DOUBLE-WALL
INDIRECT-FIRED
WATER HEATER
A Spanish language version of these instructions is available by contacting the manufacturer
listed on the rating plate.
La version espanola de estas instruccions se puede obtener al escribirle a la fábrica cuyo
nombre aparece in la placa de especificaciones.
INSTALLATION/OPERATING MANUAL
WITH PARTS LISTING AND TROUBLESHOOTING GUIDE
WARNING
To avoid damage or injury, there
must be no materials stored
against the indirect water heater
and proper care shall be taken to
avoid unnecessary contact
(especially by children) with the
indirect water heater.

Do not store or use
gasoline or other
flammable liquids in
the vicinity of this
water heater or any
other appliance.
For your family’s comfort, safety, and convenience, we
recommend this water heater be installed and serviced by
a plumbing professional.
238-45085-00E REV 6/16
CONGRATULATIONS!
You have just purchased one of the finest water heaters
on the market today!
This installation, operation, and instruction manual will
explain in detail the installation and maintenance of your
new Indirect water heater. We strongly recommend that
you contact a plumbing professional for the installation of
this water heater.
We require that you carefully read this manual, as well as
the enclosed warranty, and refer to it if questions arise. If
you have any specific questions concerning your
warranty, please consult the plumbing professional from
whom your water heater was purchased. For your
records we recommend that you write the model, serial
number and installation date of your water heater in the
back of this manual.
This manual should be kept with the water heater.
We’re committed to providing you with the finest water
heater made.
2
CAUTION
The maximum boiler water supply temperature to the indirect
heat exchanger must not exceed 240°F (115°C).
NOTICE
Insulation blankets are not required for this water heater. This
water heater meets or exceeds the ASHRAE/IES 90.1b standards
with respect to insulation and standby loss requirements.
TABLE OF CONTENTS
IIIIIIIVVVIVIIVIIIIXXXI-
IMPORTANT INFORMATION…………….…
SPECIFICATIONS………………………………
GENERAL INFORMATION…………………...
PRE INSTALLATION…………………………..
WATER CONNECTIONS………………………
ELECTRICAL CONNECTIONS………………
OPERATING INSTRUCTIONS………………..
MAINTENANCE………………………………...
TROUBLESHOOTING GUIDE………………..
PARTS LIST……………………………………...
NOTES…………………………………………….
3
4
8
11
14
18
23
26
29
32
34
36
SECTION I
IMPORTANT INFORMATION
-READ CAREFULLYThe equipment must be installed in accordance with those
installation regulations required in the area where the installation
is to be made. These regulations must be carefully followed in all
cases. Authorities having jurisdiction shall be consulted before
installations are made.
All wiring on water heaters installed in the USA must be in
accordance with the National Electrical Code and/or local
regulations; or in Canada, installed in accordance with the
Canadian Electrical Code and/or local regulations.
The following terms are used throughout this manual to bring
attention to the presence of hazards of various risk levels, or to
important information concerning product life.
CAUTION
DANGER
Indicates a potentially
hazardous situation, which,
if not avoided, may result
in moderate, or minor
injury or property damage.
Indicates an imminently
hazardous situation, which,
if not avoided, will result in
death, serious injury, or
substantial property
damage.
NOTICE
WARNING
Indicates special
instructions on installation,
operation or maintenance,
which are important but
not related to personal
injury hazards.
Indicates a potentially
hazardous situation, which,
if not avoided, could result
in death, serious injury, or
substantial property
damage.
4
Important Info continued-
DANGER
DO NOT store or use gasoline or other flammable,
combustible, or corrosive vapors and/or liquids in the vicinity
of this or any other appliance.
IF YOU SMELL GAS:

DO NOT try to light any appliance.

DO NOT touch any electric switch; do not use any
telephone in your building.

Immediately call your gas supplier from a telephone in
another building. Follow the gas supplier’s instructions.

If you cannot reach your gas supplier, call the fire
department
DO NOT OPERATE THE APPLIANCE UNTIL THE
LEAKAGE IS CORRECTED!
Liquefied petroleum gas/propane gas is heavier than air and
will remain at floor level if there is a leak. Basements, crawl
spaces, closets, and areas below ground level will serve as
pockets for accumulation of leaking gas.
This water heater is supplied with an adjustable thermostat to
control water temperature. Hot water temperatures required
for automatic dishwasher and laundry use can cause scald
burns resulting in serious personal injury and/or death. The
temperature at which injury occurs varies with the person’s
age and the time of exposure. The slower response time of
disabled persons increases the hazards to them. NEVER allow
small children to use a hot water tap or to draw their own bath
water. NEVER leave a child or disabled person unattended in
a bathtub or shower.
To comply with NSF requirements this water heater is to be:
a)
Sealed to the floor with sealant, in a smooth and easily
cleanable way, or
b)
Installed with an optional leg kit that includes legs
and/or extensions that provide a minimum clearance of
6” beneath the water heater.
5
Important Info continued-
WARNING
Installation is not complete unless a properly sized/capacity
pressure and temperature relief valve is installed into the side
of the water heater. See the General Information section of this
manual for details.
This water heater contains very hot water under high pressure.
Do not unscrew any pipe fittings or attempt to disconnect any
components of this water heater without positively assuring the
water is cool and has no pressure. Always wear protective
clothing and equipment when installing, starting up, or
servicing this water heater to prevent scald injuries. Do not rely
on the pressure and temperature gauges to determine the
temperature and pressure of the water heater. This water
heater contains components that become very hot. Do not touch
any components unless they are cool.
Improper installation, adjustments, alteration, service or
maintenance can cause property damage, personal injury or
loss of life. Failure to follow all instructions in the proper order
can cause personal injury or death. Read and understand all
instructions, including all those contained in component
manufacturer’s manuals, which are provided with the
appliance before installing, starting-up, operating, maintaining,
or servicing this appliance. Keep this manual and literature in
legible condition and posted near the appliance for reference by
owner and service technician.
This water heater requires regular maintenance and service to
operate safely. Follow the instructions contained in this
manual.
Installation, maintenance, and service must be performed only
by an experienced, skilled, and knowledgeable installer or
service agency.
6
Important Info continued-
WARNING
It is the responsibility of the installing contractor to see that all
controls are correctly installed and are operating properly
when the installation is complete.
DO NOT operate the water heater with jumpered or absent
controls or safety devices.
DO NOT tamper with or alter the water heater and/or controls.
DO NOT operate the water heater if any external part has been
under water. Immediately call a qualified service technician to
inspect the appliance and to replace any part of the control
system that was under water.
This water heater is suitable for installation on combustible
flooring. DO NOT install this water heater on carpeting.
DO NOT operate this water heater without first being certain it
is filled with water.
Flammable items, pressurized containers, or any other potential
fire hazardous articles must never be placed on or adjacent to
the heater. Containers of flammable gases should not be stored
or used in the same room with this water heater.
Hydrogen gas can be produced in an operating water heater
that has not had water drawn from the tank for a long period of
time (generally two weeks or more). Hydrogen gas is extremely
flammable. To prevent the possibility of injury under these
conditions, we recommend that the water faucet be opened for
several minutes at the kitchen sink before you use any electrical
appliance that is connected to the hot water system. If hydrogen
is present, there will be unusual sounds such as air escaping
through the pipes as hot water begins to flow. Do not smoke or
have open flame near the faucet at the time it is open.
7
SECTION II
SPECIFICATIONS
ANODES
COLD WATER OUTLET
3/4” NPT
HOT WATER OUTLET
3/4” NPT
WIRING JUNCTION BOX
TEMPERATURE AND
PRESSURE RELIEF VALVE
FROM BOILER SUPPLY
3/4” NPT
THERMOSTAT UNDER
COVER
TO BOILER RETURN
3/4” NPT
DRAIN COUPLING- 3/4” NPT
DRAIN VALVE – 5/8” NH
Figure 1 – Tank Layout
Table 1: Water Heater Dimension (Inches)
MODEL
40-Gal.
50-Gal.
65-Gal.
80-Gal.
A
B
C
D
E
F
22
22
22
24
41-1/8
46-1/4
59-1/4
59
34-3/8
40-1/8
53-1/8
52-7/8
41-7/8
47
60
59-3/4
5-3/8
5-3/8
5-3/8
5-3/8
27-1/2
27-1/2
27-1/2
27-1/2
8
Specifications continued-
Table 2: Water Heater Capacities
Tank
Coil
Capacity Volume
(Gal)
(Gal)
MODEL
40-Gal.
50-Gal.
65-Gal.
80-Gal.
38
46
60
75
2.5
2.5
2.5
2.5
Dry
Weight
(Lbs)
Wet
Weight
(Lbs)
170
180
196
224
470
547
695
848
Table 3: AHRI Certified Water Heater Ratings
MODEL
40-Gal
50-Gal
65-Gal
80-Gal
First Hour
Rating
(Gal/Hr)
Continuous
Draw
Rating
(Gal/Hr)
Standby
Heat Loss
Rating
(°F/Hr)
Minimum
Output of
Heat Source
(BTU/Hr)
Minimum
Heat Source
Flow Rate
(Gal/Min)
123
133
148
158
98
98
98
98
1.1
0.9
0.7
0.6
65,000
65,000
65,000
65,000
8.0
8.0
8.0
8.0
NOTE: These certified ratings were obtained with a heat source
output and flow rate as specified in Table 3 and a 180°F boiler water
supply temperature. Other results will be obtained under different
conditions.
Table 4: Water Heater Performance
MODEL
40-Gal.
50-Gal.
65-Gal.
80-Gal.
Maximum First
Hour Rating
(Gal/Hr) @
140 °F 115 °F
190
285
200
295
210
305
225
320
Continuous
Draw Rating
(Gal/Min) @
140 °F 115 °F
2.6
4.2
2.6
4.2
2.6
4.2
2.6
4.2
Approximate
Boiler Output
Needed For
Ratings
(BTU/hr)
140,000
140,000
140,000
140,000
NOTE: Based on 200 °F boiler water temperature and 50 °F potable
water inlet temperature.
9
Specifications continued-
Table 5: Water Heater Performance
MODEL
40-Gal.
50-Gal.
65-Gal.
80-Gal.
Hot Water
Coil Heat
Availability Transfer Area
(Minutes)
(Sq Ft)
6.8
14.2
8.6
14.2
10.8
14.2
13.5
14.2
Pressure Drop at
Rated Heat
Source Flow Rate
(Feet of Head)
2.4
2.4
2.4
2.4
NOTICE
If the boiler takes longer to heat up from a cold start
than the water availability as noted above, hot water
shortage may occur.
Hot water availability is based on drawing 80% of the
heated tank volume at 4 gallons per minute flow rate.
The maximum heat transfer through the coil (heat
input) of the water heater at 240°F boiler water supply
temperature and 210°F potable water temperature is
23,500 Btu/hr. Potable water temperature is limited to
below 210 °F and nominal water-containing capacity
is below 120 gallons for all indirect-fired models.
Accordingly, per Part HLW-101.2, Section IV of the
ASME Boiler and Pressure Vessel Code, all indirectfired products listed are exempted from compliance
with the code.
10
SECTION III
GENERAL INFORMATION
FEATURES
This water heater contains the following features:
HEAT EXCHANGER -- The heat exchanger (coil) has 3/4” NPT
female fittings.
Water heaters with a double-wall heat exchanger meet the Uniform
Plumbing Code for installation in all potable water systems. The doublewall construction provides protection in the event that either the potable
or hydronic heat exchanger barrier is penetrated. The fluid will move
along in integrated leak path within the heat exchanger, leaving the
exchanger through a weep hole located in the fittings. If a confirmed leak
occurs, contact the plumbing professional who installed the water heater
or the manufacturer, listed on the rating plate, for additional guidance.
This indirect-fired water heater is appropriate for all potable heating
systems, even where a single-wall exchanger is not approved by the
authority having jurisdiction.
ADJUSTABLE THERMOSTAT – The temperature may be adjusted
from approximately 80°F to approximately160°F. The thermostat is
factory set at 120°F. It is recommended that lower temperatures be used
to avoid the risk of scalding. Refer to the “Warnings” and the section on
SCALDING in “Section VII – Operating Instructions.” It is further
recommended, in all cases, that the water temperature 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 and
minimizes scale formation.
Setting the water heater temperature at 120°F will reduce the risk of
scalds. Some states require settings to specific lower temperatures.
11
General Info continued-
TEMPERATURE AND PRESSURE RELIEF VALVE
WARNING
Keep clear of the combination temperature and pressure relief
valve discharge line outlet. The discharge may be hot enough to
cause scald injury. The water is under pressure and may splash.
For protection against excessive temperatures and pressure, install
temperature and pressure protective equipment required by local
codes, but not less than a combination temperature and pressure
relief valve certified by a nationally recognized testing laboratory
that maintains periodic inspection of production of listed equipment
or materials as meeting the requirements of the Standard for Relief
Valves and Automatic Gas Shutoff Devices for Hot Water Supply
Systems, ANSI Z21.22 and the Standard CAN1-4.4 Temperature,
Pressure, Temperature and Pressure Relief Valves and Vacuum
Relief Valves. The combination temperature and pressure relief
valve must be marked with a maximum set pressure not to exceed
the maximum working pressure of the water heater. The
combination temperature and pressure relief valve must also have
an hourly rated temperature steam BTU discharge capacity not less
than the hourly rating of the water heater. The supplied
combination temperature and pressure relief valve, when properly
installed and unrestricted, will discharge the maximum input
produced by a 240°F (115°C) boiler supply temperature. A lower
boiler supply temperature will reduce the input required to be
discharged in the event of excessive potable water temperatures.
Install the combination temperature and pressure relief valve into
the opening provided and marked for this purpose on the water
heater.
Some models may already be equipped or supplied with a
temperature and pressure relief valve. Verify that the combination
temperature and pressure relief valve complies with local codes. If
the temperature and pressure relief valve does not comply with
local codes, replace it with one that does.
12
General Info continued-
WARNING
Install a discharge line so that water discharged from the
temperature and pressure relief valve will exit within six (6) inches
above, or any distance below, the structural floor and cannot
contact any live electrical part. The discharge line is to be installed
to allow for complete drainage of both the temperature and pressure
relief valve and the discharge line. The discharge opening must not
be subjected to blockage or freezing. DO NOT thread, plug, or cap
the discharge line. It is recommended that a minimum clearance of
four (4) inches be provided on the side of the water heater for
servicing and maintenance of the combination temperature and
pressure relief valve
Do not place a valve between the combination temperature and
pressure relief valve and the tank!
SACRIFICIAL ANODES — Two sacrificial anode rods have been
installed in the tank head to extend tank life. The removal of any anodes,
except for inspection and/or replacement, will nullify the warranty. The
anode rods should be inspected annually to determine the amount of
sacrificial decay and replaced when necessary to prolong tank life. Water
conditions in your area will influence the time interval for inspection and
replacement of the anode rod. The use of a water softener may increase
the speed of anode consumption. More frequent inspection of the anode
is needed when using softened (or phosphate treated) water. Contact the
plumbing professional who installed the water heater or the
manufacturer, listed on the rating plate, for anode replacement
information.
WARNING
This product contains one or more chemicals known to the State of
California to cause cancer, birth defects, or reproductive harm.
13
SECTION IV
PRE-INSTALLATION
UNPACKING
INSPECT SHIPMENT carefully for any signs of damage. If
damage is noted, do not install the product. Contact the shipper or
manufacturer. All equipment is carefully manufactured, inspected,
and packed. Our responsibility ceases upon delivery of the
packaged water heater to the carrier in good condition.
NOTE: Any claims for damage or shortage in shipment must be
filed immediately against the carrier by the consignee.
This water heater MUST be installed indoors out of the wind and
weather.
IMPORTANT DECISIONS REQUIRED BEFORE
INSTALLATION
SIZING
1. Boiler DOE Heating Capacity – The indirect-fired water
heater will provide the rated performance only if used in
conjunction with a heat source with a DOE heating
capacity (Heat Output) at least as much as the minimum
noted in Table 3. If the heat source has less capacity, the
output of the tank will be reduced. To determine the
approximate reduction in output from the tank use the
following formula:
New Rating = (maximum continuous draw rating) x
Actual Output of Heat Source
Minimum Output of Heat Source
For example, what would the continuous draw rating be if a 50gallon indirect-fired water heater were installed with a heat
source having a DOE heating capacity of 55,000 BTU/h?
Answer:
New Rating
= 98 gal/hr x (55,000 BTU/h)/(65,000 BTU/h)
= 98 gal/hr x 0.846 = 83 gal/hr
14
Pre-installation continued-
NOTICE
Increasing the boiler DOE heating capacity above the
values listed in Table 3 will not increase the rating of
the water heater.
2. Circulator Sizing – Refer to Table 5 for the corresponding
pressure drop through the coil for the given model. Calculate
the pressure drop of all straight pipe and fittings on the supply
and return of the water heater at the selected flow rate. Add
the piping/fitting pressure drop to the pressure drop through
the water heater coil.
Select a circulator that will provide an appropriate flow rate at
the combined pressure drop.
SYSTEM ZONE CONTROL
The indirect-fired water heater must be installed as a zone
separate from the space heating system. The domestic hot
water zone’s piping and circulator must be sized for a
minimum flow rate with all zones in use and a maximum flow
rate with only the water heater in use. For this reason, the
preferred method of zone control is with circulators.
1.
2.
3.
Circulators – With space heating zones using
circulators, the indirect-fired heater should be added
as an additional zone with a circulator.
Zone Valves – Select a valve with a low-pressure
drop to assure adequate flow through the water heater.
Hybrid – The space heating zone can be zoned using
zone valves and the indirect-fired heater zoned with a
circulator.
15
Pre-installation continued-
DOMESTIC HOT WATER PRIORITY
Two options are available, Priority and Non-Priority.
1. Priority – Demand for space heating is interrupted or
postponed until the domestic hot water demand is satisfied.
This option provides maximum delivery of domestic hot
water. Priority is recommended when:
a) Boiler net output is 100,000 Btu per hour or less, or
b) When boiler output required to satisfy domestic hot
water demand is at least 50% of the boiler output
required to satisfy space heating demand, or
c) When an interruption in space heating can be tolerated
during a long domestic hot water draw.
2. Non-Priority – Boiler output is divided between space
heating and domestic hot water heating. Delivery of
domestic hot water can be reduced during simultaneous
space and domestic hot water heating operations,
depending on such factors as boiler output, boiler oversizing, number of space heating zones calling for heat, and
the ratio of domestic hot water load to space heating load.
Component Location
CAUTION
This water heater must be located in an area where leakage of the
tank, water line connections, or the temperature and pressure relief
valve will not result in damage to the area adjacent to the water
heater or to lower floors of the structure. When such locations
cannot be avoided, a suitable drain pan must be installed under the
water heater. The drain pan depth must be suitable for draining and
collecting water. The drain pan can be purchased from your
plumbing professional. The drain pan must be piped to an adequate
drain. The piping must be at least ¾ inch in diameter and pitched
for proper drainage.
16
Pre-installation continued-
Clearance from Combustible Materials
Top
0”
Sides
0”
Front
0”
Rear
0”
Table 6 – Combustible Material Clearances
Recommended Service Clearances
Non-Piping
Side
4”
Front
(Thermostat)
16”
Rear
0”
T & P Relief
Valve Side
4”
Table 7 – Service Clearances
CAUTION
Do not drop water heater. Do not bump water heater jacket against
floor.
Appliance Location
1. Boiler Location – Locate the indirect-fired water heater as
close to the boiler as practical.
2. Fixture Locations – For fastest delivery of hot water, place
the indirect-fired water heater close to points of use.
Additional Recommended Components
1. Shut-off Valves – Allows isolation of water heater from
domestic water system and/or boiler system during service.
2. Unions – Allows water heater movement during service if
adequate clearance cannot be provided.
3. Thermal Expansion Tank – If the water heater is installed in
a closed water supply system, such as one having a back-flow
preventer in the cold water line, provide thermal expansion
control. Contact the water supplier or local plumbing inspector
for additional information.
WARNING
Do not plug the inlet and outlet tappings of tankless heater left
installed in the boiler.
17
Pre-installation continued-
MOVE THE WATER HEATER TO A PERMANENT
POSITION BY SLIDING OR WALKING.
NOTICE
For California installation this water heater must be braced,
anchored, or strapped to avoid falling or moving during an
earthquake. See instructions for correct installation procedures.
Instructions may be obtained from California Office of the State
Architect, 400 P Street, Sacramento, CA 95814.
SECTION V
WATER CONNECTIONS
WARNING
FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED
TEMPERATURE AND PRESSURE RELIEF VALVE WILL
RELEASE THE MANUFACTURER FROM ANY CLAIM
WHICH MIGHT RESULT FROM EXCESSIVE
TEMPERATURE AND PRESSURES.
Hydrogen gas can be produced in an operating water heater that
has not had water drawn from the tank for a long period of time.
HYDROGEN GAS IS EXTREMELY FLAMMABLE. To prevent
the possibility of injury under these conditions, we recommend the
hot water faucet be opened for several minutes at the kitchen sink
before you use any electrical appliance that is connected to the hot
water system. If hydrogen is present, there will be an unusual
sound such as air escaping through the pipes as hot water begins to
flow. Do not smoke or have open flame near the faucet at the time
it is open.
Keep clear of the temperature and pressure relief valve discharge
line outlet. The discharge may be hot enough to cause scald injury.
The water is under pressure and may splash.
18
Water Connections continued-
CAUTION
If sweat fittings are to be used, DO NOT apply heat to the nipples
on top of the water heater. Sweat the tubing to the adapter before
fitting the adapter to the water connections. It is imperative that
heat is not applied to the nipples containing a plastic liner.
INSTALL TEMPERATURE AND PRESSURE RELIEF
VALVE (if not factory installed)
WARNING
Temperature and pressure relief valve discharge piping must be
piped near the floor to eliminate potential of severe burns. Do
not pipe in any area where freezing could occur. Do not install
any shut-off valves, plugs or caps to the temperature and
pressure relief valve or piping.
INSTRUCTIONS FOR POTABLE CONNECTIONS
1. BEFORE PROCEEDING WITH THE INSTALLATION,
CLOSE THE MAIN WATER SUPPLY VALVE. After
shutting off the main water supply, open a faucet to relieve the
water line pressure to prevent any water from leaking out of
the pipes while making the water connections to the water
heater. After the pressure has been relieved, close the faucet.
The COLD water inlet and HOT water outlet are identified on
the top of the water heater. Make the proper plumbing
connections between the water heater and the plumbing system
to the house. Install a shut-off valve in the cold water supply
line.
2. If this water heater is installed in a closed water supply system,
such as one having a back-flow preventer in the cold water
supply, provisions must be made to control thermal expansion.
DO NOT operate this water heater in a closed system without
provisions for controlling thermal expansion. Warranties do
not cover damages from thermal expansions such as pressure
bulges and/or deformities. A properly sized expansion tank
will alleviate most problems. Your water supplier or local
19
Water Connections continued
plumbing inspector should be contacted on how to control this
situation.
3. After installation of the water lines, open the main water
supply valve and fill the water heater. While the water heater is
filling, open several hot water faucets to allow air to escape
from the water system. When steady streams of water flow
through the faucets, close them and check all water
connections for possible leaks.
4. NEVER OPERATE THE WATER HEATER WITHOUT
FIRST BEING CERTAIN THAT IT IS FILLED WITH
WATER.
INSTRUCTIONS FOR BOILER CONNECTIONS
The indirect-fired heater connection labeled “To Boiler Return”
should be piped to the boiler return piping as close to the boiler as
possible and especially after any flow control or check valves in
the space heating return piping. The use of a union and a shut-off
valve is recommended. The use of a flow control or check valve is
required to prevent back flow through the water heater during
operation of the space heating system. Pipe and fittings between
the boiler and indirect-fired water heater should be ¾” diameter or
larger.
CAUTION
Maximum boiler water supply temperature to the indirect
heat exchanger must not exceed 240°F (116°C).
CONNECT WATER BOILER SUPPLY PIPING
1. For a space heating system that utilizes ZONE VALVES, refer
to Figure 2. The indirect-fired water heater connection labeled
“FROM BOILER SUPPLY” should be piped to the boiler
supply piping. Mount the circulator making sure the flow arrow
points toward the water heater. The use of shut-off valves and
unions are recommended for future service convenience. The
use of an air separator and vent is recommended to eliminate air
in the system. Pipe and fittings between the boiler and indirectfired water heater must be ¾” diameter or larger.
20
Water Connections continued-
Figure 2 - Water Boiler Piping with Zone Valves
2. For a space heating system that utilizes CIRCULATORS, refer
to Figure 3. The indirect-fired water heater connection labeled
“FROM BOILER SUPPLY” should be piped to the boiler
supply piping. Mount the circulator making sure the flow arrow
points toward the water heater. The use of shut-off valves and
unions are recommended for future service convenience. The
use of an air separator and vent is recommended to eliminate air
in the system. Pipe and fittings between the boiler and indirectfired water heater must be ¾” diameter or larger.
Figure 3 - Water Boiler Piping with Circulators
21
Water Connections continued-
CONNECT STEAM BOILER SUPPLY PIPING
Figure 4 represents a typical steam boiler connection diagram.
Refer to the boiler installation manual or contact the boiler
manufacturer for an appropriate piping diagram. The use of a
union, shut-off valves, and a drain valve is recommended for
future service convenience. The use of an in-line “Y”-style strainer
is required to prevent accumulation of sludge in the water heater’s
coil.
Figure 4 – Typical Steam Boiler Connections (connections available
below the water line)
NOTICE
Typical steam boiler without connections available below the water line
is not recommended due to insufficient water temperature, especially
during warmer months when the space heating system is not
operational. Boiler water temperature at the bottom of a steam boiler
can be 50°F lower than the boiler’s water temperature limit setting
during such periods.
FILL BOILER SYSTEM
1. On new boiler installations, do not purge the boiler or space
heating system through the water heater. During any boiler or
space heating system flushing, cleaning, or purging, the water
heater should be isolated to avoid possible attack on the carbon
steel coil by chemical additives.
2. Purge air from boiler/water heater piping.
3. Check system for leaks. Repair as necessary.
22
SECTION VI
ELECTRICAL CONNECTIONS
Install electric wiring in accordance with National Electric Code or
the Canadian Electrical Code and local regulations. See the
boiler’s installation manual for wiring diagrams.
DANGER
Positively assure all electrical connections are unpowered before
attempting installation or service of electrical components or
connections of the water heater or building. Lock out all electrical
boxes with padlock once power is turned off.
WARNING
When installed, the water heater must be electrically grounded in
accordance with local codes or, in the absence of local codes,
with the National Electrical Code, ANSI/NFPA 70, and /or the
CSA C22.1 Electric Code.
Failure to properly wire electrical connections to the water heater
may result in serious physical harm.
Electrical power may be from more than one source. Make sure
all power is off before attempting any electrical work.
The thermostat incorporates a manual reset temperature-limiting
device. Please refer to the TROUBLESHOOTING GUIDE section
for manual reset operation.
The thermostat incorporates a manual adjustable temperature
indicator to change the potable water temperature. Please refer to
WATER TEMPERATURE ADJUSTMENT in the OPERATING
INSTRUCTIONS section for proper instruction in adjusting water
temperature. Turn off all power related to the boiler and heating
system before proceeding with the electrical connections.
23
Electrical Connections continued-
The thermostat switch is a single pole, single throw device. The
field connections shall be used as a control for one leg of the
electrical circuit. The thermostat switch can be used in the range of
24 to 480 volts with a maximum current load of 15 amps. Any and
all wiring shall be sized and installed to satisfy the voltage and
amperage used. All wiring shall be done in accordance with all
applicable local and state codes.
GENERAL INSTALLATIONS
If a circulator is used to control the heating fluid flow from the
water heater to the boiler, a zone relay is required between the
water heater thermostat and the boiler. Connect the white wire on
the water heater to one leg of the circulator. The second leg of the
circulator is to be connected to “L2” (120V neutral). Connect the
white wire on the water heater to one leg of the zone relay. The
second leg of the zone relay is to be connected to “L2” (120V
neutral). The contact side of the zone relay is to be connected to
the boiler operating control (see figure 5). Connect the black wire
on the water heater to “L1” (120V hot). These connections enable
water heater thermostat to control the circulator, the zone relay,
and the boiler operating control.
Figure 5 – Electrical Connection with Circulator
24
Electrical Connections continued-
If a zone valve to used to control the heating fluid flow from the
boiler to the water heater, a zone step-down transformer is
required between the water heater thermostat and the zone valve.
Connect the white wire on the water heater to one leg of the
transformer primary side. The second leg of the primary side is to
be connected to “L2” (120V neutral). The secondary side of the
transformer is to be connected to the zone valve coil. The contact
side of the zone valve is to be connected to the boiler operating
control. Connect the black wire on the water heater to “L1” (120V
hot) (see figure 6). These connections enable the water heater
thermostat to control the zone valve and the boiler operating
control.
Figure 6 – Electrical Connection with Zone Valve
Other installations may require slightly different wiring
arrangements. In all cases it is important to remember that the
thermostat on the water heater only controls one leg of the system.
25
SECTION VII
OPERATING INSTRUCTIONS
WARNING
Water heaters are heat-producing appliances. To avoid damage
or injury there must be no materials stored against the water
heater, and proper care must be taken to avoid unnecessary
contact (especially by children) with the water heater.
UNDER NO CIRCUMSTANCES SHALL FLAMMABLE
MATERIALS, SUCH AS GASOLINE OR PAINT THINNER
BE USED OR STORED IN THE VICINITY OF THE WATER
HEATER OR IN ANY LOCATION FROM WHICH FUMES
COULD REACH THE WATER HEATER.
Installation or service of this water heater requires ability
equivalent to that of a licensed tradesman in the field
involved. Plumbing and electrical work are required.
SYSTEM START-UP
Follow boiler installation instructions to place boiler in operation.
SEQUENCE OF OPERATIONS
1. Thermostat senses stored water temperature drops below
desired setting.
a. Domestic hot water priority only: Normally closed contacts
open to interrupt space heating.
2. Thermostat satisfied.
a. Thermostat contacts open, turning off domestic hot water
circulator and de-energizing relay.
b. Normally open contacts open, stopping boiler operation.
c. Domestic hot water priority only: Normally closed contacts
close, returning boiler control to space heating.
26
Operating Instructions continued-
WATER TEMPERATURE ADJUSTMENT
WARNING
SCALDING
This water heater can deliver scalding temperature water at any
faucet in the system. Be careful whenever using hot water to avoid
scalding injury. By setting the thermostat on this water heater to
obtain an increased water temperature, you may create the
potential for scald injury. To protect against injury, you should
install an ASSE approved mixing valve (a device to limit the
temperature of water to protect against scald injury via mixing
hot and cold water supply) in the water system. This valve will
reduce point of discharge temperature in branch supply lines.
Such valves are available from the manufacturer of this water
heater or a local plumbing supplier. Please consult with a
plumbing professional.
Table 8 details the approximate relationship of water
temperature and time with regard to scald injury and may be
used as a guide in determining the safest water temperature for
your applications.
APPROXIMATE
TIME/TEMPERATURE
RELATIONSHIPS IN SCALDS
120°F
More than 5 minutes
125°F
1 ½ to 2 minutes
130°F
About 30 seconds
135°F
About 10 seconds
140°F
Less than 5 seconds
145°F
Less than 3 seconds
150°F
About 1 ½ seconds
155°F
About 1 second
Table 8 – Scald Relationships
Figure 7 - Scald Warning
27
Operating Instructions continued-
CAUTION
Before adjusting the thermostat, turn off all power supplied to the
indirect-fired water heater.
The potable water temperature can be changed by adjusting the
thermostat. Before any work is done on the water heater,
disconnect all power to the water heater and heat source (boiler)
by opening the switch(s) at the main electrical circuit breaker or
fuse box. Remove the access panel and fold the insulation outward
away from the control. Adjust the thermostat dial using a
screwdriver until the minimum acceptable temperature is achieved.
The thermostat has been factory preset to 120°F (49°C).
Remember that lower temperature settings are more energy
efficient. Rotate the temperature dial clockwise
to increase
water temperature. Rotate the thermostat dial counter-clockwise
to decrease the temperature setting. Replace the insulation
making sure that the control is well covered and that the plastic
terminal shield has not been displaced. Replace the access panel.
The water heater is now ready for operation and the main switch
can be closed.
Figure 8 – Thermostat
After the indirect-fired water heater completes a heat-up cycle,
check the water temperature at a faucet. Allow enough water to
flow to ensure that the water temperature reflects the tank
temperature. Adjust the water heater’s temperature setting as
necessary.
28
Operating Instructions continued-
Adjusting to a lower temperature setting will not immediately
affect water temperature. Draw sufficient water or allow the water
heater to remain idle until a heat-up cycle is initiated. After the
heater’s heat-up cycle is complete, check the water temperature at
a faucet to determine if further adjustment is necessary.
Adjusting to a higher temperature may not immediately affect
water temperature. If a heat-up cycle begins, allow the heat-up
cycle to complete before checking the water temperature. If a heatup cycle does not begin, draw sufficient water or allow the water
heater to remain idle until a heat-up cycle is initiated. After the
heater’s heat-up cycle is complete, check the water temperature at
a faucet to determine if further adjustment is necessary.
SECTION VIII
MAINTENANCE
This indirect-fired water heater is intended to provide a service life
of many years. Components that require service, however, may be
subject to failure. Failure to use the correct procedures or parts in
these circumstances may make the water heater unsafe.
The owner should arrange to have the following inspections and
simple maintenance procedure performed by qualified service
personnel at the frequencies suggested.
1. Boiler and Domestic Water Piping (Annual) – Check all
piping for signs of leakage at joints, unions, and shut-off
valves. Repair as needed.
2. Temperature-Pressure Relief Valve (Annual)- The
temperature-pressure relief valve should be checked to ensure
that it is in operating condition. To check the relief valve, lift
the lever at the end of the valve several times. The valve
should seat properly and operate freely. If water does not flow,
remove and inspect for obstructions or corrosion. Replace with
a new valve of the recommended capacity as necessary. Do not
attempt to repair the valve, as this could result in improper
operation and a tank explosion. In areas with poor water
conditions, it may be necessary to inspect the temperaturepressure relief valve more often than once a year.
Maintenance continued-
29
CAUTION
Before manually operating the valve, make sure that a
drain line has been attached to the valve to direct the
discharge to an open drain. Failure to take this precaution
could mean contact with extremely hot water discharging
from the valve during this checking operation.
If the temperature–pressure relief valve on the heater discharges
periodically or continuously, it may be due to thermal expansion of
water in a closed water supply system, or it may be due to a faulty
relief valve.
Thermal expansion is the normal response of water when it is
heated. In a closed system, thermal expansion will cause the
system pressure to build until the relief valve actuation pressure is
equaled. Then the relief valve will open, allowing some water to
escape, slightly lowering the pressure. Contact your water supplier
or local plumbing inspector on how to control this situation.
ABOVE ALL, DO NOT PLUG THE TEMPERATURE AND
PRESSURE RELIEF VALVE. THIS IS NOT A SOLUTION
AND CAN CREATE A HAZARDOUS SITUATION.
3. Anode Inspection and Replacement - This water heater is
equipped with multiple sacrificial anodes. Anodes protect the
glass-lined tank from corrosion by sacrificing themselves
through electrolysis. When the anode material is consumed,
there is no more protection and corrosion of the tank
accelerates.
Inspection of the anode every year allows you to identify a
spent anode and replace. Replace the anode when its diameter
is 3/8 of an inch, or every other year, which ever is first.
Aggressive, very hot and softened water causes rapid
consumption of the anode, requiring frequent inspections.
Anodes are available from your distributor or from the
manufacturer.
30
Maintenance continued-
To inspect or replace an anode:
The anodes on this water heater are easily accessible from the top of
the heater making replacement simple and quick.
a. Turn the water heater electricity off for the zone containing
the indirect-fired water heater. Flow water until the
discharge is cool or allow enough time for the potable water
to cool naturally. Connect a hose to the drain valve. Locate
the hose’s discharge in an area where any remaining hot
water will not cause any damage or injury.
b. Open the drain valve to flush any sediment out of the
bottom to the heater.
c. Shut off the cold water supply. Make sure all hot water
fixtures and circulating pumps are turned off.
d. Wait for water flow from the hose to stop. Remove the
anode using a socket of the appropriate size. Do not use an
impact wrench.
e. Inspect and replace the anode as required. Use pipe tape or
sealant when reinstalling the anode.
f. Close the drain valve. Open a hot water fixture to allow air
to escape. Open the cold water supply to the heater and
allow the tank to fill.
g. Check your anode and drain valve for leaks.
h. Turn the water heater electricity on for the zone containing
the indirect-fired water heater.
4. Sediment (Annual, but harsh water quality may dictate more
frequent service)- Depending on water conditions, a varying
amount of sediment may collect in the tank. Levels requiring
service are indicated by a small temperature difference in the
supply and return lines (See also “Scale” below). Repeated
flushing usually clears such material. As a preventive measure,
water should be drawn from the tank at the drain valve until it
runs clear.
5. Scale (Annual)- Hard water may cause scale to build-up on the
outside of the heat exchanger coil. A water softener will prevent
this problem (See also “Sediment” above). Symptoms would be
reduced recovery capacity or reduced temperature differential
between boiler supply and return lines. Repeated flushing should
resolve the problem.
31
SECTION IX
PROBLEM
No hot water at
faucet
TROUBLESHOOTING GUIDE
CAUSE
SOLUTION
Boiler does not
Refer to boiler installation
operate
instructions
Check main service switch
Check fused disconnect
Circulator does not
Check power supply
operate
Replace as necessary
Temperature high
Determine reason for trip.
limit on thermostat
Depress red “RESET”
tripped
button on thermostat
Improper thermostat
setting or calibration
Zone valve does not
open (if used)
Electrical problem
(relay, wiring, etc.)
Scale build-up
Water at faucet
too hot
Clogged cold water
filter or boiler supply
strainer (if used)
Thermostat set too
high
Improper system
plumbing
Improper system
wiring
32
Adjust tank thermostat to
appropriate setting.
See Section VII
Check power supply
Replace as necessary
Check fuse and replace
Check circuit breaker and
reset (if applicable)
Check power supply
If boiler, circulator, and tank
are operating satisfactorily,
coil may have scale coating.
See Section VIII:
Maintenance
Clean or replace filter or
strainer
Adjust thermostat setting.
See Section VII
Compare plumbing to
Section V
Compare wiring to Section
VI
Trouble Shooting Guide continued-
PROBLEM
Insufficient hot
water
Boiler cycles
more than 5
times per day in
summer
CAUSE
Thermostat setting
too low
Undersized boiler
with no priority to
domestic hot water
Peak use of hot
water is greater than
tank storage
capacity
Faulty tank
thermostat
Excessive demand
Faulty thermostat
Boiler high limit set
too low
33
SOLUTION
Adjust thermostat to higher
setting. See Section VII
Rewire for priority
Determine peak usage and
compare to tank capacity
Replace thermostat
Reduce demand or consider
larger tank
Replace thermostat
Increase boiler high limit
setting
SECTION X
PARTS LIST
PART NAME & DESCRIPTION
1. Electrical Outlet Cover
2. Conduit Grounding Cover
3. Outlet Anode Device
4. Hole Closure
5. Hex Head Anode
6. Inlet Diptube
7. Escutcheon
8. T&P Relief Valve
9. Heat Exchanger Escutcheon
10. Thermostat Bracket
11. Access Cover
12. Drain Valve
13. Thermostat Protector
14. Thermostat
34
Contact your supplier or plumbing professional for replacement
parts or contact the company at the address given on the rating
plate of the water heater.
Provide the part name, model, and serial numbers of the water
heater when ordering parts.
READ THE WARRANTY FOR A FULL EXPLANATION OF THE
LENGTH OF TIME THAT PARTS AND THE WATER HEATER ARE
WARRANTED.
Manufactured under one or more of the following U.S. Patents: 5,277,171;
5,341,770; 5,372,185; 5,485,879; 5,574,822; 5,596,952; 5,660,165; 5,682,666;
5,761,379; 5,943,984; 5,954,492; 5,988,117; 6,056,542; 6,142,216; 6,442,178;
6,684,821; 6,935,280; 7,063,132; 7,063,133; 7,007,748; 7,270,087; 7,334,419;
7,337,517; 7,409,925; 7,458,341; 7,559,293; 7,621,238; 7,634,976; 7,650,859;
7,665,210; 7,665,211; 7,699,026; 7,866,168; 7,900,589; 7,971,560; 7,992,526
8,082,888; 8,146,772; Other U.S. and Foreign patent applications pending.
Current Canadian Patents: 2,092,105; 2,107,012; 2,108,186; 2,112,515; 2,143,031;
2,239,007; 2,262,174; 2,314,845; 2,409,271; 2,476,685; 2,504,824; 2,548,958
Complete the following information and retain for future reference:
Model No:
Serial No:
Service Phone
Days: Nights:
Address:
Supplier:
Supplier Phone No:
35
NOTES
36
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