RESIDENTIAL GAS WATER HEATERS Instruction Manual

RESIDENTIAL GAS WATER HEATERS Instruction Manual
Instruction Manual
RESIDENTIAL GAS WATER HEATERS
POWER VENT/POWER DIRECT VENT GAS MODELS
WITH DIRECT SPARK IGNITION
MODELS 650(Y,H)TPDT/675(Y,H)TPDT SERIES 140/141
• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
Thank you for buying this energy efficient water heater.
We appreciate your confidence in our products.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, CALL THE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
PRINTED 0415
1
331985-000
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE.................................3
Filling The Water Heater..........................................................23
APPROVALS..................................................................................3
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH
GENERAL SAFETY INFORMATION..............................................4
OF MASSACHUSETTS................................................................24
Precautions...............................................................................4
VENTING INSTALLATION...........................................................25
Grounding Instructions..............................................................4
Vent Installation Considerations..............................................25
Hydrogen Gas Flammable........................................................4
Polypropylene Installations......................................................26
INTRODUCTION............................................................................7
Vent Pipe Termination.............................................................27
Abbreviations Used...................................................................7
Planning The Vent System......................................................27
Qualifications.............................................................................7
Installation Of Horizontal Through The Wall Vent System.......27
Preparing For The Installation...................................................7
Direct Vent Terminal Installation..............................................28
DIMENSIONS AND CAPACITY DATA............................................8
Installation Sequence..............................................................28
Rough In Dimensions: 50 Gallon Unit.......................................8
Termination Clearances Sidewall Power Vent.........................29
Rough In Dimensions: 75 Gallon Unit.......................................8
Termination Clearances Sidewall Direct Vent..........................30
FEATURES AND COMPONENTS...............................................10
Vertical Vent Terminal Installation............................................31
Controls And Switches............................................................13
Direct Vent Diagram................................................................32
INSTALLATION CONSIDERATIONS...........................................14
Concentric Vent Installation.....................................................33
Locating The Water Heater.....................................................14
Low Profile Termination Installation.........................................36
Insulation Blankets..................................................................15
LIGHTING AND OPERATION LABELS........................................37
Combustion Air And Ventilation...............................................15
TEMPERATURE REGULATION..................................................38
Unconfined Space...................................................................16
CONTROL SYSTEM OPERATION..............................................39
Confined Space.......................................................................16
Overview.................................................................................39
Fresh Air Openings For Confined Spaces...............................16
Control System Navigation......................................................39
Outdoor Air Through Two Openings........................................16
User Settings & Control System Menus..................................42
Outdoor Air Through One Opening.........................................16
FOR YOUR INFORMATION.........................................................47
Outdoor Air Through Two Horizontal Ducts.............................17
Start Up Conditions.................................................................47
Air From Other Indoor Spaces................................................17
Operational Conditions............................................................47
INSTALLATION REQUIREMENTS..............................................18
Chemical Vapor Corrosion......................................................18
PERIODIC MAINTENANCE.........................................................48
Water Piping............................................................................18
Venting System Inspection......................................................48
Power Supply..........................................................................18
Anode Rod INSPECTION.......................................................48
Mixing Valves..........................................................................19
Powered Anode Rod (optional models)...................................49
Gas piping...............................................................................19
Temperature-Pressure Relief Valve Test.................................49
Gas Supply Systems...............................................................20
Draining and Flushing.............................................................49
Gas Pressure Requirements...................................................20
Service....................................................................................50
Supply Gas Regulator.............................................................20
LEAKAGE CHECKPOINTS..........................................................51
Space Heating And Potable Water System.............................21
TROUBLESHOOTING.................................................................52
Closed Water Systems............................................................21
Installation Checklist................................................................52
Thermal Expansion.................................................................21
Sequence Of Operation...........................................................52
Temperature-Pressure Relief Valve.........................................22
Sequence Of Operation Flow Chart........................................53
Condensate Piping..................................................................22
Operational Problems..............................................................54
Condensate Drain Installation.................................................23
Fault And Alert Conditions.......................................................55
Installation Instructions............................................................23
WIRING DIAGRAM......................................................................57
High Altitude Installations........................................................23
NOTES.........................................................................................58
2
SAFE INSTALLATION, USE AND SERVICE
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and
how to avoid the risk of injury.
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.
This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This
water heater can cause low level exposure to some of the substances listed in the Act.
APPROVALS
3
GENERAL SAFETY INFORMATION
PRECAUTIONS
HYDROGEN GAS FLAMMABLE
DO NOT USE THIS APPLIANCE IF ANY PART HAS
BEEN EXPOSED TO FLOODING OR WATER DAMAGE.
Immediately call a qualified service technician to inspect
the water heater and to make a determination on what steps
should be taken next.
Explosion Hazard
If the unit is exposed to the following, do not operate heater
until all corrective steps have been made by a qualified service
technician.
Flammable hydrogen gases
may be present.
1. External fire.
Keep all ignition sources away
from faucet when turning on
hot water.
2. Damage.
3. Firing without water.
GROUNDING INSTRUCTIONS
Hydrogen gas can be produced in a hot water system served by
this water heater that has not been used for a long period of
time (generally two weeks or more). Hydrogen gas is extremely
flammable. To reduce the risk of injury under these conditions, it is
recommended that a hot water faucet served by this water heater
be opened for several minutes before using any electrical appliance
connected to the hot water system. 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.
This water heater must be grounded in accordance with the National
Electrical Code and/or local codes. These must be followed in all
cases. Failure to ground this water heater properly may also cause
erratic control system operation.
This water heater must be connected to a grounded permanent
wiring system; or an equipment grounding conductor must be
run with the circuit conductors and connected to the equipment
grounding terminal or lead on the water heater.
Verify the power to the water heater is turned off before performing any service procedures. The
Enable/Disable switch on front panel disables the 24 volt gas valve. Electrical supply must be
turned off at circuit breaker serving water heater.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Explosion Hazard
Overheated water can cause
water tank explosion.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
This manual must remain with the
water heater.
CAUTION
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Improper installation, use and service may result
in property damage.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
•
Feel water before bathing or
showering.
•
•
•
•
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
4
Do not operate water heater if exposed to flooding or water
damage.
Inspect anode rods regularly, replace if damaged.
Install in location with drainage.
Fill tank with water before operation.
Properly sized thermal expansion tanks are required on all
closed water systems.
Refer to this manual for installation and service.
GENERAL SAFETY INFORMATION
5
GENERAL SAFETY INFORMATION
Fire or Explosion Hazard
Fire Hazard
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
For continued protection against
risk of fire:
Do not install water heater on
carpeted floor.
Do not operate water heater if
exposed to flooding or water
damage.
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas
pressure.
Use only the gas shown on the water heater rating plate.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended
periods of non-use.
Fire and Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Use joint compound or Teflon tape
compatible with propane gas.
Leak test gas connections
before placing the water heater in
operation.
Disconnect gas piping at main
gas shutoff valve before leak
testing.
Install sediment trap in accordance
with NFPA 54.
Breathing Hazard - Carbon Monoxide Gas
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Fire and Explosion Hazard
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Do not use water heater with any gas
other than the gas shown on the rating
plate.
Excessive gas pressure to gas valve can
cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
technician for installation and service.
CAUTION
Property Damage Hazard
• All water heaters eventually leak.
• Do not install without adequate drainage.
Electrical Shock Hazard
•
Turn off power to the water heater
before performing any service.
•
Label all wires prior to disconnecting
when performing service. Wiring errors
can cause improper and dangerous
operation.
•
•
Verify proper operation after servicing.
Failure to follow these instructions can
result in personal injury or death.
6
INTRODUCTION
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
The principal components of the water heater are identified in
Features And Components on Page10 & Page 11 in this manual.
Use this reference to locate and identify various components on
the water heater.
ABBREVIATIONS USED
See the Installation Checklist and Troubleshooting on page
52. By using this checklist the user may be able to make
minor operational adjustments and avoid unnecessary service
calls. However, service and diagnostic procedures should only
be performed by a Qualified Service Agency.
Abbreviations found in this Instruction Manual include :
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• AHRI - Air-Conditioning, Heating and Refrigeration Institute
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• CSA - Canadian Standards Association
NOTE: Costs to correct installation errors are not covered
under the limited warranty.
QUALIFICATIONS
2. Be sure to turn off power when working on or near the electrical
system of the water heater. Never touch electrical components
with wet hands or when standing in water.
QUALIFIED INSTALLER OR SERVICE AGENCY
Installation and service of this water heater requires ability
equivalent to that of a Qualified Agency (as defined by ANSI below)
in the field involved. Installation skills such as plumbing, air supply,
venting, gas supply and electrical supply are required in addition to
electrical testing skills when performing service.
3. The installation must conform to all instructions contained in
this manual and the local code authority having jurisdiction.
These shall be carefully followed in all cases. Authorities having
jurisdiction should be consulted before installation begins if
there are any questions regarding compliance with local, state
or national codes.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualified Agency” - “Any
individual, firm, corporation or company that either in person or
through a representative is engaged in and is responsible for (a)
the installation, testing or replacement of gas piping or (b) the
connection, installation, testing, repair or servicing of appliances
and equipment; that is experienced in such work; that is familiar
with all precautions required; and that has complied with all the
requirements of the authority having jurisdiction.”
In the absence of local codes, the installation must comply
with the current editions of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and the National Electrical Code, NFPA 70.
All documents are available from the Canadian Standards
Association, 8501 East Pleasant Valley Road, Cleveland, OH
44131. NFPA documents are also available from the National
Fire Protection Association, 1 Batterymarch Park, Quincy,
MA 02269.
If you are not qualified (as defined by ANSI above) and licensed or
certified as required by the authority having jurisdiction to perform
a given task do not attempt to perform any of the procedures
described in this manual. If you do not understand the instructions
given in this manual do not attempt to perform any procedures
outlined in this manual.
4. If after reading this manual you have any questions or
do not understand any portion of the instructions, call
the toll free number on the back cover of this manual for
technical assistance. In order to expedite your request,
please have the full Model, Serial and Series number
of the water heater you are working with available for
the technician. This information is located on the water
heater’s rating plate.
PREPARING FOR THE INSTALLATION
1. Read the entire manual before attempting to install or operate
the water heater. Pay close attention to the General Safety
Information on Page 4 through Page 6. If you don’t follow the
safety rules, the water heater may not operate safely. It could
cause property damage, injury and/or death.
5. Carefully plan the placement of the water heater. Examine
the location to ensure that it complies with the requirements
in Locating The Water Heater on Page 14 and the Rough In
Dimensions on Page 8.
.
6. For installation in California this water heater must be braced
or anchored to avoid falling or moving during an earthquake.
See instructions for correct installation procedures.
Instructions may be obtained from California Office of the
State Architect, 1102 Q Street, Suite 5100, Sacramento, CA
95811.
This manual contains instructions for the installation, operation,
and maintenance of the water heater. It also contains warnings
throughout the manual that you must read and be aware of.
All warnings and all instructions are essential to the proper
operation of the water heater and your safety.
Detailed installation diagrams are also found in this manual.
These diagrams will serve to provide the installer with a
reference. It is essential that all venting, water piping, gas piping
and wiring be installed as shown.
7. Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5. See Commonwealth of Massachusetts
on Page 24.
Particular attention should be given to the installation of
thermometers at the locations indicated in the piping diagrams as
these are necessary for checking the operation of the water heater.
7
DIMENSIONS AND CAPACITY DATA
ROUGH IN DIMENSIONS: 50 GALLON UNIT
Figure 1: DIMENSIONS FOR 50 GALLON UNIT
ROUGH IN DIMENSIONS: 75 GALLON UNIT
Figure 1A: DIMENSIONS FOR 75 GALLON UNIT
Table 1 – ROUGH-IN-DIMENSIONS
Units
50G
75G
A
B
C
D
E
F
G
H
I
Inches
66.75
49.25
22.00
15.75
3.00
8.00
8.00
62.00
65.00
cm
169.5
125.09
55.88
40.00
7.62
20.32
20.32
157.48
165.1
Inches
65.25
45.64
27.75
16.00
3.71
8.00
7.93
57.36
58.98
cm
165.7
115.9
70.5
40.6
9.4
20.3
20.1
145.7
149.8
Top Inlet and Outlet: 50G - 3/4” NPT; 75G - 1” NPT
Side Inlet and Outlet: 3/4” NPT
Gas Inlet: 1/2” NPT
Condensate drain outlet: 1/2” NPT
8
DIMENSIONS AND CAPACITY DATA
Table 2 – CAPACITY, GAS AND ELECTRICAL CHARACTERISTICS
Approximate Capacity
*Manifold Pressure
Electrical Characteristics
U.S. Gals.
Liters
Gas Type
“WC
kPA
Volts/Hz
Amperes
50
189
Nat./LP
0
75
284
Nat/LP
0
0
120/60
<5
0
120/60
<5
*The manifold pressure is the factory setting and is not adjustable. A negative pressure will be seen with just the blower running without
the Gas Control Valve open.
All models - Maximum Supply Pressure: 14 inches W.C. (3.48kPa)
Minimum Supply Pressure for Natural Gas: 3.50” (.87kPa)
Minimum Supply Pressure for Propane Gas: 8.00” (1.99kPa)
Minimum pressure must be maintained under both load and no load (dynamic and static) conditions.
Table 3 – RECOVERY CAPACITIES
Input
Recovery Capacities
Rating
(Btu/hr)
Rating
(kW)
100,000
29.3
Temp.
Rise
F
30
40
50
60
70
80
90
100
110
120
130
140
C
17
22
28
33
39
44
50
56
61
67
72
78
GPH
387
291
233
194
166
145
129
116
106
97
90
83
LPH
1465
1102
882
734
628
549
488
439
401
367
341
314
Recovery capacity based on 96% thermal efficiency.
9
FEATURES AND COMPONENTS
50 GALLON UNIT
**29
20
23
21
5
22
10
**14
**15
5
1
12
18
21
16
8
7
6
25
11
ACCESS PANEL
17
24
33
18
35 Caution: This access panel covers
13
32
a 2” NPT plug that was required
during the manufacturing of this
water heater. This 2” NPT flange is
not a cleanout fitting, removing the
2” NPT plug and using this fitting as
a cleanout could void your warranty.
19
31
26, 27
9
34 (SEE
ACCESS
PANEL
CAUTION)
3
30
2
VACUUM RELIEF
VALVE
28
*INSTALL PER
LOCAL CODES
*CAUTION HARNESS HAS 120 VAC. IN OPERATION.
**See Venting Installation and Condensate Piping for more information.
Figure 1B: 50 GALLON UNIT
10
4
FEATURES AND COMPONENTS (CONT.)
75 GALLON UNIT
**29
5
10
20
21
23
22
**15
8
7
5
18
21
**14
12
6
11
17
25
13
1
24
18
3
16
2
26, 27
31
4
35
33
19
32
34
30
VACUUM RELIEF
VALVE
28
*INSTALL PER
LOCAL CODES
*CAUTION HARNESS HAS 120 VAC. IN OPERATION.
**See Venting Installation and Condensate Piping for more information.
Figure 1C: 75 GALLON UNIT
11
9
FEATURES AND COMPONENTS (CONT.)
1: Control Assembly
2: Blocked Intake Switch
3: Blocked Outlet Switch
4: Blower Prover Switch
5: Blower Assembly
6: Burner Assembly
7: Flame Sensor
8: Igniter Assembly
9: Junction Box
10: Gas Control Valve Assembly
11: Display Board
12: Top Plastic Enclosure
13: Display Enclosure
**14: Exhaust Elbow Assembly
**15: Condensate Drain Outlet
16: Enable / Disable Switch
17: Display Overlay
18: Hot Water Outlet
19: Gas Supply
20: Main Manual Gas Shutoff Valve
21: Union
22: Inlet Water Shutoff Valve
23: Cold Water Inlet
24: Inlet Dip Tube
25: T/P Relief Valve
26: Rating Plate
27: Labels
28: Drain Valve
** 29: Vent Terminal
30: Drain Pan
31: Anode Rod
32: Insulation
33: Temperature Probe
34: Access Door
35: Spark Module
12
CONTROLS AND SWITCHES
close. The pressure switch is connected to the blower pressure tap
by a piece of tygon tubing. This tubing must be connected in order for
the switch to change the electrical contacts. The controller requires
that the electrical contacts on this air flow switch be open before it will
allow the blower to come on.
This model is provided with three pressure switches. These switches
are essential to the safe and proper operation of the unit. All switches
are wired in series. The controller is set up to shut the unit down
whenever there is a failure of any of the switches. It is important to
understand the purpose of each switch.
BLOCKED OUTLET SWITCH
The Blocked Exhaust Switch is set up to shut the unit off when a buildup of positive pressure in the exhaust vent pipe occurs. This switch
is a positive pressure switch that requires an increase in pressure to
change the electrical contacts from normally closed to open. When
this switch prevents the unit from igniting, most likely the exhaust is
blocked by some means. Check to see if the condensate is allowed
to flow freely from the exhaust elbow and for obstructions in the
exhaust venting and exhaust vent terminal. Also verify that the vent
length does not exceed the maximum allowed as shown in the Vent
Section of this manual.
BLOCKED INTAKE SWITCH
The Blocked Intake Switch is set up to shut the unit off when a
build-up of negative pressure in the intake air pipe occurs. This
switch is a negative pressure switch that requires an increase in
negative pressure to change the electrical contacts from normally
closed to open. The switch is connected to the pressure tap on the
PVC pipe connected to the inlet of the blower. When this switch
prevents the unit from igniting, most likely the intake is blocked.
Verify that the screen on the intake air connection (conventional
vent), the intake air pipe and termination (direct vent installations)
are free of obstructions that may prevent air from entering the unit.
Insure the screen on intake air connection has been removed on
direct vent installations, see Figure 13. Also verify the intake air pipe
length does not exceed the maximum allowed as shown in the Vent
Section of this manual.
50 GALLON UNIT
WATER HEATING ENABLE/DISABLE SWITCH
IMPORTANT: The Enable/Disable switch listed in this manual is NOT
an “on/off” switch and does not disconnect 120 volt power to the CCB
and other heater components.
Water Heater’s Enable/Disable Switch. When in the “Disabled”
position the switch removes electrical power from the gas valve so
that water heating is disabled. The display, CCB, and other electrical
components will still be energized and the display will read “Water
Heating Disabled”.
SPARK IGNITER
The Spark Igniter is a device that ignites the main burner by spark.
When high voltage is applied to the igniter, spark is generated to
ignite the main burner.
75 GALLON UNIT
Figure 2
CONFIGURATION KEY
The configuration key is located inside the control box.
It provides for the ability of the heater to retain information
collected over its lifetime, even if the control board is replaced
because of failure.
BLOWER PROVER SWITCH
The Blower Prover Switch is provided on the heater to verify that
the fan is operating. It is a positive pressure switch whose electrical
contacts are normally open. When the fan increases the pressure in
the burner, the pressure switch will allow the electrical contacts to
The configuration key should stay with the heater.
13
INSTALLATION CONSIDERATIONS
LOCATING THE WATER HEATER
(such as adhesives, etc.) emit flammable vapors which can be
ignited by a gas water heater’s ignition device or main burner.
The resulting flashback and fire can cause death or serious
burns to anyone in the area.
Carefully choose a location for the new water heater. The
placement is a very important consideration for the safety of the
occupants in the building and for the most economical use of the
water heater.
Also, the water heater must be located and/or protected so it
is not subject to physical damage by a moving vehicle.
CAUTION
Property Damage Hazard
• All water heaters eventually leak.
• Do not install without adequate drainage.
Whether replacing an existing water heater or installing the
water heater in a new location observe the following critical
points:
1. The water heater must be located indoors.
2. The water heater must not be located in an area where it
will be subject to freezing temperatures.
3. Locate the water heater so it is protected and not subject
to physical damage by a moving vehicle.
4. Locate the water heater on a level surface.
5. Locate the water heater near a floor drain. The water heater
should be located in an area where leakage of the tank or
connections will not result in damage to the area adjacent
to the water heater or to lower floors of the structure. When
such locations cannot be avoided, it is recommended that
a metal drain pan, piped to adequate drain, be installed
under the water heater. Drain pan should be fabricated with
sides at least 2” deep with diameter at least 2” greater than
diameter of heater. Pan must not restrict combustion air flow.
6. Locate the water heater close to the point of major hot
water usage.
7. Locate the water heater close to a 120 VAC power supply.
See Power Supply on Page 18 for requirements.
8. Locate the water heater where an adequate supply of fresh
air for combustion and ventilation can be obtained. See
Combustion Air and Ventilation on Page 15.
9. Locate the water heater where the vent and intake air piping,
when installed, will remain within the maximum equivalent
lengths allowed. See Venting Installation on page 25.
10.D o not locate the water heater where noise (such as
the Combustion Blower) during normal operation will be
objectionable in adjacent areas.
11.Do not locate the water heater where the subsequent
installation of the vent (exhaust) or intake air terminations
would be objectionable due to noise at the termination(s).
This includes locations close to or across from windows
and doors. See Venting Installation on page 25.
When the water heater is installed directly on carpeting, the water
heater shall be installed on a metal or wood panel extending
beyond the full width and depth of the water heater by at least 3
in (76.2 mm) in any direction or, if the water heater is installed in
an alcove or closet, the entire floor shall be covered by the panel.
The panel must be strong enough to carry the weight of the heater
when full of water.
Do not locate water heater areas where flammable liquids
(vapors) are likely to be present or stored (garages, storage
and utility areas, etc.): Flammable liquids (such as gasoline,
solvents, propane (LP or butane, etc.) and other substances
14
mentioned below, see Figure 1B & Figure 1C). Failure to follow these
instructions can restrict the air flow required for proper combustion,
potentially resulting in fire, asphyxiation, serious personal injury or death.
• Do not apply insulation to the top of the water heater, as this will
interfere with safe operation of the blower assembly.
• Do not cover the control system LCD on top of the water heater.
• Do not cover the outer door, thermostat or temperature & pressure
relief valve.
•Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
•Do obtain new warning and instruction labels from the manufacturer
for placement on the blanket directly over the existing labels.
•Do inspect the insulation blanket frequently to make certain it does
not sag, thereby obstructing combustion air flow.
Minimum clearances between the water heater and combustible
construction are 0 inch at the sides and rear, 5.5” (14.0 cm) from
the front and 18” (45.7 cm) from the top. (Standard clearance.) If
clearances stated on the heater differ from standard clearances,
install water heater according to clearances stated on the heater.
COMBUSTION AIR AND VENTILATION
A gas water heater cannot operate properly without the correct
amount of air for combustion. Do not install in a confined area such
as a closet, unless you provide air as shown in the Locating The
Water Heater section. Never obstruct the flow of ventilation air.
If you have any doubts or questions at all, call your gas supplier.
Failure to provide the proper amount of combustion air can result
in a fire or explosion and cause death, serious bodily injury, or
property damage.
Adequate clearance 30” (76 cm) for servicing this water heater should
be considered before installation, such as changing the anode rods,
control system components and gas control valve.
A minimum clearance of 5.5” (14.0 cm) must be allowed for access to
replaceable and/or serviceable parts such as the thermostats, drain valve,
condensate drain, temperature-pressure relief valve, clean out opening,
and the vent connection (exhaust elbow).
When installing the heater, consideration must be given to proper
location. Location selected should be as close to the wall as practicable
and as centralized with the water piping system as possible.
Figure 3: CLEARANCES
INSULATION BLANKETS
Figure 4: COMBUSTION AIR AND VENTILATION
If this water heater will be used in beauty shops, barber shops,
cleaning establishments, or self-service laundries with dry cleaning
equipment, it is imperative that the water heater(s) be installed
direct vent so that all air for combustion and ventilation is taken
from outdoors.
Insulation blankets are available to the general public for external use
on gas water heaters but are not necessary with these products. The
purpose of an insulation blanket is to reduce the standby heat loss
encountered with storage tank heaters. Your water heater meets or
exceeds the Energy Policy Act standards with respect to insulation and
standby loss requirements, making an insulation blanket unnecessary.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorine based chemicals, refrigerants, etc.) in addition to being
highly flammable in many cases, will also react to form corrosive
acids when exposed to the combustion products of the water heater.
The results can be hazardous, and also cause product failure.
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions (For identification of components
15
UNCONFINED SPACE
FRESH AIR OPENINGS FOR CONFINED SPACES
An Unconfined Space is one whose volume IS NOT LESS THAN
50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the
total input rating of all appliances installed in the space. Rooms
communicating directly with the space, in which the appliances are
installed, through openings not furnished with doors, are considered
a part of the unconfined space.
The following instructions shall be used to calculate the size, number
and placement of openings providing fresh air for combustion,
ventilation and dilution in confined spaces. The illustrations shown
in this section of the manual are a reference for the openings
that provide fresh air into confined spaces only. DO NOT refer to
these illustrations for the purpose of vent installation. See Venting
Installation on Page 25 for complete venting installation instructions.
Makeup air requirements for the operation of exhaust fans, kitchen
ventilation systems, clothes dryers and fireplaces shall also be
considered in determining the adequacy of a space to provide
combustion, ventilation and dilution air.
OUTDOOR AIR THROUGH TWO OPENINGS
UNUSUALLY TIGHT CONSTRUCTION
In unconfined spaces in buildings, infiltration may be adequate to
provide air for combustion, ventilation and dilution of flue gases.
However, in buildings of unusually tight construction (for example,
weather stripping, heavily insulated, caulked, vapor barrier, etc.)
additional air must be provided using the methods described in the
Confined Space section that follows.
CONFINED SPACE
A Confined Space is one whose volume IS LESS THAN 50 cubic
feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input
rating of all appliances installed in the space.
Openings must be installed to provide fresh air for combustion,
ventilation and dilution in confined spaces. The required size for
the openings is dependent on the method used to provide fresh
air to the confined space AND the total Btu/hr input rating of all
appliances installed in the space.
Figure 5
The confined space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. The openings shall communicate directly with the
outdoors. See Figure 5.
DIRECT VENT APPLIANCES
Appliances installed in a Direct Vent configuration that derive all
air for combustion from the outdoor atmosphere through sealed
intake air piping are not factored in the total appliance input Btu/hr
calculations used to determine the size of openings providing fresh
air into confined spaces.
Each opening shall have a minimum free area of 1 square inch per
4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating of all
appliances installed in the enclosure. Each opening shall not be
less than 100 square inches (645 cm2).
EXHAUST FANS
Where exhaust fans are installed, additional air shall be provided
to replace the exhausted air. When an exhaust fan is installed in
the same space with a water heater, sufficient openings to provide
fresh air must be provided that accommodate the requirements
for all appliances in the room and the exhaust fan. Undersized
openings will cause air to be drawn into the room through the water
heater’s vent system causing poor combustion. Sooting, serious
damage to the water heater and the risk of fire or explosion may
result. It can also create a risk of asphyxiation.
OUTDOOR AIR THROUGH ONE OPENING
LOUVERS AND GRILLES
The free areas of the fresh air openings in the instructions that
follow do not take in to account the presence of louvers, grilles or
screens in the openings.
The required size of openings for combustion, ventilation and
dilution air shall be based on the net free area of each opening.
Where the free area through a design of louver or grille or screen is
known, it shall be used in calculating the size of opening required to
provide the free area specified. Where the louver and grille design
and free area are not known, it shall be assumed that wood louvers
will have 25% free area and metal louvers and grilles will have 75%
free area. Non motorized louvers and grilles shall be fixed in the
open position.
Figure 6
16
AIR FROM OTHER INDOOR SPACES
Alternatively a single permanent opening, commencing within 12
inches (300 mm) of the top of the enclosure, shall be provided.
See Figure 6. The water heater shall have clearances of at
least 1 inch (25 mm) from the sides and back and 6 inches (150
mm) from the front of the appliance. The opening shall directly
communicate with the outdoors or shall communicate through a
vertical or horizontal duct to the outdoors or spaces that freely
communicate with the outdoors and shall have a minimum free
area of the following:
1. 1 square inch per 3000 Btu/hr (733 mm2 per kW) of the total
input rating of all appliances located in the enclosure, and
2. Not less than the sum of the areas of all vent connectors in the space.
OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS
Figure 8
The confined space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. See Figure 8.
Each opening shall communicate directly with an additional room(s)
of sufficient volume so that the combined volume of all spaces
meets the criteria for an Unconfined Space.
Figure 7
Each opening shall have a minimum free area of 1 square inch per
1,000 Btu/hr (2200 mm2 per kW) of the aggregate input rating of
all appliances installed in the enclosure. Each opening shall not be
less than 100 square inches (645 cm2).
The confined space shall be provided with two permanent horizontal
ducts, one commencing within 12 inches (300 mm) of the top and
one commencing within 12 inches (300 mm) of the bottom of the
enclosure. The horizontal ducts shall communicate directly with the
outdoors. See Figure 7.
Each duct opening shall have a minimum free area of 1 square inch
per 2,000 Btu/hr (1100 mm2 per kW) of the aggregate input rating of
all appliances installed in the enclosure.
When ducts are used, they shall be of the same cross sectional
area as the free area of the openings to which they connect. The
minimum dimension of rectangular air ducts shall be not less than
3 inches.
17
INSTALLATION REQUIREMENTS
CHEMICAL VAPOR CORROSION
Corrosion of the flueways and vent system may occur if air for
combustion contains certain chemical vapors. Such corrosion may
result in failure and risk of asphyxiation.
Spray can propellants, cleaning solvents, refrigerator and air
conditioning refrigerants, swimming pool chemicals, calcium
and sodium chloride (water softener salt), waxes, and process
chemicals are typical compounds which are potentially corrosive.
This water heater shall not be connected to any heating
systems or component(s) used with a non-potable water heating
appliance.
Do not store products of this sort near the heater. Also, air which is
brought in contact with the heater should not contain any of these
chemicals. If necessary, uncontaminated air should be obtained
from remote or outside sources. The limited warranty is voided
when failure of water heater is due to a corrosive atmosphere. (See
limited warranty for complete terms and conditions).
All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
Toxic chemicals, such as those used for boiler treatment shall
not be introduced into this system.
When the system requires water for space heating at
temperatures higher than required for domestic water purposes,
a mixing valve must be installed.
WATER PIPING
These water heaters cannot be used in space heating
applications only.
POWER SUPPLY
The water heaters covered in this manual require a 120
VAC, 1Ø (single phase), 60Hz, 5 amp power supply and
must also be electrically grounded in accordance with local
codes or, in the absence of local codes, with the National
Electrical Code, ANSI/NFPA 70.
If any of the original wire as supplied with the water heater must
be replaced, it must be replaced with 105°C rated wiring or its
equivalent, except in the burner housing. In this case 200°C rated
wire must be used.
DEDICATED POWER WIRING AND BREAKERS
HOTTER WATER CAN SCALD:
Water heaters are intended to produce hot water. Water heated to
a temperature which will satisfy space heating, clothes washing,
dish washing, cleaning and other sanitizing needs can scald and
permanently injure you upon contact. Some people are more likely
to be permanently injured by hot water than others. These include
the elderly, children, the physically or developmentally disabled. If
anyone using hot water fits into one of these groups or if there is a
local code or state law requiring a certain temperature water at the
hot water tap, then you must take special precautions. In addition
to using the lowest possible temperature setting that satisfies your
hot water needs, a means such as a mixing valve should be used
at the hot water taps used by these people or at the water heater.
Valves for reducing point of use temperature by mixing cold and
hot water are also available:
Dedicated power supply wires, ground wiring and dedicated
circuit breakers often prevent electrical line noise and
should be considered when installing the water heater.
POWER FLUCTUATIONS AND ELECTRICAL NOISE
The water heater ’s control system requires a source of
stable clean electricity for proper operation. Connecting
the water heater to a branch circuit that is subject to
fluctuations in voltage level or electrical line noise such as
EMI (electro magnetic interference) or RFI (radio frequency
interference) may cause erratic control system operation
and malfunction.
A high quality power supply filter/suppressor must be
installed if the above conditions exist. Call the technical
support phone number listed on the back cover of this
manual for more information.
Consult a Qualified Installer or Service Agency. Follow
manufacturer’s instructions for installation of the valves.
Before changing the factory setting on the thermostat, read the
Temperature Regulation section in this manual.
NOTE: Malfunctions caused by the power supply and the
costs to install power supply filters are not covered under
the limited warranty.
18
MIXING VALVES
SEDIMENT TRAPS
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Water heated to a temperature which will satisfy clothes washing, dish
washing, and other sanitizing needs can scald and cause permanent
injury upon contact. Short repeated heating cycles caused by small
hot water uses can cause temperatures at the point of use to exceed
the water heater’s temperature setting by up to 20°F (11°C).
Some people are more likely to be permanently injured by hot water
than others. These include the elderly, children, the infirm and the
physically/mentally disabled. Table 4 shows the approximate timeto-burn relationship for normal adult skin. If anyone using hot water
provided by the water heater being installed fits into one of these
groups or if there is a local code or state law requiring a certain water
temperature at the point of use, then special precautions must be taken.
A sediment trap shall be installed as close to the gas inlet of the
water heater as practical at the time of water heater installation.
The sediment trap shall be either a tee fitting with a capped nipple
in the bottom outlet or other device recognized as an effective
sediment trap.
Contaminants in the gas lines may cause improper operation of the
gas control valve that may result in fire or explosion. Before attaching
the gas line be sure that all gas pipe is clean on the inside. To trap
any dirt or foreign material in the gas supply line, a sediment trap
must be incorporated in the piping. The sediment trap must be readily
accessible. Install in accordance with the Gas Piping section. Refer
to the current edition of the National Fuel Gas Code (ANSI Z223.1/
NFPA 54).
In addition to using the lowest possible temperature setting that
satisfies the demand of the application a Mixing Valve should be
installed at the water heater or at the hot water taps to further
reduce system water temperature.
Mixing valves are available at plumbing supply stores. Consult
a Qualified Installer or Service Technician. Follow mixing valve
manufacturer’s instructions for installation of the valves.
In all cases, the following burn table must be used.
Table 4
Water Temperature
°F (°C)
Time for 1st Degree Burn
(Less Severe Burns)
110 (43.3)
(normal shower temp.)
116 (46.7)
(pain threshold)
116 (46.7)
35 minutes
Time for Permanent
Burns
2nd & 3rd Degree
(Most Severe Burns)
Use pipe joint compound or teflon tape marked as being resistant to
the action of petroleum [Propane (L.P.)] gases.
The water heater and its gas connection must be leak tested before
placing the water heater in operation.
45 minutes
122 (50)
1 minute
5 minutes
131 (55)
5 seconds
25 seconds
140 (60)
2 seconds
5 seconds
149 (65)
1 second
2 seconds
154 (67.8)
instantaneous
1 second
The water heater and its individual Shut-off valve shall be disconnected
from the gas supply piping system during any pressure testing of that
system at test pressures in excess of 1/2 pound per square inch (3.5
kPa). It shall be isolated from the gas supply piping system by closing
its individual manual Shut-off valve during any pressure testing of the
gas supply piping system at test pressures equal to or less than 1/2
pound per square inch (3.5 kPa).
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)
GAS PIPING
Make sure gas supplied is same type listed on model rating plate. The
inlet gas pressure must not exceed 14 inch water column (3.5 kPa)
for natural and propane gas (L.P.). The minimum inlet gas pressure
shown on rating plate is that which will permit firing at rated input.
Schedule 40 Steel or Wrought Iron Pipe is the preferred material for
the gas line of this water heater. It is imperative to follow the sizing
recommendations in the latest version of the National Fuel Gas Code
if Corrugated Stainless Steel Tubing (CSST) is used as the gas line
for this water heater.
19
GAS SUPPLY SYSTEMS
5.When installing multiple water heaters in the same gas supply
system it is recommended that individual positive lock-up gas
pressure regulators be installed at each unit.
Low pressure building gas supply systems are defined as those
systems that cannot under any circumstances exceed 14” W.C. (1/2
PSI Gauge). These systems do not require pressure regulation.
Measurements should be taken to insure that gas pressures are
stable and fall within the requirements stated on the water heater
rating plate. Readings should be taken with all gas burning equipment
off (static pressure) and with all gas burning equipment running at
maximum rate (dynamic pressure). The gas supply pressure must
be stable within 1.5” W.C. from static to dynamic pressure to provide
good performance. Pressure drops that exceed 1.5” W.C. may cause
rough starting, noisy combustion or nuisance outages. Increases or
spikes in static pressure during off cycles may cause failure to ignite
or in severe cases damage to water heater gas control valves. If
your low pressure system does NOT meet these requirements, the
installer is responsible for the corrections.
All gas piping must comply with local codes and ordinances or with
the current editions National Fuel Gas Code (ANSI Z223.1/ NFPA54). Copper or brass tubing and fittings (except tin lined copper
tubing) shall not be used.
If the gas control valve is subjected to pressures exceeding 1/2 psi
(3.5 kPa), the damage to the gas control valve could result in a fire
or explosion from leaking gas.
If the main gas line Shut-off serving all gas water heaters is used,
also turn off the gas at each water heater. Leave all gas appliances
shut off until the water heater installation is complete.
A gas line of sufficient size must be run to the water heater. Consult
the current edition of National Fuel Gas Code (ANSI Z223.1/NFPA
54) and your gas supplier concerning pipe size.
High pressure building supply systems use pressures that exceed
14” W.C. (1/2 PSI Gauge). These systems must use field supplied
regulators to lower the gas pressure to less than 14” W.C. (1/2 PSI
Gauge). Appliances require gas regulators that are properly sized
for the water heater input and deliver the rating plate specified
pressures. Gas supply systems where pressure exceeds 5 PSI often
require multiple regulators to achieve desired pressures. Systems in
excess of 5 PSI building pressure should be designed by gas delivery
professionals for best performance. Water heaters connected to gas
supply systems that exceed 14” W.C. (1/2 PSI Gauge) at any time
must be equipped with a gas supply regulator.
There must be:
• A readily accessible manual shut off valve in the gas supply line
serving the water heater, and
• A sediment trap ahead of the gas control valve to help prevent dirt
and foreign materials from entering the gas control valve.
• A ground joint union of proper size between the manual shut off
valve and control valve to permit servicing of the unit.
Be sure to check all the gas piping for leaks before lighting the water
heater. Use a soapy water solution, not a match or open flame.
Rinse off soapy solution and wipe dry.
GAS PRESSURE REQUIREMENTS
All models require a minimum gas supply pressure of 3.5” W.C.(0.87
kPa) for natural gas and 8.0” W.C. (1.99 kPa) for propane. The
minimum supply pressure is measured while gas is not flowing
(static pressure) AND while gas is flowing (dynamic pressure). The
supply pressure (static and dynamic) should never fall below 3.5”
W.C.(0.87 kPa) for natural gas or 8.0” W.C. (1.99 kPa) for propane.
The supply pressure should be measured with all gas fired water
heaters connected to the common main firing at full capacity. If the
supply pressure drops more than 1.5” W.C. (0.37 kPa) as gas begins
to flow to the water heater then the supply gas system including the
gas line and/or the gas regulator may be restricted or undersized.
See Supply Gas Regulator section and Gas Piping section of this
manual. The gas control valve on all models has a maximum gas
supply pressure limit of 14” W.C.(3.48 kPa) The maximum supply
pressure is measured while gas is not flowing (static pressure) AND
while gas is flowing (dynamic pressure).
SUPPLY GAS REGULATOR
The maximum allowable gas supply pressure for this water heater
is 14 inches W.C. (3.5 kPa). Install a positive lock-up gas pressure
regulator in the gas supply line if inlet gas pressure can exceed 14
inches W.C. (3.5 kPa) at any time. Regulators must be sized/used
according to manufacturer’s specifications.
If a positive lock-up regulator is required follow these instructions:
1.Positive lock-up gas pressure regulators must be rated at or above
the input Btu/hr rating of the water heater they supply.
2.Supply gas regulators shall have inlet and outlet connections not
less than the minimum supply gas line size for the water heater
they supply
3.Positive lock-up gas pressure regulator(s) should be installed no
closer than 3 feet (1 meter) and no farther than 8 feet (2.4 meters)
from the water heater’s inlet gas connection.
4.After installing the positive lock-up gas pressure regulator(s) an
initial nominal supply pressure setting of 7.0” W.C.(1.74 kPa) for
Natural Gas and 11.0” W.C. (2.74 kPa) for Propane (LP) while
the water heater is operating is recommended and will generally
provide good water heater operation. Some additional adjustment
may be required later to maintain a steady gas supply pressure.
20
SPACE HEATING AND POTABLE WATER SYSTEM
THERMAL EXPANSION
Your water heater is equipped with inlet/outlet connections for use
in space heating applications (see Figure 9). If this water heater
is to be used to supply both space heating and potable (drinking)
water, the instructions listed below must be followed:
As water is heated, it expands (thermal expansion). In a closed
system the volume of water will grow when it is heated. As the
volume of water grows there will be a corresponding increase in
water pressure due to thermal expansion. Thermal expansion can
cause premature tank failure (leakage). This type of failure is not
covered under the limited warranty. Thermal expansion can also
cause intermittent temperature-pressure relief valve operation:
water discharged from the valve due to excessive pressure build
up. This condition is not covered under the limited warranty. The
temperature-pressure relief valve is not intended for the constant
relief of thermal expansion.
A properly sized thermal expansion tank should be installed on all
closed systems to control the harmful effects of thermal expansion.
Contact a local plumbing service agency to have a thermal
expansion tank installed.
• Be sure to follow the manual(s) shipped with the air handler or
other type heating system.
• This water heater cannot be used in space heating applications
only.
• This water heater is not to be used as a replacement for an
existing boiler installation.
• Do not use with piping that has been treated with chromates,
boiler seal or other chemicals and do not add any chemicals to
the water heater piping
• If the space heating system requires water temperatures in excess
of 120°F, a mixing valve must be installed per the manufacturer’s
instructions in the potable hot water supply to limit the risk of scald
injury.
• Pumps, valves, piping and fittings must be compatible with
potable water.
• A properly installed flow control valve is required to prevent
thermosiphoning. Thermosiphoning is the result of a continuous
flow of water through the air handler circuit during the off cycle.
Weeping (blow off) of the temperature and pressure relief valve
(T & P relief valve) or higher than normal water temperatures are
the first signs of thermosiphoning.
NOTE: To protect against untimely corrosion of hot and cold
water fittings, it is strongly recommended that di-electric unions
or couplings be installed on this water heater when connected
to copper pipe, see Figure 10 also.
• The hot water line from the water heater should be vertical past
any mixing valve or supply line to the heating system to remove
air bubbles from the system Do not connect the water heater to
any system or components previously used with non-potable
water heating appliances when used to supply potable water.
Figure 10
Figure 10 show the typical attachment of the water piping to
the water heater. The water heater is equipped with 3/4 inch
NPT water connections for 50 gallon unit and 1 inch NPT water
connections for 75 gallon unit..
NOTE: If using copper tubing, solder tubing to an adapter before
attaching the adapter to the water heater connections. Do not
solder the water lines directly to the water heater connections.
It will harm the dip tube and damage the tank, T & P Valve and
Pipe Insulation (if supplied)
Figure 9
CLOSED WATER SYSTEMS
Fit pipe insulation over the incoming cold water line and the hot
water line. Make sure that the insulation is against the top cover of
the heater.Fit T & P valve insulation over valve. Make sure that the
insulation does not interfere with the lever of the T & P valve.
Water supply systems may, because of code requirements or such
conditions as high line pressure, among others, have installed
devices such as pressure reducing valves, check valves, and back
flow preventers. Devices such as these cause the water system to
be a closed system.
Secure all insulation using tape.
21
TEMPERATURE-PRESSURE RELIEF VALVE
T&P VALVE DISCHARGE PIPE REQUIREMENTS:
• Shall not be smaller in size than the outlet pipe size of the valve,
or have any reducing couplings or other restrictions.
This water heater is provided with a properly rated/sized and certified
combination Temperature-Pressure Relief Valve (T&P relief valve) by
the manufacturer. The valve is certified by a nationally recognized
testing laboratory that maintains periodic inspection of production of
listed equipment of materials as meeting the requirements for Relief
Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA 4.4, and
the code requirements of ASME.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both the
Temperature-Pressure Relief Valve and the discharge pipe.
If replaced, the new T&P valve must meet the requirements of local
codes, but not less than a combination Temperature-Pressure Relief
Valve rated/sized and certified as indicated in the above paragraph. The
new valve must be marked with a maximum set pressure not to exceed
the marked hydrostatic working pressure of the water heater (150 psi =
1,035 kPa) and a discharge capacity not less than the water heater Btu/
hr or kW input rate as shown on the water heater’s model rating plate.
• Must terminate a maximum of six inches (15.2 cm) above a
floor drain or external to the building. In cold climates, it is
recommended that the discharge pipe be terminated at an
adequate drain inside the building.
• Shall not have any valve or other obstruction between the
temperature-pressure relief valve and the drain.
NOTE: In addition to the factory installed Temperature-Pressure
Relief Valve on the water heater, each remote storage tank that may
be installed and piped to a water heating appliance must also have
its own properly sized, rated and approved Temperature-Pressure
Relief Valve installed.
Burn hazard.
Hot water discharge.
Keep clear of TemperaturePressure Relief Valve
discharge outlet.
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
The Temperature-Pressure Relief Valve must be manually
operated at least twice a year. Caution should be taken to ensure
that (1) no one is in front of or around the outlet of the TemperaturePressure Relief Valve discharge line, and (2) the water manually
discharged will not cause any bodily injury or property damage
because the water may be extremely hot. If after manually
operating the valve, it fails to completely reset and continues to
release water, immediately close the cold water inlet to the water
heater, follow the draining instructions in this manual, and replace
the Temperature-Pressure Relief Valve with a properly rated/sized
new one.
Properly sized temperaturepressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
NOTE: The purpose of a Temperature-Pressure Relief Valve is to
prevent excessive temperatures and pressures in the storage tank.
The T&P valve is not intended for the constant relief of thermal
expansion. A properly sized thermal expansion tank must be
installed on all closed systems to control thermal expansion, see
Closed Water Systems and Thermal Expansion on Page 21.
For safe operation of the water heater, the Temperature-Pressure
Relief Valve must not be removed from its designated opening nor
plugged. The Temperature-Pressure Relief Valve must be installed
directly into the fitting of the water heater designed for the relief valve.
Install discharge piping so that any discharge will exit the pipe within
6 inches (15.2 cm) above an adequate floor drain, or external to the
building. In cold climates it is recommended that it be terminated at
an adequate drain inside the building. Be certain that no contact is
made with any live electrical part. The discharge opening must not
be blocked or reduced in size under any circumstances. Excessive
length, over 30 feet (9.14 m), or use of more than four elbows can
cause restriction and reduce the discharge capacity of the valve.
If you do not understand these instructions or have any questions
regarding the Temperature-Pressure Relief Valve call the toll
free number listed on the back cover of this manual for technical
assistance.
CONDENSATE PIPING
The water heaters covered in this manual are condensing
appliances and require a building drain to be located in close
proximity to allow the condensate to drain safely.
No valve or other obstruction is to be placed between the
Temperature-Pressure Relief Valve and the tank. Do not connect
discharge piping directly to the drain unless a 6” (15.2 cm) air gap
is provided. To prevent bodily injury, hazard to life, or property
damage, the temperature-pressure relief valve must be allowed
to discharge water in adequate quantities should circumstances
demand. If the discharge pipe is not connected to a drain or other
suitable means, the water flow may cause property damage.
Condensate drains from the water heater at the exhaust elbow
located at the bottom. The field installed condensate drain line
must not be elevated above the condensate drain connection on
the condensate trap, see Figure 11. If the condensate does not
drain properly it will build up in the exhaust (vent) elbow. This will
restrict the flow of flue gases and cause the Blocked Exhaust
pressure switch to open its contacts. The control system monitors
all pressure switches, if the Blocked Exhaust Switch contacts are
open the control system will lock out and disable heating operation.
The “Blocked Exhaust” Fault message will be displayed on the
control system’s LCD.
CAUTION
Water Damage Hazard
The Condensate Cleanout Cap must be on and tight when unit is
in operation.
• Temperature-Pressure Relief Valve discharge
NOTE: If the “Blocked Exhaust “ Fault message is ever displayed
on the control system LCD, check the condensate drain first and
ensure it is not blocked.
pipe must terminate at adequate drain.
22
7. Condensate clean out cap must be on and tight when unit is in
operation.
THIS SIDE VIEW
OF EXHAUST
ELBOW AND
ARROW INDICATE
THE LOCATION OF
THE PRESSURE
PORT
EXHAUST (VENT)
ELBOW
CONDENSATE
DRAIN LINE
CONNECTION
HIGH ALTITUDE INSTALLATIONS
DRAIN LINE TO TERMINATE NO
MORE THAN 6 INCHES (15.2cm)
ABOVE DRAIN
CONDENSATE
CLEANOUT CAP
CONDENSATE DRAIN
LINE - FIELD INSTALLED
BUILDING
DRAIN
Figure 11
DO NOT remove the factory installed exhaust/condensate elbow
for any reason, see Figure 11. The water heater’s vent pipe is
under a slight positive pressure while unit is in operation. The
water trap inside of the exhaust/condensate elbow prevents flue
gases from escaping into the installed space.
Do not install any external condensate trap. The exhaust elbow
assembly has an internal condensate trap.
CONDENSATE DRAIN INSTALLATION
Installation must conform with these instructions and local building
codes.
Field supplied materials required for installation include:
• Approved PVC cement and PVC primer.
• 1/2 inch PVC pipe - minimum length to equal the distance
between the water heater and a suitable building drain.
• 1/2 inch PVC fittings (elbows, couplings, and adapters)
necessary to install a condensate drain line between the Exhaust/
Condensate Elbow Assembly and a suitable building drain.
• Floor mounted standoffs to brace the drain line.
This high ef ficiency water heater is cer tified for use
without modification for an altitude of 10,100 feet (3,078
m). Consult the factor y for installation at altitudes over
10,100 feet (3,078 m).
Some gas utility companies derate their gas for altitude,
making it unnecessar y to install high altitude orifices. Call
the local gas or utility company to verify BTU content.
Due to the input rate reduction at high altitudes, the output
rating of the water heater is also reduced and should
be compensated for in the sizing of the equipment for
applications.
INSTALLATION NOTES
1. The condensate drains from the water heater’s covered by
this instruction have PH levels between 4.3 and 5.0. Install a
commercially available neutralizing kit if required by local codes.
Lower PH levels are acidic. Do not connect a metal condensate
drain line, such as copper pipe, to the water heater for this reason.
2. The field installed condensate drain line must not be less than
1/2 inch PVC in size.
3. DO NOT remove, modify or alter the factory condensate trap.
FILLING THE WATER HEATER
INSTALLATION INSTRUCTIONS
1. Ensure the water heater’s enable/disable switch is in the
“disable” position.
2. Install a 1/2 inch PVC condensate drain line between
condensate drain connection on the Exhaust/Condensate
Elbow and a suitable building drain with a slight downward
slope to drain. The exhaust elbow has a “built in” condensate
trap. Do not install an additional trap in the condensate drain
piping. See Figure 12.
3. Terminate the condensate drain piping with an elbow above the
drain. Ensure that any discharge will exit the condensate drain
line no more than 6 inches (15.2 cm) above a suitable building
drain, or external to the building, see Figure 11.
NOTE: In cold climates it is recommended the condensate drain be
terminated at a suitable drain inside the building.
4. Ensure the condensate drain line is not elevated above the
condensate drain connection on the Exhaust/Condensate
Elbow, see Figure 11.
5. Brace the condensate drain line with floor mounted standoffs
every three feet.
6. Ensure the condensate drains freely during start up and the
condensate clean out cap is on and tight when unit is in operation.
Never use this water heater unless it is completely full of water.
To prevent damage to the tank, the tank must be filled with water.
Water must flow from the hot water faucet before turning ON gas
to the water heater.
To fill the water heater with water:
1. Close the water heater drain valve by turning the handle to the
right (clockwise). The drain valve is on the lower front of the
water heater.
2. Open the cold water supply valve to the water heater.
NOTE: The cold water supply valve must be left open when the
water heater is in use.
3. To insure complete filling of the tank, allow air to exit by opening
the nearest hot water faucet. Allow water to run until a constant
flow is obtained. This will let air out of the water heater and the
piping.
4. Check all water piping and connections for leaks. Repair as
needed.
23
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS
For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed
in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by
the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the
area of the venting, including but not limited to decks and porches, the following requirements should be satisfied:
INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled
equipment, the installing plumber or gasfitter should observe that a hard wired carbon monoxide detector with an alarm and battery
back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter should
observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling,
building or structure served by the sidewall horizontal vented gas fueled equipment. It should be the responsibility of the property owner
to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.
In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired
carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner should
have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a battery
operated carbon monoxide detector with an alarm should be installed.
APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above
provisions should comply with NFPA 720 and be ANSI/UL 2034 listed and CSA certified.
SIGNAGE A metal or plastic identification plate should be permanently mounted to the exterior of the building at a minimum
height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating
appliance or equipment. The sign should read, in print size no less than one-half (1/2) inch in size, GAS VENT DIRECTLY
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.
INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment should not approve the
installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance
with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54
as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the
dwelling, building, or structure used in whole or in part for residential purposes.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product
Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment,
the instructions provided by the manufacturer for installation of the equipment and the venting system should include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer
of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue
gases, but identifies special venting systems, the following requirements should be satisfied by the manufacturer:
1. The referenced special venting system instructions should be included with the appliance or equipment installation instructions; and
2. The special venting systems should be Product Approved by the Board, and the instructions for that system should include
a parts list and detailed installation instructions.
A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting
instructions, all parts lists for venting instructions, and/or all venting design instructions should remain with the appliance or
equipment at the completion of the installation.
24
VENTING INSTALLATION
combustion air intake during severe cold weather. To prevent
the recirculation of flue gases, maintain as much distance as
possible between the combustion air intake and the exhaust
vent terminal refer to Figure 16 and Figure 17 on Page 29 &
Page 30 respectively.
Approved vent and intake air pipe materials:
PVC pipe materials:
• DWV ASTM-D2665 or CSA B181.2
• Schedule 40, 80, 120 ASTM-D1785 or CSA B137.3
• SDR Series ASTM-2241 or CSA B137.3
CPVC pipe materials:
• CPVC 41 ASTM-D2846 or CSA B137.6
• Schedule 40, 80 ASTM-F441 or CSA B137.6
• SDR Series ASTM-F442
Polypropylene - See page 26
• M & G Duravent PolyPro vent system
• Centrotherm InnoFlue vent system
NOTE:
The use of cellular core PVC (ASTM F891), cellular core CPVC,
or Radel® (polyphenolsulfone) in non-metallic venting systems is
prohibited. Covering non-metallic vent pipe and fittings with thermal
insulation is prohibited.
If the water heater is being installed as a replacement for
an existing power vented heater in pre-existing venting,
a thorough inspection of existing venting system must be
performed prior to any installation work. Verify that correct
material as detailed above has been used, and that the
minimum or maximum vent lengths and terminal location as
detailed in this manual have been met. Carefully inspect the
entire venting system for any signs of cracks or fractures,
particularly at joints between elbows and other fittings and
straight runs of vent pipe. Check system for signs of sagging
or other stresses in joints as a result of misalignment of any
components in the system. If any of these conditions are
found, they must be corrected in accordance with the venting
instructions in this manual before completing installation and
putting the water heater into service.
VENT INSTALLATION CONSIDERATIONS
This water heater can be vented using room air for intake
combustion air, or direct vented so that all intake air for
combustion comes from the outside through a sealed pipe.
This water heater may be installed in 4 separate orientations
depending on the requirements of the building and the water
heater. The installer must decide which method is most
appropriate for each installation. These orientations are:
1. Vertical Termination - vertical vent termination through
unenclosed or enclosed areas with roof penetration, refer
to Vertical Vent Terminal Installation on Page 31.
2. Through-the-Wall Termination - horizontal vent termination
directly through an outside wall, see Figure 12 on page 27..
3. Horizontal Direct Vent - using Through-the-Wall Termination
to exhaust flue products and piping to bring combustion air
to the water heater from the outside. See Figure 15 on
Page 28 and Figure 23 and Figure 24 on page 32.
4. Vertical Direct Vent - using a vertical vent termination to
exhaust flue products and piping to bring combustion air
to the water heater from outside, see Figure 21 & Figure
22 on Page 32.
NOTE: For water heaters in locations with high ambient
temperatures above 100°F (38°C) it is recommended that CPVC
or Polypropylene pipe and fittings be used.
All vent (exhaust) pipes must be pitched a minimum of a 1/4” per
foot back to the water heater to allow drainage of condensation.
Never operate the water heater unless it is vented to the outdoors.
The instructions in this section of the manual must be followed
to avoid choked combustion or recirculation of flue gases. Such
conditions cause sooting of the combustion chamber, burners and
flue tubes and creates a risk of asphyxiation.
In cold climates any water vapor remaining in the flue gases
will condense into a cloud of vapor at the point where the
vent system exits the building. Special consideration is
recommended, before locating the vent termination near
walkways, windows and building entrances.
For direct vent application where combustion air might be supplied
from extremely cold ambient through fresh air intake piping
system, it is recommended that a backflow preventer be installed
at the intake vent terminal close to the blower before proceeding
with installation of the rest of the fresh air intake piping. Call the
technical support phone number listed on the back cover of this
manual for more information.
Direct venting into dead spaces such as alleys, atriums,
and inside corners can cause recirculation of flue gases.
Recirculation of flue gases will cause sooting, and icing of the
25
POLYPROPYLENE INSTALLATIONS
Polypropylene vent systems do not use cement to connect the pipe
and elbow sections but use a push together gasket seal method.
Do not attempt to connect Polypropylene with sealant cement. All
vent connections MUST be secured by the vent manufacturer’s joint
connector. The installer must use a specific vent starter adapter at
the flue connection. The adapter is supplied by the vent manufacturer
to adapt to its vent system.
The water heater has been approved to be installed with
Polypropylene vent material as shown in Table 5 and Table 6. The
approved application of single wall, non-flexible, non-concentric
Polypropylene vent material is offered by two specific manufacturers
(Centrotherm ECO Systems and DuraVent Polypropylene). These
listed products must be installed by following the vent manufacturer’s
instructions. Refer to Table 7 on Page 27 to determine the maximum
pipe length and number of elbows that can be used.
In order to be in full compliance with UL 1738 or ULC-S636 and to
meet the requirements of the water heater manufacturer, you must
use the metal joint connector rings, available from the Polypropylene
vent manufacturer, to stiffen the joints of 2”, and 3” diameter pipes.
Insulation should not be used on Polypropylene venting materials.
The use of insulation will cause increased vent wall temperatures,
which could result in vent pipe failure.
Use only the adapters and vent system listed in Tables below. DO
NOT mix vent systems of different types or manufacturers. Failure
to comply could result in severe personal injury, death, or substantial
property damage.
Installations must comply with applicable national, state, and local
codes. For Canadian installation, Polypropylene vent must be
listed as a ULC-S636 approved system. If Polypropylene vent is
not required by your local code, you may use either PVC or CPVC
pipes for your water heater that allows non-metallic venting material
installations.
Table 5
M & G Duravent PolyPro
Nominal Pipe
Diameter
Adapter
Ring
Connector Connector
Flue Outlet Adapter
2”
2PPS-AD
PPS-PAC
3”
3PPS-AD
PPS-PAC
90 Degree
Elbow
Vent Material
Terminal(s)
2PPS-LB
2PPS-E90
2PPS
2PPS & 2PPS-BG for Exhaust;
2PPS-E90 & 2PPS-BG for Intake (Direct Vent
only)
3PPS-LB
3PPS-E90
3PPS
3PPS & 3PPS-BG for Exhaust;
3PPS-E90 & 3PPS-BG for Intake (Direct Vent
only)
Table 6
Centrotherm InnoFlue SW
Nominal Pipe
Diameter
Adapter
Ring
Connector Connector
Flue Outlet Adapter
2”
ISAGL
0202
IAFC02
3”
ISAGL
0303
IAFC03
90 Degree
Elbow
Vent Material
Terminal(s)
IANS02
ISELL0287
ISVL02
ISVL02 & IASPP02 for Exhaust;
ISELL0287 & IASPP02 for Intake (Direct Vent
only)
IANS03
ISELL0387
ISVL03
ISVL03 & IASPP03 for Exhaust;
ISELL0387 & IASPP03 for Intake (Direct Vent
only)
26
VENT PIPE TERMINATION
INSTALLATION OF HORIZONTAL THROUGH THE
WALL VENT SYSTEM
The first step is to determine where the vent pipe will terminate. See
Figures 12 through 20. The vent may terminate through a sidewall
as shown in Figures 12, 14 and 15 or through the roof as shown
in 18, 19 and 20.
If you are installing your system so that it vents through roof, please
refer to section titled VERTICAL VENT TERMINAL INSTALLATION.
VENT TERMINAL INSTALLATION, SIDEWALL
1. Install the vent terminal by using the cover plate as a template to
mark the hole for the vent pipe to pass through the wall. BEWARE
OF CONCEALED WIRING AND PIPING INSIDE THE WALL.
The vent system must terminate so that proper clearances are
maintained as cited in local codes or the current edition of the
National Fuel Gas Code, (ANSI Z223.1, 12.9.1 through 12.9.4). See
Figure 16 and Figure 17.
2. If the Vent Terminal is being installed on the outside of a finished
wall, it may be easier to mark both the inside and outside wall.
Align the holes by drilling a hole through the center of the
template from the inside through to the outside. The template
can now be positioned on the outside wall using the drilled hole
as a centering point for the template.
Instructions on proper installation through a sidewall are provided
in Figures 12, 14 and 15.
Plan the vent system layout so that proper clearances are
maintained from plumbing and wiring.
Vent pipes serving power vented water heaters are classified by
building codes as vent connectors. Required clearances from
combustible materials must be provided in accordance with
information in this manual under Locating The Water Heater and
Installation Requirements, and with the National Fuel Gas Code
and local codes.
3. A) MASONRY SIDE WALLS
PLANNING THE VENT SYSTEM
Plan the route of the vent system from the exhaust elbow to the
planned location of the vent terminal.
1.Layout total vent system to use a minimum of vent pipe and elbows.
2.This water heater is capable of venting flue gases in equivalent
feet of pipe as listed in Table 7.
2” Maximum
Pipe - ft. (m)
40 (12.19)
35 (10.66)
30 (9.14)
25 (7.62)
20 (6.09)
15 (4.57)
3” Maximum
Pipe - ft. (m)
120 (36.57)
115 (35.05)
110 (33.52)
105 (32)
100 (30.48)
95 (28.95)
The minimum vent length for each of the pipe size is one 90° elbow
plus 2’ and 7’ (0.61 m and 2.1 m) of straight pipe for air intake and
exhaust vent respectively and the appropriate termination.
Chisel an opening approximately one half inch (1.3 cm) larger
than the marked circle.
B) WOODEN SIDE WALLS
Drill a pilot hole approximately one quarter inch (0.64 cm)
outside of the marked circle. This pilot hole is used as a starting
point for a saws-all or sabre saw blade. Cut around the marked
circle staying approximately one quarter inch (0.64 cm) outside
of the line. (This will allow the vent to easily slide through the
opening. The resulting gap will be covered up by the Vent
Terminal wall plate.) Repeat this step on inside wall if necessary.
Cut a length of pipe about 3.5 inches (8.9 cm) longer than the wall
thickness at the opening. Glue the vent terminal to this section
of pipe. Slide the wall plate over the pipe to stop against the vent
terminal. Place a bead of caulking (not supplied) around the gap
between the pipe and cover plate. Apply enough to fill some of
the gap between the pipe and wall. Place some of the caulking on
the back of the plate to hold it against the wall after installation.
If the vent pipe is installed up to the wall, with a coupling on the
end against the wall opening, the pipe with the vent terminal can
be prepared for gluing before inserting through the wall. Slide the
pipe through the wall and insert into the coupling on the other side
of the wall, making sure that the vent terminal ends up pointed in
the correct position, see Figure 12.
Table 7
Number of
90° Elbows
1
2
3
4
5
6
NOTE: The equivalent feet (m) of pipe listed above are exclusive
of the termination. That is, the termination, with an installed
screen, is assumed to be in the system and the remainder of
the system must not exceed the lengths and number of elbows
shown in Table 7.
If using 2” inch vent pipe: A 2” diameter vent pipe must be
inserted and fastened to the exhaust elbow assembly.
If using 3” inch vent pipe: Two inches (5.1cm) of 2” diameter pipe
must be inserted and fastened to the exhaust elbow assembly
before adding a 2’ x 3” reducer to acquire the desired pipe
diameter. A 3” coupling (supplied locally-a schedule 40 DWV)
vent terminal must be obtained. A 3” diameter screen is supplied
in the vent kit.
Figure 12: VENT TERMINATION
27
DIRECT VENT TERMINAL INSTALLATION
B.) WOODEN SIDE WALLS Drill a pilot hole approximately
one quarter inch outside of the marked circle. This
pilot hole is used as a starting point for a saws-all or
sabre saw blade. Cut around the marked circle staying
approximately one quarter inch outside of the line.
(This will allow the vent pipe to easily slide through
the opening. The resulting gap will be covered by the
vent terminal cover plates.) Repeat this step on the
inside wall if necessary.
2. Cut a length of pipe about 3.5” (8.9 cm) longer than the
wall thickness at the opening.
3. Glue the air intake terminal to the section of the pipe.
4. Slide the wall plate over pipe to stop against air intake terminal.
5. Place a bead of caulking (not supplied) around the gap between
the pipe and the wall. Place some of the caulking on the
back of the plate to hold it against the wall after installation.
6. If the air intake pipe is installed up to the wall, with a coupling on the
end against the wall opening, the pipe with the air intake terminal can
be prepared for gluing before inserting through the wall. Slide the
pipe through the wall and insert into coupling on the other side of
the wall, making sure that the air intake terminal ends up pointed in the
correct position (Figure 14 and Figure 15).
The air intake provided on the unit contains an air intake screen to
prevent large particles from entering the unit.
Figure 13: Air Intake Screen
When the unit is to be set up as a direct vent, the air intake screen
must be removed. The air intake pipe may then be glued to the air
intake (see Figure 13) provided on the unit.
This unit consists of two terminals - an air intake terminal and an
exhaust vent terminal. The air intake terminal is a 2” 90° pvc elbow
with an air intake screen and the exhaust vent terminal is a 2” straight
pvc coupling with a mesh wire screen.
Note: to prevent exhausting products from circulating to the air intake
in windy/cold areas, the maximum practical distance between these
two terminals is recommended.
Figure 14
INSTALLATION SEQUENCE
1. After the points of termination have been determined,
use the cover plates as templates to mark the holes for
the vent pipes to be inserted through the wall. BEWARE OF
CONCEALED WIRING AND PIPING INSIDE OF WALL. If the
vent terminals are being installed on the outside of a finished
wall, it may be easier to mark both the inside and outside
wall. Align the holesby drilling a hole through the center of the
template from the inside through to the outside. The template
can now be positioned on the outside wall using the drilled holes
as a centering point for the template.
A.) MASONRY SIDE WALLS Chisel an opening approximately
1/2” (1.3 cm) larger than the marked circle.
Figure 15
28
TERMINATION CLEARANCES SIDEWALL POWER VENT
POWER VENT
(using room air for combustion)
EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION
G
V
D
H
A
v E
L
v
B
FI XE D
CLOSED
V
F
B
B
C
OPERABLE
V
OPERABLE
V
B
B
FI XE D
CLOSED
M
X
V
A
V
X
V
K
J
B
V
VENT TERMINAL
X
AIR SUPPLY INLET
AREA WHERE TERMINAL IS NOT PERMITTED
Figure 16
Vent terminal clearances for “Power Vent” installations. Power Vent configurations use room air for combustion.
US INSTALLATIONS
1
US INSTALLATIONS
Clearance to each side
of center line extended
above meter/regulator
assembly
3 feet (91 cm) within a
height 15 feet (4.5 m)
above the meter/regulator
assembly*
Clearance to service
regulator vent outlet
3 feet (91 cm)*
A
Clearance above grade,
veranda, porch, deck or 12 inches (30 cm)
balcony
B
Clearance to window
or door that may be
opened
C
Clearance to
permanently closed
window
12 inches (30 cm)*
J
Clearance to a non
mechanical air supply
inlet into building or
combustion air inlet to
any other appliance
D
Vertical clearance to
ventilated soffit located
above the terminal
within a horizontal
12 inches (30 cm)*
distance of 2 feet (61
cm) from the center line
of the terminal
K
Clearance to a
mechanical air supply
inlet
E
Clearance to
unventilated soffit
12 inches (30 cm)*
L
Clearance above paved
sidewalk or paved
7 feet (2.13 m)
driveway located on
public property
F
Clearance to outside
corner
2 feet (60 cm)*
M
Clearance under
veranda, porch, deck, or 12 inches (30 cm) ‡
balcony
G
Clearance to inside
corner
18 inches (45 cm)*
4 feet (1.2 m) below
or to side of opening;
1 foot (30 cm) above
opening
H
I
1
4 feet (1.2 m) below or to
side of opening; 1 foot
(30 cm) above opening.
3 feet (91 cm) above if
within
10 feet (3 m) horizontally
1 In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.
† A vent shall not terminate where it may cause hazardous frost or ice accumulations on adjacent property surfaces.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.
29
TERMINATION CLEARANCES SIDEWALL DIRECT VENT
DIRECT VENT
(using outdoor air for combustion)
EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION
G
V
D
H
A
v E
L
v
B
FI XE D
CLOSED
V
F
OPERABLE
V
B
B
C
OPERABLE
V
B
FI XE D
CLOSED
M
X
V
B
V
X
V
K
J
A
B
V
VENT TERMINAL
X
AIR SUPPLY INLET
AREA WHERE TERMINAL IS NOT PERMITTED
Figure 17
Vent terminal clearances for “Direct Vent” installations. Direct Vent configurations use outdoor air for combustion.
US INSTALLATIONS
1
A
Clearance above grade,
veranda, porch, deck or
balcony
B
6 inches (15 cm)
for appliances up to
10,000 Btu/hr (3 kW),
9 inches (23 cm) for
Clearance to window or
appliances between
door that may be opened 10,000 Btu/hr (3 kW)
and 50,000 Btu/hr (15
kW), 12 inches (30 cm)
for appliances above
50,000 Btu/hr (15 kW)
12 inches (30 cm)
US INSTALLATIONS
H
Clearance to each side
3 feet (91 cm) within a height
of center line extended
15 feet (4.5 m) above the
above meter/regulator
meter/regulator assembly*
assembly
I
Clearance to service
regulator vent outlet
3 feet (91 cm)*
J
Clearance to a non
mechanical air supply
inlet into building or
combustion air inlet to
any other appliance
6 inches (15 cm) for
appliances up to 10,000
Btu/hr (3 kW), 9 inches (23
cm) for appliances between
10,000 Btu/hr (3 kW) and
50,000 Btu/hr (15 kW), 12
inches (30 cm) for appliances
above 50,000 Btu/hr (15 kW)
3 feet (91 cm) above if within
10 feet (3 m) horizontally
C
Clearance to
permanently closed
window
D
Vertical clearance to
ventilated soffit located
above the terminal within
12 inches (30 cm)*
a horizontal distance of
2 feet (61 cm) from the
center line of the terminal
K
Clearance to a
mechanical air supply
inlet
E
Clearance to unventilated
12 inches (30 cm)*
soffit
L
Clearance above
paved sidewalk or
7 feet (2.13 m)†*
paved driveway located
on public property
F
Clearance to outside
corner
2 feet (60 cm)*
M
Clearance under
veranda, porch, deck,
or balcony
G
Clearance to inside
corner
18 inches (45 cm)*
6 inches (15 cm)*
1
12 inches (30 cm) ‡*
1 In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.
† A vent shall not terminate where it may cause hazardous frost or ice accumulations on adjacent property surfaces.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.
30
VERTICAL VENT TERMINAL INSTALLATION
WHEN TERMINATING THROUGH A ROOF, THE FOLLOWING
SPECIFICATIONS PERTAINING TO TERMINAL LOCATION
MUST BE FOLLOWED.
1. Proper support must be provided for all pipe protruding through
the roof.
2. The vertical roof terminations should be sealed with a plumbing
roof boot or equivalent flashing.
3. The air intake termination and the exhaust vent termination
must penetrate the same side of roof.
4. The center line of the air intake termination and the center line
of the exhaust vent termination must be no closer than 24”
(61cm). See Figure 18 and Figure 19.
FLAT ROOF INSTALLATION
On flat roof installations the air intake and the exhaust vent
terminations must be a minimum of 24 inches (60 cm) above any
parapet, vertical wall or structure within 10 feet (3 m) horizontally.
See Figure 20.
Figure 20
Figure 18
Figure 19
31
DIRECT VENT DIAGRAM
12” MINIMUM CLEARANCE
ABOVE HIGHEST ANTICIPATED
SNOW LEVEL
12” MINIMUM CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL
Figure 21
Figure 22
24” MINIMUM SEPARATION. EXHAUST
MUST BE AT SAME LEVEL OR ABOVE
INTAKE TERMINAL.
SNORKELING IS ALLOWED TO ACHIEVE
PROPER CLEARANCE. THE SNORKEL
MUST BE SECURELY SUPPORTED.
Figure 23
Figure 24
32
CONCENTRIC VENT INSTALLATION
INSTALLATION VERTICAL ROOF TERMINATION
This water heater is certified for concentric venting with concentric
vent kit #9006328005. Follow instructions below for proper
installations.
1. Determine best location for termination kit.
NOTE: Roof termination is preferred since it is less
susceptible to damage, has reduced chances to intake contaminants,
and less visible vent vapors.
Table 8 – KIT COMPONENTS
2. Cut 1 hole (5 in. diameter)
3. Partially assemble concentric vent termination kit.
a) Cement Y concentric fitting to larger diameter kit
pipe, see Figure 25.
b) Cement rain cap to smaller diameter kit pipe, see Figure 25.
Field supplied pipe and fittings are required to complete the
installation.
STAINLESS STEEL
SCREW AND NUT
This concentric vent termination kit may be used with 3 inch diameter
pipe systems.
SAFETY CONSIDERATIONS
Figure 27
Installing and servicing water heating equipment can be hazardous
due to gas and electrical components. Installation and service of
the concentric vent termination requires ability equivalent to that of
a qualified installer or qualified service technician, see Page 7. All
precautions in the literature, on tags, and labels attached to the unit
must be observed.
NOTE: Instead of cementing the smaller pipe to the rain cap, a
stainless steel screw may be used to secure the 2 components
together when field disassembly is desired for cleaning, see Figure
27. Locate the drill location dimple on the outside of the rain cap;
at this location, drill a 3/16” hole through the cap and the inner
pipe wall with the path of the hole perpendicular to the inner pipe
NOT the outside of the cap; insert the screw and tighten the bolt;
do not over tighten.
Follow all safety codes. Wear safety glasses and work gloves.
When using alternate screw method, failure to drill adequate holes
may cause cracking of PVC components, allowing combustion
products to be recirculated. Failure to follow this warning could
result in personal injury or death.
Do not operate the heater with rain cap removed or recirculation
of combustion products may occur. Water may also collect inside
larger combustion-air pipe and flow to the burner enclosure.
Failure to follow this warning could result in product damage or
improper operation, personal injury or death.
Figure 25
4. Install Y concentric fitting and pipe assembly through
structure’s hole and field supplied roof boot/flashing.
Figure 26
* Dimension 19.50 in. may also be shortened by cutting the
pipes, provided in the kit, to 12 in. minimum.
** Dimension 36.10 will change accordingly as dimension
19.50 in. is shortened.
Do not use field-supplied couplings to extend pipes. Airflow restriction
will occur and the heater pressure switch may cause intermittent
operation.
Figure 28
33
INSTALLATION SIDE WALL TERMINATION
NOTE: Do not allow insulation or other materials to accumulate
inside pipe assembly when installing through hole.
5. Secure assembly to roof structure as shown in Figure 28
using field supplied metal strapping or equivalent support
material.
NOTE: Ensure termination height is above the roof surface or
anticipated snow level as shown in Figure 28.
6. Inst all rain c ap and small diameter pipe assembly in
r o o f p e n e t r a t i o n a s s e m b l y, E n s u r e s m a l l d i a m e t e r
pipe is cemented and bottomed in Y concentric fitting.
7. Cement water heater combustion air intake and vent pipes to
concentric vent termination assembly. See Figure 28 for
proper pipe attachment.
Figure 30
8. Operate heater through 1 heat cycle to ensure combustion
air and vent pipes are properly connected to concentric vent
termination connections.
1. Determine best location for termination kit.
NOTE: Consideration for the following should be used when
determining an appropriate location for the termination kit:
FLAT ROOF INSTALLATION
• Termination kit positioned where the vent vapors will not damage
plants/shrubs or air conditioning equipment.
• Termination kit positioned so it will not be affected by wind eddy
that may allow recirculation of combustion products, or airborne
leaves, or light snow.
• Termination kit positioned where it will not get damaged or be
subjected to foreign objects, such as stones, balls, etc.
• Termination kit positioned where the vent vapors will not be
objectionable.
When installing a concentric termination vertically through a flat
roof, the termination’s vent cap must be a minimum of 10 feet (3
m) away from any parapet, vertical wall or structure as shown
in Figure 29.
If this required 10 foot (3 m) distance to a parapet, vertical wall
or structure cannot be maintained, standard terminations must
be used. See Vertical Vent Termination Installation.
NOTE: See Venting Installation section (starting on Page 25) in this
manual for additional vent location requirements.
2. Cut 1 hole (5 in. diameter).
3. Partially assemble concentric vent termination kit.
CONCENTRIC TERMINATION(S)
MUST BE A MINIMUM OF 10 FEET
(3 m) AWAY FROM ANY PARAPET,
VERTICAL WALL OR
STRUCTURE.
a) Cement the Y concentric fitting to larger diameter kit pipe, see
Figure 25.
b) Cement the rain cap to the smaller diameter kit pipe, see Figure
25.
NOTE: Instead of cementing the smaller pipe to the rain cap, a
field-supplied stainless steel screw may be used to secure the 2
components together when field disassembly is desired for cleaning,
see Figure 27.
When using alternate screw assembly method, drill clearance hole
in rain cap and pilot hole in vent pipe for screw being used. Failure
to drill adequate holes may cause cracking of PVC components,
allowing combustion products to be recirculated. Failure to follow
this warning could result in personal injury or death.
Do not operate the heater with rain cap removed or recirculation
of combustion products may occur. Water may also collect inside
larger combustion-air pipe and flow to the burner enclosure. Failure
to follow this warning could result in product damage or improper
operation, personal injury or death.
4. Install Y concentric fitting and pipe assembly through structure’s
hole.
NOTE: Do not allow insulation or other materials to accumulate
inside pipe assembly when installing through hole.
CONCENTRIC TERMINATION
FLAT ROOF CLEARANCE
5. Install rain cap and small diameter pipe assembly in Y concentric
fitting and large pipe assembly. Ensure small diameter pipe is
bottomed and cemented in Y concentric fitting.
Figure 29
34
MULTI-CONCENTRIC VENT TERMINATIONS
6. Ensure the Y connection is oriented so the air intake side of Y is
on top, see Figure 31.
When two or more water heaters are direct vented with concentric
vent terminations near each other, each water heater must be
individually vented. NEVER common vent this water heater. When
two or more water heaters are direct vented using concentric vent
terminations, the water heaters may be vented as shown in Figure
32 and Figure 33.
7. Secure assembly to structure as shown in Figure 31 using fieldsupplied metal strapping or equivalent support material.
NOTE: Ensure termination location clearance dimensions
are as shown in Figure 30, 32 and 33. When extending the
length of the 4” pipe, the added length beyond 21-1/8” must
be deducted from the maximum equivalent feet of vent pipe.
NOTE: If assembly needs to be extended to allow side wall
thickness requirement, the 2 pipes supplied in the kit may
be replaced by using same diameter, field-supplied SDR-26
PVC (D2241) pipe. Do not extend 21 1/8” (53.6 cm) dimension
more than 60” (1.5 m). See Figure 25.
Do not use field-supplied couplings to extend pipes. Air flow
restriction will occur and the heater pressure switch may
cause intermittent operation.
8. Cement heater combustion-air and vent pipes to concentric vent
termination assembly. See Figure 31 for proper pipe orientation
and attachment.
9. Operate heater through 1 heat cycle to ensure combustion-air and
vent pipes are properly connected to concentric vent termination
connections.
Figure 32 CONCENTRIC VENT TERMINATIONS FOR
HORIZONTAL DIRECT VENTING
Figure 33 CONCENTRIC VENT TERMINATIONS FOR
VERTICAL DIRECT VENTING THROUGH A ROOF
Figure 31
35
LOW PROFILE TERMINATION INSTALLATION
This water heater is certified for sidewall direct venting with IPEX
System 636 Low Profile Vent Kit. Follow instructions below for proper
installations.
To Boiler Intake
Air Connection
All termination kits must be located and installed in accordance with
local codes or the current editions of the National Fuel Gas Code
(ANSI Z223.1/NFPA 54).
From Boiler Vent
Pipe Connection
1. Once the proper location has been determined, cut 2 holes in the
wall large enough to accomodate the pipe. Pipe diameters and
distance between hole centers can be found in Table 9.
12”
Min to
OverHang
Possible Orientations
2. Slide both the intake and exhaust pipes through the holes. Solvent
cement both pipes to the base of the vent termination kit, follow the
solvent cementing procedures outlined in the IPEX System 636
Installation Guide, which is available on the web www.ipexinc.com.
Vent/Air
Termination
3. To fasten the Base to the wall, use the supplied screws and anchors.
A 3/16” (5mm) hole, 1-3/16” (30mm) deep, will need to be drilled for
the anchors. Locate the anchor hole using the base as a template.
12”
Min
Grade or
Snow Line
4. Screw the Cap to the Base using the supplied screws.
5. Once the vent termination and pipes are secured, the wall
penetrations will need to be sealed from the interior using a PVCcompatible sealant material.
Figure 35
6. All vent pipes and air inlets must terminate at the same height to
avoid possibility of severe personal injury, death, or substantial
property damage.
12” Min between Edge of Air
Inlet and Adjacent Vent Outlet
Vent
8. Operate heater through 1 heat cycle to ensure combustion-air and
vent pipes are properly connected to concentric vent termination
connections.
Air
Air Piping
Vent Base
Vent/Air
Termination
Vent Cap
Vent Piping
Figure 36
Figure 34
Table 9
Low Profile Termination Kits - Dimensions
AOS Kit
Number
9008952005
9008933005
IPEX Part
Number
196984
196985
Description
2” Flush Mount Vent Kit
3” Flush Mount Vent Kit
Pipe Outside Hole Spacing
Diameter
(ctr to ctr)
2.375”
5.6”
3.5”
5.6”
Table 10
Each Kit Contains
Qty
1
1
8
4
Item Description
Base (two holes)
Cap (one hole)
Stainless Steek Screws
Plastic Anchors
36
LIGHTING AND OPERATION LABELS
Set the “ENABLE/DISABLE” switch on the
control panel to the “DISABLE” position.
Operating Set Point:
Status: Heating
130° F
UP
Wait five (5) minutes to clear out any gas.
Then smell for gas, including near the floor.
If you smell gas,
STOP! Follow “B” in
the safety information above on this label.
If you don’t smell gas, go to the next step.
OFF
GAS O
N
Menu
Help
DN
Set the “ENABLE/DISABLE” switch on the
control panel to the “ENABLE” position.
Set the “ENABLE/DISABLE” switch on the
control panel to the “ENABLE” position.
Set the ENABLE/DISABLE switch on the
control panel to the “DISABLE” position.
37
TEMPERATURE REGULATION
It is recommended that lower water temperatures be used to avoid
the risk of scalding. It is further recommended, in all cases, that the
water temperatures be set for the lowest temperature which satisfies
your hot water needs. This will also provide the most energy efficient
operation of the water heater.
Valves for reducing the point-of-use temperature by mixing cold and
hot water are available. Also available are inexpensive devices that
attach to faucets to limit hot water temperatures. Contact a licensed
plumber or the local plumbing authority.
The table below shows the approximate time-to-burn relationship for
normal adult skin. Short repeated heating cycles caused by small hot water
uses can cause temperatures at the point of use to exceed the thermostat
setting by up to 20°F/11°C. If you experience this type of use, you should
consider using lower temperature settings to reduce scald hazards.
In all cases, the following burn table must be used. Its appearance
may be altered to comply with each manual’s style, but the content
must remain unchanged. NOTE: If the manual is to be used outside
of the United States, metric equivalents (Celsius) must be added to
the table.
Table 11
HOT WATER CAN SCALD: Water heaters are intended to produce
hot water. Water heated to a temperature which will satisfy space
heating, clothes washing, dish washing, and other sanitizing needs
can scald and permanently injure you upon contact. Some people
are more likely to be permanently injured by hot water than others.
These include the elderly, children, the infirm, or physically/mentally
handicapped. If anyone using hot water from this heater fits into
one of these groups or if there is a local code or state law requiring
a certain temperature water at the hot water tap, then you must
take special precautions. In addition to using the lowest possible
temperature setting that satisfies your hot water needs, a means
such as a mixing valve, should be used at the hot water taps used
by these people or at the water heater. Mixing valves are available
at plumbing supply or hardware stores. Follow manufacturer’s
instructions for installation of the valves. Before changing the factory
setting on the thermostat, read the Temperature Regulation section
in this manual.
Water Temperature
°F (°C)
Time for 1st Degree Burn
(Less Severe Burns)
110 (43.3)
(normal shower temp.)
116 (46.7)
(pain threshold)
116 (46.7)
35 minutes
Time for Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
45 minutes
122 (50)
1 minute
5 minutes
131 (55)
5 seconds
25 seconds
140 (60)
2 seconds
5 seconds
149 (65)
1 second
2 seconds
154 (67.8)
instantaneous
1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)
HI LIMIT SWITCH (ECO)
This water heater is equipped with an ECO (energy cut out) non
adjustable high temperature limit switch. The ECO is a normally
closed switch that opens (activates) on a rise in temperature. The
ECO is located inside the Temperature Probe (two red wires). The
ECO switch contacts will open when the water temperature reaches
approximately 202°F (94°C) and close at approximately 140°F (49°C).
Never allow small children to use a hot water tap, or to draw their own
bath water. Never leave a child or handicapped person unattended
in a bathtub or shower.
If the ECO activates (contacts open) due to abnormally high water
temperatures in the storage tank the control system will immediately
de-energize the 24 VAC Gas Control Valve and end the current
heating cycle. The control system will lock out disabling further
heating operation. The control system will display the Energy Cut
Out (ECO) Fault message on the LCD screen. It is important that
a Qualified Service Technician be contacted to determine the
reason for the ECO activation before resetting the ECO. Once the
reason has been determined and corrected the ECO can be reset
as follows:
SETTING THE WATER HEATER TEMPERATURE AT 120°F/49°C
WILL REDUCE THE RISK OF SCALDS. Some states require settings
at specific lower temperatures.
The water temperature is controlled using the Temperature Control
on the Display at the front of the unit (See Figure 1B and Figure
1C). This control utilizes a temperature probe to determine the tank
temperature. The temperature probe is located behind the heater’s
front display.
The temperature may be adjusted from 90°F/32°C to 160°F/71°C. The
temperature was preset to 120°F/49°C before the heater was shipped
from the factory. It is recommended that lower water temperature be
used to avoid the risk of scalding. It is further recommended, in all
cases, that the water temperature be set for the lowest temperature
which satisfies your hot water needs. This will also provide the most
energy efficient operation of the water heater and minimize scale
formation.
Should the ECO activate, the water temperature must drop below
140°F (49°C) before the control system can be reset. Once the water
temperature has cooled below this point the power supply to the water
heater must be turned off and on again to reset the control system.
Contact your dealer or servicer if continued high limit switch operation
occurs.
38
CONTROL SYSTEM OPERATION
OVERVIEW
• The operational buttons are used to enter/exit menus, select
menu items, activate adjustment modes and confirm or cancel
new user settings. The operational buttons are multifunctional,
their current function is defined by the text that appears directly
above each button on the LCD screen.
The water heaters covered in this manual are equipped with an
electronic control system that regulates water temperature inside
the storage tank. Heating cycles and ignition are managed by the
control system. The ECO (energy cut out), Flame Sensor, pressure
switches and Temperature Probe is monitored by the control system.
The Combustion Blower, Igniter and the 24 Volt Gas Control Valve
are all energized by the control system.
THE DESKTOP SCREEN
During normal operation the control system will display the Desktop
screen on the LCD which is the default screen. The control system
will return to the Desktop screen when there are no active Fault or
Alert conditions or when there has been no user input for several
minutes.
The main components of the control system are a UIM (user interface
module) and a CCB (central control board). The UIM is located on
the top front side of the water heater. The CCB is mounted on top of
the water heater inside a protective enclosure. This unit is equipped
with an Enable/Disable switch. To operate unit, make sure the switch
is set to Enable.
• Manufacturer and water heater model information is displayed
in Title Bar at the top of the Desktop screen. Menu titles are
displayed in the Title Bar when navigating the control system
menus.
• The Operating Set Point is also shown on the Desktop screen.
The Operating Set Point is the temperature at which the control
system will maintain the water inside the storage tank.
• Beneath the Operating Set Point is the Status line. The Status
line shows the current operational state of the control system in
real time. See Table 13 for a description of the various operating
states.
• The Desktop screen also displays animated Status Icons to
convey operational information, see Table 12 for a complete list
and description of the Status Icons.
CONTROL SYSTEM NAVIGATION
All operational information and user settings are displayed and
accessed from the UIM. The UIM houses the control system's LCD
(liquid crystal display) and five snap acting (momentary) user input
buttons; an up, down and three multifunction operational buttons
below the LCD, see Figure 37.
USER INPUT BUTTONS
• The up and down buttons are used to navigate menus and adjust
user settings.
UIM (user interface module)
Desktop Screen Shown
LCD Screen
Information
Display
Title Bar
MANUFACTURER / MODEL INFORMATION
Operating Set Point
120°F
Status: Heating
Status Icons
OFF
DN
GAS O
N
MENU
UP
HELP
Operational buttons are multifunctional. Their current function is defined by
the text that appears directly above each button on the LCD screen.
Figure 37
39
Up & Down buttons:
navigate menus,
adjust user settings
3 Operational buttons:
enter/exit menus,
select menu items,
activate adjustment modes,
confirm/cancel changes.
STATUS ICONS
The Status Icons are displayed on the Desktop screen and convey operational and diagnostic information. The icons are described in the
table below.
Table 12 – STATUS ICONS
Icon
Description
Water temperature in the tank has fallen. Shaded area of the animated thermometer icon will rise and fall in response to
water temperature in the storage tank as sensed from the Temperature Probe.
Water temperature in the tank has reached the Operating Set Point. The control system enters the Standby mode.
The control is unable to initiate a heating cycle. This will happen whenever a Fault condition is detected by the control system
or when the Enable/Disable switch on front panel is in disable position. Display will read “Status: Water Heating Disabled”.
The Combustion Blower is being energized.
The Blower Prover pressure switch contacts have closed. The check mark icon is visual confirmation of contact closure.
The Igniter is being energized.
OFF
The 24 Volt Gas Control Valve is being energized.
GAS O
N
The control system has sensed flame at the Main Burner from the Flame Sensor.
The control system has declared a Fault condition and must be inspected/serviced by a Qualified Service Technician. Fault
message details can be viewed in the Current Fault menu. Heating operation is disabled (control system lock out) until the
condition that caused the Fault is corrected. Water Heating Enable/Disable Switch must be cycled off and on to reset the
control system.
NOTE: Cycling Water Heating Enable/Disable Switch will not reset the control system if the condition that caused the Fault
has not been corrected.
The control system has declared an Alert condition and must be inspected/serviced by a Qualified Service Technician. The
water heater will continue to operate during an Alert condition.
40
OPERATING STATES
The current operational state of the water heater is displayed on the Desktop screen as the Status. The common operational states are
described in the table below.
Table 13 – OPERATING STATES
State
Standby
Input Verification
Description
The water heater is not in an active heating cycle. IE: the Tank Temperature is at or above the Operating Set Point minus
temperature differential.
The control system is conducting a diagnostic check at the beginning of a heating cycle.
Water Heating
Disabled
A Fault condition is detected by the control or when the Enable/Disable switch on front panel is an open circuit.
Pre-Purge
The Combustion Blower is energized to flush residual flue gases from the combustion chamber prior to ignition.
Igniter
Gas Control Valve
On
Inter-Purge
Heating
Post-Purge
Fault
Heating Disabled
The Igniter is energized and is ready to ensure proper ignition.
The 24 Volt Gas Control Valve is energized and opens to allow fuel gas to flow to the Main Burner.
The Combustion Blower is energized to flush residual fuel gas from the combustion chamber after a failed ignition attempt.
Ignition was successful, flame sensing current has been established. The water in the storage tank is being heated.
The Combustion Blower is energized to flush residual flue gases from the combustion chamber at the end of a heating
cycle.
The control system has detected a Fault condition. Heating operation is disabled (control system lock out) until the Fault
condition is corrected. Water Heating Enable/Disable Switch must be cycled off and on to reset the control system.
NOTE: Cycling Water Heating Enable/Disable Switch will not reset the control system if the condition that caused the Fault
has not been corrected.
The heating is disabled by the Enable/Disable switch in front of the unit.
CONTROL SYSTEM MENUS
From the Desktop screen pressing the Operational button directly below Menu on the LCD will display the Main Menu. This is where all
control system menus are located. The table below describes the control system menus.
Table 14 – CONTROL SYSTEM MENUS
Menu
Description
Temperatures
Most commonly accessed menu. Contains the Operating Set Point and Differential user settings.
Heater Status
This menus displays the current state of all pressure switches and the ECO (open/closed). The on/off status of the
Combustion Blower, 24 Volt Gas Control Valve, Igniter, Flame Sensor and other monitored water heater components
are displayed in this menu.
Display Settings
Temperature units (°F or °C), the LCD appearance (brightness/contrast) and backlight delay user adjustable settings
are located in this menu.
Heater Information
Elapsed time of operation, total heating cycle time, heating cycle count, heating on time along with UIM and CCB
software revisions can be viewed in this menu.
Current Fault
Displays any current Alert or Fault messages.
Fault History
This control system menu retains a list of the last nine (9) Fault and Alert messages with a time stamp. The newest
event will replace the oldest. Fault history memory is cleared after 30 days.
Fault Occurrence
This control system menu retains a running total of how many times each Fault condition has occurred since the water
heater was first installed. Fault occurrences numbers are saved in the CCB memory indefinitely.
NOTE: if the CCB is replaced during service the fault occurrence historical information for the water heater is lost.
Restore Factory Defaults
This control system feature allows the user to restore control system user settings to their factory default settings.
Display Settings preferences ARE NOT changed when factory defaults are restored.
Help Screens
Text based operational and user information explaining how to change user settings, navigate the control system menus
and icon descriptions.
41
USER SETTINGS & CONTROL SYSTEM MENUS
TEMPERATURES
OPERATING SET POINT AND DIFFERENTIAL ADJUSTMENT
The Operating Set Point is adjustable from 90°F (42°C) to 160°F (71°C). The factory setting is 120°F (49°C). The Differential is adjustable
from 2° to 20°. The factory setting is 8°. These user settings are accessed from the Temperatures menu. These instructions explain how to
adjust these settings and navigate the control system.
When the water temperature sensed by the control system from the Temperature Probe reaches the Operating Set Point the control system
will end the heating cycle. A heating cycle will be activated again when the sensed water temperature drops below the Operating Set Point
minus the Differential setting.
NOTE: Set the Operating Set Point to the lowest setting which produces an acceptable hot water supply for most efficient use. Lower
Differential settings may cause excessive heating cycles (short-cycling) which can cause premature failure of components such as the
Igniter. Set the Differential at the highest setting which produces an acceptable hot water supply to prevent short cycling.
DESCRIPTION/ACTION
DISPLAY
From the Desktop screen, press the Operational Button under
MENU. The Main Menu screen will be displayed.
MANUFACTURER / MODEL INFORMATION
Operating Set Point
Status: Standby
MENU
The Main Menu is where all control system menus are listed,
see Table 14 for a complete list and description of control
system menus. Use the Up and Down Buttons to view all
control system menus from the Main Menu.
120°F
HELP
Main Menu
Temperatures
Heater Status
Display Settings
Heater Information
Current Fault
With Temperatures menu selected (highlighted in black) in
the Main Menu screen, press the Operational Button under
“SELECT” to enter the Temperatures menu.
If the Temperatures menu is not selected use the Up and Down
Buttons to select this menu item.
SELECT
With the Operating Set Point selected in the Temperatures
menu, press the Operational Button underneath “CHANGE” to
activate the adjustment mode for this menu item.
BACK
HELP
Temperatures
Operating Set Point
Differential
Tank Probe Offset
If Operating Set Point is not selected use the Up and Down
Buttons to select this menu item.
NOTE: Higher Temperature settings increase wear and
operating costs. Set the Operating Set Point to the lowest
setting which produces an acceptable hot water supply. This
will always provide the most energy efficient operation and
longer life.
CHANGE
With the adjustment mode for the Operating Set Point activated
the selection bar will change from a black fill to a black outline.
120°F
8°F
0°F
BACK
HELP
Temperatures
Operating Set Point
Differential
Tank Probe Offset
Use the Up and Down Buttons to change the current setting.
Press the Operational Button under "UPDATE" to save the
new setting. Press the Operational Button under "CANCEL" to
discard changes and return to the previously saved setting.
NOTE: Use this same procedure to change the Differential
setting and other adjustable user settings in the control system
menus.
UPDATE
42
140°F
8°F
0°F
CANCEL
TEMPERATURES (CONT)
DESCRIPTION/ACTION
DISPLAY
• Tank Probe Offset - adjustable user setting, range -5° to +5°F
(factory setting 0°F).
The Tank Probe Offset is used to calibrate control system
temperature sensing. This offsets to more effectively read
point of use temperature in the tank. This feature can also be
used to compensate for building recirculation loops (hot water
returning to the storage tank) that may cause the heating cycles
to terminate prematurely.
Temperatures
Operating Set Point
Differential
Tank Probe Offset
Example: If the current sensed temperature from the temperature
probe is 120°F (49°C) and the Offset setting for the probe is
adjusted to a value other than 0°, the control system would
calibrate or “offset” the sensed temperature from the probe.
Heating cycles would be activated and deactivated based on
the calibrated (offset) temperature.
CHANGE
140°F
8°F
0°F
BACK
NOTE: The Tank Probe Offset should only be used if the hot
water supply temperature varies greatly from the Operating
Set Point setting. These settings are adjusted in the same
way described for the Operating Set Point and Differential
Adjustment.
HEATER STATUS
DESCRIPTION/ACTION
DISPLAY
Select Heater Status from the Main Menu and press the Operational
Button under "SELECT" to enter this menu. This menu contains non
adjustable operational information. Use the Up & Down Buttons to
navigate the menu.
Top of Menu
• Status - displays the current Operating State, see Table 13 –
Operating States for a description of the various operational
states.
• ECO Contact, Blocked Inlet PS, Blocked Outlet PS, Blower
Prover PS - displays the current state of the switch contacts;
open or closed.
• Igniter On, Gas Control Valve On - displays whether or not
the control system is currently energizing these water heater
components; yes = energized, no = de-energized.
• Flame Detected - displays whether or not the control system
has detected Main Burner flame during ignition from the Flame
Sensor.
Bottom of Menu
43
HELP
DISPLAY SETTINGS
DESCRIPTION/ACTION
DISPLAY
Select Display Settings from the Main Menu and press the
Operational Button under "SELECT" to enter this menu. This menu
contains adjustable display options for viewing information on the
LCD screen. Use the Up & Down Buttons to navigate the menu.
Display Settings
• Temperature Units - Adjustable user setting that changes
temperature units display to Celsius °C or Fahrenheit °F.
• Backlight Delay - Adjustable user setting that determines how
long the LCD backlight remains illuminated after a key has
been pressed. Available settings are; Always Off, 10, 30 or 60
seconds and Always On.
• Contrast - Adjustable user setting to adjust the LCD screen
contrast between text and background.
NOTE: These settings are adjusted in the same way described
for the Operating Set Point and Differential Adjustment.
Temperature Units
Backlight Delay
Contrast
°F
30s
60%
CHANGE
HELP
BACK
HEATER INFORMATION
DESCRIPTION/ACTION
DISPLAY
Select Heater Information from the Main Menu and press the
Operational Button under "SELECT" to enter this menu. This menu
contains non adjustable operational information.
Top of Menu
• Elapsed Time - Total accumulated time the control system
(water heater) has been energized.
• Burner On Time - Total accumulated time the control system
has been in the heating operating state; burner run time.
• Total Cycle Count - Total accumulated count of heating
cycles.
• Config CRC - A number associated with the configuration
data.
• CCB Version - Software version for central control board.
• UIM Version - Software version for user interface module.
NOTE: Historical data is stored in the CCB's memory. If this CCB
is replaced during servicing the historical data on the CCB being
replaced will be lost. The data stored in the new circuit board will
no longer reflect the entire history of the water heater.
The Elapsed Time, Burner On Time and Cycle Count indicate
age, usage and wear.
If the Cycle Count per day is high (divide cycle count by days
to determine cycles per day) or the cycle duration is short
(determine burner on time total minutes, divide burner on time
total minutes by cycle count) consider raising the Differential
setting to avoid short cycling and excessive component wear,
see Operating Set Point and Differential Adjustment.
This historical data can also be used to assist facilities managers
in forecasting planned replacement of equipment to help avoid
lengthy and costly hot water supply interruptions.
• Use External Enable - Enable/ Disable external control
function.
• External Enable Status - Status of external enable if Use
External Enable is Yes.
• Ignition Trials - The maximum number of ignition trials before
lockout.
44
Bottom of Menu
CURRENT FAULT
DESCRIPTION/ACTION
DISPLAY
Select Current Fault from the Main Menu and press the Operational
Button under "SELECT" to enter this menu. This menu contains non
adjustable operational information. Use the Up & Down Buttons to
navigate the menu.
Blocked Exhaust
Fault occurred 2 mins ago
Restriction in exhaust pipe.
Check exhaust pipe and
termination for blockage.
This menu contains the current Fault or Alert error message. The
time the Fault or Alert message occurred appears directly below.
A brief description of what causes the particular Fault or Alert
condition appears below that. Pressing the Operational Button
under "ADVANCED" will give more detailed service information and
a list of possible causes for the Fault or Alert condition.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
If there is no Fault or Alert condition active this menu will not contain
any information, "(none)" will be shown next to Current Fault in the
Main menu.
CHANGE
BACK
ADVANCED
FAULT HISTORY
DESCRIPTION/ACTION
DISPLAY
Select Fault History from the Main Menu and press the Operational
Button under "SELECT" to enter this menu. This menu contains non
adjustable operational information. Use the Up & Down Buttons to
navigate the menu.
Fault History
1:
This menu contains a list of the last nine (9) Fault and Alert messages
with a time stamp. The newest event will replace the oldest.
2:
Press the Operational Button under "VIEW" to view details for each
Fault or Alert message stored.
3:
NOTE: fault history memory is cleared after 30 days.
4:
Blocked Air Intake (A7)
51 mins ago
Blocked Exhaust (A8)
54 mins ago
Low Gas Pressure (A6)
57 mins ago
Blower Prover Failure (AC)
VIEW
BACK
HELP
FAULT OCCURRENCE
DESCRIPTION/ACTION
DISPLAY
Select Fault Occurrence from the Main Menu and press the
Operational Button under "SELECT" to enter this menu. This menu
contains non adjustable operational information. Use the Up & Down
Buttons to navigate the menu.
This menu contains a running total of how many times each Fault
condition has occurred since the water heater was first installed.
NOTE: Historical data is stored in the CCB's memory. If this CCB
is replaced during servicing the historical data on the CCB being
replaced will be lost. The data stored in the new circuit board will no
longer reflect the entire history of the water heater.
RESTORE FACTORY DEFAULTS
DESCRIPTION/ACTION
DISPLAY
Select Restore Factory Defaults from the Main Menu and press the
Operational Button under "SELECT" to enter this menu.
Restore Factory Defaults
To restore the adjustable user settings to their factory default
settings press the Operational Button underneath “YES.” The
display will show text confirming the factory default settings have
been restored.
Are you sure you want to
restore the system to factory
defaults?
Press the Operational Button underneath “BACK” to exit the Restore
Factory Defaults menu.
YES
45
NO
SERVICE CONTACT INFORMATION
The control system has a discrete menu that Installing contractors and/or qualified service technician can access to enter contact information
for their customers. This contact information will be displayed with all Fault and Alert messages.
DESCRIPTION/ACTION
DISPLAY
From the Desktop Screen press and hold down the middle
(unmarked) Operational Button for 30 seconds and then release it.
Service Contact Information
Using the UP and DOWN buttons select (highlighted in black) the
"Show Contact Information" menu item.
Show Contact Information
Change Contact Name
Change Contact Phone
Current Contact Info:
Press the Operational Button under "CHANGE" to activate the
adjustment mode for this parameter.
(000) 000-0000
Access Code
This will launch a discrete menu where personalized contact
information can be entered.
CHANGE
With the adjustment mode for "Show Contact Information"
activated the selection bar will change from a black fill to a black
outline.
No
BACK
HELP
Service Contact Information
Show Contact Information
Change Contact Name
Change Contact Phone
Current Contact Info:
Use the Up and Down Buttons to change the setting from "No" to
"Yes" and press the Operational Button underneath "UPDATE" to
save the new setting.
Yes
(000) 000-0000
Access Code
NOTE: The Access Code at the bottom of the Service Contact
Information screen is for manufacturing purposes only. There are
no user settings or information accessed through this menu item.
UPDATE
Using the UP and DOWN buttons select (highlighted in black) the
"Change Contact Name" menu item.
CANCEL
Service Contact Information
Show Contact Information
Change Contact Name
Change Contact Phone
Current Contact Info:
Press the Operational Button under "SELECT" to open the Change
Contact Name menu.
Yes
(000) 000-0000
Access Code
SELECT
Follow the on screen instructions to enter your name or the name
of your company. There is a maximum of 20 character spaces for
this purpose.
BACK
HELP
Enter the service contact below:
Use the -> and <- keys to move between
characters. Use the UP and DOWN keys to
change the character.
When finished press the Operational Button "UPDATE" to save the
new Contact Name. The control system will return to the discrete
menu.
NAME: _
<Using the UP and DOWN buttons select (highlighted in black) the
"Change Contact Phone" menu item and press the Operational
Button under "SELECT".
->
UPDATE
Service Contact Information
Show Contact Information
Change Contact Name
Change Contact Phone
Current Contact Info:
YOUR COMPANY NAME HERE
(123) 456-7890
Access Code
Follow the on screen instructions to enter a new Contact Phone
number and press the Operational Button under "UPDATE" to save
the new phone number.
When the new Contact Name and Contact Phone number have
both been updated, press the Operational Button under "BACK" to
return to the Desktop screen.
BACK
46
Yes
HELP
FOR YOUR INFORMATION
START UP CONDITIONS
the anode rod is one of a rotten egg smell in the hot water. The
smell is a result of four factors which must all be present for the
odor to develop:
SMOKE/ODOR
It is not uncommon to experience a small amount of smoke and odor
during the initial start-up. This is due to burning off of oil from metal
parts, and will disappear in a short while.
a. A concentration of sulfate in the supply water.
b. Little or no dissolved oxygen in the water.
THERMAL EXPANSION
c. A sulfate reducing bacteria which has accumulated within the
water heater (this harmless bacteria is nontoxic to humans).
d. An excess of active hydrogen in the tank. This is caused by the
corrosion protective action of the anode rod.
Smelly water may be eliminated or reduced in some water heater
models by replacing the anode rod(s) with one of less active material,
and then chlorinating the water heater tank and all water lines. Contact
the local water heater supplier or a qualified service agency for further
information concerning an Anode Rod Replacement Kit and this
chlorination treatment.
If the smelly water persists after the anode rod replacement and
chlorination treatment, we can only suggest that chlorination or aeration
of the water supply be considered to eliminate the water problem.
Water supply systems may, because of such events as high line
pressure, frequent cut-offs, the effects of water hammer among
others, have installed devices such as pressure reducing valves,
check valves, back flow preventers, etc. to control these types of
problems. When these devices are not equipped with an internal
by pass, and no other measures are taken, the devices cause the
water system to be closed. As water is heated, it expands (thermal
expansion) and closed systems do not allow for the expansion of
heated water.
Do not remove the anode rod leaving the tank unprotected. By
doing so, all warranty on the water heater tank is voided.
AIR IN HOT WATER FAUCETS
The water within the water tank expands as it is heated and increases
the pressure of the water system. If the relieving point of the water
heater’s temperature-pressure relief valve is reached, the valve will
release excess pressure. The temperature-pressure relief valve is
not intended for the constant relief of thermal expansion. This is an
unacceptable condition and must be corrected. It is recommended
that any devices installed which could create a closed system have
a by-pass and/or the system have an expansion tank or device to
relieve the pressure built by thermal expansion in the water system.
Expansion tanks are available for ordering through a local plumbing
contractor. Contact the local water heater supplier or qualified service
agency for assistance in controlling these situations.
HYDROGEN GAS: 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
explosive. To prevent the possibility of injury under these conditions,
we recommend the hot water faucet, located farthest away, be
opened for several minutes before any electrical appliances
which are connected to the hot water system are used (such as a
dishwasher or washing machine). If hydrogen gas is present, there
will probably be an unusual sound similar to air escaping through the
pipe as the hot water faucet is opened. There must be no smoking
or open flame near the faucet at the time it is open.
OPERATIONAL CONDITIONS
SMELLY WATER
In each water heater there is installed at least one anode rod
(see Figure 1B and Figure 1C) for corrosion protection of the
tank. Certain water conditions will cause a reaction between this
rod and the water. The most common complaint associated with
47
PERIODIC MAINTENANCE
VENTING SYSTEM INSPECTION
by protecting the glass-lined tank from corrosion. Adverse water
quality, hotter water temperatures, high hot water usage, hydronic
heating devices, and water softening methods can increase the rate
of anode rod depletion. Once the anode rod is depleted, the tank
will start to corrode, eventually developing a leak.
Certain water conditions will cause a reaction between the anode
rod and the water. 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. IMPORTANT: Do not
remove this rod permanently as it will void any warranties. A special
anode rod may be available if water odor or discoloration occurs.
NOTE: This rod may reduce but not eliminate water odor problems.
The water supply system may require special filtration equipment
from a water conditioning company to successfully eliminate all
water odor 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.
At least once a year examine the vent system. Points of inspection
are as follows:
The anode rod should be inspected after a maximum of three years
and annually thereafter until the condition of the anode rod dictates
its replacement. NOTE: artificially softened water requires the anode
rod to be inspected annually.
1. Check for obstructions and/or deterioration of the intake air and/
or vent piping and the intake air and vent terminations. Replace
immediately where needed.
The following are typical (but not all) signs of a depleted anode rod:
2. The debris screens in the intake air and vent terminations should
be cleaned of foreign material and soot.
* The majority of the rods diameter is less than 3/8”.
NOTE: Do not reach inside the vent termination when the heater
is in operation.
* Significant sections of the support wire (approx. 1/3 or more of the
anode rod’s length) are visible.
3. Check all vent system connections for leakage and repair or
reseal as necessary.
If the anode rod show signs of either or both it should be replaced.
NOTE: Whether re-installing or replacing the anode rod, check for
any leaks and immediately correct if found.
Be sure the vent piping is properly connected to prevent escape
of dangerous flue gasses which could cause deadly asphyxiation.
In replacing the anode:
Obstructions and deteriorated vent systems may present serious
health risk or asphyxiation.
1. Turn off gas supply to the water heater.
Chemical vapor corrosion of the flue and vent system may occur
if air for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium chloride,
waxes, bleach and process chemicals are typical compounds which
are potentially corrosive.
3. Drain approximately 5 gallons of water from tank (Refer to
“Draining and Flushing” for proper procedures). Close drain valve.
2. Shut off the water supply and open a nearby hot water faucet to
depressurize the water tank.
4. Remove old anode rod.
5. Use Teflon® tape or approved pipe sealant on threads and install
new anode rod.
If after inspection of the vent system you found sooting or
deterioration, something is wrong. Call the local gas utility to correct
the problem and clean or replace the flue and venting before
resuming operation of the water heater.
6. Turn on water supply and open nearby hot water faucet to purge
air from water system. Check for any leaks and immediately correct
any if found.
ANODE ROD INSPECTION
Restart the water heater as directed.
Each water heater contains at least one anode rod, which will slowly
deplete (due to electrolysis) prolonging the life of the water heater
Figure 38
48
POWERED ANODE ROD (OPTIONAL MODELS)
If the Temperature-Pressure Relief Valve on the water heater
weeps or discharges periodically, this may be due to thermal
expansion.
To insure a long, trouble-free operating life, certain models of
water heaters covered in this manual are factory equipped with
a powered anode system. The anode rod is of a permanent
design and does not need replacing unless damaged.
Inspection and cleaning should be performed once a year.
NOTE: Excessive water pressure is the most common cause of
Temperature-Pressure Relief Valve leakage. Excessive water
system pressure is most often caused by “thermal expansion”
in a “closed system.” See Closed Water Systems and Thermal
Expansion on Page 21. The Temperature-Pressure Relief Valve
is not intended for the constant relief of thermal expansion.
NOTE: Follow the instructions to drain the water heater storage
tank first. Remove the powered anodes from the water heater by
loosening the 3/4” NPT bushing that forms the top of the anode
rods. Do not disassemble the retaining nut and wire terminal
from the top while installed in the water heater, the anode rods
electrode may fall inside the tank. Remove the entire anode rod
from the water heater prior to inspection. Clean the anode rods
with a soft cloth and reinstall. Follow the instructions for filling
the water heater when finished.
Temperature-Pressure Relief Valve leakage due to pressure
build up in a closed system that does not have a thermal
expansion tank installed is not covered under the limited
warranty. Thermal expansion tanks must be installed on all
closed water systems.
TEMPERATURE-PRESSURE RELIEF VALVE TEST
DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF
VALVE OPENING. THIS CAN CAUSE PROPERTY DAMAGE, SERIOUS INJURY OR DEATH.
Burn hazard.
Hot water discharge.
Keep clear of TemperaturePressure Relief Valve
discharge outlet.
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
It is recommended that the Temperature-Pressure Relief Valve
should be checked to ensure that it is in operating condition every
6 months.
Properly sized temperaturepressure relief valve must be
installed in opening provided.
When checking the Temperature-Pressure Relief Valve operation,
make sure that (1) no one is in front of or around the outlet of the
Temperature-Pressure Relief Valve discharge line, and (2) that the
water discharge will not cause any property damage, as the water may
be extremely hot. Use care when operating valve as the valve may be
hot.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
To check the temperature-pressure relief valve, lift the lever at the end of
the valve several times, see Figure 39. The valve should seat properly
and operate freely.
DRAINING AND FLUSHING
It is recommended that the water heater storage tank be drained
and flushed every 6 months to reduce sediment buildup. The
water heater should be drained if being shut down during freezing
temperatures. See Figure 1B & Figure 1C in this manual for the
location of the water heater components described below.
If after manually operating the valve, it fails to completely reset
and continues to release water, immediately close the cold
water inlet to the water heater and drain the water heater, see
Draining and Flushing on page 49. Replace the TemperaturePressure Relief Valve with a properly rated/sized new one, see
Temperature-Pressure Relief Valve on Page 22 for instructions
on replacement.
Burn hazard.
TEMPERATURE-PRESSURE
RELIEF VALVE
Hot water discharge.
Keep hands clear of drain
valve discharge.
DISCHARGE PIPE
Figure 39
49
TO DRAIN THE WATER HEATER STORAGE TANK:
7. Flush the water heater storage tank to remove sediment and
allow the water to flow until it runs clean.
8. Close the water heater drain valve when flushing is completed.
9. Remove the drain hose.
10.Fill the water heater - see Filling The Water Heater in this manual.
11.Turn on the electrical supply to place the water heater back in
operation.
12.Allow the water heater to complete several heating cycles to
ensure it is operating properly.
1. Turn off the electrical supply to the water heater.
2. Turn off the gas supply at the Main Gas Shutoff Valve if the
water heater is going to be shut down for an extended period.
3. Ensure the cold water inlet valve is open.
4. Open a nearby hot water faucet and let the water run until the
water is no longer hot.
5. Close the cold water inlet valve to the water heater.
6. Connect a hose to the water heater drain valve and terminate it to
an adequate drain.
7. Open the water heater drain valve and allow all the water to drain
from the storage tank.
8. Close the water heater drain valve when all water in the storage
tank has drained.
9. Close the hot water faucet opened in Step 4.
10.If the water heater is going to be shut down for an extended
period, the drain valve should be left open.
SERVICE
If a condition persists or you are uncertain about the operation of the
water heater contact a qualified service technician.
Use this guide to check a leaking water heater. Many suspected
Leakers are not leaking tanks. Often the source of the water can be
found and corrected.
TO FLUSH THE WATER HEATER STORAGE TANK:
If you are not thoroughly familiar with gas codes, your water heater,
and safety practices, contact your gas supplier or qualified installer
to check the water heater.
1. Turn off the electrical supply to the water heater.
2. Ensure the cold water inlet valve is open.
3. Open a nearby hot water faucet and let the water run until the
water is no longer hot. Then close the hot water faucet.
4. Connect a hose to the drain valve and terminate it to an adequate
drain.
5. Ensure the drain hose is secured before and during the entire
flushing procedure. Flushing is performed with system water
pressure applied to the water heater.
6. Open the water heater drain valve to flush the storage tank.
Read this manual first. Then before checking the water heater make
sure the gas supply has been turned “OFF”, and never turn the gas
“ON” before the tank is completely full of water.
50
LEAKAGE CHECKPOINTS
Never use this water heater unless it is completely filled with water.
To prevent damage to the tank, the tank must be filled with water.
Water must flow from the hot water faucet before turning “ON” gas
to the water heater.
B:Anode
Rod
Connection
A:Inlet &
Outlet
A *Condensation may be seen on pipes in humid weather or pipe
connections may be leaking.
G:Recirculation
Connection
B. *The anode rod fitting may be leaking.
C:T & P
Connection
C. Small amounts of water from temperature-pressure relief valve
may be due to thermal expansion or high water pressure in your
area.
D:T & P Outlet
D. *The temperature-pressure relief valve may be leaking at the
tank fitting.
E . Water from a drain valve may be due to the valve being slightly
opened.
G:Recirculation
Connection
F. *The drain valve may be leaking at the tank fitting.
H:Cleanout
G. Leakage from recirculation plug or pipe connection.
H. Leakage from the plug under the cleanout cover.
E:Drain
Valve
I. Leakage from the temperature probe connection (Not shown in
figure).
J:Flue Outlet
Figure 40
F:Drain Valve
Connection
J. Condensate from the exhaust connection.
Leakage from other water heaters, water lines, or ground seepage
should also be checked.
* To check where threaded portion enters tank, insert cotton
swab between jacket opening and fitting. If cotton is wet, follow
“Draining” instructions in the “Periodic Maintenance” section and
then remove fitting. Put pipe dope or teflon tape on the threads
and replace. Then follow “Filling the Water Heater” instructions
in the “Installing the New Water Heater” section.
51
TROUBLESHOOTING
INSTALLATION CHECKLIST
Flow Chart.
The list below represents some of the most critical installation
requirements that, when overlooked, often result in operational
problems, down time and needless parts replacement. This is not
a complete list. Before performing any troubleshooting procedures
use the list below to check for installation errors. Costs to correct
installation errors are not covered under the limited warranty.
Ensure all installation requirements and instructions in this manual
have been maintained and followed.
1.
When the control system is first powered, during boot up, the
blower will run momentarily and stop, and the control system
will display water heater model information during initialization.
After a few moments the control system LCD which is part of
the UIM (user interface module) will display the default screen
known as the Desktop screen.
2. If the control system determines that the actual water
temperature inside the tank is below the programmed
Operating Set Point minus the Differential setting, a heating
cycle is activated.
WATER HEATER LOCATION
1. Ensure proper clearances to combustibles are maintained and
there is sufficient room to service the water heater.
3. The control system then performs selected diagnostic system
checks. This includes confirming the blocked exhaust, blocked
intake and ECO (energy cut out) switch contacts are closed.
The Blower Prover Switch contacts are confirmed open.
2. Ensure the area is free of corrosive elements and flammable
materials.
VENTING
4.
3. Ensure the intake air and/or vent (exhaust) piping is the correct
size for the installed length.
If all diagnostic checks are successfully passed, the control
system energizes the Combustion Blower for pre-purge.
5. The control system must confirm the Blower Prover Switch
contacts close after the Combustion Blower is energized.
4. Ensure the maximum equivalent feet of pipe has not been
exceeded for the intake air and/or vent pipe.
6. If the Blower Prover Switch contacts are confirmed closed the
control system energizes the spark igniter.
5. Ensure the maximum number of elbows has not been exceeded
in the intake air and/or vent pipe.
7.
6. Ensure all exterior clearances for the intake air, vent and
concentric terminations are maintained. These clearances and
those cited by local and national codes must be maintained.
After a few seconds, the control system energizes the 24V
Gas Control Valve allowing gas to flow to the Main Burner.
8. The control system monitors the flame sensor to confirm a
flame is present at the Main Burner. If a flame is not verified
during the ignition trial period the control system will try for
ignition up to two more times. If flame can not be verified after
three trials for ignition, the control system will lock out and
display the Ignition Failure Fault message.
7. If venting direct vent, ensure the screen located in air intake at
the water heater was removed.
GAS SUPPLY AND PIPING
9. If a flame is verified, the control system will enter the
heating mode where it will continue heating the water until
the Operating Set Point is reached. At this point, the control
system will de-energize the 24 V Gas Control Valve and
enter the post-purge cycle (60 seconds).
8. Ensure the supply gas line to each water heater meets the
minimum supply gas line size requirements.
CONDENSATE DRAIN
9. Ensure the condensate drain is properly connected to the
exhaust elbow on the water heater and draining freely to a
suitable floor drain.
10. The control system de-energizes the spark igniter.
11. The Combustion Blower will run for the duration of the postpurge cycle to purge the water heater of all combustion gases.
When the post-purge cycle is complete, the blower is deenergized and will coast to a stop.
ELECTRICAL CONNECTIONS
10.Ensure the water heater is properly grounded. Flame sensing
requires an adequate earth ground. If the water heater is not
properly grounded it will cause Ignition Failure.
12. The control system now enters the standby mode while
continuing to monitor the internal storage tank water
temperature and the state of other system devices. If the tank
temperature drops below the Operating Set Point minus the
Differential setting, the control will automatically return to Step
2 and repeat the operating cycle.
SEQUENCE OF OPERATION
Read the Sequence of Operation below before attempting to
correct any operational problems. See the Sequence Of Operation
52
SEQUENCE OF OPERATION FLOW CHART
If tank temperature drops below Operating Set Point minus
Differential setting a heating cycle is activated
Control System performs diagnostic checks
Normal State of all pressure switches and ECO are checked
Blower Prover pressure switch verified open
All other pressure switches and ECO are verified closed
NO
Control System Locks Out
Displays Fault Msg
Combustion Blower is energized
Pre-Purge cycle
Blower Prover switch contacts confirmed
closed by control system
NO
Igniter is energized
24 V Gas Valve is energized
gas flows to Main Burner
Is flame sensed at the Main Burner ?
(control system monitors the flame sensor)
YES
Water is heated to
set point
NO
24 V Gas Valve
de-energized
24 V Gas Valve
de-energized
60 second
Inter-Purge cycle
60 second
Post-Purge cycle
Retries up to
two more times
Water heater goes
into standby mode
Control System
Locks Out
“Ignition Failure”
Fault Msg is
displayed
Figure 41
53
Control System Locks Out
“Blower Prover Open”
Fault Msg is displayed
OPERATIONAL PROBLEMS
If the Main Burner ignites momentarily but does not sustain
ignition allow the water heater to try to ignite up to two
more times until control system locks out and the Ignition
Failure Fault message is displayed on the control system's
LCD. If the water heater is experiencing rough starts see Rough Starting, Rough Operation on this page. For
momentary ignition problems without rough starting check
the following:
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
•
•
•
•
Incorrect manifold (offset) gas pressure.
Undersized supply gas line (low volume of supply gas).
Low Gas Pressure
See the list of possible causes and things to check and repair
for the Ignition Failure Fault message.
• Clogged/blocked intake air screen(s).
• Clogged/blocked Main Burner.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
This section of the manual is intended to be an aid in correcting
common operational problems, it is not all inclusive. The installer
may be able to observe and correct certain problems which might
arise when the water heater is first put into operation or when it is
re-fired after a prolonged shutdown. However, only qualified service
technician should perform any service procedures on the water
heater.
NOTE: Call the technical support phone number listed on the back
cover of this manual for further technical assistance or to locate a
qualified service technician in your area.
NOT ENOUGH OR NO HOT WATER
• No power to the water heater, check breaker, fuses.
• Enable/Disable switch in “disabled” position. Set to enable
to allow unit to operate.
• Hot water supply valve(s) to fixtures closed.
• Operating Set Point is set too low, Differential setting is set
too high.
• Temperature Probe Offset setting are causing the heating
cycles to terminate prematurely.
• The heating capacity of the water heater has been exceeded,
the water heater is unable to meet demand.
• Colder incoming water temperature lengthening the time
required to heat water to desired temperature.
• Hot water piping leaks, open faucets, water heater drain
valve leaking or open.
• Sediment or lime scale accumulation may be affecting water
heater operation.
ROUGH STARTING, ROUGH OPERATION
Fire and Explosion Hazard
Do not use water heater with any gas
other than the gas shown on the rating
plate.
Excessive gas pressure to gas valve can
cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
technician for installation and service.
WATER IS TOO HOT
•
•
•
•
NOISY OPERATION
•
•
•
•
•
•
Undersized supply gas line (low volume of supply gas).
Low Gas Pressure.
Excessive supply gas pressure.
Excessive manifold (offset) gas pressure.
Incorrect Fuel Type
Vent (exhaust) gas recirculation at the vent and intake air pipe
terminations on Direct Vent installations.
• Excessive equivalent lengths of intake air and/or vent (exhaust)
piping installed.
• Clogged/blocked intake air screen(s).
• Clogged/blocked the Main Burner.
• Normal operating noise of electrical components; Combustion
Blower, transformer hum, relay contact closure.
REPLACEMENT PARTS
Replacement parts may be ordered from the manufacturer,
authorized service agencies or distributors. When ordering parts
be sure to have the complete water heater Model Number, Serial
Number and Series Number available. This information can be
found on the rating plate affixed to the water heater.
MOMENTARY IGNITION
For more information or technical support call the phone number(s)
listed on the back cover of this manual
CAUTION
Burn Hazard
•
The combustion chamber and burner sleeve
and housing become very hot during operation.
•
Do not reach into the burner housing or
combustion chamber if the water heater
is still hot.
•
Allow the water heater to cool and always use
gloves when handling the main burner.
Operating Set Point is set too high.
Temperature Probe Offset settings improperly set.
If installed check Thermostatic Mixing Valve settings.
Lime build-up on temperature probes. Inspect and clean.
54
FAULT AND ALERT CONDITIONS
are operational problems. This is not a complete list. Along with
each of the Fault and Alert messages described there will be a list
of possible causes and things to check and repair.
FAULT CONDITIONS
When the control system declares a Fault condition it will display a
Fault message on the control system's LCD with an exclamation "!"
mark. The control system will lock out and disable heating operation
until the condition is corrected. The water heater must be serviced
by a qualified service technician before operation can be restored.
Only qualified service technician, as defined in Qualifications using
appropriate test equipment, should perform any service procedures
on the water heater.
NOTE: If you are not qualified and licensed or certified as required
by the authority having jurisdiction to perform a given task do not
attempt to perform any of the diagnostic or service procedures
described in the following section.
ALERT CONDITIONS
When the control system declares an Alert condition it will display
an Alert message on the control system's LCD with a question "?"
mark. The water heater will continue to operate during an Alert
condition but the water heater must be serviced by a qualified
service technician as soon as possible.
If you do not understand the instructions in the following section do
not attempt to perform any procedures.
Call the technical support phone number listed on the back cover of
this manual for further technical assistance or to locate a qualified
service technician in your area.
RESETTING CONTROL SYSTEM LOCK OUTS
To reset the control system from a lock out condition; turn off the
switch in front of the unit for approximately 20 seconds and then
back on. Keep in mind: if the condition that caused the Fault has
not been corrected, the control system will continue to lock out.
DIAGNOSTIC CHECKS
Electrical Shock Hazard
•
Turn off power to the water heater
before performing any service.
•
Label all wires prior to disconnecting
when performing service. Wiring errors
can cause improper and dangerous
operation.
•
•
Verify proper operation after servicing.
Failure to follow these instructions can
result in personal injury or death.
The following section, Fault And Alert Messages lists some of the
messages the control system will display on the LCD when there
FAULT AND ALERT MESSAGES
Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualified service technician
in your area.
•
•
•
•
•
•
•
•
•
•
POSSIBLE CAUSES - CHECK/REPAIR
DISPLAYED FAULT/ALERT MESSAGE
Using a manometer, ensure that gas supply pressure is above
minimum requirement listed on heater’s data plate and does not
drop more than 1.5”W.C. when unit fires.
Ensure wire connections to gas valve are clean and tight.
Ensure wire connections to flame sensor are clean and tight.
Ensure wire connections to spark igniter are clean and tight.
Inspect flame sensor, clean/replace as needed.
Inspect spark igniter, realign igniter gap as needed.
Ensure adequate electrical ground to heater.
Ignition Failure
Fault occurred 2 mins ago
Flame not detected. Clean
flame rod. Check gas supply.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
Blocked Exhaust
If Blocked Exhaust error occurs when blower is running, check for
restrictions in exhaust pipe, including exhaust elbow, condensate
drain, and outside termination. Also check exhaust pipe installation
(size/length) per manual.
If Blocked Exhaust error occurs before blower runs, make sure
pressure switch connections are clean and tight. Check pressure
switch continuity/resistance. Switch should be closed (continuity/0
ohms). Replace switch if open (no continuity).
Other possible causes: high wind conditions and excessive
negative air pressure in building.
Fault occurred 2 mins ago
Restriction in exhaust pipe.
Check exhaust pipe and
termination for blockage.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
55
BACK
ADVANCED
FAULT AND ALERT MESSAGES (CONT)
Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualified service technician
in your area.
POSSIBLE CAUSES - CHECK/REPAIR
DISPLAYED FAULT/ALERT MESSAGE
• Ensure excessive wind is not pressurizing the intake air or exhaust
pipe.
• Confirm wire connections of the blower prover switch are clean,
tight, and not jumped/shorted.
• Use multi-meter to check continuity/resistance of blower prover
pressure switch. Switch should be open (no continuity) when
blower is not operating. Replace switch if contacts are closed when
blower is off.
Blower Operation Error
Fault occurred 2 mins ago
The blower prover switch is
closed out of sequence.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
Blower Prover Open
Fault occurred 2 mins ago
The blower prover switch remains
open after the blower has been
energized.
• Confirm that blower runs during a call for heat.
• If blower runs, confirm sensing tube is connected and clear of
obstructions, blower port for sensing tube is clear of obstructions,
and wire connections for blower prover switch are clean and tight.
• If all above conditions are met, replace pressure switch.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
Blocked Air Intake
• If Blocked Intake error occurs before blower runs, make sure
pressure switch connections are clean and tight. Check pressure
switch continuity/resistance. Switch should be closed (continuity/0
ohms). Replace switch if open (no continuity).
• If Blocked Intake error occurs when blower is running, check for
restrictions in intake pipe, including intake air connection, outside
termination, and inlet condensate drains (if installed).
• Other possible causes: High wind conditions, excessive negative
air pressure in building.
Fault occurred 2 mins ago
Restriction in air intake. Check
intake pipe and termination for
blockage.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
• Ensure wire connections to upper temperature probe are clean and
tight.
• Using a thermometer, check the water temperature of the heater.
• Use a multi-meter and check for continuity between the two red
wires of the upper temperature probe.
• If the two red wires are open (no continuity) and water temperature
is below 160°F, replace upper temperature probe.
• If the water temperature exceeds 195°F, turn off electric power and
gas supply and call Tech Support for further instructions.
BACK
ADVANCED
Energy Cut Out (ECO)
Fault occurred 2 mins ago
Tank temperature is excessive.
The water heater has been
disabled.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
Alert:
No Water
Alert occurred 2 mins ago
• Confirm the water heater is full of water.
• Confirm the powered anode wire connections are tight and free of
debris or moisture (i.e. rust, solder, metal pipe shavings).
• Confirm proper electrical ground to the water heater.
No water detected by Powered
anode.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
* Applies to models with powered anode option.
56
BACK
ADVANCED
WIRING DIAGRAM
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND
DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.
Figure 42: WIRING SCHEMATIC
57
NOTES
58
NOTES
59
60
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