Titan Low NOx Power Burner Manual
Instruction Manual
commercial gas water heaters
MODELS GPG/GPV-540A, 650A AND 740A
SERIES 104/105
INSTALLATION - OPERATION - SERVICE
- MAINTENANCE - LIMITED WARRANTY
500 Tennessee Waltz Parkway
Ashland City, TN 37015
www.statewaterheaters.com
Low Lead Content
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;
not use any phone in your building.
do
• 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.
We appreciate your confidence in our products.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
place these instructions adjacent to heater and notify owner to keep for future reference.
PRINTED 0714
195047-003
Table Of Contents
Safe Installation, Use and Service���������������������������������������� 3
Barometric Draft Control Assembly������������������������������������������������ 18
Approvals������������������������������������������������������������������������������������������ 3
Vent Connection������������������������������������������������������������������������������ 18
General Safety Information�������������������������������������������������4-5
Horizontal (Side-Wall) Venting for GPV Models������������������������ 18-19
Precautions��������������������������������������������������������������������������������������� 5
Direct Venting for GPV Models������������������������������������������������������� 19
Grounding Instructions���������������������������������������������������������������������� 5
Termination Clearances Sidewall Power Vent�������������������������������� 20
Hydrogen Gas Flammable���������������������������������������������������������������� 5
Termination Clearances Sidewall Direct Vent�������������������������������� 21
Introduction����������������������������������������������������������������������������������� 6
Water Heater Installation������������������������������������������������������ 24
Abbreviations Used��������������������������������������������������������������������������� 6
Water Line Connections������������������������������������������������������������������ 24
Qualifications������������������������������������������������������������������������������������ 6
T&P Valve Discharge Pipe�������������������������������������������������������������� 24
Start Up Requirements��������������������������������������������������������������������� 6
Installation Diagrams - Top Inlet/Outlet Usage������������������������������� 25
Preparing for the Installation������������������������������������������������������������� 6
Heater Wiring�����������������������������������������������������������������������������25-26
Features And Components�������������������������������������������������������� 7
Gas Piping����������������������������������������������������������������������������������26-27
High Limit Switch������������������������������������������������������������������������������� 7
Gas Line Leak Testing�������������������������������������������������������������������� 27
Electronic Ignition Control����������������������������������������������������������������� 7
Purging�������������������������������������������������������������������������������������������� 27
Barometric Draft Control������������������������������������������������������������������� 7
Start-up and OPERATION������������������������������������������������������������ 28
Combustion Chamber Observation Port������������������������������������������ 7
Prior to Start Up������������������������������������������������������������������������������ 28
Uncrating������������������������������������������������������������������������������������������� 7
Sequence of operation�������������������������������������������������������28-29
Installation Considerations����������������������������������������������� 8-12
Lighting & Operation Label������������������������������������������������������������� 30
Rough In Dimensions������������������������������������������������������������������������ 8
Adjustments������������������������������������������������������������������������������������ 31
Locating The Water Heater������������������������������������������������������������� 10
Adjustment Procedure for Fire-Rate, Low NOX and High Elevation
(Fine-Tune)�������������������������������������������������������������������������������������� 31
Clearances�������������������������������������������������������������������������������������� 10
Insulation Blanket�����������������������������������������������������������������������������11
maintenance����������������������������������������������������������������������������������� 34
Hard Water���������������������������������������������������������������������������������������11
Venting System and Barometric Draft Control������������������������������� 34
Circulation Pumps����������������������������������������������������������������������������11
General�������������������������������������������������������������������������������������������� 34
High Altitude Installations................................................................ 12
Remote Storage Tank Temperature Control����������������������������������� 34
Installation Requirements������������������������������������������������ 13-16
Temperature-Pressure Relief Valve Test�����������������������������������34-35
Gas Supply Systems........................................................................ 13
Anode Rod Inspection�������������������������������������������������������������������� 35
Supply Gas Regulator��������������������������������������������������������������������� 13
Draining and Flushing��������������������������������������������������������������������� 35
Power Supply���������������������������������������������������������������������������������� 13
Recommended Procedure for Periodic Removal or Lime Deposits
from the Tank Type Commercial Water Heaters�����������������������35-36
Water Temperature Control and Mixing Valves������������������������� 13-14
Dishwashing Machines������������������������������������������������������������������� 14
DeLiming Solvents�������������������������������������������������������������������������� 36
Closed Water Systems�������������������������������������������������������������������� 14
Tank Cleanout Procedure��������������������������������������������������������������� 36
Thermal Expansion������������������������������������������������������������������������� 14
Deliming Using Flo-Jug Method.................................................36-37
Temperature-Pressure Relief Valve������������������������������������������ 14-15
Power Burner................................................................................... 37
Contaminated Air���������������������������������������������������������������������������� 15
Gas Control Valve............................................................................ 38
Air Requirements���������������������������������������������������������������������������� 15
service��������������������������������������������������������������������������������������������� 38
Unconfined Space��������������������������������������������������������������������������� 16
Electrical Servicing������������������������������������������������������������������������� 38
Confined Space������������������������������������������������������������������������������� 16
Venting Installation������������������������������������������������������������� 16-19
Troubleshooting��������������������������������������������������������������������38-39
Fresh Air Opening for Confined Spaces����������������������������������������� 16
For your information���������������������������������������������������������������� 40
Outdoor Air Through Two Openings����������������������������������������������� 16
Start up Conditions������������������������������������������������������������������������� 40
Outdoor Air Through One Opening������������������������������������������� 16-17
Operational Conditions������������������������������������������������������������������� 40
Outdoor Air Through Two Horizontal Ducts������������������������������������ 17
Water Piping Diagrams���������������������������������������������������������� 41-55
Outdoor Air Through Two Vertical Ducts���������������������������������������� 17
MANIFOLD KITS��������������������������������������������������������������������������������� 56
Air From Other Indoor Spaces�������������������������������������������������������� 17
replacement parts list������������������������������������������������������� 57-58
Venting����������������������������������������������������������������������������������������17-18
Warranty���������������������������������������������������������������������������������������� 59
2
Safe Installation, Use and Service
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and
how to avoid the risk of injury.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances
known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of
potential exposure to such substances.
WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive
harm. This appliance can cause low level exposure to some of the substances listed in the Act.
APPROVALS
Low Lead Content
Note: ASME construction is optional on the water heaters covered in this manual.
3
General Safety Information
Fire or Explosion Hazard
Fire Hazard
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
•
•
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas
pressure.
Use only the gas shown on the water heater rating label.
Maintain required clearances to combustibles.
For continued protection against
risk of fire:
Do not install water heater on
carpeted floor.
Do not operate water heater if
any part has been exposed to
flooding or water damage.
Keep ignition sources away from faucets after extended
periods of non-use.
Fire and Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Use joint compound or Teflon tape
compatible with propane gas.
Leak test before placing the
water heater in operation.
Disconnect gas piping and main
gas shutoff valve before leak
testing.
Install sediment trap in
accordance with NFPA 54.
Fire and Explosion Hazard
Do not use water heater with any gas
other than the gas shown on the rating
label.
Excessive gas pressure to gas valve can
cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
technician for installation and service.
CAUTION
Property Damage Hazard
• All water heaters eventually leak.
Jumping out control circuits or components can
result in property damage, personal injury or death.
• Do not install without adequate drainage.
•
•
Electrical Shock Hazard
•
Turn off power to the water heater
before performing any service.
•
Label all wires prior to disconnecting
when performing service. Wiring errors
can cause improper and dangerous
operation.
•
•
Verify proper operation after servicing.
•
Service should only be performed by a qualified service
technician using proper test equipment.
Altering the water heater controls and/or wiring in any way
could result in permanent damage to the controls or water
heater and is not covered under the limited warranty.
Altering the water heater controls and/or wiring in any way
could result in altering the ignition sequence allowing gas to
flow to the main burner before the hot surface igniter is at
ignition temperature causing delayed ignition which can
cause a fire or explosion.
Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the water heater warranty.
Failure to follow these instructions can
result in personal injury or death.
4
General Safety Information
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Explosion Hazard
Overheated water can cause
water tank explosion.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
This manual must remain with the
water heater.
CAUTION
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Improper installation, use and service may result
in property damage.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
•
Feel water before bathing or
showering.
•
•
•
•
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Do not operate water heater if any part has been exposed
to flooding or water damage.
Inspect anode rods regularly, replace if damaged.
Install in location with drainage.
Fill tank with water before operation.
Properly sized thermal expansion tanks are required on all
closed water systems.
Refer to this manual for installation and service.
Verify the power to the water heater is turned off before performing any service procedures.
General Safety Information
Precautions
Hydrogen Gas Flammable
DO NOT USE THIS water heater IF ANY PART HAS
BEEN EXPOSED TO FLOODING OR WATER DAMAGE.
Immediately call a qualified service technician to inspect the
water heater and to make a determination on what steps
should be taken next.
Explosion Hazard
If the unit is exposed to the following, do not operate heater
until all corrective steps have been made by a qualified
service technician.
Flammable hydrogen gases
may be present.
1. External fire.
2. Damage.
3. Firing without water.
Keep all ignition sources away
from faucet when turning on
hot water.
GROUNDING INSTRUCTIONS
Hydrogen gas can be produced in a hot water system served
by this water heater that has not been used for a long period of
time (generally two weeks or more). Hydrogen gas is extremely
flammable. To reduce the risk of injury under these conditions,
it is recommended that a hot water faucet served by this water
heater be opened for several minutes before using any electrical
appliance connected to the hot water system. If hydrogen is
present there will probably be an unusual sound such as air
escaping through the pipe as the water begins to flow. There
should be no smoking or open flame near the
faucet at the time it is open.
This water heater must be grounded in accordance with the
National Electrical Code and/or local codes. These must be
followed in all cases.
This water heater must be connected to a grounded, permanent
wiring system; or an equipment grounding conductor must be
run with the circuit conductors and connected to the equipment
grounding terminal or lead on the water heater, see Figures 20
and 21.
5
Introduction
Thank You for purchasing this water heater. Properly installed
and maintained, it should give you years of trouble free service.
Abbreviations Used
Warranty on this product is limited and could be void in the
event the unit is not installed per the instructions in this manual
and/or not started up by an authorized factory trained service/
start-up provider.
Abbreviations found in this Instruction Manual include :
Preparing For The Installation
•
•
•
•
•
•
•
ANSI - American National Standards Institute
ASME - American Society of Mechanical Engineers
AHRI - Air-Conditioning, Heating and Refrigeration Institute
NEC - National Electrical Code
NFPA - National Fire Protection Association
UL - Underwriters Laboratory
CSA - Canadian Standards Association
1.Read the “General Safety” section, page 4-5 of this manual
first and then the entire manual carefully. If you don’t follow
the safety rules, the water heater will not operate properly.
It could cause DEATH, SERIOUS BODILY INJURY AND/OR
PROPERTY DAMAGE.
Qualifications
Qualified Installer or Service Agency
Installation and service of this water heater requires ability
equivalent to that of a Qualified Agency (as defined by ANSI
below) in the field involved. Installation skills such as plumbing,
air supply, venting, gas supply and electrical supply are required
in addition to electrical testing skills when performing service.
This manual contains instructions for the installation, operation,
and maintenance of the gas-fired water heater. It also contains
warnings throughout the manual that you must read and be
aware of. All warnings and all instructions are essential to the
proper operation of the water heater and your safety. Since we
cannot put everything on the first few pages, READ THE ENTIRE
MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE
THE WATER HEATER.
2. The installation must conform with these instructions and the
local code authority having jurisdiction. In the absence of local
codes, the installation must comply with the current editions
of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or CAN/
CSA-B149.1 the Natural Gas and Propane Installation 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.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualified Agency” - “Any
individual, firm, corporation or company that either in person or
through a representative is engaged in and is responsible for (a)
the installation, testing or replacement of gas piping or (b) the
connection, installation, testing, repair or servicing of appliances
and equipment; that is experienced in such work; that is familiar
with all precautions required; and that has complied with all the
requirements of the authority having jurisdiction.”
3. If after reading this manual you have any questions or do
not understand any portion of the instructions, call the local
gas utility or the manufacturer whose name appears on the
rating plate.
If you are not qualified (as defined by ANSI above) and licensed
or certified as required by the authority having jurisdiction
to perform a given task do not attempt to perform any of the
procedures described in this manual. If you do not understand
the instructions given in this manual do not attempt to perform
any procedures outlined in this manual.
4. Carefully plan the place where you are going to put the
water heater. Correct combustion, vent action, and vent pipe
installation are very important in preventing death from possible
carbon monoxide poisoning and fires.
START UP REQUIREMENTS
This product requires a formal Start-Up by an authorized
service/
Examine the location to ensure the water heater complies with
the “Locating the New Water Heater” section in this manual.
5. For California installation this water heater must be braced,
anchored, or strapped to avoid falling or moving during
an earthquake. See instructions for correct installation
procedures. Instructions may be obtained from California
Office of the State Architect, 400 P Street, Sacramento,
CA 95814.
start-up provider that has been approved by the manufacturer
for this specific product. Call 1-800-527-1953 to locate the
nearest authorized start-up provider and arrange a factory
start-up. Please provide as much notice as possible, preferably
2 weeks. Please have the model and serial number ready when
you call.
6. Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5.00.
This start-up is required to activate the warranty and ensure
safe, efficient operation.
6
FEATURES AND COMPONENTS
high limit switch
BAROMETRIC DRAFT CONTROL
The dual bulb controller (fig. 1) contains the high limit (energy cutoff)
sensor. The high limit switch interrupts main burner gas flow should
the water temperature reach 205°F (96°C).
The heater is equipped with a double acting barometric draft
control. This control assembly is factory adjusted to automatically
regulate the chimney draft imposed on the unit.
In the event of high limit switch operation, the appliance cannot be
restarted unless the water temperature is reduced by at least 20°F
(11°C) and the high limit reset button on front of limit control (fig.1)
is depressed.
Continued manual resetting of high limit control, preceded by higher
than usual water temperature is evidence of high limit switch operation.
The following is a possible reason for high limit switch operation:
• A malfunction in the thermostatic controls would allow the gas
control valve to remain open causing water temperature to
exceed the thermostat setting. The water temperature would
continue to rise until high limit switch operation.
Contact your dealer or service agent if continued high limit switch
operation occurs.
BAROMETRIC DRAFT CONTROL
FIGURE 3.
COMBUSTION CHAMBER OBSERVATION PORT
The combustion chamber observation access panel is located
above and to the left of the burner. A plug located under the
panel is inserted into the combustion chamber wall. See Figure
4. This plug should not be removed except, in rare cases, when
the combustion chamber requires cleaning or replacement.
DIGITAL THERMOSTAT
FIGURE 1.
electronic ignition control
Each heater is equipped with a Honeywell ignition module. The
Direct Spark Ignition Control Module controls the ignition
sequence and gas control operation of the water heater.
FIGURE 4.
uncrating
Uncrate the heater by removing the outside mat and top locator.
The shipping pallet must be removed from the unit. It may be
possible to simply unbolt the base from the pallet and, with
the help of 2 or more persons, work the unit off the pallet.
Some units will be too heavy and will require the use of jacks
or lifting equipment to safely remove the pallet and move the
unit into position. Be careful when moving this heater. It will
tip over easily.
MPLS., MN 55422
ASSEMBLED IN MEXICO
Explosion hazard. Can cause
serious injury or death.
This device can malfunction if
it gets wet. Never try to use a
device that has been wet - replace it.
S8600M
CONTINUOUS RE-TRY
100% SHUTOFF IP
90 SEC. TRIAL FOR IGNITION
24V, 60Hz
PV=1A MAX., MV=1A MAX
If module has been used with
vent damper, It will only work
with damper connected.
The heater is shipped with a draft control. The draft control is
shipped in a separate carton. It should be installed as received
without any alterations.
Discard the shipping crate and packaging cartons in an
appropriate manner.
IGNITION MODULE
FIGURE 2.
7
installation considerations
Rough In Dimensions
HORIZONTAL & DIRECT VENTING
GPV MODELS
STANDARD BAROMETRIC DRAFT CONTROL
GPG MODELS
MA X IMUM TOTAL 7 5
EQUIVALENT FEET INTAKE
AND EXHAUST ALLOWED.
FIGURE 5.
TABLE 1 . Models GPG/GPV-540A Through GPG/GPV-740A
Models
A
B
C
GPG/GPV
540A
80 3/4
73
32 1/4
2,051
1,854
819
GPG/GPV
650A
80 3/4
73
32 1/4
2,051
1,854
GPG/GPV
740A
80 3/4
73
2,051
1,854
819
D
E
F
9
6
229
152
9
8
819
229
32 1/4
9
229
Gas
Conn.
Approx.
Ship. Wt.
G
H
I
26 1/2
93
29 1/2
48 1/2
1*
950
673
2,362
749
1,232
25.4
431 kg
26 1/2
93
29 1/2
48 1/2
1*
950
203
673
2,362
749
1,232
25.4
431 kg
8
26 1/2
93
29 1/2
48 1/2
1*
950
203
673
2,362
749
1,232
25.4
431 kg
*Minimum gas supply pipe is 1 1/4”, reference Table 11 for gas supply pipe size.
8
installation considerations
TABLE 2. HEATER PERFORMANCE DATA GPG/GPV MODELS
Models
Storage
Capacity
U.S. Gals. (Litres)
Input Rating
BTU/HR.
Nat.
Recovery Rating
GPH
100°F Rise*
Recovery Rating
GPH
140°F Rise*
GPG/GPV-540A
85 (261)
540,000
523.6
374
GPG/GPV-650A
85 (261)
650,000
630
450
GPG/GPV-740A
85 (261)
740,000
718
512
Current Draw
120V
GOHz 1 Phase
6.0 Amps
*Based on 80% thermal efficiency.
NOTE:To compensate for the effects of high altitude areas above 2000 feet, recovery ratings should be reduced approximately
4% for every 1000 feet above sea level.
TABLE 3. GAS AND ELECTRICAL CHARACTERISTICS
Gas Supply Pressure
Model
Type of Gas
Minimum
Maximum
Gas Manifold Pressure
Volts/Hz
Amperes
All Models
Natural
8.0" W.C. (2.0 kPa)
14" W.C. (3.48 kPa)
4.7" W.C. (1.18 kPa)
120/60
<5
* All models are available in Natural Gas only.
Model
GPG/GPV-540A
GPG/GPV-650A
Min. Dynamic Gas Supply Line Pressure
Max. Static Gas Supply Line Pressure
Gas Manifold Pressure
Gas Orifice Size
Air Inlet Damper Dial Setting
Combustion Emissions Range
GPG/GPV-740A
8" w.c. (2 kPa) When heater is ON
14" w.c. (3.5 kPa) When heater is OFF
4.7" w.c.(1.1 kPa) (Ref.)*
4.7" w.c. 1.1 kPa) (Ref.)*
4.7" w.c.(1.1 kPa) (Ref.)*
1/2”
11/16”
N/A
3**
4.5**
5.6**
Flue Gas O2: 5 - 6.5%** (or CO2 reading 8-9%)
* Note: Flue gas excess O2 below 3% may cause combustion chamber premature failure; flue gas excess O2 above 7% may cause rough
operation or incomplete combustion. Final manifold pressure settings should be based on flue O2/CO2 reading!
** Note: Air inlet damper setting needs to be adjusted at field for direct vent and/or high elevation installations.
9
Installation Considerations
locating the water heater
Flammable items, pressurized containers or any other potential
fire hazardous articles must never be placed on or adjacent to
the heater. Open containers or flammable material should not be
stored or used in the same room with the heater.
CAUTION
Property Damage Hazard
The heater must not be located in an area where it will be
subject to freezing.
• All water heaters eventually leak.
Locate it near a floor drain. The heater should be located
in an area where leakage from heater or connections will
not result in damage to adjacent area or to lower floors of
the structure.
• Do not install without adequate drainage.
When such locations cannot be avoided, a suitable metal drain
pan should be installed under heater. Such pans should be
fabricated with sides at least 2” (50.8 mm) deep, with length
and width at least 2” (50.8 mm) greater than diameter of
heater and must be piped to an adequate drain. Pan must
not restrict combustion air flow.
When installing the heater, consideration must be given to
proper location. Location selected should be as close to the
stack or chimney as practicable, with adequate air supply and
as centralized with the piping system as possible.
clearances
Fire or Explosion Hazard
These heaters are designed for installation on non-combustible
flooring in an alcove with clearances to combustible construction
of 6” (152.4 mm) from the sides and rear, 24” (610 mm)
from the top with a 6” (152.4 mm) minimum between vent
pipe and ceiling.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas
pressure.
Minimum clearance from flue pipe to combustible material is
6” (152.4 mm), see Figure 7.
Use only the gas shown on the water heater rating label.
Maintain required clearances to combustibles.
Units which are to be installed on combustible flooring must
be supported by a full layer of hollow concrete blocks, from
8" to 12" thick and extending 12" (minimum) beyond the
heater in all directions. The concrete blocks must provide an
unbroken concrete surface under the heater with the hollows
running continuously and horizontally. A 3/16 inch steel plate
must cover the concrete blocks. See Figure 6.
Keep ignition sources away from faucets after extended
periods of non-use.
Read instruction manual before
installing, using or servicing
water heater.
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 in such areas if they are installed
18" (457.2 mm) or more above the floor. This may reduce the risk
if location in such an area cannot be avoided.
PROPER INSTALLATION ON COMBUSTIBLE FLOORING
FIGURE 6.
In all installations the minimum combustible clearances
from barometric draft control surface or vent piping shall be
6” (152 mm). Vent piping passing through a combustible wall
or ceiling must be a continuous run (no joints) and retain
6” (152 mm) clearance unless an approved reducing thimble
is used.
Do not install this water heater directly on a carpeted floor. A fire
hazard may result. Instead the water heater must be placed on a metal
or wood panel extending beyond the full width and depth by at least
3" (76.2 mm) in any direction. If the heater is installed in a carpeted
alcove, the entire floor shall be covered by the panel. Also, see the
DRAINING requirements in MAINTENANCE Section.
A service clearance of 30" (762 mm) should be maintained from
serviceable parts, such as relief valves, baffles, thermostats,
cleanout openings or drain valves.
The heater shall be located or protected so it is not subject to physical
damage by a moving vehicle.
10
• DO NOT cover the instruction manual. Keep it on the side of
the water heater or nearby for future reference.
• DO obtain new warning and instruction labels from the
manufacturer for placement on the blanket directly over the
existing labels.
• DO inspect the insulation blanket frequently to make certain it
does not sag, thereby obstructing combustion air flow.
HARD WATER
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 the Maintenance Section in this manual for sediment and
lime scale removal procedures.
Circulation pumps
A circulating pump is used when a system requires a circulating
loop or there is a storage tank used in conjunction with the water
heater. See Water Piping Diagrams in this manual for installation
location of circulating pumps.
See the Circulation Pump Wiring Diagrams in this manual for
electrical hookup information. Install in accordance with the
current edition of the National Electrical Code, NFPA 70 or the
Canadian Electrical Code, CSA C22.1.
All-bronze circulating pumps are recommended for used with
commercial water heaters.
Figure 7.
Some circulating pumps are manufactured with sealed bearings
and do not require further lubrication. Some circulating pumps
must be periodically oiled. Refer to the pump manufacturer’s
instructions for lubrication requirements.
INSULATION BLANKET
CIRCULATING PUMP WIRING DIAGRAM
STORAGE TANK OR BUILDING RECIRCULATION
Breathing Hazard - Carbon Monoxide Gas
FIELD SUPPLIED TEMPERATURE CONTROL
INSTALLED IN THE STORAGE TANK
OR CIRCULATING LOOP RETURN LINE
Do not obstruct water heater air intake
with insulating blanket.
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH WATER HEATER AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
Gas and carbon monoxide detectors
are available.
L1 HOT
Install water heater in accordance with
the instruction manual.
L
120 VAC
POWER
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
CIRC
PUMP
MOTOR
L2 NEUTRAL
Insulation blankets are available to the general public for
external use on gas water heaters but are not necessary
with these products. The purpose of an insulation blanket
is to reduce the standby heat loss encountered with storage
CIRCULATING
PUMPcovered
WIRINGby
DIAGRAM
tank heaters. The
water heaters
this manual meet
TANK
OR BUILDING
RECIRCULATION
or exceedSTORAGE
the Energy
Policy
Act standards
with respect to
insulation and standby heatFIELD
lossSUPPLIED
requirements,
making
an
TEMPERATURE
CONTROL
insulation blanket unnecessary.
INSTALLED IN THE STORAGE TANK
L2 NE
FIGURE 8.
CIRCULATING PUMP WIRING DIAGRAM
DISHWASHER LOOP WITH TOGGLE SWITCH
DISHWASHER
TOGGLE
SWITCH
OR CIRCULATING LOOP RETURN LINE
NOTE: USE
SEPARATE
120 VAC to
POWER
Should
you
choose
apply an insulation blanket to this
SUPPLY FOR PUMP CIRCUIT. DO NOT
heater,
you WITH
should
follow
instructions. See the
SHARE POWER
WATER HEATER
AS THIS these
MAY CAUSE ELECTRICAL LINE NOISE AND
Features
and
Components
section
of this manual for
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
identification
of components mentioned below. Failure to
HOT
follow theseL1instructions
can restrict the air flow required for
proper combustion, potentially resulting in fire, asphyxiation,
serious personal injury
120 VACor death.
CIRC
POWER
NOTE: USE
SUPPLY FO
POWER WIT
CAUSE ELE
TO ERRATI
FIELD SUPPLIED TEMPERATURE
CONTROL INSTALLED IN THE
CIRCULATING LOOP RETURN LINE
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT SHARE
POWER WITH WATER HEATER AS THIS MAY
CAUSE ELECTRICAL LINE NOISE AND LEAD
TO ERRATIC CONTROL SYSTEM OPERATION.
L1 HOT
PUMP
120 VAC
POWER
• DO NOT apply insulation to the top of theMOTOR
water heater, as this
will interfere with safe operation of the draft control.
L2 NEUTRAL
• DO NOT cover the gas control valve, thermostat or the
Temperature-Pressure Relief Valve.
• DO NOT allow insulation to come within 2” (5 cm) of the burners,
to prevent blockage of combustion air flow to the burners.
CIRC
PUMP
MOTOR
L2 NEUTRAL
FIGURE 9.
11
HIGH ALTITUDE INSTALLATIONS
Your State water heater has been designed to operate at
altitudes below 2000 Ft. (609.6 m). For appliance installation
locations with elevations above 2000 Ft. (609.6 m), special
considerations need to be taken. Adjustments for high altitude
can only be made by an State authorized GPG/GPV Start-up
Agent. To ensure your water heater operates properly at high
elevation, an State authorized GPG/GPV Start-up Agent will
readjust the air-intake damper setting and the gas manifold
pressure (if required).
Fire and Explosion Hazard
Under no circumstances should the
input exceed the rate shown on the
water heater’s rating label.
Overfiring could result in fire or
explosion.
Gas and carbon monoxide detectors are
available.
NOTE: Some gas utility companies derate the heating value
of the supplied gas at high elevation. Your authorized start-up
agent must adjust for actual heating value of the gas at the time
of start up.
Breathing Hazard - Carbon Monoxide Gas
Under no circumstances should
the input exceed the rate shown
on the water heater’s rating label.
Overfiring could result in damage to
the water heater and sooting.
Gas and carbon monoxide detectors
are available.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
12
Installation Requirements
4. When installing multiple water heaters in the same gas supply
system it is recommended that individual positive lock-up gas
pressure regulators be installed at each unit.
Gas supply Systems
Low pressure building gas supply systems are defined as those
systems that cannot under any circumstances exceed 14”
W.C. (1/2 PSI Gauge). These systems do not require pressure
regulation. Measurements should be taken to insure that gas
pressures are stable and fall within the requirements stated on
the water heater rating plate. Readings should be taken with
all gas burning equipment off (static pressure) and with all gas
burning equipment running at maximum rate (dynamic pressure).
The gas supply pressure must be stable within 1.5” W.C.
from static to dynamic pressure to provide good performance.
Pressure drops that exceed 1.5” W.C. may cause rough starting,
noisy combustion or nuisance outages. Increases or spikes
in static pressure during off cycles may cause failure to ignite
or in severe cases damage to appliance gas valves. If your
low pressure system does NOT meet these requirements, the
installer is responsible for the corrections.
Power Supply
The water heaters covered in this manual require a 120 VAC,
1Ø (single phase), 60Hz, 15 amp power supply and must also
be electrically grounded in accordance with local codes or, in the
absence of local codes, with the National Electrical Code, ANSI/
NFPA 70 or the Canadian Electrical Code, CSA C22.1.
WATER TEMPERATURE CONTROL AND Mixing Valves
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
High Pressure building supply systems use pressures that
exceed 14” W.C. (1/2 PSI Gauge). These systems must use field
supplied regulators to lower the gas pressure to less than 14”
W.C. (1/2 PSI Gauge). Water heaters require gas regulators that
are properly sized for the water heater input and deliver the rating
plate specified pressures. Gas supply systems where pressure
exceeds 5 PSI often require multiple regulators to achieve desired
pressures. Systems in excess of 5 PSI building pressure should
be designed by gas delivery professionals for best performance.
Water heaters connected to gas supply systems that exceed 14”
W.C. (1/2 PSI Gauge) at any time must be equipped with a gas
supply regulator.
Feel water before bathing or showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Water heated to a temperature which will satisfy clothes washing, dish
washing, and other sanitizing needs can scald and cause permanent
injury upon contact. Short repeated heating cycles caused by small
hot water uses can cause temperatures at the point of use to exceed
the water heater’s temperature setting by up to 20°F (11°C).
All models require a minimum gas supply pressure of 8.0" W.C.
for natural gas and propane gas. The minimum supply pressure
is measured while gas is flowing (dynamic pressure). The supply
pressure should never fall below 8.0" W.C. for natural gas. The
supply pressure should be measured with all gas fired appliances
connected to the common main firing at full capacity. If the supply
pressure drops more than 1.5” W.C. as gas begins to flow to the
water heater then the supply gas system including the gas line and/
or the gas regulator may be restricted or undersized. See Supply
Gas Regulator section and Gas Piping section of this manual. The
gas valve on all models has a maximum gas supply pressure limit
of 14” W.C. The maximum supply pressure is measured while gas
is not flowing (static pressure).
Some people are more likely to be permanently injured by hot water
than others. These include the elderly, children, the infirm and the
physically/mentally disabled. Table 4 shows approximate time-to-burn
relationship for normal adult skin. If anyone using hot water provided
by the water heater being installed fits into one of these groups or if
there is a local code or state law requiring a certain water temperature
at the point of use, then special precautions must be taken.
In addition to using the lowest possible temperature setting that
satisfies the demand of the application a Mixing Valve should be
installed at the water heater (see Figure 10) or at the hot water taps
to further reduce system water temperature.
SUPPLY GAS REGULATOR
Mixing valves are available at plumbing supply stores. Consult a
Qualified Installer or Service Agency. Follow mixing valve manufacturer’s
instructions for installation of the valves.
The maximum allowable gas supply pressure for this water heater is
14" W.C. (3.48 kPa). Install a positive lock-up gas pressure regulator
in the gas supply line if inlet gas pressure can exceed 14" W.C.
(3.48 kPa) at any time. Regulators must be sized/used according to
manufacturer’s specifications.
If a positive lock-up regulator is required follow these instructions:
1. Positive lock-up gas pressure regulators must be rated at or above
the input Btu/hr rating of the water heater they supply.
2. Positive lock-up gas pressure regulator(s) should be installed no closer
than 3 equivalent feet (1 meter) and no farther than 8 equivalent
feet (2.4 meters) from water heater’s inlet gas connection.
3. After installing the positive lock-up gas pressure regulator(s), an
initial nominal supply pressure setting of 8.0" W.C. (2 kPa) while
water heater is operating is recommended and will generally
provide good water heater operation. Some additional adjustment
maybe required later to maintain a steady gas supply pressure.
Table 4.
Water Temperature °F
Time for 1st Degree Burn
(Less Severe Burns)
110
116
116
122
131
140
149
154
(normal shower temp.)
(pain threshold)
35 minutes
1 minute
5 seconds
2 seconds
1 second
instantaneous
Time for Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
45 minutes
5 minutes
25 seconds
5 seconds
2 seconds
1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978)
13
A properly sized thermal expansion tank must be installed on
all closed systems to control the harmful effects of thermal
expansion. Contact a local plumbing service technician to have a
thermal expansion tank installed.
HOT WATER
OUTLET
See Water Line Connections on page 24 and the Water Piping
Diagrams beginning on page 41.
12” TO 15”
(30-38 cm)
TEMPERED WATER
OUTLET
Temperature-pressure relief valve
CHECK
VALVE
COLD
WATER
INLET
CHECK
VALVE
Explosion Hazard
MIXING
VALVE
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
TO TANK
INLET
Properly sized temperaturepressure relief valve must be
installed in opening provided.
FIGURE 10.
Dishwashing Machines
Can result in overheating and
excessive tank pressure.
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 pressure between these limits.
Can cause serious injury or death.
This water heater is provided with a properly rated/sized and certified
combination Temperature-Pressure Relief Valve (T&P valve) by
the manufacturer. The valve is certified by a nationally recognized
testing laboratory that maintains periodic inspection of production
of listed equipment of materials as meeting the requirements for
Pressure Relief Valves for Hot Water Supply Systems, ANSI Z21.22
• CSA 4.4, and the code requirements of ASME.
The National Sanitation Foundation also recommends
circulation of 180°F (82°C) water. The circulation flow rate
should be just enough to provide 180°F (82°C) water at the
point of take-off to the dishwashing machine.
If replaced, the new T&P valve must meet the requirements
of local codes, but not less than a combination TemperaturePressure Relief Valve rated/sized and certified as indicated in
the above paragraph. The new valve must be marked with a
maximum set pressure not to exceed the marked hydrostatic
working pressure of the water heater (150 psi = 1,035 kPa) and
a discharge capacity not less than the water heater Btu/hr or kW
input rate as shown on the water heater’s model rating label.
Adjust flow by throttling a full port ball valve installed in
the circulating line on the outlet side of the pump. Never
throttle flow on the suction side of a pump. See Water Piping
Diagrams in this manual.
Closed Water Systems
NOTE: In addition to the factory installed Temperature-Pressure
Relief Valve on the water heater, each remote storage tank that
may be installed and piped to a water heating appliance must also
have its own properly sized, rated and approved TemperaturePressure Relief Valve installed. Call the toll free technical
support phone number listed on the back cover of this manual
for technical assistance in sizing a Temperature-Pressure Relief
Valve for remote storage tanks.
Water supply systems may, because of code requirements or
such conditions as high line pressure, among others, have
installed devices such as pressure reducing valves, check
valves, and back flow preventers. Devices such as these
cause the water system to be a closed system.
Thermal Expansion
For safe operation of the water heater, the Temperature-Pressure
Relief Valve must not be removed from its designated opening
nor plugged. The Temperature-Pressure Relief Valve must be
installed directly into the fitting of the water heater designed for
the pressure relief valve . Install discharge piping so that any
discharge will exit the pipe within 6 inches (15.2 cm) above an
adequate floor drain, or external to the building. In cold climates
it is recommended that it be terminated at an adequate drain
inside the building. Be certain that no contact is made with any
live electrical part. The discharge opening must not be blocked
or reduced in size under any circumstances. Excessive length,
over 30 feet (9.14 m), or use of more than four elbows can cause
restriction and reduce the discharge capacity of the valve.
As water is heated, it expands (thermal expansion). In a
closed system the volume of water will grow when it is heated.
As the volume of water grows there will be a corresponding
increase in water pressure due to thermal expansion. Thermal
expansion can cause premature tank failure (leakage). This
type of failure is not covered under the limited warranty.
Thermal expansion can also cause intermittent TemperaturePressure Relief Valve operation: water discharged from the
valve due to excessive pressure build up. This condition is
not covered under the limited warranty. The TemperaturePressure Relief Valve is not intended for the constant relief
of thermal expansion.
14
Contaminated Air
No valve or other obstruction is to be placed between the
Temperature-Pressure Relief Valve and the tank. Do not connect
discharge piping directly to the drain unless a 6” (15.2 cm)
air gap is provided. To prevent bodily injury, hazard to life, or
property damage, the relief valve must be allowed to discharge
water in adequate quantities should circumstances demand. If
the discharge pipe is not connected to a drain or other suitable
means, the water flow may cause property damage.
Breathing Hazard - Carbon Monoxide Gas
Install water heater in accordance with
the Instruction Manual and NFPA 54 or
CAN/CSA-B149.1.
To avoid injury, combustion and ventilation
air must be taken from outdoors.
Do not place chemical vapor emitting
products near water heater.
CAUTION
Water Damage Hazard
• Temperature-Pressure Relief Valve discharge
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
pipe must terminate at adequate drain.
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.
T&P Valve Discharge Pipe Requirements:
• Shall not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both
the Temperature-Pressure Relief Valve and the discharge
pipe.
• Must terminate a maximum of six inches above a floor
drain or external to the building. In cold climates, it is
recommended that the discharge pipe be terminated at an
adequate drain inside the building.
• Shall not have any valve or other obstruction between the
pressure relief valve and the drain.
Combustion air that is contaminated can greatly diminish the life
span of the water heater and water heater components such as
hot surface igniters and burners. Propellants of aerosol sprays,
beauty shop supplies, water softener chemicals and chemicals
used in dry cleaning processes that are present in the combustion,
ventilation or ambient air can cause such damage.
Do not store products of this sort near the water heater. Air which
is brought in contact with the water heater should not contain any
of these chemicals. If necessary, uncontaminated air should be
obtained from remote or outdoor sources. The limited warranty
is voided when failure of water heater is due to a corrosive
atmosphere. (See limited warranty for complete terms and
conditions).
Air requirements
Burn hazard.
Hot water discharge.
Breathing Hazard - Carbon Monoxide Gas
Install water heater in accordance with
the Instruction Manual and NFPA 54 or
CAN/CSA-B149.1.
To avoid injury, combustion and ventilation
air must be taken from outdoors.
Do not place chemical vapor emitting
products near water heater.
Keep clear of TemperaturePressure Relief Valve
discharge outlet.
The Temperature-Pressure Relief Valve must be manually operated
at least twice a year. Caution should be taken to ensure that (1) no
one is in front of or around the outlet of the Temperature-Pressure
Relief Valve discharge line, and (2) the water manually discharged
will not cause any bodily injury or property damage because
the water may be extremely hot. If after manually operating the
valve, it fails to completely reset and continues to release water,
immediately close the cold water inlet to the water heater, follow the
draining instructions in this manual, and replace the TemperaturePressure Relief Valve with a properly rated/sized new one.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
For safe operation an adequate supply of fresh uncontaminated
air for combustion and ventilation must be provided.
An insufficient supply of air can 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 sooting of the combustion chamber, burners and
flue tubes and creates a risk of asphyxiation.
NOTE: The purpose of a Temperature-Pressure Relief Valve is to
prevent excessive temperatures and pressures in the storage tank.
The T&P valve is not intended for the constant relief of thermal
expansion. A properly sized thermal expansion tank must be
installed on all closed systems to control thermal expansion, see
Closed Water Systems and Thermal Expansion on page 14.
Do not install the water heater in a confined space unless an
adequate supply of air for combustion and ventilation is brought
in to that space using the methods described in the Confined
Space section that follows.
If you do not understand these instructions or have any questions
regarding the Temperature-Pressure Relief Valve call the toll
free number listed on the back cover of this manual for technical
assistance.
Never obstruct the flow of ventilation air. If you have any doubts
or questions at all, call your gas supplier. Failure to provide the
proper amount of combustion air can result in a fire or explosion
and cause property damage, serious bodily injury or death.
15
Unconfined Space
Direct Vent Appliances
An Unconfined Space is one whose volume IS NOT LESS THAN
50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the
total input rating of all appliances installed in the space. Rooms
communicating directly with the space, in which the appliances
are installed, through openings not furnished with doors, are
considered a part of the unconfined space.
Appliances installed in a Direct Vent configuration that derive all
air for combustion from the outdoor atmosphere through sealed
intake air piping are not factored in the total appliance input Btu/
hr calculations used to determine the size of openings providing
fresh air into confined spaces.
Makeup air requirements for the operation of exhaust fans,
kitchen ventilation systems, clothes dryers and fireplaces shall
also be considered in determining the adequacy of a space to
provide combustion, ventilation and dilution air.
Where exhaust fans are installed, additional air shall be provided
to replace the exhausted air. When an exhaust fan is installed
in the same space with a water heater, sufficient openings to
provide fresh air must be provided that accommodate the
requirements for all appliances in the room and the exhaust fan.
Undersized openings will cause air to be drawn into the room
through the water heater’s vent system causing poor combustion.
Sooting, serious damage to the water heater and the risk of fire
or explosion may result. It can also create a risk of asphyxiation.
Exhaust Fans
Unusually Tight Construction
In unconfined spaces in buildings, infiltration may be adequate
to provide air for combustion, ventilation and dilution of flue
gases. However, in buildings of unusually tight construction (for
example, weather stripping, heavily insulated, caulked, vapor
barrier, etc.) additional air must be provided using the methods
described in the Confined Space section that follows.
Louvers and Grilles
The free areas of the fresh air openings in the instructions that
follow do not take in to account the presence of louvers, grilles or
screens in the openings.
Confined Space
The required size of openings for combustion, ventilation and
dilution air shall be based on the “net free area” of each opening.
Where the free area through a design of louver or grille or screen
is known, it shall be used in calculating the size of opening
required to provide the free area specified. Where the louver and
grille design and free area are not known, it shall be assumed
that wood louvers will have 25% free area and metal louvers and
grilles will have 75% free area. Non motorized louvers and grilles
shall be fixed in the open position.
A Confined Space is one whose volume is less than 50 cubic
feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input
rating of all appliances installed in the space.
Openings must be installed to provide fresh air for combustion,
ventilation and dilution in confined spaces. The required size for
the openings is dependent on the method used to provide fresh
air to the confined space and the total Btu/hr input rating of all
appliances installed in the space.
VENTING INSTALLATION
Fresh Air Openings For Confined Spaces
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. The openings shall communicate directly with the
outdoors. See Figure 11.
Each opening shall have a minimum free area of 1 square inch
per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating
of all appliances installed in the enclosure. Each opening shall
not be less than 100 square inches (645 cm2).
The following instructions shall be used to calculate the size,
number and placement of openings providing fresh air for
combustion, ventilation and dilution in confined spaces. The
illustrations shown in this section of the manual are a reference
for the openings that provide fresh air into confined spaces
only. DO NOT refer to these illustrations for the purpose of vent
installation. See Venting Installation on pages 17 through 23 for
complete venting installation instructions.
Outdoor Air Through One Opening
Outdoor Air Through Two Openings
Figure 12.
Alternatively a single permanent opening, commencing within 12
inches (300 mm) of the top of the enclosure, shall be provided.
See Figure 11. The water heater shall have clearances of at
least 1 inch (25 mm) from the sides and back and 6 inches (l50
mm) from the front of the water heater. The opening shall directly
communicate with the outdoors or shall communicate through a
Figure 11.
The confined space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
16
vertical or horizontal duct to the outdoors or spaces that freely
communicate with the outdoors and shall have a minimum free
area of the following:
The confined space shall be provided with two permanent vertical
ducts, one commencing within 12 inches (300 mm) of the top and
one commencing within 12 inches (300 mm) of the bottom of the
enclosure. The vertical ducts shall communicate directly with the
outdoors. See Figure 14.
1. 1 square inch per 3000 Btu/hr (733 mm2 per kW) of the total
input rating of all appliances located in the enclosure, and
2. Not less than the sum of the areas of all vent connectors
in the space.
Each duct opening shall have a minimum free area of 1 square
inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input
rating of all appliances installed in the enclosure.
Outdoor Air Through Two Horizontal Ducts
When ducts are used, they shall be of the same cross sectional
area as the free area of the openings to which they connect.
The minimum dimension of rectangular air ducts shall be not less
than 3" (76.2 mm).
Air From Other Indoor Spaces
Figure 13.
The confined space shall be provided with two permanent
horizontal ducts, one commencing within 12 inches (300 mm)
of the top and one commencing within 12 inches (300 mm)
of the bottom of the enclosure. The horizontal ducts shall
communicate directly with the outdoors. See Figure 13.
Figure 15.
Each duct opening shall have a minimum free area of 1 square
inch per 2,000 Btu/hr (1100 mm2 per kW) of the aggregate input
rating of all appliances installed in the enclosure.
The confined space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. See Figure 15.
When ducts are used, they shall be of the same cross sectional
area as the free area of the openings to which they connect.
The minimum dimension of rectangular air ducts shall be not
less than 3 inches.
Each opening shall communicate directly with an additional
room(s) of sufficient volume so that the combined volume of all
spaces meets the criteria for an Unconfined Space.
Outdoor Air Through Two Vertical Ducts
Each opening shall have a minimum free area of 1 square inch
per 1,000 Btu/hr (2200 mm2 per kW) of the aggregate input rating
of all appliances installed in the enclosure. Each opening shall
not be less than 100 square inches (645 cm2).
The illustrations shown in this section of the manual are a
reference for the openings that provide fresh air into confined
spaces only.
Do not refer to these illustrations for the purpose of vent
installation. See Venting Installation on pages 17-18 for complete
venting installation instructions.
venting
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.
Remove all soot or other obstructions from the chimney that will
retard a free draft.
Type B venting is recommended with these heaters.
This water heater must be vented in compliance with all local
codes, the current revision of the National Fuel Gas Code
(ANSI-Z223.1) and with the Category I Venting Tables.
If any part of the vent system is exposed to ambient temperatures
below 40°F (4.4°C) it must be insulated to prevent condensation.
• Do not connect the heater to a common vent or chimney with
solid fuel burning equipment. This practice is prohibited by
many local building codes as is the practice of venting gas
fired equipment to the duct work of ventilation systems.
Figure 14.
17
• Where a separate vent connection is not available and the
vent pipe from the heater must be connected to a common
vent with an oil burning furnace, the vent pipe should enter
the smaller common vent or chimney at a point above the
large vent pipe.
Vent connectors making horizontal runs must have a minimum
upward slope toward the chimney or vent of 1/4 inch per foot.
Vent connector length should be kept as short as possible.
Be sure that the vent pipe does not extend beyond the inside
wall of a chimney.
In venting systems where a continuous or intermittent
back (positive) draf t is found to exist, the cause must
be determined and corrected. In some cases, a special
vent cap may be required. Do not install this unit on the
positive draft side of a venting system being served by a
power exhauster.
BAROMETRIC DRAFT CONTROL ASSEMBLY
A double-acting barometric draft control assembly is provided
with each unit. The draft control assembly must be installed
without alteration. This assembly is factory adjusted for horizontal
application only and must be attached to the heater as shown in
Figure 16. The outlet of the draft control assembly may be rotated
to face in direction needed. The assembly must be fitted to the
jacket cover such that it is plumb and level to the ground. Fasten
the draft control assembly to the top cover using sheet metal
screws at three locations, or more, as required.
HORIZONTAL (SIDE-WALL) VENTING FOR GPV MODELS
An exhaust vent hood, vent hood and a flue reducer are
supplied with any unit intended for through-the-wall horizontal
venting. These parts must be installed without alteration. The
vent hood adapter is designed for use with Selkirk Metalbestos
Model PS or Model G venting. See Figure 17.
Dampers or other obstructions must not be installed between the
heater and the barometric draft control assembly.
Do not adjust settings on gate. Counterweight washers are
factory adjusted and should result in breeching pressure
measurements at the combustion test hole within the range shown
in Table 3. See Figure 16.
Refer to Table 6 for limitations of venting system design for
horizontal venting.
Table 6.
NOTE: A negative draft 0.02” to 0.07” w.c. must be maintained in
the vent piping. When installed, the damper gate must pivot freely
in the ring guides. This gate will automatically adjust to regulate
the chimney draft imposed on the heater.
GPV-540A thru 740A
Flue Outlet Dia. (Inches/mm)
9" (228.6)
Flue Reducer
Dimensions - Supplied (Inches/mm)
9" x 8"
228.6 x 203.2
Minimum Outlet Vent Dia. (Inches/mm)
Maximum Number
Of Elbows
8" (203.2)
90°
45°
4
8
Maximum Total Vent System
Length, Equiv. Feet/Meters
75
(23 m)
When calculating the equivalent length of a venting system each
90° elbow is equivalent to 10 feet (3 m) of straight pipe. In no case
45° elbow is equivalent to 5 feet (1.5 m) of straight pipe. In no
case may the sum of the straight pipe lengths and the equivalent
length of the elbows exceeds 80 feet (24.3 m).
Note the minimum vent diameter in Table 2.
Refer to Table 7. for the correct vent terminal size for each heater.
The dimensions noted in Table 7. refer to Figure 17.
PROPER DRAFT CONTROLLER AND
VENT PIPE INSTALLATION
Figure 16.
Table 7.
VENT CONNECTION
Heater
Model
Vent connections must be made to an adequate stack
or chimney. Refer to the National Fuel Gas Code (current
edition) or to the vent pipe manufacturer’s gas vent and
chimney sizing table to properly design and size the venting
system. Refer to Table 5 for the vent pipe size required for
installation to the barometric draft control assembly outlet.
Terminal
Model
A
B
C
D
Rough-In
Dimensions
VH-1-8”
19-7/8”
13”
10-9/16”
8-5/8”
11-1/16”
GPV-540A
Thru
GPV-740A
Table 5. BAROMETRIC DRAFT CONTROL
ASSEMBLY OUTLET SIZE
Model
Flue Outlet
GPG-540A
9″ (228.6 mm)
GPG-650A
9″ (228.6 mm)
GPG-740A
9″ (228.6 mm)
FIGURE 17.
Where an existing chimney or vent is to be used, be sure that
the chimney or vent has adequate capacity for the number
and sizes of gas appliances being vented through it. Inspect
the chimney or vent and remove all soot or other obstructions
which will retard free draft.
Use only the sidewall vent terminal supplied with the heater.
These terminals are specifically listed for use on these
State heaters.
18
SIDEWALL TERMINATION INSTALLATION
6. Install the flue reducer included with the exhaust hood between
the vent system and the heater.
1. If installing only vent (exhaust) piping in a Power Vent
configuration through a sidewall; ensure that all exterior sidewall
clearance requirements for the termination, shown in Figure
18A on page 20, are being maintained. These clearances and
those cited by local and national codes must be maintained.
7. Seal all vent connections and venting with sealants supplied
by vent pipe manufacturer or with a high-temperature
silicone sealant suitable for continuous temperatures of
500°F (260°C). Acceptable sealant include Dow Corning 736
or equivalent.
2. If installing both intake air and vent piping in a Direct Vent
configuration through a sidewall; ensure that all exterior sidewall
clearance requirements for the terminations, shown in Figure
18B on page 21, for the vent and intake air termination are
being maintained. These clearances and those cited by local
and national codes must be maintained.
DIRECT VENTING - FOR BTPV MODELS
All exhaust vent terminal, flue reducer, and intake vent terminal
are supplied with any unit intended for direct venting. These
parts must be installed without alteration.
This heater is category III appliance when used in a direct
vent application. All national and local codes pertaining to the
installation of such an appliance must be followed.
VENT SYSTEM INSTALLATION
This heater is a category III appliance when horizontally vented
through a wall using the supplied sidewall vent terminal. All national
and local codes pertaining to the installation of such venting
systems must be followed.
Horizontal portions of the exhaust vent system must be
installed with a minimum upward slope of 1/4” (6.35 mm) per
foot of length.
Horizontal portions of the vent system must be installed with a
minimum upward slope of 1/4” per foot of length.
Selkirk metalbestos model PS or G vent is approved for use as
exhaust venting on these models. Model PS is a double-wall
vent with a 1” (25.4 mm) air space between pipes. Model G is
a single-wall variation of model PS for use where combustible
clearance is not a concern. See Table 8.
All joints and seams in the venting system must be sealed gas
tight. If a silicone sealer is used, it must have a continuous
temperature rating of at least 500°F (260°C); Dow Corning
736 or equivalent must be used.
Table 8.
Selkirk Metalbestos Model PS
Clearance to Combustibles
Interior
6" (152.4 mm)
Exterior
6" (152.4 mm)
CAUTION
Use only the vent hood supplied with this kit. Only supplied hood
provides required clearances from combustibles, both through
the wall and the exterior siding. Termination of a sidewall vent
system with a device other than the supplied vent hood could
affect system performance and result in a safety hazard.
8” diameter PVC or galvanized pipe is approved for use as
intake venting on these models. Class 63, 100, 125, 200, and
schedule 40 pipe may be used for PVC pipe. Intake venting
must be adequately supported to avoid unnecessary stress on
vent hood, venting, or burner.
IMPORTANT
See Table 9. limitations on venting system design for direct
vent installations.
Plan the layout of the vent system backward from the vent
termination to the water heater.
Table 9.
1. Use the layout of the vent system backward from the vent
termination to the water heater.
Dimension in Inches (mm)
BEWARE OF CONCEALED WIRING AND PIPING INSIDE
OF WALL. REFER TO TABLE 7 FOR THE MAXIMUM WALL
THICKNESS “B” FOR EACH MODEL.
GPV-540A thru 740A
Flue Outlet Dia.
Flue Reducer Dimension (Supplied)
Min. Exhaust Vent Dia. Inch (mm)
Min. Intake Vent Dia. Inch (mm)
2. Slide hood through opening from outside. Fasten hood to
exterior wall with anchors and screws supplied.
Maximum Number Of Elbows, Intake
3. Install covers plate and fasten to inside wall with 4 screws.
Maximum Number Of Elbows, Exhaust
9 (229)
90°
45°
90°
45°
Max.
Min.
Max.
9 x 8 (229 x 203)
8 (203)
8 (203)
4
8
4
8
75 (23 m)
3 ( 1 m)
75 (23 m)
Min.
6 (1.8)
4. Attach a seal ring (Meltalbestos SR or equivalent) to the
vent hood collar, see Figure 7. Attach Selkirk Metalbestos
model PS or model G venting to the seal ring following the
venting manufacturer’s instructions. For total safety, it is
recommended that only venting listed for use with category
III appliances (positive vent pressure, non-condensing)
should be used between the heater and the vent hood, even
through national or local codes may allow the use of type B
or single-wall vent.
Note: Barometric draft control is not used in direct vent installations
as the venting system must be sealed.
5. Install the remaining vent sections back to the heater, following
the venting manufacturer’s instructions on assembling and
sealing joints. Follow good venting practice regarding properly
supporting vent system and keeping the number of offsets to
a minimum. See Table 6 for the maximum allowable number
of elbows in venting system.
When calculating the equivalent length of a venting system each
90 elbow is equivalent to 10 feet of straight pipe. Each 45 elbow
is equivalent to 5 feet (1.5 m) of straight pipe. Do not exceed the
maximum number of elbows as shown in Table 9. In no case may
the sum of the straight pipe lengths and the equivalent lengths of
the elbows exceed the values shown in Table 9.
Total Intake Vent Length, Equiv. Ft.
Total Exhaust Vent Length, Equiv. Ft.
19
Termination Clearances Sidewall Power Vent
POWER VENT
(using room air for combustion)
EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION
G
V
D
H
A
v E
L
v
B
FI XE D
CLOSED
V
F
OPERABLE
V
OPERABLE
V
B
B
C
B
B
FI XE D
CLOSED
V
M
X
V
K
J
A
X
V
B
V
X
VENT TERMINAL
AIR SUPPLY INLET
AREA WHERE TERMINAL IS NOT PERMITTED
Figure 18A
Vent terminal clearances for “Power Vent” installations. Power Vent configurations use room air for combustion.
Canadian Installations
A
Clearance above grade,
veranda, porch, deck or 12 inches (30 cm)
balcony
B
Clearance to window
or door that may be
opened
1
6 inches (15 cm) for appliances up to
10,000 Btu/hr (3 kW), 12 inches (30
cm) for appliances between 10,000
Btu/hr (3 kW) and 100,000 Btu/hr (30
kW), 36 inches (91 cm) for appliances
above 100,000 Btu/hr (30 kW)
US Installations
2
12 inches (30 cm)
4 feet (1.2 m) below
or to side of opening;
1 foot (30 cm) above
opening
Canadian Installations
H
I
Clearance to each side
of center line extended
above meter/regulator
assembly
Clearance to service
regulator vent outlet
1
US Installations
3 feet (91 cm) within a height 15 feet
(4.5 m) above the meter/
regulator assembly
3 feet (91 cm) within a
height 15 feet (4.5 m)
above the meter/regulator
assembly*
3 feet (91 cm)
3 feet (91 cm)*
6 inches (15 cm) for appliances up
to 10,000 Btu/hr (3 kW), 12 inches
(30 cm) for appliances between
10,000 Btu/hr (3 kW) and 100,000
Btu/hr (30kW), 36 inches (91cm)
for appliances above 100,000 Btu/
hr (30 kW)
6 feet (1.83 m)
C
Clearance to
permanently closed
window
12 inches (30 cm)*
12 inches (30 cm)*
J
Clearance to a non
mechanical air supply
inlet into building or
combustion air inlet to
any other appliance
D
Vertical clearance to
ventilated soffit located
above the terminal
within a horizontal
12 inches (30 cm)*
distance of 2 feet (61
cm) from the center line
of the terminal
12 inches (30 cm)*
K
Clearance to a
mechanical air supply
inlet
E
Clearance to
unventilated soffit
12 inches (30 cm)*
12 inches (30 cm)*
L
Clearance above paved
sidewalk or paved
7 feet (2.13 m)†
driveway located on
public property
F
Clearance to outside
corner
2 feet (60 cm)*
2 feet (60 cm)*
M
Clearance under
veranda, porch, deck, or 12 inches (30 cm) ‡
balcony
G
Clearance to inside
corner
18 inches (45 cm)*
18 inches (45 cm)*
4 feet (1.2 m) below or to
side of opening; 1 foot
(30 cm) above opening.
3 feet (91 cm) above if
within
10 feet (3 m) horizontally
7 feet (2.13 m)
12 inches (30 cm) ‡
1 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code.
2 In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings where it may
cause hazardous frost or ice accumulations on adjacent property surfaces.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.
20
2
Termination Clearances Sidewall Direct Vent
DIRECT VENT
(using outdoor air for combustion)
EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION
G
V
D
H
A
v E
L
v
B
FI XE D
CLOSED
V
F
B
B
C
V
OPERABLE
V
OPERABLE
B
B
FI XE D
CLOSED
V
M
X
V
K
J
A
X
V
B
V
VENT TERMINAL
X
AIR SUPPLY INLET
AREA WHERE TERMINAL IS NOT PERMITTED
Figure 18B
Vent terminal clearances for “Direct Vent” installations. Direct Vent configurations use outdoor air for combustion.
Canadian Installations
A
Clearance above grade,
veranda, porch, deck or
balcony
B
6 inches (15 cm) for appliances
up to 10,000 Btu/hr (3 kW), 12
inches (30 cm) for appliances
Clearance to window or
between 10,000 Btu/hr (3 kW)
door that may be opened
and 100,000 Btu/hr (30 kW), 36
inches (91 cm) for appliances
above 100,000 Btu/hr (30 kW)
12 inches (30 cm)
1
US Installations
2
Canadian Installations
1
US Installations
Clearance to each side
3 feet (91 cm) within a height 15
of center line extended
feet (4.5 m) above the meter/
above meter/regulator
regulator assembly
assembly
3 feet (91 cm) within a height
15 feet (4.5 m) above the
meter/regulator assembly*
I
Clearance to service
regulator vent outlet
3 feet (91 cm)
3 feet (91 cm)*
6 inches (15 cm)*
J
Clearance to a non
mechanical air supply
inlet into building or
combustion air inlet to
any other appliance
6 inches (15 cm) for appliances up
to 10,000 Btu/hr (3 kW), 12 inches
(30 cm) for appliances between
10,000 Btu/hr (3 kW) and 100,000
Btu/hr (30 kW), 36 inches (91 cm)
for appliances above 100,000 Btu/
hr (30 kW)
6 inches (15 cm) for
appliances up to 10,000
Btu/hr (3 kW), 9 inches (23
cm) for appliances between
10,000 Btu/hr (3 kW) and
50,000 Btu/hr (15 kW), 12
inches (30 cm) for appliances
above 50,000 Btu/hr (15 kW)
6 feet (1.83 m)
3 feet (91 cm) above if within
10 feet (3 m) horizontally
12 inches (30 cm)
6 inches (15 cm)
for appliances up to
10,000 Btu/hr (3 kW),
9 inches (23 cm) for
appliances between
10,000 Btu/hr (3 kW)
and 50,000 Btu/hr (15
kW), 12 inches (30 cm)
for appliances above
50,000 Btu/hr (15 kW)
H
C
Clearance to
permanently closed
window
D
Vertical clearance to
ventilated soffit located
above the terminal within
12 inches (30 cm)*
a horizontal distance of
2 feet (61 cm) from the
center line of the terminal
12 inches (30 cm)*
K
Clearance to a
mechanical air supply
inlet
E
Clearance to unventilated
12 inches (30 cm)*
soffit
12 inches (30 cm)*
L
Clearance above
paved sidewalk or
7 feet (2.13 m)†
paved driveway located
on public property
7 feet (2.13 m)†*
F
Clearance to outside
corner
2 feet (60 cm)*
2 feet (60 cm)*
M
Clearance under
veranda, porch, deck,
or balcony
12 inches (30 cm) ‡*
G
Clearance to inside
corner
18 inches (45 cm)*
18 inches (45 cm)*
6 inches (15 cm)*
2
12 inches (30 cm) ‡
1 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code.
2 In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings where it may
cause hazardous frost or ice accumulations on adjacent property surfaces.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.
21
DIRECT VENT SYSTEM INSTALLATION
11. Use an expansion joint between any two fixed points in the
exhaust venting system wherever the expansion may exceed
1/4”. Selkirk Metalbestos model PS and model G venting
will expand by one inch per 100°F in gas temperature per
100 feet of vent length. The expansion can be calculated by
the following formula:
Plan the vent system backwards from the vent hood to the heater.
1. Use the inside wall cover plate as a template to mark two
holes in the appropriate places on the wall. Cut holes
1/2” (12.7 mm) larger to facilitate easy installation of vent hoods,
see Figures 18B and 19.
BEWARE OF CONCEALED WIRING AND PIPING INSIDE
WALL. REFER TO TABLE 3 FOR THE MAXIMUM WALL
THICKNESS “B” FOR EACH MODEL.
2. Slide hoods through openings from outside. Fasten hoods
to exterior wall with anchors and screws supplied.
3. Install cover plate and fasten to inside wall with 4 screws
Expansion =
Inches
If the expansion calculated is greater than 1/4”, an expansion
joint must be used between the two fixed points.
4. Attach a seal ring (Selkirk Metalbestos Model SR or
equivalent) to the vent hood collar, see Figure 19.
13. Attach the flue reducer to the vent system using a seal ring.
Attach this ring to the venting using the inner vee bands as
outlined in Steps 5-7.
15. Attach 8” air-intake connector back to the 6” burner air inlet
with 8” x 6” reducer. Prime and cement each joint to assure
gas-tight construction.
7. Position the inner vee bands around the inner pipe flanges
and tighten the screws securing the bands.
16. Seal all joints at the vent hoods with silicone sealant. Also
seal the joints at the flue collar and air inlet adapter. Joint
on the exhaust side must be sealed with high-temp silicone
sealant, Dow Corning 736 or equivalent.
8. Align the outer channel band with the outer pipe grooves and
tighten the screws securing the bands.
9.Repeat steps 6-8 for each successive pipe length until the
venting reaches the heater.
10.Follow the manufacturer’s instructions for proper support and
guide spacing for horizontal runs of pipe, see Table 10.
Table 10.
F
8" - GPG-540A thru 740A
15' 3"
15' 3"
5/100
14. Attach 8” air-intake connector to intake vent hood collar. It
may be necessary to use a slip-slip coupling to fit the pipe to
the intake vent hood.
6.Fill the grooves in both inner vee bands with high-temp silicone
sealant, Dow Corning 736 or equivalent.
S
x
12. Attach the flue reducer included in the exhaust vent hood
package to the flue collar on the heater.
5. Attach a properly sized length of Selkirk Metalbestos model
PS or model G venting to the exhaust vent adapter using the
inner vee bands, see Figures 19 and 19B.
Vent Diameter
Vent length between
two fixed points, feet
S = Maximum spacing between two guides or a support
and a guide in either a vertical or horizontal direction.
F = Maximum height above a guide or support for free
standing system above a roof or parapet wall.
22
FIGURE 19B.
FIGURE 19.
23
water heater installation
Water Line Connections
T&P Valve Discharge Pipe
The water piping installation must conform to these instructions
and to all local code authority having jurisdiction. Good practice
requires that all heavy piping be supported.
Explosion Hazard
Read and observe all requirements in the following sections
before installation of the water piping begins:
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
1. Water Temperature Control and Mixing Valves on page 13.
2. Dishwashing Machines on page 14.
Properly sized temperaturepressure relief valve must be
installed in opening provided.
3. Temperature-Pressure Relief Valve on page 14-15.
4. Closed Systems and Thermal Expansion on page 14.
5. For multiple water heater installations see Water Piping
Diagrams beginning on page 41.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
Water (potable) Heating And Space Heating
1. All piping components connected to this unit for space
heating applications shall be suitable for use with potable
water.
This water heater is provided with a properly rated/sized and
certified combination temperature - pressure (T&P) relief
valve by the manufacturer. See Temperature-Pressure Relief
Valve on pages 14-15 for information on replacement and
other requirements.
2. Toxic chemicals, such as those used for boiler treatment,
shall NEVER be introduced into this system.
3. This unit may NEVER be connected to any existing
heating system or component(s) previously used with a
non-potable water heating appliance.
CAUTION
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 beginning on page 39 of this
manual for suggested piping arrangements.
Water Damage Hazard
• Temperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
5. These water heaters cannot be used in space heating
applications only
Install a discharge pipe between the T&P valve discharge opening
and a suitable floor drain. Do not connect discharge piping
directly to the drain unless a 6” (15.2 cm) air gap is provided.
To prevent bodily injury, hazard to life, or property damage, the
relief valve must be allowed to discharge water in adequate
quantities should circumstances demand. If the discharge pipe is
not connected to a drain or other suitable means, the water flow
may cause property damage.
Thermometers (not Supplied)
Thermometers should be obtained and field installed as shown
in the installation diagrams.
Thermometers are installed in the system as a means of
detecting the temperature of the outlet water supply.
T&P Valve Discharge Pipe Requirements:
Water Piping Diagrams
• Shall not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restrictions.
This manual provides detailed water piping diagrams for typical
methods of application for the water heaters, see Water Piping
Diagrams beginning on page 41.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
The water heater may be installed by itself, or with a separate
storage tank. When used with a separate storage tank, the
circulation may be either by gravity or by means of circulating
pump. Adjust flow by throttling a full port ball valve installed in the
circulating line on the outlet side of the pump. Never throttle flow
on the suction side of a pump. See the Water Piping Diagrams
beginning on page 41.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both
Temperature-Pressure Relief Valve and the discharge pipe.
• Must terminate a maximum of six inches above a floor
drain or external to the building. In cold climates, it is
recommended that the discharge pipe be terminated at an
adequate drain inside the building.
Call the toll free technical support phone number listed on the
back cover of this manual for further assistance in sizing a T&P
valve for remote storage tanks.
• Shall not have any valve or other obstruction between the
relief valve and the drain.
24
Installation Diagrams - Top Inlet/Outlet Usage
heater wiring
Use of the top inlet water connection requires an inlet dip tube
(refer to Figure 20). The tube is supplied in the heater. Follow
caution labels if applying heat to this fitting. Do not allow pipe
dope to contact the plastic tube during installation.
Tube Inlet Installation
All electrical work must be installed in accordance with the
current edition of the National Electrical Code ANSI/NFPA No.
70 or Canadian Electrical Code CSA C22.1 and must conform
to all local code authority having jurisdiction. AN ELECTRICAL
GROUND IS REQUIRED TO REDUCE RISK OF ELECTRICAL
SHOCK OR POSSIBLE ELECTROCUTION.
If any of the original wire as supplied with the water heater must be
replaced, use only type 105°C thermoplastic or equivalent 2500C
type F must be used for the flame sensor and igniter leads.
The controls of this water heater are polarity sensitive. Be
certain to properly wire the hot and neutral connections.
Figure 20.
Figure 21.
25
Figure 22.
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.
Schedule 40 Steel or Wrought Iron Pipe is the preferred material
for the gas line of this water heater. It is imperative to follow the
sizing recommendations in the latest version of the National Fuel
Gas Code if Corrugated Stainless Steel Tubing (CSST) is used as
the gas line for this water heater.
Size the main gas line in accordance with Table 11. The figures
shown are for straight lengths of pipe at 0.5 in. W.C. pressure drop,
which is considered normal for low pressure systems. Note: Fittings
such as elbows, tees and line regulators will add to the pipe pressure
drop. Also refer to the latest version of the National Fuel Gas Code.
The heater is not intended for operation at higher than 14.0" W.C.natural gas, (1/2 pound per square inch gage) supply gas pressure.
Exposure to higher supply pressure may cause damage to the
gas valve which could result in fire or explosion. If overpressure
has occurred such as through improper testing of gas lines or
26
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.
two threads. Use compounds resistant to the action of liquefied
petroleum gases.
Gas Meter Size – Natural Gases Only
Be sure 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 gas meter is too small, ask
the gas company to install a larger meter having adequate capacity.
Table 11. MAXIMUM CAPACITY OF PIPE IN
CUBIC FEET OF GAS PER HOUR
(Based upon a Pressure Drop of 0.5 inch Water Column and
0.6 Specific Gravity Gas and max. gas pressure of .5 psig)
GAS PIPING AND SEDIMENT TRAP INSTALLATION
NOMINAL IRON PIPE SIZE (INCHES)
LENGTH
IN FEET
1/2
3/4
1
10
175
360
680
20
120
250
465
950
1,460 2,750 4,350
7,700
15,800
30
97
200
375
770
1,180 2,200 3,520
6.250
12.800
40
82
170
320
660
990
1,900 3,000
5,300
10,900
50
73
151
285
580
900
1,680 2,650
4,750
9,700
60
66
138
260
530
810
1,520 2,400
4,300
8,800
70
61
125
240
490
750
1,400 2,250
3,900
8,100
80
57
118
220
460
690
1,300 2,050
3,700
7,500
90
53
110
205
430
650
1,220 1,950
3,450
7,200
100
50
103
195
400
620
1,150 1,850 3,250
6,700
125
44
93
175
360
550
1,020 1,650 2,950
150
40
84
160
325
500
1 1/4 1 1/2
2
2 1/2
3
4
1,400 2,100 3,950 6,300 11,000 23,000
950
1,500
2,650
6,000
5,500
175
37
77
145
300
460
850
1,370
2,450
5,000
200
35
72
135
280
430
800
1,280
2,280
4,600
Figure 23.
Table 11A.
Gas Line Leak Testing
LENGTH
IN
METERS
3.0
1/2"
3/4"
1"
2"
2 1/2"
3"
4"
51
105
199
410
615
1160
1845
3221
6735
6.1
35
73
142
278
428
805
1277
2255
4626
9.1
28
59
110
225
346
644
1031
1830
3748
12.2
24
50
94
193
290
556
878
1552
3192
Nominal Iron Pipe Sizes, Millimeters
1 1/4" 1 1/2”
15.2
21
44
83
170
264
492
776
1391
2840
18.3
19
40
76
155
237
445
703
1259
2577
21.3
18
37
70
143
220
410
659
1142
2372
24.4
17
35
64
135
202
381
600
1083
2196
2108
27.4
16
32
60
126
190
357
571
1010
30.5
15
30
57
117
182
337
542
952
1962
38.1
13
27
51
105
161
299
483
864
1757
45.7
12
25
47
95
146
278
439
776
1610
53.3
11
23
42
88
135
249
401
717
1464
61.0
10
21
40
82
126
234
375
688
1347
Fire and Explosion Hazard
Use joint compound or Teflon tape
compatible with propane gas.
Leak test before placing the water
heater in operation.
Disconnect gas piping and main gas
shutoff valve before leak testing.
Install sediment trap in accordance
with NFPA 54.
Any time work is done on the gas supply system perform a leak
test to avoid the possibility of fire or explosion.
1. For test pressures exceeding 1/2 psi (3.45 kPa) disconnect
the water heater and its Main Gas Shutoff Valve from the
gas supply piping system during testing, see Figure 23. The
gas supply line must be capped when disconnected from the
water heater.
It is important to guard against gas valve fouling from contaminants
in gas ways. Such fouling may cause improper operation, fire
or explosion.
2. For test pressures of 1/2 psi (3.45 kpa) or less, the water
heater need not be disconnected, but must be isolated from
the supply gas line by closing the Main Gas Shutoff Valve
during testing.
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.
3. Coat all supply gas line joints and connections upstream of the
water heater with a non-corrosive soap and water solution to
test for leaks. Bubbles indicate a gas leak. Do not use matches,
candles, flame or other sources of ignition for this purpose.
To trap any dirt or foreign material in the gas supply line, a
sediment trap must be incorporated in the piping (see Figure 23).
The sediment trap must be readily accessible and not subject to
freezing conditions. Install in accordance with recommendations
of serving gas suppliers. Refer to the latest version of the National
Fuel Gas Code.
4. Repair any leaks before placing the water heater in operation.
Purging
To prevent damage, care must be taken not to apply too much
torque when attaching gas supply pipe to gas valve inlet.
Gas line purging is required with new piping or systems in which air
has entered.
Apply joint compounds (pipe dope) sparingly and only to the
male threads of pipe joints. Do not apply compounds to the first
Purging should be performed per the current edition of NFPA 54 the
National Fuel Gas Code.
27
START-UP and OPERATION
• Attach a gas pressure gauge or manometer to upstream side
of main gas cock and a gas pressure gauge or manometer to
the manifold pressure tapping.
• Check voltage at disconnect switch to make certain that it
matches that shown on the burner label.
• Apply a few drops of No. 20 SAE non-detergent oil to the
motor bearings.
• Drill max. 5/16" hole in breeching as close as possible to flue
connection on heater to install stack thermometer and
combustion analyzing equipment. (See Figure 16).
•You are now ready to begin the burner start up procedure.
Fire or Explosion Hazard
Gas line purging is required with new piping or systems in
which air has entered.
To avoid risk of fire or explosion purge discharge must not
enter into confined areas or spaces where ignition can occur.
The area must be well ventilated and all sources of ignition
must be deactivated or removed.
Installation and start up of this water heater requires abilities and
skills equivalent to that of a licensed tradesman in the field involved,
see Qualifications on page 6.
Do not place the water heater in operation if any part has been under
water. Immediately call a qualified service technician to inspect the
water heater and to replace any part of the control system and any
gas control which has been under water.
Read instruction manual before
installing, using or servicing
water heater.
Light the water heater in accordance with the Lighting and Operation
Instruction label on the water heater and in this manual on pages 25.
Prior to Start Up
Before attempting start up, thoroughly study and know the exact
Sequence Of Operation. See written Sequence Of Operation on
page 28.
This product requires a formal Start-Up by an authorized service/
start-up provider that has been approved by the manufacturer for
this specific product. Call 1-800-527-1953 to locate the nearest
authorized start-up provider and arrange a factory start-up. Please
provide as much notice as possible, preferably 2 weeks. Please
have the model and serial number ready when you call.
This start-up is required to activate the warranty and ensure safe,
efficient operation.
Warranty on this product is limited and could be void in the event
the unit is not installed per the instructions in this manual and/or not
started up by an authorized factory trained service/start-up provider.
The following test equipment should be on hand: (all test equipment
must be acclimated to ambient temperature before calibration and use.)
1. CO2 indicator (Fyrite or similar) or O2 analyzer
2. CO indicator (Monoxor or similar)
3. Stack thermometer
4. Draft Gauge or inclined manometer
5. Two U-tube manometers or calibrated 0-10" and 0-35" w.c.
pressure gauges.
6. Combination volt/ammeter.
Be certain that the water heater is full of water, that air is purged from
the gas and water lines and that there are no leaks in the gas and
water lines. Ensure all inlet water valves are open.
Filling The Water Heater
Follow these steps to fill the water heater prior to start up.
1. Close the heater drain valve.
2. Open a nearby hot water faucet to permit air in system to escape.
3.Fully open the cold water inlet valve allowing the piping and
water heater to fill with water.
4. Close hot water faucet opened in Step 2 as water starts to flow.
Read SEQUENCE OF OPERATION section of this manual prior
to lighting and operating this water heater.
With above conditions satisfied, start the unit in accordance with the
instructions on the operating label attached to the heater. For your
convenience a copy of the instructions are shown on pages 30.
SEQUENCE OF OPERATION
10. The voltage generates a spark at the ignitor that lights the pilot.
The following information will describe the Sequence of Operation
for this water heater.
11. If the pilot does not light (or flame signal is less than 1 micro A)
within 15 seconds system locks out and must be reset by turning
burner switch “OFF” for a minimum of 1 minute. During system
lockout, blower still runs.
1. Power on.
2. Heater in standby mode.
3. Thermostat calls for heat.
4. Blower motor starts.
12. When the pilot flame is established (flame is sensed by flame
rod), the main gas valve is energized.
5. Blower operation closes the normally open blower prover / blocked
outlet safety pressure switch.
13. Main gas flows to main burner where it’s ignited by the pilot
flame. Now heater is in Heating Mode.
6. On proof of airflow, Honeywell S8680J flame control module
energized.
14. During the Heating Mode:
7. 45 seconds prepurge cycle begins.
8.Following prepurge cycle, the pilot gas valve is energized.
9. At the same time, the electronic spark generator in the module
produces a high voltage spark pulse output.
28
If gas line pressure drops below the setting point, the flame
module is de-energized, gas valves closed, blower still runs.
If gas line pressure drops below the setting point then gas line
pressure increases to above the setpoint, heater starts again
from purging cycle.
17. Thermostat is satisfied, switch opens.
If gas line pressure fluctuates around the setpoint too quick
(less than a second) burner may still run with excessive gas
valve ON/OFF cycle you must turn off the unit immediately,
re-adjust the gas line regulator and/or install a larger gas
supply line!
18. Power is interrupted to the flame control module and blower
motor. Gas valves are closed.
19. Heater is in Standby Mode.
If the blower inlet and/or intake hood, or flue outlet/hood is/
are blocked for any reason, the safety switches will open,
which will de-energize the flame control module.
20. Thermostat is satisfied, switch opens.
21. Power is interrupted to burner, turning off blower and ignition
control module. Solenoid and main gas valves are closed.
15. The spark generator is off.
22. Insufficient blower pressure causes safety pressure switches
to open.
16. The flame module monitors pilot flame current. Should the
flame failure occur during the Heating Mode, the unit will
start again from purging cycle.
29
LIGHTING & OPERATION LABEL
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING: If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal injury or
loss of life.
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.
A. This appliance is equipped with an ignition device which
automatically lights the burner.
Do NOT try to light burner by hand.
• If you cannot reach your gas supplier, call the fire department.
B. BEFORE LIGHTING: 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.
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,
don’t try to repair it, call a qualified service technician.
Force or attempted repair may result in a fire or explosion.
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.
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.
E. Do not operate appliance unless unit is filled with water
and inlet lines are fully open.
FIGURE “A”
FIGURE “B”
“OFF POSITION”
“ON POSITION”
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above on this label.
8. Turn on all electric power to the appliance.
9. Set thermostat to desired setting.
2.Remove appliance thermostat cover. Rotate thermostat
to lowest setting.
dial counterclockwise
10. Turn switch to “ON” position.
3. Turn off all electric power to the appliance.
4. This appliance is equipped an ignition device which
automatically lights the burner. Do NOT try to light the
burner by hand.
5.Refer to diagrams above. Turn top knob of gas control
clockwise to “OFF” position (Figure A).
6. Wait five (5) minutes to clear out any gas. If you then smell gas,
STOP! Follow “B” in the safety information above
on this label. If you don’t smell gas, go to next
step.
7. Turn top knob of gas control counterclockwise
“ON” (Figure B).
to
11.Heater will automatically begin operation. Blower motor
will run approximately 40 seconds, then pilot gas valve
will open. Upon confirming the pilot flame the main gas
valve will open and the heater will operate in heating
mode. Reference “Sequence of Operation” section of
manual for details.
12.Heater is equipped with an ignition module which locks
out after one (1) unsuccessful ignition attempt. Blower
motor will continue to run. If lockout occurs, turn burner
switch to “OFF” position for at least one minute, then turn
the switch back to “ON”. Heater will automatically begin
operation.
13.Replace thermostat control cover.
14. If the appliance will not operate, follow the instructions
“TO TURN OFF GAS APPLIANCE” and call your service
technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1.Remove thermostat control cover.
4. Turn off all electric power to the appliance if service is
to be performed.
2. Set thermostat to lowest setting.
5. Turn top knob of gas control to the “OFF” position. Refer
to Step 5 of ‘OPERATING INSTRUCTION” above.
3. Turn burner switch to “OFF”.
6.Replace thermostat control cover.
Figure 24. Label for Natural Gas Models
30
Adjustments
Important Note: Final gas and air settings should be based
on flue gas CO 2 or O 2 reading (see Table 3). Increase burner
manifold pressure will increase fire rate and flue gas CO2 reading.
Increase air damper setting will decrease fire rate and decrease
flue gas CO2 reading. Adjustable air damper is preset for the rated
fire-rate prior to delivery, should not be re-adjusted unless it’s
a high elevation application and/or a direct vent (long air intake
vent) application.
A minimum dynamic gas supply pressure of 8” w.c. for natural
gas is required before making any adjustment to the gas control
pressure regulator. Attempts to adjust the regulator during periods
of low gas supply pressure could result in overfiring of the heater
when the gas supply pressure returns to normal.
1. Check gas line pressure with a manometer.
Set initial gas line pressure at 9-10” w.c. before turning the
heater “ON”.
1.Fire Rate Adjustment (including direct vent installation).
Read gas line pressure and gas manifold pressure when the
heater main gas is “ON”.
a. M a k e s u r e t h e g a s s u p p l y l i n e p r e s s u r e r e a d s
8” w.c. (2 kPa) or higher when the heater is running.
Adjust gas line regulator setting if the gas line pressure drops
below 8” w.c. when heater main gas is “ON”.
Check heater gas manifold pressure (see Table 3) using a
manometer connected to the manifold pressure tap on the
Robertshaw gas control valve, see Figure 32.
b.R e m o v e t h e p r e s s u r e r e g u l a t o r c o v e r s c r e w
(Figure 32) and adjust the pressure by tuning the adjustment
screw w/a small screwdriver clockwise to increase gas pressure
into the burner and fire rate. Counterclockwise to decrease gas
pressure and input rate.
c. Clock gas meter, repeat above Step (b) to achieve the
specific input rate.
d. Measure f lue gas O 2 and/or CO 2 (see Table 10) for
acceptable O 2 /CO 2 range.
Important Note: Use gas manifold pressure as initial setup only.
The final air and gas settings should be based on fire rate and
flue gas 0 2 /C02 reading, see Table 10 for normal 0 2 /C02 reading.
Excessive gas line pressure drop and/or burner manifold
pressure too low may cause burner start /operate with
excessive noise!
2. Cycle the burner “ON” and “OFF” several times to check
its operation. Make sure the gas line pressure is below
14” w.c. when burner is “OFF”. If gas line pressure exceeds 14”
w.c. when the burner is off, the gas supply line size must be
increased to correct this problem (see Table 9 for gas pipe size).
If the O2 or CO2 reading is within the acceptable range, then
proceed to Step (f).
If the O 2 or CO 2 reading is out of range, adjust air
damper is required.
e.Repeat Steps (b), (c), (d) if air damper is adjusted.
f. Cycle heater ON/OFF.
g.Replace the gas regulator cover, pressure tap and
tighten the damper center bolt.
2. Adjustment for Low NOx Emission Application.
3. Check the operation of the limiting and operating controls.
4. Check the vent system seams and joints and ensure that there
is no discharge of flue products into the room. For standard
vertical vent systems, check the barometric damper control to
make sure it operates freely and there is no discharge of flue
products into the room.
5. Check the input rate by clocking the gas meter.
ADJUSTMENT PROCEDURE FOR FIRE-RATE, LOW
NOX AND HIGH ELEVATION (Fine-Tune)
The water heater is preset at factory for Low Nox emission
combustion. Due to the installation variations, fine-tune
adjustments may be required. To lower NOx emission level
(30PPM corrected at 3% O 2 or lower is required by SCAQMD),
air damper setting may need to be slightly increased. To
increase air damper setting, loosen the center nut of the inlet
air damper, rotate the damper clockwise slightly, then tighten
the center nut. After re-set the air damper, cycle heater
ON/OFF and check fire-rate and flue gas CO 2 /O 2 reading.
3. Adjustment for High Elevation Application
An acceptable input rate is within 2% of the rated input for the
model. Should it be necessary to adjust the gas pressure to the
burner and/or air damper of the blower to obtain the full input rate,
these steps should be followed:
Installation above 2000 feet sea level requires new air damper
settings. All final settings should be based on flue gas CO2 /O 2
reading, see Table 3. To increase air damper setting, loosen the
center bolt of the inlet air damper, rotate the damper clockwise
slightly, then tighten the center bolt. After re-setting the air
damper, cycle heater ON/OFF and check fire-rate and flue
gas CO 2 /O 2 reading.
Never set burner combustion too lean (causing noisy operation)
or too rich (causing combustion chamber premature failure)
see Table 3 for proper settings.
UNDER NO CIRCUMSTANCES SHOULD THE INPUT RATE
EXCEED THE INPUT RATE SHOWN IN THE HEATER RATING
PLATE. OVERFIRING COULD RESULT IN DAMAGE OR
SOOTING OF THE HEATER.
Never set the air damper outside of its adjustment range
of the rated fire rate unless authorized by an A. O. Smith
Service Center.
SHOULD OVERHEATING OCCUR OR GAS SUPPLY FAIL TO SHUT
OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO THE
APPLIANCE.
31
PREMIX LOW NOx BURNER - EXPLODED VIEW FOR GPG MODELS
FIGURE 25.
For all parts on this burner contact: Wayne Combustion Systems, 801 Glasgow Ave., Fort Wayne, IN 46803
32
PREMIX LOW NOx BURNER - EXPLODED VIEW FOR GPV MODELS
FIGURE 26.
For all parts on this burner contact: Wayne Combustion Systems, 801 Glasgow Ave., Fort Wayne, IN 46803
33
mAINTENANCE
venting system and BAROMETRIC DRAFT CONTROL
heater where the thermostat senses the drop in water temperature
and activates main burner operation of the water heater.
The heater is equipped with a double acting barometric draft
control. This control assembly is factory adjusted to automatically
regulate the chimney draft imposed on the unit. The damper gate
must pivot freely in the ring guides. See Figure 27.
If the storage tank temperature control is out of calibration, replace
with new control.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL
TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE
TO THE Water heater.
temperature-Pressure relief Valve test
Burn hazard.
Hot water discharge.
Keep clear of TemperaturePressure Relief valve
discharge outlet.
BAROMETRIC DRAFT CONTROL
Figure 27.
Examine the venting system every six months for obstructions
and/or deterioration of the vent piping.
Remove all soot or other obstructions from chimney which will
retard free draft.
It is recommended that the Temperature-Pressure Relief Valve should
be checked to ensure that it is in operating condition every 6 months.
GENERAL
When checking the Temperature-Pressure Relief Valve operation,
make sure that (1) no one is in front of or around outlet of TemperaturePressure Relief Valve discharge line, and (2) that water discharge
will not cause any property damage, as water may be extremely hot.
Use care when operating valve as valve may be hot.
Water heater maintenance includes periodic tank flushing and
cleaning, and removal of lime scale. The power burner should be
inspected and adjusted to maintain proper combustion. Refer to
Table 12. A periodic inspection of the venting system and barometric
damper should be made. Where used, the water heating system
circulating pump should be oiled per manufacturer's instructions.
To check the pressure relief valve, lift lever at the end of valve several
times, see Figure 28. The valve should seat properly and operate freely.
If after manually operating the valve, it fails to completely reset and
continues to release water, immediately close the cold water inlet to
the water heater and drain the water heater, see Draining And Flushing
on page 32. Replace the Temperature-Pressure Relief
Following are the instructions for performing some of the
recommended maintenance. Power burner inspection and
adjustment should be performed by a competent technician.
Table 12.
Valve with a properly rated/sized new one, see Temperature-Pressure
Relief Valve on pages 14-15 for instructions on replacement.
RECOMMENDED MAINTENANCE SCHEDULE
FOR THE BTP HEATER
COMPONENTS
OPERATION
INTERNAL
Flushing
Monthly
Tank
Sediments
Removal
Semi-Annually
Lime Scale
Removal
As Required
REQUIRED
Unlime
Delimer
Relief Valve
Inspect
Semi-Annually
Circulating Pump
and Power
Burner Motor
Oiling
Quarterly
SAE No. 20
Non-Detergent
Motor Oil
Power Burner
and Ignition
Device
Inspection
and
Adjustment
Semi-Annually
Combustion Test
Kit and Test
Specifications
Main Burner
Vent System and
Inspect
Semi-Annually
Barometric
Damper
Inspect
Semi-Annually
Anode(s)
Inspect
Annually
Figure 28.
If the Temperature-Pressure Relief Valve on water heater weeps
or discharges periodically, this may be due to thermal expansion.
NOTE: Excessive water pressure is the most common cause of
Temperature-Pressure Relief Valve leakage. Excessive water system
pressure is most often caused by "thermal expansion" in a "closed
system." See Closed Water Systems and Thermal Expansion on
page 14. The Temperature-Pressure Relief Valve is not intended for
the constant relief of thermal expansion.
Draft Gauge
remote storage tank temperature control
Water temperature in remote storage tank (if used) is controlled by the
storage tank temperature control. The sensing element is mounted
in the hot water storage tank, see Water Piping Diagram section.
Temperature-Pressure Relief Valve leakage due to pressure build
up in a closed system that does not have a thermal expansion
tank installed is not covered under the limited warranty. Thermal
expansion tanks must be installed on all closed water systems.
A change in water temperature in the storage tank lower than the
tank temperature control setting will cause the sensor to activate the
circulating pump. The pump then circulates the water through the
DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF
VALVE OPENING. THIS CAN CAUSE PROPERTY DAMAGE,
SERIOUS INJURY OR DEATH.
34
It is recommended that the water heater storage tank be drained
and flushed every 6 months to reduce sediment buildup. The
water heater should be drained if being shut down during freezing
temperatures. See Features And Components in this manual for
the location of the water heater components described below.
TO DRAIN THE WATER HEATER STORAGE TANK:
1. Turn off the electrical supply to the water heater.
2. Turn off the gas supply at the Main Gas Shutoff Valve if the
water heater is going to be shut down for an extended period.
3. Ensure the cold water inlet valve is open.
4. Open a nearby hot water faucet and let the water run until the
water is no longer hot.
5. Close the cold water inlet valve to the water heater.
6. Connect a hose to the water heater drain valve and terminate
it to an adequate drain.
7. Open the water heater drain valve and allow all the water to
drain from the storage tank.
8. Close the water heater drain valve when all water in the
storage tank has drained.
9. Close the hot water faucet opened in Step 4.
10.If the water heater is going to be shut down for an extended
period, the drain valve should be left open.
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
Properly sized temperaturepressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
anode rod inspection
CAUTION
Property Damage Hazard
TO FLUSH THE WATER HEATER STORAGE TANK:
1. Turn off the electrical supply to the water heater.
2. Ensure the cold water inlet valve is open.
3. Open a nearby hot water faucet and let the water run until the
water is no longer hot. Then close the hot water faucet.
4. Connect a hose to the drain valve and terminate it to an
adequate drain.
5. Ensure the drain hose is secured before and during the entire
flushing procedure. Flushing is performed with system water
pressure applied to the water heater.
6. Open the water heater drain valve to flush the storage tank.
7. Flush the water heater storage tank to remove sediment and
allow the water to flow until it runs clean.
8. Close the water heater drain valve when flushing is completed.
9. Remove the drain hose.
10.Fill the water heater - see Filling The Water Heater in this manual.
11. Turn on electrical supply to place water heater back in operation.
12.Allow the water heater to complete several heating cycles to
ensure it is operating properly.
• Avoid water heater damage.
• Inspection and replacement of anode rod required.
The anode rod is used to protect the tank from corrosion. Most
hot water tanks are equipped with an anode rod. The submerged
rod sacrifices itself to protect the tank. Instead of corroding tank,
water ions attack and eat away the anode rod. This does not affect
water’s taste or color. The rod must be maintained to keep tank in
operating condition.
Anode rod deterioration depends on water conductivity, not
necessarily water condition. A corroded or pitted anode rod indicates
high water conductivity and should be checked and/or replaced more
often than an anode rod that appears to be intact. Replacement
of a depleted anode rod can extend the life of your water heater.
Inspection should be conducted by a qualified technician, and at a
minimum should be checked annually after warranty period.
Artificially softened water is exceedingly corrosive because the
process substitutes sodium ions for magnesium and calcium ions.
Use of a water softener may decrease the life of water heater tank.
recommended procedure for periodic
removal of lime deposits from tank type
commercial water heaters
The anode rod should be inspected after a maximum of three
years and annually thereafter until condition of anode rod dictates
its replacement. Anode replacement is not covered by warranty.
NOTE: artificially softened water requires the anode rod to be
inspected annually.
The amount of calcium carbonate (lime) released from water is
in direct proportion to water temperature and usage, see chart.
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.
Lime accumulation not only reduces the life of equipment but also
reduces efficiency of the heater and increases fuel consumption.
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.
The time between cleaning will vary from weeks to months
depending upon water conditions and usage.
The depth of lime buildup should be measured periodically. Heaters
equipped with cleanouts will have about 2" of lime buildup when
the level of lime has reached the bottom of the cleanout opening. A
schedule for deliming should then be set up,based on the amount
of time it would take for a 1" buildup of lime. It is recommended that
the water heater initially be inspected after 6 months.
Example 1:
Initial inspection after 6 months shows 1/2" of lime accumulation.
Therefore, the heater should be delimed once a year.
Example 2:
Initial inspection after 6 months shows 2" of lime accumulation.
Therefore, the heater should be delimed every 3 months.
Draining and flushing
Burn harzard.
Hot water discharge.
Keep hands clear of drain
valve discharge.
35
Pounds of Lime Deposited Per Year
180
Prepare the Water Heater
180°F
210
To delime the water heater using the Flo-Jug method, first
prepare the heater for deliming.
For 10 Grain Hardness Lime
Deposited vs. Temperature
and Water Use
Data From Purdue Bulletin 74
170°F
150
160°F
120
Explosion Hazard
90
Flammable hydrogen gases
may be present.
150°F
60
Keep all ignition sources away
from faucet when turning on
hot water.
140°F
30
120°F
300
900
1500
2100
2700
3300
3900
Gallons of Hot Water Used Per Day
Do not smoke or have open flame or sparks in vicinity of heater.
Do not mix UN•LIME with other chemicals. Do not allow contact
with magnesium, aluminum or galvanized metals.
Figure 29.
deliming solvents
UN•LIME is recommended for deliming. UN•LIME is a patented
food grade acid which is safe to handle and does not create the
harmful fumes which are associated with other products.
Chemical Hazard
UN•LIME may be obtained from your dealer, distributor or
water heater manufacturer. Order Part Number 9005416105,
1 gallon, packed 4 gallons per case or Part Number 9005417105,
5 gallon container.
• Product contains phosphoric acid.
• Keep out of reach of children.
• Use rubber or neoprene gloves.
NOTE: Un•Lime is not available for use in Canada.
Hydrochloric base acids are not recommended for use on glass
lined tanks.
Observe handling instructions on label of product being used.
Contains phosphoric acid. In case of external contact, flush with
cool water. If irritation persists, get medical attention. If swallowed,
give 1 or 2 glasses of water or milk and call physician.
tank Cleanout Procedure
Get immediate medical attention for eyes. Keep out of reach
of children.
NOTE: THE USE OF RUBBER OR NEOPRENE GLOVES IS
RECOMMENDED, ESPECIALLY IF YOU HAVE ANY OPEN
SORES OR CUTS TO AVOID UNNECESSARY IRRITATION OR
DISCOMFORT.
The following practices will ensure longer life and enable the
unit to operate at its designed efficiency:
1. Once a month the heater should be flushed. Open drain valve
and allow two gallons of water to drain from heater. Inlet water
valve should remain open to maintain pressure in tank.
2. A cleanout opening is provided for periodic cleaning of the tank.
Gas must be shut off and heater drained before opening cleanout.
1. Turn off fuel and/or power supply to heater. Also, turn off power
to any electrical device or equipment, which is attached, or part
of the system.
2. Open hot water side of faucet closest to heater and allow water
to run until it is cool enough to handle safely.
3. Close cold water inlet valve to heater.
4. Connect hose to drain valve at bottom of heater and start draining
heater into suitable floor drain area.
5. Remove pressure relief valve while heater is draining. NOTE:
Do not replace pressure relief valve until deliming is completed.
Pressure relief valve opening will also act as a vent in case of
possible contact between the delimer and the anode rod(s),
which may produce flammable hydrogen-air mixtures.
6. If pressure relief valve appears to be limed-up, place it in a clean
glass or plastic container adequate in size so that you can pour
enough UN•LIME® into container to cover the valve and allow
space for foaming. When foaming stops, run fresh cool water into
the container and rinse the pressure relief valve for a few minutes.
7. If heater does not drain completely after a reasonable length
of time, turn off the main water supply valve to stop water from
entering the tank due to a by-pass problem or defective cold
water inlet valve. Also, check for clogged drain valve opening.
Heater must be completely drained before introducing UN•LIME.
8. Remove the cleanout cover and place a clean plastic bucket
next to the cleanout opening.
Partially open the cold water inlet valve to allow time to
accomplish the following and then close the valve.
To clean heater through cleanout opening, proceed as follows:
3. Drain heater.
4. Remove outer cover plate from lower side of heater jacket.
5. Remove six (6) hex head screws securing tank cleanout plate
and remove plate.
6. Remove lime, scale, or sediment using care not to damage
the glass lining.
7. Inspect cleanout plate gasket, if new gasket is required,
replace with part no. 9004099215.
8. Install cleanout plate. Be sure to draw plate up tight by
tightening screws securely.
9. Replace outer jacket cover plate.
In some water areas the sediment might not be removed
by this method and may result in the water heater making
rumbling or boiling noises. To dissolve and remove these more
stubborn mineral deposits, UN•LIME Professional Delimer
should be used.
DELIMING USING FLO-JUG METHOD
UN•LIME in the 5 gallon size is recommended for deliming of all
models. Contact your local dealer, distributor or, water heater
manufacturer:
36
While the water is being run through the tank, insert a
stiff wire, copper tube flattened at one end or an opened
wire coat hanger through the cleanout opening and
scrape out any loose deposits of scale or sediment. This
is an economical way to avoid unnecessary usage of the
deliming solution.
Normally, lime removal will be completed within one hour.
Severe build-up of lime may take longer than an hour to complete
descaling.
Note: To check UN•LIME for continued use, place some scale
or white chalk in a glass with a small amount of UN•LIME. If
the material is vigorously dissolved by the UN•LIME, it can be
reused; if not, the UN•LIME should be replaced.
Repeat the opening and closing of the cold water inlet valve
as necessary but be sure the heater is completely drained
when ready to introduce the UN•LIME.
Upon completion, reinstall the cleanout cover and use a new
cleanout cover gasket (part number 9004099215).
Remove the drain valve.
9. Install the long plastic male adapter insert fitting into the drain
valve opening of heater after applying Teflon tape or paste to
threads. Tighten firmly by hand and use wrench or adjustable
pliers to check for secure connection. Do not over tighten to
avoid damage to threads and fittings.
Prepare the Up-N-Down Transfer Kit
The next step is the preparation on the Up-N-Down Transfer Kit,
if you have not already done so:
1. With the 5 gallon Up-N-Down container in the vertical
position, unscrew the plastic vent cap in the handle and
pierce the plastic membrane over the vent boss under the
cap to allow the container to vent.
Figure 30.
power Burner
Keep the area around the burner clear and free of combustible
materials, gasoline or other flammable liquids or vapors.
Do not obstruct burner air openings or ventilation grilles for
combustion air.
Note: If your container does not have the vent cap and vent
boss, drill a 3/16” hole in the handle. When you have finished
deliming you will be able to plug this drilled vent with the
stainless steel screw that is supplied with the kit.
2. Remove the container’s cap and cut the plastic membrane
located in the 3/4” IPT opening in the cap. Take care to not
damage the threads.
3. Find the 3/4” male adapter, apply teflon tape to the threaded
end and screw it into the 3/4” IPT opening in the cap.
4. Put cap with male adapter back on the container and slide
3/4” hose over end of male adapter and fasten in place using
hose clamp provided.
Delime using Flo-Jug Method
5. Slide the hose clamp over end of hose and slide hose over
the male adapter in the water heater drain opening and
secure in place using hose clamp.
TYPICAL MAIN BURNER FLAME
Figure 31.
The main burner flames (Figure 31) should be visually checked
once a year for proper operation. This can be observed through
the observation port on the burner housing. Burner flame should
be blue. DO NOT use the observation port on the side of the tank
to inspect the burner flame.
6. Lift container to the “Pour” Position, see Figure 30, being
careful to keep the vent in the handle above the liquid level
and pour the UN•LIME into the heater.
7. Lower container, you may have to place the container on its
empty carton to prevent the UN•LIME from flowing back into
the container.
1. Add a few drops of no. 20 non-detergent oil (GPG/GPV-540A
thru 740A) into the oil tubes once every three months.
2. At least annually, contact a qualified service technician for
a burner readjustment, cleaning and other than routine
maintenance.Should the main burner or burner air openings
require cleaning, remove the burner and clean with a soft
brush. Clean main burner orifice with a suitable soft material.
8. Let UN•LIME remain in the heater for 5 minutes and then
lower the container to the “Drain” Position, see Figure 30.
9. Deliming activity is indicated by foaming on the surface of the
UN•LIME. If there is deliming activity, repeat steps 6 thru 8.
37
Gas Control Valve
Figure 32 shows the combination gas control valves used on
these heaters.
If gas control valve becomes defective, repairs should not
be attempted. A new valve should be installed in place of
defective one.
Figure 32.
SERVICE
ELECTRICAL SERVICING
The installer may be able to observe and correct certain problems
which may arise when the unit is put into operation. HOWEVER,
it is recommended that only a qualified service technician or
qualified agencies, using appropriate test equipment, be allowed
to service the heater.
As preliminary step, check wiring against diagram, check for
grounded, broken or loose wires. Check all wire ends to be sure
that they are making good contact.
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND
DANGEROUS OPERATION.
VERIFY PROPER OPERATION AFTER SERVICING.
Troubleshooting
loose connections or a locked rotor. If the rotor cannot be freed
the motor and blower assembly must be replaced.
BURNER LOCKOUT ONCE IN A WHILE
JUMPING OUT COMPONENTS AND/OR CIRCUITS DURING
TROUBLESHOOTING CAN CAUSE SERIOUS PROBLEMS
WITH THE POWER BURNER’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 A. O. SMITH EQUIPMENT.
Under this condition, the burner operates properly for days, and burner
lockout occurs once in a while. The root causes for the burner occasional
lockout include: (1) Gas inlet pressure too low; (2) Condensation over the
ignitor area; (3) the pilot flame is too weak to light the main flame reliably;
(4) the pilot air/gas ratio is out of range causing pilot flame to be unreliable.
ALTERING THE IGNITION MODULE AND / OR CONTROL
BOX 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.
2. Install manometers for gas inlet pressure, manifold pressure, and
pilot gas pressure, see Figure 32 for the pressure ports location).
1. Turn burner switch to “OFF” position and turn off the main
gas valve (Robertshaw®).
3. Check for the gas inlet pressure, reset the service regulator (if
required) to get 8” w.c. (2.0 kPa) - 10” w.c. (2.4 kPa) inlet pressure
while the burner is in the “OFF” position.
4. Turn the burner “ON”,
NOTE: ANY BYPASS OR ALTERATION OF UNITS SAFETIES
WILL RESULT IN VOIDING APPLIANCE WARRANTY.
Before performing any troubleshooting familiarize yourself with
the particular appliance. State power burners are supplied with
Honeywell® ignition control systems and Robertshaw® gas control
valves, see Figures 25 and 32.
Refer to the SEQUENCE OF OPERATION and burner exploded view,
see Figure 22 and the wiring diagram located on page 25, and the
troubleshooting section of burner manual before continuing.
• Take blower pressure at the pressure port during the purge cycle, see Figure 25 for location.
• Take the pilot gas pressure at the same pressure port during
the ignition period (following 45 seconds purge cycle).
• The pilot gas pressure should be 0.6” - 0.9” w.c. higher
than blower pressure, if not, adjust the pilot gas regulator (during
the ignition cycle, see Figure 25.
• If burner lights on during the ignition cycle, cycle the
unit on/off several times to ensure pilot system is
reliable. Turn off the burner, then follow Step 6.
Make sure the appliance is connected to a 120 Vac power supply,
burner switch is “ON” and manual gas valve is in the “ON” position, and
all electrical connections are secure before continuing to troubleshoot
this appliance.
5. Turn the burner “OFF”, follow burner manual instructions to remove
the pilot assembly (also refer to Figure 25 in this manual) and
procedures to check pilot assembly. Items to check for the pilot
system include:
MOTOR WILL NOT RUN
• Check for condensation over ignitor area.
1. Confirm 120 Vac. Also, to verify correct polarity, check for
120 Vac between black wire and G.
• Check for the ignitor gap (1/8” - 3/16”).
• Check for the thermal cutoff continuity by ohm meter,
replace it if the thermal cutoff is open.
• Check for the low gas pressure switch by ohm meter
(while pilot gas pressure is 7” w.c. [1.7 kPa] or higher).
If there is no voltage, check for a loose connection or open switch
at the high limit or thermostat.
2. If there is 120 volts between black wire and white wire, check for
38
• Check for the continuity between the flame rod and
sensor connection at Honeywell flame control module by
the ohm meter.
• Check for ignitor wire connections and spark leakage
(call AOS service center for steps of spark leakage checking).
•Following burner manual instructions to re-install the
pilot assembly.
• If 24V is detected for a period of 15 seconds, check for the changes
of gas supply line pressure when the pilot gas valve is energized.
If no visible pressure change during the pilot ignition period, check
for loose connection of the pilot valve or a defective pilot gas valve.
• Adjust the pilot gas regulator setting during the pilot ignition period
(15 seconds window). Do not set too much or too little pilot gas.
This adjustment should only be performed during the 15 seconds
ignition period. A clockwise or counter-clockwise 0.5 to 1 turn should
be able to correct the problem. Refer to burner manual for detailed
pilot gas setting procedure.
6. Turn on the Robertshaw gas valve, turn the burner switch to “ON”
position. Cycle the heater ON/OFF several times to ensure the
problem is solved.
MOTOR RUNS CONTINUOUSLY, PREPURGE TIME ELAPSES
BUT MAIN FLAME NOT ESTABLISHED (BURNER LIGHT
NEVER ON)
• If still no pilot flame inside the burner, check for the spark ignitor
wiring, ignitor tip location and visually check the spark (burner
pilot assembly needs to be taken out for the visual check). Refer
to the burner manual for detailed spark ignition troubleshooting
procedures.
1. When the heater is first installed, gas line must be purged
properly prior to start-up. This heater is equipped with a flame
control module that only allows one “trial for ignition” for
15 seconds and locks out if no flame signal is detected. For initial
start-up, two or more resets may be required to ensure that all the
air has been purged from the gas pilot line. To reset the heater, turn
the burner power switch to “OFF” position for at least one minute,
then turn it back “ON”.
6. Pilot flame established but not detected by the flame control
module. Use Micro Amp meter to measure flame signal during the
pilot ignition period. Refer to burner manual for testing procedures.
• If pilot flame is confirmed visually through the burner peek hole, and
the flame signal is zero, the thermal-cutoff safety switch (mounted
nearby the flame rod, inside the burner mixing chamber) may be
broken or check for loose wire connections or low gas switch
(mounted inside control panel) may be broken. If the thermal
cutoff switch or low gas switch is broken (by checking the switch
continuity), the switches must be replaced before the heater can
operate again.
2. Check for gas supply line manual valves in “ON” position, and line
pressure. Make sure the pilot manual gas cock (nearby the main
gas valve) is fully open.
3. After the 45-seconds prepurge cycle, the pilot gas valve (mounted
on the panel) “click” sound should be heard. If you hear the pilot
gas energized, proceed to Step 5.
4. Check 24 Vac control circuit in the following systematic approach:
• If it’s confirmed that the thermal cutoff switch is damaged (open),
call the State Technical Center to analyze the root cause (too lean
combustion) and proper gas/air ratio adjustment. Flashback will
cause the thermal cutoff switch to be broken (open).
• Check for 24V between “24V” and “GND” of Honeywell Flame
Control Module, which is located inside the burner control panel.
If voltage is OK, proceed to Step 5.
• If there’s no voltage, check for 24V between the air switch “COM”
terminal and GND (the air switch is mounted on the control panel,
the switch cover needs to be removed to access the wiring
terminal “COM” and “NO”). If there’s no 24 V, check for a loose
connection between the 24V transformer and air switch, or a
defective transformer.
• If the flame signal is not zero but below 1µA, relocate flame rod
or replace flame rod will be required. Refer to burner manual for
detailed procedure of replacing flame rod.
MOTOR RUNS CONTINUOUSLY, BURNER LIGHTS ON
MOMENTARILY THEN LOCKS OUT OR EXCESSIVE ON/
OFF CYCLE
• If there’s 24V at “COM” terminal, check for 24V between the air
switch terminal “NO” (normally open) and GND. If there’s no 24V,
the air switch pressure may be set too high or a defective air switch
or loose connections of pressure sensing tubings. To lower the air
switch setting, make sure the blower is running and blower wheel
and air inlet are free from dirt, counterclockwise turn the switch
setting-screw until the switch is closed. Call the State Technical
Center before you reset the switch.
Under this condition, the burner will start the purge cycle again, then pilot
ignition and main flame cycle. If main flame cannot be sustained:
1. Make sure main manual gas valve (right after the Robertshaw gas
valve) is fully open;
2. Check for 24V at the Robertshaw gas valve when the main gas light
is on. If there’s no 24V at the valve, check loose wire connection.
• If there’s 24V at “NO” terminal of the air switch, check for 24V
at the air intake pressure switch connectors, (this switch is only
supplied for direct vent systems). If there’s no 24V at the switch
connectors, check for loose connections, air intake blockage, or
a defective air switch.
3. Check for gas supply line pressure. The gas line pressure
before the valve should be maintained at minimum
8” w.c. when main flame is “ON”. If the gas line pressure drops
below 8” w.c. (2 kPa), the service regulator pressure setting must
be increased to keep 8” w.c. (2 kPa) minimum gas pressure. After
adjusting the gas regulator setting, turn off the heater, make sure
the gas line pressure does not exceed 14” w.c. (3.5 kPa) if it does
exceed 14” w.c. (3.5 kPa) static pressure, the gas supply line size
must be increased accordingly to avoid gas line pressure exceeding
14” w.c. (3.5 kPa)
• Do not proceed to Step 5 unless 24V is detected at “24V” terminal
of the Honeywell Module.
5. As soon as the pilot gas valve is energized, check for the burner
pilot flame through the burner peek-hole. If the pilot flame is
established inside the burner, then proceed to Step 6.
4. Check the gas valve manifold pressure (refer to Table 10), see
ADJUSTMENT PROCEDURE to adjust the manifold pressure.
• Turn the burner switch to “OFF” position for at least one minute to
reset the heater.
5. Check for defective gas valve for failing to open or shut off.
• Check for 24V between “PV” terminal and “MV/PV” terminal
after 45 seconds prepurge cycle (this 24V may only last
15 seconds starting after 45S prepurge). If there’s no 24V at the
“PV” terminal ever, and there’s 24V at “24V” terminal, the Honeywell
flame control module needs to be replaced.
6. Verify that the air supply is adequate. The air inlet screen or blower
wheel may be restricted.
7. Check the installation for proper ventilation, see AIR
REQUIREMENTS.
39
8. Verify the air switch setting is not too high.
GAS FAILS TO SHUT OFF
9. Check the venting system for the correct sizing, excessive or
insufficient draft, and proper operation of the barometric draft
control, see VENTING.
Check for defective gas valve or thermostat. If operation is
incorrect, replace.
NOISY BURNER OPERATION
REPLACEMENT PARTS
1. Check for flue gas excess O2 or CO2 reading (refer to Table 3). If
combustion is too lean (flue gas O2 reads more than 7.5%), the
combustion flame front may not be stable, which will cause noisy
operation. See ADJUSTMENT.
Replacement parts may be ordered through State
dealers, unauthorized servicers or distributors. Refer to
the Yellow Pages for where to call or contact the State Water
Heaters, 500 Tennessee Waltz Parkway, Ashland City, TN 37015,
1-800-821-2017 or visit our website at www.statewaterheaters.com
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. .
2. Check the venting system for the correct sizing, excess or
insufficient draft, and proper operation of the barometric draft
control, see VENTING.
3. If the burner operation is still noisy, then remove the burner, examine
the burner diffuser, blast-tube tip, anti-flashback corrugated tube,
center mixing, refer to the burner manual for details.
For Your Information
c. A sulfate reducing bacteria which has accumulated
within the water heater (this harmless bacteria is
nontoxic to humans).
start up conditions
SMOKE/ODOR
d. An excess of active hydrogen in the tank. This is caused
by the corrosion protective action of the anode rod.
It is not uncommon to experience a small amount of smoke and
odor during the initial start-up. This is due to burning off of oil
from metal parts, and will disappear in a short while.
Smelly water may be eliminated or reduced in some water
heater models by replacing the anode rod(s) with one of less
active material, and then chlorinating water heater tank and all
water lines.
STRANGE SOUNDS
Possible noises due to expansion and contraction of some metal
parts during periods of heat-up and cool-down do not necessarily
represent harmful or dangerous conditions.
Contact the local water heater supplier or service agency for
further information concerning an Anode Rod Replacement Kit
and this chlorination treatment.
Condensation causes sizzling and popping within the burner area
during heating and cooling periods and should be considered
normal. See “Condensation" section in this manual.
If smelly water persists after anode rod replacement and chlorination
treatment, we can only suggest that chlorination or aeration of the
water supply be considered to eliminate the water problem.
CONDENSATION
Whenever the water heater is filled with cold water, some
condensate will form while the burner is on. A water heater may
appear to be leaking when in fact the water is condensation.
This usually happens when:
Do not remove the anode rod leaving the tank unprotected. By
doing so, all warranty on the water heater tank is voided.
“AIR” IN HOT WATER FAUCETS
HYDROGEN GAS: Hydrogen gas can be produced in a hot
water system that has not been used for a long period of time
(generally two weeks or more). Hydrogen gas is extremely
flammable and explosive. To prevent the possibility of injury under
these conditions, we recommend the hot water faucet, located
farthest away, be opened for several minutes before any electrical
appliances which are connected to the hot water system are
used (such as a dishwasher or washing machine). If hydrogen
gas is present, there will probably be an unusual sound similar to
air escaping through the pipe as the hot water faucet is opened.
There must be no smoking or open flame near the faucet at the
time it is open.
a. A new water heater is filled with cold water for the first time.
b. Burning gas produces water vapor in water heaters,
particularly high efficiency models where flue temperatures
are lower.
c. Large amounts of hot water are used in a short time and the
refill water in the tank is very cold.
Moisture from the products of combustion condense on the cooler
tank surfaces and form drops of water which may fall onto the
burner or other hot surfaces to produce a “sizzling” or “frying” noise.
operational conditions
HIGH WATER TEMPERATURE SHUT OFF SYSTEM
HOT WATER ODOR
This water heater is equipped with a manual reset type high limit
(Energy Cutout) switch. The high limit switch interrupts the main
burner gas flow should water temperature reach 203°F (95°C).
In each water heater there is installed at least one anode rod for
corrosion protection of the tank. Certain water conditions will
cause a reaction between this rod and the water. The most
common complaint associated with the anode rod is one of a
“rotten egg smell” in the hot water. The smell is a result of four
factors which must all be present for the odor to develop:
In the event of high limit switch operation, the water heater
cannot be restarted unless the water temperature is reduced
to approximately 120F (49C). The high limit reset button on the
front of the thermostat then needs to be depressed. See Figure 2
for the location of the reset button.
a. A concentration of sulfate in the supply water.
b. Little or no dissolved oxygen in the water.
40
41
ALT. COLD WATER
CONNECTION
HOT WATER
TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (1 UNIT) WITH VERTICAL STORAGE TANK
COLD WATER
SUPPLY
EXPANSION
TANK
DRAIN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
HOT WATER RETURN
FROM FIXTURES
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
water Piping Diagrams
42
HOT WATER TO FIXTURES
ALTERNATE
LOCATION
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (1 UNIT) WITH HORIZONTAL STORAGE TANK
DRAIN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
RETURN FROM
FIXTURES
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
43
HOT
WATER
RETURN
TEMPERED
WATER
OUTLET
COLD
HOT
HOT
WATER
OUTLET
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
EXPANSION
TANK
COLD WATER
SUPPLY
TEMPERED
WATER
RETURN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (1 UNIT) WITH MIXING VALVE TWO TEMPERATURE
DRAIN
PIPE T&P TO
OPEN DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
44
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
PIPE T&P TO
OPEN DRAIN
HOT WATER
TO FIXTURES
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (2 UNITS)
COLD WATER
SUPPLY
EXPANSION
TANK
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
HOT WATER
RETURN
LEGEND
45
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (2 UNITS) WITH VERTICAL STORAGE TANK
ALTERNATE
COLD WATER
CONNECTION
HOT WATER
TO FIXTURES
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
COLD WATER
SUPPLY
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
EXPANSION
TANK
LEGEND
46
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (2 UNITS) WITH VERTICAL STORAGE TANK
ALTERNATE
COLD WATER
CONNECTION
HOT WATER
TO FIXTURES
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
COLD WATER
SUPPLY
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
EXPANSION
TANK
LEGEND
47
PIPE T&P TO
OPEN DRAIN
HOT WATER TO FIXTURES
DRAIN
EXPANSION
TANK
COLD WATER
SUPPLY
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
ALTERNATE
LOCATION
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (2 UNITS) WITH HORIZONTAL STORAGE TANK
LEGEND
HOT WATER
RETURN FROM
FIXTURES
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
48
EXPANSION TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
HOT WATER
TO FIXTURES
PRE-HEATED
WATER TO
BOOSTER
DRAIN
BOOSTER
HEATER
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
BOOSTER WATER RETURN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
BOOSTER WATER
TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
1st HEATER
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE (2 UNITS) TWO TEMPERATURE
LEGEND
49
PRE-HEATER
PRE-HEATER
MUST BE IDENTICAL HEATERS
PIPE T&P TO
OPEN DRAIN
DRAIN
BOOSTER RETURN
(IF USED)
EXPANSION
TANK
COLD WATER
SUPPLY
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
HOT OUTLET
AT STORED
TEMPERATURE
BOOSTED
WATER
OUTLET
TYPICAL
BOOSTER
HEATER
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE (2 UNITS) WITH BOOSTER TWO TEMPERATURE
LEGEND
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
50
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
PIPE T&P TO
OPEN DRAIN
HOT WATER
TO FIXTURES
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI-FLUE (3 UNITS)
DRAIN
EXPANSION
TANK
COLD WATER
SUPPLY
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
51
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
ALT. COLD WATER
CONNECTION
EXPANSION TANK
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
COLD WATER
SUPPLY
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
HOT WATER TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
HEATER
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI-FLUE (3 UNITS) WITH VERTICAL STORAGE TANK
AOS
STORAGE TANK
52
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
AOS
STORAGE TANK
HOT WATER TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI-FLUE (3 UNITS) WITH HORIZONTAL STORAGE TANK
ALTERNATE
LOCATION
PIPE T&P TO
OPEN DRAIN
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
EXPANSION TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
53
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
FINISHED FLOOR
HOT WATER
TO FIXTURES
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE FLUE (4 UNITS)
PIPE T&P TO
OPEN DRAIN
DRAIN
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
COLD WATER
SUPPLY
EXPANSION
TANK
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
54
HEATER
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI-FLUE (4 UNITS) WITH VERTICAL STORAGE TANK
AOS
STORAGE TANK
ALT. COLD
WATER
CONNECTION
HOT WATER
TO FIXTURES
DRAIN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
55
HEATER
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
DRAIN
AOS
STORAGE TANK
ALTERNATE
LOCATION
PIPE T&P TO
OPEN DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
HOT WATER
TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI-FLUE (4 UNITS) WITH HORIZONTAL STORAGE TANK
LEGEND
EXPANSION TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
manifold kits
Dimensions shown are for minimum space occupied by the water heaters
assemblies.
Space for the barometric draft control assemblies, combustion clearances
and servicing must be added.
PRIOR TO START UP
IMPORTANT
Factory Start-Up is required for activating warranty and assuring maximum
operating performance. Contact your local sales representatives or
Authorized Start-Up Agent to arrange a FREE Certified Start-Up.
56
1
2
COMMERCIAL TANK TYPE WATER HEATER
REPLACEMENT PARTS LIST
MODELS GPG/GPV-540A THRU 740A
SERIES 104
4
3
9
9A
9B
GPV VENT KIT
8
8A
8C
8B
5
CLEANOUT ASSEMBLY
3
10
6
7
RELIEF
VALVE
STATE WATER HEATERS
125 Southeast Parkway, Franklin, TN 37068
1-800-821-2017
www.statewaterheaters.com
57
BAROMETRIC
DRAFT CONTROL
ItemDescription
GPG-540A
GPG-650A
GPG-740A
1......... Anode, Plug.......................................................................9003892005(4).............9003892005(4).............. 9003892005(4)
2......... Baffle, Flue........................................................................9006832005(24)...........9006832005(24)............ 9006832005(24)
3......... Valve, Relief.........................................................................9006187205................. 9006187205.................. 9006187205
4......... Thermostat W.E.C.O............................................................9004529005................. 9004529005.................. 9004529005
5......... Cover, Front.............................................................................181260......................... 181260.......................... 181260
6......... Valve, Drain..........................................................................9003906015................. 9003906015.................. 9003906015
7......... Burner Assembly.................................................................... 195036-2...................... 195036-1........................ 195036
8......... Cleanout Assembly
........... (includes the following items)
........... 8A....... Cleanout Cover........................................................9005797205................. 9005797205.................. 9005797205
........... 8B....... Gasket......................................................................9004099215................. 9004099215.................. 9004099215
........... 8C...... Screw - Thread Rolling.............................................9004100215................. 9004100215.................. 9004100215
10....... Barometric Draft Control......................................................9500007350................. 9500007350.................. 9500007350
ItemDescription
GPV-540A
GPV-650A
GPV-740A
1......... Anode, Plug.......................................................................9003892005(4).............9003892005(4).............. 9003892005(4)
2......... Baffle, Flue........................................................................9006832005(24)...........9006832005(24)............ 9006832005(24)
3......... Valve, Relief.........................................................................9006187205................. 9006187205.................. 9006187205
4......... Thermostat W.E.C.O............................................................9004529005................. 9004529005.................. 9004529005
5......... Cover, Front.............................................................................181260......................... 181260.......................... 181260
6......... Valve, Drain............................................................................. 26273-4......................26273-4............................26273-4
7......... Burner Assembly.................................................................... 196795-2....................196795-1........................... 196795
8......... Cleanout Assembly
........... (includes the following items)
........... 8A....... Cleanout Cover........................................................9005797205................. 9005797205.................. 9005797205
........... 8B....... Gasket......................................................................9004099215................. 9004099215.................. 9004099215
........... 8C...... Screw - Thread Rolling.............................................9004100215................. 9004100215.................. 9004100215
9......... GPV Vent Kit.........................................................................900007229................ 900007230....................... 900007230
........... (includes the following items, 2 pieces of hood required for direct vent)
........... 9A....... Hood, Vent - Side Wall...................................................................................................................................
........... 9B....... Reducer - Flue...............................................................................................................................................
*Items not illustrated.
# Quantities, if more than one, shown in parenthesis next to part number.
Part numbers underlined are recommended stock items for emergency replacement.
58
Commercial
Water Heater
Limited Warranty
Effective
What's NOT covered
For 3 Years, in the event of a tank leak, we will repair or, at our
• Problems caused by improper: gas supply line sizing, gas type,
venting, connections, combustion air, voltage, wiring, or fusing
For 1 Year, in the event of part failure, we will repair or, at our
discretion, replace the defective part.
• Failure to follow applicable codes
We warrant this product against defects in materials or
workmanship as described in this document if installed within
the United States or Canada and provided the product remains
at its original place of installation.
• Abuse, misuse, accident, fire, flood, Acts of God
Warranty coverage begins the date of installation OR the date of
manufacture if installation cannot be verified.
• Failure to conduct authorized factory start up if required
discretion, replace the defective water heater.
• Failure to follow printed instructions
• Improper installation, sizing, delivery, or maintenance
• Claims related to rust, noise, smell, or taste of water
• Alterations to the water heater
• Non-outdoor heaters installed outdoors
What's covered
• Damages due to a failure to allow for thermal expansion
Subject to these terms, in the event of defect in materials and/
or workmanship resulting in a tank leak during the first three
years, we will:
• Replace the water heater should the tank leak.
• Heat exchanger failure due to lack of adequate / proper supply
of water
• Heaters moved from their original location
• Service trips to explain proper installation, use, or maintenance
of the product/unit or to describe compliance requirements
under applicable codes and regulations
Subject to these terms, in the event of a defect in materials and/or
workmanship appearing during the first year, we will:
• Repair or, at our discretion, replace any part of the water
heater covered under this limited warranty excluding parts
subject to normal maintenance (Example: non-electronic
anode rod, filter, etc)
• Charges related to accessing your heater including but not
limited to door/wall removal, equipment rental, etc.
• Replacement parts after expiration of this warranty
Service/labor, shipping, delivery, installation, handling or any
other costs are not covered at any time under this warranty.
Limitations
Any replacement part or product will be warranted only for
the unexpired portion of the original water heater’s limited
warranty period.
NOTWITHSTANDING ANYTHING ELSE TO THE CONTRARY,
THIS IS YOUR SOLE AND EXCLUSIVE WARRANTY.
ALL OTHER WARRANTIES INCLUDING A WARRANTY
OF MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE ARE EXPRESSLY DISCLAIMED. SELLER SHALL
NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL,
SPECIAL, PUNITIVE OR OTHER INDIRECT DAMAGES. TOTAL
LIABILITY ARISING AT ANY TIME SHALL NOT EXCEED THE
PURCHASE PRICE PAID WHETHER BASED ON CONTRACT,
TORT, STRICT LIABILITY OR ANY OTHER LEGAL THEORY.
If an identical model is no longer available due to a change in law,
regulation, or standard, we will replace the product with one having
comparable capacity and input. In these instances, the owner will
have the option of paying the difference between what was paid for
the original model and the new model with the additional features,
or receiving a refund of the portion of the purchase price, on a
pro-rata basis allocable to the unexpired portion of the warranty.
Service Inquiries:
For service inquiries call the telephone number listed below. Be prepared to provide the following information:
name, address, and telephone number; the model and serial number of the water heater; proof of installation; and a clear description
of the problem.
For your records, fill in the product:
Serial: ___________________
Model: ___________________
U.S. Customers:
State Water Heaters
500 Tennessee Waltz Parkway
Ashland City, Tennessee 37015
800-365-0024
www.statewaterheaters.com
59
500 Tennessee Waltz Parkway, Ashland City, TN 37015
Technical Support: 800-365-8170 • Parts: 800-821-2017
www.statewaterheaters.com
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