State Industries 705 Series 200 Water Heater Operation and Installation Manual

ANS Z21.10.3

●

CSA 4.3

Direct Vent Tankless Water Heater

Operation and Installation Manual

Models:

305

505

705

FOR INDOOR APPLICATIONS ONLY

Models 305 and 505 are Energy Star Qualified

Table of Contents .................... 2

Consumer Safety Information .. 4

Operating Instructions .............. 5

Maintenance ............................ 8

Error Codes ............................. 9

Installation Instructions ............ 13

Warranty .................................. 38

INSTALLER: Leave this manual with the appliance.

CONSUMER: Retain this manual for future reference.

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.

Table of Contents

Specifications ..................................................... 3

Consumer Safety Information

Safety Definitions ............................................. 4

Safety Behaviors and Practices ....................... 4

Safety Features ............................................... 4

Description of Operation ................................... 5

Operating Instructions

Features Available on Temperature

Controllers ....................................................... 5

Setting the Temperature .................................. 6

Temperature Options Without

a Temperature Controller ................................ 6

Temperature Ranges ....................................... 7

Setting Controller to Mute ................................ 7

Maintenance

Cleaning ...................................................... 8

Vent System ................................................ 8

Motors ......................................................... 8

Temperature Controller ............................... 8

Lime / Scale Build-up .................................. 8

Snow Accumulation..................................... 8

Visual Inspection of Flame .......................... 8

Error Codes

Error Code Table ....................................... 9, 10

Trouble Shooting for Common Issues ........... 11

Accessing Operating Information .................. 11

Water Quality ................................................. 11

Flushing the Heat Exchanger ........................ 12

(Error Code: LC or 00)

Installation Instructions ................................... 13

General Instructions ...................................... 13

Clearances from Appliance ........................... 14

Attachment of the Water Heater .................... 14

Electrical Connection ..................................... 15

Gas Piping

General Instructions ................................ 15

Pipe Sizing Procedure - Example ........... 16

Water Piping

General Instructions ................................ 17

Pressure Relief Valve .............................. 17

Freeze Protection .................................... 17

Freeze Protection Piping ............................... 18

Recommended Piping for Basic Installation .. 19

Recommended Piping for

Circulation Systems ....................................... 20

Optional Piping for Circulation Systems ........ 21

Venting Instructions

Intake / Exhaust Guidelines .................... 22

Condensate ............................................. 22

Maximum Vent Length ............................ 23

Venting Products ........................................... 24

Flue Terminal Clearances

(ANS Z21.10.3 ● CSA 4.3

) ............................ 25

Additional Clearances - Vent Terminal .......... 26

Flue Installation for 305 and 505 Models ...... 27

Flue Installation for 705 Model ................ 28, 29

High Altitude Installation ................................ 30

Connecting Multiple Water Heaters ............... 30

Temperature Controller Installation

Location ................................................... 31

Configurations ......................................... 31

Cable Lengths and Size .......................... 31

Mounting the Controller ........................... 32

Operating Instructions ................................... 33

Technical Data

Pressure Drop Curve ..................................... 34

Outlet Flow Data ............................................ 34

Space Heating ............................................... 35

Dimensions .................................................... 36

Ladder Diagram ............................................. 37

Warranty ...................................................... 38, 39

2 305, 505, 705 Indoor Manual

Model

Minimum Gas Consumption Btu/h

Maximum Gas Consumption Btu/h

Hot water capacity (Min - Max) *

Hot water capacity (45°F rise)

Default Temperature Setting (no controller)

Temperature Controller Default Setting

Maximum Temp Setting (Commercial) **

Maximum Temp Setting (Residential)

Minimum Temperature Setting

Weight

Efficiency Rating

Noise level

Normal

Electrical Consumption Standby

Anti-frost Protection

By-Pass Control

Minimum Gas Supply

Pressure

Maximum Gas Supply

Pressure

Natural Gas

Propane

Natural Gas

Propane

Type of Appliance

Operation

Approved Gas Type

Connections

Ignition System

Electric Connections

Water Temperature Control

Water Supply Pressure

Maximum Water Supply Pressure

Temperature Control Cable

Energy Star Qualified

Specifications

305

180,000

0.6 - 7.5 GPM

(2.3 - 28.4 L/min)

6.6 GPM (25.0 L/min)

505

15,000

199,000 Natural Gas

190,000 Propane Gas

0.6 - 9.4 GPM

(2.3 - 35.5 L/min)

7.4 GPM (28.0 L/min)

Natural Gas

7.1 GPM (26.9 L/min)

Propane Gas

705

19,000

237,000

0.6 - 9.8 GPM

(2.3 - 37 L/min)

8.8 GPM (33.5 L/min)

120º F (49º C)

104º F (40º C)

160º F (71º C) 185º F (85º C)

Selectable at 120º F (49º C) or at 140º F (60º C) 140º F (60º C)

98º F (37º C)

50 lb (23 kg) 55 lb (25 kg)

65 W

84%

49 dB

79 W

2 W

99 W

100 W 116 W

Fixed Electronic

5.0 inch W.C.

8.0 inch W.C.

10.5 inch W.C.

13.5 inch W.C.

Direct Vent, Temperature controlled continuous flow gas hot water system.

With or without temperature controls, mounted in kitchen, bathroom, etc.

Natural Gas or Propane - Ensure unit matches gas type it's being installed on.

Gas Supply: 3/4" MNPT, Cold Water Inlet: 3/4" MNPT, Hot Water Outlet: 3/4" MNPT

Direct Electronic Ignition

Appliance: AC 120 Volts, 60Hz. Temperature Control: DC 12 Volts (Digital)

Simulation Feedforward and Feedback.

Minimum Water Pressure: 20 PSI (Recommended 30-80 PSI for maximum performance)

150 PSI

Yes

Non-Polarized Two Core Cable (Minimum 22 AWG)

Yes No

* Minimum flow may vary slightly depending on the temperature setting and the inlet water temperature.

** for commercial and hydronic applications requiring higher temperatures

Specifications are subject to change without prior notice.

The maximum inlet gas pressure must not exceed the value specified by the manufacturer. The minimum value listed is for the purpose of input adjustment.

305, 505, 705 Indoor Manual 3

Consumer Safety Information

Safety Definitions

This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others.

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

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

CAUTION Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices.

Safety Behavior and Practices

WARNING

• Keep the area around the appliance clear and free from combustible materials, gasoline, and other flammable vapors and liquids.

• 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.

• This appliance is equipped with a three-prong plug for your protection against shock hazard and should be plugged directly into a properly grounded threeprong receptacle. Do not cut or remove the ground prong from this plug.

• Any alteration to the appliance or its controls can be dangerous and will void the warranty.

• Always check the water temperature before entering a shower or bath.

Safety Features

• Overheat: The appliance will automatically shut down when the appliance exceeds a predetermined temperature.

• Power Surge Fuse: A glass fuse protects against overcurrent. If the fuse blows then all indicator lamps will be off.

• Flame Failure: The appliance will automatically shut down if the burner flame is extinguished.

• Power Failure: The appliance will cut off the gas if it loses electrical power.

• Fusible Link: In case the overheat feature does not prevent the temperature from rising then the fusible link will break shutting off the appliance.


Description of Operation

This appliance is one of the most advanced water heaters available. It provides a continuous supply of hot water at a preset temperature. This appliance is direct vent where air is brought in from the outside and combustion gases are exhausted to the outside.

While electricity, water, and gas supplies are connected, this appliance produces hot water whenever a hot water tap is open.

Ignition is electronic. There is no pilot light consuming gas while the water heater is not being used. The gas burner lights automatically when the hot water tap is opened and goes out when the tap is closed.

Installation of the temperature controller is highly recommended. The temperature controller can set the temperature within a specific range and can provide error codes to diagnose any problems.

The temperature of the outgoing hot water is constantly monitored. This appliance may adjust the water flow in order to maintain the temperature setting. The water flow may vary from summer to winter due to the difference in ground water temperature.

Operating Instructions

Features Available on Temperature Controllers

The temperature controller is supplied with the appliance. Dimensions (inches): 3.5 W x 4.75 H x 0.75 D

In Use

Indicator

Priority

Indicator

Temperature

Display

Priority

Button

Temperature

Selection

On/Off

Button

Features

Error Codes

Description

When a fault is detected an error code flashes at the temperature

In Use Indicator Indicates that hot water is being supplied (i.e. a hot water tap is open).

Used to turn the water heater On or Off. On/Off Button

Priority Button /

Indicator

Indicates that this controller is setting the temperature . Priority can be switched to another controller by pressing its Priority

Button when no hot water is running.

Temperature Display Shows the temperature setting.

Thermostat Increases or decreases the temperature setting.


Setting the Temperature

DANGER Hot water can be dangerous, especially for infants or children, the elderly, or infirm. There is hot water scald potential if the thermostat is set too high.

Water temperatures over 125º F (51º C) can cause severe burns or scalding resulting in death.

Hot water can cause first degree burns with exposure for as little as:

3 seconds at 140º F (60º C)

20 seconds at 130º F (54º C)

8 minutes at 120º F (48º C)

Test the temperature of the water before placing a child in the bath or shower.

Do not leave a child or an infirm person in the bath unsupervised.

1. Press the “Priority button” on the temperature controller. The green Priority light will glow indicating that this controller is controlling the temperature and that the water heater is ready to supply hot water.

NOTICE While any hot water is being provided, the temperature setting can only be adjusted between 98º F and

110º F.

The priority can only be changed while no hot water is running. obtain the desired temperature setting.

All hot water sources are able to provide water at this temperature setting until it is changed again at this or another temperature controller.

NOTICE Check local codes for the maximum water temperature setting allowed when used in nursing homes, schools, day care centers, and all other public applications.

NOTICE If a newly installed unit with a temperature controller has not been powered for at least 6 hours then the temperature will return to the default setting of 104º F (40º C) if power is interrupted.

NOTICE There may be a variation between the temperature displayed on the temperature controller and the temperature at the tap due to weather conditions or the length of pipe to the water heater.

Temperature Options Without a Temperature Controller

The default temperature setting for this appliance installed without a temperature controller is 120º F

(49º C). If desired the temperature setting can be changed to 140º F (60º C) by adjustment of a dip switch.

Set dip switch 5 to ON to obtain 140º F water temperature setting.

Set dip switch 5 to OFF (default) to obtain 120º F

WARNING DO NOT adjust the other dip switches unless specifically instructed to do so.

120º F (49º C)

Switch No.

O

F

F

ON

1

2

3

4

5

6

7

8

140º F (60º C)

Switch No.

O

F

F

ON

1

2

3

4

5

6

7

8


Temperature Ranges

This water heater will attempt to provide hot water at the temperature setting even when the water flow is varied or when more than 1 tap is in use. The water heater can deliver water at only one temperature setting at a time.

The available temperatures for a given model are provided below.

Model Temperature Settings Available (ºF)

305

505

705

98 100 102 104 106 108 110 115 120

125

*

130

*

135

*

140

*

150

**

160

**

98 100 102 104 106 108 110 115 120

125

*

130

*

135

*

140

*

150

**

98 100 102 104 106 108 110 115 120 125 130 135 140

150

**

160

**

160

**

185

**

185

**

Temp in Celsius ºC 37 38 39 40 41 42 43 46 49 52 54 57 60 66 71 85

* Re-setting the Maximum Temperature

Models 305 and 505 have a default maximum temperature of 120º F (49º C) and an option to increase the maximum temperature to 140 ºF (60 ºC). Temperature settings from 125-140 ºF (52-60 ºC) are available by setting dip switch 6 to ON in the SW1 bank of 8 dip switches.

Model 705 has a default maximum temperature of 140 ºF (60 ºC).

** Commercial Controller

These settings require the commercial controller which is for commercial and hydronic applications requiring higher temperatures. When the commercial controller is connected, these higher temperatures are available on all controller models in the system.

The commercial controller is intended for commercial and hydronic applications only. If commercial controller is used in a residential dwelling for a hydronics application, a mixing valve must also be installed to limit the potable hot water temperature to a safe temperature. Water temperatures over 125º F (51º C) can cause severe burns or scalding. Refer to the Danger Alert on water temperatures. The manufacturer shall not, in any event, be liable for damages resulting from such misuse or misapplication.

Suggested temperatures are

• Kitchen 120 ºF (49º C)

• Shower 98º - 110º F (37º - 43º C)

These temperatures are suggestions only.

A temperature lower than 98º F (37º C) can be obtained at the tap by mixing with cold water.

To change the temperature scale from Celsius to Fahrenheit or vice versa, press and hold the “On/Off” button for

5 seconds while the water heater is OFF.

Controller Mute

To eliminate the beeps when keys are pressed or to turn the beeps back on, press and hold both the ▲and ▼ buttons until a beep is heard (approximately 5 seconds).


Maintenance

WARNING

Turn off the electrical power supply, the manual gas valve and the manual water control valve whenever servicing the unit.

Repairs and maintenance should be performed by a qualified service technician. The appliance should be inspected annually by a qualified service technician.

Verify proper operation after servicing.

Cleaning

It is imperative that control compartments, burners, and circulating air passageways of the appliance be kept clean.

Clean as follows:

1. Turn off and disconnect electrical power. Allow to cool.

2. Remove and clean the water inlet filter.

3. Remove the front panel by removing 4 screws.

4. Use pressurized air to remove dust from the main burner, heat exchanger, and fan blades. Do not use a wet cloth or spray cleaners on the burner.

Do not use volatile substances such as benzene and thinners. They may ignite or fade the paint.

5. Use soft dry cloth to wipe cabinet.

Vent System

The vent system should be inspected at least annually for blockages or damage.

Motors

Motors are permanently lubricated and do not need periodic lubrication. Keep fan and motor free of dust and dirt by cleaning annually.

Temperature Controller

Use a soft damp cloth to clean the temperature controller. Do not use solvents.

Lime / Scale Build-up

If you receive Error Code “LC”, refer to the procedure,

Flushing the Heat Exchanger. Refer to the section on

Water Quality to see if your water needs to be treated or conditioned. (When checking maintenance code history, “00” is substituted for “LC”.)

Snow Accumulation

Keep the area around flue terminal free of snow and ice. The appliance will not function properly if the intake air or exhaust is impeded (blocked or partially blocked) by obstructions.

Visual Inspection of Flame

The burner must flame evenly over the entire surface when operating correctly. The flame must burn with a clear, blue, stable flame. See the parts breakdown of the burner for the location of the view ports.

The flame pattern should be as shown in the figures below.


Error Codes

This appliance has the ability to check its own operation continuously. If a fault occurs, an error code will flash on the Display of the temperature controller. This assists with diagnosing the fault and may enable you to overcome a problem without a service call. Please identify the code displayed when inquiring about service.

WARNING Some of the checks below may need to be done by a qualified service technician. Call a service technician for any remedy that involves gas or electricity. Call a service technician if you have any doubt or reservation about performing the remedy yourself.

Table

Code Fault

02 No burner operation during freeze protection mode

Remedy

Service Call

10 Air Supply or Exhaust

Blockage

11

12

No Ignition

Flame Failure

Ensure approved venting materials are being used.

Check that nothing is blocking the flue inlet or exhaust.

Check all vent components for proper connections.

Ensure vent length is within limits.

Ensure condensation collar was installed correctly.

Verify dip switches are set properly.

Check fan for blockage.

Check that the gas is turned on at the water heater, gas meter, or cylinder.

Ensure gas type and pressure is correct.

Ensure gas line, meter, and/or regulator is sized properly.

Bleed all air from gas lines.


Ensure appliance is properly grounded.

Disconnect all 2-Unit or Multi-Unit connections to isolate the problem.

Ensure igniter is operational.

Check igniter wiring harness for damage.

Check gas solenoid valves for open or short circuits.

Remove burner cover and ensure all burners are properly seated.

Remove burner plate and inspect burner surface for condensation or debris.

Check that the gas is turned on at the water heater and gas meter. Check for obstructions in the flue outlet.

Ensure gas line, meter, and/or regulator is sized properly.

Ensure gas type and pressure is correct.

Bleed all air from gas lines.

Ensure proper venting material was installed.

Ensure condensation collar was installed properly.

Ensure vent length is within limits.


Ensure appliance is properly grounded.

Disconnect keypad.

Disconnect all 2-Unit or Multi-Unit connections to isolate the problem.

Check power supply for loose connections.

Check power supply for proper voltage and voltage drops.

Ensure flame rod wire is connected.

Check flame rod for carbon build-up.

Disconnect and reconnect all wiring harnesses on unit and PC board.

Check all components for electrical short.

Check gas solenoid valves for open or short circuits.

Remove burner plate and inspect burner surface for condensation or debris.


Table

Code

14

16

32

33

34

52

61

71

72

LC

No

code

Fault

Thermal Fuse

Over Temperature

Warning

Outgoing Water

Temperature Sensor

Fault

Heat Exchanger

Outgoing Temperature

Sensor Fault

Combustion Air

Temperature Sensor

Fault

Remedy

Check gas type of unit and ensure it matches gas type being used.

Check for restrictions in air flow around unit and vent terminal.

Check for low water flow in a circulating system causing short-cycling.

Ensure dip switches are set to the proper position.

Check for foreign materials in combustion chamber and/or exhaust piping.

Check heat exchanger for cracks and/or separations.

Check heat exchanger surface for hot spots which indicate blockage due to scale buildup. Refer to instructions in manual for flushing heat exchanger.

Measure resistance of safety circuit.

Ensure high fire and low fire manifold pressure is correct.

Check for improper conversion of product.


Check for low water flow in a circulating system causing short-cycling.

Check for foreign materials in combustion chamber and/or exhaust piping.

Check for clogged heat exchanger.

Check sensor wiring for damage.

Measure resistance of sensor.

Clean sensor of scale build-up.

Replace sensor.




Replace sensor.





Ensure fan blade is tight on motor shaft and is in good condition.

Replace sensor.

Check modulating gas solenoid valve wiring harness for loose or damaged terminals.

Measure resistance of valve coil.

Ensure fan will turn freely.

Check wiring harness to motor for damaged and/or loose connections.

Measure resistance of motor winding.

Check wiring harness to all solenoids for damage and/or loose connections.

Measure resistance of each solenoid valve coil.

Modulating Solenoid

Valve Signal Abnormal

Combustion Fan

Failure

SV0, SV1, SV2, and

SV3 Solenoid Valve

Circuit Fault

Flame Sensing Device

Fault

Scale Build-up in Heat

Exchanger (when checking maintenance code history, “00” is substituted for “LC”)

Nothing happens when water flow is activated.

Ensure flame rod is touching flame when unit fires.

Check all wiring to flame rod for damage.

Remove flame rod and check for carbon build-up; clean with sand paper.

Check inside burner chamber for any foreign material blocking flame at flame rod.

Measure micro amp output of sensor circuit with flame present.

Replace flame rod.

Flush heat exchanger. Refer to instructions in manual.

Replace heat exchanger.

Clean inlet water supply filter.

On new installations ensure hot and cold water lines are not reversed.

Check for bleed over. Isolate unit from building by turning off hot water line to building.

Isolate the circulating system if present. Open your pressure relief valve; if water is flowing, there is bleed over in your plumbing.

Ensure you have at least the minimum flow rate required to fire unit.

Ensure turbine spins freely.

Measure the resistance of the water flow control sensor.

Check for DC shorts at components.


Trouble Shooting for Common Issues

I don’t have any hot water when I open the tap.

Make sure there is gas, water, and electricity to the water heater (power is turned on and the gas is turned on).

When I was using the hot water, the water got cold.

If you adjusted the flow from the tap to lessen it, you may have gone below the minimum flow required. This water heater requires a minimum flow rate to operate.

(See the specification page for the flow rate of your model.) Decrease the temperature setting at the temperature controller or increase the water flow.

White smoke comes out of the exhaust.

During colder weather when the exhaust temperature is much hotter than the outside air, the exhaust fumes condense producing water vapor.

When I open a hot tap, I do not immediately get hot water.

Hot water must travel through your plumbing from the water heater to the faucet. The time period for hot water to reach your fixture is determined by the amount of water in the plumbing system between the water heater and the fixture, water pressure, and the flow rate of the fixture.

After I turn off the hot water tap, the fan on the water heater continues to run.

The fan is designed to continue running for a short time after the flow of water stops. This is to ensure constant water temperatures during rapid starting and stopping, as well as exhausting any residual gas flue products from the unit.

To display the most recent error codes press and hold the “On/Off” button for 2 seconds. While holding the “On/

Off” button press the ▲ button. The last 9 error codes will flash one after the other. To exit this mode press the

“On/Off” and ▲ button as before.

To display the water flow through the water heater press and hold the ▲ button for 2 seconds and without releasing the ▲ button press the “On/Off” button.

To display the outlet water temperature press and hold the ▼ button for 2 seconds and without releasing the ▼ button press the “On/Off” button.

Water Quality

Consideration of care for your water heater should include evaluation of water quality. If the water quality exceeds the target levels provided in the table, you may want to treat or condition the water.

* Source: Part 143 National Secondary Drinking Water

Regulations

Total Hardness

Aluminum *

Chlorides *

Maximum Level

Up to 200 mg / L

Up to 0.2 mg / L

Up to 250 mg / L

Copper * Up to 1.0 mg / L

Iron *

Manganese * pH *

TDS (Total Dissolved

Solids) *

Zinc *

Up to 0.3 mg / L

Up to 0.05 mg / L

6.5 to 8.5

Up to 500 mg / L

Up to 5 mg / L


Flushing the Heat Exchanger (Error Code: LC or 00)

An “LC” or “00” error code indicates the unit is beginning to lime up and must be flushed. Failure to flush the appliance will cause damage to the heat exchanger. Damage caused by lime build-up is not covered by the unit’s warranty. After flushing, reset the LC fault code by turning off the power to the unit and turning the power back on.

1. Disconnect electrical power to the water heater.

2. Close the shutoff valves on both the hot water and cold water lines (V3 and V4).

3. Connect pump outlet hose (H1) to the cold water line at service valve V2.

4. Connect drain hose (H3) to service valve V1.

5. Pour approximately 4 gallons of virgin, food grade, white vinegar or citric acid into pail.

6. Place the drain hose (H3) and the hose (H2) to the pump inlet into the cleaning solution.

7. Open both service valves (V1 and V2) on the hot water and cold water lines.

8. Operate the pump and allow the cleaning solution to circulate through the water heater for at least 45 minutes.

9. Turn off the pump.

10. Rinse the cleaning solution from the water heater as follows: a. Remove the free end of the drain hose (H3) from the pail. b. Close service valve, (V2), and open shutoff valve, (V4).

Do not open shutoff valve, (V3). c. Allow water to flow through the water heater for 5 minutes d. Close service valve, (V1), and open shutoff valve, (V3).

11. Disconnect all hoses.

12. Remove the in-line filter at the cold water inlet and clean out any residue. Place filter back into unit.

13. Restore electrical power to the water heater.

H3

V1

Water Heater

V3

V2

I n-line

Filter

V4

Gas Supply

Cold Water Line

Hot Water Line

H2

H1

5 gallon pail of virgin, food grade, white vinegar (or virgin,

food grade, citric acid).

Circulating Pump

3/4" Ball Valve

3/4" Union

Check Valve

Pressure Relief Valve

KEY

S

Pressure Regulator

Circulating Pump

Boiler Drain Valve

Solenoid Valve


Installation Instructions

Only properly trained and qualified installers should install this appliance. The warranty may be voided due to improper installation or installation by a non-qualified installer.

It is highly recommended that all installers attend a product knowledge class.

General Instructions

WARNING

Do not use substitute materials.

• Follow the installation instructions and those in Care

and Maintenance for adequate combustion and ventilation air.

Use only parts certified with the appliance.

• This appliance must be installed by a state qualified or licensed contractor. It is the responsibility of the person having the water heater installed to ensure the installing contractor has proper licenses and permits for installing water heaters in your location.

It is highly recommended that installers attend a product knowledge class to ensure customer satisfaction and warranty coverage. Failure to comply with state and local codes pertaining to water heater installations may void the warranty.

• This appliance is not to be installed outdoors.

• A qualified installer or service technician should install the appliance, inspect it, and leak test it before use.

• The appliance should be located in an area where water leakage of the unit or connections will not result in damage to the area adjacent to the appliance or to lower floors of the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow.

• The flow of combustion and ventilation air shall not be obstructed.

• This appliance is not suitable for use in an application such as a pool or spa heater that uses chemically treated water . (This appliance is suitable for filling large or whirlpool bath tubs with potable water.)

• The installation must conform with local codes or, in the absence of local codes, with the National Fuel

Gas Code, ANSI Z223.1/NFPA 54, or the Natural

Gas and Propane Installation Code, CSA B149.1.

• If a water heater is installed in a closed water supply system, such as one having a backflow preventer in the cold water supply line, means shall be provided to control thermal expansion. Contact the water supplier or local plumbing inspector on how to control thermal expansion.

• The appliance, when installed, 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 appliance and its appliance main gas valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.5 kPa) (13.84 in W.C.).

• Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance.

• Keep the air intake location free of chemicals such as chlorine or bleach that produce fumes. These fumes can damage components and reduce the life of your appliance.

• The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.5 kPa) (13.84 in W.C.).


Appliance

to top

to Combustibles to Non-

Combustibles

Top of

Heater

Back of

Heater

Front of

Heater

Sides of

Heater

Floor/

Ground

Vent

305

505

705

305

505

705

6 inches

(152 mm)

12 inches

(305 mm)

2 inches

(51 mm)

2 inches

(51 mm)

0 (zero) 0 (zero) 0 (zero) 0 (zero)

6 inches

(152 mm)

2 inches

(51 mm)

12 inches

(305 mm)

0 (zero)

24 inches

(610 mm)

2 inches

(51 mm)

12 inches

(305 mm)

6 inches

(152 mm)

1/2 inch

(13 mm)

12 inches

(305 mm)

4 inches * 0 (zero)

24 inches

(610 mm)

1/2 inch

(13 mm)

2 inches

(51 mm)

0 (zero) to side to floor/ground

* 4 inches (102 mm) for enclosed area; 1 inch (26 mm) for unenclosed area.

The clearance for servicing is 24 inches in front of the water heater.

For closet installation: 305, 505: clearance is 6 inches (152 mm) from the front.

705: clearance is 24 inches (610 mm) from the front. to front

Attachment of the Water Heater

1. Identify the installation location and confirm that the installation will meet all required clearances.

2. Securely attach the water heater to the wall using any of the holes in the wall installation brackets which are at the top and bottom of the water heater. Ensure that the attachment strength is sufficient to support the weight. Refer to the weight of the water heater in the Specifications section. wall installation brackets


The water heater requires a standard 3 prong 120 VAC, 60 Hz properly grounded wall outlet. Plug the 6ft long power cord into the wall outlet.

Gas Piping

General Instructions

• A manual gas control valve must be placed in the gas supply line to the water heater. A union can be used on the connection above the shut off valve for the future servicing or disconnection of the unit.

• Check the type of gas and the gas inlet pressure before connecting the water heater. If the water heater is not of the gas type that the building is supplied with, DO NOT connect the water heater.

Contact the dealer for the proper unit to match the gas type.

• Check the gas supply pressure immediately upstream at a location provided by the gas company. Supplied gas pressure must be within the limits shown in the Specifications section.

• Before placing the appliance in operation all joints including the heater must be checked for gas tightness by means of leak detector solution, soap and water, or an equivalent nonflammable solution, as applicable. (Since some leak test solutions, including soap and water, may cause corrosion or stress cracking, the piping shall be rinsed with water after testing, unless it has been determined that the leak test solution is non-corrosive.)

• Always use approved connectors to connect the unit to the gas line. Always purge the gas line of any debris before connection to the water heater.

• The gas supply line shall be gas tight, sized, and so installed as to provide a supply of gas sufficient to meet the maximum demand of the heater and all other gas consuming appliances at the location without loss of pressure.

• Any compound used on the threaded joint of the gas piping shall be a type which resists the action of liquefied petroleum gas (propane / LPG).

• Refer to an approved pipe sizing chart if in doubt about the size of the gas line.


Gas Piping

Pipe Sizing Procedure - Example

The gas supply must be capable of handling the entire gas load at the location. Gas line sizing is based on gas type, the pressure drop in the system, the gas pressure supplied, and gas line type. Refer to the National Fuel

Gas Code, NFPA 54, for proper gas line sizing. The below information is provided as an example.

1. Determine the cubic feet per hour of gas required by dividing the gas input (on the rating plate) by the heating value of the gas (available from the local gas company). The gas input needs to include all gas products at the location and the maximum BTU usage at full load when all gas products are in use.

Gas

Cubic Feet per Hour (CFH) =

/

3

)

2. Use the table for your gas type to find the pipe size required for your cubic feet per hour of gas and your pipe length.

Example: The heating value of propane gas for your location is 2516 BTU / FT 3 .

The gas input is 190,000 BTU/HR. Additional appliances at the location require 75,000 BTU/HR.

Therefore the cubic feet per hour = (190,000+75,000) / 2516 = 105.3 FT 3 / HR.

If the pipe length is 100 ft then the 3/4 inch pipe size capable of supplying 197 FT

3 will be adequate.

/ HR of propane gas

Pipe Sizing Table - Natural Gas

cubic feet per hour Schedule 40 Metallic Pipe

Inlet Pressure: less than 2 psi (55 inches W.C.)

Pressure Drop: 0.3 inches W.C.

Specific Gravity: 0.60

Length

3/4

Pipe Size (inches)

1 1 1/4 1 1/2

90

100

125

150

175

200

50

60

70

80

10

20

30

40

188 353 726 1090

151 284 583 873

129 243 499 747

114 215 442 662

104 195 400 600

95 179 368 552

89 167 343 514

83 157 322 482

79 148 304 455

70 131 269 403

63 119 244 366

58 109 224 336

54 102 209 313

Pipe Sizing Table - Propane Gas

cubic feet per hour Schedule 40 Metallic Pipe

Inlet Pressure: 11.0 inches W.C.

Pressure Drop: 0.5 inches W.C.

Specific Gravity: 1.50

Pipe Size (inches)

Length

50

60

80

100

10

20

30

40

125

150

175

200

200 418 787 1620

160 336 632 1300

137 287 541 1110

122 255 480 985

110 231 434 892

101 212 400 821

94 197 372 763

89 185 349 716

84 175 330 677

74 155 292 600

67 140 265 543


General Instructions

• A manual water control valve must be placed in the water inlet connection to the water heater before it is connected to the water line. Unions may be used on both the hot and cold water lines for future servicing and disconnection of the unit.

• The piping (including soldering materials) and components connected to this appliance must be approved for use in potable water systems.

• Purge the water line to remove all debris and air.

Debris will damage the water heater.

• Toxic chemicals such as those used for boiler water treatment are not to be introduced to the potable water used for space heating.

• If the appliance will be used as a potable water source, it must not be connected to a system that was previously used with a nonpotable water heating appliance.

• Ensure that the water filter on the water heater is clean and installed.

Pressure Relief Valve

• An approved pressure relief valve is required by the

American National Standard (ANSI Z21.10.3) /

Canadian Standard (CSA 4.3) for all water heating systems.

• The relief valve must comply with the standard for

Relief Valves and Automatic Gas Shutoff Devices

for Hot Water Supply Systems ANSI Z21.22 and /or the standard Temperature, Pressure, Temperature and Pressure Relief Valves and Vacuum Relief

Valves, CAN1-4.4.

• The relief valve must be rated up to 150 psi and to at least the maximum BTU/hr of the appliance.

• The discharge from the pressure relief valve should be piped to the ground or into a drain system to prevent exposure or possible burn hazards to humans or other plant or animal life. Follow local codes. Water discharged from the relief valve could cause severe burns instantly, scalds, or death.

• The pressure relief valve must be manually operated once a year to check for correct operation.

• The relief valve should be added to the hot water outlet line according to the manufacturer’s instructions. DO NOT place any other type valve or shut off device between the relief valve and the water heater.

• Do not plug the relief valve and do not install any reducing fittings or other restrictions in the relief line.

The relief line should allow for complete drainage of the valve and the line.

• If a relief valve discharges periodically, this may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation.

Do not plug the relief valve.

• Neither this water heater nor the American National

Standard (ANSI Z21.10.3) / Canadian Standard

(CSA 4.3) requires a combination temperature and pressure relief valve for this appliance. However, local codes may require a combination temperature and pressure relief valve.

Freeze Protection

The freeze protection features include electrical heating elements and intermittent firing of the burner.

Freeze protection may be disabled if electricity or gas is not supplied, or if there is an error preventing the water heater from functioning. Loss of freeze protection may result in water damage from a burst heat exchanger or water lines.

The installation of auto drain down solenoid valves is optional. However, it is strongly recommended that these valves be installed to prevent damage from freezing in case the normal freeze protection should become disabled. Any product damage due to freezing will not be covered by the warranty.

In addition, the solenoid valves should be connected electrically to a surge protector with terminals that attaches to the PC board in the unit. This allows the solenoid valves to operate if the water heater is disabled due to an error code.

The solenoid valves and the surge protector with terminals are available for purchase separately.


Vacuum

Breaker

NOTICE

Warranty does not cover damage due to freezing.

When electrical power and gas are supplied to the water heater, it will not freeze in environments as cold as -30º F when protected from direct wind exposure.

In the event of a power failure at temperatures below freezing the water heater should be drained of all water to prevent freezing damage.

The unit may be drained manually. However, it is highly recommended that drain down solenoid valves be installed that will automatically drain the unit if power is lost. It is also recommended that a surge protector with terminals be installed that attaches to the PC board in the unit and allows the solenoid valves to operate if the unit is disabled due to an error code.

When the electrical power to the water heater fails, the

3/4” solenoid valve closes (stopping the flow of water into the heater) and the 1/2” solenoid valve opens

(allowing the water heater and associated piping to drain. Ensure that you run the drain for the solenoids to the outside environment to prevent discharging water inside the building causing water damage).

Water Heater

3/4" Gas Connection

NOTE:

Heat trace ALL water pipe and fittings located outside home (attic, crawl space) or building structure. (ALL water pipe and fittings shown above the dashed line in the drawing.)

NOTE:

ALL pipe and fittings shown below dashed line should be located inside home or building structure.

The vacuum breaker line should be located inside the building structure.

3/4" Ball Valve

3/4" Union

Check Valve


KEY

S

Minimum 3/4" Hot Water

Supply Line

1/2" Minimum

Normally Open

Solenoid Valve

Pressure Regulator

Circulating Pump

Boiler Drain Valve

Solenoid Valve

S

Gas Supply

3/4" Minimum

Normally Closed

Solenoid Valve

Minimum 3/4"

Cold Water

Supply Line

Route to Floor Drain

This is not an engineered drawing. It is intended only as a guide and not as a replacement for professionally engineered project drawings. This drawing is not intended to describe a complete system. It is up to the contractor/engineer to determine the necessary components and configuration of the particular system being installed. This drawing does not imply compliance with local building code requirements. It is the responsibility of the contractor/engineer to ensure installation is in accordance with all local building codes. Confer with local building officials before installation.


Recommended Piping for Basic Installation

Water Heater

Equipment List QTY

Water Heaters 1

Plumbing Installation

Kit (Optional)

(3/4" Fittings Include:

2 Unions, 2 Ball Valves,

2 Drain Valves and

1 Pressure Relief Valve.)

1

3/4" Gas Connection

3/4" Ball Valve

3/4" Union

Check Valve


3/4" Hot Water Supply Line

For Building Fixtures

KEY

S

Pressure Regulator

Circulating Pump

Boiler Drain Valve

Solenoid Valve

Gas Supply

3/4" Cold Water Supply Line



Recommended Piping for Circulation Systems

NOTE:

For residential and commercial applications, this piping arrangement maintains full warranty.

Water Heater

Equipment List QTY

Water Heaters 1


Kit (Optional)



2 Drain Valves and


1

For this application:

Pump should be controlled by an Aquastat, Timer or Combination Aquastat and

Timer.

Pump to be sized to maintain circulation loop temperature.

The pump should be sized to overcome the pressure loss through the tank water heater, and supply and return plumbing.

Pump to be of bronze or stainless construction.

3/4" Gas Connection

Gas Supply

IMPORTANT: Connect the building return line to the hot water supply line as close as possible to the water heater.

Minimum 3/4" Cold Water Supply Line

Tank Water Heater to be Sized for

Heat Loss of Circulation Loop.

Building Supply

Electric Water

Heater

Building

Fixtures

Expansion Tank

3/4" Ball Valve

3/4" Union

Check Valve


KEY

S

Pressure Regulator

Circulating Pump

Boiler Drain Valve

Solenoid Valve



Optional Piping for Circulation Systems

NOTE:

For residential and commercial applications, this piping arrangement reduces the warranty to the following:

3 years on heat exchanger

3 year on parts

Full warranty will be maintained if an on-demand recirculation system in incorporated. Refer to the Limited

Warranty.

For this application:

Water Heater Equipment List QTY

Water Heaters 1


Kit (Optional)



2 Drain Valves and


1

Pump should be controlled by an Aquastat,

Timer or Combination Aquastat and Timer.

Pump to be sized to maintain circulation loop temperature.

A minimum of 3 GPM flow is recommended for the circulation system.

The pump should be sized to overcome the pressure loss through the water heate r, supply and return plumbing.

Pump to be of bronze or stainless construc tion.

3/4" Gas Connection

Gas Supply

Note: Water heater outlet temperature cannot be adjusted when circulation pump is running.

Minimum 3/4" Hot Water

Supply Line

(Optional)

2-6 Gallon

Storage Tank

(To eliminate cold water sandwich effect caused by frequent On/Off operation)

Minimum 3/4“ Cold Water Supply Line

Expansion Tank

Building Fixture Outlets

3/4" Ball Valve

3/4" Union

Check Valve


KEY

S

Pressure Regulator

Circulating Pump

Boiler Drain Valve

Solenoid Valve



Instructions

Intake / Exhaust Guidelines

Refer to the specific instructions on your vent product for additional installation requirements.

• This water heater is a direct vent water heater and therefore is certified and listed with the vent system. You must use vent components that are certified and listed with the water heater model.

• Do not combine vent components from different manufacturers.

• The vent system must vent directly to the outside of the building and use outside air for combustion.

• Venting should be as direct as possible with a minimum number of pipe fittings.

• Avoid dips or sags in horizontal vent runs by installing supports per the vent manufacturer’s instructions.

• Support horizontal vent runs every four feet and all vertical vent runs every six feet or in accordance with local codes.

• Vent diameter must not be reduced.

• Do not connect the venting system with an existing vent or chimney.

• Do not common vent with the vent pipe of any other water heater or appliance.

• Vent connections must be firmly pressed together so that the gaskets form an air tight seal.

• On the 305 and 505 models, the vent piece connected to the water heater must be secured with one self-tapping screw.

• Refer to the instructions of the vent system manufacturer for component assembly instructions.

• If the vent system is to be enclosed, it is suggested that the design of the enclosure shall permit inspection of the vent system. The design of such enclosure shall be deemed acceptable by the installer or the local inspector.

NOTICE

If it becomes necessary to access an enclosed vent system for service or repairs, the manufacturer is not responsible for any costs or difficulties in accessing the vent system. Warranty does not cover obtaining access to an enclosed vent system.

Condensate

Condensate formation can occur in high efficiency direct vent appliances. To prevent condensate damage follow these instructions.

WARNING

If the condensate collector is not used, the drain pipe must be capped to prevent exhaust gases and condensate from entering the building. The cap is supplied on the appliance.

• Vertical terminations must incorporate a condensate drain and trap as close as possible to the appliance.

• Slope any horizontal venting 1/4 inch per foot (19 mm / m), towards the heater if the condensate collector is used, or towards the exhaust terminal if the condensate collector is not used.

• Dispose of condensate per local codes.

• The condensate trap must contain a minimum of 3 inches (75 mm) of water.

NOTICE

Provisions must be made to prevent the condensate from entering the water heater. Without proper drainage or disposal, condensate will damage the heat exchanger.

• This water heater has an integrated condensate collector.

• Regions of cold climate will create more condensate in the vent system. The condensate collector should be used in cold climates.


Instructions

Maximum Vent Length

1. Determine the number of 90 degree elbows in the vent system. (Two 45 degree elbows count as one 90 degree elbow.)

2. Refer to the table to find the maximum vent length based on the number of elbows.

3. Follow the applicable note.

Example: If you have one elbow then your maximum vent length is 35 feet (10.7 m). If your actual length is greater than 15 ft (4.6 m) then move dip switch no. 1 (SW1) to OFF.

0 1 2

Number of 90° Elbows

3 4 5 6

41 ft 1

(12.5 m)

35 ft 2

(10.7 m)

29 ft 3

(8.8 m)

23 ft 4

(7.0 m)

17 ft 4

(5.2 m)

11 ft 4

(3.4 m)

5 ft 4

(1.5 m) dip switch no. 1 (SW1) to OFF.

If the length is greater than 15 ft (4.6 m) then move dip switch no. 1 (SW1) to OFF. dip switch no. 1 (SW1) to OFF.

Notes 1234

O

F

F

Switch No.

ON

1

2

3

4

5

6

7

8

NOTICE

If you have a longer vent length, dip switch no. 1 is required to be in the OFF position. This ensures the water heater will run properly. Blocked flue error codes and shutdowns may result if dip switch no. 1 is not in the correct position. On the 505 model, the maximum water flow capacity will be reduced by about 10% when dip switch no. 1 is OFF.


Products

Listed and Tested Vent Products for the 305 and 505 Models

Manufacturer Product

Ubbink

Heat-Fab

Rolux Vent System

Saf-T Vent SC system

Metal-Fab Corr/Guard Vent/Air

Intake System

Parts

Refer to the manufacturer’s technical literature for specific part numbers and instructions.

Listed and Tested Vent Products for the 705 Model

Manufacturer Product

Appliance

Adapter

Heat-Fab Saf-T Vent 9401AMTK

Vertical

Termination

5400CI

Horizontal

Termination

9492

Horizontal

Concentric

Termination

NA

Adjustable

Horizontal

Concentric

Termination

NA

Z-Flex Z-Vent 2SVSNA04.5 2SVSRCF4 2SVSTPX4 NA NA

ProTech

Systems

FasNSeal FSAAU4 * FSRC4 * FSBS4 *

FSDVPTB04LH *

FSDVWT4

Metal-Fab Corr/Guard 4CGOA 4CGSWC 4CGSWMCM

4CG7HT90

4CG7HT

FSDVWMTP4LH,

FSEDVWMTP4LH

NA

Vent Manufacturer Contact Information for Installation Instructions and Parts Lists:

Ubbink

Telephone: 866-677-4960

500 Tennessee Waltz Parkway

Ashland City, TN 37015

Heat-Fab

Telephone: 800-772-0739

Fax: 413-863-4803

E-mail: [email protected]

Web Site: www.heatfab.com

Z-Flex

Telephone: 800-654-5600

Fax: 888-889-3539


Web Site: www.novaflex.com

ProTech Systems, Inc.

Telephone: 800-766-3473

518-463-7284

Fax: 518-463-5271


Web Site: www.protechinfo.com

Metal-Fab Inc.

Telephone: 800-835-2830

316-943-2351

Fax: 316-943-2717


Web Site: www.metal-fabinc.com


Flue Terminal Clearances (

ANS Z21.10.3 ● CSA 4.3)

INSIDE

CORNER DETAIL

G

H

A

I

M

D

E

L

B

F

C

FIXED

CLOSED

OPERABLE

B

B

OPERABLE

B

FIXED

CLOSED

B

B

A

J

K

X

V

AIR SUPPLY INLET

VENT TERMINAL

AREA WHERE

TERMINAL IS NOT

PERMITTTED

D

I

J

E

F

G

Ref

A

B

C

H

K

Clearance above grade, veranda, porch, deck, or balcony

Clearance to window or door that may be opened

Clearance to permanently closed window

Vertical clearance to ventilated soffit, located above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal

Clearance to unventilated soffit

Clearance to outside corner

Clearance to inside corner

Clearance to each side of center line extended above meter/ regulator assembly

Clearance to service regulator vent outlet

Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance

Clearance to a mechanical air supply inlet

Clearance above paved sidewalk or paved driveway located on public property

Clearance under veranda, porch, deck, or balcony

12 inches (30 cm)

12 inches (30 cm)

*

*

*

*

*

*

*

12 inches (30 cm)

3 feet (91 cm) above if within

10 feet (3 m) horizontally

*

*

L

M

1 A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

2 Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

∗ For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, clearances are in accordance with local installation codes and the requirements of the gas supplier.


Additional Clearances - Vent Terminal

Local codes supersede these clearances.

•

Avoid termination locations near a dryer vent.

•

Avoid termination locations near commercial cooking exhaust.

Vent terminal (represents concentric vent terminal for the water heater)

V

60"

(1.52 m) vertically between water heater terminals

36"

(0.91 m) to ventilated or unventilated soffit or eve vent; or to a deck or porch

12"

(0.30 m ) to an inside corner

V

12"

V

(0.30 m) between water heater terminals at same level

V

24"

(0.61 m) to wall or parapet

V

INSIDE

CORNER

(1.52 m) between water heater terminals at different levels

V

60"

V

V

12"

V

(0.30 m) between water heater terminals at same level


Horizontal Termination without using the Condensate Collector

WARNING

If the condensate collector is not used, the drain pipe must be capped to prevent exhaust gases and condensate from entering the building. The cap is supplied on the appliance.

* The condensate collector must be used in horizontal terminations if a vertical rise in the vent system exceeds 5ft.

Maximum Height *

5 feet (1.52 m)

Regions of cold climate will create more condensate in the vent system.

The condensate collector should be used in cold climates.

If more than one elbow is used in the vertical section the condensate collector must be used.

Horizontal Termination using the Condensate Collector

Vertical Termination

(condensate collector must be used in all installations)

Condensate

Trap

3 in (75 mm) minimum

Condensate Collector

Condensate

Trap



Bracket

Securing Screw

To adjust the condensate collector position or to replace the female vent top with a male vent top:

1. Loosen the 4 screws at the rear bracket

2. Slide the bracket away from the female vent top.

3. Remove the 4 screws attaching the female vent top to the water heater.

4. Lift up the female vent top and reposition as desired (or replace with a male vent top).

5. Install the 4 screws at the vent top and tighten the

4 screws at the bracket.

Secure the first vent component to the water heater with one self-tapping screw at the hole located above the condensate collector.


Air Intake Assembly

The air intake system consists of a field supplied 4 inch diameter stainless steel, Schedule 40 PVC, ABS or CPVC pipe. A maximum 6 feet of semi-rigid flexible aluminum ducting can also be used. Foil wrapped dryer vent and cell core products are not authorized.

The air intake has a zero clearance to combustibles.

Air Intake Connection

1.Drill 2 small holes at the end of the air intake pipe.

2.Slide the pipe over the air intake terminal.

3.Using a level, ensure the pipe is straight up and down.

4.With self tapping screws, attach the pipe to the air intake terminal.

5.Apply a bead of silicone around the pipe and air intake terminal, ensuring an air tight connection.

1

3

2

4

Exhaust Pipe Assembly

Refer to the manufacturer’s installation instructions for the specific exhaust vent system.

Venting Clearances to Combustibles

Enclosed Unenclosed

Vent Size

Horizontal &

Vertical

Horizontal &

Vertical

4" (102 mm) 4" (102 mm) 1" (26 mm)

Horizontal Terminations

The air intake must be located in relation to the exhaust as shown below. The air intake must angle 1/4 inch per foot to the termination to prevent entry of rain.

6

”

Vent

12”

4”

8

”

Optional

Intake

Intake

EXHAUST

COMBUSTION AIR /

INTAKE

The vent termination and air intake must be in the same pressure zone and face the same direction.

12” MIN. ABOVE

GRADE OR

SNOW LEVEL

SLOPE INTAKE AND EXHAUST

TOWARD OUTSIDE TERMINATION

MINIMUM 1/4" PER FOOT


Horizontal with Concentric Termination

SLOPE INTAKE AND EXHAUST

TOWARD OUTSIDE TERMINATION

MINIMUM 1/4" PER FOOT

12” MIN. ABOVE

GRADE OR

SNOW LEVEL

Vertical Terminations

The air intake requires a return bend or two 90º elbows to prevent entry of rain.

The vent termination and air intake must be in the same pressure zone.

3”

MAX

3”

MAX

12” MIN

12”

MIN

12” MIN

COMBUSTION

AIR PIPE

ANTICIPATED

SNOW LEVEL

EXHAUST PIPE

3”

MAX

12” MIN

12” MIN

3”

12” MIN


Set dip switches 2 and 3 to the values shown in table below for your altitude. The default setting for the appliance is 0-2000 ft (0-610 m) with switches No. 2 and No. 3 in the OFF position.

WARNING DO NOT adjust the other dip switches unless specifically instructed to do so.

Switch No. 2

Switch No. 3

0-2000 ft

(0-610 m)

OFF

OFF

Switch No.

O

F

F

ON

4

5

6

7

8

1

2

3

2001-5200 ft

(610-1585 m)

OFF

ON

O

F

F

Switch No.

ON

1

2

3

4

5

6

7

8

5201-7700 ft

(1585-2347 m)

ON

OFF

O

F

F

Switch No.

ON

4

5

6

7

8

1

2

3

7701-10200 ft

(2347-3109 m)

ON

ON

Switch No.

O

F

F

ON

4

5

6

7

8

1

2

3

Connecting Multiple Water Heaters

The 2-Unit connection cable is an optional accessory that connects 2 water heaters and allows them to function as one hot water source.

The Multi-Unit connection kit and Multi-Unit connection cables are optional accessories that connect 2 to 5 water heaters and allow them to function as one hot water source.

The Multi-Unit connection kit includes a PC board and one Multi-Unit connection cable.

Refer to the instructions that come with the accessory for complete installation information.

Guidelines

• Do not install both the 2-Unit connection cable and the Multi-Unit connection kit because they are not designed to operate together.

• Water heaters should be installed less than 18 inches apart so that the cables will reach between units and to prevent temperature fluctuations (cold water sandwich effect) when the water is shut off and turned back on.

• Temperature settings can only be changed on the controller for the primary unit.

Number of Connected Water Heaters:

2

3

4

5

Accessories Necessary:

(1) 2-Unit connection cable

or

(1) Multi-Unit connection kit


and

(1) Multi-Unit connection cable


and

(2) Multi-Unit connection cables


and

(3) Multi-Unit connection cables



Location

Indoor models have their controller built into the front panel. Additional controllers can also be installed.

• The controller should be out of reach of small children.

• Avoid locations where the controller may become hot (near the oven or radiant heater).

• Avoid locations in direct sunlight. The digital display may be difficult to read in direct sunlight.

• Avoid locations where the temperature controller could be splashed with liquids.

• Do not install in locations where it can be adjusted by the public.

Configurations

A maximum of 4 temperature controllers can be installed for a water heater or bank of water heaters.

Controllers can only be wired in parallel. Controllers cannot be wired in series.

If 4 temperature controllers are installed, simultaneously press the Priority and On/Off buttons on the fourth controller until a beep sounds.

Water

Heater

Wire controllers in parallel

Controllers

Cable Lengths and Size

The cable for the temperature controller should be a non-polarized two-core cable with a minimum gauge of 22 AWG. The maximum cable length from each controller to the water heater depends on the total number of wired controllers connected to the water heater.

Number of Wired

Controllers

1

2

3 or 4

Maximum Cable Length for each

Controller to Water Heater

328 ft (100 m)

164 ft (50 m)

65 ft (20 m)



Mounting the Controller

Follow the procedure below to install additional controllers.

1. Determine a suitable location for the controller.

2. Make three holes in the wall as shown.

3. Run the cable between the controller and the water heater or the controller and the other controller.

4. Remove the face plate from the temperature controller using a screwdriver.

5. Connect the cable to the temperature controller.

6. Mount the controller to the wall using the holes drilled in step 2.

7. Disconnect the power from the water heater.

8. Remove the cover of the water heater.

9. Remove the plastic cover from the PCB and electrical connections.

10. Thread the cable through the access hole at the base of the unit and connect the wires to the controller terminals on the right hand side bottom of the PCB.

11. Secure the controller cable using the clamp provided.

12. Replace plastic cover over PCB and then replace the cover of the water heater.

WARNING

Do not attempt to connect the temperature controllers with the power on. There is 120 volt potential, next to the temperature controller connections inside the unit.

Do not connect the temperature controller to the

120VAC terminals provided for the optional solenoid drain valves.

All service and wiring should be performed by a registered installer. securing screw wiring hole securing screw

1-21/32"

REMOTE CONTROL

CONNECTION TERMINALS

3-5/16"

REMOTE

CONTROL CABLE


CABLE CLAMP

Operating Instructions

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.

A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, do not try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance using the ON/OFF button.

6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow “B” in the safety information above. If you don’t smell gas, go to the next step.

4. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

7. Turn the manual gas valve counterclockwise to the full ON position.

8. Turn on all electric power to the appliance using the ON/OFF button.

5. Locate the manual gas valve on the side of the heater. Turn the manual valve clockwise to the full OFF position.

9. Set the thermostat to desired setting.

Manual Valve

CLOSE OPEN

10. Open a hot water tap. If the appliance will not operate, follow the instructions “To Turn Off Gas

To Appliance” and call your service technician or gas supplier. See manual for additional information.

TO TURN OFF GAS TO APPLIANCE

1. Turn off all electric power to the appliance using the ON/OFF button.

2. Set the thermostat to lowest setting.

3. Locate the manual gas valve on the side of the heater. Turn the manual valve clockwise to the full

OFF position.


Technical Data

45

40

35

30

25

20

15

10

5

0

305 505 705

Water Flow (gpm)

34

10.0

9.0

8.0

7.0

6.0

5.0

4.0

3.0

2.0

1.0

0.0

0

705

505

305

Data

25 125 150 50 75 100

delta T - Temperature Rise (ºF)

305, 505, 705 Indoor Manual

50

40

30

20

10

0

100

90

80

70

60

If the water heater is to be used for both water (potable) heating and space heating then the following apply.

• The piping and components connected to the water heater shall be suitable for use with potable water.

• Toxic chemicals, such as used for boiler treatment, shall not be introduced into the potable water.

• The water heater shall not be connected to any heating system or components previously used with a nonpotable water heating appliance.

• When the system requires water for space heating at temperatures higher than required for other uses, a means such as a mixing valve shall be installed to temper the water for other uses in order to reduce the scald hazard potential.

Space heating applications are considered commercial applications for warranty purposes.

Temperature Setting

When using this appliance to provide domestic hot water it is recommended that the domestic hot water temperature be reduced to acceptable temperatures in accordance with local codes. In the absence of local codes it is recommended that the domestic hot water temperature be set to 140º F (60º C) or lower in accordance with UPC 501.6 by using mixing valves or the temperature controller for the water heater.

Pumps

Only use pumps of brass or stainless steel construction. Do not use pumps of iron construction as they will oxidize and clog the inlet filter on the appliance.

Pumps circulating water through the water heater must be sized to overcome the pressure loss through the water heater, the heating system, and any additional plumbing pressure losses. The pressure drop curve based on the water heater model is provided in this manual.

Replacement

When replacing an existing space heating application’s water heating source (boiler, tank water heater, tankless water heater, etc.) with these water heaters, ensure that the water heaters are sized to adequately provide the necessary BTU input for the desired space heating application. These water heaters are designed to maintain a constant outlet temperature and will supply only the necessary amount of BTU’s to maintain that temperature.

Depending on the application the maximum BTU rating of the unit may not be achieved.

Iron Components

Do not use these water heaters directly for space heating applications involving iron radiators or applications with any iron components. Iron components may oxidize creating rust that will clog the inlet filter of the water heater.


Dimensions

305 and 505 Models 705 Model

A

A B

L B

C

D

C

D

10.8600

K

E H

F J

G I

DIM DESCRIPTION

E

305

505

in (mm)

14 (355.6)

9.6 (244.5)

22.9 (582)

25.5 (648.2)

3.6 (91)

4.3 (110)

2.8 (70)

1.1 (27)

4.3 (109)

3.5 (89)

1.6 (40)

2.0 (50)

1.6 (41)

H

F J

I

G

705

in (mm)

A Width

B Depth *

C Height - Unit

D Height - with brackets

E Hot Water Outlet - from wall *

F Hot Water Outlet - from center

G Cold Water Inlet - from wall *

H Cold Water Inlet - from center

I Gas Connection - from wall *

J Gas Connection - from center

K

From base to gas connection

From base to cold connection

From base to hot connection

18.5 (470)

9.1 (230.5)

23.6 (600)

25.2 (639.8)

4.3 (110)

2.4 (61)

3.7 (94)

2.0 (52)

2.2 (56.2)

4.3 (110)

1.6 (40)

2.0 (50)

1.6 (41)

* This is the minimum dimension from the wall. The wall bracket is adjustable to allow an additional 1.57 inches

(40 mm).


K

Diagram

HOT NEUTRAL

3A(FUSE)

FROST SENSING

SWITCH

ARRESTER

VARISTOR

GND

ANTI-FROST HEATER

VARISTOR

RELAY 1

IG

IGNITION

E

SWITCHING

POWER SUPPLY

PG DC170V DC12V

D

DC12.6V

DC5V

DC40V

A B

INDOOR MODEL ONLY

A

QS

A SG

M

A

M

A SG

BY-PASSFLOW

CIRCUIT

BY-PASS SERVOMODEL ONLY

RELAY 1

SG

RELAY

DRIVING

CIRCUIT

SV0

THERMALFUSE

SV1

SV2

SV3

B

SG

OUTGOING WATER

THERMISTOR

HEAT EXCHANGER

THERMISTOR

THERMISTOR

CIRCUIT

AIR TEMPERATURE

THERMISTOR

SG

B

CPU

PROCESSING

UNIT

SG

C SG

A B C

MODULATING

VALVEPOWER

CONTROL

CIRCUIT

SG

D E

MODULATING

SOLENOID

VALVE

POV

COMBUSTION

FAN

FAN

FAN

CONTROL

CIRCUIT

PG

A

FLAME ROD

FR

FLAME

DETECTING

CIRCUIT

SG

A

GND

B

REMOTE

CONTROLLER

CIRCUIT

SG

305, 505, 705 Indoor Manual

REMOTE

CONTROLLER

37

Warranty

What is covered?

This Warranty covers any defects in materials or workmanship when the product is installed and operated according to written installation instructions, subject to the terms within this Limited Warranty document. This

Warranty applies only to products that are installed by a factory authorized or licensed contractor. Improper installation may void this Warranty. It is strongly suggested that you use a factory authorized or licensed installer who has attended a product knowledge class before installing this water heater. This Warranty extends to the original purchaser, but only while the product remains at the site of the original installation. This Warranty only extends through the first installation of the product and terminates if the product is moved or reinstalled at a new location.

How long does coverage last?

Item

Period of Coverage (from date of purchase)

Residential Applications

12 years *

Commercial Applications including radiant heating

5 years * Heat Exchanger

All Other Parts and

Components

Reasonable Labor

5 years * 5 years *

1 year

* Note: Period of coverage is reduced to 3 years from date of purchase when used as a circulating water heater within a hot water circulation loop, where the water heater is in series with a circulation system and all circulating water flows through the water heater, and where an on-demand recirculation system is not incorporated.

On-demand recirculation is defined as a hot water recirculating loop or system that utilizes existing hot and cold lines or a dedicated return line, and only activates when hot water is used. It can be activated by a push button, motion sensor, or voice activation but not by a temperature sensor. A timer added to a standard recirculating pump is not considered as on-demand.

There is no warranty coverage on product installed in a closed loop application, commonly associated with space heating only applications.

Use of an commercial controller in a residential dwelling will reduce the warranty coverage to that of a commercial warranty application.

The integrated controller on indoor models has a 1 year warranty on parts.

What will be done?

Repair or replacement of the covered product or any part or component that is defective in materials or workmanship as set forth as follows. Payment of reasonable labor charges associated with the repair or replacement of any such part or component. All repair parts must be genuine OEM parts. All repairs or replacements must be performed by an individual or servicing company that is properly trained, factory authorized or licensed to do the type of repair.

Replacement of the product may be authorized by the manufacturer only. The manufacturer does not authorize any person or company to assume for it any obligation or liability in connection with the replacement of the product. If it is determined that repair of a product is not possible, the product will be replaced with a comparable product, at the manufacturer’s discretion. If a component or product returned to the manufacturer is found to be free of defects in material or workmanship, or damaged by improper installation or damaged during return shipping, the warranty claim for product, parts and labor may be denied.


Warranty

How do I get service?

You must contact a factory authorized/licensed contractor or authorized service provider for the repair of a product under this Warranty. For the name of a qualified/authorized service provider please contact your place of purchase, call 1-866-677-4960 or write to 500 Tennessee Waltz Parkway, Ashland City, TN 37015.

Proof of purchase is required to obtain warranty service. You may show proof of purchase with a dated sales receipt.

What is not covered?

This Warranty does not cover any failures or operating difficulties due to the following:

•

accident, abuse, or misuse

•

alteration

•

misapplication

•

force majeure

•

improper installation (such as but not limited to inadequate water quality, condensate damage, improper venting, incorrect gas type, incorrect gas or water pressure, or absence of a drain pan under the appliance)

•

improper maintenance (such as but not limited to scale buildup, freeze damage, or vent blockage)

•

incorrect sizing

•

any other causes other than defects in materials or workmanship

This Warranty does not apply to any product whose serial number or manufacture date has been defaced. This

Warranty does not cover any product used in an application that uses chemically treated water such as a pool or spa heater. This appliance is suitable for filling large or whirlpool bath tubs with potable water. Refer to the Water

Quality Section in the Operation and Installation Manual.

No one is authorized to make any other warranties on behalf of the manufacturer. Except as expressly provided herein, there are no other warranties, expressed or implied, including, but not limited to warranties of merchantability or fitness for a particular purpose, which extend beyond the description of the warranty herein and further the manufacturer shall not be liable for indirect, incidental, special, consequential or other similar damages that may arise, including lost profits, damage to person or property, loss of use, inconvenience, or liability arising from improper installation, service or use. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.

Limitation on implied warranties

Any implied warranties of merchantability and fitness arising under state law are limited in duration to the period of coverage provided by this limited Warranty, unless the period provided by state law is less. Some states do not allow limitations on how long an implied Warranty lasts, so the above limitation may not apply to you.

This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state.


U287-084 (00)

Printed in Japan 09.01

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