Tankless Non-Condensing Concentric Vent Gas Conversion Instructions (100267297)

Tankless Non-Condensing Concentric Vent Gas Conversion Instructions (100267297)
Gas Conversion-110C,310C,510C
1W5220
100267297
This water heater is configured for Natural Gas from the factory. However, if a field conversion to Propane Gas is
necessary, the conversion kit supplied with the water heater must be used and installed by a qualified service agency*.
Before you install the components in this Propane Gas conversion kit, verify the type of gas that will be used to fuel the
unit. An improper field conversion could cause potentially dangerous conditions that may cause an explosion or
fire resulting in property damage, bodily injury or both.
• This conversion kit shall be installed by a qualified service agency* or a gas utility service technician in
accordance with Manufacturer’s written instructions and all applicable codes and requirements of the
authority having jurisdiction. The information in these instructions must be followed to minimize the risk
of fire or explosion or to prevent property damage, personal injury or death. The qualified service agency*
is responsible for the proper installation of this kit. The installation is not proper and complete until
WARNING the operation of the converted appliance is checked as specified in the manufacturer’s instructions
suppied with the kit.
• If your water heater has been converted to use a different gas type in the past, the manufacturer
does NOT recommend converting it again.
• IN CANADA, THE CONVERSION SHALL BE CARRIED OUT IN ACCORDANCE WITH THE REQUIREMENTS
OF THE PROVINCIAL AUTHORITIES HAVING JURISDICTION AND IN ACCORDANCE WITH THE
REQUIREMENTS OF THE CSA-B149.1, NATURAL GAS AND PROPANE INSTALLATION CODE.
Ensure that each manifold nozzle
includes a gasket prior to installation.
10. Install each LP Gas Manifold Nozzle as shown in Figure 3.
NOTE: The parts are keyed and cannot be installed incorrectly.
11. After making sure that the manifold nozzles are secure, install the Small LP Gas
manifold cover using the 20 screws that were removed during step Manifold Nozzles
5. See Figure 1.
LP Gas Manifold Nozzles
Qty: 2 Small / 1 Large
Manifold gasket
12. Set the Dip switches on the PCB to the correct position for propane. See the figures below for the proper propane
DIP switch settings.
Qty: 1
Part No. : 319143-581
Qty: 1
Before servicing the water heater, make sure that electrical power and gas service to the
water heater is turned OFF. Failure to do so may result in bodily injury, death, or property
WARNING damage.
Procedure:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Turn off power supply.
Turn off both gas and water valves to the water heater.
Remove the front cover.
Once the front cover is removed, place it in a safe location to prevent accidental Remove
the 20 screws.
damage. With the internal components exposed, locate the gas manifold near
the center of the unit.
Use a Phillips screwdriver to remove the 20 screws on the manifold plate
shown in Figure 1.
Figure 1
Remove the manifold plate. (Figure 2)
Remove the manifold gasket from the manifold plate. Discard it.
Install the new manifold gasket onto the manifold plate. Ensure that the gasket
is not compromised in any way. If it is, do not install the gasket. Replace it
with a new one. (Part number: 319143-581)
Refer to Figure 3 and identify the proper location for each LP Gas Manifold
Nozzle. The nozzle attachments are of two types: One small and one large. The
smaller nozzle attachments are for the left two sections and the larger one is for
the right section.
Figure 2
510C
110C / 310C
<Upper bank of
DIP switches>
Gas type
Gas type
Propane
Gas Conversion Label
Figure 3
Hand tighten the screws. Do not overtighten as this may damage or crack the components.
Do not use a powered screwdriver.
* A qualified service agency is any individual, firm, corporation or company which either in person or through a
representative is engaged in and is responsible for the connection, utilization, repair or servicing of gas utilization
equipment or accessories; who is experienced in such work, familiar with all precautions required, and has
complied with all of the requirements of the authority having jurisdiction.
Tools Required:
• Phillips Screwdriver / Manometer / Gas Leak Detector
Included Items: 319143-580
Large LP Gas
Manifold Nozzle
ON
1 2 3 4 5 6 7 8 9 10
Propane
OFF
Change to the above position.
(No.1 SW : ON No.2 SW : OFF)
WARNING
ON
1 2 3 4 5 6 7 8
OFF
•
•
•
DIP switches
Change to the above position.
(No.1 SW : ON No.2 SW : OFF)
Upper bank of
DIP Switches
Turn off the power before changing the DIP switch settings.
Only change the DIP switches specified above for the conversion to propane.
Failure to properly set the DIP switches could cause carbon monoxide
poisoning, resulting in severe personal injury or death.
13. Verify that the gas supply pressure is within an acceptable range. For instructions, see “Gas Supply and Gas Pipe
Sizing for Propane” on the reverse side of this instruction sheet.
14. Turn power ON and turn on the gas supply.
15. Check for gas leaks around the manifold plate as fol-
Gas Conversion Label
This water heater was converted on
/
/
(day-month-year)
to Propane gas with kit No. 319143-580
by
lows:
a. Turn on a nearby hot water faucet.
b. Check for gas leaks by running a gas leak detector
along the edges of the manifold plate. If you find a
leak, do not proceed. Replace the manifold gasket
with a new one. (Part number: 319143-581)
16. Turn the water supply off.
Rating
17. After the water heater has completed its post-purge
Plate
process, turn off the gas supply and turn off power to
the water heater
18. Check the manifold pressures as described on the
reverse side of this instruction sheet.
19. Install the front cover with three screws.
20. Fill out all items on the gas conversion sticker with a
permanent marker. Affix the label on the heater as
shown in Figure 4.
Figure 4
21. Restart the water heater according to the Installation
Manual and Owner’s Guide. Verify proper operation before returning the water heater to service.
(name and address of organization making this conversion, who accepts the responsibility for the correctness
of this conversion).
Ce chauffe-eau a été converti le
/
/
(année-mois-jour)
pour le gaz propane avec le kit n ° 319143-580
par
(nom et adresse de l’organisme qui a effectué la
conversion), qui accepte l’entière responsabilité de la
qualité de la conversion.
110C
310C
510C
Model
(AT-KJr3U-CV) (AT-K5U-CV) (AT-D3U-CV)
Inlet Gas Pressure
Pression de gaz d’entrée
Min. 8.0” W.C. (1.99 kPa)
Max. 14.0” W.C. (3.48 kPa)
Min.
Manifold Gas inches WC
Pressure
(pouces c.e.)
Pression de
Max.
gaz du
inches WC
collecteur (pouces c.e.)
BTU Input
Entrée BTU
0.56
0.55
1.8
3.5
0.51
3.7
Max.
BTU/h
15,000
15,000
15,000
Min.
BTU/h
140,000
190,000
199,000
Affix the label on the front cover in a conspicuous
location as close as possible to the rating plate on
the side case.
Collez l’étiquette sur la couverture dans un endroit
bien en vue le plus près possible de la plaque signalétique sur le boîtier de côté.
1W5240
(continued overleaf)
Adjusting the manifold pressure can cause unexpected combustion conditions during operation,
which can cause a health hazard, damage the water heater, and/or shorten its lifespan.
Therefore, the manifold pressure must only be changed by a qualified service agency or a gas
WARNING utility service technician in accordance with Manufacturer’s written instructions and all applicable
codes and requirements of the authority having jurisdiction.
• The minimum and maximum inlet gas pressures for propane are:
Checking maximum and minimum manifold pressure
i. Ensure that the water heater is not in operation.
ii. Remove the screw off the manifold port of the water heater. (Fig.A)
iii. Connect a manometer to the manifold port using a silicon tube (Fig. B). Ensure that this connection is secure enough to
prevent a gas leak.
iv. Turn on power supply to the water heater.
v. Turn on both gas and water valves to the water heater.
vi. Turn on hot water fixtures to produce a high flow. If an isolation valve is installed, hook up a water hose to the hot outlet
and run water at maximum rate.
vii. Verify the MAX and MIN settings as follows:
a. Press and hold the”MAX” button on the computer board. (See Figure C.)
b. Compare the reading on the manometer to the values in the table below. If it does not fall within the acceptable
range, refer to “Adjusting maximum manifold pressure.”
c. Press and hold the “MIN” button on the computer board. (See Figure C.)
d. Compare the reading on the manometer to the values in the table below. If it does not fall within the acceptable
range, refer to “Adjusting minimum manifold pressure.”
Adjusting maximum manifold pressure
•
GAS SUPPLY AND GAS PIPE SIZING FOR PROPANE
WARNING
Press and hold down the “MAX” button on the computer board. While holding down the “MAX” button, press either the
“Increase” or “Decrease” button to increase or decrease the manifold gas pressure, respectively (Fig. C). Do not push the
increase or decrease button for more than two seconds at a time. Refer to the manometer to verify that pressure has
been set to the desired value.
Adjusting minimum manifold pressure
Press and hold down the “MIN” button on the computer board. While holding down the “MIN” button, press either the
“Increase” or “Decrease” button to increase or decrease the manifold gas pressure, respectively (Fig. C). Do not push the
increase or decrease button for more than two seconds at a time. Refer to the manometer to verify that pressure has
been set to the desired value.
viii. After gas pressure has been set, turn off the power supply and turn off both gas and water valves. Next, remove the
manometer tube, and replace the port screw securely. If the screw isn’t fastened securely at this time, it may cause a gas leak.
•
Fig. A
Fig. C
Fig. B
MAX. button
MIN. button
Increase button
Decrease button
110C / 310C computer board
Computer
board
Silicone
Tube
Computer
board
Manifold port
Models for Propane
Manifold Pressure
Inch
W.C.
(Pa)
BTU Input
BTU/h
Increase button
To manometer
Decrease button
110C
Max.
1.5 to 1.8
(374 to 448)
0.44 to 0.56
(110 to 139)
140,000
Min.
15,000
Max.
Min.
MIN. button
MAX. button
310C
Max.
2.7 to 3.5
(673 to 872)
0.44 to 0.56
(110 to 139)
190,000
Min.
15,000
Max.
Min.
510C
Max.
2.9 to 3.7
(722 to 922)
0.44 to 0.56
(110 to 139)
199,000
Min.
15,000
Max.
Min.
Inlet gas pressure
Propane
Min. 8.0” W.C. (1.99 kPa) – Max. 14.0” W.C. (3.48 kPa)
• Size the gas pipe to supply the necessary volume of gas for the water heater.
Refer to and follow the requirements listed in the current edition of ANSI Z223.1/
NFPA 54 (USA), CAN/CSA B149.1 (Canada), or local codes. Otherwise, flow capabilities
and output temperatures will be limited.
• When the gas connections are completed, it is necessary to perform a gas leak test
either by applying soapy water to all gas fittings and observing for bubbles or by using
a gas leak detection device.
i. The water heater and its individual shutoff valve must be disconnected from
the gas supply piping system during any pressure testing of that system at test
pressures in excess of 1/2 psi (3.5 kPa).
ii. The water heater must be isolated from the gas supply piping system by closing
its individual manual shutoff valve during any pressure testing of the gas supply
piping system at test pressures equal to or less than 1/2 psi (3.5 kPa).
• Regarding high altitude installation after gas conversion, refer to the section of “HIGH
ALTITUDE INSTALLATIONS” in the installation manual. (P. 12)
-Propane (LP) Supply Piping-
Maximum Capacity of Propane (LP) Based on 11" W.C. supply pressure at a 0.5" W.C. pressure drop
Unit: kBTU per hour
Pipe Size
Length
Diameter
20'
30'
40'
50'
60'
70'
80'
90'
100'
125'
150'
200'
10'
(3.0m) (6.1m) (9.1m) (12.2m) (15.2m) (18.3m) (21.3m) (24.4m) (27.4m) (30.5m) (38.1m) (45.7m) (61.0m)
1/2"
268
184
148
126
112
101
93
87
82
77
68
62
53
3/4"
567
393
315
267
237
217
196
185
173
162
146
132
112
1"
1,071
732
590
504
448
409
378
346
322
307
275
252
213
913
834
771
724
677
630
567
511
440
976
866
787
675
1 1/4"
2,205 1,496 1,212 1,039
1 1/2"
3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023
2"
510C computer board
Gas type
6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496 1,260
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