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RESIDENTIAL ULTRA LOW NOx GAS WATER HEATER
• INSTALLATION • OPERATION • SERVICE • MAINTENANCE •
LOW LEAD
CONTENT
CAUTION
TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION
RELATIVE TO YOUR SAFETY. PLEASE READ THOROUGHLY
BEFORE INSTALLING AND USING THIS APPLIANCE.
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER
AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED IN U.S.A. 1112
PART NO. 325321-000
1
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
P
Q
Inches
CM
66 5/8
169.22
58 3/4
149.23
30 15/16
76.99
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
24 7/8
63.2
53 7/8
136.8
TABLE 2, RECOVERY RATINGS ARE BASED ON 80% THERMAL EFFICIENCY
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
GPH
°C
LPH
36
72
80
90
100 108 110 120 126 130 140
243 203 182 145 134 122 104 101
91
81
73
67
66
60
57
56
52
17
44
50
56
60
61
67
70
72
78
20
40
23
50
28
54
30
60
33
70
39
40
920 767 688 549 509 460 392 381 344
306 277 254 251 228 217 213 199
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
120/60
<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.
54) and the National Electric Code (NFPA 70). These publications are
available from The National Fire Protection Association, 1 Batterymarch
Park, Quincy, MA 02269
FOREWORD
The design of these models comply with the current edition of ANSI
Z21.10.3/CSA 4.3 an automatic storage water heater.
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
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.
Abbreviations Found In This Manual:
•
CSA-Canadian Standards Association
•
ANSI-American National Standards Institute
•
NFPA-National Fire Protection Association
•
AHRI-Air Conditioning, Heating and Refrigeration Institute
•
UL-Underwriters Laboratories
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.
This gas-fired water heater is design certified by Underwriters
Laboratories Inc. under American National Standard/CSA Standard for
Gas Wtare Heaters ANSI Z21.10.3•CSA 4.3 (current edition).
The installation must conform with these instructions and the local code
authority having jurisdiction. In the absence of local codes, installations
should comply with the National Fuel Gas Code (ANSI Z223.1/NFPA
2
GENERAL SAFETY
3
TABLE OF CONTENTS
Page
ROUGH-IN DIMENSIONS.............................................................
FOREWORD .................................................................................
GENERAL SAFETY INFORMATION
Precautions ................................................................................
Preparing for the Installation ......................................................
Grounding Instructions...............................................................
Chemical Vapor Corrosion .........................................................
Extended Non-use Periods ........................................................
Insulation Blankets.....................................................................
High Altitude Installations...........................................................
Circulating Pump .......................................................................
INSTALLATION INSTRUCTIONS
Required Ability ..........................................................................
Locating The Heater ..................................................................
Clearances.................................................................................
Hard Water ................................................................................
Air Requirements .......................................................................
Unconfined Space .....................................................................
Confined Space .........................................................................
Venting .......................................................................................
Vent Connection ........................................................................
Thermometers ...........................................................................
Combination Water (Potable) and Space Heating .....................
Mixing Valves .............................................................................
System Connections ..................................................................
Relief Valve ...............................................................................
Page
2
2
Gas Piping ................................................................................ 9
Purging ..................................................................................... 10
Gas Meter Size ......................................................................... 10
Gas Pressure Regulator ........................................................... 10
OPERATION................................................................................. 10
To Operate The Heater ............................................................. 10
Heater Wiring ............................................................................ 11
Lighting Instructions .................................................................. 12
Temperature Regulation ........................................................... 13
Checking Venting ...................................................................... 13
HIgh Temperature Limit Switch ................................................. 13
SERVICE INFORMATION ............................................................ 14-15
Main Burner and Igniter ............................................................ 14
Checking Gas Input .................................................................. 14
Vent System.............................................................................. 14
Blower Maintenance ................................................................. 15
Relief Valve ............................................................................... 15
Hot Water Odor ......................................................................... 15
Winter Protection ...................................................................... 15
Replacement Parts ................................................................... 15
Draining and Flushing ............................................................... 15
CHECKLIST ................................................................................. 15-16
Condensation............................................................................ 16
Anode Rod Inspection .............................................................. 16
Service and Repair ................................................................... 16
TROUBLESHOOTING ................................................................. 17-19
4
4
4
5
5
5
5
6
6
6
6
6
6-7
7
7
7-8
8
8
8
8
9
9
GENERAL SAFETY
INFORMATION
PRECAUTIONS
DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN UNDER
WATER. Immediately call a qualified service technician to inspect the
water heater and to replace any part of the control system and any gas
control which has been under water.
IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO NOT OPERATE
HEATER UNTIL ALL CORRECTIVE STEPS HAVE BEEN MADE BY A
QUALIFIED SERVICEMAN.
1.
2.
3.
4.
EXTERNAL FIRE.
DAMAGE.
FIRING WITHOUT WATER.
SOOTING.
3.
If after reading this manual you have any questions or do not
understand any portion of the instructions, call the local gas utility
or the manufacturer whose name appears on the rating plate.
4.
Carefully plan the place where you are going to put the water heater.
Correct combustion, vent action, and vent pipe installation are
very important in preventing death from possible carbon monoxide
poisoning and fires, see Figures 3 through 8A.
Examine the location to ensure the water heater complies with the
“Locating the New Water Heater” section in this manual.
5.
For California installation this water heater must be braced, anchored,
or strapped to avoid falling or moving during an earthquake. See
instructions for correct installation procedures. Instructions may be
obtained from California Office of the State Architect, 400 P Street,
Sacramento, CA 95814.
6.
Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5.00.
7.
Complies with SCAQMD rule #1146.2 and districts having equivalent
NOx requirements.
Heater must be protected from freezing downdrafts during shutdown periods.
PREPARING FOR THE INSTALLATION
1.
2.
Read the “General Safety” section, page 3 of this manual first and
then the entire manual carefully. If you don’t follow the safety rules,
the water heater will not operate properly. It could cause DEATH,
SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.
This manual contains instructions for the installation, operation, and
maintenance of the gas-fired water heater. It also contains warnings
throughout the manual that you must read and be aware of. All warnings
and all instructions are essential to the proper operation of the water
heater and your safety. Since we cannot put everything on the first few
pages, READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO
INSTALL OR OPERATE THE WATER HEATER.
The installation must conform with these instructions and the local
code authority having jurisdiction. In the absence of local codes,
installations shall comply with the National Fuel Gas Code ANSI
Z223.1/NFPA 54 current addition. This publication is available from
the CSA International, 8501 East Pleasant Valley Rd., Cleveland
Ohio 44131, or The National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02269.
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.
4
CHEMICAL VAPOR CORROSION
HIGH ALTITUDE INSTALLATIONS
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.
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.)
EXTENDED NON-USE PERIODS
WARNING
HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER SYSTEM
SERVED BY THIS HEATER THAT HAS NOT BEEN USED FOR A LONG
PERIOD OF TIME (GENERALLY TWO WEEKS OR MORE). HYDROGEN
GAS IS EXTREMELY FLAMMABLE. To reduce the risk of injury under
these conditions, it is recommended that the hot water faucet be opened
for several minutes at the kitchen sink before using any electrical water
heater 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.
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.
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.
INSULATION BLANKETS
Insulation blankets available to the general public for external use on gas
water heaters are not required for use on this water heater. The purpose
of an insulation blanket is to reduce the standby heat loss encountered
with storage tank water heaters. This 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.
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 manufacturer for
placement on the blanket directly over the existing labels.
•
Do inspect the insulation blanket frequently to make certain it does
not sag, thereby obstructing combustion air flow.
The input reduction is primarily achieved by reducing the size of the main
burner orifices. To do this, the main burner orifices require replacement
with orifices sized for the particular installation elevation. Correct orifice
sizing and parts may be obtained from your distributor or manufacturer.
When ordering, be sure to state the model number and the altitude of
the location where the water heater is being installed.
Upon completion of derating of the heater, adjustment to the gas pressure
regulator may be required. See CHECKING THE GAS INPUT section
in this manual for inlet and manifold pressure requirements.
Also due to the input rating reduction required at high altitudes, the output
rating of the water heater is also reduced and should be compensated
for in the sizing of the equipment for application.
5
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.
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.
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.
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.
Drain pans suitable for these heaters are available from your distributor
or Water Heater Parts Fulfillment, 125 Southeast Parkway, Franklin,
TN 37068.
INSTALLATION INSTRUCTIONS
For appliance installation locations with elevations above 7700 feet
(610 meters), refer to HIGH ALTITUDE INSTALLATIONS section of this
manual for input reduction procedure.
REQUIRED ABILITY
INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES
ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE
FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, ELECTRICAL
AND GAS SUPPLY WORK ARE REQUIRED.
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.
LOCATING THE HEATER
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.
HARD WATER
Where hard water conditions exist, water softening or the threshold type
of water treatment is recommended. This will protect the dishwashers,
coffee urns, water heaters, water piping and other equipment.
See MAINTENANCE section for details of tank cleanout procedure.
AIR REQUIREMENTS
REFER TO THE CURRENT EDITION OF THE "NATIONAL FUEL GAS
CODE ANSI Z223.1/NFPA 54.
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
installed in a carpeted alcove or closet, the entire floor shall be covered
by the panel. Also, see the drain requirements.
KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE
MATERIALS, GASOLINE AND OTHER FLAMMABLES, VAPORS AND
LIQUIDS.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION OR VENTILATING
AIR.
THE WATER SUPPLY PRESSURE SHOULD NOT EXCEED 80 PSI
(551.58 kPa). IF THIS OCCURS, A PRESSURE REDUCING VALVE
WITH A BYPASS SHOULD BE PLACED ON THE SUPPLY TO THE
ENTIRE HOUSE IN ORDER TO MAINTAIN EQUAL HOT AND COLD
WATER PRESSURES.
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
POTENTIAL FIRE HAZARDOUS 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
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.
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.
THE HEATER MUST NOT BE LOCATED IN AN AREA WHERE IT WILL
BE SUBJECT TO FREEZING.
6
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.
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.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATING
AIR. ADEQUATE AIR FOR COMBUSTION AND VENTILATION MUST
BE PROVIDED FOR SAFE OPERATION.
VENTING
UNCONFINED SPACE
WARNING
In buildings of conventional frame, brick, or stone construction,
unconfined spaces may provide adequate air for combustion, ventilation
and draft hood dilution.
THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST BE
FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULATION
OF FLUE GASES. SUCH CONDITIONS CAUSE SOOTING OR RISKS
OF FIRE AND ASPHYXIATION.
If the 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.
This water heater must be protected from freezing downdrafts.
Remove all soot or other obstructions from the chimney that will retard
a free draft.
CONFINED SPACE
Type B venting is recommended with these water heaters.
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).
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 Table.
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
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, AN EXPANSION TANK MUST BE PROVIDED.
FIGURE 2.
7
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.
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.
As water is heated, it expands (thermal expansion). In a closed system, the
volume of water will increase. As the volume of water increases, there will
be a corresponding increase in water pressure due to thermal expansion.
Thermal expansion can cause premature tank failure (leakage). This type
of failure is not covered under the limited warranty. Thermal expansion
can also cause intermittent temperature-pressure relief valve operation:
water discharged from the valve due to excessive pressure build up. The
temperature-pressure relief valve is not intended for the constant relief
of thermal expansion. This condition is not covered under the limited
warranty.
A properly-sized thermal expansion tank should be installed on all closed
systems to control the harmful effects of thermal expansion. Contact a
plumbing service agency or your retail supplier reguarding the installation
of a thermal expansion tank.
MIXING VALVES
FIGURE 3.
VENT CONNECTION
DANGER
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.
Children, the elderly and the physically
or mentally disabled are at highest risk
for scald injury.
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.
Feel water before bathing or showering.
Temperature limiting devices such as
mixing valves must be installed when
required by codes and to ensure safe
temperatures at fixtures.
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.
Water heated to a temperature which will satisfy clothes washing, dish
washing, and other sanitizing needs can scald and cause permanent
injury upon contact. Short repeated heating cycles caused by small hot
water uses can cause temperatures at the point of use to exceed the
water heater’s temperature setting by up to 20°F (11°C).
THERMOMETERS (Not Supplied)
Thermometers should be obtained and field installed as shown in Figure 3.
Thermometers are installed in the system as a means of detecting the
temperature of the outlet water supply.
Some people are more likely to be permanently injured by hot water than
others. These include the elderly, children, the infirm and the physically/
mentally disabled. Table 1 shows the approximate time-to-burn
relationship for normal adult skin. If anyone using hot water provided by
the water heater being installed fits into one of these groups or if there
is a local code or state law requiring a certain water temperature at the
point of use, then special precautions must be taken.
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.
In addition to using lowest possible temperature setting that satisfies demand of
application a Mixing Valve should be installed at water heater (see Figure 3)
or at hot water taps to further reduce system water temperature.
2. These water heaters connot be used in space heating applications
only.
3.
Toxic chemicals, such as those used for boiler treatment, shall
NEVER be introduced into this system.
4.
This unit may NEVER be connected to any existing heating system
or component(s) previously used with a non-potable water heating
appliance.
5.
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.
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Mixing valves are available at plumbing supply stores. Consult a Qualified
Installer or Service Agency. Follow mixing valve manufacturer’s instructions
for installation of the valves.
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).
8
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.
TABLE 4. GAS SUPPLY LINE SIZES (IN INCHES)*
Water Temperature °F
Time for 1st Degree Burns
(Less Severe Burns)
110
116
116
122
131
140
149
154
(normal shower temp.)
(pain threshold)
35 minutes
1 minute
5 seconds
2 seconds
1 second
instantaneous
Time for Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
See SERVICE INFORMATION section for procedure and precautions.
45 minutes
5 minutes
25 seconds
5 seconds
2 seconds
1 seconds
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.
GAS PIPING
Contact your local gas service company to ensure that adequate gas service
is available and to review applicable installation codes for your area.
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)
Size the main gas line in accordance with Table 4. The figures shown
are for straight lengths of pipe at 0.5" W.C. (.125 kPa) 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.
HOT WATER
OUTLET
12” TO 15”
(30-38 cm)
TEMPERED WATER
OUTLET
WARNING
The minimum gas supply pressure for input adjustment is 6.0" W.C.(1.49
kPa) for natural gas.
CHECK
VALVE
COLD
WATER
INLET
SYSTEM CONNECTIONS
THE HEATER IS NOT INTENDED FOR OPERATION AT HIGHER THAN
14" W.C. (3.49 kPa) 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.
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.
IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING FROM
CONTAMINANTS IN THE GAS WAYS. SUCH FOULING MAY CAUSE
IMPROPER OPERATION, FIRE OR EXPLOSION.
RELIEF VALVE
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.
CHECK
VALVE
MIXING
VALVE
TO TANK
INLET
FIGURE 4.
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.
TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS SUPPLY
LINE, A SEDIMENT TRAP MUST BE INCORPORATED IN THE PIPING
(SEE FIG. 5). THE SEDIMENT TRAP MUST BE READILY ACCESSIBLE
AND NOT SUBJECT TO FREEZING CONDITIONS. INSTALL IN
ACCORDANCE WITH RECOMMENDATIONS OF SERVING GAS
SUPPLIERS. REFER TO THE CURRENT EDITION OF THE NATIONAL
FUEL GAS CODE.
ASME ratings cover pressure relief capacities. ANSI ratings cover release
rate with temperature actuation.
In addition to the water heater 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.
To prevent damage, care must be taken not to apply too much torque
when attaching gas supply pipe to gas valve inlet.
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.
WARNING
THE PURPOSE OF RELIEF VALVE IS TO AVOID EXCESSIVE PRESSURE
OR TEMPERATURE INTO THE STEAM RANGE, WHICH MAY CAUSE
SCALDING AT FIXTURES, TANK EXPLOSION, SYSTEM OR HEATER
DAMAGE. NO VALVE IS TO BE PLACED BETWEEN THE RELIEF
VALVE AND TANK.
Your local code authority may have other specific relief valve requirements.
A DRAIN LINE MUST BE CONNECTED TO THE RELIEF VALVE TO
DIRECT DISCHARGE TO A SAFE LOCATION TO AVOID SCALDING OR
WATER DAMAGE. THIS LINE MUST NOT BE REDUCED FROM THE
SIZE OF THE VALVE OUTLET AND MUST NOT CONTAIN VALVES,
9
PURGING
TABLE 5 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"
1"
1 1/4"
1 1/2"
2"
2 1/2"
3"
4"
10
175
360
680
1400
2100
3960
6300
11000 230000
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
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
NORMAL IRON PIPE SIZES (INCHES)
INPUT IN KW
1 1/4"
1 1/2"
3.0
51
1/2" 3/4"
105
199
1"
410
615
1160
2"
1845
2 1/2"
3221
3"
6735
6.1
35
73
142
278
428
805
1277
2255
4626
CAUTION
PURGING SHOULD BE PERFORMED BY PERSONS EXPERIENCED
IN THIS TYPE GAS SERVICE. TO AVOID RISK OF FIRE OR
EXPLOSION, PURGE DISCHARGE MUST NOT ENTER CONFINED
AREAS OR SPACES WHERE IGNITION CAN OCCUR. THE AREA
MUST BE WELL VENTILATED AND ALL SOURCES OF IGNITION MUST
BE INACTIVATED OR REMOVED.
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.
4"
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
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.
FIGURE 5. GAS PIPING AND SEDIMENT TRAP INSTALLATION
The minimum gas supply pressure for input adjustment must not be less
than 6" w.c. (1.49 kPa) for natural gas.
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 6. GAS PRESSURE
Type of
Gas
Input
Manifold Pressure
Natural
75,100 Btu/hr
22 KW/hr
4.0 in. W.C.
1.12 kPa
OPERATION
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.
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 WATER
HEATER NEED NOT BE DISCONNECTED, BUT MUST BE ISOLATED
FROM THE SUPPLY PRESSURE TEST BY CLOSING THE MANUAL GAS
SHUTOFF VALVE.
WARNING
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.
10
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, 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 6. WIRING DIAGRAM AND SCHEMATIC
11
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
VACATION
A
!
2.
C
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
COOLER
and HOTTER
buttons together and
holding for 1 second. Then press the HOTTER
button.
8.
If the appliance will not operate, follow the
instructions "TO TURN OFF GAS TO APPLIANCE"
and call your technician or gas supplier.
9.
WATER TEMPERATURE ADJUSTMENT
HOTTER
COOLER
1.
B
VERY
HOT
WARM
WARNING
STOP! Read the safety information above
on this label.
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.
is approximately 120°F (49°C).
3.
Turn the "ON/OFF" swich on the blower control to the
"OFF" position.
CAUTION: Hotter water increases the risk
of scald injury. Consult the instruction
manual before changing temperatures.
4.
This appliance is equipped with a device which
automatically lights the burner.
DO NOT TRY TO LIGHT THE BURNER BY HAND.
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.
12
TEMPERATURE REGULATION
.
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 through Water Heater Parts Fulfillment, 125 Southeast
Parkway, Franklin, TN 37068.
Water
Temperature
°F (°C)
Time for 1st
Degree Burn
(Less Severe Burns)
Time for Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
110 (43.3)
(normal shower temp.)
116 ( 46.6)
(pain threshold)
116 ( 46.6)
35 minutes
45 minutes
1 minute
5 minutes
131 (55)
5 seconds
25 seconds
140 (60)
2 seconds
5 seconds
122 (50)
149 (65)
154 (67.7)
1 second
2 seconds
instantaneous
1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978)
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
decreases temperature and pressing the "HOTTER" button increases
the temperature
Temperature Setting
Display
ABC
C-Flashing = approx. 160°F (71°C)
C = approx. 150°F (66°C)
B = approx. 140°F (60°C)
A = approx. 130°F (54°C)
= approx. 120°F (49°C)
WARM = approx. 80°F (27°C)
FIGURE 7.
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.
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).
13
CHECKING VENTING
FOR YOUR SAFETY AND SATISFACTORY OPERATION, IT IS
RECOMMENDED THAT THIS HEATER BE CHECKED ONCE A YEAR
BY A COMPETENT SERVICE PERSON.
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
Installation codes and these instructions. Determine that there is
no blockage or restriction, leakage, corrosion and other deficiencies
which could cause an unsafe condition.
3.
4.
5.
6.
7.
USERS OF THIS APPLIANCE SHOULD BE AWARE THAT GAS
COMPONENTS WEAR OUT OVER A PERIOD OF TIME. THE GAS
CARRYING COMPONENTS OF THIS APPLIANCE 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:
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.
BURNER HEAD
ASSEMBLY
BURNER TUBE
ASSEMBLY
Follow the lighting instruction. Place the water heater being
inspected in operation. Adjust thermostat so appliance shall operate
continuously.
H.S.I.
ASSEMBLY
Test for vent system leakage after 5 minutes of main burner
operation.
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.
If improper venting is observed during any of the above tests, the
venting system must be corrected.
FIGURE 8. MAIN BURNER AND IGNITER ASSEMBLY
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.
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.
WARNING
FAILURE TO CORRECT BACK DRAFTS MAY CAUSE AIR
CONTAMINATION AND UNSAFE CONDITIONS.
WARNING
SOOT BUILD-UP INDICATES A PROBLEM THAT REQUIRES
CORRECTION BEFORE FURTHER USE. CONSULT WITH A
QUALIFIED SERVICE TECHNICIAN.
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.
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.
WARNING
CHECKING GAS INPUT
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.
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.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO
SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO
THE APPLIANCE.
TABLE 7
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.
14
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
8.
•
9.
Compare the actual input rate to that given on the heater’s rating plate.
In the example, the full input rate should be 75,100 Btu/h (22 Kw) for
natural gas.
VENT SYSTEM
Examine the venting system every 6 months for obstructions and/or
deterioration of vent piping.
BLOWER MAINTENANCE
For safety and satisfactory operation it is recommended that the blower
be checked once a year by a competent service person.
1.
2.
3.
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.
When deliming has been completed, the heater should be flushed
for 3 to 5 minutes with fresh water.
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 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.
10. Flo-Jug cleanup:
MOTOR - The motor is factory oiled and sealed and requires no
further maintenance.
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.
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.
•
Allow scale to separate from UN•LIME and settle on bottom of
Flo-Jug.
•
Pour off UN•LIME into plastic container and check for reuse.
•
Rinse sediment from Flo-Jug.
DRAINING AND FLUSHING
RELIEF VALVE
It is recommended that the tank be drained and flushed
every 6 months to remove sediment which may build up
during operation. The water heater should be drained if
being shut down during freezing temperatures. To drain the
tank, perform the following steps:
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
1. Turn off the gas to the water heater at the manual gas
shut off valve.
2. Open a nearby hot water faucet until the water is no
longer hot.
3. Close the cold water inlet valve.
4. Connect a hose to the drain valve and terminate it to an
adequate drain or external to the building.
5. Open the water heater drain valve and allow all of the
water to drain from the tank. Flush the tank with water
as needed to remove sediment.
6. Close the drain valve, refill the tank, and restart the
heater as directed in this manual.
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.
WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO
SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO THE
APPLIANCE.
If the water heater heater is going to be shut down for an
extended period, the drain valve should be left open.
HOT WATER ODOR
iMPORTANT: ccondensation may occur when refilling the
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.
tank and should not be confused with a tank leak.
Occasionally water softener companies recommend removal of heater
anodes for odor reasons.
15
WATER HEATER MAKES SOUNDS
CHECKLIST
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.
NOT ENOUGH OR NO HOT WATER
1.
Look for leaking or open hot water faucets. Check for excessive
usage.
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.
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.
2.
Sediment and water scale accumulations may cause rumbling
noises. See MAINTENANCE or contact your dealer for details of
flushing the heater.
3.
If you cannot identify or remedy the condition, contact your dealer.
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.
3.
If the heater was installed when incoming water temperatures were
warm, colder incoming temperatures will create the effect of less
hot water.
4.
The thermostat water temperature adjusting dial may be set too low.
Droplets from the bottom of the flue may be due to corrosive combustion
products or improper vent. Check with your dealer for more information.
5.
If you cannot determine the cause of the problems, contact your
dealer.
ANODE ROD INSPECTION
Each water heater contains at least one anode rod, which will slowly
deplete (due to electrolysis) prolonging the life of the water heater
by protecting the glass-lined tank from corrosion. Adverse water
quality, hotter water temperatures, high hot water useage, and water
softening methods can increase the rate of anode rod depletion. Once
the anode rod is depleted, the tank will start to corrode, eventually
developing a leak.
WATER TEMPERATURE IS TOO HOT
1.
The thermostat water temperature adjusting dial may be set too high.
2.
If lowering control setting does not reduce the water temperature
contact your dealer.
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.
2.
Call your gas company.
Certain water conditions will cause a reaction between the anode
rod and the water. The most common complaint associated with the
anode rod is a "rotten egg smell" produced from the presence of
hydrogen sulfide gas dissolved in the water. IMPORTANT: Do not
remove this rod permanently as it will void any warranties. The parts
list includes a special anode rodthat can be ordered if water odor or
discoloration occurs. NOTE: This rod may reduce but not eliminate
water odor problems.
WATER LEAKAGE IS SUSPECTED
1.
2.
Check to see if the heater drain valve is tightly closed.
The apparent leakage might be condensation. In warm or humid
locations, condensation can accumulate and run from within the
heater or its piping.
•
•
3.
4.
Artificially softened water is exceedingly corrosive because the
process substitutes sodium ions for magnesium and calcium ions. The
use of a water softener may decrease the life of the water heater tank.
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.
The anode rod should be inspected after a maximum of three years
and annually thereafter until the condition of the anode rod dictates its
replacement. NOTE: Artificially softened water requires the anode rod
to be inspected annually.
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.
The following are typical (but not all) signs of a depleted anode rod:
*
The majority of the rods diameter is less than 3/8"
*
Significant sections of the support wire (approx. 1/3 or more of
the anode rods length) are visible.
If the anode rod shows signs of either or both it should be replaced.
NOTE: Whether re-installing or replacing the anode rod, check for any
leaks immediately, correct if found.
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.
In replacing the anode:
1. Turn off gas supply to the water heater.
2. Shut off the water supply and open a nearby hot water faucet to
depressurize the water tank.
3. Drain approximately 5 gallons of water from the tank (Refer to
"Draining and Flushing" for proper procedures). Close drain
valve.
4. Reomve old anode rod.
5. Use Teflon® tape or approved pipe sealant on threads and install
new anode rod.
6. Turn on water supply and open nearby hot water faucet to purge
air from water system. Check for any leaks and immediately
correct any if found.
If you cannot identify or correct the source of water leakage:
•
Close the main shutoff valve in the gas supply pipe at the heater.
See Figure 5, page 9.
•
Close the valve which feeds water to the cold water inlet at the
top of the heater.
•
Contact your dealer.
16
Restart the water heater as directed under "Operating Your Water
Heater." See the repair parts illustration for anode rod location.
TROUBLESHOOTING
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.
For your safety, water heater service should be performed only
by a qualified service technician. Read the GENERAL SAFETY
INFORMATION section first.
Figure 9
WATER HEATING CYCLE
SERVICE AND REPAIR
(GAS AND ELECTRIC POWER ARE ON,“OFF/ON” SWITCH IS
ON)
1) CALLS FOR HEAT
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.
A) THERMOSTAT SENSES NEED FOR HEATING WATER
B) CONTACTS CLOSE IN THERMOSTAT, POWER (115 VAC)
FLOWS TO BLOWER MOTOR
2) BLOWER MOTOR ROTATES BLOWER WHEEL
A) BLOWER WHEEL SPEED INCREASES
B) WHEEL SPEED INCREASES, AIR PRESSURE SWITCH
CONTACTS CLOSE
3) 120 VAC FLOWS TO HOT SURFACE IGNITER
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.
4) MAIN BURNER IGNITES
A) GAS FLOWS TO MAIN BURNER PORTS AND IS IGNITED
5) GAS VALVE SENSES BURNER FLAME
6) BURNER HEATS WATER
A) BURNER HEATS WATER TO THERMOSTAT SETTING
B) CONTACTS IN THERMOSTAT OPEN,
C) CYCLE IS COMPLETED
17
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 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 ANODE ROD)
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.
18
WARNING: DO NOT BY-PASS ANY CONTROLS TO MAKE HEATER OPERATE.
OPERATE ONLY AS WIRED FROM FACTORY.
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.
#
1
LED STATUS
PROBLEM
SOLUTION
The gas control valve/thermostat
has sensed inadequate or no earth
ground.
1 Ensure the wall outlet (power supply) is properly
grounded.
2 Ensure all ground connections/wires on the water
heater are securely connected.
1 Ensure the wall outlet/power supply is properly wired.
2
3
The gas control valve/thermostat
has sensed reversed polarity in the
120 VAC power supply.
Pressure switch circuit remaining
closed for more than 5 seconds
after heating cycle begins.
Blower may not start in this
condition.
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.
1 Ensure air pressure switch circuit wiring is correct and
the air pressure switch is not jumpered.
2 Replace the air pressure switch.
1 Ensure the air pressure switch sensing tube is properly
connected at both ends and is not kinked or damaged.
4
Pressure switch circuit remains
open longer than 5 seconds after
the blower is energized.
Blower may run continuously in
this condition.
2 Ensure the correct size of vent and intake air pipe (direct
vent products) was used per the installation instructions
in the manual that came with the water heater.
3 Ensure maximum number of elbows or maximum
equivalent feet of vent or intake air pipe has not been
exceeded per the installation instructions in the manual
that came with the water heater.
4 Ensure there are no obstructions in the vent or intake air pipe.
1 Check wiring to the hot surface igniter assembly replace igniter assembly if wiring is damaged or worn.
2 Check resistance of the igniter at igniter assembly
plug - should be between 11 and 18 ohms at room
temperature (77° F at plug end) - replace igniter if open
or shorted.
5
The gas control valve/thermostat
has detected an open igniter circuit.
3 Check igniter assembly plug and the socket on the gas
control valve/thermostat for good connection.
4 Replace igniter assembly if the plug is worn or damaged.
5 Replace the gas control valve/thermostat if the igniter
assembly socket on the bottom of the control is worn or
damaged.
1 Ensure flame sensor is making good contact with the
burner flame and ensure flame is steady. Also ensure
supply and manifold gas pressures are within the
requirements in the installation manual.
Ignition/flame failure.
6
The gas control valve/thermostat
has reached the maximum number
of retries (3) for ignition and is
currently locked out for one hour.
Cycle the power to the water heater
off and on to reset.
2 Gas supply is turned off - pressure is too low.
3 Ensure the flame sensor is clean - use fine steel wool
to clean the flame sensor.
4 Check igniter assembly plug and the socket on the
bottom of the gas control valve/thermostat for good
connection. Replace igniter assembly if the plug is worn
or damaged. Replace the gas control valve/thermostat if
socket is worn or damaged.
5 Replace igniter assembly.
19
#
7
8
9
10
11
12
13
14
LED STATUS
PROBLEM
SOLUTION
Self diagnostic check has detected
a problem with the gas valve driver
circuit, internal microprocessor, or
other internal circuits.
The gas control valve/thermostat
has sensed main burner flame out
of proper sequence.
Water temperature in the tank has
exceeded 195° F and has activated
the ECO (energy cut off) high
temperature limit.
Self diagnostic check has detected
that one or both of the temperature
adjust buttons are stuck.
Self diagnostic check has detected
the water temperature sensor
(located in the control valve's
immersion probe) is either open or
shorted.
Self diagnostic check has detected
the FV (flammable vapor) sensor is
either open or shorted.
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 cleared
- replace the gas control valve/thermostat.
1 Turn the power off for 10-20 seconds then on again to
clear these error codes.
2 Replace the gas control valve/thermostat if this error
code persists.
1 Turn the power off for 10-20 seconds then on again to
clear these error codes.
2 Replace the gas control valve/thermostat if the error
code persists.
1 Press and release both temperature adjust buttons
several times - cycle water heater power off and on.
2 Replace the gas control valve/thermostat if the error
code persists.
1 Turn the power off for 10-20 seconds then on again to
clear these error codes.
2 Replace the gas control valve/thermostat if the error
code persists.
1 Turn off power to the water heater. Ensure all FV
sensor wiring, the ignitor assembly plug, and the ignitor
assembly socket on the bottom of the Intellivent control
are making good contact. Repair or replace any
worn/damaged components that are not making good
connection.
2 Replace the FV sensor.
1 Do not touch any electrical switch, do not use any
phone in your building, and do not try to light any
appliance.
15
Self diagnostic check has detected
the presence of flammable vapors
from the FV (flammable vapor)
sensor.
2 Smell around the water heater to ensure there are
no gas leaks at the gas control valve/thermostat, in
the supply gas line(s), or any other type of flammable
vapor(s) in the area.
3 Carefully inspect the area surrounding the water heater
for any substances such as gasoline, paint, paint
thinners, varnish, or cleaners that could emit flammable
vapors. Remove anything that can potentially emit
flammable vapors from the area and store it properly in
a different location.
4 Call the technical information support phone number
shown on the water heater labeling for further
assistance.
16
1 On models equipped with a dilution air intake screen on
The gas control valve/thermostat
the blower assembly - check/clean this screen.
has detected the air pressure switch
circuit is opening repeatedly during 2 On models equipped with a combustion air intake
one heating cycle.
screen on the base ring (bottom) of the water heater check/clean the screen.
LDO (Lint, Dust, and Oil) lockout
condition.
3 Ensure intake air screen(s) on models so equipped are
not obstructed.
20
NOTES
21
NOTES
22
NOTES
23
ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU
ARE UNSUCCESSFUL, CONTACT RESIDENTIAL TECHNICAL ASSISTANCE AT 1-800-527-1953
COPYRIGHT © 2012, INC. ALL RIGHTS RESERVED.
24

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