check AC input.
All time.
alarm #
Check AC input.
All time.
alarm #
Replace optional
sensor.
All time.
UpperSensor
Replace limit
sensor.
All time.
LowerSensor
Sensor 1 (limit
sonsor) resistance
out of acceptable
range
SENSOR1
DCDC output
unstable.
POWER
Retry>max.
detected by IGN
state machine.
Recycle > max.
detected by IGN
state machine.
SLO_RETRY
WaitForRecovery
state. Resume
normal operation
when debounced
normal.
WaitForRecovery
state. Resume
normal operation
when debounced
normal.
WaitForRecovery
state. Resume
normal operation
when debounced
normal.
WaitForRecovery
state. Resume
normal operation
when debounced
normal.
WaitForRecovery
state. Resume
normal operation
when debounced
normal.
WaitForRecovery
state. Resume
normal operation
when debounced
normal.
Soft lockout.
SLO_RECYCLE
Soft lockout.
Line voltage power ZERO_CROSSING
issues, too noisy, or
frequency out of
normal range.
Line voltage
low/high.
AC_LINE
Sensor 2 (averaging SENSOR2
sonsor) resistance
out of acceptable
range
Table 6
Service
Detection
Remote
Suggestion (After
Time
Display
Error Matured)
Clean flame rod.
Flame sensing FlameSenseCur
active.
rentLow
Check END SW. In an IGN
alarm #
cycle.
Error Codes
– 26 –
Check AC input. If When flame
alarm #
stable, replace
sensing active.
control.
Check gas supply, When heating
burner and
required.
harness.
Check gas supply, When heating
burner and
required.
harness.
SoftLockout
SoftLockout
Detect Conditions
Alarm (ERROR) Name
Valve relays
SLO_ELECTRONICS
shorted/open, other
internal electronic
failures
Flame out of
SLO_FLAME_SEQ
sequence.
Control Action
Soft lockout.
Check gas supply,
burner and
harness.
Flame detected
FLAME_IN_PREPURGE Soft lockout.
Check gas supply,
before trial.
burner and
harness.
Flame detected after FLAME_IN_POSTPURGE Soft lockout.
Check gas supply,
trial.
burner and
harness.
Sensor 1 or Sensor OVER_TEMP
Non-volatile Hard
Check Appliance
2 reporting greater
Lockout for Europe. operation and limit
than 200°F.
Auto-reset for
sensor.
domestic.
Valve relays welded ELECTRONICS
Non-volatile Hard
Replace control.
5 times.
Lockout for Europe.
Auto-reset for
domestic.
Table 6 (cont’d)
Soft lockout.
Service
Detection
Suggestion (After
Time
Error Matured)
Replace control.
All time.
Error Codes
– 27 –
During a
heating cycle.
Remote
Display
SoftLockout
SoftLockout
Before ignition. SoftLockout
After a heating SoftLockout
cycle.
All time.
OverTemp
During a
heating cycle.
Hard Lockout
X) PARTS REFERENCE ILLUSTRATION
1
24
22
2
25 21 17 16
23
20
5
18
19
6
9
7
8
10
12
11
15
14
13
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Part Name and Description
Drafthood
Dip Tube (Top)
Dip Tube (Front) (optional, not shown)
Dip Tube (Back) (optional, not shown)
Flue Baffles
Cleanout Gasket
Cleanout Cover
Cleanout Cover Jacket
Drain Valve
Main Burner Tube(s)
Burner Tray
Pilot Burner Assembly
Main Burner Manifold
No.
14
15
16
17
18
19
20
21
22
23
24
25
Figure 25 Repair Parts Listing
– 28 –
Part Name and Description
Gas Valve
Main Burner Orifice(s)
Control Box Cover
Transformer
Wiring Harness
Anode Rod(s)
T&P Valve
Integrated Control CCA
Upper Temperature Sensor/ECO
Lower Temperature Sensor
Flue Damper
Power Cord
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