American Water Heater AHCG3/HCG360T120 Operating instructions

American Water Heater AHCG3/HCG360T120 Operating instructions
HIGH EFFICIENCY AHCG3/HCG360T120 thru AHCG3/HCG3100T250
COMMERCIAL GAS WATER HEATER
GAS-FIRED POWER BURNER
FOR DOMESTIC HOT WATER
• INSTALLATION • OPERATION • SERVICE • MAINTENANCE • LIMITED WARRANTY
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
– Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
– WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch;
do not use any phone in your
building.
• Immediately call your gas supplier
from a neighbor's phone. Follow the
gas supplier's instructions.
• If you cannot reach your gas supplier,
call the fire department.
– Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
Thank you for buying this energy efficient water heater from
American Water Heaters. We appreciate your confidence
in our products.
CAUTION
TEXT PRINTED OR UNDERLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY. PLEASE
READ THOROUGHLY BEFORE INSTALLING AND USING
THIS APPLIANCE.
PO Box 1597, 500 Princeton Road
Johnson City, TN 37605
www.americanwaterheater.com
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND
NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED 0608
1
198154-000
HIGH EFFICIENCY AHCG3/HCG360T120 thru AHCG3/HCG3100T250 ROUGH-IN-DIMENSIONS
GAS VALVE PIPING
AHCG3/HCG360T120
1/2" NPT
AHCG3/HCG3100T150 thru 100T250
3/4" NPT
Table 1. RECOVERY CAPACITIES - NATURAL GAS / L.P.
AHCG3/ Input
HCG3
Approx.
Gas
Gallon
BTU/Hr. Usage Capacity
TEMPERATURE RISE - DEGREES °F - GALLONS PER HOUR
30
40
50
60
70
80
90
100 110 120 130 140
60T120 120,000 nat/lp
60
461 345 276 230 197 173 154 138 126 115 106 99
100T150 150,000 nat/lp
100
576 432 345 288 247 216 192 173 157 144 133 123
100T199 199,900 nat/lp
100
767 575 460 384 329 288 256 230 209 192 177 164
100T250 250,000 nat/lp
100
960 720 576 480 411 360 320 288 262 240 221 206
Approx.
TEMPERATURE RISE - DEGREES C - Liters PER HOUR Liter
AHCG3/
Gas
HCG3
kW-Hr
60T120
35
nat/lp
227
1744 1308 1046 872 747 654 581 523 476 436 402 374
100T150
44
nat/lp
379
2179 1635 13081090 934 817 726 654 594 545 503 467
100T199
58
nat/lp
379
2904 2178 1743145212451089 968 871 792 726 670 622
100T250
73
nat/lp
379
3632 2724 2179181615571362 1211 1090 991 908 838 778
Usage Capacity
17
22
28
33
39 44
50
56
61
67
72
78
Recovery capacities are based on 95% thermal efficiency.
FOREWORD
These designs comply with the current version of the American National
Standard for Gas Water Heaters, Volume III, ANSI Z21.10.3 / CSA 4.3 as
an automatic circulating tank water heater, and automatic storage water
heaters.
In addition to these instructions, the equipment shall be installed in
accordance with those installation regulations in force in the local area
where the installation is to be made. These shall be carefully followed
in all cases. Authorities having jurisdiction should be consulted before
installations are made.
Detailed installation diagrams are found in this manual. These diagrams will
serve to provide the installer with a reference for the materials and methods
of piping necessary. It is highly essential that all water, gas piping and wiring
be installed as shown on the diagrams.
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 or CAN/CSA-B149.1, the Natural Gas and
Propane Installation Code and CSA C22.1, the Canadian Electrical Code.
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.
Particular attention should be given to the installation of thermometers at the
locations indicated on the diagrams as these are necessary for checking the
proper functioning of the heater.
2
TABLE OF CONTENTS
PAGE
ROUGH-IN DIMENSIONS..................................................................
FOREWORD......................................................................................
FEATURES.........................................................................................
Water Temperature Control............................................................
High Limit Switch (E.C.O.).............................................................
Dishwashing Machine Requirement...............................................
Circulating Pump............................................................................
INSTALLATION INSTRUCTIONS......................................................
Required Ability..............................................................................
Insulation Blankets.........................................................................
Locating The Heater.......................................................................
Clearances.....................................................................................
Hard Water.....................................................................................
Air Requirements...........................................................................
Mechanical Exhausting of Room Air..............................................
Unconfined Space..........................................................................
Confined Space..............................................................................
Chemical Vapor Corrosion.............................................................
Venting...........................................................................................
Vent Pipe Termination....................................................................
Installation Requirements for the
Commonwealth of Massachusetts................................................
Direct Venting.................................................................................
Direct Vent Terminal Installation (Sidewall)....................................
Installation Sequence.....................................................................
Vertical Vent Terminal Installation..................................................
Installation Sequence.....................................................................
Installation of Vent System.............................................................
Vent Pipe Preparation....................................................................
Control and Switches..............................................................
Blower Prover Switch.....................................................................
Blocked Outlet Prover Switch.........................................................
Blocked Inlet Prover Switch...........................................................
Low Gas Pressure Switch..............................................................
On/Off Switch.................................................................................
Hot Surface Igniter.........................................................................
GAS PIPING.......................................................................................
Connection of Gas Pipe.................................................................
Purging...........................................................................................
Gas Meter Size - City Gases Only.................................................
Gas Pressure Regulation...............................................................
PAGE
Gas Valves..................................................................................... 15
SYSTEM CONNECTIONS................................................................. 15
Thermometers................................................................................ 15
Relief Valve.................................................................................... 15
Water Line Connections................................................................ 15
Heater Wiring................................................................................ 16
USING THE ELECTRONIC CONTROLLER..................................... 17
Overview....................................................................................... 17
Operating States........................................................................... 17
Adjusting the Operating Set Point................................................. 18
Changing the Display Units........................................................... 19
Fault and Warning Conditions....................................................... 19
Access to the Current Fault or Warning........................................ 19
Viewing the Fault History.............................................................. 20
PRIOR TO START-UP....................................................................... 20
Required Ability............................................................................. 20
OPERATING INSTRUCTIONS.......................................................... 21
Adjustment Procedure (Initial Start-Up) 120 and 150 Models....... 21
Adjustment Procedure (Initial Start-Up) 199 and 250 Models....... 21
Cathodic Protection....................................................................... 22
Precautions................................................................................... 22
GENERAL INFORMATION................................................................ 22
Power Burner................................................................................ 22
High Limit...................................................................................... 22
High Altitude Installations.............................................................. 22
MAINTENANCE................................................................................ 22
General......................................................................................... 22
Maintenance Schedule ................................................................ 22
Flushing......................................................................................... 26
Draining......................................................................................... 26
Sediment Removal........................................................................ 26
Lime Scale Removal..................................................................... 26
Anode Inspection and Replacement............................................. 26,27
Drain Valve and Access Panels.................................................... 27
Relief Valve................................................................................... 27
Circulating Pump........................................................................... 27
Vent System.................................................................................. 27
INSTALLATION DIAGRAMS............................................................. 28-32
Manifold Kits.................................................................................. 33
CHECKLIST AND SERVICE INFORMATION................................... 34
TROUBLE-SHOOTING..................................................................... 34,35
LIMITED WARRANTY....................................................................... 36
2
2
3,4
3
4
4
5
4-12
6
6
5
5
6
6
6
6
6
6
6
6-10
7
10
10
10
11
11
12
12
13
13
13
13
13
13
13
13
14
15
15
15
FEATURES
DANGER
A CHECKLIST AND SERVICE INFORMATION section are included at the rear
of this manual. By using this checklist the user may be able to make minor
operational adjustments and save himself unnecessary service calls. However,
the user should not attempt repairs which are not listed in this section.
THIS WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE
THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT WATER
TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHER AND
LAUNDRY USE CAN CAUSE SCALD BURNS RESULTING IN SERIOUS
PERSONAL INJURY AND/OR DEATH. THE TEMPERATURE AT WHICH
INJURY OCCURS VARIES WITH THE PERSON’S AGE AND THE TIME
OF THE EXPOSURE. THE SLOWER RESPONSE TIME OF CHILDREN,
AGED OR DISABLED PERSONS INCREASES THE HAZARDS TO THEM.
NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER TAP, OR TO
DRAW THEIR OWN BATH WATER. NEVER LEAVE A CHILD OR DISABLED
PERSON UNATTENDED IN A BATHTUB OR SHOWER.
WATER TEMPERATURE CONTROL
THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE THE
GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET TEMPERATURES.
IMPORTANT
IT IS REQUIRED THAT A QUALIFIED SERVICE TECHNICIAN PERFORM
THE INITIAL FIRING OF THE HEATER. AT THIS TIME THE USER SHOULD
NOT HESITATE TO ASK THE TECHNICIAN ANY QUESTIONS WHICH HE
MAY HAVE IN REGARD TO THE OPERATION AND MAINTENANCE OF
THE UNIT.
The water temperature is controlled using the Temperature Control Button
on the Display at the front of the unit (See Figure 1). This control utilizes
two temperature probes to determine the tank temperature. The primary
temperature probe is located at the top of the tank and the other is near
the water inlet.
The temperature may be adjusted from 90°F/32°C to 180°F/82°C. The
thermostat was adjusted 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
3
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.
DISHWASHING MACHINE REQUIREMENT
All dishwashing machines meeting the National Sanitation Foundation
requirements are designed to operate with water flow pressures between
15 and 25 pounds per square inch (103 Kpa and 173 Kpa). Flow pressures
above 25 pounds per square inch (173 Kpa), or below 15 pounds per square
inch (103 Kpa), will result in improperly sanitized dishes. Where pressures
are high, a water pressure reducing or flow regulating control valve should
be used in the 180°F (82°C) line to the dishwashing machine, and should
be adjusted to deliver water between these limits.
SETTING THE WATER HEATER TEMPERATURE AT 120°F/49°C WILL
REDUCE THE RISK OF SCALDS. Some states require settings at specific
lower temperatures.
Figure 1 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.
Temperature Setting
Time to Produce 2nd & 3rd
Degree Burns on Adult Skin
180°F/82°C
Nearly Instantaneous
170°F/77°C
Nearly Instantaneous
160°F/71°C
About 1/2 Second
150°F/66°C
About 1-1/2 Seconds
140°F/60°C
Less than 5 Seconds
130°F/54°C
About 30 Seconds
120°F/49°C
More than 5 Minutes
The National Sanitation Foundation also recommends circulation of 180°F
(82°C) water. Where this is done, the circulation should be very gentle so
that it does not cause any unnecessary turbulence inside the water heater.
The circulation should be just enough to provide 180°F (82°C) water at the
point of take-off to the dishwashing machine. Adjust flow by means of the
plug cock in the circulating line. (See installation diagrams.)
CIRCULATING PUMP
A circulating pump is used when a system requires a circulating
loop or there is a storage tank used in conjunction with the heater.
Refer to the piping diagrams at rear of manual for electrical hookup
information and install in accordance with the current edition of the
National Electrical Code, NFPA 70 or the Canadian Electrical Code,
CSA C22.1.
FIGURE 1.
Valves for reducing point-of-use temperature by mixing cold and hot water are
available (see Figure 2). Also available are inexpensive devices that attach
to faucets to limit hot water temperatures. Contact a licensed plumber or the
local plumbing authority.
All bronze circulators are recommended for used with commercial
water heaters.
Although circulators are oiled and operated by the manufacturer
some circulators must be oiled again before operated. Please refer
to manufacturer's instructions.
INSTALLATION INSTRUCTIONS
REQUIRED ABILITY
INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES
ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE
FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, GAS SUPPLY
AND ELECTRICAL WORK ARE REQUIRED.
INSULATION BLANKETS
Insulation blankets available to the general public for external use
on gas water heaters are not approved for use on your water heater.
The purpose of an insulation blanket is to reduce the standby heat
loss encountered with storage tank water heaters. Your water heater
meets or exceeds the ASHRAE/IES 90.1 1999 standards with respect
to insulation and standby loss requirements, making an insulation
blanket unnecessary.
FIGURE 2.
HIGH LIMIT SWITCH (E.C.O.)
WARNING
The top immersion well of the dual bulb controller also contains the high limit
(energy cutoff) sensor. The high limit switch interrupts the main burner gas
flow should the water temperature reach approximately 202°F/94°C.
Should you choose to apply an insulation blanket to this heater, you should
follow these instructions. Failure to follow these instructions can result in
fire, asphyxiation, serious personal injury or death.
Should the high limit switch activate, the control system will automatically reset
the unit once the water temperature in the tank falls below 140°F/60°C. If the
unit is manually shut down and restarted, as long as the temperature in the
tank is lower than 160°F/71°C, the unit will reset and initiate operation.
• Do not apply insulation to the top, or the upper 15" (38 cm) of the water
heater, as this will interfere with safe operation.
• Do not cover the temperature & pressure relief valve.
High limit switch operation is the likely cause when higher than normal water
temperatures occur with a recurring need to restart the water heater. This
could be due to a malfunctioning thermostat allowing the gas valve to remain
open and the burner to continue firing even after water temperature in the
tank has already reached the set point. Contact your dealer or servicer if
continued high limit switch operation occurs.
• Do not cover the instruction manual. Keep it on the side of the water
heater or nearby for future reference.
• Do obtain new labels from manufacturer for placement on the blanket
directly over the existing labels.
4
LOCATING THE HEATER
WARNING
WARNING
This water heater is a condensing unit and requires a drain
to be located in close proximity to allow the condensate
to drain safely. The condensate drains from the unit at
the exhaust elbow located at the bottom of the unit. Note:
It is important that the condensate hose not be elevated
above the exhaust elbow (see Figure 3). The condensate
build-up will block the exhaust outlet, which will cause
improper operation.
THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH AS
GAS WATER HEATERS IN ROOMS, GARAGES OR OTHER AREAS
WHERE GASOLINE, OTHER FLAMMABLE LIQUIDS OR ENGINE
DRIVEN EQUIPMENT OR VEHICLES ARE STORED, OPERATED OR
REPAIRED. FLAMMABLE VAPORS ARE HEAVY AND TRAVEL ALONG
THE FLOOR AND MAY BE IGNITED BY THE HEATER’S IGNITER OR
MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION. SOME LOCAL
CODES PERMIT OPERATION OF GAS APPLIANCES IF INSTALLED 18
INCHES (46 cm) OR MORE ABOVE THE FLOOR. THIS MAY REDUCE
THE RISK IF LOCATION IN SUCH AN AREA CANNOT BE AVOIDED.
THE HEATER SHALL BE LOCATED OR PROTECTED SO IT IS NOT
SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE.
DO NOT LOCATE THE HEATER WHERE NOISE FROM THE EXHAUST
OR INTAKE WILL BE OBJECTIONABLE. THIS INCLUDES LOCATIONS
CLOSE TO OR ACROSS FROM WINDOWS AND DOORS. AVOID
ANCHORING THE VENT AND INTAKE PIPES DIRECTLY TO FRAMED
WALLS, FLOORS OF CEILINGS UNLESS RUBBER ISOLATION PIPE
HANGERS ARE USED. THIS PREVENTS ANY VIBRATIONS FROM
BEING TRANSMITTED INTO THE LIVING SPACES.
FIGURE 3.
WARNING
WARNING
FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY OTHER
POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON
OR ADJACENT TO THE HEATER. OPEN CONTAINERS OF FLAMMABLE
MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM
WITH THE HEATER.
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER.
IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT
THE APPLIANCE AND TO REPLACE ANY PART OF THE CONTROL
SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER.
When installing the heater, consideration must be given to proper location.
Location selected should be as close to the intake and exhaust termination
points as practicable, with adequate air supply and as centralized with the
piping system as possible.
CLEARANCES
These heaters are approved for installation on combustible flooring in an
alcove when the minimum clearances from any combustion construction are
followed as indicated in Figure 4.
THE HEATER MUST NOT BE LOCATED IN AN AREA WHERE IT WILL BE
SUBJECT TO FREEZING.
In all installations the minimum combustible clearances from any vent piping
shall be 0". Vent piping passing through a combustible wall or ceiling must
be a continuous run (no joints).
LOCATE IT NEAR A FLOOR DRAIN. THE HEATER SHOULD BE LOCATED
IN AN AREA WHERE LEAKAGE FROM THE HEATER OR CONNECTIONS
WILL NOT RESULT IN DAMAGE TO THE ADJACENT AREA OR TO LOWER
FLOORS OF THE STRUCTURE.
A service clearance of 24" (61 cm) should be maintained from serviceable
parts such as relief valves, flue baffles, flue damper devices, thermostats,
cleanout openings or drain valves.
When such locations cannot be avoided, it is recommended that a suitable
drain pan, adequately drained, be installed under the appliance.
Water heater life depends upon water quality, water pressure and the
environment in which the water heater is installed. Water heaters are
sometimes installed in locations where leakage may result in property
damage, even with the use of a drain pan piped to a drain. However,
unanticipated damage can be reduced or prevented by a leak detector or
water shut-off device used in conjunction with a piped drain pan. These
devices are available from some plumbing supply wholesalers and retailers,
and detect and react to leakage in various ways:
Always disconnect electrical power before servicing the unit.
• Sensors mounted in the drain pan that trigger an alarm or turn off the
incoming water to the water heater when leakage is detected.
• Sensors mounted in the drain pan that turn off the water supply to the entire
home when water is detected in the drain pan.
• Water supply shut-off devices that activate based on the water pressure
differential between the cold water and hot water pipes connected to the
water heater.
FIGURE 4.
• Devices that will turn off the gas supply to a gas water heater while at the
same time shutting off its water supply.
*ILLUSTRATION OF MINIMUM COMBUSTIBLE CLEARANCES IN AN
ALCOVE.
5
HARD WATER
If the confined space is within a building of tight construction, air for combustion
and ventilation must be obtained from outdoors. When directly communicating
with the outdoors through vertical ducts, two permanent openings, located
in the above manner, shall be provided. Each opening shall have a free
area of not less than one square inch (6.5 cm²) per 4000 Btuh of the total
input of all appliances in the enclosure. If horizontal ducts are used, each
opening shall have a free area of not less than one square inch (6.5 cm²) per
2000 Btuh of the total input of all appliances in the enclosure.
Where hard water conditions exist, water softening or the threshold type of
water treatment is recommended. This will protect the dishwashers, coffee
urns, water heaters, water piping and other equipment.
See MAINTENANCE section for details of tank cleanout procedure.
AIR REQUIREMENTS
CHEMICAL VAPOR CORROSION
KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE MATERIALS,
GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS.
WARNING
CORROSION OF THE FLUE WAYS AND VENT SYSTEM MAY OCCUR IF
AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS. SUCH
CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATING AIR.
WARNING
Spray can propellants, cleaning solvents, refrigerator and air conditioning
refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes, and
process chemicals are typical compounds which are potentially corrosive.
FOR SAFE OPERATION PROVIDE ADEQUATE AIR FOR COMBUSTION
AND VENTILATION. AN INSUFFICIENT SUPPLY OF AIR WILL CAUSE
RECIRCULATION OF COMBUSTION PRODUCTS RESULTING IN
CONTAMINATION THAT MAY BE HAZARDOUS TO LIFE. SUCH A CONDITION
OFTEN WILL RESULT IN A YELLOW, LUMINOUS BURNER FLAME, CAUSING
CARBONING OR SOOTING OF THE COMBUSTION CHAMBER, BURNERS
AND FLUE TUBES AND CREATES A RISK OF ASPHYXIATION.
PRODUCTS OF THIS SORT SHOULD NOT BE STORED 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.
MECHANICAL EXHAUSTING OF ROOM AIR
VENTING
Where an exhaust fan is installed in the same room with a heater, sufficient
openings for air must be provided in the walls. UNDERSIZED OPENINGS WILL
CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE HEATER’S
VENTING SYSTEM, CAUSING POOR COMBUSTION. SOOTING MAY
RESULT IN SERIOUS DAMAGE TO THE HEATER AND RISK OF FIRE OR
EXPLOSION. IT CAN ALSO CREATE A RISK OF ASPHYXIATION.
WARNING
THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST BE
FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULATION
OF FLUE GASES. SUCH CONDITIONS CAUSE SOOTING OR RISKS OF
FIRE AND ASPHYXIATION.
Heater must be protected from freezing downdrafts during shutdown periods.
UNCONFINED SPACE
In buildings of conventional frame, brick or stone construction, unconfined
spaces may provide adequate air for combustion and ventilation.
WARNING
NEVER OPERATE THE HEATER UNLESS IT IS VENTED TO THE
OUTDOORS AND HAS ADEQUATE AIR SUPPLY TO AVOID RISKS OF
IMPROPER OPERATION, FIRE, EXPLOSION OR ASPHYXIATION.
If the unconfined space is within a building of tight construction
(buildings using the following construction: weather stripping, heavy
insulation, caulking, vapor barrier, etc.), air for combustion and ventilation
must be obtained from outdoors. The installation instructions for confined
spaces in tightly constructed buildings must be followed to ensure adequate
air supply.
VENT PIPE TERMINATION
NOTE: Before installing venting, determine place of vent pipe termination.
See Figures 5a & b and 6a & b before proceeding.
CONFINED SPACE
CAUTION
DO NOT TERMINATE THE VENTING WHERE NOISE FROM THE
EXHAUST OR INTAKE WILL BE OBJECTIONABLE. THIS INCLUDES
LOCATIONS CLOSE TO OR ACROSS FROM WINDOWS AND DOORS.
AVOID ANCHORING THE VENT AND INTAKE PIPES DIRECTLY TO
FRAMED WALLS, FLOORS OR CEILINGS UNLESS RUBBER ISOLATION
PIPE HANGERS ARE USED. THIS PREVENTS ANY VIBRATIONS FROM
BEING TRANSMITTED INTO THE LIVING SPACES.
When drawing combustion air from inside a conventionally constructed
building to a confined space, such a space shall be provided with two
permanent openings, ONE IN OR WITHIN 12" (31 cm) OF THE ENCLOSURE
TOP AND ONE IN OR WITHIN 12" (31 cm) OF THE ENCLOSURE BOTTOM.
Each opening shall have a free area of at least one square inch (6.5 cm²)
per 1000 Btuh appliances in the enclosure, but not less than 100 square
inches (645 cm²).
6
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 shall 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 shall 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 shall 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 shall
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 shall
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 shall be installed.
APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above
provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and CSA certified.
SIGNAGE A metal or plastic identification plate shall 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 shall 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 shall 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 shall
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 shall be satisfied by the manufacturer:
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation
instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall 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 shall remain with the appliance or
equipment at the completion of the installation.
7
U.S. POWER VENT
FIGURE 5a.
CAUTION
TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE
IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN
THESE TWO TERMINALS IS RECOMMENDED.
CANADIAN POWER VENT
FIGURE 5b.
8
U.S. DIRECT VENT
FIGURE 6a.
CAUTION
TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE
IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN
THESE TWO TERMINALS IS RECOMMENDED.
CANADIAN DIRECT VENT
FIGURE 6b.
9
IMPORTANT
FOR ALL
MODELS
The vent system must terminate so that proper clearances are maintained
as cited in local codes or the current editions of the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 or the Natural Gas and Propane Installation Code,
CAN/CSA-B149.1.
Do not terminate the exhaust vent terminal over public area where condensate
or vapor can cause nuisance or hazard.
Plan the vent system layout so that proper clearances are maintained from
plumbing and wiring.
Vent pipes serving power vented appliances are classified by building codes
as "vent connectors". Required clearances from combustible materials must
be provided in accordance with information in this manual under LOCATION
OF HEATER and CLEARANCES, and with National Fuel Gas Code and
local Codes.
FIGURE 8.
IMPORTANT
IMPORTANT
WHEN LOCATING THE TERMINALS ON A SIDEWALL, THE FOLLOWING
SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE
FOLLOWED.
Plan the layout of the vent system backwards from the vent termination to
the appliance.
WARNING
1. The intake vent terminal and the exhaust vent terminal must terminate on
the same exterior wall and must be located at a minimum of 24" (61cm)
from the vertical centerline of the exhaust vent terminal (see Figure 9). In
colder climates increasing the 24" (61cm) minimum will reduce possibility
of frost over from side winds blowing exhaust vapors to the air intake of
the direct vent.
USE ONLY THE VENT TERMINALS SUPPLIED WITH THIS UNIT.
TERMINATION OF A VENT SYSTEM WITH A DEVICE OTHER THAN
THE SUPPLIED VENT TERMINATIONS WILL AFFECT SYSTEM
PERFORMANCE AND RESULT IN A SAFETY HAZARD.
DIRECT VENTING
2. The horizontal centerline of the intake vent terminal may not be located
lower than the horizontal centerline of the exhaust vent terminal
(see Figure 9).
The air intake provided on the unit contains a mesh screen (see Figure 7)
to prevent large particles from entering the unit.
INSTALLATION SEQUENCE
For installations in the City of Los Angeles, California Category IV PVC Pipe
such as that manufactured by Brownline Pipe Company, must be used as
vent pipe material
CAUTION
Vent terminals supplied with the heater must be used.
NOTE: BEFORE BEGINNING INSTALLATION OF ANY VENT PIPE READ
THE VENT PIPE MANUFACTURER'S INSTALLATION INSTRUCTIONS.
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.
FIGURE 7.
2. 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 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 holes as a centering point for the template.
WARNING
WHEN THE UNIT IS TO BE SETUP AS A DIRECT VENT, THE MESH
SCREEN MUST BE REMOVED. THE INLET VENT PIPE MAY THEN BE
GLUED TO THE AIR INTAKE (see Figure 8) PROVIDED ON THE UNIT.
3. A) MASONRY SIDE WALLS
Chisel an opening approximately 1/2" (1.3 cm) larger than the marked
circle.
DIRECT VENT TERMINAL INSTALLATION
IMPORTANT
THIS UNIT CONSISTS OF TWO VENT TERMINALS - AN INTAKE VENT
TERMINAL AND AN EXHAUST VENT TERMINAL. THE INTAKE VENT
TERMINAL IS A 3" 45° PVC ELBOW WITH A DOME MESH WIRE SCREEN
AND THE EXHAUST VENT TERMINAL IS A 3" 45°PVC ELBOW 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
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.
4. Cut a length of 3" PVC pipe about 3.5" (8.9 cm) longer than the wall
thickness at the opening.
10
VERTICAL VENT TERMINAL INSTALLATION
5. Glue the intake vent terminal to the section of the pipe.
6. Slide the wall plate over the pipe to stop against intake vent terminal.
IMPORTANT
7. 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.
WHEN TERMINATING THROUGH A ROOF, THE FOLLOWING
SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE
FOLLOWED.
8. 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 coupling on the other side of the wall,
making sure that the vent terminal ends up pointed in the correct position
(See Figure 9).
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 intake vent termination and the exhaust vent termination must
penetrate the same side of roof.
4. The center line of the intake vent termination and the center line of the
exhaust vent termination must be no closer than 24" (61cm).
5. The intake vent terminal and the exhaust vent terminal must be oriented
facing downward and the same direction.
The specifications are displayed in Figure 10 & 11.
NOTE: Exhaust vent terminal is installed using the same procedure.
INSTALLATION SEQUENCE
NOTE: BEFORE BEGINNING INSTALLATION OF ANY VENT PIPE, READ
“VENT PIPE PREPARATION” SECTION ON PAGE 12.
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 roof.
2. Drill a pilot hole approximately 1/4" (6 mm) 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 the line. (This will allow the vent pipe to easily slide
through the opening). The resulting gap will be covered by the roof
boot/flashing.
3. Suspend the pipe through the center of the hole using proper support.
4. Slide roof boot or equivalent flashing over pipe and secure roof boot
equivalent flashing to roof.
FIGURE 9.
5. Seal around flashing.
6. Terminate intake terminal and exhaust vent terminal facing down as
shown in Figure 11.
FIGURE 10.
FIGURE 11.
11
INSTALLATION OF VENT SYSTEM
Propane Installation Code which requires the vent system components
be certified to ULC S636.
WARNING
This water heater has been design certified to be vented with PVC pipe
certified and marked as complying with ULC S636. This water heater is
supplied with a 2 inch 22.5 degree termination elbow that is a special fitting
that must be used with the appliance. Any outlet piping, fittings and glue used
to vent this appliance that is not supplied by the manufacturer must comply
with the ULC S636 requirements.
THE OPTIONAL INTAKE VENTING ARRANGEMENT AND THE EXHAUST
VENTING ARRANGEMENT MUST BE INSTALLED TO RUN DIRECTLY TO
THE OUTDOORS AND NOT IN ANY WAY BE CONNECTED TO ANOTHER
VENTING SYSTEM (I.E. FURNACE, DRYERS OR SPACE HEATERS). IT
IS CRUCIAL THAT THE VENTING ARRANGEMENT BE KEPT SEPARATE
FROM OTHER VENTING SYSTEMS. IF THIS WARNING IS IGNORED, AND
THE SYSTEM IS VENTED INCORRECTLY, IT MAY CAUSE IMPROPER
OPERATION, FIRE, EXPLOSION, OR ASPHYXIATION.
PVC Materials should use ASTM D-2564 Grade Cement; CPVC Materials
should use ASTM F-493 Grade Cement and ABS Materials should use ASTM
D-2235 Grade Cement.
1. Plan the route of the vent system from the vent termination to the planned
location of the appliance. Layout the total vent system to use the minimum
of vent pipe and elbows possible.
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.
2. The installer may add up to a MAXIMUM OF FIFTY (50) EQUIVALENT
FEET (15.2 m) of pipe to the exhaust venting arrangement. This addition
of FIFTY (50) EQUIVALENT FEET (15.2 m) of pipe on both the intake
venting arrangement and exhaust venting arrangement must include any
3" PVC elbows which equals (5) EQUIVALENT FEET (1.5 m) of pipe.
3. It is important that condensate not be allowed to buildup in the exhaust
vent pipe. To prevent this from happening the pipe should be installed with
a slight, 1/8" (3mm) per 5' (152 cm) of pipe maximum downward slope.
4. The vent system should be supported every 5' (152 cm) of vertical run
and every 3' (91cm) of horizontal run of vent pipe length.
NOTE: for Water Heaters in locations with high ambient temperatures (above
100°F or 38°C) and/or insufficient dilution air, it is recommended that CPVC or
ABS pipe and fittings (MUST USE SUPPLIED VENT TERMINAL) be used.
Table 2. VENT LENGTH TABLE
Number
of 90°
Elbows
ONE (1)
TWO (2)
THREE (3)
FOUR (4)
FIVE (5)
SIX (6)
3" Minimum
Pipe (Ft./M.)
7/2
7/2
7/2
7/2
7/2
7/2
3" Maximum
Pipe (Ft./M.) 45/13.7
40/12.2
35/10.7
30/9.1
---
---
NOTE: Stress levels in the pipe and fittings can be significantly increased by
improper installation. If rigid pipe clamps are used to hold the pipe in place,
or if the pipe cannot move freely through a wall penetration, the pipe may
be directly stressed, or high thermal stresses may be formed when the pipe
heats up and expands. Install accordingly to minimize such stresses.
4"
Maximum
Pipe (Ft./M.)
115/35
110/33.5
105/32
100/30.5
95/29
90/27.4
VENT PIPE PREPARATION
1. INITIAL PREPARATION
A.Make sure the solvent cement you are planning to use is designed for the specific application you are attempting.
4" PVC may be used for a MAXIMUM intake of ONE HUNDRED TWENTY
(120) EQUIVALENT FEET (36.6m) and a MAXIMUM exhaust of ONE
HUNDRED TWENTY (120) EQUIVALENT FEET (36.6m). The maximum
number of 90° elbows with the 4" venting is six (6) on the intake and six (6)
on the exhaust. A 90° elbow is equal to five (5) equivalent feet (1.5m) of pipe.
One (1) 90° elbow is equal to two (2) 45° elbows. Any venting configuration
using less than 50 equivalent feet should use 3" venting. See Table 2.
The 3" venting ter m i n a l s ( p r o v i d e d ) m u s t b e u s e d w i t h t h e
3" vent pipe. Two, approved 4" vent terminals (not provided) must be used
with 4" vent pipe. See replacement parts list for terminals.
B.Know the physical and chemical characteristics and limitations of
the PVC, PVC cellular core, ABS or CPVC piping materials that you
are about to use.
C.Know the reputation of your pipe and cement manufacturer and
their products.
D.Know your own qualifications or those of your contractor. The solvent
welding technique of joining PVC, PVC cellular core, ABS or CPVC
pipe is a specialized skill just as any other pipe fitting technique.
IMPORTANT
When multiple units are direct vented through a wall (3" or 4" venting), all intake
vent terminals should be no lower than the highest exhaust vent terminal.
U.S. INSTALLATIONS
NOTE: This unit can be vented using only PVC (Class 160, ASTM D-2241
Schedule 40, ASTM D-1785 ; or Cellular Core Schedule 40 DWV, ASTM
F-891) , Schedule 40 CPVC (ASTM F-411), or ABS (ASTM D-2661) pipe.
The fittings, other than the TERMINATIONS should be equivalent to PVCDWV fittings meeting ASTM D-2665 (Use CPVC fittings, ASTM F-438 for
CPVC pipe and ABS fittings, ASTM D-2661/3311 for ABS pipe. If CPVC or
ABS pipe and fittings are used, then the proper cement must be used for
all joints, including joining the pipe to the Termination (PVC Material). PVC
Materials should use ASTM D-2564 Grade Cement; CPVC Materials should
use ASTM F-493 Grade Cement and ; ABS Materials should use ASTM
D-2235 Grade Cement.
E.Closely supervise the installation and inspect the finished job before
start-up.
F. Contact the manufacturer, supplier, or competent consulting agency
if you have any questions about the application or installation of
PVC, PVC cellular core, ABS or CPVC pipe.
G.Take the time and effort to do a professional job. Shortcuts will only
cause you problems and delays in start-up. The majority of failures
in these systems are the result of shortcuts and/or improper joining
techniques.
2.SELECTION OF MATERIALS
PRIMER
It is recommended that Tetrahydrofuran (THF) be used to prepare the surfaces
of pipe and fittings for solvent welding. Do not use water, rags, gasoline or
any other substitutes for cleaning PVC cellular core, ABS or CPVC surfaces.
A chemical cleaner such as MEK may be used.
CANADIAN INSTALLATIONS
This water heater must comply with CAN/CSA B149.1 - Natural Gas and
12
LOW GAS PRESSURE SWITCH
CEMENT
The cement should be a bodied cement of approximately 500 to 1600
centipoise viscosity containing 10-20% (by weight) virgin PVC material
solvated with tetrahydrofuran (THF). Small quantities of dimethyl formamide
(DMF) may be included to act as a retarding agent to extend curing time.
Select the proper cement; Schedule 40 cement should be used for Schedule
40 pipe. Never use all-purpose cements, commercial glues and adhesives
or ABS cement to join PVC or CPVC pipe and fittings.
(SEE FIGURE 12)
The Low Gas Switch (LGS) is a single-pole, normally open pressure switch
that will close its contacts when a rising pressure of 5.0 in. (1.25Kpa) W.C.
is encountered. The contacts will open when the pressure falls below the
fixed set point of 4.8"WC (1.18Kpa) for natural gas models and 8.5"WC
(2.08Kpa) for propane models. The LGS monitors the gas supply pressure
to the heater. If the gas supply falls below 5.0 in. (1.25Kpa) W.C., the main
burner is extinguished (if heater is running) or the heater will not start up.
SAFETY PRECAUTION: PRIMERS AND CEMENTS ARE EXTREMELY
FLAMMABLE AND MUST NOT BE STORED OR USED NEAR HEAT OR
OPEN FLAME. ALSO, USE ONLY IN A WELL-VENTILATED AREA.
ON/OFF SWITCH
The ON/OFF Switch is a single-pole, single-throw rocker switch. This switch
provides 120V from the line source to the heater.
CONTROLS AND SWITCHES
CAUTION
All models are provided with four 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.
THE WATER HEATER IS POLARITY SENSITIVE. BEFORE APPLYING
ELECTRICITY TO THIS HEATER BE CERTAIN THAT SUPPLY NEUTRAL
WIRE TO GROUND CHECK INDICATES ZERO VOLTAGE.
HOT SURFACE IGNITER
The Hot Surface Igniter is a device that ignites the main burner by high
temperature (>1800°F or >982°C). When 120VAC is applied to the igniter,
sufficient heat is generated to ignite the main burner. Although improvements
have been made to strengthen the igniter, it is still fragile and care must be
taken when handling the igniter to prevent breakage.
GAS PIPING
Contact your local gas service company to ensure that adequate gas service
is available and to review applicable installation codes for your area.
Size the main gas line in accordance with Table 3. The figures shown are
for straight lengths of pipe at 0.5" (125Pa) W.C. pressure drop, which is
considered normal for low pressure systems Note that fittings such as elbows
and tees will add to the pipe pressure drop.
CAUTION
DO NOT USE FLEXIBLE GAS PIPING.
FIGURE 12.
TABLE 3. MAXIMUM CAPACITY OF PIPE IN CUBIC FEET OF GAS PER HOUR
(Based upon a Pressure Drop of 0.5") Water Column and 0.6 Specific
Gravity Gas and max. gas pressure of 0.5 psig)
BLOWER PROVER SWITCH
(SEE FIGURE 12)
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 close. The pressure switch is connected to the burner
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.
LENGTHNORMAL IRON PIPE SIZES (INCHES)
IN INPUT IN THOUSANDS BTU/HR
FEET 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3"
4"
10
175 360 680 1400 2100 3960 6300 11000 23000
20
120 250 485 950 1460 2750 4360 7700 15800
30
97 200 375 770 1180 2200 3520 6250 12800
40
82 170 320 660
990 1900 3000 5300 10900
50
73 151 285 580
900 1680 2650 4750 9700
60
66 138 260 530
810 1520 2400 4300 8800
70
61 125 240 490
750 1400 2250 3900 8100
80
57 118 220 460
690 1300 2050 3700 7500
90
53 110 205 430
650 1220 1950 3450 7200
100
50 103 195 400
620 1150 1850 3250 6700
125
44
93 175 360
550 1020 1650 2950 6000
150
40
84 160 325
500 950 1500 2650 5500
175
37
77 145 300
460 850 1370 2450 5000
200
35
72 135 280
430 800 1280 2280 4600
BLOCKED OUTLET PROVER SWITCH
(SEE FIGURE 12)
The Blocked Outlet Prover Switch is set up to shut the unit off when a build-up
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 there is no more
than fifty equivalent feet (15.2 m) of three inch PVC vent pipe on the exhaust.
LENGTHNORMAL IRON PIPE SIZES (INCHES)
IN
INPUT IN KW
METERS 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3"
3.0
51 105 199 410
615 1160 1845 3221
6.1
35
73 142 278
428 805 1277 2255
9.1
28
59 110 225
346 644 1031 1830
12.2
24
50
94
193
290 556 878 1552
15.2
21
44
83
170
264 492 776 1391
18.3
19
40
76
155
237 445 703 1259
21.3
18
37
70
143
220 410 659 1142
24.4
17
35
64
135
202 381 600 1083
27.4
16
32
60
126
190 357 571 1010
30.5
15
30
57
117
182 337 542
952
38.1
13
27
51
105
161 299 483
864
45.7
12
25
47
95
146 278 439
776
53.3
11
23
42
88
135 249 401
717
61.0
10
21
40
82
126 234 375
688
BLOCKED INLET PROVER SWITCH
(SEE FIGURE 12)
The Blocked Inlet Prover Switch is set up to shut the unit off when a build-up
of negative pressure in the intake vent 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 flange connected to the inlet of the blower. When this
switch prevents the unit from igniting, most likely the intake is blocked by some
means. Check to see if there is no more than fifty equivalent feet (15.2 m) of
three inch PVC vent pipe on the intake. Also verify that the intake and intake vent
terminal is free of obstructions that may prevent air from entering the unit.
13
4"
6735
4626
3748
3192
2840
2577
2372
2196
2108
1962
1757
1610
1464
1347
WARNING
THE HEATER IS NOT INTENDED FOR OPERATION AT HIGHER THAN
10.5" (2.59 KPa) WATER COLUMN SUPPLY GAS PRESSURE. HIGHER
GAS SUPPLY PRESSURES REQUIRE SUPPLEMENTAL REDUCING
SERVICE REGULATION. EXPOSURE TO HIGHER GAS SUPPLY
PRESSURE MAY CAUSE DAMAGE TO THE GAS CONTROLS WHICH
COULD RESULT IN FIRE OR EXPLOSION. IF OVERPRESSURE HAS
OCCURRED SUCH AS THROUGH IMPROPER TESTING OF GAS LINES
OR EMERGENCY MALFUNCTION OF THE SUPPLY SYSTEM THE GAS
VALVE MUST BE CHECKED FOR SAFE OPERATION. MAKE SURE
THAT THE OUTSIDE VENTS ON THE SUPPLY REGULATORS AND THE
SAFETY VENT VALVES ARE PROTECTED AGAINST BLOCKAGE. THESE
ARE PARTS OF THE GAS SUPPLY SYSTEM, NOT THE HEATER. VENT
BLOCKAGE MAY OCCUR DURING ICE STORMS.
IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING FROM
CONTAMINANTS IN THE GAS WAYS. SUCH FOULING MAY CAUSE
IMPROPER OPERATION, FIRE OR EXPLOSION.
IF COPPER SUPPLY LINES ARE USED THEY MUST BE INTERNALLY
TINNED AND CERTIFIED FOR GAS SERVICE.
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
DIRT LEG (SOMETIMES CALLED A SEDIMENT TRAP OR DRIP LEG) MUST
BE INCORPORATED IN THE PIPING (SEE FIGURE 13). THE DIRT LEG MUST
BE READILY ACCESSIBLE AND NOT SUBJECT TO FREEZING CONDITIONS.
INSTALL IN ACCORDANCE WITH RECOMMENDATIONS OF SERVING GAS
SUPPLIERS. REFER TO THE NATIONAL FUEL GAS CODE.
FIGURE 14b. AHCG3/HCG3100T150 Models Only
FIGURE 13.
CONNECTION OF GAS PIPE
1. When connecting gas pipe to unit, apply wrench to flange only. Note:
Do not use wrench on gas valve or gas bracket. See Figure 14a, b, c.
2. PERFORM THE GAS LEAK TEST ANY TIME WORK IS DONE ON A GAS
SYSTEM TO AVOID THE POSSIBILITY OF FIRE OR EXPLOSION WITH
PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
FIGURE 14c. AHCG3/HCG360T120 Models Only
The Gas Leak Test is performed as follows: Paint pipe connections upstream
of gas control with a rich soap and water solution to test for leaks before
operating main burner. Bubbles indicate gas leak. To stop leak, tighten pipe
connections. After piping connections are checked, turn on main burner. With
main burner in operation, paint pipe joints (including flanges), pilot gas tubing
connections and control inlet and outlet with rich soap and water solution.
Bubbles indicate gas leak. To stop leak, tighten flange screws, joints and
pipe connections. Replace part if leak can’t be stopped.
To prevent damage, care must be taken not to apply too much torque when
attaching gas supply pipe to gas valve inlet.
Apply joint compounds (pipe dope) sparingly and only to the male threads of
pipe joints. Do not apply compound to the first two threads. Use compounds
resistant to the action of liquefied petroleum gases.
FIGURE 14a. AHCG3/HCG3100T199 & AHCG3/HCG3100T250 Models Only
14
RELIEF VALVE
DISCONNECT THE APPLIANCE AND ITS MANUAL GAS SHUTOFF
VALVE FROM THE GAS SUPPLY PIPING SYSTEM DURING ANY
SUPPLY PRESSURE TESTING EXCEEDING 1/2 PSIG (3.45Kpa). GAS
SUPPLY LINE MUST BE CAPPED WHEN DISCONNECTED FROM THE
HEATER. FOR TEST PRESSURES OF 1/2 PSIG (3.45Kpa) OR LESS, THE
APPLIANCE NEED NOT BE DISCONNECTED, BUT MUST BE ISOLATED
FROM THE SUPPLY PRESSURE TEST BY CLOSING THE MANUAL GAS
SHUTOFF VALVE.
This heater is equipped with an approved temperature and pressure relief
valve. ASME ratings cover pressure relief. CSA ratings cover release rate
with temperature actuation.
FOR SAFE OPERATION OF THE WATER HEATER, THE RELIEF VALVE(S)
MUST NOT BE REMOVED OR PLUGGED.
BEFORE PLACING THE HEATER IN OPERATION, CHECK FOR GAS
LEAKAGE. USE SOAP AND WATER SOLUTION OR OTHER MATERIAL
ACCEPTABLE FOR THE PURPOSE OF LOCATING GAS LEAKS. DO NOT
USE MATCHES, CANDLES, FLAME OR OTHER SOURCES OF IGNITION
FOR THIS PURPOSE.
PURGING
In addition to the appliance relief valve, each remote storage tank
which may be used in conjunction with this appliance shall also be
installed with a properly sized, rated and approved temperature (ANSI)
and pressure (ASME) relief valve(s). This relief valve shall comply
with the standard for relief valves for hot water supply systems. ANSI
Z21.22-CSA 4.4.
Your local code authority may have other specific relief valve
requirements.
Gas line purging is required with new piping or systems in which air has
entered.
WARNING
CAUTION
THE PURPOSE OF A RELIEF VALVE IS TO AVOID EXCESSIVE
PRESSURE OR TEMPERATURE INTO THE STEAM RANGE, WHICH
MAY CAUSE SCALDING AT FIXTURES, TANK EXPLOSION, SYSTEM
OR HEATER DAMAGE. NO VALVE IS TO BE PLACED BETWEEN THE
RELIEF VALVE AND THE TANK.
PURGING SHOULD BE PERFORMED BY PERSONS EXPERIENCED IN
THIS TYPE OF GAS SERVICE. TO AVOID RISK OF FIRE OR EXPLOSION,
PURGE DISCHARGE MUST NOT ENTER CONFINED AREAS OR
SPACES WHERE IGNITION CAN OCCUR. THE AREA MUST BE WELL
VENTILATED AND ALL SOURCES OF IGNITION MUST BE INACTIVATED
OR REMOVED.
A DRAIN LINE MUST BE CONNECTED TO THE RELIEF VALVE TO
DIRECT DISCHARGE TO A SAFE LOCATION TO AVOID SCALDING OR
WATER DAMAGE. THIS LINE MUST NOT BE REDUCED FROM THE
SIZE OF THE VALVE OUTLET AND MUST NOT CONTAIN VALVES OR
RESTRICTIONS, NOR SHOULD IT BE LOCATED IN FREEZING AREAS.
DO NOT THREAD OR CAP THE END OF THIS LINE. RESTRICTED OR
BLOCKED DISCHARGE WILL DEFEAT THE PURPOSE OF THE VALVE
AND IS UNSAFE. THE DISCHARGE LINE SHALL BE INSTALLED TO
ALLOW COMPLETE DRAINAGE OF BOTH THE VALVE AND LINE.
GAS METER SIZE - CITY GASES ONLY
Be sure that the gas meter has sufficient capacity to supply the full rated gas
input of the water heater as well as the requirements of all other gas fired
equipment supplied by the meter. If the gas meter is too small, ask the gas
company to install a larger meter having adequate capacity.
GAS PRESSURE REGULATION
WATER LINE CONNECTIONS
Main line gas pressure to the water heater should be between a maximum
10.5" (2.59Kpa) W.C. (14.0"/3.45Kpa for propane) and a minimum as shown
in Table 4: that is, for Natural Gas, 4.8" (1.18Kpa) W.C. and 8.5" (2.08Kpa) for
Propane Gas. The inlet gas pressure must not exceed the maximum value.
A service regulator must be installed within 10' (305 cm) of unit.
This manual provides detailed installation diagrams (see back section of this
manual) for typical methods of application for the water heaters.
The water heater may be installed by itself, or with a separate storage
tank.
WARNING
CLOSED SYSTEM
FAILURE TO INSTALL A PRESSURE REGULATOR WITHIN 10 FEET OF
THE WATER HEATER CAN RESULT IN LEAKAGE OF FLUE GASES INTO
THE SURROUNDING ROOM. SERIOUS PERSONAL INJURY OR DEATH
COULD RESULT FROM INHALATION OF CARBON MONOXIDE GAS.
CAUTION
A closed system will exist if a check valve (without bypass), pressure reducing
valve (without bypass), or a water meter (without bypass) is installed in the
cold water line between the water heater and street main (or well).
GAS VALVES
WARNING
Excessive pressure may develop causing premature tank failure or
intermittent relief valve operation. This type of failure is not covered
by the limited warranty. An expansion tank or a similar device may be
required in the inlet supply line between the appliance and the meter or
valve to compensate for the thermal expansion of water under supply
pressure.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO
SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO THE
APPLIANCE.
SYSTEM CONNECTIONS
If a water heater is installed in a closed water system, check local codes
or contact the water supplier or local plumbing inspector on how to control
this situation.
The system installation must conform to these instructions and to the local
code authority having jurisdiction. Good practice requires that all heavy
piping be supported.
THERMOMETERS (Not Supplied)
WATER (POTABLE) HEATING AND SPACE HEATING
Thermometers should be obtained and field installed as shown in the
installation diagrams.
1.All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
Thermometers are installed in the system as a means of detecting the
temperature of the outlet water supply.
2.Toxic chemicals, such as those used for boiler treatment, shall
NEVER be introduced into this system.
15
3.This unit may never be connected to any existing heating system or
component(s) previously used with non-potable water heating
appliance.
CONDITIONER MUST BE INSTALLED IF THE ABOVE CONDITIONS EXIST.
MALFUNCTIONS CAUSED BY A POOR ELECTRICAL SUPPLY ARE NOT
COVERED UNDER YOUR WARRANTY.
4.When the system requires water for space heating at temperatures higher
than required for domestic water purposes, a tempering valve must be
installed. Please refer to installation diagrams on pages 23 through 28 in
back of manual for suggested piping arrangements.
The controller is wired to the heater as shown in Figure 15. The model and
rating plate provides the electrical information needed to size the complete
heater branch supply.
All electrical work must be installed in accordance with the National
Electrical Code, NFPA 70 or the Canadian Electrical Code, CSA C22.1
and local requirements.
HEATER WIRING
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE
MUST BE REPLACED, IT MUST BE REPLACED WITH 105°C OR ITS
EQUIVALENT, EXCEPT IN THE BURNER HOUSING. IN THIS CASE USE
200°C WIRE.
When installed, the appliance must be electrically grounded in
accordance with local codes or, in the absence of local codes,
with the National Electrical Code, ANSI/NFPA 70 or the Canadian
Electrical Code, CSA C22.1.
THE COMPUTER CONTROL REQUIRES A SOURCE OF STABLE CLEAN
ELECTRICITY FOR PROPER OPERATION. INSTALLING THE HEATER
ON A BRANCH CIRCUIT THAT HAS ELECTRONIC NOISE, IS SUBJECT
TO FLUCTUATIONS IN VOLTAGE LEVEL OR HAS AN APPLIANCE
WHICH GENERATES EMF OF RFI INTERFERENCE CAN CAUSE
THE CONTROLLER TO MALFUNCTION. A HIGH QUALITY POWER
DO NOT ENERGIZE THE BRANCH CIRCUIT BEFORE THE HEATER TANK
IS FILLED WITH WATER.
NOTE: This controller is Polarity Sensitive. If the Hot and Neutral Supply
Voltage is reversed, the controller will not sense flame. Verify polarity before
connecting the unit.
FIGURE 15.
16
USING THE ELECTRONIC CONTROLLER
1.Overview
Interaction with the water heater controller is done through an up, a down, and three operation buttons. These buttons are illustrated to the right. Operation
of the three lower buttons is defined immediately above them on the screen. The [UP] and [DN] buttons are used to navigate through the menus and make
adjustments to the water heater.
While the water heater is operating, the user interface will display the desktop screen (if there are no active faults or warnings). An example of this screen
is shown to the right. The first temperature on this screen is the temperature of the water inside the tank. The second temperature on this screen is the
Operating Set Point. The Operating Set Point is the temperature at which the water heater will maintain the water inside the tank. The third line on the
screen is a text description of the Operational State of the water heater (please see Operating States for more details).
The following status icons describe graphically operational details of the heater. The legend of all the status icons is listed below.
17
2. Operating States
In the main desktop screen, there are some specific Operating States that are indicated on the status line. These are summarized below:
3. Adjusting the Operating Set Point
ACTION:
Press Change then use the UP and DOWN buttons to change the Set
Point.
The Operating Set Point of this water heater determines the regulated
temperature for the water in the tank. This parameter is adjusted in the
Temperature menu. Items in this menu allow you to monitor different temperature readings in the tank along with adjusting the Operating Set Point
and Differential.
Note: This procedure can also be used to change the Differential. The
Tank, Upper and Lower Temperatures are not user changeable. They are
determined by the temperature probes on the heater.
ACTION:
From the desktop screen, press Menu.
DISPLAY:
DISPLAY:
ACTION:
From the Main Menu, press Select to enter the "Temperatures" screen.
ACTION:
Press Update to accept the change or Cancel to reset it.
DISPLAY:
DISPLAY:
18
4. Changing the Display Units
There are two types of conditions that can occur during operation. These
are Warnings and Faults:
The display interface to the heater has the option of selecting between degrees Fahrenheit and degrees Celsius for temperature displays. This can be
found in the “Display Settings” menu. Also in this menu, you may adjust how
the backlight operates and the contrast of the LCD screen.
• Warnings: This is a non-safety related condition that the control has
detected that may cause the water heater to operate in a less than optimal
condition, but does not pose a safety concern.
ACTION:
From the Main Menu, press the Down button to highlight "Display Settings" then press Select.
NOTE: When these conditions occur, continued heating cycles will continue
and the heater will attempt to regulate the water in the tank to the Operating
Set Point.
DISPLAY:
Example of a Warning:
ACTION:
Use the UP and DOWN buttons to highlight the desired setting. Then
press Change. Again, use the UP and DOWN buttons to scroll through the
options for that setting.
• Faults: This is a safety related condition that has been detected by the
heater.
NOTE: When these conditions occur, the water heater will not continue any
further heating cycles and the water will no longer be heated until the condition is corrected and, in most cases, power has been cycled.
DISPLAY:
Example of a Fault:
ACTION:
Press Update to accept the change or Cancel to reject it.
Advanced Diagnostics Information
When a fault or warning has been declared, advanced information can be
found in the control. By pressing the Advanced button, detailed information
can be found regarding diagnosing and resolving the problem.
DISPLAY:
WARNING: Usage of the Advanced information requires ability equivalent to that of a licensed tradesmen in the field involved.
6. Access to the Current Fault or Warning
When a fault or warning has been detected by the control, it will automatically
be displayed on the screen and the back light will blink. If you choose to
leave the current fault or warning by pressing the Back key, you can always
return to the fault screen through the menu.
5. Fault and Warning Conditions
This water heater is equipped with electronic controls that have the ability
to monitor almost all aspects of the water heater operation. In the case that
there is an undesirable or unsafe condition that occurs, the water heater
controls will detect this condition and determine the appropriate action. Part
of this is displaying the information on the LCD in plain text that accurately
describes the condition and diagnostics information that can be used to
correct the issue.
19
7. Viewing the Fault History
ACTION:
To get to the current fault information screen, press Menu.
The controller for this water heater will store a history of ten of the last Fault
and Warning conditions that occurred. This is stored in the Fault History.
Along with all the information about the fault, including a estimate time of
when the fault occurred, information regarding the advanced diagnostics for
that fault can be accessed at any time.
DISPLAY:
ACTION:
Press the DOWN button for more information.
DISPLAY:
ACTION:
Press the DOWN button to highlight "current Fault" and press Select.
DISPLAY:
ACTION:
Press the DOWN key to scroll through the fault history. If you select a
specific fault or warning, you may press the VIEW button to view details
regarding this fault.
DISPLAY:
ACTION:
Press the DOWN button for more information.
DISPLAY:
8. Viewing Information About the Heater
The electronic control for this water heater monitors many different aspects
of the water to ensure safe and optimal operation. Much of the information
monitored is available to view in two areas of the control. The first is the
"Heater Status" and; the second is "Heater Information." These items can be
selected through the main menu in the same fashion as described above.
In these menus, detailed information about the water heater and the current
status of specific conditions can be found.
PRIOR TO START UP
REQUIRED ABILITY
Be certain that the water heater is full of water, that air is purged from all lines,
there are no leaks (gas and water), and all inlet water lines are open.
INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES
ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE
FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, GAS SUPPLY
AND ELECTRICAL WORK ARE REQUIRED.
The following test equipment should be on hand (all test equipment must be
acclimated to ambient temperature before calibration and use.)
Before attempting start-up, thoroughly study and familiarize yourself with
the exact sequence of operation and all other details on the specific heater
being used.
– Two U-tube manometers or calibrated pressure gages that can read
0-10" (0-2.5Kpa) and 0-35" (0-8.7Kpa) W.C. pressure gauges.
• Attach a gas pressure gauge or manometer to the upstream side of
main gas cock and a gas pressure gauge or manometer to the manifold
pressure tap (see Figure 15).
The power burner is equipped with an ignition system which automatically
sequences prepurge and ignition, senses and ignites main burner flame and
sequences burner operation. Heater is equipped with an ignition control which
locks out after three unsuccessful ignition attempts. Familiarize yourself with
the sequence of operation of this unit prior to start-up.
• You are now ready to begin the burner start-up procedure.
20
OPERATING INSTRUCTIONS
5. Check the vent system seams and joints and ensure that there is no
discharge of flue products into the room.
IMPORTANT
IT IS RECOMMENDED THAT A QUALIFIED SERVICE TECHNICIAN
PERFORM THE INITIAL FIRING OF THE HEATER. AT THIS TIME THE
USER SHOULD ASK THE TECHNICIAN ANY QUESTIONS IN REGARD
TO THE OPERATION AND MAINTENANCE OF THE UNIT.
6. Check the input rate.
For appliance installation locations with elevations above 6500 feet
(1982 meters) refer to HIGH ALTITUDE INSTALLATIONS section of this
manual.
a. Attach a pressure gauge (manometer) to the manifold pressure tap (Figure 16) and refer to Table 4, page 20 for correct pressure.
CAUTION
BEFORE PROCEEDING WITH THE OPERATION OF THE UNIT, MAKE
SURE HEATER AND SYSTEM ARE FILLED WITH WATER AND ALL AIR
IS EXPELLED FROM HEATER AND PIPING.
b. Use this formula to “clock” the meter. Be sure other gas consuming appliances are not operating during this interval.
NEVER OPERATE THE HEATER WITHOUT FIRST BEING CERTAIN IT IS
FILLED WITH WATER AND A TEMPERATURE AND A PRESSURE RELIEF
VALVE IS INSTALLED IN THE RELIEF VALVE OPENING OF THE HEATER.
DO NOT ATTEMPT TO OPERATE HEATER WITH COLD WATER INLET
VALVE CLOSED.
3600
X H = Btuh
T
Should it be necessary to adjust the gas pressure to the burner, to obtain
the full input rate, the steps below should be followed:
FILLING:
1. Close the heater drain valve.
2. Open a nearby hot water faucet to permit the air in the system to escape.
3. Fully open the cold water inlet pipe valve allowing the heater and piping
to be filled.
4. Close the hot water faucet as water starts to flow.
5. The heater is ready to be operated.
T = Time in seconds to burn 1 cubic foot of gas. (With a stopwatch read
the gas meter and measure the amount of time required for the
heater to consume 1 cubic foot of gas.)
H =Heating value of gas (in Btu’s per cubic foot of gas).
Btuh = Actual heater input rate, in Btuh.
EXAMPLE: (Using AHCG3/HCG3100T150 heater)
T = 25.25 seconds
H = 1050 Btu/ft.3
BTUH = ?
THE MAIN MANUAL GAS SHUTOFF VALVE MUST HAVE BEEN CLOSED
FOR AT LEAST FIVE (5) MINUTES. THIS WAITING PERIOD IS AN
IMPORTANT SAFETY STEP. ITS PURPOSE IS TO PERMIT GAS THAT
MIGHT HAVE ACCUMULATED IN THE COMBUSTION CHAMBER TO
CLEAR. IF YOU DETECT GAS AT THE END OF THIS PERIOD, DO NOT
PROCEED WITH LIGHTING. RECOGNIZE THAT GAS ODOR, EVEN IF
IT SEEMS WEAK, MAY INDICATE THE PRESENCE OF ACCUMULATED
GAS SOMEPLACE IN THE AREA WITH A RISK OF FIRE OR EXPLOSION.
SEE THE FRONT PAGE FOR STEPS TO BE TAKEN.
3600
X 1050 = 150,000 Btuh (44 Kw)
25.25
For high altitude installations, compare result to the derated input required
for the elevation at the installation location.
c. Remove the pressure regulator cover screw (Figure 16) and adjust the
pressure by turning the adjusting screw with a small screwdriver. Do
not exceed 4.0" (1 kPa) natural gas models and 10.0" W.C. (2.5Kpa)
on the propane models.
DO NOT USE THIS HEATER IF ANY PART HAS BEEN UNDER WATER.
IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT
THE HEATER AND TO REPLACE ANY PART OF THE CONTROL SYSTEM
AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER.
LIGHT THE UNIT IN ACCORDANCE WITH THE OPERATING
INSTRUCTIONS LABEL ATTACHED TO THE HEATER.
Clockwise to increase gas pressure and input rate.
Counterclockwise to decrease gas pressure and input rate.
d. “Clock” the meter as in step (b) above.
e. Repeat steps (c) and (d) until the specified input rate is achieved.
f. Turn the manual gas valve to “OFF”. Replace the pressure regulator
cover screw. Remove the pressure gauge or manometer from the
manifold pressure tap. Replace the set screw in the manifold pressure
tap. If the gas pressure regulator cannot be adjusted to give the full input rating with sufficient gas pressure at the valve, check to ensure the unit is equipped with the correct orifice.
THESE INSTRUCTIONS ARE REPEATED IN THE LIGHTING AND
OPERATING LABEL ILLUSTRATION ON PAGE 20 IN THIS MANUAL.
ADJUSTMENT PROCEDURE
Initial Start-up - AHCG3/HCG360T120 thru AHCG3/HCG3100T150
Main line gas pressure to the water heater for natural gas should be between
a maximum of 10.5" (2.59Kpa for natural gas) W.C. (14.0"/3.45Kpa for
propane) and a minimum as shown in Table 4: that is, for Natural Gas, 4.8
(1.18Kpa) W.C. and 8.5" (2.08Kpa) for Propane Gas. The inlet gas pressure
must not exceed the maximum value. A service regulator must be installed
within 10' (305 cm) of the unit.
ADJUSTMENT PROCEDURE
Initial Start-up - AHCG3/HCG3100T199Tthru 100T250
Main line gas pressure to the water heater for natural gas should be between
a maximum of 10.5" (2.59Kpa for natural gas) W.C. (14.0"/3.45Kpa for
propane) and a minimum as shown in Table 4: that is, for Natural Gas 4"
(.98Kpa) W.C. and 9.0" (1.97Kpa) for Propane Gas. The inlet gas pressure
must not exceed the maximum value. A service regulator must be installed
within 10' (305 cm) of the unit.
1. Check gas line pressure with a manometer.
2. Check manifold pressure (see Table 4, page 20) using a pressure
gauge (manometer) connected to the manifold pressure tap on the
gas control valve, (Figure 15).
or counterclockwise
to decrease gas pressure to obtain 4.0" (1 kPa)
for natural gas and 10.0" W.C. (2.5 Kpa) for L.P. Gas.
The AHCG3/HCG3100T199 and AHCG3/HCG3100T250 models incorporate
a new gas control, which operates at 0"W.C. (0kPa) for both natural and
propane gas. These models are configured prior to being shipped from the
factory and no adjustments are necessary prior to startup. The controller
monitors the air-flow and makes adjustments to the fan speed which in
effect controls the amount of gas flow. Therefore, the unit will self-adjust
to acquire the correct amount of input.
3. Cycle the burner on and off several times to check its operation.
Once the unit is installed and filled with water and the inlet pressures
confirmed, simply turn the switch "on" and observe operation. Cycle the unit
4. Check the operation of the limit and operating controls.
"off" and "on" several times to ensure proper operation.
If full rate adjustment is required, remove cover screw from top of the
gas control valve, (Figure 15).
Using a small screwdriver, turn adjusting screw clockwise
to increase
21
HIGH ALTITUDE INSTALLATIONS
WARNING
UNDER NO CIRCUMSTANCES SHOULD THE INPUT EXCEED THE RATE
SHOWN ON THE HEATER RATING PLATE. OVER FIRING COULD RESULT
IN DAMAGE OR SOOTING OF THE HEATER.
WARNING
The AHCG3/HCG3100T199 and AHCG3/HCG3100T250 heaters are certified
for use without modifications for altitudes up to 10,100 ft. (3078 m). The
AHCG3/HCG360T120 and AHCG3/HCG3100T150 heaters are certified for
use without modifications for altitudes up to 7,700 ft. (2347 m). Installations
above these altitudes may require replacement of the burner orifice. Call the
800 number listed on the unit for requirements.
CATHODIC PROTECTION
CAUTION
HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER SYSTEM
SERVED BY THIS HEATER THAT HAS NOT BEEN USED FOR A LONG
PERIOD OF TIME (GENERALLY TWO 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 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.
Some gas utility companies derate their gas for altitude, making it unnecessary
to install high altitude orifices. Call the local gas or utility company to verify
BTU content.
Due to the input rating reduction at high altitudes, the output rating of the
appliance is also reduced and should be compensated for in the sizing of
the equipment for applications.
PRECAUTIONS
MAINTENANCE
IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO NOT OPERATE
HEATER UNTIL ALL CORRECTIVE STEPS HAVE BEEN MADE BY A
QUALIFIED SERVICEMAN.
GENERAL
KEEP APPLIANCE AREA CLEAR AND FREE FROM COMBUSTIBLE
MATERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS AND
LIQUIDS. (SEE WARNING ON PAGE 5, LOCATING THE HEATER).
1. FLOODING TO OR ABOVE THE LEVEL OF THE BURNER OR CONTROLS
2. EXTERNAL FIRING
3. DAMAGE
Water heater maintenance includes periodic tank flushing and cleaning, and
removal of lime scale. The unit should be inspected and adjusted to maintain
proper combustion. Refer to the following table. A periodic inspection of the
venting system should be made. Where used, the water circulating pump
should be oiled.
4. FIRING WITHOUT WATER
5. SOOTING
NEVER OPERATE THE HEATER WITHOUT FIRST BEING CERTAIN
IT IS FILLED WITH WATER AND A TEMPERATURE AND PRESSURE
RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE OPENING OF
THE HEATER.
MAINTENANCE SCHEDULE
Following are the instructions for performing some of the recommended
maintenance. Unit inspection and adjustment should be performed by a
competent technician.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF,
TURN OFF THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE.
GENERAL INFORMATION
POWER BURNER
COMPONENT
The initial start-up procedure of the unit is provided on page 18.
Tank
The sequence of operation of the unit is provided on page 15.
It is important to note that the controller has a reset button on the control
box, Figure 1. The reset button is a safety device and would not normally
be used.
Tank
HIGH LIMIT
The high limit (not adjustable) is factory set to cutout at 202°F (94°C). The
controller must be manually reset by depressing the reset button on front of
the control when water temperature drops to below 160°F (71°C).
Natural Gas
AHCG3/HCG360T
120 thru AHCG3/
HCG3100T150
Propane Gas
AHCG3/HCG360T
120 thru AHCG3/
HCG3100T150
Natural Gas
AHCG3/HCG3100T
199 thru AHCG3/
HCG3100T250
Propane Gas
AHCG3/HCG3100T
199 thru AHCG3/
HCG3100T250
Maximum Gas
Supply Pressure
10.5" WC
(2.59kpa)
14.0" WC
(3.45kpa)
10.5" WC
(2.59kpa)
14.0" WC
(3.45kpa)
Nominal Gas
Supply Pressure
7.0" WC
(1.74Kpa)
11.0" WC
(2.74Kpa)
7.0" WC
(1.74Kpa)
11.0" WC
(2.74Kpa)
Minimum Gas
Supply Pressure
4.8" WC
(1.18 Kpa)
8.5" WC
(2.08 Kpa)
4.8" WC
(1.18 Kpa)
8.5" WC
(2.08 Kpa)
4.0" WC
(0Kpa)
10.0" WC
(0Kpa)
0" WC
(0Kpa)
0" WC
(0Kpa)
Manifold Pressure
Blower
Lime Scale
Removal
Clean Inlet
Screen and
Blower Wheel
Vent System
Inspect
22
INTERVAL
REQUIRED
Sediment
Monthly
Flushing
Removal
Relief Valve
Inspect
TABLE 4
GAS SUPPLY
SPECIFICATIONS
OPERATION
Semi Annually
UN-LIME®
Delimer
Semi
Annually
As Required
Soft Brush
Every 3
Months
Joints should
be sealed
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING:
If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal injury or loss of life.
AHCG3/HCG360T120 MODELS ONLY.
23
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal injury or loss of life.
OPERATING INSTRUCTIONS
TURN OFF GAS TO APPLIANCE
AHCG3/HCG3100T150 MODELS ONLY.
24
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING:
If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal injury or loss of life.
OPERATING
OPERATINGINSTRUCTIONS
INSTRUCTIONS
TURNOFF
OFFGAS
GASTO
TOAPPLIANCE
APPLIANCE
TURN
AHCG3/HCG3100T199 & AHCG3/HCG3100T250 MODELS ONLY.
25
FLUSHING
1.Turn off the heater electrical disconnect switch.
2.Open the drain valve and allow water to flow until it runs clean.
3.Close the drain valve when finished flushing.
4.Turn on the heater electrical disconnect switch.
DRAINING
The heater must be drained if it is to be shut down and exposed to freezing
temperatures. Maintenance and service procedures may also require draining
the heater.
1. Turn off the heater electrical disconnect switch.
2. Close the cold water inlet valve to heater.
FIGURE 16.
3. Open a nearby hot water faucet to vent the system.
To dissolve and remove the more stubborn mineral deposits, manufacturer's
UN•LIME® Professional Delimer should be used.
4. Open the heater drain valve.
5. If the heater is being drained for an extended shutdown, it is suggested
the drain valve be left open during this period.
The manufacturer's UN•LIME® Professional Delimer is an easy to handle
patented food grade acid formulated specifically for lime scale removal
from all types of water using equipment. Available in 1 gallon (3.8L)
(part no. 4763) and 5 gallon (19L) (part no. 4813) sizes. Hydrochloric base
acids are not recommended for use on glass-lined tanks.
• Follow FILLING instructions when restoring hot water service.
SEDIMENT REMOVAL
Form No. 4800, entitled “Why, When and How”, describes tank cleaning
methods and materials. UN•LIME and the booklet may be obtained through
your company's dealer or distributor.
Waterborne impurities consist of the particles of soil and sand which settle
out and form a layer of sediment on the bottom of the tank.
For convenience, sediment removal and lime scale removal should be
performed at the same time.
The cleanout opening is shown in Figure 16. To clean heater through cleanout
opening, proceed as follow:
LIME SCALE REMOVAL
1. Turn off water inlet valve, the heater electrical disconnect switch and open
drain valve.
The amount of calcium carbonate (lime) released from water is in
direct proportion to water temperature and usage. The higher the water
temperature or water usage, the more lime deposits are dropped out of
the water. This is the lime scale which forms in pipes, heaters and on
cooking utensils.
2. Remove outer cover plate from lower side of heater jacket.
3. Remove cover from cleanout opening.
Lime accumulation not only reduces the life of the equipment but also reduces
efficiency of the heater and increases fuel consumption.
4. Remove lime, scale or sediment using care not to damage the
glass-lining.
The usage of water softening equipment greatly reduces the hardness of the
water. However, this equipment does not always remove all of the hardness
(lime). For this reason it is recommended that a regular schedule for deliming
be maintained.
5. Inspect cleanout plate gasket: If new gasket is required, call toll-free
number on jacket for replacement number.
The depth of lime buildup should be measured periodically. Heaters will
have about 3" (7.6cm) of lime buildup when the level of lime has reached
the bottom of the cleanout opening or about 1" (2.5cm) of lime buildup if
it has reached the drain valve opening. A schedule for deliming should be
set up, based on the amount of time it would take for a 1" (2.5cm) buildup
of lime.
6. Install cleanout plate. Be sure to draw plate up tight by tightening screws
securely.
7. Close drain valve, open water inlet line and turn on the power burner
electrical disconnect switch.
Example 1:
Initial inspection shows 1/2" (1.3cm) of lime accumulation. Therefore, the
heater can be delimed once a year.
8. Check for water leakage.
9. Replace outer jacket cover plate.
Example 2 :
Initial inspection shows 2" (5cm) of lime accumulation. Therefore, the
heater should be delimed every 3 months.
POWERED ANODE SYSTEM
Sediment and lime scale removal may be accomplished through the cleanout
opening furnished on the heater, see Figure 25. The heater must be drained,
see DRAINING, before removing cleanout cover on tank.
The AHCG3/HCG360T120 thru AHCG3/HCG3100T250 heaters are factory
equipped with a powered anode system. The anodes are of a permanent
design and do not need replacing unless damaged.
26
DRAIN VALVE AND ACCESS PANELS
The heaters are equipped with a 3/4" drain valve.
to build until the relief valve actuation pressure is equaled. Then, the
relief valve will open, allowing some water to escape, slightly lowering
the pressure.
An access panel covers the cleanout opening in the tank which is sealed by
a gasket and cover, figure 25.
Contact your water supplier or local plumbing inspector on how to control
this situation.
RELIEF VALVE
Two common corrections are listed in the Checklist and Service Information
which appears later in this manual.
At least twice a year, the temperature and pressure relief valve should be
checked to ensure that it is in operating condition. To check the relief valve,
lift the lever at the end of the valve several times. The valve should seat
properly and operate freely.
ABOVE ALL, DO NOT PLUG THE TEMPERATURE AND PRESSURE
RELIEF VALVE. THIS IS NOT A SOLUTION AND CAN CREATE A
HAZARDOUS SITUATION.
If water does not flow, remove and inspect for obstructions or corrosion.
Replace with a new valve of the recommended size as necessary. Inspection
of the valve should be performed at least every three years. Do not attempt
to repair the valve, as this could result in improper operation and a tank
explosion. In areas with poor water conditions, it may be necessary to inspect
the T&P valve more often than every three years.
CIRCULATING PUMP
The water heating system may include a circulating pump. Where used, it
should be lubricated as directed by the circulator manufacturer.
VENT SYSTEM
CAUTION
Examine the vent system every 3 months. Points of inspection are
as follows:
BEFORE MANUALLY OPERATING THE VALVE, MAKE SURE THAT A
DRAIN LINE HAS BEEN ATTACHED TO THE VALVE TO DIRECT THE
DISCHARGE TO AN OPEN DRAIN. FAILURE TO TAKE THIS PRECAUTION
COULD MEAN CONTACT WITH EXTREMELY HOT WATER PASSING OUT
THE VALVE DURING THIS CHECKING OPERATION.
1. Check for obstructions and/or deterioration of vent piping and vent hood.
Replace immediately where needed.
If the temperature and pressure relief valve on the heater discharges
periodically or continuously, it may be due to thermal expansion of water in
a closed water supply system, or, it may be due to a faulty relief valve.
2. Vent pipe and vent hood screen should be cleaned of foreign material and
soot. The screen is located inside the vent hood outlet and is accessible
from the outside of the hood. Do not reach inside the vent hood when
the heater is in operation.
Thermal expansion is the normal response of water when it is heated.
In a closed system, thermal expansion will cause the system pressure
3. Check all vent system connections for leakage and reseal as required
using Hi Temp Silicone sealer or equivalent.
27
INSTALLATION DIAGRAMS
ONE TEMPERATURE - ONE HEATER VERTICAL STORAGE TANK FORCED CIRCULATION
WITH OR WITHOUT BUILDING RECIRCULATION
CAUTION: IF BUILDING COLD
WATER SUPPLY HAS A BACKFLOW PREVENTER, CHECK
VALVE OR WATER METER WITH
CHECK VALVE PROVISIONS
FOR THERMAL EXPANSION
OF WATER IN THE HOT WATER
SYSTEM MUST BE PROVIDED
NOTE: CONNECT RETURN
L I N E F R O M H O T WAT E R
CIRCULATING LOOP (IF USED)
TO COLD WATER INLET LINE.
CAUTION: If the plumbing
requires the use of pipes
with dissimilar material (for
example, steel and copper),
use dielectric unions to
prevent an electro-galvanic
action between the piping
components with dissimilar
materials.
* PIPE TO OPEN DRAIN
INSTALL IN ACCORDANCE
WITH LOCAL CODES
ONE TEMPERATURE - ONE HEATER HORIZONTAL STORAGE TANK
FORCED CIRCULATION WITH OR WITHOUT BUILDING RECIRCULATION
DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED
SAFE TEMPERATURE AT FIXTURES. SEE WATER
TEMPERATURE CONTROL WARNING ON PAGE
4. IF HIGHER PREHEAT TEMPERATURES ARE
NECESSARY TO OBTAIN ADEQUATE BOOSTER
OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT
WATER SUPPLIED TO FIXTURES.
*PIPE TO OPEN DRAIN
INSTALL IN ACCORDANCE
WITH LOCAL CODES
CAUTION: If the plumbing
requires the use of pipes
with dissimilar material (for
example, steel and copper),
use dielectric unions to
prevent an electro galvanic action between
the piping components with
dissimilar materials.
28
TWO TEMPERATURE - ONE HEATER HIGH TEMPERATURE
WITH OR WITHOUT BUILDING RECIRCULATION
DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED
SAFE TEMPERATURE AT FIXTURES. SEE WATER
TEMPERATURE CONTROL WARNING ON PAGE 4. IF
HIGHER PREHEAT TEMPERATURES ARE NECESSARY
TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN
ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO
FIXTURES.
CAUTION: IF BUILDING COLD WATER SUPPLY HAS A
BACK-FLOW PREVENTER, CHECK VALVE OR WATER
METER WITH CHECK VALVE PROVISIONS FOR
THERMAL EXPANSION OF WATER IN THE HOT WATER
SYSTEM MUST BE PROVIDED.
*PIPE RELIEF VALVE TO OPEN DRAIN.
NOTE:
I F T E M P E R E D W AT E R I S
RECIRCULATED, RETURN LINE SHOULD
BE CONNECTED AT POINT “A”.
INSTALL IN ACCORDANCE WITH LOCAL
CODES.
CAUTION: If the plumbing
requires the use of pipes
with dissimilar material (for
example, steel and copper),
use dielectric unions to
prevent an electro-galvanic
action between the piping
components with dissimilar
materials.
29
TWO TEMPERATURE - TWO HEATERS HIGH TEMPERATURE
WITH OR WITHOUT BUILDING RECIRCULATION
CAUTION: If the plumbing
requires the use of pipes
with dissimilar material (for
example, steel and copper),
use dielectric unions to
prevent an electro-galvanic
action between the piping
components with dissimilar
materials.
TWO TEMPERATURE - THREE HEATERS (TWO PRE-HEATERS/ONE BOOSTER HEATER)
WITH OR WITHOUT BUILDING RECIRCULATION
CAUTION: If the plumbing
requires the use of pipes
with dissimilar material (for
example, steel and copper),
use dielectric unions to
prevent an electro-galvanic
action between the piping
components with dissimilar
materials.
MUST BE IDENTICAL HEATERS
FOR MULTIPLE HEATER INSTALLATION SEE MANIFOLD KIT
SPECIFICATIONS, PAGE 33.
DANGER
CAUTION: IF BUILDING COLD WATER SUPPLY HAS A BACK-FLOW
PREVENTER, CHECK VALVE OR WATER METER WITH CHECK VALVE
PROVISIONS FOR THERMAL EXPANSION OF WATER IN THE HOT
WATER SYSTEM MUST BE PROVIDED.
30
TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE
AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON
PAGE 4. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO
OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE
FOR HOT WATER SUPPLIED TO FIXTURES.
TWO TEMPERATURE - TWO HEATERS (ONE PRE-HEATER/ONE BOOSTER HEATER)
WITH OR WITHOUT BUILDING RECIRCULATION
* PIPE RELIEF VALVE TO OPEN DRAIN
DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE
AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON
PAGE 4. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO
OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE
FOR HOT WATER SUPPLIED TO FIXTURES.
**140°F (60°C) TO 150°F (66°C) SHOULD BE MAXIMUM WATER
TEMPERATURE MAINTAINED IN THE PRE-HEATERS.
120°F (49°C) SHOULD BE THE MINIMUM TEMPERATURE OF WATER
IN THE PRE- HEATERS.
CONNECT CIRCULATING LINE FROM FIXTURES, IF USED, TO
COLD WATER SUPPLY LINE OF PRE-HEATER.
CONNECT CIRCULATING LINE OF 180°F (82°C) OR BOOSTED WATER,
IF USED, TO INLET WATER LINE TO BOOSTER.
INSTALL IN ACCORDANCE WITH LOCAL CODES.
CAUTION: If the plumbing requires
the use of pipes with dissimilar
material (for example, steel and
copper), use dielectric unions to
prevent an electro-galvanic action
between the piping components
with dissimilar materials.
31
TWO TEMPERATURE - ONE HEATER HIGH TEMPERATURE
WITH RECIRCULATION OF SANITIZING LOOP
CAUTION: If the plumbing requires
the use of pipes with dissimilar
material (for example, steel and
copper), use dielectric unions to
prevent an electro-galvanic action
between the piping components
with dissimilar materials.
NOTE 1: TOGGLE SWITCH CONTROLS 180°F (82°C) WATER
CIRCULATION. INSTALL ON OR CLOSE TO DISHWASHER. TOGGLE
SWITCH MUST BE CLOSED (ON) DURING THE RINSE OPERATION AND
OPEN (OFF) WHEN DISHWASHER IS NOT OPERATING OR WHEN ON
LONG STANDBY.
DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE
AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON
PAGE 5. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO
OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE
FOR HOT WATER SUPPLIED TO FIXTURES.
NOTE 2: INSTALL LINE TEMPERATURE CONTROL IN AN UNINSULATED
TEE BEYOND THE DISHWASHER TAKEOFF IN THE SANITIZING LOOP.
CONTROL SHOULD BE SET AT 185°F (85°C).
CAUTION: IF BUILDING COLD WATER SUPPLY HAS A BACK-FLOW
PREVENTER, CHECK VALVE OR WATER METER WITH CHECK VALVE
PROVISIONS FOR THERMAL EXPANSION OF WATER IN THE HOT
WATER SYSTEM MUST BE PROVIDED.
NOTE 3: ADJUST PLUG COCK SO THE SANITIZING LOOP FLOW RATE
DOES NOT CAUSE UNNECESSARY TURBULENCE IN THE TANK.
*PIPE RELIEF VALVE TO OPEN DRAIN
NOTE 4: IF TEMPERED WATER IS RECIRCULATED, RETURN LINE
SHOULD BE CONNECTED AT POINT A.
INSTALL IN ACCORDANCE WITH LOCAL CODES
32
MANIFOLD KITS
Precision cut type “L” all copper manifold kits assure water flow balance of all units. Without this balance, the full water heating and storage
potential of the system cannot be achieved. Plus, the units with the higher water flow may have a shortened life.
Dimensions shown are for minimum space occupied by the water heaters assemblies.
Space for the venting system and unit servicing must be added.
CAUTION: If the plumbing requires
the use of pipes with dissimilar
material (for example, steel and
copper), use dielectric unions to
prevent an electro-galvanic action
between the piping components
with dissimilar materials.
33
CHECKLIST AND SERVICE INFORMATION
2.Some of the electrical components of the water heater make sounds
which are normal.
IMPORTANT
The installer may be able to observe and correct certain problems which
might arise when the unit is put into operation or when it is re-fired
after a prolonged shutdown. HOWEVER, it is recommended that only
qualified servicemen, using appropriate test equipment, be allowed to
service the heater.
WATER LEAKAGE IS SUSPECTED
1.Check to see if the water heater drain valve is tightly closed. Also check the cleanout opening for leakage.
BE SURE TO TURN OFF THE ELECTRICITY WHENEVER POSSIBLE OR
APPROPRIATE WHILE CHECKING EQUIPMENT.
2.The apparent leakage may be condensation which forms on cool surfaces of the heater and piping.
WARNING
3.If the outlet of the relief valve is leaking it may represent:
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN
SERIOUS PERSONAL INJURY OR DEATH.
CAUTION: LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN
SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER
AND DANGEROUS OPERATION.
BURNER OPERATIONAL PROBLEMS
1. Refer to TROUBLESHOOTING.
When such a condition is encountered, local codes or inspection agency
should be consulted to determine which system is acceptable in your area.
See CLOSED SYSTEM section in this manual also.
NOT ENOUGH OR NO HOT WATER
1. Be certain the electrical disconnect switch serving the water heater is in the ON position.
TROUBLE-SHOOTING
2. Check the fuses.
1. Verify that the allowable vent length has not been exceeded and that the
blower inlet screen has been removed if direct venting.
• The electrical disconnect switch usually contains fuses.
2. Verify that the condensation, which WILL be present in the heater and
exhaust vent, will drain.
3. The capacity of the heater may have been exceeded by a large demand
for hot water.
•
3. Check supply wire polarity - hot to hot and neutral to neutral and no
"stray" current in neutral.
Large demands require a recovery period to restore water
temperature.
4. Heater is properly grounded.
4. Colder incoming water temperature will lengthen the time required to
heat water to the desired temperature.
Checking these four (4) items first will often result in a timely solution to the
service call.
• If the heater was installed when incoming water temperature was warm, colder water creates the effect of less hot water.
WARNING
JUMPING OUT COMPONENTS AND/OR CIRCUITS DURING
TROUBLESHOOTING CAN CAUSE SERIOUS PROBLEMS WITH THE
UNIT’S OPERATING SEQUENCE AND IGNITION SAFETY. IF YOU DO
NOT HAVE THE PROPER TEST EQUIPMENT, I.E. A VOLT-OHM METER
AND A MICROAMMETER, DO NOT ATTEMPT TO TROUBLESHOOT OR
REPAIR EQUIPMENT.
5. Look for hot water wastage and leaking or open hot water faucets.
6. Sediment or lime scale may be affecting water heater operation. Refer
to MAINTENANCE for details.
7. Burner may not be firing at proper rate.
• Check gas pressure. Adjust to obtain required manifold pressure.
ALTERING THE CONTROLLER AND/OR CONTROLLER WIRING IN
ANY WAY COULD RESULT IN INTERNAL DAMAGE TO THE MODULE
CIRCUITS, POSSIBLY ALTERING THE IGNITION SEQUENCE ALLOWING
GAS VALVES TO OPEN BEFORE THE HOT SURFACE IGNITER IS UP TO
IGNITION TEMPERATURE.
8. Burner fan wheel may be dirty.
• Clean fan wheel with a stiff brush.
9. Condensate hose may be blocked where it connects to the exhaust
elbow.
NOTE: ANY BYPASS OR ALTERATION OF THE UNITS SAFETIES WILL
RESULT IN VOIDING THE APPLIANCE WARRANTY.
• Verify the condensate drains from the unit without restriction.
Before performing any troubleshooting familiarize yourself with the particular
appliance.
WATER IS TOO HOT
Refer to the SEQUENCE OF OPERATION and the connection diagram
located on page 15 before continuing.
1. Refer to WATER TEMPERATURE CONTROL.
Make sure the appliance is connected to a 120V AC power supply, manual
gas valve is in the ON position, and all electrical connections are secure
before continuing to troubleshoot this appliance.
WATER HEATER MAKES SOUNDS
1. Sediment or lime scale accumulations cause rumbling and pounding
noises when the heater is operating.
• Excessive water pressure.
• Excessive water temperature.
• Faulty relief valve.
Excessive water pressure is the most common cause of relief valve leakage.
It is often caused by a “closed system”. If a check valve is in the inlet system
it will not permit the expanded hot water volume to equalize pressure with
the main. The relief valve must release this water or the water heater or
plumbing system will be damaged. Refer to MAINTENANCE-RELIEF VALVE
section in this manual.
VERIFY PROPER OPERATION AFTER SERVICING.
• Contacts click or snap as the heater starts and stops.
• Transformers often hum.
CAUTION
THE WATER HEATER IS POLARITY SENSITIVE. BEFORE APPLYING
ELECTRICITY TO THIS HEATER BE CERTAIN THAT SUPPLY HEATED
WIRE TO GROUND CHECK INDICATES ZERO VOLTAGE.
• The sounds are normal, however, the tank bottom should be cleaned.
Refer to MAINTENANCE for details.
34
MOTOR WILL NOT RUN
MOTOR RUNS, BURNER LIGHTS MOMENTARILY,
THEN LOCKS OUT
1. Confirm 120V AC to the controller. Also, to verify correct polarity, check
for 120 V AC between hot supply and ground.
1. Reset the appliance two more times to ensure that all of the air has been
purged from the gas line.
If there is no voltage, check for a loose connection where it connects to
the controller.
2. If the burner lights momentarily but does not sustain ignition, verify that
the inlet pressure is not greater than 10.5" WC (2.59 kPa) for natural
gas and 14.0" WC (3.45 kPa) for propane gas or lower than the minimal
supply pressure which is 4.0" WC (.09kPa) for natural gas and 11.0"WC
(2.74 kPa) for propane gas. Also, verify that the manifold pressure is
correct, that is, 4.0"WC (.98kPa) for natural gas and 10.0"WC (2.46kPa)
for propane gas for the AHCG3/HCG360T120 & AHCG3/HCG3100T150
models and 0"WC (0kPa) for both natural and propane gas AHCG3/
HCG3100T199 & AHCG3/HCG3100T250 models. If the manifold
pressure is not correct then adjust accordingly. See "ADJUSTMENT
PROCEDURE" in "OPERATING INSTRUCTIONS" sections for manifold
pressure adjustment procedure.
2. If there is 120 volts to the controller, check for loose connections or a
locked rotor. If the rotor cannot be freed the motor and blower assembly
must be replaced.
MOTOR RUNS, PREPURGE TIME ELAPSES BUT MAIN
FLAME NOT ESTABLISHED.
1. Check to see if main manual gas valve is open.
2. Check for a loose connection at the transformer, or a defective
transformer.
3. Check for the reversed polarity in the supply wiring. This controller is
polarity sensitive. If the hot and neutral supply wires are reversed, the
controller will not sense flame. Reverse the supply wires and try to fire
the unit.
3. Check for a loose connection at the gas valve.
4. Check for open pressure switches or open reset button. Check for
blockage in the intake and exhaust venting or at the vent hoods. If no
blockage is found, check vinyl tubing for cuts or crimps. If this tubing is
damaged it must be replaced. If these steps do not eliminate the problem,
replace the pressure switches.
NOTE: Always turn off and disconnect main supply wiring before servicing
the unit.
4. Check connecting wire to the flame sensor. Verify that the flame sensor
has not been damaged in any way.
5. Check to see if there is resistance across the igniter terminal with an
OHM meter. If there is no continuity, the igniter is broken and should be
replaced.
5. Verify that the air supply is adequate. The air inlet screen or blower wheel
may be restricted. Also, check the installation for proper ventilation. See
AIR REQUIREMENTS.
If the igniter appears to function properly, then verify that the inlet
pressure is within the range shown in Table 4. The gas valve supplied on
the appliance is not designed to open against a higher inlet pressure of
10.5"WC (2.59kPa) for natural gas and 14.0"WC (3.45kPa) for propane
gas. At this time, also check to make sure the inlet pressure is not lower
than 4.0"WC (.98kPa) for natural gas and 11.0"WC (2.74kPa) for propane
gas. If the inlet pressure is not within these limits then adjust the supply
pressure accordingly.
6. Check the venting system for the correct sizing, excess or insufficient.
See VENTING.
7. Check for maximum inlet pressure of 10.5"WC (2.59 kPa) for natural gas
and 14.0"WC (3.45 kPa) for propane gas and the manifold pressure which
is 4.0"WC (.98 kPa) for natural gas and 10.0"WC (2.46 kPa) for propane
gas for the AHCG3/HCG360T120 & AHCG3/HCG3100T150 models and
0"WC (o kPa) for both natural and propane gas AHCG3/HCG3100T199 &
AHCG3/HCG3100T250 models. Please note that the manifold pressure
listed is the maximum value for the manifold pressure. Do not set the
manifold pressure higher than the value show in Table 4. OVER FIRING
the heater will result in a rough ignition and/or noisy operation.
If the inlet pressure falls within the allowable limits, then verify that the
manifold pressure, when the gas is fully open, with the heater running, is as
called out in Table 4: that is, 4.0"WC (.98kPa) for natural gas and 10.0"WC
(2.46kPa) for propane gas for the 120 and 150 models and 0"WC (0kPa)
for both natural and propane gas 199 and 250 models. If the manifold
pressure is not correct then adjust accordingly. See "ADJUSTMENT
PROCEDURE" in "OPERATING INSTRUCTIONS" sections for manifold
pressure adjustment procedure.
8. Confirm that the air inlet screen (see Figures 7 & 8) is free of
obstructions.
CAUTION
6. If the inlet and manifold pressures are within the limits specified in step 5,
then reset the appliance. Verify 24V AC at the gas valve during the three
(3) second ignition trial, after the igniter reaches operating temperature.
If 24V AC at the gas valve is not seen during this period, the controller
must be replaced.
Do not reach into the burner housing or combustion chamber if the heater is
still hot. Allow the heater to cool and always use gloves as the combustion
chamber and the burner sleeve and housing can become very hot after
operation. OVER FIRING is a dangerous condition that must be corrected
immediately.
GAS FAILS TO SHUT OFF
If there is 24V AC at the gas valve during the four second ignition trial
and the manifold pressure does not increase above 0" W.C. then verify
that the manual gas control valve is in the “ON” position (see page 20).
If the valve is in the “ON” position and the previous voltage and gas
pressure conditions are met, then the gas valve is defective and must
be replaced.
Check for defective gas valve or thermostat. If operation is incorrect, replace.
REPLACEMENT PARTS
Replacement parts may be ordered through dealers, authorized servicers
or distributors. Refer to the Yellow Pages for where to call or contact the
manufacturer. When ordering parts be sure to state the quantity, part number
and description of the items including the complete model and serial number
as it appears on the product. Refer to the parts list for more information.
Note that a positive manifold pressure reading of approximately
1.5" (.38 kPa) W.C. is normal during the prepurge portion of the ignition
cycle due to the location of the gas orifice.
35
Commercial Limited Warranty
American Water Heater Company, the warrantor, extends the following LIMITED WARRANTY to the owner of this water heater.
1.
THE TANK
If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable water
therein, during the first THREE years after initial installation, the warrantor will supply a complete new American water heater of equivalent size and
current model. Some government agencies are requiring energy efficient standards for water heaters. In the event regulations prohibit sale of a model
of equivalent size and construction, American Water Heater Company will provide a model which complies with the regulations of your area, in which
case the consumer will be charged the difference in price between the like replacement and the energy efficient model required. The warranty on the
replacement water heater will be limited to the unexpired term of the original warranty.
2. ALL OTHER PARTS
If within ONE year after initial installation of this water heater, any part or portion shall prove upon examination by the warrantor to be defective in
material or workmanship, the warrantor will repair or replace such part or portion at its option.
3. CONDITIONS AND EXCEPTIONS
This warranty shall apply only when the water heater is installed in accordance with local plumbing and building codes, ordinances and regulations,
the printed instructions provided with it and good industry practices. In addition, a temperature and pressure relief valve, certified by A.G.A./CGA and
approved by the American Society of Mechanical Engineers, must have been installed.
a. This warranty shall apply only when the heater is:
(1) used at temperatures not exceeding the maximum calibrated setting of its thermostat;
(2) used at water pressure not exceeding the working pressure shown on the heater;
(3) filled with potable water, free to circulate at all times and with the tank free of damaging water sediment or scale deposits;
(4) used in a non-corrosive and non-contaminated atmosphere;
(5) used with factory approved anode(s) installed;
(6) in its original installation location;
(7) in the United States, its territories or possessions, and Canada;
(8) sized in accordance with proper sizing techniques for commercial and/or residential water heaters;
(9) bearing a rating plate which has not been altered, defaced or removed, except as required by the warrantor;
(10) used in an open system or in a closed system with properly sized and installed thermal expansion tank;
(11) operated with properly installed dirt leg;
(12) fired with the fuel for which it was factory built;
(13) fired at the factory rated input;
(14) operated with the inner and outer combustion chamber doors in place.
b. Any accident to the water heater, any misuse, abuse (including freezing) or alteration of it, any operation of it in a modified form, any use of insulation blankets, or any attempt to repair tank leaks will void this warranty.
c. This warranty is void if a device acting as a backflow prevention device (check valves etc.) is installed in the cold water supply the heater is connected to, unless an effective method of controlling thermal expansion is also installed at the heater(s) and operational at all times. The relief
valve installed on the heater is not an acceptable method.
4. SERVICE AND REPAIR EXPENSES
Under the limited warranty the warrantor will provide only a replacement water heater or part thereof. The owner is responsible for all other costs.
Such costs may include but are not limited to:
a. Labor charges for service removal, repair or reinstallation of the water heater or any component part;
b. Shipping, delivery, handling, and administrative charges for forwarding the new heater or replacement part from the nearest distributor and returning the claimed defective heater or part to such distributor.
c. All cost necessary or incidental for any material and/or permits required for installation of the replacement heater or part.
5. LIMITATIONS ON IMPLIED WARRANTIES
Implied warranties, including the warranty of merchantability imposed on the sale of this heater under state or provincial law are limited to one (1)
year duration for the heater or any of its parts. Some states and provinces do not allow limitation on how long an implied warranty lasts, so the above
limitation may not apply to you.
6. CLAIM PROCEDURE
Any claim under the warranty should be initiated with the dealer who sold the heater, or with any other dealer handling the warrantor’s products. If
this is not practicable, the owner should contact:
U.S. Customers
American Water Heater Company
PO Box 1597, 500 Princeton Road
Johnson City, TN 37605
a.
b.
The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by the warrantor.
Dealer replacements are made subject to in-warranty validation by warrantor.
7. DISCLAIMERS
NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE MERCHANTABILITY
OF THE HEATER OR THE INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF THE HEATER. THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPERTY OR OTHER
CONSEQUENTIAL DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY
PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR IN TORT.
a. Some states or provinces do not allow the exclusion or limitation of the incidental or consequential damage, so the above limitations or exclusions
may not apply to you.
b. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or province to province.
Fill in the following for your own reference. Keep it. Registration is not a condition of warranty. The model and serial number are found on the heater’s rating plate.
Model No._ _________________________________ Serial No._________________________________ Date Installed___________________________
Dealer’s Name______________________________________________________________________________________________________________
Dealer’s Address___________________________________________________________________ Phone No.________________________________
City and State/Province_______________________________________________________________Zip/PostalCode____________________________
KEEP THIS WARRANTY POSTED ADJACENT TO THE HEATER FOR FUTURE REFERENCE
36
NOTES:
37
NOTES:
38
NOTES:
39
PO Box 1597, 500 Princeton Road
Johnson City, TN 37605
Phone: 1-800-456-9805
www.americanwaterheater.com
40
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