GAS-FIRED COMMERCIAL WATER HEATER (Ultra Low NOx)

GAS-FIRED COMMERCIAL WATER HEATER (Ultra Low NOx)
GAS-FIRED COMMERCIAL WATER HEATER
(Ultra Low NOx)
WARNING
If the information in these
instructions is not followed exactly, a
fire or explosion may result causing
property damage, personal injury or
death.
-
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
- WHAT TO DO IF YOU SMELL GAS
 Do not try to light any appliance.
 Do not touch any electrical switch;
do not use any phone in your
building.
 Immediately call your gas supplier
from a neighbor’s phone. Follow
the gas supplier’s instructions.
 If you cannot reach your gas
supplier, call the fire department.
-
For your family’s comfort, safety and
convenience, it is recommended this
water heater be installed and
serviced by a plumbing professional.
Ambler, PA 19002
Tech Service (800) 334-3393
Service Parts (800) 538-2020
Warranty Service (800) 531-2111
INSTALLATION/OPERATION MANUAL
WITH TROUBLESHOOTING GUIDE
PLACE THESE INSTRUCTIONS ADJACENT TO WATER HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE
238-50463-00C REV 12/14
SECTION I: IMPORTANT INFORMATION
READ CAREFULLY
This gas-fired water heater is design certified by CSA International under the American National Standard, Z21.10.3
(as indicated on the rating plate) and CAN/CGA 4.3-M (as indicated on the rating plate) available from CSA Standards
Association, 5060 Spectrum Way, Mississauga, Ontario, CANADA L4W 5N6.
This water heater must be installed in accordance with local codes. In the absence of local codes, it must be installed
in compliance with the National Fuel Gas Code (ANSI Z223.1-Latest Edition), or in Canada CAN/CGA B149.1 Natural
Gas Installation Code (Latest Edition) or CAN/CGA B149.2 Propane Installation Code (Latest Edition).
The following terms are used throughout this manual to bring attention to the presence of hazards at various risk
levels, or to important information concerning product life.
DANGER
CAUTION
Indicates an imminently hazardous situation, which, if
not avoided, will result in death, serious injury or
substantial property damage.
Indicates potentially hazardous situation, which, if not
avoided, may result in moderate or minor injury or
property damage.
NOTICE
WARNING
Indicates special instructions on installation, operation
or maintenance, which are important but not related to
personal injury hazards.
Indicates a potentially hazardous situation, which, if
not avoided, could result in death, serious injury or
substantial property damage.
NOTICE
This water heater has a limited warranty. The warranty for this water heater is valid only if the water heater has been
installed, maintained and operated in accordance with these instructions.
TABLE OF CONTENTS
SECTION I: IMPORTANT INFORMATION ............... 2 SETION VIII: ELECTRICAL CONNECTIONS ........ 25
SECTION II: SPECIFICATIONS................................ 5 SECTION IX: OPERATING INSTRUCTIONS ......... 26
SECTION III: GENERAL INFORMATION ................. 6 SECTION X: MAINTENANCE................................. 35
SECTION IV: INSTALLATION INSTRUCTIONS ...... 8 SECTION XI: DIAGNOSTIC AND
SECTION V: VENTING ........................................... 13 TROUBLESHOOTING GUIDE ................................. 39
SECTION VI: WATER CONNECTIONS.................. 19 SECTION XII: PARTS LIST .................................... 58
SECTION VII: GAS CONNECTIONS ...................... 23
2
DANGER
DO NOT store or use gasoline or other flammable, combustible, or corrosive vapors and/or liquids in the vicinity of this or
any other appliance.
This water heater is equipped with an adjustable thermostat to control water temperature. Hot water temperatures
required for automatic dishwasher and laundry use can cause scald burns resulting in serious personal injury and/or
death. The temperature at which injury occurs varies with the person’s age and the time of exposure. The slower
response time of disabled persons increases the hazards to them. NEVER allow small children to use a hot water tap,
or to draw their own bath water. NEVER leave a child or disabled person unattended in a bathtub or shower.
Toxic chemical, such as those used for boiler treatment, must not be introduced into potable water used for space
heating.
This water heater must not be connected to an existing heating system or component(s) previously used with a nonpotable water heating appliance.
All piping components connected to this water heater for space heating applications must be suitable for use with
potable water.
WARNING
Improper installation, adjustments, alteration, service or maintenance can cause property damage, personal injury or
loss of life. Failure to follow all instructions in the proper order can cause personal injury or death. Read and
understand all instructions, including all those provided with the appliance before installing, starting-up, operating,
maintaining or servicing this appliance. Keep this manual and literature in legible condition with this water heater for
reference by owner and service technician.
This water heater requires regular maintenance and service to operate safely. Follow the instructions contained in this
manual.
Installation, maintenance, and service must be performed only by a qualified, skilled and knowledgeable installer or
service provider.
Installation is not complete unless a temperature and pressure relief valve is installed into the proper location at the top
of this water heater.
It is the responsibility of the installing contractor to see that all controls are correctly installed and are properly operating
when the installation is complete.
This water heater is suitable for installation on combustible flooring. Do not install water heater directly on carpeting.
DO NOT operate this water heater without first being certain it is filled with water.
DO NOT tamper with or alter the water heater and/or controls.
DO NOT operate water heater with jumpered or absent controls or safety devices.
DO NOT operate water heater if any external part has been under water. Immediately call a qualified service technician
to inspect the appliance and to replace any part of the control system including gas controls, which has been under
water.
DO NOT attempt to use this water heater with any gas other than the type listed on the rating plate. Do not attempt to
convert this water heater for use with a gas other than the type for which it is equipped. Failure to use the proper gas
can create an unsafe condition resulting in property damage, bodily injury, or death. Consult your local gas supplier or
gas company if there are any questions.
Incorrect operation of this appliance may create a hazard to life and property and will nullify the warranty.
DO NOT operate this water heater if the input rate exceeds the rate shown on the water heater rating plate.
This water heater contains very hot water under high pressure. Do not unscrew any pipe fittings nor attempt to
disconnect any components of this water heater without positively assuring the water is cool and is not under pressure.
Always wear protective clothing and equipment when installing, starting up or servicing this water heater to prevent scald
injuries. Do not rely on the temperature gauges to determine the temperature. Do not touch any components unless
they are cool.
This water heater must be properly vented and connected to an approved vent system in good condition. DO NOT
operate water heater with the absence of an approved vent system. A clean and unobstructed vent system is
necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward
maintaining the water heater’s efficiency.
3
WARNING
This water heater needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air. Insufficient air supply will cause a recirculation of combustion products resulting in
contamination that may be hazardous to life. This will result in carboning or sooting of the combustion chamber, burner,
and flue tubes and creates a risk of asphyxiation.
Water heater materials of construction, products of combustion and the fuel contain carbon monoxide, nitrogen oxides,
aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the
state of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing,
respirators and equipment when servicing or working nearby this water heater.
Flammable items, pressurized containers or any other potential fire hazardous articles must never be placed on or
adjacent to the water heater. Open containers of flammable material should not be stored or used in the same room
with this water heater.
Insulation blankets are not required for this water heater. This water heater meets or exceeds the ASHRAE/IES 90.1b
(latest edition) standards with respect to insulation and standby loss requirements.
Setting the water temperature to the maximum set point can result in scalding hot water delivered to the faucets. It is
highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the
installation. See following section in this Installation/Operation Manual to change the maximum setpoint limit (max
setpoint). Make sure the water heater control display is not in a public area that can result in the temperature settings
being improperly adjusted.
Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long
period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the possibility of injury
under these conditions, we recommend the hot water faucet to be open for several minutes at the kitchen sink before
you use any electrical appliance, which is connect to the hot water system. If hydrogen is present, there will be unusual
sounds such as air escaping through the pipes as hot water begins to flow. Do not smoke or have open flame near the
faucet at the time it is open.
WARNING
Basements, crawl spaces, closets and areas below ground level will serve as pockets for accumulation of leaking gas.
Before lighting, smell all around the appliance area for gas. Be sure to smell next to the floor.
IF YOU SMELL GAS:
 DO NOT try to light any appliance.
 DO NOT touch any electric switch; do not use any telephone in your building.
 Immediately call your gas supplier from a telephone in another building. Follow the gas supplier’s instructions.
 If you cannot reach your gas supplier, call the fire department.
DO NOT OPERATE THE APPLIANCE UNTIL THE LEAKAGE IS CORRECTED!
To comply with NSF requirements this water heater is to be: Sealed to the floor with sealant, in a smooth and easily
cleanable way.
4
SECTION II: SPECIFICATIONS
Figure 1. Dimensional Layout.
Table 1. Specifications.
Model Description
Model Number
Capacity
(Gal.)
UCG100H199
UCG100H270
UCG100H399
100
100
100
Input BTU/Hr.
NAT. & L.P.
199,999
270,000
399,999
1st Hour
Delivery at
100°F Rise
(Gal.)
267
336
463
Model Description
Input kW/Hr.
Model Number
Capacity
Liters
UCG100H199
UCG100H270
UCG100H399
379
379
371
NAT. & L.P.
58.6
79.1
117.2
1st Hour
Delivery at
56°C Rise
Liters
1011
1272
1736
C
B
A
Floor to Vent Floor
to
Top of Dia.
Vent (in) Cold
Water
(in.)
Conn.
(in)
73 ¼
6
10
73 ¼
6
10
77 ¼
8
10
D
Floor
to
T& P
(in)
E
Floor
to Hot
Water
Conn.
(in)
52 ½ 55 ½
52 ½ 55 ½
52 ½ 55 ½
E
D
C
B
A
Floor to Vent Floor Floor Floor
to to Hot
Top of Dia. to
Vent (mm) Cold T&P Water
Water (mm) Conn.
(mm)
(mm)
Conn.
(mm)
1861 152 254 1334 1410
1861 152 254 1334 1410
1962 203 254 1334 1410
5
G Water Gas Relief
F
Floor to Floor Conn. Conn. Valve
Top of to Gas Dia. Dia. (in.)
Water Conn. (in.) (in.)
Heater (in)
(in)
69 ¾
69 ¾
69 ¾
63 ¼
63 ¼
63 ¼
G
F
Floor to Floor to
Gas
Top of
Water Conn.
Heater (mm)
(mm)
1772
1772
1772
1607
1607
1607
1½
1½
1½
¾
¾
¾
¾
1
1
Water Gas Relief
Conn. Conn. Valve
Dia. Dia. (mm)
(mm) (mm)
38
38
38
19
19
19
19
19
25
SECTION III: GENERAL INFORMATION
FEATURES
This water heater contains the following features:
MAIN POWER ON/OFF SWITCH
The front panel of this water heater has an ON/OFF switch, which has markings when the main power is turned on to
indicate power to the water heater.
COMBUSTION SYSTEM
This water heater is equipped with a self-compensating negative pressure pre-mix combustion system. As the blower
operates, air is drawn in through the air intake and into a venturi, which pulls gas from the gas valve. The gas and air is
then mixed in the combustion blower and sent through the transition tube into the burner. The Direct Spark Ignition
System (DSI) then ignites the gas/air fuel mixture to produce flue products (combustion). The flame sensor signals the
ignition control board (described below), that a flame is present.
HONEYWELL INTEGRATED CONTROL
Consists of a control board and a water heater display. An attractive digital water heater display is on the top front of the
water heater for precisely setting and displaying the temperature setpoint and monitoring the status of the water heater.
Pressing the temperature UP and DOWN buttons changes the temperature setpoint. The temperature format may be
displayed in degrees F or degrees C. The water heater display will show diagnostic codes in the event the water heater
needs servicing. The temperature readings of the tank sensor can be monitored in Service Mode. Also in Service Mode,
the display can show up to 10 previous error codes to further aid in servicing the water heater.
The single control board has plug in wiring harnesses to reduce the chance of mis-wiring. The control board controls all
ignition, temperature, and combustion blower functions. The control board controls the combustion blower, ignition
timings, and gas valve to control the combustion system in order to maintain the desired tank temperature. The sequence
of operation is described in detail in the Diagnostic Section at the back of this Installation and Operating Instruction
Manual.
ADJUSTABLE THERMOSTAT
This water heater is equipped with an adjustable thermostat as part of the Integrated Control System to control water
temperature. Hot water temperatures required for automatic dishwasher and laundry use can cause scald burns resulting
in serious personal injury and/or death.
The temperature may be adjusted from about 70°F (21°C) to about 180°F (82°C). The thermostat was adjusted to 70°F
(21°C) before the water heater was shipped from the factory. It is recommended that lower temperatures be used to
avoid the risk of scalding. Refer to the “Warnings” and the section on SCALDING in “Section V: Water Connections”. It is
further recommended, in all cases, that the water temperature be set for the lowest temperature, which satisfies your hot
water requirements for the installation. This will also provide the most energy efficient operation of the water heater and
minimizes scale formation.
Setting the water heater temperature at 120°F (49°C) will reduce the risk of scalds. Some states require setting lower
temperatures for specific installations.
The top immersion well of the single sensor control also contains a redundant sensor for the high limit (energy cutoff).
The high limit circuit interrupts the main burner gas flow should the water temperature exceed approximately 200°F
(93°C). Error code “65” will be shown on the water heater control display if the high limit temperature has been exceeded.
Should the high limit switch activate, it must be manually reset. This should only be done by a service technician after the
cause of overheating has been corrected. Refer to the section on “Accessing Service Mode on the Display” in the
Diagnostic section of this Installation and Instruction Manual.
Contact your qualified installing contractor, service provider or manufacturer listed on the rating plate if continued high
limit operation occurs.
LATCHES
The latches allow easy access for servicing the water heater from the top. Simply remove the two latches for servicing
and re-latch upon completion. No tools are required to obtain access to the top of the water heater.
6
WARNING
Keep clear of combination temperature and pressure relief valve discharge line outlet. The discharge may be
hot enough to cause scald injury. The water is under pressure and may splash.
For protection against excessive temperatures and pressure, install temperature and pressure protective equipment
required by local codes, but not less than a combination temperature and pressure relief valve certified by a
nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or
materials as meeting the requirements of the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot
Water Supply Systems, ANS Z21.22 and the Standard CAN1-4.4 Temperature, Pressure, Temperature and
Pressure Relief Valves and Vacuum Relief Valves. The combination temperature and pressure relief valve must be
marked with a maximum set pressure not to exceed the maximum working pressure of the water heater. The
combination temperature and pressure relief valve must also have an hourly rated temperature steam BTU
discharge capacity not less than the hourly rating of the water heater.
Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose
on the water heater.
Note: Some models may already be equipped or supplied with a combination temperature and pressure relief valve.
Verify that the combination temperature and pressure relief valve complies with local codes. If the combination
temperature and pressure relief valve does not comply with local codes, replace it with one that does. Follow the
installation instructions above on this page.
Install a discharge line so that water discharged from the combination temperature and pressure relief valve will exit
within six (6) inches (15.2 cm) above, or any distance below the structural floor and cannot contact any live electrical
part. The discharge line is to be installed to allow for complete drainage of both the combination temperature and
pressure relief valve and the discharge line. The discharge opening must not be subjected to blockage or freezing.
DO NOT thread, plug or cap the discharge line. It is recommended that a minimum clearance of four (4) inches
(10.2 cm) be provided on the side of the water heater for servicing and maintenance of the combination temperature
and pressure relief valve.
Do not place a valve between the combination temperature and pressure relief valve and the tank.
DISHWASHING MACHINE REQUIREMENTS
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. Flow pressures above 25 pounds per square inch, or below
15 pounds per square inch, will result in improperly sanitized dishes.
The National Sanitation Foundation also recommends circulation of 180°F water. Where this is done, the circulation
should be very gentle so that it does not cause any unnecessary turbulence inside the water heater. The circulation
should be just enough to provide 180°F water at the point of take-off to the dishwashing machine. Adjust flow by means
of the valve in the circulation line.
SACRIFICIAL ANODES – Three sacrificial anode rods have been installed in the tank head to extend tank life. The
anode rods should be inspected periodically for corrosion and replaced when necessary to prolong tank life. Water
conditions in your area will influence the time interval for inspection and replacement of the anode rods. The use of a
water softener may increase the speed of anode consumption. More frequent inspection of the anodes is needed when
using softened (or phosphate treated) water. Contact the installing contractor, or service provider that installed the
water heater or the manufacturer listed on the rating plate for anode replacement information.
7
SECTION IV: INSTALLATION INSTRUCTIONS
WARNING
INSTALLATION OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED
TRADESPERSON IN THE FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, GAS SUPPLY AND
ELECTRICAL WORK ARE REQUIRED.
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE FOLLOWING:
 Liquefied petroleum gases/propane gas and natural gas have an odorant added by the gas supplier that aids in
detection of the gas.
 Most people recognize this odor as a “sulfur” or “rotten egg” smell.
 Other conditions, such as “odorant fade” can cause the odorant to diminish in intensity, or “fade”, and not be as
readily detectable.
 If you have a diminished sense of smell, or are in any way unsure of the presence of gas, immediately contact
your gas supplier from a telephone in another building.
 Gas detectors are available. Contact your gas supplier or plumbing professional for more information.
Liquefied petroleum gases/propane gas is heavier than air and will remain at floor level if there is a leak. Basements,
crawl spaces, closets and areas below ground level will serve as pockets for accumulation of leaking gas. Before
lighting, smell all around the appliance area for gas. Be sure to smell next to the floor.
IF YOU SMELL GAS:
 Do not try to light any appliance.
 Do not touch any electric switch; do not use any telephone in your building.
 Immediately call your gas supplier from a telephone in another building. Follow the gas supplier’s instructions.
 If you cannot reach your gas supplier, call the fire department.
DO NOT OPERATE THE APPLIANCE UNTIL THE LEAKAGE IS CORRECTED!
This water heater must be located in an area where leakage of the tank, water line connections, or the combination
temperature and pressure relief valve will not result in damage to the area adjacent to the water heater or to lower
floors of the structure. When such locations cannot be avoided, a suitable drain pan must be installed under the water
heater. The drain pan depth must be suitable for draining and collecting water, and have a minimum length and width
of at least four (4) inches (10.0 cm) measured from the jacket of the water heater. The drain pan, as described above,
can be purchased from your plumbing professional. The water heater might need to be placed on blocks inside drain
pan to fit in standard size pan. The drain pan must be piped to an adequate drain. The piping must be at least ¾ inch
(2.0 cm) in diameter and pitched for proper drainage.
Water heaters are heat producing appliances. To avoid damage or injury there must be no materials stored against the
water heater and proper care must be taken to avoid unnecessary contact (especially by children) with the water heater
components. UNDER NO CIRCUMSTANCES SHALL FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT
THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER, VENT-AIR INTAKE SYSTEM OR IN
ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER OR VENT-AIR INTAKE SYSTEM.
Failure to adhere to these installation and operating instructions may create a hazard to life and property and will nullify
the warranty.
Sacrificial anode rods have been installed in the tank head of the water heater to extend tank life. The removal of these
anodes for any reason will nullify the warranty. In areas where water is unusually active, an odor may occur at the hot
water faucet due to a reaction between the sacrificial anode and the impurities in the water. If this should happen,
alternative anodes may be purchased from the supplier that installed this water heater. This will minimize the odor while
protecting the tank. Additionally, the water heater should be flushed with appropriate dissolvers to eliminate any bacteria.
Note: 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
DSA Headquarters Office, 1102 Q Street, Suite 5100, Sacramento, California 95811.
This water heater MUST be installed indoors out of the wind and weather.
8
This water heater MUST NOT be installed in any location where gasoline or flammable vapors are likely to be
present, unless the installation is such to eliminate the probable ignition of gasoline or flammable vapors.
CAUTION
The National Fuel Gas Code (ANSI Z233.1- latest edition) or in Canada The Natural Gas Installation Code
CAN/CGA (B149.1 - latest edition), expressly prohibits the following:
a. Installation of a water heater in a bathroom, bedroom, or any occupied room normally kept closed.
b. Installation of a water heater in a garage, unless the unit is installed so that the burner and ignition devices are at
least eighteen (18) inches (45.8 cm) above floor level and protected to avoid damage by a moving vehicle.
If the buildings cold water supply has a back-flow preventer, check valve or water meter with check valve, provisions
for thermal expansion of water in the hot water system must be provided.
The location of this water heater is of the utmost importance. Before installing this water heater, you should read the
Installation section of these instructions. After reading these Installation and Operating Instructions, select a location for the
water heater where the floor is level and is easily accessible to water lines, gas supply (type identified on the rating plate),
an adequate open drain, and a chimney or exhaust gas vent. DO NOT locate the water heater where water lines could
be subjected to freezing temperatures. Make sure the cold water pipes are not located directly above the gas
control box or any other electrical control so that condensate during humid weather does not drip on the controls.
This installation must allow access to the front of the water heater and adequate clearance must be provided for servicing
and operating this water heater. The water heater may be installed on either a combustible or non-combustible floor. If the
water heater is to be installed directly on carpeting, it must be installed on top of a metal or wood panel (or equivalent)
extending beyond the full width and depth of the appliance by at least three (3) inches (7.6 cm) in any direction or, if the
appliance is to be installed in an alcove or closet, the entire floor must be covered by the panel. The minimum clearances
to combustibles for this water heater are given in the following pages. A minimum of 24 inches front clearance must be
provided for inspection and servicing. Adequate clearances must be provided for easy access to controls by service
personnel to enable proper cleaning, servicing, and operation of the water heater.
Water heater corrosion and component failure can be caused by the heating and breakdown of airborne chemical vapors.
Examples of some typical compounds that are potentially corrosive are: spray can propellants, cleaning solvents,
refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes and process
chemicals. These materials are corrosive at very low concentration levels with little or no odor to reveal their presence.
NOTICE
DAMAGE TO THE WATER HEATER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY
THE WARRANTY. DO NOT OPERATE THE WATER HEATER IF EXPOSURE HAS OR WILL OCCUR. DO NOT
STORE ANY POTENTIALLY CORROSIVE COMPOUNDS IN THE VICINITY OF THE WATER HEATER.
UNPACKING
1.
2.
3.
Inspect carefully for any signs of damage
All equipment is carefully manufactured, inspected and packed.
Any claims for damage or shortage in shipment must be filed immediately with the manufacturer noted on the
rating plate label.
LOCATE WATER HEATER
1.
2.
3.
4.
5.
6.
Locate water heater in front of final position before removing crate.
LOCATE so that venting connections will be short and direct.
THIS WATER HEATER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOOR.
Proper venting practices must be considered when selecting a location for this water heater. For exact venting
specifications, please consult the Venting section of these Installation and Operating Instructions.
It is recommended that minimum clearances shown in figure 2b be provided on the sides and top of the water
heater for servicing and maintenance of the water heater.
Increase distances to provide clearance for servicing.
9
Input
Front, sides and Rear “A”
Less than or equal to 270,000 BTUH
0 in. (0.0 CM)
399,999 BTUH
0 in. (0.0 CM) (2 in. Rear
ONLY)
Figure 2a. Minimum Clearance To Combustible Material.
Figure 2b. Recommended Minimum Clearances For Service Access.
10
REMOVE CRATE
1. Remove all banding and pry off crate sides carefully so as not to damage the water heater.
2. Carefully roll/lift the water heater from the crate base.
CAUTION
Do not drop water heater. Do not bump water heater jacket against floor.
Do not bump exhaust vent pipe against crate or other objects. This will damage the heater and cause it to be inoperable
or create nuisance problems.
MOVE WATER HEATER TO PERMANENT POSITION by sliding or walking.
INSTALL TEMPERATURE AND PRESSURE RELIEF VALVE (if not already installed).
DANGER
Temperature setting should not exceed safe temperature at fixtures. See water temperature control warning in Section
VI, “Water Connections”. If higher preheat temperatures are necessary to obtain adequate booster output, add an ASSE
approved mixing device for hot water supplied to fixtures.
WARNING
Temperature and pressure relief valve discharge piping must be piped near floor to eliminate potential of severe burns.
Do not pipe in any area where freezing could occur. Do not install any shut-off valves, plugs or caps to the temperature
and pressure relief valve or piping.
This water heater must be located in an area where the general public does not have access to set temperatures.
AIR REQUIREMENTS
1. Do not obstruct the flow of ventilating air.
2. For safe operation, adequate air is needed for combustion and ventilation. Sooting may result in serious damage
to the water heater and risk of fire or explosion. It can also create a risk of asphyxiation. Such a condition often
will result in a yellow, luminous burner flame, causing carboning or sooting of the combustion chamber, burner
and flue tubes.
WARNING
IMPORTANT-The flow of combustion and ventilating air must not be obstructed.
MECHANICAL EXHAUSTING OF ROOM AIR - Where an exhaust fan is installed in the same room with this
water heater and combustion air is drawn from inside the room, sufficient openings for air must be provided in the
walls. UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE WATER
HEATER’S VENTING SYSTEM, CAUSING POOR COMBUSTION THAT MAY BE HAZARDOUS TO LIFE. SOOTING
MAY RESULT IN SERIOUS DAMAGE TO THE WATER HEATER AND RISK OF FIRE OR EXPLOSION, WHICH CAN
ALSO CREATE A RISK OF ASPHYXIATION. Refer to local codes and /or National Fuel Gas Code (ANSI Z223.1Latest Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.2
Propane Installation Code (Latest Edition) for proper air opening sizing.
CONFINED SPACES
If the water heater is installed in a confined space (volume is less than 50 ft.3/1000 BTU (15 m3/0.29 kW) per hour of the
total input rating of all gas appliances in that space), air must be supplied through two permanent openings. One opening
must be within 12 inches (30.5 cm) from the top of the enclosure and one within 12 inches (30.5 cm) of the bottom. The
openings must be protected by metal louvers or 1/4” (6.4 mm) min. mesh metal screen. The size of the openings are as
follows:
11
CAUTION
The draft hood relief opening of the water heater and combustion air inlet must be in the same atmospheric pressure
zone. Large exhaust fans in kitchens and other locations can lower the air pressure inside an enclosure and interfere
with the proper operation and venting of the water heater. In these cases, the water heater should be installed in a
separate room with the combustion and ventilation air supplied directly from outdoors as previously described.
1. If the openings communicate directly with an additional room(s) of sufficient volume, each opening must have a
minimum free area opening of 1 in.2/1000 BTU (2.54cm2/0.29kW) per hour of the total input rating of all gas
appliances in the confined space, but not less than 100 in.2 (254 cm2).
2. If the openings communicate with the outdoors through horizontal ducts, each opening must have a minimum free
area of 1 in.2/2000 BTU (2.54cm2/0.59kW) per hour of the total rating of all gas appliances in the enclosure.
3. If the openings communicate directly with the outdoors or through vertical ducts with the outdoors, each opening must
in
have a minimum free area of 1 in.2 /4000 BTU (2.54cm2/1.18kW) per hour of the total rating of all gas appliances
the enclosure.
ALL AIR FROM INSIDE THE BUILDING
The confined space must be provided with two permanent openings communicating directly with an additional room(s) of
sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of
all gas utilization equipment installed in the combined space must be considered in making this determination. Each
opening must have a minimum free area of 1 in.2/1000 BTU (2.54cm2/0.29kW) per hour of the total input rating of all gas
utilization equipment in the confined space, but not less than 100 square inches (254cm2). One opening must be within
12 inches (30.5 cm) of the top and one within 12 inches (30.5 cm) of the bottom of the enclosure.
UNCONFINED SPACES
In unconfined spaces in buildings, infiltration may be adequate to provide air for combustion, ventilation and dilution of flue
gases. However, in buildings of tight construction (for example, weather stripping, heavily insulated, caulked, vapor
barrier, etc.), additional air may need to be provided using the methods described above under CONFINED SPACES: All
Air From Outdoors or SPECIALLY ENGINEERED INSTALLATIONS.
SPECIALLY ENGINEERED INSTALLATIONS
The requirements noted under CONFINED SPACES above must not necessarily govern when special engineering,
approved by the authority having jurisdiction, provides an adequate supply of air for combustion, ventilation, and dilution
of flue gases.
CHEMICAL VAPOR CORROSION
Corrosion of the flue ways and vent system will occur if air for combustion contains certain chemical vapors. Such
corrosion may result in poor combustion and create a risk of asphyxiation, as well as reducing the life of the water
heater. Spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool
chemicals, calcium and sodium chloride, waxes and process chemicals are corrosive. Products of this sort should not
be stored near the water heater or outside by the air intake (if applicable).
12
SECTION V: VENTING
WARNING
The venting system must be installed properly following all local codes or in the absence of local codes, the latest
edition of the National Fuel Gas Code (ANSI Z223.1- latest edition), or in Canada, The Natural Gas Installation Code
(B149.1-00 latest edition) or CAN/CGA B149.2 Propane Installation Code (Latest Edition).
Failure to properly install the venting system could result in property damage, personal injury, or death.
Carefully inspect the venting system of a replacement water heater installation before connecting to the venting
system. All joints in the vent connector must be securely fastened with screws and fit tightly together. Inspect the
venting system for signs of deterioration (rust and perforation) and replace any sections that are not in good condition.
The chimney must be lined and in good condition. Check to make sure the venting system is properly sized for the
water heater. If the venting system was previously sized for another gas appliance that has been removed, the venting
system may now be too large. Refer to the latest edition of the National Fuel Gas Code (ANSI Z223.1-latest edition), or
in Canada, the Natural Gas and Propane Installation Code (B149.1-00 latest edition) for the correct sizing of venting
systems and common venting with another gas appliance. Do not vent this water heater into the venting system of
another gas appliance designed to vent under positive pressure.
The water heater should be installed as close as practical to the venting system to minimize the vent connector length
required. Refer to local codes for the distance limitations on vent connector lengths. At the completion of the water
heater installation, the burner and venting system must be checked for proper operation with all other commonly
vented appliances in operation. Check for spillage of flue products around the outside relief opening of the drafthood
after several minutes of operation. The flame from a match should be drawn into the drafthood. Do not use the water
heater or connected equipment if spillage is detected until the problem is corrected. Refer to the latest edition of the
National Fuel Gas Code, or in Canada, the Natural Gas and Propane Installation Code for complete details on the
“Procedure to Be Followed to Place Equipment in Operation”.
This water heater has been shipped with a draft hood for which it was designed with reference to the horizontal and
vertical planes. If removed, the draft diverter must be replaced in the same position and secured to the jacket top by the
screws with which it was installed.
This water heater must be connected to a lined masonry chimney or venting system approved by local codes or
ordinances. The vent connector used to attach the draft hood outlet to the chimney or approved vent must be of the same
diameter as the draft diverter outlet or larger. For proper venting in certain installations, a larger vent connector may be
needed. Consult venting tables in ANSI standard (Z223.1- latest edition), National Fuel Gas Code and CAN/CGA
(B149.1 or B149.2-latest editions) Natural Gas and Propane Installation Code, or local code officials for proper application
for your area.
Optional Intake Venting
The venting instructions must be followed to avoid restricted combustion or recirculation of flue gases.
conditions cause sooting or risks of fire and asphyxiation.
Such
WARNING
The intake vent system must be properly installed. Failure to properly install the vent system could result in property
damage, personal injury, or death.
Use only the vent terminals provided or factory authorized terminals for venting this water heater.
The water heater requires its own separate intake venting system.
Do not terminate the venting where noise from intake venting will be objectionable. This includes locations close to or
across from windows and doors. Avoid anchoring the intake vent pipes directly to framed walls, floors, or ceilings unless
rubber isolation pipe hangers are used. This prevents any vibrations from being transmitted into the living spaces.
Do not exceed the venting distances or the number of elbows listed in this manual. Exceeding the maximum venting
distances may cause the water heater to malfunction or cause an unsafe condition.
DO NOT operate this water heater until the venting installation is complete and the piping completed. Failure to
complete installation before operation can result in property damage, personal injury, or death.
13
NOTICE
For installations in Canada, field supplied vent piping must comply with CAN/CGA B149.1 (latest edition) and be
certified to the Standard For Type BH, Class II, 65°C, Gas Venting Systems, ULC S636. Components of this listed
system shall not be interchanged with other vent systems or unlisted pipe/fittings. All components and specified primers
and cements of the certified vent system must be from a single system manufacturer and not intermixed with other
system manufacturer’s vent system parts. The supplied vent connector and vent termination are certified under ULC
S636 and are also certified as part of the water heater. Refer to the following tables for approved venting materials,
primers, and cements. All approved primers and cements are to be used within their marked time limitations.
Approved Venting Materials





For installations in CANADA
 ULC S636 approved CAN-COM VENTING
SYSTEM schedule 40 PVC for flue gas venting
rated Class II, 65°C (components provided with
water heater)
 IPEX ULC S636 approved schedule 40 PVC (all
other vent pipe/ fittings)
For installations in the US only
PVC Sch. 40, 80 (ASTM D-1785)
PVC DWV (ASTM-D2665)
CPVC Sch. 40, 80 (ASTM-F441)
CPVC (ASTM D2846)
ABS Sch. 40 DWV (ASTM D2661)
Approved Primers and Cements




For installations in CANADA
 IPEX ULC S636 approved PVC Primer and Cement
for flue gas venting rated Class II, 65°C
For installations in the US only
PVC and CPVC Primer (ASTM F-656)
PVC Cement (ASTM D-2564)
CPVC Cement (ASTM F493)
ABS Primer and Cement (ASTM D-2235)
NOTICE
Before beginning installation of any vent pipe, read the vent pipe manufacturer’s installation instructions.
Do not install the water heater in any location where the ambient temperature may fall below freezing. Water heater
must be protected from freezing downdrafts during shutdown periods.
CAUTION
The vent shall terminate a minimum of 12 inches above expected snowfall level to prevent blockage of vent termination.
The horizontal centerline of the exhaust vent terminal (if applicable) must not be located lower than the horizontal
centerline of the air intake terminal if vented through the same wall.
A service drain loop must be installed in the drain tubing to serve as a condensate trap to prevent flue gases from
escaping into the room.
NEVER locate the air intake where exhaust gases from other appliances can be introduced into the intake.
CAUTION
Check to make sure flue gases do not recirculate into the air intake terminal when using direct venting. If the water heater is
having service issues, flue recirculation may be a contributing factor. Even when the minimum vent terminal separation
distances are followed, recirculation may still occur depending upon the location outside the building, the distance from other
buildings, proximity to corners, weather conditions, wind patterns, and snow depth. Periodically check to make sure that flue
recirculation is not occurring. Signs of flue gas recirculation include frosted or frozen intake terminals, condensate in the intake
terminal and venting system, oxidation or white chalk material on the flame sensor or igniter shield. Correction to flue
recirculation may involve relocating the air intake to another side of the building, or using inside air for combustion. Check to be
sure the intake is not obstructed, especially during periods of below freezing weather.
High levels of dust and debris such as road and construction dust, insects, and tree pollen may clog the burner resulting in poor
performance and damage to the water heater. Avoid air intake locations where debris can be created such as exhaust
ventilation hoods, gravel parking lots, and near outdoor spotlights that attract bugs. For these installations, an air intake filter
kit, part number 239-47330-00A, is available as an accessory service part from the installer of this water heater. The air intake
filter kit is not designed to filter out airborne contaminants or chemicals that may damage the water heater.
14
Figure 3. Intake Vent Terminal Clearances (Referencing Other Appliance Venting Locations).
Canadian
1
Installations
US Installations
2
Canadian
1
Installations
US Installations
3 feet (91 cm) within a
height 15 feet (4.6 m)
above the
meter/regulator
assembly
36 inches
(91 cm)
*b
A=
Clearance above
grade, veranda,
porch, deck or
balcony
12 inches
(30 cm)
12 inches
(30 cm)
H=
Clearance to each side
of center line extended
above meter/regulator
assembly
B=
Clearance to window
or door that may be
opened
36 inches
(91 cm)
I=
Clearance to service
regulator vent outlet or
oil tank vent
C=
Clearance to
permanently closed
window
*b
4 feet (1.2 m)
below or to the
side of opening;
12 inches (30
cm) above
opening
*b
J=
36 inches
(91 cm)
D=
Vertical clearance to
ventilated soffit
located above the
terminal within a
horizontal distance of
2 feet (61 cm) from
the center line of the
terminal
Clearance to
unventilated soffit
*b
*b
K=
Clearance to nonmechanical air supply
inlet to building or the
combustion air inlet to
any other appliance
Clearance to a
mechanical air supply
inlet
*b
*b
L=
7 feet
(2.13 m)†
7 feet
(2.13 m)†
F=
Clearance to outside
corner
*b
*b
M=
Clearance above paved
sidewalk or paved
driveway located on
public property
Clearance under a
veranda, porch, deck, or
balcony
12 inches (30 cm) ‡
*b
G=
Clearance to inside
corner
36 inches
(91 cm)*a
36 inches
(91 cm)*a
E=
6 feet
(1.83 m)
2
*b
4 feet (1.2m)
below or to side
of opening; 12
inches (30 cm)
above opening.
3 feet (91 cm)
above if within
10 feet
horizontally
In accordance with the current CAN/CGA-B149 Installation Codes.
2
In accordance with the current ANSI Z223.1-(Latest Edition)/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.
‡ Permitted only if a veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.
*a) A minimum clearance value determined by testing in accordance with section 2.20.
*b) “Clearance in accordance with local installation codes and the requirements of the gas supplier”.
15
Vent pipes serving power vented appliances are classified by building codes as “vent connectors”. Required clearances
from combustible materials must be provided in accordance with information in this manual under LOCATION OF
WATER HEATER and CLEARANCES, and with National Fuel Gas Code and local codes.
Horizontal Installation
In a horizontal application, it is important that moisture is not to be allowed to buildup in the intake vent pipe. To prevent
this from happening, the pipe should be installed with a slight downward slope so the moisture will run back away from
the water heater. The vent system must be supported every 5 feet of vertical run and every 3 feet of horizontal run of vent
pipe length.
CAUTION
Failure to properly support the vent piping with hangers and clamps may result in damage to the water heater or venting
system.
WARNING! DO NOT USE 2”
VENT WITH UCG100H399
MODELS
Figure 4. Typical Horizontal Intake Vent System.
16
Vertical Installation
Vertical venting system must be supported every 5 feet of vertical run and every 3 feet of horizontal run of vent pipe
length.
CAUTION
Failure to properly support the vent piping with hangers and clamps may result in damage to the water heater or venting
system.
WARNING! DO NOT USE 2”
VENT WITH UCG100H399
MODELS
Figure 5. Typical Vertical Intake Vent System Installation.
17
Through The Wall Venting With Low Ground Clearance:
When venting cannot exit through the wall at a height greater than or equal to 12” (30.5 cm) (and above expected snow
level) from the ground, then the installation must be modified as shown below (see Figure 6).
WARNING! DO NOT USE 2”
VENT WITH UCG100H399
MODELS
Figure 6. Vent Terminal (Low Ground Clearance).
Maximum Vent Length
Table 2. Maximum Intake Vent Length.
Model Number
UCG100H199
UCG100H270
UCG100H399
Max Vent
Length (feet) 2”
20
20
N/A
Max Vent
Length (feet) 3"
50
50
25
Max Vent
Length (feet) 4"
75
75
50
Determining required vent length
1. Determine the total length of straight vent pipe (in feet) required for the intake.
2. Add 5 feet of venting for every 90° elbow.
3. Add 2 ½ feet of venting for every 45° elbow.
4. Total vent length cannot exceed “Max Vent Length” on the venting table shown above.
Example of Total Vent Length for UCG100H199 installation:
A 3” venting system has a total of three 90-degree elbows and a total straight pipe length of 30 feet.
Equivalent vent length for elbows: 3 x 5 feet = 15 feet.
Total equivalent vent distance = 30 feet + 15 feet = 45 feet total equivalent vent length. This is below
the maximum allowed distance of 50 feet for this model using 3” vent.
18
SECTION VI: WATER CONNECTIONS
NOTE: BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN WATER SUPPLY VALVE.
After shutting off the main water supply, open a faucet to relieve the water line pressure to prevent any water from leaking
out of the pipes while making the water connections to the water heater. After the pressure has been relieved, close the
faucet. The COLD water inlet and HOT water outlet are identified on the front of the water heater. Make sure the diptube
is in place before making the cold water connection. Make the proper plumbing connections between the water heater
and the plumbing system to the house. Install a shut-off valve in the cold water supply line.
CAUTION
If sweat fittings are to be used, DO NOT apply heat to the nipples on the side of the water heater. Sweat the tubing to
the adapter before fitting the adapter to the water heater connections. It is imperative that heat is not applied to the
nipples containing a plastic liner.
WARNING
FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED TEMPERATURE AND PRESSURE RELIEF VALVE WILL
RELEASE THE MANUFACTURER FROM ANY CLAIM WHICH MIGHT RESULT FROM EXCESSIVE
TEMPERATURE AND PRESSURES.
NOTICE
If this water heater is installed in a closed water supply system, such as the one having a back-flow preventer in the
cold water supply, provisions must be made to control thermal expansion. DO NOT operate this water heater in a
closed system without provisions for controlling thermal expansion. Warranties do not cover damages from thermal
expansions such as pressure bulges and/or deformities. Your water supplier or local plumbing inspector should be
contacted on how to control this situation.
After installation of the water lines, open the main water supply valve and fill the water heater. While the water heater is
filling, open several hot water faucets to allow air to escape from the water system. When a steady stream of water flows
through the faucets, close them and check all water connections for possible leaks. NEVER OPERATE THE WATER
HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER.
Table 3. Scald Times.
APPROXIMATE TIME/TEMPERATURE RELATIONSHIPS IN SCALDS
120°F (49°C)
More than 5 minutes
125°F (52°C)
1½ to 2 minutes
130°F (54°C)
About 30 seconds
135°F (57°C)
About 10 seconds
140°F (60°C)
Less than 5 seconds
145°F (63°C)
Less than 3 seconds
150°F (66°C)
About 1½ seconds
155°F (68°C)
About 1 second
19
WARNING
Keep clear of combination temperature and pressure relief valve discharge line outlet. The discharge may be
hot enough to cause scald injury. The water is under pressure and may splash.
For protection against excessive temperatures and pressure, install temperature and pressure protective equipment
required by local codes, but not less than a combination temperature and pressure relief valve certified by a nationally
recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials as
meeting the requirements of the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply
Systems, ANSI Z21.22 and the Standard CAN1-4.4 Temperature, Pressure, Temperature and Pressure Relief Valves
and Vacuum Relief Valves. The combination temperature and pressure relief valve must be marked with a maximum
set pressure not to exceed the maximum working pressure of the water heater. The combination temperature and
pressure relief valve must also have an hourly rated temperature steam BTU discharge capacity not less than the
hourly rating of the water heater.
Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose on
the water heater.
Note: Some models may already be equipped or supplied with a combination temperature and pressure relief valve.
Verify that the combination temperature and pressure relief valve complies with local codes. If the combination
temperature and pressure relief valve does not comply with local codes, replace it with one that does. Follow the
installation instructions above on this page.
Install a discharge line so that water discharged from the combination temperature and pressure relief valve will exit
within six (6) inches (15.2 cm) above, or any distance below the structural floor and cannot contact any live electrical
part. The discharge line is to be installed to allow for complete drainage of both the combination temperature and
pressure relief valve and the discharge line. The discharge opening must not be subjected to blockage or freezing.
DO NOT thread, plug or cap the discharge line. It is recommended that a minimum clearance of four (4) inches (10.2
cm) be provided on the side of the water heater for servicing and maintenance of the combination temperature and
pressure relief valve.
Do not place a valve between the combination temperature and pressure relief valve and the tank.
Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a
long period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the
possibility of injury under these conditions, we recommend the hot water faucet to be open for several
minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water
system. If hydrogen is present, there will be an unusual sound such as air escaping through the pipes as hot
water begins to flow. Do not smoke or have open flame near the faucet at the time it is open.
SCALDING
This water heater can deliver scalding temperature
water at any faucet in the system. Be careful
whenever using hot water to avoid scalding injury.
Certain appliances such as dishwashers and
automatic clothes washers may require increased
temperature water. By setting the thermostat on this
water heater to obtain the increased temperature
water required by these appliances, you may create
the potential for scald injury. To protect against injury,
you should install an ASSE approved mixing valve in
the water system. This valve will reduce point of
discharge temperature by mixing cold and hot water in
branch supply lines. Such valves are available from
the manufacturer of this water heater or a local
plumbing supplier. Please consult with a plumbing
professional for installation of mixing valves.
20
TO FILL THE WATER HEATER
1. Close the water heater drain valve by turning the knob clockwise. If alternative water connections are provided but
not used, make certain they are plugged (i.e. rear connections).
2. Open the cold water supply shut-off valve.
3. Open several hot water faucets to allow air to escape from the system.
4. When a steady stream of water flows from the faucets, the water heater is filled. Close the faucets and check for
water leaks at the water heater drain valve, combination temperature and pressure relief valve and the hot and cold
water connections.
5. To restore operation of water heater refer to operating instruction label on the water heater.
TO DRAIN THE WATER HEATER
Should it become necessary to completely drain the water heater, make sure you follow the steps below:
1. Reduce the thermostat setpoint to the lowest setting. Depress the control panel rocker switch on the front of the
control box to the “OFF” position and disconnect the power to the water heater.
2. Shut off the gas supply to the water heater.
3. Close the cold water supply shut-off valve.
4. Open the drain valve on the water heater by turning the slot on the valve counter-clockwise. The drain valve has
threads on the end that will allow the connection of a standard hose coupling.
5. Open a hot water faucet to allow air to enter the system.
To refill the water heater, refer to “To Fill the Water Heater
ALTERNATE SPACE HEATING WATER CONNECTIONS
DANGER
Toxic chemical, such as those used for boiler treatment, must not be introduced into potable water used for space
heating.
This water heater must not be connected to an existing heating system or component(s) previously used with a nonpotable water heating appliance.
All piping components connected to this water heater for space heating applications must be suitable for use with
potable water.
WARNING
When the system requires water for space heating at temperatures higher than required for other means, an ASSE
approved mixing valve must be installed to temper the water for those uses in order to reduce the scald hazard potential.
Failure to properly pipe this water heater may result in improper operation and damage to the water heater or structure.
Oxygen contamination of this water heater will cause corrosion of iron and steel components, and can lead to water
heater failure.
21
Connect the system supply and return piping to the water heater.
Refer to Figure 7 and Figure 8 for installation examples. Maintain a minimum 1/2” clearance from hot water piping to
combustible materials.
Figure 7. Alternate Space Heating Connections.
Figure 8. Typical Plumbing Schematic for Zoned Heating.
22
SECTION VII: GAS CONNECTIONS
The gas supply lines must meet all requirements of the National Fuel Gas Code (ANSI Z223.1-Latest Edition), or in
Canada CAN/CGA B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B 149.2 Propane Installation Code
(Latest Edition).
The maximum permissible gas supply pressure is fourteen (14.0) inches (3.5 kPa) water column for natural and propane
gas.
1. Connect this water heater only to the type of gas as shown on the rating plate. Use clean black iron pipe or
equivalent material approved by local codes and ordinances. (Dirt and scale from the pipe can enter the gas valve
and cause it to malfunction). The inlet gas line must have a minimum length of three (3) inches (7.6 cm) drip leg
(sediment trap) installed as close to the water heater’s gas valve as possible. A ground joint union must be installed
as close to the water heater as possible in the gas supply line feeding the water heater to permit servicing of the
water heater. Compounds used on the threaded joints of the gas piping must be resistant to the action of liquefied
petroleum gases/propane gas. DO NOT apply pipe dope to the gas valve inlet and make certain that no pipe dope
has become lodged in the inlet screen of the gas valve. Extreme care must be taken to ensure no pipe dope enters
the gas valve. Avoid excessive torque when tightening the gas supply line to the gas valve. Excessive torque may
result in cracking of the gas valve housing and could create a gas leak. The suggested maximum torque is 31.5 ft.
lbs. (4.4 kg-m).
WARNING
The manufacturer of this water heater will not be liable for any damage or injury caused as a result of a cracked gas
inlet as a result of excessive torque.
2. This water heater and its gas connection must be leak tested before placing the water heater in operation. Check for
gas leaks with a soap and water solution and a brush or a commercial leak detector fluid. NEVER USE A MATCH OR
OPEN FLAME FOR TESTING!
CAUTION
The water heater and individual shutoff valve must be disconnected from the gas supply piping system during any
pressure testing of the system at test pressures in excess of 1/2 psi (3.5 kPa). The water heater must be isolated from
the gas supply piping system by closing its manual shutoff valve during any pressure testing of the gas supply system
at test pressures equal to or less than 1/2 psi (3.5 kPa). The supply line must be capped when not connected to the
water heater.
3. While checking for leaks care must be taken to prevent solution from contacting the electrical connections at the
control. If electrical connections at the control become wet, they must be thoroughly dried before attempting to
operate the water heater.
GAS METER SIZE – NATURAL GASES ONLY
Be sure that the gas meter has sufficient capacity to supply the full rated gas input of the water heater as well as the
requirements of all other gas fired equipment supplied by the meter. If the gas meter is too small, ask the gas company to
install a larger meter having adequate capacity.
If copper supply lines are used, they must be internally tinned and certified for gas service.
GAS PRESSURE REGULATION
Main line gas pressure to the water heater should be between a maximum 14.0 inch W.C. and a minimum supply
pressure as shown on the rating plate. The inlet gas pressure must not exceed the maximum value. In some
installations, a regulator sized for the input rating of the water heater will need to be installed just ahead of the inlet gas
connection to the water heater to reduce excess gas pressure or surges in gas pressure.
BEFORE PLACING THE WATER HEATER IN OPERATION, CHECK FOR GAS LEAKAGE. USE SOAP AND WATER
SOLUTION OR OTHER MATERIAL ACCEPTABLE FOR THE PURPOSE OF LOCATING GAS LEAKS.
23
WARNING
DO NOT USE MATCHES, CANDLES, FLAME OR OTHER SOURCES OF IGNITION FOR THIS PURPOSE.
WARNING
Water heaters are heat-producing appliances. To avoid damage or injury there must be no materials stored against the
water heater or direct vent system, and proper care must be taken to avoid unnecessary contact (especially by children)
with the water heater and direct vent system. UNDER NO CIRCUMSTANCES SHOULD FLAMMABLE MATERIALS,
SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER OR
IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER.
Installation or service of this water heater requires ability equivalent to that of a licensed tradesman in the field involved.
Plumbing, air supply, venting, gas supply and electrical work are required.
Light the unit in accordance with the operating instructions label attached to the water heater.
Under no circumstances should the input rate exceed the input rate shown on the water heater rating plate. Over firing
could result in damage or sooting of the water heater.
If the unit is exposed to the following, do not operate water heater until all corrective steps have been made by a factory
authorized independent service contractor or qualified service professional.
1. Flooding to or above the level of the burner or controls
2. External firing
3. Damage
4. Firing without water
5. Sooting
NEVER OPERATE THE WATER HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER AND A
TEMPERATURE AND PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE OPENING OF THE
WATER HEATER.
WARNING
Do not run out of propane gas. Damage to the water heater may occur.
24
SETION VIII: ELECTRICAL CONNECTIONS
WARNING
Turn off or disconnect the electrical power supply to the water heater before servicing. Label all wires prior to
disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper
operation after servicing.
All electrical wiring must be installed and grounded in accordance with local codes, or in the absence of local codes, the
National Electrical Code, ANSI/NFPA 70 and/or CSA C22.2 Electrical Code.
The water heater must be wired to a 120 VAC, 60 Hz, 15A power supply. The water heater must be wired on a separate
circuit and breaker. If a flexible line cord and plug is permitted by local code, then provide a three wire grounding type
receptacle within reach of the line cord provided on the control box. Do not plug the line cord into a receptacle that can
have the power supply interrupted by a switch that is used to control lights or another appliance.
If wiring in conduit is required, cut the line cord close to the control board and make the appropriate wiring connections.
Install an electrical conduit connector on the outside jacket of the water heater. Refer to the wiring diagram for the correct
connections to each wire lead.
CAUTION
This water heater must be wired on a separate circuit. Failure to wire on a separate circuit may cause improper
operation or failure of the electrical components of the water heater. Refer to the “Electrical Connections” section of the
Installation and Operating Instructions Manual for complete instructions on electrical wiring and connections to the water
heater.
Do not energize the electric circuit before the water heater tank is filled with water.
Figure 9. Wiring Diagram and Schematic.
25
SECTION IX: OPERATING INSTRUCTIONS
Lighting And Shutdown Instructions
WARNING
Water heaters are heat-producing appliances. To avoid damage or injury there must be no materials stored against the
water heater or vent system, and proper care must be taken to avoid unnecessary contact (especially by children) with
the water heater and vent system. UNDER NO CIRCUMSTANCES SHOULD FLAMMABLE MATERIALS, SUCH AS
GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER OR IN ANY
LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER.
Installation or service of this water heater requires ability equivalent to that of a licensed tradesman in the field involved.
Plumbing, air supply, venting, gas supply and electrical work are required.
Light the unit in accordance with the operating instructions label attached to the water heater.
Under no circumstances should the input rate exceed the input rate shown on the water heater rating plate. Over firing
could result in damage or sooting of the water heater.
If the unit is exposed to the following, do not operate water heater until all corrective steps have been made by a factory
authorized independent service contractor or qualified service professional.
1. Flooding to or above the level of the burner or controls
2. External firing
3. Damage
4. Firing without water
5. Sooting
NEVER OPERATE THE WATER HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER AND A
TEMPERATURE AND PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE OPENING OF THE
WATER HEATER.
GENERAL INSTRUCTIONS
TO FILL THE WATER HEATER
1. Close the water heater drain valve by turning the knob or valve stem clockwise. If alternative water connections are
provided but not used, make certain they are plugged (i.e. rear connections).
2. Open the cold water supply shut-off valve.
3. Open several hot water faucets to allow air to escape from the system.
4. When a steady stream of water flows from the faucets, the water heater is filled. Close the faucets and check for
water leaks at the water heater drain valve, combination temperature and pressure relief valve and the hot and cold
water connections.
SEQUENCE OF OPERATION
1. Thermostat starts with heating cycle
2. Blower ON
3. Blower pre-purge
4. Spark rod sparks to the burner and gas valve opens – burner ignition
5. Main burner ON
6. Flame signal confirmed
7. Thermostat satisfied
8. Gas valve closes - Main burner OFF
9. Blower post-purge
26
LIGHTING AND SHUT-DOWN INSTRUCTIONS
Figure 10. Lighting Instruction Label.
Table 4. TEMPERATURE ADJUSTMENT.
APPROXIMATE TIME/TEMPERATURE RELATIONSHIPS IN SCALDS
120°F (49°C)
More than 5 minutes
125°F (52°C)
1½ to 2 minutes
130°F (54°C)
About 30 seconds
135°F (57°C)
About 10 seconds
140°F (60°C)
Less than 5 seconds
145°F (63°C)
Less than 3 seconds
150°F (66°C)
About 1½ seconds
155°F (68°C)
About 1 second
27
DANGER
Hotter water increases the risk of scald injury. Scalding may occur within five (5) seconds at a temperature setting
of 140F (60C). To protect against hot water injury, install an ASSE approved mixing valve in the water system.
This valve will reduce point of discharge temperature by mixing cold and hot water in branch water lines. A licensed
plumbing professional or local plumbing authority should be consulted.
This water heater is equipped with an energy cut out device to prevent overheating. Should overheating occur or
the gas supply fail to shut off, turn off the manual gas control valve to the appliance and call a qualified service
technician.
CAUTION
This water heater, when set at a lower temperature setting, is not capable of producing hot water of sufficient
temperature for sanitizing purposes.
NOTICE
The lower the temperature setting, the greater the energy efficiency, both to heat the water and to maintain the
storage temperature during standby periods. Lower water temperatures also extend tank life. Remember, no water
heating system will provide exact temperatures at all times. Allow a few days of operation at this setting to
determine the correct temperature setting consistent with the requirements for the installation.
Condensation does not mean your tank is leaking. Over 40% of reported tank leaks on installation are proven to be
condensation. To avoid unnecessary expense and inconvenience, make sure the tank is leaking before calling a
service person.
CAUTION
Combustion Air/Gas Ratio: Efficiency
This water heater is factory equipped with a Honeywell gas valve/air mixing venturi system designed and set to
maintain appropriate combustion excess air level (air/gas ratio) under normal operating conditions. The water
heater excess air level is field adjustable in order to optimize water heater efficiency. When the excess air level is
adjusted, an accurate and recently calibrated combustion gas analyzer, which correctly measures carbon monoxide
(CO) and carbon dioxide (CO2) levels in the exhaust gas, as well as an accurate gas pressure manometer, are
mandatory. Carbon dioxide levels in the exhaust gas greater than 11.5% provide high efficiency. Carbon Monoxide
levels increase with increasing CO2 levels. Only individuals, installers or service technicians properly trained,
qualified and experienced with adjusting the Honeywell gas/air mixing venturi system, and with access to accurate
equipment, should attempt to adjust the air/gas ratio. See service manual for instructions.
DANGER
DO NOT adjust the air/gas ratio unless you are qualified, experienced and properly trained in the Honeywell gas
valve/air mixing venturi system air/gas ratio adjustment process and are using accurate, certified CO2, CO and gas
pressure measurement equipment.
If the factory set air/gas ratio is changed, the exhaust gas concentration of CO2 and CO and the gas control gas
pressure MUST be monitored and properly adjusted no less than every 6 months thereafter.
28
TEMPERATURE ADJUSTMENT (24V CONTROL SYSTEM)
The water heater temperature setting is adjusted by using the control display mounted to the front of the water heater.
The water heater thermostat is set at the lowest setpoint of 70F when shipped from the factory. The control display
shows the temperature setpoint in degrees Fahrenheit (F) or degrees Celsius (C), and the status of the water heater
(“Idle” or “Heating”). If the water heater is functioning normally, the display will also show “Operational”.
For energy efficient operation of your water heater, the suggested initial temperature setting is 120F (49C). During the
winter season, or any cold period, you may desire a higher temperature setting to adjust for the colder incoming water.
This adjustment, however, may cause additional condensation to form on the cooler tank surface. This does not mean
the tank is leaking. During summer months, the warmer incoming water temperatures will benefit the performance of your
water heater and reduce the amount of condensation developed.
Condensation does not mean your tank is leaking. Over 40% of reported tank leaks on installation are proven to be
condensation. To avoid unnecessary expense and inconvenience, make sure the tank is leaking before calling a service
person.
WARNING
If the water heater display does not show “Operational” in the “Status” indicator, there may be an operating
malfunction with the water heater. If this is the case, a numeric code will be displayed. Refer to the label next to the
display for the definition of the error code and call your plumbing professional or service agent to service the water
heater. Do not try to reset the water heater without having a qualified service person to diagnose and correct the
problem. If the display is blank or does not show an error code, make sure there is power to the water heater.
Setting the water temperature to the maximum set point can result in scalding hot water delivered to the faucets. It
is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of
the installation. See following section to change the maximum setpoint limit (max setpoint). Make sure the water
heater control display is not in a public area that can result in the temperature settings being improperly adjusted.
See previous warning on scalds and an ASSE approved mixing valve.
NOTICE
When the maximum setpoint is reached, the display will show “Max Setpoint” without the setpoint value. The
maximum setting is equal to approximately 180˚F (82˚C).
The default temperature setpoint from the factory is 70˚F (21˚C).
29
Water Heater Display and Control Buttons
Shown flashing
in display only when
temp is adjusted
Sequence of
operation Indicator
Reads "Idle” or “Heating"
Status Indicator
Read "Operational"
or "Service Needed"
Temperature
Up Button
°F
setpoint
idle
Status Operational
SELECT
SET
Temperature Setpoint
in Degrees F or Degrees C
Range 70 - Max °F
Range 21 - Max °C
Temperature
Down Button
Set button
Select button
To Increase Setpoint Temperature
Step 1: Depress and hold “Temperature Up” button until desired setpoint temperature appears in the display.
°F
idle
Status Operational
SELECT
SET

Step 1
Step 2: “Setpoint” indicator begins flashing in the display after pressing “Temperature Up” button.
"Setpoint"
flashes
°F
setpoint
idle
Status Operational
SELECT
SET
Step 2
30

Step 3: Press “SET” button for new setting to take effect immediately. “Setpoint” will stop flashing. If the “SET” button is
not pressed, the new temperature setting will take effect in approximately 10 seconds.
"Setpoint" flashes
for 10 seconds
°F
setpoint
idle
Status Operational

SELECT
SET
Step 3
Press SET Button for setting to
to take effect immediately
To Decrease Setpoint Temperature
Step 1: Depress and hold “Temperature Down” button until desired setpoint temperature appears in the display.
°F
idle
Status Operational
SELECT
SET

Step 1
Step 2: “Setpoint” indicator begins flashing in the display after pressing “Temperature Down” button.
"Setpoint"
flashes
°F
setpoint
idle
Status Operational
SELECT
SET
Step 2
31

Step 3: Press “SET” button for new setting to take effect immediately. The setpoint will stop flashing. If the “SET” button
is not pressed, the new temperature setting will take effect in approximately 10 seconds.
"Setpoint" flashes
for 10 seconds
°F
setpoint
idle
Status Operational

SELECT
SET
Press SET for setting to
take effect immediately
Step 3
To Change Temperature Format in Display from F to C or ˚C to ˚F:
Step 1: Press “SELECT” button until “F/C” is displayed.
°F
°F/°C
idle
Status Operational

SELECT
Press select
SET
Step 1
Step 2: Press “SET” button to change temperature format. Symbol “F/C” will flash.
°F
°F/°C
idle
Status Operational

SELECT
SET
Step 2
32
“°F/°C” Flashes
Step 3a: Press “Temperature Up” button to change temperature format to C.
Changes to "°C"
°C
°F/°C
idle
Status Operational
SELECT
SET

“°F/°C” Flashes
Step 3a
Step 3b: Press “Temperature Down” button to change temperature format to F.
Changes to "°F"
“°F/°C” Flashes
°F
°F/°C
idle
Status Operational
SELECT
SET

Step 3b
Step 4: Press “SET” button to confirm ˚F or ˚C format. “F/C” will stop flashing. Setpoint display will appear in the
format selected (˚F or ˚C) in 10 seconds.
Symbol "°F/°C" Stops Flashing
°F
°F/°C
idle
Status Operational
SELECT

SET
Step 4
33
Press Set
Step 5: Pressing “SELECT” button will return display to setpoint in format selected (˚F or ˚C) immediately.
Setpoint shown in °F
°F
idle
Status Operational

SELECT
SET
Press select
Step 5
An automatic gas shut-off device (ECO) is incorporated in the sensor and control board which will shut off all gas supply
to the burner if the water heater temperature exceeds 200°F (93°C). Should the ECO function (open), the water
temperature should be reduced to approximately 120°F (49°C) and follow applicable Lighting Instructions to place the
water heater in operation. The water heater must have the problem corrected by a qualified service person before putting
the water heater back in operation. It is recommended that all service work be performed by a qualified service agency.
If the water heater is to remain idle for 30 days or more or is subjected to freezing temperatures while shut off, the water
heater and piping should be fully drained (See “To Drain the Water Heater”) and the drain valve should be left fully open.
WARNING
Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long
period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the possibility of
injury under these conditions, we recommend the hot water faucet to be open for several minutes at the kitchen sink
before you use any electrical appliance which is connected to the hot water system. If hydrogen is present, there
will be an unusual sound such as air escaping through the pipes as hot water begins to flow. Do not smoke or have
open flame near the faucet at the time it is open.
NOTICE
IMPORTANT- In the event of an emergency, turn off the gas and electric to the appliance.
IMPORTANT- The water heater should be inspected at a minimum annually by a qualified service technician
for damaged components and/or joints not sealed. DO NOT operate this water heater if any part is found
damaged or if any joint is found not sealed
WARNING
Water heaters are heat producing appliances. To avoid damage or injury there must be no materials stored against
the water heater or vent system, and proper care must be taken to avoid unnecessary contact (especially by
children) with the water heater and vent system. UNDER NO CIRCUMSTANCES SHALL FLAMMABLE
MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS
WATER HEATER, VENT SYSTEM OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER
HEATER OR VENT SYSTEM.
34
SECTION X: MAINTENANCE
DANGER
DO NOT ATTEMPT TO REPAIR GAS VALVE.
DO NOT ATTEMPT TO REPAIR IGNITION MODULE.
DO NOT ATTEMPT TO REPAIR VENTURI.
DO NOT ATTEMPT TO REPAIR THERMOSTAT BOARD.
DO NOT ATTEMPT TO REPAIR TRANSFORMER.
DO NOT ATTEMPT TO REPAIR FLOW SWITCH.
GENERAL
KEEP APPLIANCE AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE AND OTHER
FLAMMABLE VAPORS AND LIQUIDS.
Water heater maintenance includes periodic tank flushing and cleaning, and removal of lime scale. The unit should be
inspected and adjusted to maintain proper combustion. Refer to Table 5, “Suggested Maintenance Schedule”. A periodic
inspection of the venting system should be made.
BURNER FLAME CHECK
At the time of installation and at monthly intervals, a visual check of the burner flames should be made to determine if they
are burning properly. The main burner may be seen through the sight glass window on the side of the combustion insert
mounting bracket (Figure 11). The burner flames should be a blue flame near the burner surface in a uniform flame
pattern. Occasional yellow or white streaks are normal.
Figure 11. Sight Glass Location
35
MAINTENANCE SCHEDULE
Following are the instructions for performing some of the recommended maintenance. Unit inspection and adjustment
should be performed by a competent technician.
Table 5. Suggested Maintenance Schedule.
COMPONENT
Tank
OPERATION
Sediment Removal
INTERVAL
Monthly
REQUIRED
Flushing
Anode Rods
Inspect
Semi-Annually
Replace as Required
Relief Valve
Check Operation
Semi-Annually
Proper Operation
Blower
Inspect
As Required
Proper Operation
Vent Air Intake System
Clean Inlet Screen
Every 3 Months
Free of Debris
Ignition System
Inspect
Annually
Clean of dust and dirt
Combustion System
Inspect
Monthly
Confirm S-OP
FLUSHING WATER HEATER
1.
2.
3.
4.
Turn OFF the water heater electrical disconnect switch.
Open the drain valve and allow water to flow until it runs clean.
Close the drain valve when finished flushing.
Turn ON the water heater electrical disconnect switch.
DRAINING WATER HEATER
The water heater must be drained if it is to be shut down and exposed to freezing temperatures. Maintenance and
service procedures may also require draining the water heater.
1. Turn off the water heater electrical disconnect switch.
2. Connect a hose to the drain valve.
3. Locate hose’s discharge in an area where hot water will not cause any damage or injury.
4. Close the cold water inlet valve to water heater.
5. Open a nearby hot water faucet to vent the system.
6. Open the heater drain valve.
7. If the water heater is being drained for an extended shutdown, it is suggested the drain valve be left open during this
period.
FILLING WATER HEATER
1. Close the water heater drain valve by turning the valve stem clockwise. If alternative water connections are provided
but not used, make certain they are plugged (i.e. rear connections).
2. Open the cold water supply shut-off valve.
3. Open several hot water faucets to allow air to escape from the system.
4. When a steady stream of water flows from the faucets, the water heater is filled. Close the faucets and check for
water leaks at the water heater drain valve, combination temperature and pressure relief valve and the hot and cold
water connections.
SEDIMENT AND LIME SCALE REMOVAL
Waterborne impurities consist of the particles of soil and sand, which settle out and form a layer of sediment on the
bottom of the tank.
The amount of calcium carbonate (lime) released from water is in direct proportion to water temperature and usage. The
higher the water temperature or water usage, the more lime deposits are dropped out of the water. This is the lime scale,
which forms in pipes, water heaters and on cooking utensils.
Lime accumulation not only reduces the life of the equipment but also reduces efficiency of the water 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 of deliming be
maintained.
36
The depth of the buildup should be measured periodically. Water heaters will have about 3 inches of lime buildup when
the level of lime has reached the bottom of the cleanout opening or about 1 inch of lime buildup if it has reached the drain
valve opening. A schedule for deliming should be set up, based on the amount of time it would take for a 1/2 inch buildup
of lime.
Example 1: Initial inspection shows ½ an inch of lime accumulation. Therefore, the water heater can be delimed once a
year.
To remove sediment and lime scale
1.
2.
3.
4.
5.
6.
7.
8.
9.
Drain the heater. Refer to DRAINING THE WATER instructions in this section.
Remove outer cover plate from lower side of water heater jacket.
Remove cover and gasket from cleanout opening.
Remove lime, scale or sediment using care not to damage the glass-lining.
Inspect cleanout plate gasket: Replace gasket if necessary (Contact Bradford White Local Distributor for correct
part number).
Install gasket and cleanout plate. Be sure to draw plate up tight by tightening screws securely.
Close the drain valve. Open a hot water fixture to allow air to escape. Open the cold water supply to water
heater and allow the tank to fill. Follow the lighting instructions.
Check for water leakage.
Install outer jacket cover plate.
ANODE INSPECTION AND REPLACEMENT
This water heater is equipped with multiple sacrificial anodes. Anodes protect the glass-lined tank from corrosion by
sacrificing themselves through electrolysis. When the anode material is consumed, there is no more protection and
corrosion of the tank accelerates.
Inspection of the anode every 6 months allows you to identify the rate of anode degradation. The anode should be
replaced when its diameter is 3/8 of an inch, or annually whichever is first. Aggressive, very hot and softened water
causes rapid consumption of the anode requiring frequent inspections. The replacement anodes rods are available from
your plumbing professional.
To inspect or replace an anode
The anodes on this water heater are easily accessible from the top of the water heater making replacement simple and
quick. Use the following procedure to remove and inspect the anodes.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Drain the heater. Refer to DRAINING THE WATER HEATER instructions in this section.
Flush the heater. Refer to FLUSHING THE WATER HEATER instructions in this section.
Remove the plastic plug covering the anode.
Remove the anode using a socket of the appropriate size. Sometimes a breaker bar will need to be used. Do not
use an impact wrench.
Inspect and replace the anode as required. Use pipe tape or sealant when reinstalling the anode.
Close the drain valve. Open a hot water fixture to allow air to escape. Open the cold water supply to water heater
and allow the tank to fill.
Check your anode and drain valve for leaks.
Replace the plastic cover that covers the anode.
Follow the lighting instructions.
DRAIN VALVE AND TANK ACCESS PANEL
The water heaters are equipped with a ¾ inch drain valve.
An access panel covers the cleanout opening in the tank, which is sealed by a gasket and cover.
RELIEF VALVE
At least twice a year, the temperature and pressure relief valve should be checked to ensure that it is in operating
condition. To check the relief valve, lift the lever at the end of the valve several times. The valve should seat properly
and operate freely.
If water does not flow, remove and inspect for obstructions or corrosion. Replace with a new valve of the recommended
size as necessary. A thorough inspection of the valve should be performed at least every three years by removing the
temperature and relief valve from the tank. Do not attempt to repair the valve, as this could result in improper operation
and a tank explosion. In areas with poor water conditions, it may be necessary to inspect the T&P valve more often than
the recommended maintenance schedule
37
CAUTION
Before manually operating the valve, make sure that a drain line has been attached to the valve to direct the discharge
to an open drain. Failure to take this precaution could mean contact with extremely hot water passing out the valve
during this checking operation.
If the temperature and pressure relief valve on the water heater discharges periodically or continuously, it may be due to
thermal expansion of water in a closed water supply system, or, it may be due to a faulty relief valve.
Thermal expansion is the normal response of water when it is heated. In a closed system, thermal expansion will cause
the system pressure to build until the relief valve actuation pressure is equaled. Then, the relief valve will open, allowing
some water to escape, slightly lowering the pressure.
Contact your water supplier or local plumbing inspector on how to control this situation.
WARNING
Above all, do not plug the temperature and pressure relief valve. This is not a solution and can create a hazardous
situation.
VENT AND AIR INTAKE SYSTEM
Examine the vent and air intake system every 3 months. Points of inspection are as follows:
1. Check for obstructions and/or deterioration of vent piping and vent terminal. Replace immediately where needed.
2. Vent pipe and vent terminal screen should be cleaned of any foreign material. The screen is located inside the vent
terminal outlet and is accessible from the outside of the vent terminal elbow. Do not reach inside the vent terminal
when the water heater is in operation.
3. Check all venting system connections for leakage and reseal as required.
COMBUSTION SYSTEM INSPECTION
Inspect the operation of the combustion system monthly. Use the following procedure to inspect the combustion system.
1. Turn off the main power switch of the water heater.
2. Adjust the thermostat to the Min. setting.
3. Remove the top of the combustion surround by unlatching it.
4. While observing the ignition module, turn on the main power switch.
5. Adjust thermostat to the Max. setting.
6. Watch the ignition display as the controller goes through the sequence of operation as previously described.
7. Upon ignition, observe the main burner flame.
8. Readjust thermostat to previous setting.
9. Replace combustion surround top and latch it securely in place.
WARNING
Do not run out of propane gas. Damage to the water heater may occur.
38
SECTION XI: DIAGNOSTIC AND TROUBLESHOOTING GUIDE
DIRECT SPARK HONEYWELL INTEGRATED CONTROL SYSTEM
SEQUENCE OF OPERATION
1. When the tank temperature drops below the temperature setpoint on the display, the control sends power to the
combustion blower for a 30 second pre-purge period, circulator turns on and damper opens.
2. At the end of the pre-purge period, the control sends high voltage through the spark cable to the spark rod to spark to
the burner. The gas valve also opens. When the burner lights, a microamp current is generated through the flame
sense rod allowing the control to detect burner flame. The sparking then ceases and the flame is monitored by the
flame sense circuit until the tank temperature reaches the thermostat setpoint and turns off the gas valve.
3. If the burner fails to light, the gas valve closes, sparking to the burner stops, and the combustion blower continues to
operate for 60 seconds to purge the heat exchanger of unburned gas. The ignition trial is repeated. The control will
make 3 attempts to ignite the burner. If the burner fails to light after the third attempt, the control enters “Soft
Lockout”, which is an idle period for 60 minutes. There will be an error code 62 or 63 shown on the water heater
display indicating that the control cycled through the maximum number of ignition retries for ignition. The control will
make another 3 ignition attempts after the 1 hour waiting period.
4. If the exhaust vent should become blocked, the exhaust vent temperature switch will open and the gas valve closes.
The combustion blower will continue to operate. An error code 26 is shown on the water heater display. Removing
the blockage and resetting the switch will resume normal operation.
5. The burner flame is monitored by the flame sense circuit and if the flame should extinguish, the gas valve closes and
the combustion blower will operate to purge the heat exchanger before making an attempt to relight the burner.
There may be 3 attempts to relight the burner before going into the Soft Lockout period explained previously.
6. The burner will continue to operate during the heating cycle until the tank temperature reaches the setpoint. The gas
valve opens and the combustion blower continues to operate for 30 seconds to purge the heat exchanger of flue
gases.
7. If for some reason, the tank temperature should exceed 200°F (93°C), than the control closes the gas valve and goes
into a “Hard Lockout” state and will not operate until reset by a qualified service person. The display will read error
code “65”, which indicates the tank high limit temperature has been exceeded. No attempt should be made to reset
the control until a service person has corrected the cause of the high limit condition. Refer to the diagnostic service
section at the end of this Installation and Operating Instruction Manual.
ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY (FOR SERVICE PERSONNEL
ONLY)
(270,000 BTU/hr and below)
*See supplement included with 399,999 BTU/hr models for this information.*
The display has a “Service Mode” for changing the maximum setpoint and accessing information in aiding servicing of the
water heater. This procedure is for service and installation personnel only. To enter the Service Mode, follow the steps
illustrated below:
WARNING
The following procedure is for service and installation personnel only. Resetting lockout conditions
without correcting the malfunction can result in a hazardous condition.
39
Step 1: Press “Select” and “Temperature Up” buttons together and hold for 3 seconds until “Max Setpoint” is
shown in the display.
“Max Setpoint” next
to Temperature
Setpoint value.
Max
Setpoint
°F
idle
Status Operational
SELECT
SET

NOTICE
Approximately 12 minutes after the last button press, the display will automatically return to the “User Mode”.
Simultaneously pressing the “Select” and “Temperature Up” buttons will switch the display immediately to the “User
Mode”.
Step 2: Pressing “Select” button will change display to next mode
Water
Temp
°F
idle
Status Operational

SET
SELECT
The following is the sequence of modes available in “Service Mode” by pressing the “Select”
button:
Error Code Number (Display/Reset). This is only shown if there is an operating error in the “User Mode”.
Error Code Shown in
Water Heater Display
Status
Service Needed
SELECT
Lockout RESET
40
1. Max Setpoint (Display/Change)
“Max Setpoint” value
in Water Heater
Max
Setpoint
°F
idle
Status Operational
SET
SELECT
2. Water Temperature Sensor Reading.
°F Water
Temp
idle
Status Operational

SET
SELECT
3. Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle)
µA
Flame
Current
Heating
Status Operational

SELECT
SET
41
4. Setpoint (Display/Change)
setpoint
°F
idle
Status Operational

SET
SELECT
5. ˚F/˚C (Display/Change)
°F
°F/°C
idle
Status Operational

SET
SELECT
6. Differential (Display only – shows the differential of the thermostat)
°F Differential
idle
Status Operational

SELECT
SET
42
7. Software Version (Display only)
Soft
idle
Status Operational
SELECT
SET
8. Error Code History (Displays if there are present error codes or up to 10 previous error codes). Water Heater Display
will show -- if there are no error codes.
No current error codes
idle
Status Operational

SET
SELECT
43
To change the Maximum Setpoint Limit (Max Setpoint) for the temperature setpoint
WARNING
Setting the water temperature to the maximum set point can result in scalding hot water delivered to the
faucets. It is highly recommended that the maximum setpoint be adjusted to the lowest temperature
possible for the needs of the installation. See following section to change the maximum setpoint limit
(max setpoint). Make sure the water heater control display is not in a public area that can result in the
temperature settings being improperly adjusted. See previous warning on scalds and an ASSE approved
mixing valve.
Step 1: In service mode press the “Select” button until “Max Setpoint” is displayed.
°F
Max
Setpoint
idle
Status Operational

SET
SELECT
Step 2: Press “Set” button to enter setting mode. “Max Setpoint” will flash to indicate setting mode.
"Max Setpoint“ Flashes
°F
Max
Setpoint
idle
Status Operational

SELECT
SET
44
Step 3: Press the “UP” or “DOWN” buttons to change the maximum setpoint value. This will limit the maximum
setpoint the user can select. Note: The maximum setpoint is approximately 180˚F (82˚C).
"Max Setpoint" continues to flash
while making adjustments
°F
Max
Setpoint
idle
Status Operational
SET
SELECT

Step 4: Press “Set” button to confirm new “Max Setpoint” value and stop setting mode.
"Max Setpoint" stops flashing
Max
Setpoint
°F
idle
Status Operational


SET
SELECT
Step 5: Approximately 12 minutes after the last button press, the Water Heater Display will go back to “User
Mode”. It will read “Max Setpoint” without showing a temperature value if the temperature setpoint is at the
maximum setting. The Water Heater Display can be set back to the “User Mode” immediately by pressing both the
“Temperature Up” and “Select” buttons together for 3 seconds.
Max
Setpoint
idle
Status Operational

SELECT
SET
Exiting Service
45
Display of Water Temperature
Step 1: In Service Mode, Press the “Select” button until “Water Temp” is displayed in the upper right section of
the water heater display. This is the reading for the tank sensor.
Water
Temp
°F
idle
Status Operational

SET
SELECT
To Display Flame Sense Current of the Pilot Flame Sensor
The pilot flame sense current is available only when the burners are in operation. Step 1: Make sure the
status displays “Heating” or draw enough hot water to start the burners. Step 2: Enter the “Service Mode”
described previously. Step 3: Press the “Select” button until a number value is displayed with “Flame Current”
to the right of the number. The value displayed is in microamps (µA).
Flame
Current
µA
Heating
Status Operational

SELECT
SET
46
To Display and Change Temperature Setpoint
Step 1: In “Service Mode” press the “Select” button until “Setpoint” is shown in the water heater display.
setpoint
°F
idle
Status Operational

SET
SELECT
Step 2: Press the “Set” button to enter the setting mode. “Setpoint” will flash in the water heater display.
"Setpoint" Flashes
°F
setpoint
idle
Status Operational

SELECT
SET
NOTICE
Note: The maximum temperature that can be set in the Water Heater Display is limited to the “Max
Setpoint” described previously. To change the “Max Setpoint”, refer to the procedure “To Change the
Maximum Setpoint Limit…” described previously under “Accessing the Service Mode on the Water
Heater Display”.
Step 3: To raise the temperature setpoint, press the “Temperature Up” button until the desired temperature is
shown on the water heater display.
"Setpoint" Flashes
°F
setpoint
idle
Status Operational
SET
SELECT
47

Step 4: To lower the temperature setpoint, press the “Temperature Down” button until the desired temperature
is shown on the water heater display.
"Setpoint" Flashes
°F
setpoint
idle
Status Operational
SELECT
SET

Step 5: When the desired setpoint is reached on the water heater display, press the “Set” button to confirm the
new setpoint. “Setpoint” stops flashing in the water heater display.
"Setpoint" Stops Flashing
°F
setpoint
idle
Status Operational

SELECT
SET
To Change Temperature Format in Display from ˚F to ˚C or ˚C to ˚F:
Step 1: While in “Service Mode”, press “Select” button until “˚F/˚C” is shown in the upper right portion of the
water heater display.
°F
°F/°C
idle
Status Operational

SET
SELECT
48
Step 2: Press “Set” button to change temperature format. “˚F/˚C” symbol will flash in the water heater display.
"°F/°C" Flashes
°F
°F/°C
idle
Status Operational

SELECT
SET
Step 3a: Press “Temperature Up” button to change temperature format to ˚C.
Changes to "°C"
"°F/°C" Flashes
°C °F/°C
idle
Status Operational
SELECT
SET

Step 3b: Press “Temperature Down” button to change temperature format to ˚F.
Changes to "°F"
"°F/°C" Flashes
°F
°F/°C

idle
Status Operational
SELECT
SET
49
Step 4: Press “Set” button to confirm ˚F or ˚C format. ˚F/˚C will stop flashing.
"°F/°C" Symbol Stops Flashing
°F
°F/°C
idle
Status Operational

SELECT
SET
Step 5: Pressing “Select” button will return display to setpoint in format selected (˚F or ˚C) immediately.
Setpoint shown in °F
°F
idle
Status Operational

Lower Sensor
SELECT
SET
50
How to reset the control from Lockout Conditions:
WARNING
The following procedure is for service and installation personnel only. Resetting lockout conditions without correcting
the malfunction can result in a hazardous condition.
If an error code is displayed (except for #4, low flame sense current), the water heater will be in a “lockout condition” with
the water heater display showing the error code number and “Service Needed” in the status section of the display
window. Error codes 62 (maximum number of retries detected) and 63 (maximum number if ignition recycles detected)
are “Soft Lockouts” in which the control can be reset in the “User Mode” by pressing the lower right button under “Lockout
Reset” shown in the lower right portion of the display. The control will also go through 3 attempts to relight the burners
every hour in the soft lockout condition.
Resetting Error Codes in Soft Lockout Condition
Error Code Shown in
Water Heater Display
Status
Service needed

SELECT
Lockout RESET
Press for 2
seconds
All other error codes will put the water heater into a “Hard Lockout” condition, in which the water heater will not operate
and cannot be reset in the “User Mode”. To reset a hard lockout, first enter the “Service Mode” described earlier by
pressing both the “Temperature Up” and “Select Buttons” at the same time for 3 seconds. Then press the lower right
button under “Lockout Reset” in the water heater display and hold for 3 seconds.
Resetting Error Codes in Hard Lockout Condition
Error Code Shown in
Water Heater Display
Status Service
Needed

SELECT
SET

Step 1: Press for 3 seconds to enter
service mode.
51
Status Service
Needed
SELECT
Lockout RESET
Step 2: Press for 3 seconds to reset
control in service mode.
Error Codes and Error History Display:
If there is an operating problem with the water heater, an error code number will appear on the water heater
display with “Service Needed” to the right of the “Status” indicator. The error code label is located below the
water heater display and the following section in this Installation and Operating Instruction Manual explains the
error codes with corrective actions to repair the water heater.
Example of Error Code in the Display:
idle
Service Needed
SET
SELECT
Error Code History
In “Service Mode” pressing the “Select” button after the “Software Version” (item 8 in the previously described
sequence of service modes) will show an error code history, if there have been any previous operating
problems with the water heater. If the display shows --, there is not a current error code.
The Water Heater Display will provide up to 10 previous error codes. The oldest error code will be stored in
code index #1 and the most recent in code index #10 (if there are 10 error codes).
To view previous error codes
Step 1:
In “Service Mode” press the “Select” button until the next display after the “Software Version”. If there are no
current error codes, the display will show -- .
No Current Error Code
°F
idle
Status Operational

SELECT
SET
52
Step 2:
Press the “Temperature Down” button to select the error code index, starting with the most recent error code
“10”.
Error Code Index
idle
Status Operational
SET
SELECT

Step 3:
Press the “Select” button to view the error code for “code 10”. If there is a number displayed, note what the
number is. The label next to the water heater display will identify the code number. If no number is displayed
with only a “--” in the water heater display, then there has not been an error code for error code index 10.
No Error Code Shown for
Code Index 10
idle
Status Operational

SET
SELECT
Step 4:
Press the “Temperature Down” button to change to the previous code index, code #9.
Error Code Index
idle
Status Operational
SELECT
SET
53

Step 5:
Press the “Select” button for code index #9 to view if there are any code numbers.
Stored Error Code
For Code Index #9
idle
Status Operational

SELECT
SET
Step 6: Continue pressing the “Temperature Down” button to change to the next error code index and press
“Select” to view the error code number, if any, for that index number. Continue on to index #1, the oldest error
code index. The water heater display will store up to 10 error codes with the oldest code starting in code index
#1 with the most recent code in code index #10.
°F
setpoint
idle
Status
Operational

SELECT
SET

Exiting Service Mode
Step 7: 10 seconds after the last button press, the Water Heater Display will revert back to the current error
code display. To exit Service Mode, press Temperature Up button and Select Button for 3 seconds.
54
DIAGNOSTIC ERROR CODES AND TROUBLESHOOTING PROCEDURES FOR EF MODELS
WITH HONEYWELL INTEGRATED DIRECT SPARK IGNITON CONTROL SYSTEM
Error
Code
Definition of Code
No code –
blank
display
4
Low Flame Sense
Current
6
Flame Sensed Out of
Normal Sequence
(Before Opening Gas
Valve or After
Closing Gas Valve)
23
Flame Detected
Before Ignition
24
Flame Detected After
Heating Cycle
Completes
26
Exhaust Vent Limit
Switch Open
32
Sensor Reading
Faulty
57
Flame Rod Shorted
to Ground
58
AC Line Frequency
Error – Signal Too
Noisy or Frequency
Incorrect
59
Line Voltage Too
Low or High
61
DC Output Voltage
Unstable
Cause of Problem and Actions Taken to Correct
 Check power supply to the water heater.
 Make sure water heater is plugged in and the breaker is on.
 Check if there is 120 volts power supply to the LINE connections on the
control board.
 If 120 volts is present, check for 24 volts output to SECONDARY terminals on
the Control Board.
 Check for loose wires, defective transformer.
 Check wire harness connections from display to the control board.
 Determine flame sense current in the Service Mode with the water heater
operating.
 If less than 4.0 microamps, check burner flame sense rod and wire.
 Clean flame sense rod with emery cloth.
 If problem is not solved, check for debris clogging burner or replace flame
sense rod.
 Check to make sure gas valve has closed.
 No voltage should be present at the gas valve before or after ignition cycle.
 Make sure wire positions on the wire harness are correct.
 If gas valve is stuck open, replace.
 Check to make sure gas valve has closed.
 No voltage should be present at the gas valve before the ignition cycle.
 Make sure wire positions on the wire harness are correct.
 If gas valve is stuck open, replace.
 Check to make sure gas valve has closed.
 No voltage should be present at the gas valve before the ignition cycle.
 Make sure wire positions on the wire harness are correct.
 If gas valve is stuck open, replace.
 Check to see if the exhaust vent high limit switch, located on the draft hood
has opened.
 Depress the red manual reset button on the high limit switch.
 If it resets with a “click”, the switch has opened.
 Check for evidence of blockage in the exhaust vent.
 If there is evidence of blockage in the exhaust, call your Plumbing
Professional to the clear blockage.
 Do not continue to operate the water heater with the blockage in the exhaust
vent.
 Resistance of sensor out of operating range.
 Check continuity of wire harness to sensor, and if O.K., replace sensor.
 Pilot flame sensor rod is shorted to ground.
 Check to see if flame sensor wire has bare spots touching metal parts of if
flame sensor rod is touching the burner or other metal parts.
 Replace if flame sense wire is damaged or flame rod is bent.
 Check line voltage frequency to the water heater.
 Determine if there are wide fluctuations.
 Call an electrician if the problem persists.
 The water heater should be on a separate line.
 Check line voltage to the water heater.
 Determine cause of low or high voltage.
 Call an electrician or your utility.
 The water heater should be on a separate line.
 Check line voltage to the water heater for erratic readings.
 Also check wiring to make sure there are no shorts.
 If power supply and wiring are O.K., replace control board.
55
Error
Code
Definition of Code
62
Maximum Number of
Retries Detected
63
Maximum Number of
Ignition Recycles
Detected
64
Electronics Failure
65
High Water
Temperature (Over
200°F (93°C))
Cause of Problem and Actions Taken to Correct
 Burner is either not lighting or not staying lit during ignition cycle.
 Check inlet gas pressure for minimum pressure on rating label.
 Can you hear sparking to the burner?
 Check high voltage cable connections.
 Check inlet gas pressure to the gas valve making sure the pressure is within
the limits specified on the rating label.
 Check gas valve wire harness for broken wires or shorts.
 Check outlet gas pressure.
 If 24 volts is present to the terminals at the gas valve, replace gas valve.
 Check for voltage output to the blue gas valve wires on the control board pins.
 If during the ignition trial period, there is no voltage present at the control
board pin terminals for the blue wires leading to the gas valve, then replace
the control board.
 Replace spark rod if insulator is damaged or rod is loose.
 Check to make sure combustion blower is operating when thermostat calls for
heat.
 If blower is not running check for 120 volts to blower harness and then at
blower pin connections.
 Replace control, wire harness, or blower if defective.
 Check to make sure vent terminals are clear of debris or snow and ice.
 Make sure the condensate drain flows freely.
 Burner flame is lost during run cycle, and then re-established on ignition cycle.
Check inlet gas pressure.
 Is gas pressure dropping below the minimum operating pressure on the rating
label after the gas valve opens?
 Is the gas pipe size to the water heater adequate?
 Check the condition of the burner.
 Clean or replace as needed.
 Check the burner flame and observe the microamp output on the run cycle.
 Replace burner if clogged with dirt and debris.
 Replace spark rod or flame sensor if damaged.
 Check to make sure vent terminals are clear of debris or snow and ice.
 Make sure the condensate drain flows freely.
 Replace control board.
 Water temperature in tank has exceeded 200°F (93°C).
 Check tank sensor.
 Make sure sensor is fully inserted into the well (clip on sensor wire secures
sensor in place).
 Check sensor reading.
 If not within specifications, replace sensor.
 If sensor and wire harnesses check O.K., replace control board.
56
Procedure for Checking Thermostat Sensors
Set the thermostat above water temperature (See temperature adjustment section) and observe system through one (1)
complete cycle. Make sure system operates as desired.
To check the upper sensor assembly, compare the resistance of the sensor terminals (yellow and black lead for upper
sensor) as measured by an ohmmeter to the water temperature as measured by an accurate thermometer. Thermistor
resistance increases as the temperature decreases. The tables below show the correct sensor resistance at various
temperatures. Replace the sensor if the ohm reading in the chart does not approximate the reading from the sensor at
the temperature measured in the tank.
In Degrees F
°F
0
1
2
3
4
5
6
7
8
9
40
26109
25400
24712
24045
23399
22771
22163
21573
21000
20445
50
19906
19383
18876
18383
17905
17440
16990
16553
16128
15715
60
15314
14925
14548
14180
13823
13477
13140
12812
12494
12185
70
11884
11592
11308
11032
10763
10502
10248
10000
9760
9526
80
9299
9078
8862
8653
8449
8250
8057
7869
7685
7507
90
7333
7165
7000
6839
6683
6531
6383
6238
6098
5961
100
5827
5697
5570
5446
5326
5208
5094
4982
4873
4767
110
4663
4562
4464
4368
4274
4183
4094
4006
3922
3839
120
3758
3679
3602
3527
3453
3382
3312
3244
3177
3112
130
3048
2986
2925
2866
2808
2752
3697
3643
2590
2538
140
2488
2439
2391
2344
2298
2253
2209
2166
2124
2083
150
2043
2004
1966
1928
1891
1856
1820
1786
1753
1720
160
1688
1656
1625
1595
1566
1567
1509
1481
1454
1427
170
1402
1376
1351
1327
1303
1280
1257
1235
1213
1191
180
1170
1150
1129
1110
1090
1071
1053
1035
1017
999
190
982
965
949
933
917
901
886
871
857
842
200
828
814
801
788
775
762
749
737
725
713
°C
0
10
20
30
40
50
60
70
80
90
0
32648
19898
12492
8057
5327
3602
2488
1752
1256
916
1
31026
18968
11942
7722
5117
3468
2400
1693
1216
888
2
29495
18088
11419
7403
4917
3340
2316
1637
1177
861
6
24166
14998
9572
6268
4201
2878
2011
1432
1037
763
7
23010
14322
9165
6016
4042
2774
1942
1385
1005
741
8
21915
13680
8778
5775
3889
2675
1876
1340
974
719
9
20879
13071
8409
5546
3742
2579
1813
1297
944
698
In Degrees C
3
4
5
28049 26682 25389
17253 16461 15710
10922 10450 10000
7099
6808
8532
4726
4543
4368
3217
3099
2986
2235
2157
2083
1582
1530
1480
1140
1105
1070
835
810
786
57
SECTION XII: PARTS LIST
Water Heater Full Assembly
(270,000 BTU/h and Below)
1 Surround Assembly
Combustion Assembly
2 (Specify model)
3 Ignition Control Assembly
4 Draft Hood (Specify model)
5 Swell Latch
6 Front Hot Water Outlet
7 Baffle 2” Flue (Specify Model)
8 Control Display
9 Front Cold Water Inlet
10 Plastic Hole Closure
11 No Handle Brass Drain Valve
12 Cleanout Access Cover
13 Screw 5/16-18 x 3/4” HH Grade 5
14 Cleanout Cover
15 T&P (Specify Model)
16 Hot Water Outlet Plastisert Nipple
17 Anode
18 Cold Water Inlet (Hydrojet) Assembly
19 Cleanout Gasket (Specify Model)
Customer must specify complete model number and
serial number when ordering service parts.
SEE SUPPLEMENT INCLUDED WITH
UCG100H399 UNITS FOR PARTS LIST.
58
2 Combustion Assembly
1
2
3
4
5
6
7
8
9
10
11
12
Combustion Assembly (Specify model)
Blower/Gas Valve Assembly (Specify model)
Burner Assembly (Specify model)
Blower – (Specify model)
Gasket & Screw
Transition Tube
Gasket Blower Transition
Gasket Transition Tube
1/4 – 20 Nut
Screw 8-32 x ¼” RHCR
Gasket Flame Sense
Gasket Igniter
13
14
15
16
17
18
19
20
21
22
23
24
Sensor – Flame Sense
Igniter – Direct Spark Ignition
Blower / Burner Mounting Plate
Gasket Burner (Specify Model)
Burner (Specify Model)
Burner Mount Assembly
Sight Glass Assembly
Gasket Sight Glass
Reducer ¾ x ½ NPT
Nipple ½ NPT x 3”
Gas Valve
Venturi
Customer must specify complete model number and serial number when ordering service parts.
59
3 Ignition Control Assembly and Harnesses
1
2
3
4
5
6
7
8
Control Panel
Control
Transformer
Display Panel
Screw
Switch Main Power
Control Display
Weld Stud
9
10
11
12
13
14
15
16
Hex Nut
Ignition Control Harness
Power Cord Harness
T-Stat Sensor Harness
High Voltage Spark Cable
Blower/Circ/Damper Harness
Ground Wire
Flame Sense Harness
Customer must specify complete model number
and serial number when ordering service parts.
Manufactured under one or more of the following U.S. Patents: 5,277,171; 5,341,770; 5,372,185; 5,485,879; 5,574,822;
5,596,952; 5,660,165; 5,682,666; 5,761,379; 5,943,984; 5,954,492; 5,988,117; 6,056,542; 6,142,216; 6,442,178;
6,684,821; 6,935,280; 7,063,132; 7,063,133; 7,007,748; 7,270,087; 7,334,419; 7,337,517; 7,409,925; 7,458,341;
7,559,293; 7,621,238; 7,634,976; 7,650,859; 7,665,210; 7,665,211; 7,699,026; 7,866,168; 7,900,589; 7,971,560;
7,992,526 8,082,888; 8,146,772; Other U.S. and Foreign patent applications pending. Current Canadian Patents:
2,092,105; 2,107,012; 2,108,186; 2,112,515; 2,143,031; 2,239,007; 2,262,174; 2,314,845; 2,409,271; 2,476,685;
2,504,824; 2,548,958
60
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