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- A.O. Smith
- SBD 30 150
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MODELS SBD 30 150 AND SBD 30 199
COMMERCIAL GAS, GLASS-LINED, TANK-TYPE WATER HEATER
• INSTALLATION • OPERATION • MAINTENANCE • LIMITED WARRANTY
Thank you for buying this energy efficient water heater from
A.O. Smith Water Products Company. We appreciate your confidence in our products.
CAUTION
TEXT IN BLACK BOLD TYPE OR UNDERLINED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ
THOROUGHLY BEFORE INSTALLING AND USING THIS
APPLIANCE.
Printed in U.S.A. 1004
500 LINDAHL PARKWAY
ASHLAND CITY, TN 37015 www.statewaterheaters.com
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER
AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
1
PART NO. 196310-001
ROUGH-IN-DIMENSIONS
FIGURE 1
TABLE 1 - HEATER PERFORMANCE DATA
Model
Input
Rate
Btuh
Approx.
Tank
Cap.
SBD 30 150 150,000 NAT 32 Gal
Approx.
Eff. %
80
F
C 11°C 17°C 22°C 28°C 33°C 39°C 44°C 50°C 56°C 61°C 67°C 72°C 78°C
GPH
RECOVERY RATING CAPACITIES (GPH) AT TEMPERATURE RISE SHOWN
20°F
727
30°F
485
40°F
364
50°F
291
60°F 70°F 80°F 90°F 100°F 110°F 120°F 130°F 140°F
242 208 182 162 145 132 121 112 104
44 kW/Hr. NAT 121 Litres
SBD 30 150 150,000 LP 32 Gal 80
LPH
GPH
2752 1836 1378 1102
727 485 364 291
916
242
787
208
689
182
613
162
549
145
500
132
458
121
424
112
394
104
44 kW/Hr. LP 121 Litres
SBD 30 199 199,900 NAT 32 Gal
59 kW/Hr. NAT 121 Litres
SBD 30 199 182,000 LP 32 Gal
53 kW/Hr. LP 121 Litres
80
80
LPH
GPH
LPH
GPH
LPH
2752 1836 1378 1102
969
882
646
588
485
441
388
3668 2445 1836 1469 1223 1049 916
353
3339 2226 1669 1336
916
323
294
1113
787
277
252
954
689
242
221
837
613
215
814
196
742
549
194
734
177
670
500
176
666
160
606
458
162
613
147
557
424
149
564
136
515
394
139
526
126
477
FOREWORD
These designs comply with ANSI Z21.10.3 as a Booster type water heater.
These heaters may be installed on combustible floors.
Detailed installation diagrams are found in this manual. These diagrams will serve to provide the installer with a reference for the materials and methods of piping necessary. It is highly essential that all water, gas piping and wiring be installed as shown on the diagrams.
In addition to these instructions, the equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.
Particular attention should be given to the installation of thermometers at the locations indicated on the diagrams as these are necessary for checking the proper functioning of the heater.
The heater is designed to operate on natural gas.
The installation must conform to these instructions and the local code authority having jurisdiction. In the absence of local codes, the installation must comply with the latest editions of the
National Fuel Gas Code, ANSI Z223.1/NFPA 54 and the National
Electrical Code, NFPA 70, documents are available from the
National Fire Protection Association, 1 Batterymarch Park, Quincy,
MA 02269.
2
TABLE OF CONTENTS
Page
ROUGH-IN-DIMENSIONS ..................................................... 2
FOREWORD .......................................................................... 2
GENERAL SAFETY INFORMATION ....................................... 3
Precautions ....................................................................... 3
Grounding Instructions ...................................................... 3
Chemical Vapor Corrosion ................................................ 3
Improper Combustion ...................................................... 3-4
Extended Non-Use ............................................................ 4
Insulation Blankets ............................................................ 4
High Altitude Installation .................................................... 4
FEATURES ............................................................................ 4
Self-Cleaning Hydro-Cannon ............................................ 4
High Limit Switch .............................................................. 4-5
Electronic Ignition Control ................................................. 5
Exhaust Inducer (Blower Assy.) ......................................... 5
Circulating Pump ............................................................... 5
Dishwashing Machine Requirement ................................ 5
INSTALLATION INSTRUCTIONS ........................................... 6
Required Ability .................................................................. 6
Uncrating ........................................................................... 6
Locating The Heater .......................................................... 6
Levelling ............................................................................ 6
Clearances ........................................................................ 6
Air Requirements ............................................................. 6-7
Venting .............................................................................. 7-8
Multiple Heater Manifold .................................................... 8
Water Line Connections ................................................... 8
Water (Potable) Heating and Space Heating .................... 8
Thermometers (Not Supplied) .......................................... 8
Relief Valve ........................................................................ 8
Gas Piping ......................................................................... 9
Gas Pressure Regulator ................................................ 9-10
Heater Wiring .................................................................... 10
Page
INSTALLATION DIAGRAMS ................................................ 11-17
OPERATION ......................................................................... 18
General ............................................................................ 18
SEQUENCE OF OPERATION .............................................. 18
Lighting and Operation .................................................... 19
Water Temperature Control ............................................. 20
PREVENTIVE MAINTENANCE ............................................ 20
Check The Ignitor Assembly ........................................... 20
Ignitor Assembly .............................................................. 20
Main Burner ................................................................... 20-21
Gas Valves ....................................................................... 21
Checking The Input ......................................................... 21
Venting System ................................................................ 21
Remote Storage Tank Temperature Control ................... 21
Relief Valve ...................................................................... 22
Hot Water Odor ................................................................ 22
Anode Rod Inspection ..................................................... 22
Flushing ........................................................................... 22
Draining ........................................................................... 22
Recommended Procedure For Periodic
Removal of Lime Deposits From Tank Type
Commercial Water Heaters .......................................... 22-23
Deliming Solvents ........................................................... 23
Tank Cleanout Procedures ........................................... 23-24
Ignition Module System ................................................... 24
System Diagnostics ........................................................ 24
SERVICE ............................................................................. 24
Electrical Servicing .......................................................... 24
Replacement Parts ......................................................... 24
Sequence of Operation Flow Chart ................................. 25
Operational Checklist ...................................................... 26
Limited Warranty ............................................................. 27
GENERAL SAFETY INFORMATION
PRECAUTIONS
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER
WATER. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.
CHEMICAL VAPOR CORROSION
WARNING
CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY
OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN
CHEMICAL VAPORS. SUCH CORROSION MAY RESULT IN
FAILURE AND RISK OF ASPHYXIATION.
IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO NOT
OPERATE HEATER UNTIL ALL CORRECTIVE STEPS HAVE
BEEN MADE BY A QUALIFIED SERVICEMAN.
1. EXTERNAL FIRE.
2. DAMAGE.
3. FIRING WITHOUT WATER.
4. SOOTING
GROUNDING INSTRUCTIONS
This water heater must be grounded in accordance with the
National Electric Code and/or local codes. These must be followed in all cases.
This water heater must be connected to a grounded metal, permanent wiring system; or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the water heater, see
Figure 9.
Spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride (water softener salt), waxes, and process chemicals and typical compounds which are potentially corrosive.
Do not store products of this sort near the heater. Also, air which is brought in contact with a the heater should not contain any of these chemicals. If necessary, uncontaminated air should be obtained from remote or outside sources. The limited warranty is voided when failure of water heater is due to a corrosive atmosphere. (Refer to the limited warranty for complete terms and conditions.
IMPROPER COMBUSTION
WARNING
ATTIC AND/OR EXHAUST FANS OPERATING ON THE PREMISES
WITH A WATER HEATER CAN RESULT IN CARBON MONOXIDE
POISONING AND DEATH.
3
OPERATION OF THESE FANS CAN PRODUCE A NEGATIVE
DRAFT IN THE AREA OF THE WATER HEATER PREVENTING
THE PRODUCTS OF COMBUSTION FROM EXHAUSTING
THROUGH THE CHIMNEY OR VENT PIPE.
The venting of the water heater should be inspected by a qualified service technician at the time of installation and periodically thereafter to ensure a down-draft condition does not exist.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND
VENTILATING AIR. ADEQUATE AIR FOR COMBUSTION AND
VENTILATION MUST BE PROVIDED FOR SAFE OPERATION.
EXTENDED NON-USE PERIODS
INSULATION BLANKETS
Insulation blankets available to the general public for external use on gas water heaters are not approved for use on your
State water heater. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank water heaters. Your State water heater meets or exceeds the ASHRAE/IES 90.1-1999 standards with respect to insulation and standby loss requirement making an insulation blanket unnecessary.
As elevation above sea level is increased, there is less oxygen per cubic foot of air. Therefore, the heater input rate should be reduced at high altitudes for satisfactory operation with the reduced oxygen supply. Failure to make this reduction would result in an overfiring of the heater causing sooting, poor combustion and/or unsatisfactory heater performance.
REQUIREMENTS
Ratings specified by manufacturers for most appliances apply for elevations up to 2000 feet. For elevations above 2000 feet, ratings must be reduced at the rate of 4% for each 1000 feet above sea level. For example, if a heater is rated at
120,000 Btuh at sea level, to rate the heater at 4000 feet, you subtract 4 (once for each thousand feet) x.04 (4% input reduction) x 120,000 Btuh (original rating) from the original rating. Therefore, to calculate the input rating at 4,000 feet: 4 x .04 x 120,000 =19,200
Btuh, 120,000 - 19,200 = 100,800 Btuh. At 6000 feet the correct input rating should be 91,200 Btuh.
WARNING
HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER SYSTEM
SERVED BY THIS HEATER THAT HAS NOT BEEN USED FOR A
LONG PERIOD OF TIME (GENERALLY TWO WEEKS OR MORE).
HYDROGEN GAS IS EXTREMELY FLAMMABLE.
To reduce the risk of injury under these conditions, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance connected to the hot water system. If hydrogen is present, there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow. THERE SHOULD BE NO SMOKING OR
OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.
The input reduction is primarily achieved by reducing the size of the main burner orifices. To do this, the main burner orifices require replacement with orifices sized for the particular installation elevation. Correct orifice sizing and parts may be obtained from State Water Heaters. When ordering, be sure to state the model number and the altitude of the location where the water heater is being installed.
Upon completion of derating of the heater, adjustment to the gas pressure regulator may be required. See CHECKING THE
INPUT section in this manual for inlet and manifold pressure requirements.
Also due to the input rating reduction required at high altitudes, the output rating of the appliance is also reduced and should be compensated for in the sizing of the equipment for application.
WARNING
Should you choose to apply an insulation blanket to this heater, you should follow these instructions. Failure to follow these instructions can result in fire, asphyxiation, serious personal injury or death.
• Do not apply insulation to the top of the water heater, as this will interfere with safe operation of drafthood.
• Do not cover the temperature & pressure relief valve.
• Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.
• Do obtain new labels from State Water Heaters for placement on the blanket directly over the existing labels.
HIGH ALTITUDE INSTALLATIONS
FEATURES
SELF-CLEANING HYDRO-CANNON
These units include a self-cleaning hydro-cannon installed in the front water inlet. See figure 2. The hydro-cannon must be oriented correctly for proper function. There is a marked range on the pipe nipple portion of the hydro-cannon, that must be aligned with the top of the inlet spud. A label above the jacket hole has an arrow that will point to the marked portion of the pipe nipple if the orientation is correct. If the arrow does not point within the marked range on the pipe nipple, adjust the pipe nipple to correct. A pipe union is supplied with the hydro-cannon to reduce the probability of misaligning the hydro-cannon accidentally while tightening the connection to the inlet water supply line. Improper orientation of the hydro-canon can cause poor performance of the heater and can significantly reduce outlet water temperatures during heavy draws.
WARNING
INSTALLATIONS ABOVE 2000 FEET (610 METERS) REQUIRE
REPLACEMENT OF THE BURNER ORIFICE IN ACCORDANCE
WITH SECTION 8.1.2 OF THE NATIONAL FUEL GAS CODE
(ANSI Z223.1). FAILURE TO REPLACE THE ORIFICE WILL RESULT
IN IMPROPER AND INEFFICIENT OPERATION OF THE APPLIANCE
RESULTING IN THE PRODUCTION OF INCREASED LEVELS OF
CARBON MONOXIDE GAS IN EXCESS OF SAFE LIMITS WHICH
COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
You should contact your gas supplier for any specific changes which may be required in your area.
NOTE: The inlet may have 1, 2 or 7 cross- tubes.
FIGURE 2
HIGH LIMIT SWITCH
The digital thermostat (Figure 3) contains the high limit (energy cutoff) sensor. The high limit switch interrupts main burner gas flow should the water temperature reach 203°F (195°C).
4
In the event of high limit switch operation, the appliance cannot be restarted unless the water temperature is reduced to approximately 120°F (49°C). The high limit reset button on the front of the control then needs to be depressed.
Continued manual resetting of high limit control, preceded by higher than usual water temperature is evidence of high limit switch operation. The following is a possible reason for high limit switch operation.
A malfunction in the thermostatic controls would allow the gas valve to remain open causing water temperature to exceed the thermostat setting. The water temperature would continue to rise until high limit switch operation.
Contact your dealer or service agent if continued high limit switch operation occurs.
EXHAUST INDUCER (BLOWER ASSEMBLY)
All units are equipped with a exhaust inducer. The inducer assists in drawing in fresh air to the unit for combustion and then assists in dispensing the combustion by-products into the venting leading outside.
The exhaust inducer is equipped with a gravity controlled damper to reduce the amount of heat loss through the flue, improving efficiency.
FIGURE 5 - EXHAUST INDUCER
CIRCULATING PUMP
FIGURE 3 - DIGITAL THERMOSTAT
A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the heater. Refer to the piping diagrams at rear of manual for electrical hookup information and install in accordance with the latest version of the National Electric Code ANSI/NFPA No. 70.
ELECTRONIC IGNITION CONTROL
Each heater is equipped with a ignition module. The solid state ignition control (Figure 4), ignites the main burner by utilizing a silicone nitride ignitor. The silicone nitride ignitor shuts off during the heating cycle and the main burner flame is sensed through a remote flame sensor integral to the silicone nitride ignitor assembly. The ignition control will try to ignite the main burner three times before lockout. Then it waits one hour before trying again to ignite the main burners. This is a continuous cycle.
Only all bronze circulators are used with commercial water heaters.
Although circulators are oiled and operated by the manufacturer some circulators must be oiled again before operating. Please refer to manufacturer’s instructions.
DISHWASHING MACHINE REQUIREMENT
These appliances meet the National Sanitation Foundation
Standard for sanitary installations when used with the following leg kits, Part No’s. 6570-0 and 6570-7.
FIGURE 4 - IGNITION CONTROL BOARD
5
All dishwashing machines meeting the National Sanitation
Foundation requirements are designed to operate with water flow pressures between 15 and 25 psi. Flow pressures above
25 psi, or below 15 psi, will result in improperly sanitized dishes.
Where pressures are high, a water pressure reducing or flow regulating control valve should be used in 180°F (82°C) line to the dishwashing machine, and should be adjusted to deliver water between these limits.
The National Sanitation Foundation also recommends circulation of 180 0 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 0 F water at the point of take-off to the dishwashing machine. Adjust flow by means of the plug cock in the circulating line.
INSTALLATION INSTRUCTIONS
REQUIRED ABILITY
WHEN SUCH LOCATIONS CANNOT BE AVOIDED, A SUITABLE
DRAIN PAN SHOULD BE INSTALLED UNDER THE HEATER. Such pans should be fabricated with sides at least 2" deep, with length and width at least 2" greater than the diameter of the heater and must be piped to an adequate drain. The pan must not restrict combustion air flow.
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.
For appliance installation locations with elevations above
2000 feet (610m), refer to HIGH ALTITUDE INSTALLATIONS section of this manual for input reduction procedure.
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN
SERIOUS PERSONAL INJURY OR DEATH.
LEVELING
If the unit is not level, insert the bolts which were used in crating into the legs to correct this condition.
UNCRATING
The heater is shipped with the inducer already installed. The wiring conduit runs from the thermostat to the inducer. Before turning unit on, check to make sure the wiring conduit is securely plugged into the inducer.
LOCATING THE HEATER
CLEARANCES
These heaters are approved for installation on combustible flooring in an alcove when the minimum clearance from any combustion construction are followed as indicated in figure 6.
WARNING
THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH
AS GAS WATER HEATERS IN ROOMS, GARAGES OR OTHER
AREAS WHERE GASOLINE, OTHER FLAMMABLE LIQUIDS OR
ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED,
OPERATED OR REPAIRED. FLAMMABLE VAPORS ARE HEAVY
AND TRAVEL ALONG THE FLOOR AND MAY BE IGNITED BY THE
HEATER’S PILOT OR MAIN BURNER FLAMES CAUSING FIRE OR
EXPLOSION. SOME LOCAL CODES PERMIT OPERATION OF
GAS APPLIANCES IN SUCH AREAS IF THEY ARE INSTALLED 18”
OR MORE ABOVE THE FLOOR. THIS MAY REDUCE THE RISK IF
LOCATION IN SUCH AN AREA CANNOT BE AVOIDED.
Models SBD 30 150 and 30 199 are approved for installation on non-cumbustible flooring or combustible flooring with leg kit part no. 6570.
In all installations the minimum combustible clearances from vent piping shall be 6". Vent piping passing through a combustible wall or ceiling must be a continuous run (no joints) and retain the 6" clearance unless an approved reducing thimble is used.
A service clearance of 24" should be maintained from serviceable parts, such as relief valves, flue baffles, thermostats, cleanout openings or drain valves.
The units are approved for installation with side, rear and ceiling clearances.
DO NOT INSTALL THIS WATER HEATER DIRECTLY ON A
CARPETED FLOOR. A FIRE HAZARD MAY RESULT. Instead the water heater must be placed on a metal or wood panel extending beyond the full width and depth by at least 3 inches in any direction.
If the heater is installed in a carpeted alcove, the entire floor shall be covered by the panel. Also, see the DRAINING requirements in MAINTENANCE Section.
AIR REQUIREMENTS
REFER TO THE LATEST EDITION OF THE "NATIONAL FUEL
GAS CODE" ANSI Z223.1/NFPA 54.
THE HEATER SHALL BE LOCATED OR PROTECTED SO IT IS NOT
SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE.
KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE
MATERIALS, GASOLINE AND OTHER FLAMMABLES, VAPORS
AND LIQUIDS.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION OR
VENTILATING AIR.
WARNING
FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY
OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER
BE PLACED ON OR ADJACENT TO THE HEATER. OPEN
CONTAINERS OR FLAMMABLE MATERIAL SHOULD NOT BE
STORED OR USED IN THE SAME ROOM WITH THE HEATER.
When installing the heater, consideration must be given to proper location. Location selected should be as close to the stack or chimney as practicable, with adequate air supply and as centralized with the piping system as possible.
WARNING
FOR SAFE OPERATION PROVIDE ADEQUATE AIR FOR
COMBUSTION AND VENTILATION. AN INSUFFICIENT SUPPLY
OF AIR WILL CAUSE RECIRCULATION OF COMBUSTION
PRODUCTS RESULTING IN AIR CONTAMINATION THAT MAY BE
HAZARDOUS TO LIFE. SUCH A CONDITION OFTEN WILL RESULT
IN A YELLOW, LUMINOUS BURNER FLAME, CAUSING
CARBONING OR SOOTING OF THE COMBUSTION CHAMBER,
BURNERS AND FLUE TUBES AND CREATES A RISK OF
ASPHYXIATION.
THE HEATER MUST NOT BE LOCATED IN AN AREA WHERE IT
WILL BE SUBJECT TO FREEZING.
LOCATE IT NEAR A FLOOR DRAIN. THE HEATER SHOULD BE
LOCATED IN AN AREA WHERE LEAKAGE FROM THE HEATER OR
CONNECTIONS WILL NOT RESULT IN DAMAGE TO THE
ADJACENT AREA OR TO LOWER FLOORS OF THE STRUCTURE.
Where an exhaust fan is supplied in the same room with a heater, sufficient openings for air must be provided in the walls.
UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO
THE ROOM THROUGH THE CHIMNEY, CAUSING POOR
COMBUSTION. SOOTING MAY RESULT IN SERIOUS DAMAGE
TO THE HEATER AND RISK OF FIRE OR EXPLOSION.
6
FIGURE 6 -ILLUSTRATION OF MINIMUM CLEARANCES TO COMBUSTIBLES
UNCONFINED SPACE
In buildings of conventional frame, brick, or stone construction, unconfined spaces may provide adequate air for combustion, ventilation and draft hood dilution.
If the unconfined space is within a building of tight construction
(buildings using the following construction: weather stripping, heavy insulation, caulking, vapor barrier, etc.), air for combustion, ventilation and draft hood dilution must be obtained from outdoors. The installation instructions for confined spaces in tightly constructed buildings must be followed to ensure adequate air supply.
CONFINED SPACE
When drawing combustion and dilution air from inside a conventionally constructed building to a confined space, such a space shall be provided with two permanent openings, ONE IN
OR WITHIN 12 INCHES OF THE ENCLOSURE TOP AND ONE
IN OR WITHIN 12 INCHES OF THE ENCLOSURE BOTTOM.
Each opening shall have a free area of at least one square inch per 1000 Btuh of the total input of all appliances in the enclosure, but not less than 100 square inches.
If the confined space is within a building of tight construction, air for combustion, ventilation, must be obtained from outdoors.
When directly communicating with the outdoors or communicating with the outdoors through vertical ducts, two permanent openings, located in the above manner, shall be provided. Each opening shall have a free area of not less than one square inch per 4000 Btuh of the total input of all appliances in the enclosure. If horizontal ducts are used, each opening shall have a free area of not less than one square inch per
2000 Btuh of the total input of all appliances in the enclosure.
If any part of the vent system are exposed to ambient temperatures below 40°F (4°C) it must be insulated to prevent condensation.
The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation.
1.
Seal any unused openings in the venting system.
2.
Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI
Z223.1. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.
3.
So far as is practical, close all building doors and windows and all doors between the space in which the water heater(s) connected to the venting system are located and other spaces of the building. Turn on all appliances not connected to the venting system. Turn on all exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Close fireplace dampers.
4.
Follow the lighting instruction. Place the water heater being inspected in operation. Adjust thermostat so appliance shall operate continuously.
5.
After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use.
6.
If improper venting is observed during any of the above tests, the venting system must be corrected.
WARNING
FAILURE TO CORRECT BACK DRAFTS MAY CAUSE AIR
CONTAMINATION AND UNSAFE CONDITIONS.
VENTING
WARNING
THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST
BE FOLLOWED TO AVOID CHOKED COMBUSTION OR
RECIRCULATION OF FLUE GASES. SUCH CONDITIONS
CAUSE SOOTING OR RISKS OF FIRE AND ASPHYXIATION.
• If the back draft cannot be corrected by the normal method or if a suitable draft cannot be obtained, a blower type flue gas exhauster must be employed to assure proper venting and correct combustion.
• Do not connect the heater to a common vent or chimney with solid fuel burning equipment. This practice is prohibited by many local building codes as is the practice of venting gas fired equipment to the duct work of ventilation systems.
Heater must be protected from freezing downdrafts.
Remove all soot or other obstructions from the chimney that will retard a free draft.
Type B venting is recommended with these heaters.
This water heater must be vented in compliance with all local codes, the current revision of the National Fuel Gas Code
(ANSI-Z223.1) and with the Category I Venting Tables.
FIGURE 7
7
• Where a separate vent connection is not available and the vent pipe from the heater must be connected to a common vent with an oil burning furnace, the vent pipe should enter the smaller common vent or chimney at a point above the large vent pipe.
MULTIPLE HEATER MANIFOLD
(without bypass) is installed in the cold water line between the water heater and street main (or well).
Excessive pressure may develop in such closed systems, causing premature tank failure or intermittent relief valve operation. This is not a warranty failure. An expansion tank or a similar device may be required in the inlet supply line between the appliance and the meter or valve to compensate for the thermal expansion of the water.
When horizontally manifolding two or more heaters vent as shown in Figure 8. Refer to NFPA 54/ANSI Z223.1 for venting multiple heaters.
SYSTEM CONNECTIONS
The system installation must conform to these instructions and to the local code authority having jurisdiction. Good practice requires that all heavy piping be supported.
THERMOMETERS (Not Supplied)
Thermometers should be obtained and field installed as shown in the installation diagrams.
Thermometers are installed in the system as a means of detecting the temperature of the outlet water supply.
FIGURE 8
WATER LINE CONNECTIONS
RELIEF VALVE
This manual provides detailed installation diagrams (see pages
12-17 of this manual) for typical methods of application for the water heaters.
The water heater may be installed by itself, or with a separate storage tank, on both single and two-temperature systems.
When used with a separate storage tank, the circulation may be either by gravity or by means of a circulating pump. When a circulating pump is used it is important to note that the flow rate should be slow so that there will be a minimum of turbulence inside the heater.
If a water heater is installed in a closed water system, contact the water supplier or local plumbing inspector on how to control this situation.
This water heater is equipped with a combination temperature-pressure relief valve that complies with the standard for relief valves and automatic gas shutoff devices for hot water supply system, ANSI Z21.22. FOR SAFE OPERATION OF THE
WATER HEATER, THE RELIEF VALVE(S) MUST NOT BE REMOVED
OR PLUGGED.
ASME ratings cover pressure relief capacities. A.G.A. ratings cover release rate with temperature actuation.
In addition to the appliance relief valve, each remote storage tank which may be used in conjunction with this appliance shall also be installed with a properly sized, rated and approved combination temperature (ANSI) and pressure (ASME) relief valve(s).
WATER (POTABLE) HEATING
AND SPACE HEATING
WARNING
THE PURPOSE OF RELIEF VALVE IS TO AVOID EXCESSIVE
PRESSURE OR TEMPERATURE INTO THE STEAM RANGE, WHICH
MAY CAUSE SCALDING AT FIXTURES, TANK EXPLOSION,
SYSTEM OR HEATER DAMAGE. NO VALVE IS TO BE PLACED
BETWEEN THE RELIEF VALVE AND TANK.
1. All piping components connected to this unit for space heating applications shall be suitable for use with potable water.
2. Toxic chemicals, such as those used for boiler treatment, shall NEVER be introduced into this system.
3. This unit may NEVER be connected to any existing heating system or component(s) previously used with a non-potable water heating appliance.
4. When the system requires water for space heating at temperatures higher than required for domestic water purposes, a tempering valve must be installed. Please refer to installation diagrams on pages 12 thru 17 of this manual for suggested piping arrangements.
Your local code authority may have other specific relief valve requirements.
A DRAIN LINE MUST BE CONNECTED TO THE RELIEF VALVE TO
DIRECT DISCHARGE TO A SAFE LOCATION TO AVOID SCALDING
OR WATER DAMAGE. THIS LINE MUST NOT BE REDUCED FROM
THE SIZE OF THE VALVE OUTLET AND MUST NOT CONTAIN
VALVES, RESTRICTIONS NOR SHOULD IT BE LOCATED IN
FREEZING AREAS. DO NOT THREAD OR CAP THE END OF THIS
LINE. RESTRICTED OR BLOCKED DISCHARGE WILL DEFEAT
THE PURPOSE OF THE VALVE AND IS UNSAFE. DISCHARGE
LINE SHALL BE INSTALLED TO ALLOW COMPLETE DRAINAGE
OF BOTH THE VALVE AND LINE.
CAUTION
A closed system will exist if a check valve (without bypass), pressure reducing valve (without bypass), or a water meter
See SERVICE INFORMATION section for procedure and precautions.
8
GAS PIPING
To prevent damage, care must be taken not to apply too much torque when attaching gas supply pipe to gas valve inlet.
Contact your local gas service company to ensure that adequate gas service is available and to review applicable installation codes for your area.
Size the main gas line in accordance with Table 2. The figures shown are for straight lengths of pipe at 0.5 in. W.C. pressure drop, which is considered normal for low pressure systems.
Note: Fittings such as elbows, tees and line regulators will add to the pipe pressure drop. Also refer to the latest version of the
National Fuel Gas Code.
Apply joint compounds (pipe dope) sparingly and only to the male threads of pipe joints. Do not apply compounds to the first two threads. Use compounds resistant to the action of liquefied petroleum gases.
BEFORE PLACING THE HEATER IN OPERATION, CHECK FOR GAS
LEAKAGE. Use soap and water solution or other material acceptable for the purpose in locating the leaks. DO NOT USE
MATCHES, CANDLES, FLAME OR OTHER SOURCES OF IGNITION
FOR THIS PURPOSE.
WARNING
THE HEATER IS NOT INTENDED FOR OPERATION AT HIGHER
THAN 14.0" W.C.(3.48 kPa) - NATURAL GAS, 14.0" W.C.(3.48kPa)
EXPOSURE TO HIGHER SUPPLY PRESSURE MAY CAUSE
DAMAGE TO THE GAS VALVE WHICH COULD RESULT IN FIRE
OR EXPLOSION. IF OVERPRESSURE HAS OCCURRED SUCH
AS THROUGH IMPROPER TESTING OF GAS LINES OR
EMERGENCY MALFUNCTION OF THE SUPPLY SYSTEM, THE GAS
VALVE MUST BE CHECKED FOR SAFE OPERATION. MAKE SURE
THAT THE OUTSIDE VENTS ON THE SUPPLY REGULATORS AND
THE SAFETY VENT VALVES ARE PROTECTED AGAINST
BLOCKAGE. THESE ARE PARTS OF THE GAS SUPPLY SYSTEM,
NOT THE HEATER. VENT BLOCKAGE MAY OCCUR DURING ICE
STORMS.
DISCONNECT THE HEATER AND ITS MANUAL GAS SHUTOFF
VALVE FROM THE GAS SUPPLY PIPING SYSTEM DURING ANY
SUPPLY PRESSURE TESTING EXCEEDING 1/2 PSIG. GAS
SUPPLY LINE MUST BE CAPPED WHEN DISCONNECTED FROM
THE HEATER FOR TEST PRESSURES OF 1/2 PSIG OR LESS. THE
APPLIANCE NEED NOT BE DISCONNECTED, BUT MUST BE
ISOLATED FROM THE SUPPLY PRESSURE TEST BY CLOSING
THE MANUAL GAS SHUTOFF VALVE.
GAS PIPING AND DIRT LEG INSTALLATION
TABLE 2 - GAS SUPPLY LINE SIZES (IN INCHES)*
MAXIMUM CAPACITY OF PIPE IN CUBIC FEET PER HOUR
(Based upon a Pressure Drop of 0.5 inch Water Column and
0.6 specific Gravity Gas and max. gas pressure of 0.5 psig)
LENGTH NOMINAL IRON PIPE SIZES (INCHES)
IN FEET 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3"
10 175 360 680 1400 2100
4"
3960 6300 11000 23000
20
30
120
97
250 465
200 375
950
770
1460
1180
2750 4360
2200 3520
7700 15800
6250 12800
40
50
60
70
82
73
66
61
170 320
151 285
138 260
125 240
660
580
530
490
990
900
810
750
1900 3000
1680 2650
1520 2400
1400 2250
5300 10900
4750
4300
3900
9700
8800
8100
80
90
100
125
150
175
200
57
53
50
44
40
37
35
118 220
110 205
103 195
93 175
84 160
77 145
72 135
460
430
400
360
325
300
280
690
650
620
550
500
460
430
1300 2050
1220 1950
1150 1850
1020 1650
950 1500
850 1370
800 1280
3700
3450
3250
2950
2650
2450
2280
7500
7200
6700
6000
5500
5000
4600
FIGURE 9
PURGING
Gas line purging is required with new piping or systems in which air has entered.
IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING
FROM CONTAMINANTS IN THE GAS WAYS. SUCH FOULING MAY
CAUSE IMPROPER OPERATION, FIRE OR EXPLOSION.
IF COPPER SUPPLY LINES ARE USED THEY MUST BE
INTERNALLY TINNED AND CERTIFIED FOR GAS SERVICE. BEFORE
ATTACHING THE GAS LINE, BE SURE THAT ALL GAS PIPE IS
CLEAN ON THE INSIDE.
TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS SUPPLY
LINE, A DIRT LEG (SOMETIMES CALLED SEDIMENT TRAP OR
DRIP LEG) MUST BE INCORPORATED IN THE PIPING (SEE FIG.
9). THE DIRT LEG MUST BE READILY ACCESSIBLE AND NOT
SUBJECT TO FREEZING CONDITIONS. INSTALL IN
ACCORDANCE WITH RECOMMENDATIONS OF SERVING GAS
SUPPLIERS. REFER TO THE LATEST VERSION OF THE NATIONAL
FUEL GAS CODE.
GAS METER SIZE — NATURAL GASES ONLY
Be sure the gas meter has sufficient capacity to supply the full rated gas input of the water heater as well as the requirements of all other gas fired equipment supplied by the meter. If gas meter is too small, ask the gas company to install a larger meter having adequate capacity.
GAS PRESSURE REGULATOR
The gas pressure regulator is built into the gas valve and is equipped to operate on the gas specified on model and rating
9
CAUTION
PURGING SHOULD BE PERFORMED BY PERSONS EXPERIENCED
IN THIS TYPE GAS SERVICE. TO AVOID RISK OF FIRE OR
EXPLOSION, PURGE DISCHARGE MUST NOT ENTER CONFINED
AREAS OR SPACES WHERE IGNITION CAN OCCUR. THE AREA
MUST BE WELL VENTILATED AND ALL SOURCES OF IGNITION
MUST BE INACTIVATED OR REMOVED.
plate. The regulator is factory adjusted to deliver gas to burner at correct water column pressure allowing for a nominal pressure drop through the controls.
HEATER WIRING
The minimum gas supply pressure for input adjustment must not be less than 4.5" w.c. for natural gas.
Do not subject the combination gas valve to inlet gas pressures of more than 14.0" W.C. - natural gas. A service regulator is necessary if higher gas pressures are encountered.
Manifold gas pressure in inches of water column is 3.5.
The gas pressure specified refers to flow pressure taken at pressure tap of automatic gas valve while heater is operating.
All electrical work must be installed in accordance with the latest version of the National Electrical Code ANSI/NFPA No. 70, must conform to all local code authority having jurisdiction. AN
ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF
ELECTRICAL SHOCK OR POSSIBLE ELECTROCUTION.
If any of the original wire as supplied with the appliance must be replaced, use only type 105°C thermoplastic or equivalent.
250°C type F must be used for the flame sensor leads and the spark ignition cable must be high voltage 250°C.
Figures shown are valid for 0-2000 ft. installations. See “HIGH
ALTITUDE INSTALLATIONS” for deration requirements over
2000 ft.
FIGURE 10 - SINGLE UNIT WIRING DIAGRAM
10
INSTALLATION DIAGRAMS
capacity is installed on the heater. The locations shown in the installation diagrams on the following pages are typical.
GENERAL
The type, size and location of the relief valves must be in accordance with local codes. The locations of the relief valves shown in the installation diagrams are typical. The heater has a factory installed high temperature limit switch and temperature and pressure relief valve.
Cold water lines to heater should be installed as shown in order to minimize gravity circulation of hot water to building cold water lines.
A listed temperature and pressure relief valve of adequate
The discharge opening of the temperature and pressure relief valve, located in front of the heater must be piped to an open drain and should not be subject to freezing temperatures.
Install in accordance with all local codes.
DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE
TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE
CONTROL WARNING ON PAGE 20. IF HIGHER PREHEAT
TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE
BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT
WATER SUPPLIED TO FIXTURES.
11
VERTICAL STORAGE TANK AND FORCED CIRCULATION
DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE
TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL
WARNING ON PAGE 20. IF HIGHER PREHEAT TEMPERATURES ARE
NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN
ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
HORIZONTAL STORAGE TANK AND FORCED CIRCULATION
12
TWO TEMPERATURE - ONE HEATER HIGH TEMPERATURE STORAGE
WITH RECIRCULATION OF SANITIZING LOOP
NOTE 1: TOGGLE SWITCH CONTROLS 180°F (82°C) WATER
CIRCULATION. INSTALL ON OR CLOSE TO DISHWASHING
MACHINE. TOGGLE SWITCH MUST BE CLOSED (ON) DURING
THE RINSE OPERATION AND OPEN (OFF) WHEN DISHWASHER
IS NOT OPERATING OR WHEN ON LONG STANDBY.
NOTE 2: INSTALL LINE TEMPERATURE CONTROL IN AN UNINSULATED
TEE BEYOND THE DISHWASHING MACHINE TAKEOFF IN THE
SANITIZING LOOP. CONTROL SHOULD BE SET AT 185°F
(85°C).
NOTE 3: ADJUST PLUG COCK SO THE SANITIZING LOOP FLOW RATE
DOES NOT CAUSE UNNECESSARY TURBULENCE IN THE TANK.
* TEMPERED WATER LOOP, IF USED, CONNECT TO
POINT “A”.
**PIPE RELIEF VALVE TO OPEN DRAIN.
INSTALL IN ACCORDANCE WITH LOCAL CODES.
CAUTION: IF BUILDING COLD WATER SUPPLY HAS A BACKFLOW
PREVENTER, CHECK VALVE OR WATER METER WITH CHECK
VALVE. PROVISIONS FOR THERMAL EXPANSION OF WATER
IN THE HOT WATER SYSTEM MUST BE PROVIDED.
DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE
TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL
WARNING ON PAGE 20. IF HIGHER PREHEAT TEMPERATURES ARE
NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN
ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
13
INSTALLATION DIAGRAMS-SIDE INLET/OUTLET USAGE
A listed temperature and pressure relief valve of adequate capacity is installed on the heater. The locations shown in the installation diagrams on the following pages are typical.
The discharge opening of the temperature and pressure relief valve must be piped to an open drain and should not be subject to freezing conditions. DO NOT REDUCE, BLOCK OR PLUG
THE DISCHARGE OPENING OF THE VALVE.
TWO TEMPERATURE - TWO HEATERS, ONE PRE-HEATER/ONE - BOOSTER HEATER
WITH OR WITHOUT BUILDING RECIRCULATION
DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE
TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL
WARNING ON PAGE 20. IF HIGHER PREHEAT TEMPERATURES ARE
NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN
ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
CIRCULATING RETURN LINE CONNECTION
FROM FIXTURE LOOP, IF USED, CONNECT
TO PRE-HEATER INLET.
FROM BOOSTED TEMPERATURE LOOP, IF
USED CONNECT TO BOOSTER INLET.
† AVAILABLE FROM A.O. SMITH.
* PIPE RELIEF VALVE TO OPEN DRAIN.
INSTALL IN ACCORDANCE WITH LOCAL CODES.
14
ONE OR TWO TEMPERATURE - ONE HEATERS,HIGH TEMPERATURE
STORAGE WITH OR WITHOUT RECIRCULATION
HEATER WITH OR WITHOUT MIXING VALVE
DANGER
TEMPERATURE SETTING SHOULD NOT
EXCEED SAFE USE TEMPERATURE AT
FIXTURES. SEE WATER TEMPERATURE
CONTROL WARNING ON PAGE 20. IF HIGHER
PREHEAT TEMPERATURES ARE NECESSARY
TO OBTAIN ADEQUATE BOOSTER OUTPUT,
ADD AN ANTI-SCALD VALVE FOR HOT WATER
SUPPLIED TO FIXTURES.
HEATER WITH MIXING VALVE AND RECIRCULATED SANITIZING LOOP
* PIPE RELIEF VALVE TO OPEN DRAIN.
INSTALL IN ACCORDANCE WITH LOCAL
CODES.
NOTE 1: TOGGLE SWITCH CONTROLS 180°F (82°C)
WATER CIRCULATION. INSTALL ON OR CLOSE
TO DISHWASHING MACHINE. TOGGLE SWITCH
CIRCULATING RETURN LINE CONNECTIONS.
MUST BE CLOSED (ON) DURING THE RINSE
OPERATION AND OPEN (OFF) WHEN
DISHWASHER IS NOT OPERATING OR WHEN
ON LONG STANDBY.
- TEMPERED WATER LOOP, IF USED,
CONNECT TO POINT “R”.
NOTE 2: INSTALL LINE TEMPERATURE CONTROL
IN AN UNINSULATED TEE BEYOND THE
DISHWASHING MACHINE TAKEOFF IN
THE SANITIZING LOOP. CONTROL
SHOULD BE SET AT 185°F (85°C).
NOTE 3: ADJUST PLUG COCK SO THE SANITIZING
LOOP FLOW RATE DOES NOT CAUSE
UNNECESSARY TURBULENCE IN THE
TANK.
- STORED TEMPERATURE WATER LOOP, IF
USED, CONNECT TO COLD WATER INLET.
CAUTION: IF BUILDING COLD WATER SUPPLY HAS A BACKFLOW
PREVENTER, CHECK VALVE OR WATER METER WITH CHECK VALVE.
PROVISIONS FOR THERMAL EXPANSION OF WATER IN THE HOT WATER
SYSTEM MUST BE PROVIDED.
15
TWO TEMPERATURE - TWO PRE-HEATERS WITH MIXING VALVE OR BOOSTER
HEATER WITH OR WITHOUT BUILING RECIRCULATION
TWO PRE-HEATERS WITH MIXING VALVE
DANGER
TEMPERATURE SETTING SHOULD NOT
EXCEED SAFE USE TEMPERATURE AT
FIXTURES. SEE WATER TEMPERATURE
CONTROL WARNING ON PAGE 20. IF HIGHER
PREHEAT TEMPERATURES ARE NECESSARY
TO OBTAIN ADEQUATE BOOSTER OUTPUT,
ADD AN ANTI-SCALD VALVE FOR HOT WATER
SUPPLIED TO FIXTURES.
TWO PRE-HEATERS WITH BOOSTER HEATER
16
MEDIUM TEMPERATURE - ONE HEATER WITH AUXILIARY STORAGE TANK FORCED
CIRCULATION WITH OR WITHOUT BUILDING RECIRCULATION
VERTICAL STORAGE TANK
* PIPE RELIEF VALVE TO OPEN DRAIN.
**WHEN USING AN A.O. SMITH T-140, -200,
-350 OR -400 STORAGE TANK, USE
LOWER 3/4” OPENING FOR TANK
TEMPERATURE CONTROL.
IF BUILDING CIRCULATING LOOP IS USED,
CONNECT TO AN OPENING NEAR THE
BOTTOM OF THE TANK.
HORIZONTAL STORAGE TANK
CAUTION: IF BUILDING COLD WATER SUPPLY HAS A
BACKFLOW PREVENTER, CHECK VALVE OR WATER
METER WITH CHECK VALVE. PROVISIONS FOR
THERMAL EXPANSION OF WATER IN THE HOT WATER
SYSTEM MUST BE PROVIDED.
*PIPE RELIEF VALVE TO OPEN DRAIN
INSTALL IN ACCORDANCE WITH LOCAL CODES.
DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE
TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE
CONTROL WARNING ON PAGE 20. IF HIGHER PREHEAT
TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE
BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT
WATER SUPPLIED TO FIXTURES.
17
OPERATION
IMPORTANT
A qualified person must perform the initial firing of the heater. At this time the user should not hesitate to ask the individual any questions which they may have in regard to the operation and maintenance of the unit.
An Operational Checklist is included at the rear of this manual.
By using this checklist the user may be able to make minor operational adjustments and avoid unnecessary service calls.
However, the user should not attempt repairs which are not listed under the USER column.
GENERAL
NEVER OPERATE THE HEATER WITHOUT FIRST BEING
CERTAIN IT IS FILLED WITH WATER AND A TEMPERATURE
AND PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF
VALVE OPENING OF THE HEATER.
into lockout. After the controller tries three times, it will wait one hour before trying to light the unit again. This cycle will continue until the main burners are ignited or the unit is shut down.
ADJUSTMENTS
ON INITIAL STARTUP SOME ADJUSTMENTS ARE NECESSARY.
1. CHECK MANIFOLD AND INLET GAS PRESSURES.
2. CYCLE CHECK - CHECK AT LEAST ONE BURNER OPERATION
- WHEN THERMOSTAT IS SATISFIED, BURNER WILL SHUT
OFF AND INDUCER WILL STOP RUNNING. ON CALL FOR
HEAT - THE INDUCER WILL COME ON AND CLOSE THE
PRESSURE SWITCH AND THE IGNITION SEQUENCE
DESCRIBED ABOVE WILL BEGIN, SEE “SEQUENCE OF
OPERATION”.
SEQUENCE OF OPERATION
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL
TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE
TO THE APPLIANCE.
1.
2.
3.
4.
5.
to escape.
and piping to be filled.
CAUTION
Before proceeding with the operation of the unit make sure the water heater and system are filled with water and all air is expelled.
FILLING
Close the heater drain valve by turning handle clockwise.
Open a nearby hot water faucet to permit the air in the system
Fully open the cold water inlet pipe valve allowing the heater
Close the hot water faucet as water starts to flow.
The heater is ready to be operated.
WARNING
THE GAS VALVE MUST HAVE BEEN IN THE OFF POSITION FOR
AT LEAST 5 MINUTES. This waiting period is an important safety step. Its purpose is to permit gas that may have accumulated in the combustion chamber to clear. IF YOU
DETECT GAS ODOR AT THE END OF THIS PERIOD DO NOT
PROCEED WITH LIGHTING. RECOGNIZE THAT GAS EVEN IF IT
SEEMS WEAK, MAY INDICATE PRESENCE OF ACCUMULATED
GAS SOMEPLACE IN THE AREA WITH RISK OF FIRE OR
EXPLOSION. SEE THE FRONT PAGE FOR STEPS TO BE TAKEN.
All gas and water lines leak tested and open.
Read SEQUENCE OF OPERATION
With above conditions satisfied, start the unit in accordance with the instructions on the Operating label attached to the heater. If label instructions are not legible - determine which gas valve the appliance is equipped with and use the applicable OPERATING
INSTRUCTIONS as follows: section of this manual prior to lighting and operating this appliance.
The following information will describe the Sequence of
Operation for this appliance.
1. Switch power on to unit.
2. Thermostat calls for heat.
3. Ignition Control Board performs diagnostic check on system components.
4. On completion of diagnostics check, the Ignition Control
Board sends signal to Exhaust Inducer.
5. Exhaust Inducer begins drawing air through appliance closing the Prover Switch.
6. On completion of Prover Switch engagement, the Ignition
Control Board begins the ignition cycle.
7. The Ignition Control Board provides power to the Silicon
Nitride Ignitor.
8. The Silicon Nitride Ignitor heats up for approximately 17 to
20 seconds.
9. At the end of Silicon Nitride Ignitor’s warm-up, the Ignition
Control Board opens the Gas Valve.
10. From the time the Gas Valve opens, the Ignition Control
Board waits 3 seconds and then shuts off power to the
Silicon Nitride Ignitor.
11. From the time the Silicon Nitride Ignitor’s power is shut off, the Ignition Control Board waits 3 more seconds to monitor the Flame Sensor.
12. If the Flame Sensor does not detect a strong enough flame, the Ignition Control Board shuts off the Gas Valve and allows the Exhaust Inducer to purge the unit for 20 seconds. At that time, the Ignition Control Board restarts with step 7. It will try and ignite the main burners 2 more times. If the unit does not light, the Ignition Control Board will wait one hour and then restart at step 3. This cycle will continue until the unit lights or the power is shutoff to the unit.
13. If the Flame Sensor detects a strong flame, the Ignition
Control Board will allow the unit to operate until the thermostat is satisfied.
14. Once the unit is satisfied, the Ignition Control Board will shut off the Gas Valve and the unit will be in standby mode until another call for heat is initiated by the thermostat.
Each heater is equipped with an ignition control board. The controller will try three times to light the main burner before going
18
See the flow chart on page 25 for more information.
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING
IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION
MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
•
•
•
A.
This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
B.
BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.
“WHAT TO DO IF YOU SMELL GAS”
Do not try to light any appliance.
Do not touch any electric switch; do not use any telephone in your building.
Immediately call your gas supplier from a neighbor’s telephone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
C.
Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in fire or explosion.
D.
Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.
OPERATING INSTRUCTIONS
1.
STOP! Read the safety information above on this label.
2.
Set thermostat to lowest setting.
3.
Turn off all electric power to the appliance.
4.
This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
5.
Push in gas control knob slightly and turn clockwise
to “OFF”.
6.
Wait five (5) minutes to clear out any gas.
If you then smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell gas, go on to the next step.
7.
Turn gas control knob counterclockwise
8.
Turn on all electric power to the appliance.
to “ON”.
9.
Set thermostat to desired setting.
10.
If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.
FOR YOUR SAFETY READ BEFORE OPERATING
1.
Set the thermostat to lowest setting.
2.
Turn off all electric power to appliance if service is to be performed.
3.
Push in gas control knob slightly and turn clockwise to “OFF”. Do not force.
19
WATER TEMPERATURE CONTROL
set for 120° to 180°F water temperature, but 120°F is the recommended starting point. It is suggested the dial be placed on the lowest setting which produces an acceptable hot water supply. This will always give the most energy efficient operation.
The temperature control has a 4°F fixed differential.
PREVENTIVE MAINTENANCE
CHECK THE IGNITOR ASSEMBLY
DANGER
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 TIME OF EXPOSURE. THE SLOWER
RESPONSE TIME OF CHILDREN, AGED OR DISABLED PERSONS
INCREASES THE HAZARDS TO THEM. NEVER ALLOW SMALL
CHILDREN TO USE A HOT WATER TAP, OR TO DRAW THEIR
OWN BATH WATER. NEVER LEAVE A CHILD OR DISABLED
PERSON UNATTENDED IN A BATHTUB OR SHOWER.
THE WATER HEATER SHOULD BE LOCATED IN AN AREA
WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO
SET TEMPERATURES.
SETTING THE WATER HEATER TEMPERATURE AT 120°F WILL
REDUCE THE RISK OF SCALDS. Some states or provinces require settings at specific lower temperatures.
Below you will find listed the approximate time-to-burn relationship for normal adult skin. Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the thermostat setting by up to 20°F . If you experience this type of use, you should consider using lower temperature settings to reduce scald hazards.
At least once a year, check the ignitor assembly, see Figure 11, and the main burner, see Figure 12, for proper operation. Refer to the following ignitor assembly and main burner sections.
IGNITOR ASSEMBLY
For access to ignitor assembly, unfasten two screws to burner cover and remove. Locate the burner with the ignitor assembly and remove screw holding burner to manifold. Slide burner out to access ignitor assembly.
Servicing of the ignitor assembly includes keeping the ignitor free of lint, scale or any other foreign debris.
Temperature
Setting
185°F
180°F
170°F
160°F
150°F
140°F
130°F
120°F
Time to Produce 2nd & 3rd
Degree Burns on Adult Skin
Nearly instantaneous
Nearly instantaneous
Nearly instantaneous
About 1/2 second
About 1-1/2 seconds
Less than 5 seconds
About 30 seconds
More than 5 minutes
FIGURE 11
MAIN BURNER
The main burner, see Figure 12, should display the following characteristics:
• Cause rapid ignition and carry across entire burner.
• Give reasonably quiet operation during ignition, burning, and extinction.
• Cause no excessive lifting of flame from burner ports.
Valves for reducing point-of-use temperature by mixing cold and hot water are available. Also available are inexpensive devices that attach to faucets to limit hot water temperatures. Contact a licensed plumber or the local plumbing authority.
The water temperature is controlled by a thermostat, see
Figure 3, which has two sensing elements. One sensor is located near the top of the tank and the other is near the center.
The thermostat is set in the lowest position before the heater leaves the factory.
FIGURE 12
The thermostat temperature dial, see Figure 3, is accessible by removing the control cover. The dial is adjustable and may be
20
If the preceding burner characteristics are not evident, check for accumulation of lint, scale or other foreign debris that restricts or blocks the air openings to the burner or heater.
NOTE:
1.
Remove main burners from unit.
2.
Check that burner venturi and ports are free of foreign debris.
3.
Clean burners with bristle brush and/or vacuum cleaner
- DO NOT distort burner ports or pilot location.
4.
Reinstall burners in unit. Make sure front and rear of burners are installed correctly in burner support brackets.
Also check for good flow of combustion and ventilating air to the unit. Maintain a clear area around the heater at all times.
GAS VALVES
3.
Remove the regulator adjustment sealing cap, fig. 13, and adjust the pressure by turning the adjusting screw with a screwdriver.
Clockwise to increase gas pressure and input rate.
Counterclockwise to decrease gas pressure and input rate.
4.
“Clock” the meter as in step 2 above.
5.
Repeat steps 3 and 4 until the specified input rate is achieved.
6.
Turn the gas control knob to PILOT. Remove the pressure gauge and replace the sealing cap and the allen wrench set screw in the pressure tap opening.
Figure 13 shows the type of combination manual gas control valve and regulator used on these heaters.
If the gas valve becomes defective, repairs should not be attempted. A new valve should be installed in place of the defective one.
WARNING
UNDER NO CIRCUMSTANCES SHOULD THE GAS INPUT EXCEED
THE INPUT SHOWN ON THE HEATER MODEL AND RATING
PLATE. OVERFIRING COULD RESULT IN DAMAGE OR SOOTING
OF THE HEATER.
FIGURE 13
When the heater is operating at full capacity, or full gas input, it should consume 1 cu. ft. of gas in time indicated on Table 3.
INPUT
RATE
(BTUH)
154,000
TABLE 3
APPROXIMATE TIME REQUIRED TO CONSUME
1 CU. FT. OF GAS AT FULL CAPACITY
TYPE
OF
GAS
NATURAL
BTUH
PER
CU. FT.
1050
TIME REQ’D
TO CONSUME
1 CU. FT.
OF GAS
24.5 SEC.
199,000 NATURAL 1050 19.0 SEC.
CHECKING THE INPUT
Figures shown are valid for 0-2000 ft.(0-610m) installations.
See “HIGH ALTITUDE INSTALLATIONS” for deration requirements over 2000 ft.(610m).
For appliance installation locations with elevations above
2000 feet, refer to HIGH ALTITUDE INSTALLATIONS section of this manual for input reduction procedure.
VENTING SYSTEM
1.
Attach a pressure gauge or a manometer to the gauge port and refer to the GAS PRESSURE REGULATOR section for correct manifold pressure.
Examine the venting system every six months for obstructions and/or deterioration of the vent piping.
2.
Use this formula to “clock” the meter. Be sure that other gas consuming appliances are not operating during this interval.
Remove all soot or other obstructions from chimney which will retard free draft.
3600 X H = Btuh
T
T = Time in seconds to burn one cubic foot of gas.
REMOTE STORAGE TANK
TEMPERATURE CONTROL
The water temperature in the storage tank (if used) is controlled by the storage tank temperature control. The sensing element is mounted in the hot water storage tank, see page 17.
H = Btu’s per cubic foot of gas.
Btuh = Actual heater input.
Example:
T = 15.1 seconds
H = 1050 Btu
A change in water temperature in the storage tank lower than the tank temperature control setting will cause the sensor to activate the circulating pump. The pump then circulates the water through the heater where the thermostat senses the drop in water temperature and activates main burner operation of the appliance.
If the storage tank temperature control is out of calibration, replace with new control.
Btuh = ?
19 X 1050 = 199,999 Btuh
Should it be necessary to adjust the gas pressure to the burners to obtain the full input rate, the steps below should be followed:
WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO
SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO
THE APPLIANCE.
21
RELIEF VALVE
At least once a year, the temperature and pressure relief valve should be checked to ensure that it is in operating condition. Lift the lever at the top of the valve several times until the valve seats properly and operates freely.
NOTE: Anode rod inspection may need to be made more frequently in areas subject to acid rain that obtains their water supply from surface water as the low pH will accelerate anode activity.
If the appliance installation includes other relief valves, such as in “remote” storage tanks etc., check their relief valve operation with the same frequency.
CAUTION: Close cold water inlet valve serving heater and open nearby hot water faucet to relieve the pressure in the heater before attempting to remove anode(s) for inspection.
FLUSHING
WARNING
THE WATER PASSING OUT OF THE VALVE DURING THIS
CHECKING OPERATION MAY BE EXTREMELY HOT. AVOID
CONTACT AND DISCHARGE SAFELY TO PREVENT WATER
DAMAGE.
1. Turn off the heater electrical disconnect switch.
2. Open the drain valve and allow water to flow until it runs clean.
3. Close the drain valve when finished flushing.
4. Turn on the heater electrical disconnect switch.
If the temperature and pressure relief valve on the heater discharges periodically or continuously, a problem exists. This may be due to unusually high water temperatures or pressures in the system, or to a faulty relief valve. Contact your dealer or a qualified service technician to find the cause of the problem and to correct it. This may also be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation. DO NOT
PLUG THE TEMPERATURE AND PRESSURE RELIEF VALVE.
WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO
SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO
THE APPLIANCE.
HOT WATER ODOR
On occasion, hot water may develop a strong odor. If this occurs drain the heater completely, flush thoroughly, and refill. If the problem persists, chlorination of the heater and replacement of the factory installed magnesium anodes with aluminum anodes may correct the condition.
Occasionally water softener companies recommend removal of heater anodes for odor reasons.
DRAINING
The heater must be drained if it is to be shut down and exposed to freezing temperatures. Maintenance and service procedures may also require draining the heater.
1. Turn off the heater electrical disconnect switch.
2. Close the cold water inlet valve to heater.
3. Open a nearby hot water faucet to vent the system.
4. Open the heater drain valve.
5. If the heater is being drained for an extended shutdown, it is suggested the drain valve be left open during this period.
• Follow FILLING instructions when restoring hot water service.
RECOMMENDED PROCEDURE FOR
PERIODIC REMOVAL OF LIME DEPOSITS
FROM TANK TYPE COMMERCIAL
WATER HEATERS
CAUTION
Unauthorized removal of the anode(s) will void the warranty.
For further information contact your dealer.
The amount of calcium carbonate (lime) released from water is in direct proportion to water temperature and usage, see chart.
The higher the water temperature or water usage, the more lime deposits are dropped out of the water. This is the lime scale which forms in pipes, heaters and on cooking utensils.
ANODE ROD INSPECTION
The heater tank is equipped with anode rods to provide corrosion control. At least once a year the anode rods should be checked to determine if replacement is necessary. Initially the anode rods are approximately 7/8" in diameter with a 1/8" diameter steel core wire running down the center of the anode material.
THE ANODES SHOULD BE REPLACED when the 1/8" diameter core wire is visible as this means that the anode material has been expended in the control of corrosion.
Lime accumulation not only reduces the life of the equipment but also reduces efficiency of the heater and increases fuel consumption.
The usage of water softening equipment greatly reduces the hardness of the water. However, this equipment does not always remove all of the hardness (lime). For this reason it is recommended that a regular schedule for deliming be maintained.
For models with top inlet and outlet, it is recommended that, before removing the inner cover for cleaning, inspection or removal of inner parts, you obtain two new nipple collars, part no. 74060. The nipple collars on the heater will usually be damaged when removed. New pipe collars will insure that the seal is such as to prevent leakage of flue products when properly installed.
22
The time between cleaning will vary from weeks to months depending upon water conditions and usage.
Refer to Form No. 4800, entitled “Why? When and How” for detailed description on tank inspection and cleanout. UN•LIME ® and the booklet may be obtained through your dealer or distributor.
4. Remove lime, scale, or sediment using care not to damage the glass lining.
5. Inspect cleanout plate gasket, if new gasket is required, replace with part no. 99038.
6. Install cleanout plate. Be sure to draw plate up tight by tightening screws securely.
7. Replace outer jacket cover plate.
In some water areas the sediment might not be removed by this method and may result in the water heater making rumbling or boiling noises. To dissolve and remove these more stubborn mineral deposits, UN•LIME Professional Delimer should be used.
DELIMING USING FLO-JUG METHOD
UN•LIME in the 5 gallon size is recommended for deliming.
UN•LIME with the necessary hoses and fittings to delime your heater is also available as a kit: Up-N-Down Transfer Kit. Contact your local State dealer, distributor or, State Water Heaters:
FIGURE 14
Telephone: (800) 821-2017
Fax: (800) 644-9306
Website: www.statewaterheaters.com
DELIMING SOLVENTS
State Water Heaters recommends the use of UN•LIME for deliming. UN•LIME is a patented food grade acid which is safe to handle and does not create the harmful fumes which are associated with other products.
UN•LIME may be obtained from your dealer or distributor. Order
Part Number 4763, 1 gallon, packed 4 gallons per case or Part
Number 4813, 5 gallon container.
NOTE: Un•Lime is not available for use in Canada
Hydrochloric base acids are not recommended for use on glass lined tanks.
Prepare the Water Heater
To delime the water heater using the Flo-Jug method, first prepare the heater for deliming as described in the "Why? When?
and How?" booklet, Form No. 4800. Then install the long plastic male adapter fitting into the drain valve opening of the water heater. Use teflon tape and hand tighten only. Do not overtighten.
Prepare the Up-N-Down Transfer Kit
The next step is the preparation on the Up-N-Down Transfer Kit, if you have not already done so:
1. With the 5 gallon Up-N-Down container in the vertical position, unscrew the plastic vent cap in the handle and pierce the plastic membrane over the vent boss under the cap to allow the container to vent.
CAUTION
Observe handling instructions on label of product being used.
TANK CLEANOUT PROCEDURE
Note: If your container does not have the vent cap and vent boss, drill a 3/16" hole in the handle. When you have finished deliming you will be able to plug this drilled vent with the stainless steel screw that is supplied with the kit.
The following practices will ensure longer life and enable the unit to operate at its designed efficiency:
1. Once a month the heater should be flushed. Open the drain valve and allow two gallons of water to drain from the heater.
Inlet water valve should remain open to maintain pressure in tank.
2. A cleanout opening is provided for periodic cleaning of the tank. Gas must be shut off and heater drained before opening cleanout.
2. Remove the container's cap and cut the plastic membrane located in the 3/4" IPT opening in the cap. Take care to not damage the threads.
3. Find the 3/4" male adapter, apply teflon tape to the threaded end and screw it into the 3/4" IPT opening in the cap.
4. Put cap with male adapter back on the container and slide
3/4" hose over end of male adapter and fasten in place using hose clamp provided.
To clean heater through cleanout opening, proceed as follows:
1. Drain heater.
2. Remove outer cover plate from lower side of heater jacket.
3. Remove six (6) hex head screws securing tank cleanout plate and remove plate.
23
Delime using Flo-Jug Method
5. Slide the hose clamp over end of hose and slide hose over the male adapter in the water heater drain opening and secure in place using hose clamp.
6. Lift container to the "Pour" Position, see Figure 15, being careful to keep the vent in the handle above the liquid level and pour the UN•LIME into the heater.
7. Lower container, you may have to place the container on its empty carton to prevent the UN•LIME from flowing back into the container.
8. Let UN•LIME remain in the heater for 5 minutes and then lower the container to the "Drain" Position, see Figure 15.
SYSTEM DIAGNOSTICS
Your water heater is equipped with an ignition module that incorporates a diagnostic system to assist in troubleshooting the appliance. The indicator codes on the ignition module are as follows:
9. Deliming activity is indicated by foaming on the surface of the
UN•LIME. If there is deliming activity, repeat steps 6 thru 8.
1 flash System lockout (retries or cycles exceeded)
2 flashes Pressure switch stuck close
Normally, lime removal will be completed within one hour. Severe build-up of lime may take longer than an hour to complete descaling.
3 flashes Pressure switch stuck open
4 flashes Open on high temperature limit switch (eco)
Note: To check UN•LIME for continued use, place some scale or white chalk in a glass with a small amount of UN•LIME. If the material is vigorously dissolved by the UN•LIME, it can be reused; if not, the UN•LIME should be replaced.
6 flashes 115 volt AC power reversed (check polarity)
7 flashes Low flame sense signal (make sure flame sensor is in burner flame)
8 flashes Check ignitor continuous flash -> continuous flame sensed > 5 seconds without gas valve continuous on -> internal control failure - replace ignition control module.
Use this diagnostic system in conjunction with the
“OPERATIONAL CHECKLIST” and the “SEQUENCE OF
OPERATION” to troubleshoot the appliance.
SERVICE
The installer may be able to observe and correct certain problems which may arise when the unit is put into operation. HOWEVER, it is recommended that only qualified servicemen, using appropriate test equipment, be allowed to service the heater.
FIGURE 15
IGNITION MODULE SYSTEM
As preliminary step, check wiring against diagram, check for grounded, broken or loose wires. Check all wire ends to be sure that they are making good contact.
Before calling your service agent, the following checklist should be examined to eliminate obvious problems from those requiring replacement or servicing.
ELECTRICAL SERVICING
— Check that “main manual gas shutoff valve” is fully open and that gas service has not been interrupted.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN
SERVICING CONTROLS. WIRING ERRORS CAN CAUSE
IMPROPER AND DANGEROUS OPERATION.
— Check that after following the appliance OPERATING
INSTRUCTIONS, the “Top Knob” of the appliance gas valve is in “ON” position.
VERIFY PROPER OPERATION AFTER SERVICING.
REPLACEMENT PARTS
— Check electrical supply to the appliance for possible blown
(or tripped) fusing or power interruption.
— Is the water temperature in tank below the thermostat dial setting on the appliance thermostat (calling for heat)?
— It is possible that the high limit (E.C.O.) has functioned to shut off the appliance. See FEATURES — Water Temperature
Control for reset procedure. Contact your serviceman if limit continues to function to shut off appliance.
Replacement parts may be ordered through State dealers, unauthorized servicers or distributors. Refer to the Yellow
Pages for where to call or contact the State Water Water Heaters,
500 Lindahl Parkway, Ashland City, TN 37015, 1-800-821-2017 or visit our website at www.statewaterheaters.com. When ordering parts be sure to state the quantity, part number and description of the items including the complete model and serial number as it appears on the product. Refer to the parts list for more information.
24
SEQUENCE OF OPERATION FLOW CHART
Description of this flow chart can be found in the “SEQUENCE OF OPERATION” section found on page 23.
Switch power on to unit.
Ignition
Control Board opens Gas
Valve.
Thermostat calls for heat.
Ignition Control
Board performs diagnostic check on components
Ignition Control
Board shuts off
Silicon Nitride
Ignitor after
3 seconds
Ignition Control
Board waits 3 more seconds to monitor Flame
Sensor.
Ignition Control
Board sends power to Exhaust Inducer
Did Main
Burner Light?
NO
Ignition Control
Board shuts off Gas
Valve and allows the
Exhaust Inducer to purge appliance for
20 seconds.
Exhaust Inducer engages Prover
Switch
Ignition Control
Board provides power to Silicon
Nitride Ignitor
YES
Ignition Control
Board monitors units until T’Stat is satisfied.
Silicon Nitride
Ignitor warms up for
20 seconds
25
OPERATIONAL CHECKLIST
This checklist in conjunction with “TROUBLESHOOTING” and the “SEQUENCE OF OPERATION” should be used as an on-the-job troubleshooting guide to identify the cause of incorrect system operation and suggest a remedy for its correction. Because improper piping and wiring can result in unsatisfactory system performance, it is suggested that the installation be examined before using the checklist. Be sure to refer to the correct piping and wiring diagram for the type of system that is installed.
The system should be filled with water, purged of air, valves properly set and utilities connected and ready to operate.
COMPLAINT
*Water not hot enough.
*Insufficient hot water
*See WATER TEMPERATURE
CONTROL WARNING (on
Page 20).
REMEDY
USER SERVICEMAN CAUSE
Thermostat set too low.
Set thermostat dial to a higher temperature.
Thermostat out of calibration.
Call serviceman Recalibrate thermostat. If thermostat cannot be recalibrated, replace.
Thermostat set too low.
Set thermostat dial to a higher temperature.
Thermostat out of calibration.
Call serviceman.
Recalibrate thermostat. If thermostat cannot be recalibrated, replace.
Main manual gas shutoff valve partially closed.
Open main manual gas shutoff valve to fullest extent.
Heater too small for demand.
Space usage to give heater time to restore water temperature.
Thermostat differential is too wide.
Call serviceman.
Heater recovery is slower.
Call serviceman.
Replace dual bulb controller if differential is greater than 4°F.
Check gas input. If incorrect, adjust gas pressure or replace main burner orifice.
Install drafthood or baffles as furnished with unit.
Water temperature too hot.
Thermostat set too high.
Heater makes sounds: sizzling. Condensation on outside of tank, normal.
Rumbling.
Drafthood not installed or one or more flue baffles.
Ticking or metallic sounds.
Pounding.
Call serviceman.
Set thermostat to a lower setting.
Sediment accumulation on bottom of tank.
Drain a quantity of water through drain valve. If rumbling persists, call a serviceman.
Expansion and contractionnormal.
Air chambers in piping have Drain piping system and refill.
become waterlogged.
Heater must be off while this is being done.
Combustion noises.
Adjust shutters.
Call serviceman.
Water leaks.
Gas odors.
Too much primary air.
Overfired heater; Incorrect burners or orifice for type of gas used.
Drain valve not closed
tightly.
If leakage source cannot be corrected or identified, call serviceman.
Heater is overfired.
If drain valve cannot be closed tightly, replace.
Shut off gas supply to heater and close cold water inlet valve to heater.
Shut off gas supply to heater and call a serviceman.
Delime heater.
Check and correct as necessary.
Repair or in case of suspected tank leakage, be certain to confirm before replacing heater.
Check for sooted flue passage.
Check for obstructed vent line.
Check backdraft or lack of draft.
Possible gas leaks.
Shut off gas supply to heater and call gas company at once.
26
Model SBD Limited Warranty
State Water Heaters, the warrantor, extends the following LIMITED WARRANTY to the owner of this water heater.
1.
THE TANK
If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable water therein, during the first THREE years after initial installation, the warrantor will supply a complete new State water heater of equivalent size and current model. Some government agencies are requiring energy efficient standards for water heaters. In the event regulations prohibit sale of a model of equivalent size and construction, State Water Heaters will provide a model which complies with the regulations of your area, in which case the consumer will be charged the difference in price between the like replacement and the energy efficient model required. The warranty on the replacement water heater will be limited to the unexpired term of the original warranty .
2.
ALL OTHER PARTS
If within ONE year after initial installation of this water heater, any part or portion shall prove upon examination by the warrantor to be defective in material or workmanship, the warrantor will repair or replace such part or portion at its option.
3.
CONDITIONS AND EXCEPTIONS
This warranty shall apply only when the water heater is installed in accordance with local plumbing and building codes, ordinances and regulations, the printed instructions provided with it and good industry practices. In addition, a temperature and pressure relief valve, certified by A.G.A./CGA and approved by the American Society of Mechanical Engineers, must have been installed.
a. This warranty shall apply only when the heater is used:
(1) used at temperatures not exceeding the maximum calibrated setting of its thermostat;
(2) used at water pressure not exceeding the working pressure shown on the heater;
(3) filled with potable water, free to circulate at all times and with the tank free of damaging water sediment or scale deposits;
(4) used in a non-corrosive and non-contaminated atmosphere;
(5) used with factory approved anode(s) installed;
(6) in its original installation location;
(7) in the United States, its territories or possessions, and Canada;
(8) sized in accordance with proper sizing techniques for commercial and/or residential water heaters;
(9) bearing a rating plate which has not been altered, defaced or removed, except as required by the warrantor;
(10) used in an open system or in a closed system with properly sized and installed thermal expansion tank;
(11) operated with properly installed dirt leg;
(12) fired with the fuel for which it was factory built;
(13) fired at the factory rated input;
(14) operated with the inner and outer combustion chamber doors in place.
b. Any accident to the water heater, any misuse, abuse (including freezing) or alteration of it, any operation of it in a modified form, any use of insulation blankets, or any attempt to repair tank leaks will void this warranty.
c. This warranty is void if a device acting as a backflow prevention device (check valves etc.) is installed in the cold water supply the heater is connected to, unless an effective method of controlling thermal expansion is also installed at the heater(s) and operational at all times. The relief valve installed on the heater is not an acceptable method.
4.
SERVICE AND REPAIR EXPENSES
Under the limited warranty the warrantor will provide only a replacement water heater or part thereof. The owner is responsible for all other costs. Such costs may include but are not limited to: a. Labor charges for service removal, repair or reinstallation of the water heater or any component part; b. Shipping, delivery, handling, and administrative charges for forwarding the new heater or replacement part from the nearest distributor and returning the claimed defective heater or part to such distributor.
c. All cost necessary or incidental for any material and/or permits required for installation of the replacement heater or part.
5.
LIMITATIONS ON IMPLIED WARRANTIES
Implied warranties, including the warranty of merchantability imposed on the sale of this heater under state law are limited to one (1) year duration for the heater or any of its parts. Some states do not allow limitation on how long an implied warranty lasts, so the above limitation may not apply to you.
6 .
CLAIM PROCEDURE
Any claim under the warranty should be initiated with the dealer who sold the heater, or with any other dealer handling the warrantor’s products. If this is not practicable, the owner should contact:
State Water Heaters
500 Lindahl Parkway
Ashland City, TN 37015 a. The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by the warrantor.
b. Dealer replacements are made subject to in-warranty validation by warrantor.
7.
DISCLAIMERS
NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE HEATER OR THE
INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF THE HEATER. THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER
DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPERTY OR OTHER CONSEQUENTIAL
DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR
PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR IN TORT.
a. Some states do not allow the exclusion or limitation of the incidental or consequential damage, so the above limitations or exclusions may not apply to you.
b. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Fill in the following for your own reference. Keep it. Registration is not a condition of warranty. The model and serial number are found on the heater’s rating plate.
Model No. Serial No. _________________________________________ Date Installed___________________
Dealer’s Name________________________________________________________________________________________________________
Dealer’s Address _______________________________________________________________ Phone No.___________________________
City and State____________________________________________________________________ Zip Code____________________________
KEEP THIS WARRANTY POSTED ADJACENT TO THE HEATER FOR FUTURE REFERENCE
27
500 Lindahl Parkway
Ashland City, TN 37015
Phone: 800-821-2017 Fax: 800-644-9306 www.statewaterheaters.com
28
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Table of contents
- 25 ROUGH-IN-DIMENSIONS
- 25 FOREWORD
- 26 GENERAL SAFETY INFORMATION
- 26 Precautions
- 26 Grounding Instructions
- 26 Chemical Vapor Corrosion
- 26 Improper Combustion
- 27 Extended Non-Use
- 27 Insulation Blankets
- 27 High Altitude Installation
- 27 FEATURES
- 27 Self-Cleaning Hydro-Cannon
- 27 High Limit Switch
- 28 Electronic Ignition Control
- 28 Exhaust Inducer (Blower Assy.)
- 28 Circulating Pump
- 28 Dishwashing Machine Requirement