American Water Heater BBCN375T754NV User's Manual

American Water Heater BBCN375T754NV User's Manual
MODELS BBCN375T754NV
Series 100
COMMERCIAL ULTRA LOW NOx GAS WATER HEATER
Glass-Lined Tank-type Water Heater
• INSTALLATION • OPERATION • SERVICE • MAINTENANCE • LIMITED WARRANTY
CAUTION
TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION
RELATIVE TO YOUR SAFETY. PLEASE READ THOROUGHLY
BEFORE INSTALLING AND USING THIS APPLIANCE.
www.americanwaterheater.com
American Water Heater
Johnson City, TN 37605
PRINTED IN U.S.A. 1212
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER
AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
1
PART NO. 325370-000
ROUGH-IN DIMENSIONS
TOP VIEW
*INSTALL IN ACCORDANCE WITH LOCAL CODES
FIGURE 1.
TABLE 1, DIMENSIONS
Units
A
B
C
D
E
F
G
H
J
K
L
M
Inches
CM
66 5/8
169.22
58 3/4
134.23
30 15/16
78.58
27 3/4
70.5
15 1/4
38.6
4
10.2
15 3/4
40.0
16
40.6
1 1/4
3.2
1 1/4
NPT
1/2
NPT
12 1/4
31.1
TABLE 2, RECOVERY RATINGS
INPUT RATE
75,100
BTU/H
22
KW
Recovery in US Gallons/hr or Liters/hr at Indicated Temperature Rise in Fahrenheit or Celsius
°F
30
40
50
60
70
80
90
100
110
120
130
140
GPH
243
182
145
122
104
91
81
73
66
60
56
52
°C
17
23
28
33
39
44
50
56
61
67
72
78
LPH
920
688
549
460
392
344
306
277
251
228
213
199
Recovery ratings are based on 80% thermal efficiency.
TABLE 3, GAS AND ELECTRICAL CHARACTERISTICS
Manifold Pressure
Electrical Characteristics
Type of gas
Inches W.C.
kPa
Voltz/Hz
Amperes
Natural Gas
4.0
1.12
120/160
<5
All Models: Maximum supply pressure = 14.0 in. W.C. (3.48 kPa)
Minimum supply pressure, Natural gas = 6 in. W.C. (1.49 kPa).
Minimum pressures must be maintained under both load and no load (static and dynamic) conditions.
FOREWORD
The installation must conform to these instructions and the local code
authority having jurisdiction.
The design of model BBCN375T754NV complies with the current edition
of ANSI Z21.10.3/CSA 4.3 as automatic storage or automatic circulating
tank type water heaters.
In the absence of local codes, the installation must comply with the following:
In the United States:
Current edition of the National Fuel Gas Code, ANSI Z223.1 / NFPA 54
and the National Electrical Code, NFPA 70;
Installation diagrams are found in this manual. These diagrams will serve
to provide the installer with a reference for the materials and method of
piping necessary. It is highly essential that all water and gas piping be
installed as shown on the diagrams.
In Canada:
Current edition of the Installation Code CAN/CSA-B149.1 and the
Canadian Electrical Code CSA C22.1.
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.
These are available from Canadian Standards Association, 8501 East
Pleasant Valley Road, Cleveland, OH 44131 or National Fire Protection
Association, 1 Batterymarch Park, Quincy, MA 02269.
2
TABLE OF CONTENTS
Page
Page
ROUGH-IN DIMENSIONS.............................................................. 2
FOREWORD.................................................................................. 2
GENERAL SAFETY INFORMATION.............................................. 2-4
Precautions.................................................................................... 3
Grounding Instructions............................................................... 3
Chemical Vapor Corrosion.......................................................... 3
Extended Non-use Periods......................................................... 3
Insulation Blankets..................................................................... 4
High Altitude Installations........................................................... 4
Circulating Pump........................................................................ 4
INSTALLATION INSTRUCTIONS.................................................. 4-9
Required Ability.............................................................................. 4
Locating The Heater................................................................... 4
Clearances................................................................................. 5
Hard Water................................................................................. 5
Air Requirements........................................................................ 5
Venting........................................................................................ 6
Thermometers (Not Supplied).................................................... 7
Combination Water (Potable) Heating and Space Heating........ 7
Relief Valve................................................................................. 7
Gas Piping.................................................................................. 7
Heater Wiring.............................................................................. 8
Wiring Diagram........................................................................... 8
Purging....................................................................................... 9
Gas Pressure Regulation.......................................................... 9
OPERATION.................................................................................. 9
To Operate The Heater.............................................................. 9
Lighting Instructions................................................................... 10
Temperature Regulation............................................................ 11
Checking Venting....................................................................... 11
High Temperature Limit Switch.................................................. 11
SERVICE INFORMATION............................................................. 12-13
Main Burner and Igniter............................................................. 12
Checking Gas Input................................................................... 12
Vent System.............................................................................. 12
Blower Maintenance.................................................................. 13
Relief Valve................................................................................ 13
Hot Water Odor.......................................................................... 13
Winter Protection....................................................................... 13
Replacement Parts.................................................................... 13
PREVENTIVE MAINTENANCE..................................................... 13-14
Procedure for Periodic Removal Of Lime Deposits................... 13
Deliming Solvents...................................................................... 13
Tank Cleanout Procedure.......................................................... 14
CHECKLIST.................................................................................. 15-16
Condensation............................................................................ 15
Anode........................................................................................ 15
Service & Repair........................................................................ 16
TROUBLESHOOTING.................................................................. 17-20
NOTES.......................................................................................... 21-22
LIMITED WARRANTY.................................................................... 23
GENERAL SAFETY
INFORMATION
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.
PRECAUTIONS
DO NOT USE THIS water heater 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.
Spray can propellants, cleaning solvents, refrigerator and air conditioning
refrigerants, swimming pool chemicals, calcium and sodium chloride (water
softener salt), waxes, and process chemicals are typical compounds which
are potentially corrosive. Do not store products of this sort near the heater.
Also, air which is brought in contact with the heater should not contain
any of these chemicals. If necessary, uncontaminated air should be
obtained from remote or outside sources. 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.)
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.
EXTENDED NON-USE PERIODS
WARNING
Heater must be protected from freezing downdrafts during shutdown periods.
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.
GROUNDING INSTRUCTIONS
This water heater must be grounded in accordance with the National
Electrical Code and/or local codes. These must be followed in all cases.
This water heater must be connected to a grounded 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 5.
3
INSULATION BLANKETS
INPUT section in this manual for inlet and manifold pressure
requirements.
Insulation blankets available to the general public for external use
on gas water heaters are not required for use on your water heater.
The purpose of an insulation blanket is to reduce the standby heat
loss encountered with storage tank water heaters. Your water
heater meets or exceeds the current edition of ASHRAE/IES 90.1
standards with respect to insulation and standby loss requirement
making an insulation blanket unnecessary.
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.
CIRCULATING PUMP
A circulating pump is used when a system requires a circulating
loop or there is a storage tank used in conjunction with the heater.
Refer to the piping diagrams at rear of manual for electrical hookup
information and install in accordance with the current edition of the
National Electrical Code ANSI/NFPA No. 70. In Canada refer to
Canadian Electrical Code CSA C22.1.
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.
•
Do not cover the outer door, thermostat or temperature & pressure
relief valve.
•
Do not allow insulation to come within 2" (5cm) of the floor to prevent
blockage of combustion air flow to the burner.
•
Do not cover the instruction manual. Keep it on the side of the water
heater or nearby for future reference.
•
Do obtain new warning and instruction labels from the manufacturer
for placement on the blanket directly over the existing labels.
•
Only all bronze circulating pumps 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.
INSTALLATION INSTRUCTIONS
REQUIRED ABILITY
I N STA L L AT I O N O R S ERV I C E O F T H I S WAT ER H E AT ER
REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED
TR A DESM A N IN THE FIELD IN VO LVED. PLU M BING, AIR
SUPPLY, VENTING, ELECTRICAL AND GAS SUPPLY WORK
ARE REQUIRED.
Do inspect the insulation blanket frequently to make certain it does
not sag, thereby obstructing combustion air flow.
HIGH ALTITUDE INSTALLATIONS
LOCATING THE HEATER
Water heaters covered in this manual have been tested and
approved for installation at elevations up to 7,700 feet (2,347
m) above sea level. For installation above 7,700 feet (2,347 m),
the water heater’s Btu input should be reduced at the rate of 4
percent for each 1,000 feet (305 m) above sea level which requires
replacement of the burner orifice in accordance with the National
Fuel Gas Code ANSI Z223.1/ NFPA 54. Contact your local gas
supplier for further information.
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 IF INSTALLED 18 INCHES (45.7 CM) OR
MORE ABOVE THE FLOOR. THIS MAY REDUCE THE RISK IF
LOCATION IN SUCH AN AREA CANNOT BE AVOIDED.
Failure to replace the standard orifice with the proper high altitude
orifice when installed at elevations above 7,700 feet (2,347 m)
could result in improper and inefficient operation of the water
heater, producing carbon monoxide gas in excess of the safe
limits. This could result in serious injury or death. Contact your
local gas supplier for any specific changes that may be required
in your area.
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 (7.6 CM) in any direction. If the heater is
Upon completion of derating of the heater, adjustment to the
gas pressure regulator may be required. See CHECKING THE
4
installed in a carpeted alcove or closet, the entire floor shall be covered
by the panel. Also, see the drain requirements.
WARNING
ATTIC AND/OR EXHAUST FANS OPERATING ON THE PREMISES
WITH A WATER HEATER CAN RESULT IN CARBON MONOXIDE
POISONING AND DEATH.
THIS HEATER SHALL BE LOCATED OR PROTECTED SO IT IS
NOT SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE.
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.
WARNING
FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY
OTHER POTENTIA L FIRE HA Z ARDOUS ARTICLES MUST
NEVER BE PLACED ON OR ADJACENT TO THE HEATER. OPEN
CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT BE
STORED OR USED IN THE SAME ROOM WITH THE HEATER.
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.
WARNING
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.
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.
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.
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" (5cm) deep, with
length and width at least 2" (5cm) greater than the diameter of the
heater and must be piped to an adequate drain. The pan must not
restrict combustion air flow.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATING
AIR. ADEQUATE AIR FOR COMBUSTION AND VENTILATION MUST
BE PROVIDED FOR SAFE OPERATION.
Drain pans suitable for these heaters are available from from the
manufacturer, authorized service agencies or distributors.
UNCONFINED SPACE
In buildings of conventional frame, brick, or stone construction,
unconfined spaces may provide adequate air for combustion, ventilation
and draft hood dilution.
CLEARANCES
These heaters are approved for installation on combustible flooring
in a closet having a ceiling 12" (30.5cm) above top cover and with
clearances to combustible construction of 6" (15.2cm) from flue or
vent connector, 0" (0cm) at the sides and rear and 5" (10.2cm) to
front to prevent a possible fire hazard condition. A minimum of 4"
(10.2cm) shall be allowed for installation of serviceable parts.
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.
HARD WATER
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 (30.5cm)
OF THE ENCLOSURE TOP AND ONE IN OR WITHIN 12 INCHES
(30.5cm) OF THE ENCLOSURE BOTTOM. Each opening shall have
a free area of at least one square inch per 1000 Btuh (2,225mm2/Kw) of
the total input of all appliances in the enclosure, but not less than 100
square inches (645 square cm).
Where hard water conditions exist, water softening or the threshold
type of water treatment is recommended. This will protect
the dishwashers, coffee urns, water heaters, water piping and
other equipment.
See MAINTENANCE section for details of tank cleanout procedure.
AIR REQUIREMENTS
If the confined space is within a building of tight construction, air for
combustion, ventilation, and draft hood dilution 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
(8,900mm2/Kw) 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 (4,450mm2/Kw) of the total input
of all appliances in the enclosure. For Canadian installations consult
CAN/CSA-B149.1.
REFER TO CURRENT EDITION OF THE "NATIONAL FUEL GAS
CODE ANSI Z223.1/NFPA 54. FOR CANADA CONSULT CAN/
CSA-B149.1.
KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE
MATERIALS, GASOLINE AND OTHER FLAMMABLES, VAPORS
AND LIQUIDS.
DO NOT OBSTRUCT THE FLOW OF THE COMBUSTION OR
VENTILATING AIR.
5
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.
This water 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 water heaters.
This water heater must be vented in compliance with all local codes, the
current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
and with the Category I Venting Tables.
FIGURE 2.
VENT CONNECTION
In Canada, venting shall conform to the requirements of the current
edition of the CAN/CSA B149.1-00 installation code.
Vent connections must be made to an adequate stack or chimney. Size
and install proper size vent pipe. Do not reduce pipe size to less than
that of the blower outlet.
If any part of the vent system are exposed to ambient temperatures below
35 degrees F (2 degrees C) it must be insulated to prevent condensation.
•
Do not connect the heater to a common vent or chimney with solid
fuel burning equipment. This practice is prohibited by many local
building codes as is the practice of venting gas fired equipment to
the duct work of ventilation systems.
•
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.
Horizontal runs of vent pipe must have a minimum upward slope toward
the chimney of 1/4 inch per foot (2cm per meter). Dampers or other
obstructions must not be installed in between the heater and the blower.
Be sure that the vent pipe does not extend beyond the inside wall of
the chimney.
Where a continuous or intermittent back draft is found to exist, the
cause must be determined and corrected. A special vent cap may be
required. If the back draft cannot be corrected by the normal methods or
if a suitable draft cannot be obtained, a blower type flue gas exhauster
must be employed to assure proper venting and correct combustion.
SINGLE TEMPERATURE
MIXING VALVE APPLICATION FOR TWO TEMPERATURE WATER
WARNING
TEMPERATURE SETTING SHOULD NOT EXCEED SAFE
USE TEMPERATURE AT FIXTURES. SEE TEMPERATURE
REGULATION ON PAGE 11. 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 CONNECTIONS
TEMPERED WATER LOOP, IF USED, CONNECT TO POINT "A".
STORED TEMPERATURE WATER LOOP, IF USED, CONNECT TO
COLD WATER INLET
VACUUM RELIEF
VALVE
*INSTALL PER
LOCAL CODES.
CAUTION: IF BUILDING COLD WATER SUPPLY HAS A BACK-FLOW
PREVENTER, CHECK VALVE OR WATER METER WITH CHECK
VALVE, PROVISIONS FOR THERMAL EXPANSION OF WATER IN
THE HOT WATER SYSTEM MUST BE PROVIDED.
FIGURE 3.
6
THERMOMETERS (Not Supplied)
Your local code authority may have other specific relief valve
requirements.
Thermometers should be obtained and field installed as shown in
Figure 3.
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.
Thermometers are installed in the system as a means of detecting the
temperature of the outlet water supply.
COMBINATION WATER (POTABLE) HEATING
AND SPACE HEATING
1. All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
See SERVICE INFORMATION section for procedure and precautions.
2.Toxic chemicals, such as those used for boiler treatment, shall
NEVER be introduced into this system.
The type, size and location of the relief valves must be in accordance
with local codes. The location of the relief valve is shown in Figure 1.
The heater has a factory installed high temperature limit switch.
3. This unit may NEVER be connected to any existing heating system
or component(s) previously used with a non-potable water heating
appliance.
GAS PIPING
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 diagram on
page 6 of this manual for suggested piping arrangements.
Contact your local gas service company to ensure that adequate gas service
is available and to review applicable installation codes for your area.
5. These water heaters cannot be used in space heating applications
only.
Size the main gas line in accordance with Table 4. 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 current edition of the National Fuel Gas Code. For Canadian
installations consult Canadian Installation Code CAN/CSA-B149.1.
CAUTION
A closed system will exist if a check valve (without bypass), pressure
reducing valve (without bypass), or a water meter (without bypass)
is installed in the cold water line between the water heater and street
main (or well).
WARNING
The minimum gas supply pressure for input adjustment is 6.0" kPa W.C.
for natural gas (11.0" kPa W.C. for propane).
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.
THE HEATER IS NOT INTENDED FOR OPERATION AT HIGHER THAN
14" kPa WATER COLUMN SUPPLY PRESSURE. EXPOSURE TO HIGHER
GAS SUPPLY PRESSURE MAY CAUSE DAMAGE TO THE CONTROL
WHICH COULD RESULT IN FIRE OF EXPLOSION. If overpressure has
occurred such as through improper testing of gas lines or emergency
malfunction of the supply system, the control 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.
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.
RELIEF VALVE
IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING FROM
CONTAMINANTS IN THE GAS WAYS. SUCH FOULING MAY CAUSE
IMPROPER OPERATION, FIRE OR EXPLOSION.
This water heater is equipped with a combination temperature-pressure
relief valve that complies with the standard for relief valves for hot water
supply systems Z21.22-CSA 4.4. FOR SAFE OPERATION OF THE
WATER HEATER, THE RELIEF VALVE(S) MUST NOT BE REMOVED
OR PLUGGED.
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.
ASME ratings cover pressure relief capacities. ANSI ratings cover release
rate with temperature actuation.
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. 5). 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 CURRENT EDITION OF THE NATIONAL FUEL GAS CODE.
For Canadian installations consult Canadian Installation Code CAN/
CSA-B149.1.
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). This valve
shall comply with the standard for relief valves for hot water supply
systems Z21.22-CSA 4.4.
WARNING
To prevent damage, care must be taken not to apply too much torque
when attaching gas supply pipe to gas valve inlet.
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.
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.
7
HEATER WIRING
All electrical work must be installed in the United States in accordance with the current edition of the National Electrical Code ANSI/NFPA No.
70, in Canada, with the current edition of Canadian Electrical Code CSA C22.1, 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.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND
DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.
FIGURE 4. WIRING DIAGRAM AND SCHEMATIC
8
PURGING
TABLE 4. GAS SUPPLY LINE SIZES (IN INCHES)*
MAXIMUM CAPACITY OF PIPE IN
CUBIC FEET PER HOUR
LENGTH
IN
FEET
Gas line purging is required with new piping or systems in which air
has entered.
NORMAL IRON PIPE SIZES (INCHES)
INPUT IN THOUSANDS BTU/HR
1/2" 3/4"
CAUTION
1"
1 1/4"
1 1/2"
2"
2 1/2"
10
175
360
680
1400
2100
3960
6300
11000 230000
3"
20
120
250
485
950
1460
2750
4360
7700
15800
30
97
200
375
770
1180
2200
3520
6250
12800
40
82
170
320
660
990
1900
3000
5300
10900
50
73
151
285
580
900
1680
2650
4750
9700
60
66
138
260
530
810
1520
2400
4300
8800
70
61
125
240
490
750
1400
2250
3900
8100
80
57
118
220
460
690
1300
2050
3700
7500
4"
90
53
110
205
430
650
1220
1950
3450
7200
100
50
103
195
400
620
1150
1850
3250
6700
125
44
93
175
360
550
1020
1650
2950
6000
150
40
84
160
325
500
950
1500
2650
5500
175
37
77
145
300
460
850
1370
2450
5000
200
35
72
135
280
430
800
1280
2280
4600
LENGTH
IN
METERS
3.0
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.
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 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.
NORMAL IRON PIPE SIZES (INCHES)
INPUT IN KW
1/2" 3/4"
51
105
1"
199
1 1/4"
1 1/2"
410
615
2"
1160
2 1/2"
1845
3"
The minimum gas supply pressure for input adjustment must not be less
than 6" w.c. (1.49 kPa) for natural gas and 11" w.c. (2.73 kPa).
4"
3221
6735
6.1
35
73
142
278
428
805
1277
2255
4626
9.1
28
59
110
225
346
644
1031
1830
3748
12.2
24
50
94
193
290
556
878
1552
3192
15.2
21
44
83
170
264
492
776
1391
2840
18.3
19
40
76
155
237
445
703
1259
2577
21.3
18
37
70
143
220
410
659
1142
2372
24.4
17
35
64
165
202
381
600
1083
2196
27.4
16
32
60
126
190
357
571
1010
2108
30.5
15
30
57
117
182
337
542
952
1962
38.1
13
27
51
105
161
299
483
864
1757
45.7
12
25
47
95
146
278
439
776
1610
53.3
11
23
42
88
135
249
401
717
1464
61.0
10
21
40
82
126
234
375
688
1347
Do not subject the combination gas valve to inlet gas pressures of more
than 14.0" w.c. (3.48 kPa) - natural gas. A service regulator is necessary
if higher gas pressures are encountered.
Gas pressure specified in Table 5, refer to flow pressure taken at pressure
tap of automatic gas valve while heater is operating.
TABLE 5.
Type of
Gas
Natural
Input
Manifold
Pressure
75,100 Btu/hr
22 KW/hr
4.0 in. W.C.
1.12 kPa
OPERATION
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.
It is recommended that a qualified person perform the initial firing of the
heater. At this time the user should not hesitate to ask the individual any
questions which he may have in regard to the operation and maintenance
of the unit.
TO OPERATE THE HEATER
1. Close the heater drain valve (Figure 1) by turning handle
clockwise
.
2. Open a nearby hot water faucet to permit the air in the system
to escape.
3. Fully open the cold water inlet pipe valve (Figure 1) allowing the
heater and piping to be filled.
4. Close the hot water faucet as water starts to flow.
5. The heater is ready to be operated.
FIGURE 5. GAS PIPING AND sediment trap INSTALLATION
WARNING
DISCONNECT THE HEATER AND ITS MANUAL GAS SHUTOFF VALVE
FROM THE GAS SUPPLY PIPING SYSTEM DURING ANY SUPPLY
PRESSURE TESTING EXCEEDING 1/2 PSIG (3.45 kPa). GAS SUPPLY LINE
MUST BE CAPPED WHEN DISCONNECTED FROM THE HEATER FOR TEST
PRESSURES OF 1/2 PSIG (3.45 kPa) OR LESS. THE APPLIANCE NEED
NOT BE DISCONNECTED, BUT MUST BE ISOLATED FROM THE SUPPLY
PRESSURE TEST BY CLOSING THE MANUAL GAS SHUTOFF VALVE.
DO NOT ATTEMPT TO OPERATE WATER HEATER WITH COLD
WATER INLET VALVE CLOSED.
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.
9
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.
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.
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.
•
If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in the control buttons.
Never use tools. If the control buttons will not push
in, don’t try to repair them, call a qualified service
technician. Force or attempted repair may result in a
fire or explosion.
WHAT TO DO IF YOU SMELL GAS:
•
•
•
Do not try to light any appliance.
Do not touch any electric switch;
do not use any phone in your building.
Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
D. Do not use this appliance if any part has been under
water. Immediately call a qualified service technician
to inspect the appliance and to replace any part of the
control system and any gas control which has been
under water.
OPERATING INSTRUCTIONS
5. Wait five (5) minutes
to clear out any gas.
If you then smell gas, STOP! Follow "B" in
the safety information
above on this label.
If you don't smell gas, go to next step.
6. Turn on all electrical power to the appliance.
7. Set thermostat to desired setting by first pressing the
and HOTTER
buttons together and
COOLER
holding for 1 second. Then press the HOTTER
button.
1.
8. If the appliance will not operate, follow the
instructions "TO TURN OFF GAS TO APPLIANCE"
and call your technician or gas supplier.
STOP! Read the safety information above on this label.
2. Set the thermostat to the lowest setting by first pressing
the COOLER
and HOTTER
buttons together
and holding for 1 second. Then press the COOLER
button until the WARM indicator light appears.
3. Turn the "ON/OFF" swich on the blower control to the
"OFF" position.
4. This appliance is equipped with a device which
automatically lights the burner.
DO NOT TRY TO LIGHT THE BURNER BY HAND.
9. WATER TEMPERATURE ADJUSTMENT
is approximately 120°F (49°C).
CAUTION: Hotter water increases the risk
of scald injury. Consult the instruction
manual before changing temperatures.
WARNING: TURN OFF ALL ELECTRIC
POWER BEFORE SERVICING
TO TURN OFF GAS TO APPLIANCE
A. Set thermostat to the lowest setting.
B. Turn off all the electric power to the appliance
if service is to be performed.
10
TEMPERATURE REGULATION
SETTING THE WATER HEATER TEMPERATURE AT 120°F (49°C)
(APPROX. " " MARK ON FACE OF THE TEMPERATURE ADJUSTING
DIAL) WILL REDUCE THE RISK OF SCALDS. Some States or Provinces
require settings at specific lower temperatures.
Figure 6 shows the approximate water temperatures produced at various
thermostat settings. Short repeated heating cycles caused by small hot
water uses can cause temperatures at the point of use to exceed the
thermostat setting by up to 20°F (11°C). If you experience this type of
use you should consider using lower temperature settings to reduce
scald hazards.
DANGER
THIS WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE
THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT WATER
TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHING AND
LAUNDRY USE CAN CAUSE PAINFUL SCALDING WITH POSSIBLE
SERIOUS AND PERMANENT INJURY. THE TEMPERATURE AT WHICH
INJURY OCCURS VARIES WITH THE PERSON’S AGE AND THE TIME
OF THE EXPOSURE. THE SLOWER RESPONSE TIME OF CHILDREN,
AGED OR DISABLED PERSONS INCREASES THE HAZARDS TO
THEM. NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER TAP,
OR TO DRAW THEIR OWN BATH WATER. NEVER LEAVE A CHILD
OR DISABLED PERSON UNATTENDED IN A BATHTUB OR SHOWER.
THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE
THE GENERAL PUBLIC DOES NOT HAVE ACCESS. IF A SUITABLE
AREA IS NOT AVAILABLE, A COVER SHOULD BE INSTALLED OVER
THE THERMOSTAT TO PREVENT TAMPERING.Suitable covers
are available from the manufacturer, authorized service agencies or
distributors. When ordering parts be sure to have the complete water
heater Model Number, Serial Number and Series Number available. This
information can be found on the rating label affixed to the water heater.
It is recommended that lower water temperatures be used to avoid the
risk of scalding. It is further recommended, in all cases, that the water
temperature setting be set for the lowest temperature that satisfies
your hot water needs. This will also provide the most energy efficient
operation of the water heater. The water temperature adjustment was
factory set at the lowest temperature. Pressing the "COOLER"
button
button decreases temperature and pressing the "HOTTER"
increases the temperature.
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.
To avoid any unintentional changes in water temperature settings, the
control has a tamper resistant feature for changing the temperature
setting. To change the temperature setting follow these instructions:
1. "Wake Up" the temperature indicators by holding down both the
"COOLER" and "HOTTER" temperature adjustment buttons at
the same time for one second (see Figure 6). One or two of the
temperature indicators will light up. These indicators will only remain
on for 30 seconds if no further buttons are pressed. After 30 seconds
the control will go back to "Sleep" mode.
2. Release both of the temperature adjustment buttons.
A. To decrease the temperature press and release the "COOLER"
button until desired setting is reached.
B. To increase the temperature press and release the "HOTTER"
button until the desired setting is reached.
NOTE: Holding down the button will not continue to lower or raise the
temperature setting. The button must be pressed and released for each
temperature change desired.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO
SHUT OFF, TURN OFF THE MAIN MANUAL GAS SHUTOFF VALVE
TO THE APPLIANCE. SEE FIGURE 1 (G).
CHECKING VENTING
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/NFPA 54
or the CAN/CSA-B149.1 Installation codes and these instructions.
Determine that there is no blockage or restriction, leakage, corrosion
and other deficiencies which could cause an unsafe condition.
Time to Produce
Display 2nd & 3rd Degree
Temperature Setting
BCDEF Burns on Adult Skin
F = approx. 180°F (82°C)
E = approx. 170°F (77°C)
D = approx. 160°F (71°C)
C = approx. 150°F (65°C)
B = approx. 140°F (60°C)
B = approx. 130°F (54°C)
= approx. 120°F (49°C) Nearly Instantaneous
Nearly Instantaneous
About 1/2 Second
About 1 1/2 Seconds
Less than 5 Seconds
More than 30 Seconds
More than 5 Minutes
FIGURE 6.
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. Test for vent system leakage after 5 minutes of main burner operation.
11
6. 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.
1.
2.
3.
4.
7. If improper venting is observed during any of the above tests, the
venting system must be corrected.
If preceding burner characteristics are not evident, check for accumulation
of lint or other foreign material that restricts or blocks the air openings
to the heater or burner.
Provide complete combustion of gas.
Cause rapid ignition and carryover of flame across entire burner.
Give reasonably quiet operation during ignition, burning and extinction.
Cause no excessive lifting of flames from burner ports.
WARNING
FAILURE TO CORRECT BACK DRAFTS MAY CAUSE AIR
CONTAMINATION AND UNSAFE CONDITIONS.
HIGH TEMPERATURE LIMIT SWITCH (ECO)
The water heater is equipped with a manual reset type high limit (Energy
Cutoff) sensor. The high limit switch interrupts the main burner gas flow
should the water temperature reach 195°F (90°C). The high limit switch
must be manually reset by turning the power to the water heater off for 5
seconds then back on and cannot be reset until the water temperature
drops below 120°F (49°C). It is important that a serviceman be called
to determine the reason for limit operation and thus avoid repeated
thermostat resetting.
WARNING
SOOT BUILD-UP INDICATES A PROBLEM THAT REQUIRES
CORRECTION BEFORE FURTHER USE. CONSULT WITH A
QUALIFIED SERVICE TECHNICIAN.
Should the main burner or burner air openings require cleaning, remove
the burner and clean with a soft brush. Clean main burner orifice with a
suitable soft material.
CHECK FOR GOOD FLOW OF COMBUSTION AND VENTILATING AIR
TO THE UNIT. MAINTAIN A CLEAR OPEN AREA AROUND THE HEATER
AT ALL TIMES. DO NOT STORE COMBUSTIBLES OR FLAMMABLE
LIQUIDS NEAR OR AROUND AN APPLIANCE.
CHECKING GAS INPUT
WARNING
THE ON/OFF SWITCH 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 ODOR, 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.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO
SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO
THE APPLIANCE.
For appliance installation locations with elevation above 2000 ft.(610m)
refer to HIGH ALTITUDE INSTALLATIONS section of this manual for
input reduction procedure.
With this heater in operation, determine whether it is receiving the full rated
input of gas. This may be done by timing the gas meter and measuring
gas pressure with a gauge or manometer. When the heater is operating
at full capacity (full gas input) it should consume approximately 1 cubic
foot of gas in the time shown in table 6.
TABLE 6
INPUT CHECK TIME REQUIRED TO CONSUME 1 CU. FT. OF GAS
SERVICE INFORMATION
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.
FOR YOUR SAFETY AND SATISFACTORY OPERATION, IT IS
RECOMMENDED THAT THIS HEATER BE CHECKED ONCE A YEAR
BY A COMPETENT SERVICE PERSON.
USERS OF THIS water heater SHOULD BE AWARE THAT GAS
COMPONENTS WEAR OUT OVER A PERIOD OF TIME. THE GAS
CARRYING COMPONENTS OF THIS water heater SHOULD
BE INSPECTED FOR PROPER OPERATION PERIODICALLY BY A
QUALIFIED SERVICE TECHNICIAN.
MAIN BURNER AND IGNITER
Check main burner (figure 7) at least every 6 months for proper
flame characteristics. The main burner should display the following
characteristics:
BURNER HEAD
ASSEMBLY
BURNER TUBE
ASSEMBLY
Type of Gas
BTU Per Cu. Ft.
Time Required To Consume 1 Cu. Ft. of Gas
Natural
1050
50.3 Seconds
Use this formula to “clock” the meter. Be sure that other gas consuming
appliances are not operating during this interval.
3,600 X H = Btu/h
T
T = Time in seconds needed to burn one cubic foot of gas.
H = Heating value of gas in Btu’s per cubic foot of gas.
Btuh = Actual heater input rate.
Example:
T = 47.2 seconds/ft3
H = 1,050 Btu/ft3 (natural gas)
Btuh = ?
3,600 X 1,050 = 75,100 Btu/h (22Kw)
50.3
Compare the actual input rate to that given on the heater’s rating plate.
In the example, the full input rate should be 75,000 Btu/h (22 Kw) for
natural gas.
VENT SYSTEM
Examine the venting system every 6 months for obstructions and/or
deterioration of vent piping.
H.S.I.
ASSEMBLY
FIGURE 7. MAIN BURNER AND IGNITER ASSEMBLY
12
PREVENTIVE MAINTENANCE
BLOWER MAINTENANCE
For safety and satisfactory operation it is recommended that the blower
be checked once a year by a competent service person.
RECOMMENDED PROCEDURE FOR PERIODIC
REMOVAL OF LIME DEPOSITS FROM TANK TYPE
COMMERCIAL WATER HEATERS
1. MOTOR - The motor is factory oiled and sealed and requires no
further maintenance.
2. WHEEL - Wheel must be clean of soot, ash or any other coating
which inhibits either rotation or air flow. Remove all foreign material
from vent system.
3. The pressure switch is inside the blower control box and is connected
to the blower housing with a tube. This tubing should be soft and
pliable and show no sign of deterioration.
RELIEF VALVE
At least once a year the temperature and pressure relief valve
should be checked to ensure that it is in operating condition.
(During manual operation of this valve, avoid any contact with hot
water and take preventive steps for water damage). Lift the lever
at the top of the valve several times until the valve seats properly
and operates freely.
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.
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.
FIGURE 8.
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.
WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO
SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO THE
APPLIANCE.
Lime accumulation not only reduces the life of the equipment but also
reduces efficiency of the heater and increases fuel consumption.
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 anode with aluminum anode may correct the condition.
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.
Occasionally water softener companies recommend removal of heater
anodes for odor reasons.
The time between cleaning will vary from weeks to months depending
upon water conditions and usage.
CAUTION
Unauthorized removal of heater anode will void the warranty. Replace
the anode as necessary to maintain corrosion protection. For further
information contact your dealer.
UN•LIME ® and the booklet may be obtained through your dealer
or distributor.
WINTER PROTECTION
DELIMING SOLVENTS
In regions where freezing weather is encountered, all water must be
drained from unit and piping when out of service (water shut off). Drain
valve must be left open until unit is returned to service.
UN•LIME is recommended for deliming. UN•LIME is a patented food
grade acid which is safe to handle and does not create the harmful
fumes which are associated with other products.
REPLACEMENT PARTS
UN•LIME may be obtained from your dealer, distributor or water heater
manufacturer. Order Part Number 9005416105, 1 gallon, packed 4
gallons per case or Part Number 9005417105, 5 gallon container.
Replacement par ts may be ordered from the manufacturer,
authorized service agencies or distributors. When ordering parts
be sure to have the complete water heater Model Number, Serial
Number and Series Number available. This information can be
found on the rating label affixed to the water heater. Refer to the
parts list included with the water heater from the factory for more
information or call the parts department or technical support phone
number listed on the back cover of this manual for further assistance.
NOTE: Un•Lime is not available for use in Canada. Hydrochloric base
acids are not recommended for use on glass-lined tanks.
CAUTION
Observe handling instructions on label of product being used.
13
TANK CLEANOUT PROCEDURE
2. With the Flo-Jug upright:
The following practices will ensure longer life and enable the unit to
operate at its designed efficiency:
• Take off cap, remove cover under opening and install 3/4" x 4"
pipe nipple.
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.
• Drill or punch a 3/16" vent hole in handle. A stainless steel screw
is included with the Flo-Jug kit. This screw is to be installed in
the vent hole when Flo-Jug is not in use.
2. A cleanout opening is provided for periodic cleaning of the tank.
Gas must be shut off and heater drained before opening cleanout.
• Remove drain valve from heater and insert a 3/4" x 4" nipple.
• Connect and clamp 1" I.D. x 3" hose to Flo-Jug and heater nipple.
To clean heater through cleanout opening, proceed as follows:
1. Drain heater.
3. Lift the Flo-Jug to the POUR POSITION and permit the UN•LIME
to flow into the heater as rapidly as possible.
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.
4. Place the Flo-Jug in the DELIME POSITION.
4. Remove lime, scale, or sediment using care not to damage the glass
lining.
5. Inspect cleanout plate gasket, if new gasket is required.
• Be sure to keep the vent just above the liquid level.
• It may be necessary to place the empty jug on its carton to trap
the solution in the heater.
• Allow the UN•LIME to attack the water scale for 5 minutes.
5. Lower the Flo-Jug to the DRAIN POSITION and allow the UN•LIME
to flow out of the heater as rapidly as possible.
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.
• Observe the vent holes and elevate the jug slightly if there is a
possibility of spillage.
• Deliming activity is indicated by foaming on the surface of the
solution.
6. Continue the deliming process:
• Raise jug to POUR POSITION. Allow solution to flow into heater.
• Place jug in DELIME POSITION for 5 minutes. Solution is at
work in heater.
• Lower jug to DRAIN POSITION and allow solution to flow out.
Observe foaming.
7. After one hour, or earlier if the deliming activity (foaming) stops,
inspect the tank interior.
FIGURE 9
FLO-JUG METHOD OF DELIMING
• Drain the UN•LIME back into jug, DRAIN POSITION, and then
stand jug in DELIME POSITION.
• Remove the clamp, hose and the pipe nipple from heater
drain opening.
• Observe interior through opening - a small flashlight may be
used effectively.
• If the interior still shows water scale, the deliming process should
be continued.
• To check UN•LIME for continued use or reuse, place some lime
scale or white chalk into a glass with a small amount of solution. If
the material is vigorously dissolved by the solution, the UN•LIME
can be reused. If not, the UN•LIME has been weakened and
should be replaced.
The Flo-Jug is the standard 5 gallon container for UN•LIME -or- it is
available as a deliming kit with hose and fittings. Contact your dealer
or distributor.
Figure 9 illustrates most of the following steps.
8. When deliming has been completed, the heater should be flushed
for 3 to 5 minutes with fresh water.
1. The heater should be prepared for deliming as described in the
“Why? When and How” booklet. The relief valve may also be delimed
at this time.
14
• Remove the deliming equipment, install the drain valve, open the
cold water inlet line and allow water to flow through heater and out
drain valve. Don’t forget to plug vent and cap opening in Flo-Jug.
• When a water heater is first installed and filled, the bottom of the
tank might condense water. The water accumulation, if excessive,
can drip into the floor shield. Also, during normal operation there
may be occasions when large quantities of water are drawn,
chilling the tank bottom. This too can result in condensation.
• Condensation, appearing in the vent pipe (water dripping from
draft diverter) during heater operation is evidence of poor vent
action. Possible causes are too long a vent pipe or improper
chimney operation.
9. When flushing is completed:
• Fill heater being certain to expel air from tank through a nearby
hot water faucet or, if removed, the relief valve opening.
• The heater relief valve can be washed in UN•LIME if it is limed.
• Replace relief valve if removed for deliming.
• Restore gas, oil or electrical supply to heater.
• Check for water leakage.
• Allow scale to separate from UN•LIME and settle on bottom of
Flo-Jug.
3. If the leakage is from the temperature and pressure relief valve or
its discharge pipe, it may represent a normal condition. However,
see RELIEF VALVE section on page 7. DO NOT PLUG THE
TEMPERATURE AND PRESSURE RELIEF VALVE. Also, the
leakage could be due to unusually high water pressures or
temperatures in the system, or to a faulty relief valve. Your dealer
or a qualified service technician should be called to determine the
cause of the problem and to correct it.
• Pour off UN•LIME into plastic container and check for reuse.
4. If you cannot identify or correct the source of water leakage:
• Rinse sediment from Flo-Jug.
• Close the main shutoff valve in the gas supply pipe at the heater.
See Figure 5, page 9.
CHECKLIST
• Close the valve which feeds water to the cold water inlet at the
top of the heater.
Before contacting your dealer, check the water heater to see if the apparent
malfunction is caused by some external fault. Consulting this checklist
may eliminate the need for a repair call and restore hot water service.
• Contact your dealer.
NOT ENOUGH OR NO HOT WATER
1. Occasional excessive condensation, as explained under LEAKAGE,
can cause a sizzling sound as the moisture is vaporized by the gas
flame. This is a normal sound and may be disregarded.
10. Flo-Jug cleanup:
WATER HEATER MAKES SOUNDS
1. Look for leaking or open hot water faucets. Check for excessive
usage.
2. Sediment and water scale accumulations may cause rumbling
noises. See MAINTENANCE or contact your dealer for details of
flushing the heater.
2. Your gas company can check the gas input to the heater to see that
it is correct. An underfired heater will not produce hot water at its
normal recovery rate.
3. If you cannot identify or remedy the condition, contact your dealer.
3. If the heater was installed when incoming water temperatures were
warm, colder incoming temperatures will create the effect of less
hot water.
CONDENSATION
Water vapor can condense on the cooler surfaces of the tank forming
droplets, these drip into the fire or run out on the floor. This is common at
the time of startup after installation, during periods of time when incoming
water is very cold, or the heater may be undersized for the requirements.
4. The thermostat water temperature adjusting dial may be set too low.
5. If you cannot determine the cause of the problems, contact your
dealer.
Droplets from the bottom of the flue may be due to corrosive combustion
products or improper vent. Check with your dealer for more information.
WATER TEMPERATURE IS TOO HOT
1. The thermostat water temperature adjusting dial may be set too high.
ANODE
2. If lowering control setting does not reduce the water temperature
contact your dealer.
The anode rod is used to protect the tank from corrosion. Most hot water
tanks are equipped with an anode rod. The submerged rod sacrifices
itself to protect the tank. Instead of corroding the tank, water ions attack
and eat away the anode rod. This does not affect the water’s taste or
color. The rod must be maintained to keep the tank in operating condition.
GAS SMELL AT THE HEATER
1. Close the main shutoff valve in the gas supply pipe near the heater,
see Figure 5 on page 9. The thermostat includes a gas control (top
knob) which can also be closed.
Anode deterioration depends on water conductivity, not necessarily
water condition. A corroded or pitted anode rod indicates high water
conductivity and should be checked and/or replaced more often than
an anode rod that appears to be intact. Replacement of a depleted
anode rod can extend the life of your water heater. Inspection should
be conducted by a qualified technician, and at a minimum should be
checked annually after the warranty period.
A hydrogen sulfide (rotten egg) odor may result if water contains high
sulfate and/or minerals. Chlorinating the water supply should minimize
the problem. (See EXTENDED NON-USE PERIODS).
2. Call your gas company.
WATER LEAKAGE IS SUSPECTED
1. Check to see if the heater drain valve is tightly closed.
2. The apparent leakage might be condensation. In warm or humid
locations, condensation can accumulate and run from within the
heater or its piping.
15
WATER HEATING CYCLE
NOTE: Anode must remain installed (except for inspection) to
avoid shortening tank life. See LIMITED WARRANTY. Replace
as necessary.
(GAS AND ELECTRIC POWER ARE ON,“OFF/ON” SWITCH IS ON)
1) CALLS FOR HEAT
SERVICE AND REPAIR
The water heater requires no special care other than the normal
maintenance as noted above. If you are having a problem with your
water heater, before calling for service please refer to the following
TROUBLESHOOTING sections. If service becomes necessary,
contact your dealer, installer or an authorized service agent. Do not
attempt to repair the water heater yourself. Any work performed by
unauthorized personnel may void the warranty.
2) BLOWER MOTOR ROTATES BLOWER WHEEL
Please be sure to provide the following information when writing or
e-mailing:
•
•
•
•
•
A) THERMOSTAT SENSES NEED FOR HEATING WATER
B) CONTACTS CLOSE IN THERMOSTAT, POWER (115 VAC) FLOWS TO BLOWER MOTOR
A) BLOWER WHEEL SPEED INCREASES
B) WHEEL SPEED INCREASES, AIR PRESSURE SWITCH CONTACTS CLOSE
3) 120 VAC FLOWS TO HOT SURFACE IGNITER
Model Number
Serial Number
Date of Original Purchase
Date Problem Originated
Explanation of Problem
NOTE: THE CONTROL MODULE ON THIS UNIT WILL TRY A
MAXIMUM OF THREE TIMES TO LIGHT THE UNIT. CYCLE CAN
BE RESTARTED AT ANY TIME BY TURNING OFF SWITCH AND
THEN TURNING BACK ON. IF UNIT HAS GONE THROUGH
THREE CYCLES AND DID NOT LIGHT, THEN REPAIRMAN
SHOULD BE CALLED TO CHECK OPERATION OF HEATER.
Also, please be sure to include a daytime telephone number.
TROUBLESHOOTING
4) MAIN BURNER IGNITES
Water heaters may exhibit problems that are unrelated to a
malfunction of the water heater itself. The following information and
tables may serve to answer your question about a problem that you
are having without having to call a service agent.
A) GAS FLOWS TO MAIN BURNER PORTS AND IS IGNITED
5) GAS VALVE SENSES BURNER FLAME 6) BURNER HEATS WATER
For your safety, water heater service should be performed only
by a qualified service technician. Read the GENERAL SAFETY
INFORMATION section first.
16
A) BURNER HEATS WATER TO THERMOSTAT SETTING
B) CONTACTS IN THERMOSTAT OPEN,
C) CYCLE IS COMPLETED
TROUBLESHOOTING
For your safety, water heater service should be performed only by a qualified service technician.
Read the GENERAL SAFETY INFORMATION section first.
PROBLEM
POSSILBE MALFUNCTION
SERVICE TO BE PERFORMED
1) Blower will not run.
A) "ON/OFF" control switch turned off.
Turn switch to the on position.
B) Blower unplugged.
Plug blower back into 115 vac. outlet.
C) No power at outlet.
Repair service to outlet.
D) "ON/OFF" switch defective.
Replace switch.
E) Control harness defective.
Replace control harness.
F) Blower motor defective.
Replace blower and motor.
2) Blower running, burner not on
NOT ENOUGH OR NO HOT WATER
Replace switch.
A) Fan not running fast enough to close
air switch contacts.
Check for low voltage, less than 102 vac.,
have service checked and repaired.
B) Air pressure switch defective.
Replace switch.
C) Gas valve defective.
Replace gas control valve/ thermostat.
D) Control harness defective.
Replace harness.
E) Igniter defective.
Replace ignitor.
F) Unit has completed three trials to light
and fail.
Reset cycle by turning switch off and then
back on. If unit does not light in three trials, contact a qualified person for service.
3) Thermostat problems
A) Thermostat set too low.
Set temperature control higher.
B) Thermostat or ECO defective.
Replace gas control valve/thermostat.
C) High limit control circuit open.
Replace high limit control.
4) Others
CONDENSATION
WATER LEAKS
LEAKING T&P VALVE
HOT WATER ODORS OR COLOR
(Refer to CATHODIC PROTECTION)
A) Heater undersized.
Reduce hot water usage.
B) Low gas pressure.
Contact a qualified person for service.
C) Incoming water is unusually cold.
Allow more time for heater to re-heat.
D) Leaking hot water pipes or fixtures.
Have plumber check and repair leaks.
A) Water on the floor under heater.
See "Condensation"
Improperly sealed, hot or cold supply
connections, relief valve, drain valve or
thermostat threads.
Turn off heater & water, repair unit.
Leakage from other appliances or water
lines.
Inspect other appliances near water
heater.
Condensation of flue products.
Refer to "CONDENSATION"
Thermal expansion in closed water system
Install thermal expansion tank (DO NOT
PLUG T&P VALVE)
Improperly seated valves
Check relief valve for proper operation
(DO NOT PLUG T&P VALVE)
High sulfate or mineral content in water
supply or iron or sulfate reducing bacteria
in water supply
Drain and flush heater thoroughly, chlorinate, refil and flush again then chlorinate
water supply.
17
TROUBLESHOOTING GUIDELINES
TROUBLE SHOOTING
Please check guidelines below. For your safety, water heater service should be performed only by a qualified service technician.
Read the GENERAL SAFETY INFORMATION section first.
INTELLI-VENT TROUBLESHOOTING CHART - USER CONTROL
# LED STATUS
PROBLEM
SOLUTION
B CD E F
Inadequate or no earth ground 1.Ensure the wall outlet is properly grounded.
1
sensed by the Intelli-Vent™
control.
2.Ensure all ground connections/wires on the
water heater are secure.
Power supply to Intelli-Vent™
1.Ensure the wall outlet is properly wired.
B CD E F
2
control has reversed polarity or a
high resistance to earth ground.
2.Ensure all internal 120 VAC wiring connections and
wiring harness have no reversed wires. 120 VAC
“hot” wire must connect to the on/off switch.
3. Ensure the wall outlet is properly grounded.
4. Ensure all ground connections/wires on the water
heater are secure.
WATER HEATER CONTROL
Pressure switch circuit remaining
1.Ensure air pressure switch circuit wiring is correct
B CD E F
3
closed for more than 5 seconds and the air pressure switch is not jumpered.
after heating cycle begins.
Blower does not start.
2.Secure power to water heater, check continuity of air
pressure switch contacts with wires disconnected.
Service Note:
Disconnect power - disconnect one A If pressure switch contacts show continuity (closed
wire from the air pressure switch circuit) replace the pressure switch.
or the vent temperature limit
switch. Turn power back on - B If pressure switch contacts are open and all wiring
blower should start. is correct - turn the power off for 10-20 seconds
then on again to clear the error code - if the error
code persists replace the Intelli-Vent™ control.
Pressure switch circuit remains open
1.Ensure the blower is running - check for 120 VAC to
B CD E F
4
longer than 5 seconds after the blower the blower when the heating cycle begins, check the
is energized. wiring. If the control does not energize the blower replace the Intelli-Vent™ control. If the blower fails to
Blower may run continuously in start when energized - replace the blower assembly.
this condition.
2.Ensure the air pressure switch sensing tube is properly
connected - not kinked or damaged.
3.Check continuity of vent temperature limit switch - replace
switch if contacts remain open under 160ºF (71°C).
4.Ensure the correct size of vent pipe (2”, 3”, 4”) was used
Service Note: per installation manual for vent length. Ensure maximum
To learn more about performing Air number of elbows or equivalent feet of vent pipe has not
Pressure Switch tests visit our web exceeded maximum limits.
site www.hotwater.com to download
technical bulletin A-023-06 Air Pressure
5.Ensure there are no obstructions in the vent pipe.
Switches.
6.Check air pressure switch performance - check pressure
with a digital manometer - check continuity of contacts.
(see service note in left column) If the switch proves
defective - replace the air pressure switch and or the
blower assembly as required.
7.If air pressure switch performance test results prove
the air pressure switch is working properly and error
code 4 persists - replace the Intelli-Vent™ control.
The Intelli-Vent™ control has detected
1.Check wiring to the hot surface ignitor - replace ignitor
5
an open ignitor circuit. assembly if wiring is damaged or worn.
B CD E F
Service Note:
2.Check ignitor assembly plug and the socket on the
The resistance (ohms) of a hot surface Intelli-Vent™ body for good connection. Replace
ignitor will increase over time. If the ignitor assembly and/or control if necessary.
resistance at room temperature is near
18.8 ohms - consider replacing the ignitor 3.Check resistance of ignitor at room temperature 77ºF
as a preventative measure. (25°C) at the plug end. Replace ignitor if resistance
is not within 11.5 and 18.8 ohms at room temperature.
4.If results from the above tests were good and error
code 5 persists - replace the Intelli-Vent™ control.
18
TROUBLESHOOTING GUIDELINES
TROUBLE SHOOTING
Please check guidelines below. For your safety, water heater service should be performed only by a qualified service technician.
Read the GENERAL SAFETY INFORMATION section first.
INTELLI-VENT TROUBLESHOOTING CHART - USER CONTROL
#
6
LED STATUS
B C D E F
PROBLEM
SOLUTION
1. Gas supply is turned off-pressure too low. Ensure supply and
manifold gas pressures are within requirements in installation
manual. Manifold gas pressure is non-adjustable if pressure is
off by more than 0.3” W.C. (75 Pa) replace Intelli-Vent™ control.
Ignition/flame failure.
The water heater has reached the
maximum number of retries and is
currently locked out for one hour.
2. Low supply voltage - should be 115 -125 VAC.
WATER HEATER CONTROL
Cycle the power to the water heater
off and on to reset.
3. Ensure flame sensor is making good contact with burner
flame, ensure flame is steady see #8 below.
4. Ensure the flame sensor is clean - use ultra fine steel
Service Note:
wool or Scotch-Brite™ pad to clean flame sensor.
The resistance (ohms) of a hot surface
ignitor will increase over time. If the
5. Ensure the hot surface ignitor is positioned to provide
resistance at room temperature is near
consistent ignition.
18.8 ohms - consider replacing the ignitor
6.
Check for any cracks in ignitor assembly ceramic
as a preventative measure.
insulators - replace ignitor assembly if damaged.
7. Check resistance of ignitor at room temperature (77ºF)
(25°C) at the plug end. Replace ignitor if resistance is
not within 11.5 and 18.8 ohms at room temperature.
8. Ensure correct size of vent pipe (2”, 3”, 4”) was used per
installation manual for vent length. Using larger pipe than required
may cause excessive air turbulance in combustion chamber.
7
8
9
10
11
12
13
14
B C D E F
Self diagnostic tests have found a problem
with the gas valve driver circuit, internal
microprocessor, or other internal circuits.
1. Turn the power off for 10-20 seconds then on again to
clear these error codes.
2. If any of these error codes persist or cannot be clearedreplace the Intelli-Vent™ control.
Flame signal has been sensed out of
proper sequence.
1. Turn the power off for 10-20 seconds and then on again
to clear this error code.
2. Replace the Intelli-Vent™ control if this error code persists.
Water temperature in the tank has
exceeded 195°F (91°C) and has
activated the ECO.
1. Turn the power off for 10-20 seconds then on again
to clear this error code.
B C D E F
B C D E F
B C D E F
B C D E F
B C D E F
B C D E F
B C D E F
2. Replace the Intelli-Vent™ if the error code persists.
The self diagnostic check detected one 1. Press and release temperature adjust buttons. If above
or both of the temperature adjust buttons
action does not clear error, control will continue to regulate
are stuck.
water temperature at last setting. However, settings will no
longer be adjustable - the control should be replaced.
The self diagnostic test has detected the
water temperature sensor (thermistor) is
either open or shorted.
1. Turn power off for 10-20 seconds then on again to
clear this error code.
2. Replace the Intelli-Vent™ control if this error code persist.
Self-diagnostic test found a problem with black
1. Turn off power to the water heater.
resistor wire on the ignitor assembly plug; resistor 2. Insure black resistor wire is not cut, missing, and is installed
wire is open or shorted.
between pins 3 & 4 of ignitor assembly plug. Replace ignitor
assembly if damaged or defective.
Service Note: To perform this test ohm meter 3. Unplug ignitor assembly plug from control. Check resistance
used must be capable of reading up to 2,000,000
of black resistor wire between pins 3 & 4 with an ohm meter.
ohms. Unless ohm meter used has an auto-range
3.1 If reading taken is less than 2000 (5000 for date code 0617
feature resistance should be checked twice. First
through 0709) or more than 1.7 million ohms, replace ignitor
reading will be taken using an ohms scale above
assembly. 3.2 If reading taken is between 2000 (5000 for date
1,700,000 ohms. Second reading is taken using
code 0617 through 0709) and 1.7 million ohms, replace
ohms scale just above 2,000 or 5,000 ohms.
Intelli- Vent™ control.
Service Note: Raised ridges on ignitor assembly plug identify
#1, #2, and #3 pins. The four-digit date code can be found on
side of the controller.
19
TROUBLESHOOTING GUIDELINES
TROUBLE SHOOTING
Please check guidelines below. For your safety, water heater service should be performed only by a qualified service technician.
Read the GENERAL SAFETY INFORMATION section first.
INTELLI-VENT TROUBLESHOOTING CHART - USER CONTROL
#
15
B C D E F
B C D E F
PROBLEM
SOLUTION
The self-diagnostic test determined resistance
of the black resistor wire on ignitor assembly
plug is not within tolerance.
1. Turn off power to the water heater.
Air pressure switch circuit is opening
repeatedly during one heating cycle. May be
caused by air pressure switch and/or the vent
temperature limit switch (these two switches
are wired together in a “series” circuit).
1. Ensure air pressure switch hose is not kinked or clogged;
ensure the blower housing is clear of any condensation.
WATER HEATER CONTROL
16
LED STATUS
2. Unplug the ignitor assembly plug from the control. Check
the resistance of the black resistor wire between pins
3 & 4 with an ohm meter. 2.1 If the reading taken is more
than 100,000 (50,000 for data code before 0616; 70,000
for data code 0617 through 0709) ohms replace the ignitor
assembly. 2.2 If the reading taken is less than 100,000
(50,000 for data code before 0616; 70,000 for data code
0617 through 0709) ohms replace Intelli-Vent™ control.
2. Check vent temperature limit switch - if it is determined
that the vent temperature limit switch is opening its
contacts at normal operating temperatures during heating
cycle - replace the vent temperature limit switch.
3. Ensure water heater is not over-firing. 3.1 Check burner
orifice size and ensure the correct orifice is installed;
replace as necessary. 3.2 Check manifold gas pressure
and ensure it is within 0.3” W.C. (75 Pa) of listed rating on
Intelli-Vent™ control valve. Manifold gas pressure is
non-adjustable, if manifold gas pressure is off by more
than 0.3” W.C. (75 Pa), replace the Intelli-Vent™ control.
4. Ensure condensate lines are not obstructed. Check and
clear all condensate lines including the floor condensate
drain line.
20
NOTES
21
NOTES
22
Limited Warranty
American Water Heater Company, the warrantor, extends the following LIMITED WARRANTY to the owner of this water heater.
1. THE TANK
If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable water therein, during the first THREE years after initial installation, the warrantor will supply a complete new American water heater of equivalent size
and current model. Some government agencies are requiring energy efficient standards for water heaters. In the event regulations prohibit sale
of a model of equivalent size and construction, American Water Heater Company will provide a model which complies with the regulations of your
area, in which case the consumer will be charged the difference in price between the like replacement and the energy efficient model required.
The warranty on the replacement water heater will be limited to the unexpired term of the original warranty.
2. ALL OTHER PARTS
If within ONE year after initial installation of this water heater, any part or portion shall prove upon examination by the warrantor to be defective in
material or workmanship, the warrantor will repair or replace such part or portion at its option.
3. CONDITIONS AND EXCEPTIONS
This warranty shall apply only when the water heater is installed in accordance with local plumbing and building codes, ordinances and regulations,
the printed instructions provided with it and good industry practices. In addition, a temperature and pressure relief valve, certified by A.G.A./CGA
and approved by the American Society of Mechanical Engineers, must have been installed.
a. This warranty shall apply only when the heater is:
(1)
used at temperatures not exceeding the maximum calibrated setting of its thermostat;
(2)
used at water pressure not exceeding the working pressure shown on the heater;
(3)
filled with potable water, free to circulate at all times and with the tank free of damaging water sediment or scale deposits;
(4)
used in a non-corrosive and non-contaminated atmosphere;
(5)
used with factory approved anode(s) installed;
(6)
in its original installation location;
(7)
in the United States, its territories or possessions, and Canada;
(8)
sized in accordance with proper sizing techniques for commercial and/or residential water heaters;
(9)
bearing a rating plate which has not been altered, defaced or removed, except as required by the warrantor;
(10)
used in an open system or in a closed system with properly sized and installed thermal expansion tank;
(11)
operated with properly installed dirt leg;
(12)
fired with the fuel for which it was factory built;
(13)
fired at the factory rated input;
(14)
operated with the inner and outer combustion chamber doors in place.
b. Any accident to the water heater, any misuse, abuse (including freezing) or alteration of it, any operation of it in a modified form, any use of insulation blankets, or any attempt to repair tank leaks will void this warranty.
c. This warranty is void if a device acting as a backflow prevention device (check valves etc.) is installed in the cold water supply the heater is
connected to, unless an effective method of controlling thermal expansion is also installed at the heater(s) and operational at all times. The
relief valve installed on the heater is not an acceptable method.
4. SERVICE AND REPAIR EXPENSES
Under the limited warranty the warrantor will provide only a replacement water heater or part thereof. The owner is responsible for all other costs.
Such costs may include but are not limited to:
a. Labor charges for service removal, repair or reinstallation of the water heater or any component part;
b. Shipping, delivery, handling, and administrative charges for forwarding the new heater or replacement part from the nearest distributor and returning the claimed defective heater or part to such distributor.
c. All cost necessary or incidental for any material and/or permits required for installation of the replacement heater or part.
5. LIMITATIONS ON IMPLIED WARRANTIES
Implied warranties, including the warranty of merchantability imposed on the sale of this heater under state or provincial law are limited to one (1)
year duration for the heater or any of its parts. Some states and provinces do not allow limitation on how long an implied warranty lasts, so the
above limitation may not apply to you.
6. CLAIM PROCEDURE
Any claim under the warranty should be initiated with the dealer who sold the heater, or with any other dealer handling the warrantor’s products. If
this is not practicable, the owner should contact:
U.S. Customers
American Water Heater Company
PO Box 1597, 500 Princeton Road
Johnson City, TN 37605
a. 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 MERCHANTABILITY
OF THE HEATER OR THE INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF THE HEATER. THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPERTY OR OTHER
CONSEQUENTIAL DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY
PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR IN TORT.
a. Some states or provinces do not allow the exclusion or limitation of the incidental or consequential damage, so the above limitations or exclusions may not apply to you.
b. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or province to province.
Fill in the following for your own reference. Keep it. Registration is not a condition of warranty. The model and serial number are found on the heater’s rating plate.
Model No.__________________________________ Serial No._________________________________ Date Installed_______________________
Dealer’s Name__________________________________________________________________________________________________________
Dealer’s Address___________________________________________________________________ Phone No.____________________________
City and State/Province_______________________________________________________________Zip/PostalCode________________________
KEEP THIS WARRANTY POSTED ADJACENT TO THE HEATER FOR FUTURE REFERENCE
23
www.americanwaterheater.com
P.O. Box 1597, Johnson City, TN 37605
American Water Heater
Phone: 800-456-9805 • Fax: 800-999-5210
Johnson City, TN 37605
www.americanwaterheater.com
Copyright © 2012 American Water Heater Company. All rights reserved.
24
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