Titan® Power Gas Burner Manual (195091)

Titan® Power Gas Burner Manual (195091)
Instruction Manual
commercial gas water heaters
MODELS GPG 81-140 Thru 81-370
SERIES 104/105
INSTALLATION - OPERATION - SERVICE
- MAINTENANCE - LIMITED WARRANTY
500 Tennessee Waltz Parkway
Ashland City, TN 37015
Low Lead Content
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch;
not use any phone in your building.
do
• Immediately
call your gas supplier
from a neighbor’s phone. Follow the
gas supplier’s instructions.
• If you cannot
reach your gas supplier,
call the fire department.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
Thank you for buying this energy efficient water heater.
We appreciate your confidence in our products.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
place these instructions adjacent to heater and notify owner to keep for future reference.
PRINTED 0313
195091-002
Table Of Contents
Safe Installation, Use and Service���������������������������������������� 3
Air From Other Indoor Spaces�������������������������������������������������������� 18
Approvals������������������������������������������������������������������������������������������ 3
Vent Connection������������������������������������������������������������������������������ 19
General Safety Information�������������������������������������������������4-5
Water Heater Installation�������������������������������������������������19-22
Precautions��������������������������������������������������������������������������������������� 5
Water Line Connections������������������������������������������������������������������ 19
Grounding Instructions���������������������������������������������������������������������� 5
T&P Valve Discharge Pipe�������������������������������������������������������������� 19
Hydrogen Gas Flammable���������������������������������������������������������������� 5
Installation Diagrams - Top Inlet/Outlet Usage������������������������������� 20
Introduction����������������������������������������������������������������������������������� 6
Burner Installation��������������������������������������������������������������������������� 20
Abbreviations Used��������������������������������������������������������������������������� 6
Heater Wiring���������������������������������������������������������������������������������� 21
Qualifications������������������������������������������������������������������������������������ 6
Gas Piping��������������������������������������������������������������������������������������� 22
Start Up Requirements��������������������������������������������������������������������� 6
Gas Line Leak Testing�������������������������������������������������������������������� 22
Preparing for the Installation������������������������������������������������������������� 6
Purging�������������������������������������������������������������������������������������������� 22
Features And Components�������������������������������������������������������� 7
Startup and OPERATION������������������������������������������������������������� 23
High Limit Switch������������������������������������������������������������������������������� 7
Prior to Start Up������������������������������������������������������������������������������ 23
Electronic Ignition Control����������������������������������������������������������������� 7
Sequence of operation�������������������������������������������������������23-27
Barometric Draft Control������������������������������������������������������������������� 7
Sequence of Operation Flow Chart������������������������������������������������ 24
Combustion Chamber Observation Port������������������������������������������ 7
Lighting & Operation Label������������������������������������������������������������� 25
Uncrating������������������������������������������������������������������������������������������� 7
Adjustments������������������������������������������������������������������������������������ 26
Installation Considerations����������������������������������������������� 8-12
Checking Venting���������������������������������������������������������������������������� 26
Rough In Dimensions������������������������������������������������������������������������ 8
Checking the Input�������������������������������������������������������������������������� 26
Locating The Water Heater������������������������������������������������������������� 10
Setting Burner Operation���������������������������������������������������������������� 27
Clearances�������������������������������������������������������������������������������������� 10
maintenance������������������������������������������������������������������������������28-32
Insulation Blanket�����������������������������������������������������������������������������11
Venting System and Barometric Draft Control������������������������������� 28
Hard Water���������������������������������������������������������������������������������������11
General�������������������������������������������������������������������������������������������� 28
Circulation Pumps�����������������������������������������������������������������������11-12
Remote Storage Tank Temperature Control����������������������������������� 28
High Altitude Installations................................................................ 12
Temperature-Pressure Relief Valve Test���������������������������������������� 28
Installation Requirements������������������������������������������������ 13-16
Anode Rod Inspection�������������������������������������������������������������������� 29
Gas Supply Systems........................................................................ 13
Draining and Flushing��������������������������������������������������������������������� 29
Supply Gas Regulator��������������������������������������������������������������������� 13
Recommended Procedure for Periodic Removal or Lime Deposits
from the Tank Type Commercial Water Heaters���������������������������� 29
Power Supply���������������������������������������������������������������������������������� 13
Water Temperature Control and Mixing Valves������������������������������ 13
DeLiming Solvents�������������������������������������������������������������������������� 30
Dishwashing Machines������������������������������������������������������������������� 14
Tank Cleanout Procedure��������������������������������������������������������������� 30
Closed Water Systems�������������������������������������������������������������������� 14
Deliming Using Flo-Jug Method.................................................30-31
Thermal Expansion������������������������������������������������������������������������� 14
Power Burner.............................................................................. 31-32
Temperature-Pressure Relief Valve������������������������������������������ 14-15
Gas Control Valve............................................................................ 32
Contaminated Air���������������������������������������������������������������������������� 15
service��������������������������������������������������������������������������������������������� 32
Air Requirements���������������������������������������������������������������������������� 15
Electrical Servicing������������������������������������������������������������������������� 32
Unconfined Space��������������������������������������������������������������������������� 16
Troubleshooting checklist��������������������������������������������������� 33
Confined Space������������������������������������������������������������������������������� 16
Venting Installation������������������������������������������������������������� 16-19
For your information���������������������������������������������������������������� 34
Venting�������������������������������������������������������������������������������������������� 16
Start up Conditions������������������������������������������������������������������������� 34
Barometric Draft Control Assembly������������������������������������������������ 16
Operational Conditions������������������������������������������������������������������� 34
Fresh Air Opening for Confined Spaces����������������������������������������� 17
Water Piping Diagrams����������������������������������������������������������35-49
Outdoor Air Through Two Openings����������������������������������������������� 17
MANIFOLD KITS��������������������������������������������������������������������������������� 50
Outdoor Air Through One Opening������������������������������������������������ 17
replacement parts list������������������������������������������������������� 51-52
Outdoor Air Through Two Horizontal Ducts������������������������������������ 17
Notes.............................................................................................53-54
Outdoor Air Through Two Vertical Ducts���������������������������������������� 18
Warranty���������������������������������������������������������������������������������������� 55
2
Safe Installation, Use and Service
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and
how to avoid the risk of injury.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances
known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of
potential exposure to such substances.
WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive
harm. This appliance can cause low level exposure to some of the substances listed in the Act.
APPROVALS
Low Lead Content
Note: ASME construction is optional on the water heaters covered in this manual.
3
General Safety Information
Fire or Explosion Hazard
Fire Hazard
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
For continued protection against
risk of fire:
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas
pressure.
Do not install water heater on
carpeted floor.
Do not operate water heater if
flood damaged.
Use only the gas shown on the water heater rating label.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended
periods of non-use.
Fire and Explosion Hazard
Use joint compound or Teflon tape
compatible with propane gas.
Read instruction manual before
installing, using or servicing
water heater.
Leak test before placing the
water heater in operation.
Disconnect gas piping and main
gas shutoff valve before leak
testing.
Install sediment trap in
accordance with NFPA 54.
Fire and Explosion Hazard
Do not use water heater with any gas
other than the gas shown on the rating
label.
Excessive gas pressure to gas valve can
cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
CAUTION
Property Damage Hazard
• All water heaters eventually leak.
Jumping out control circuits or components can
result in property damage, personal injury or death.
• Do not install without adequate drainage.
•
•
Electrical Shock Hazard
•
Turn off power to the water heater
before performing any service.
•
Label all wires prior to disconnecting
when performing service. Wiring errors
can cause improper and dangerous
operation.
•
•
Verify proper operation after servicing.
•
Service should only be performed by a qualified service
agent using proper test equipment.
Altering the water heater controls and/or wiring in any way
could result in permanent damage to the controls or water
heater and is not covered under the limited warranty.
Altering the water heater controls and/or wiring in any way
could result in altering the ignition sequence allowing gas to
flow to the main burner before the hot surface igniter is at
ignition temperature causing delayed ignition which can
cause a fire or explosion.
Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the water heater warranty.
Failure to follow these instructions can
result in personal injury or death.
4
General Safety Information
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Explosion Hazard
Overheated water can cause
water tank explosion.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
This manual must remain with the
water heater.
CAUTION
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Improper installation, use and service may result
in property damage.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
•
•
•
•
•
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.
Do not operate water heater if flood damaged.
Inspect anode rods regularly, replace if damaged.
Install in location with drainage.
Fill tank with water before operation.
Properly sized thermal expansion tanks are required on all
closed water systems.
Refer to this manual for installation and service.
Verify the power to the water heater is turned off before performing any service procedures.
General Safety Information
Precautions
Hydrogen Gas Flammable
DO NOT USE THIS water heater IF ANY PART HAS BEEN
UNDER WATER. Immediately call a qualified service agency
to inspect the water heater and to make a determination on
what steps should be taken next.
Explosion Hazard
If the unit is exposed to the following, do not operate heater
until all corrective steps have been made by a qualified
service agency.
Flammable hydrogen gases
may be present.
1. External fire.
Keep all ignition sources away
from faucet when turning on
hot water.
2. Damage.
3. Firing without water.
Hydrogen gas can be produced in a hot water system served
by this water 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 a hot water faucet served by this water
heater be opened for several minutes before using any electrical
appliance connected to the hot water system. If hydrogen is
present there will probably be an unusual sound such as air
escaping through the pipe as the water begins to flow. There
should be no smoking or open flame near the
faucet at the time it is open.
GROUNDING INSTRUCTIONS
This water heater must be grounded in accordance with the
National Electrical Code and/or local codes. These must be
followed in all cases.
This water heater must be connected to a grounded, 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 19.
5
Introduction
Thank You for purchasing this water heater. Properly installed
and maintained, it should give you years of trouble free service.
Abbreviations Used
Warranty on this product is limited and could be void in the
event the unit is not installed per the instructions in this manual
and/or not started up by an authorized factory trained service/
start-up provider.
Abbreviations found in this Instruction Manual include :
Preparing For The Installation
•
•
•
•
•
•
•
ANSI - American National Standards Institute
ASME - American Society of Mechanical Engineers
AHRI - Air-Conditioning, Heating and Refrigeration Institute
NEC - National Electrical Code
NFPA - National Fire Protection Association
UL - Underwriters Laboratory
CSA - Canadian Standards Association
1.Read the “General Safety” section, page 4-5 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.
Qualifications
Qualified Installer or Service Agency
Installation and service of this water heater requires ability
equivalent to that of a Qualified Agency (as defined by ANSI
below) in the field involved. Installation skills such as plumbing,
air supply, venting, gas supply and electrical supply are required
in addition to electrical testing skills when performing service.
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.
2. The installation must conform with these instructions and the
local code authority having jurisdiction. In the absence of local
codes, the installation must comply with the current editions
of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or CAN/
CSA-B149.1 the Natural Gas and Propane Installation Code.
All documents are available from the Canadian Standards
Association, 8501 East Pleasant Valley Road, Cleveland, OH
44131. NFPA documents are also available from the National
Fire Protection Association, 1 Batterymarch Park, Quincy, MA
02269.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualified Agency” - “Any
individual, firm, corporation or company that either in person or
through a representative is engaged in and is responsible for (a)
the installation, testing or replacement of gas piping or (b) the
connection, installation, testing, repair or servicing of appliances
and equipment; that is experienced in such work; that is familiar
with all precautions required; and that has complied with all the
requirements of the authority having jurisdiction.”
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.
If you are not qualified (as defined by ANSI above) and licensed
or certified as required by the authority having jurisdiction
to perform a given task do not attempt to perform any of the
procedures described in this manual. If you do not understand
the instructions given in this manual do not attempt to perform
any procedures outlined in this manual.
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.
START UP REQUIREMENTS
Examine the location to ensure the water heater complies with
the “Locating the New Water Heater” section in this manual.
This product requires a formal Start-Up by an authorized
service/
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.
start-up provider that has been approved by the manufacturer
for this specific product. Call 1-800-527-1953 to locate the
nearest authorized start-up provider and arrange a factory
start-up. Please provide as much notice as possible, preferably
2 weeks. Please have the model and serial number ready when
you call.
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.
This start-up is required to activate the warranty and ensure
safe, efficient operation.
6
FEATURES AND COMPONENTS
high limit switch
BAROMETRIC DRAFT CONTROL
The dual bulb controller (fig. 1) contains the high limit (energy cutoff)
sensor. The high limit switch interrupts main burner gas flow should
the water temperature reach 205°F (96°C).
The heater is equipped with a double acting barometric draft
control. This control assembly is factory adjusted to automatically
regulate the chimney draft imposed on the unit.
In the event of high limit switch operation, the appliance cannot be
restarted unless the water temperature is reduced by at least 20°F
(11°C) and the high limit reset button on front of limit control (fig.1)
is depressed.
Continued manual resetting of high limit control, preceded by higher
than usual water temperature is evidence of high limit switch operation.
The following is a possible reason for high limit switch operation:
• A malfunction in the thermostatic controls would allow the gas
control valve to remain open causing water temperature to
exceed the thermostat setting. The water temperature would
continue to rise until high limit switch operation.
Contact your dealer or service agent if continued high limit switch
operation occurs.
BAROMETRIC DRAFT CONTROL
FIGURE 3.
COMBUSTION CHAMBER OBSERVATION PORT
The combustion chamber observation access panel is located
above and to the left of the burner. A plug located under the
panel, see fig. 5, is inserted into the combustion chamber wall.
This plug should not be removed except, in rare cases, when
the combustion chamber requires cleaning or replacement.
DIGITAL THERMOSTAT
FIGURE 1.
electronic ignition control
Each heater is equipped with a Honeywell ignition module. The
Direct Spark Ignition Control Module controls the ignition
sequence and gas control operation of the water heater.
FIGURE 4.
uncrating
Uncrate the heater by removing the outside mat and top locator.
The shipping pallet must be removed from the unit. It may be
possible to simply unbolt the base from the pallet and, with
the help of 2 or more persons, work the unit off the pallet.
Some units will be too heavy and will require the use of jacks
or lifting equipment to safely remove the pallet and move the
unit into position. Be careful when moving this heater. It will
tip over easily.
The heater is shipped with a burner and draft control. The
burner and draft control are shipped in separate cartons. They
should be installed as received without any alterations.
Discard the shipping crate and packaging cartons in an
appropriate manner.
IGNITION MODULE
FIGURE 2.
7
installation considerations
Rough In Dimensions
FIGURE 5.
TABLE 1 . Models GPG 81-140 Thru 81-370
APPROX. SHIP. WT.
MODELS
A
B
C
D
E
G
H
J
(LBS.)
GAS
ASME
IN
OUT
STD.
GPG 81-140
74 3/4"
65"
26 3/4"
6"
21 3/8"
27 3/4"
38"
85 1/4"
1/2
658
556
1 1/2"
1 1/2"
GPG 81-199
GPG 81-270
74 3/4"
74 3/4"
65"
65"
26 3/4"
26 3/4"
6"
8"
21 3/8"
21 3/8"
27 3/4"
27 3/4"
38"
38"
85 1/4"
85 1/4"
1/2
3/4
635
632
545
547
1 1/2"
1 1/2"
1 1/2"
1 1/2"
GPG 81-370
74 3/4"
65"
26 3/4"
8"
21 3/8"
27 3/4"
38"
85 1/4"
3/4
731
634
1 1/2"
1 1/2"
8
installation considerations
TABLE 2. HEATER PERFORMANCE DATA GPG MODELS
STORAGE
CAPACITY
U.S. GALLONS
MODELS
INPUT RATING BTU/HR.
RECOVERY RATE
[email protected]°F RISE
RECOVERY RATE
[email protected]°F RISE
MAXIMUM
AMPERES
120V, 60Hz, 10
GPG 81-140
81
140,000
136
97
5
GPG 81-199
81
199,000
193
138
5
GPG 81-270
81
270,000
262
187
5
GPG 81-370
81
370,000
359
256
5
Models with letter “A” following the model number have the optional ASME tank construction.
**The GPG 81-370 is available in natural gas only.
TABLE 3. GAS AND ELECTRICAL CHARACTERISTICS
Gas Supply Pressure
Model
Type of Gas
Minimum
Maximum
Gas Manifold Pressure
Volts/Hz
Amperes
All Models
Natural
4.5" W.C. (1.12 kPa)
14" W.C. (3.48 kPa)
3.5" W.C. (0.87 kPa)
120/60
<5
All Models
* Propane
4.5" W.C. (1.12 kPa)
14" W.C. (3.48kPa)
3.5" W.C. (0.87 kPa)
120/60
<5
* Model GPG 81-370 is not available in Propane
9
Installation Considerations
locating the water heater
The heater must not be located in an area where it will be
subject to freezing.
CAUTION
Locate it near a floor drain. The heater should be located
in an area where leakage from heater or connections will
not result in damage to adjacent area or to lower floors of
the structure.
Property Damage Hazard
• All water heaters eventually leak.
When such locations cannot be avoided, a suitable metal
drain pan should be installed under heater. Such pans
should be fabricated with sides at least 2” deep, with length
and width at least 2” greater than diameter of heater and
must be piped to an adequate drain. Pan must not restrict
combustion air flow.
• Do not install without adequate drainage.
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.
clearances
These heaters are approved for installation on non-combustible
flooring in an alcove when the minimum clearance from
combustion or non-combustible construction are followed as
indicated in Figure 7 and Table 4.
Fire or Explosion Hazard
Units which are to be installed on combustible flooring must
be supported by a full layer of hollow concrete blocks, from
8" to 12"
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
thick and extending 12" (minimum) beyond the heater in all
directions. The concrete blocks must provide an unbroken
concrete surface under the heater with the hollows running
continuously and horizontally. A 3/16 inch steel plate must
cover the concrete blocks. See Figure 5.
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas
pressure.
Use only the gas shown on the water heater rating label.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended
periods of non-use.
Read instruction manual before
installing, using or servicing
water heater.
PROPER INSTALLATION ON COMBUSTIBLE FLOORING
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 igniter or main
burner flames causing fire or explosion. Some local codes permit
operation of gas appliances in such areas if they are installed 18”
or more above the floor. This may reduce the risk if location in
such an area cannot be avoided.
In all installations the minimum combustible clearances from
barometric draft control surface or vent piping shall be 6”
(152mm). Vent piping passing through a combustible wall or
ceiling must be a continuous run (no joints) and retain 6”
(152mm) clearance unless an approved reducing thimble is used.
Do not install this water heater directly on a carpeted floor. A fire
hazard may result. Instead the water heater must be placed on a
metal or wood panel extending beyond the full width and depth by at
least 3 inches in any direction. If the heater is installed in a carpeted
alcove, the entire floor shall be covered by the panel. Also, see the
DRAINING requirements in MAINTENANCE Section.
Table 4. Installation Clearances
FIGURE 6.
A service clearance of 24” (610mm) should be maintained from
serviceable parts, such as relief valves, baffles, thermostats,
cleanout openings or drain valves.
The heater shall be located or protected so it is not subject to physical
damage by a moving vehicle.
Flammable items, pressurized containers or any other potential
fire hazardous articles must never be placed on or adjacent to
the heater. Open containers or flammable material should not be
stored or used in the same room with the heater.
10
A
B
C
D
(RIGHT SIDE)
(LEFTSIDE)
(BACK)
(CEILING)
GPG 81-140
6" (15.24 cm)
6" (15.24 cm)
6" (15.24 cm)
21" (53.34 cm)
GPG 81-199
6" (15.24 cm)
6" (15.24 cm)
6" (15.24 cm)
21" (53.34 cm)
GPG 81-270
6" (15.24 cm)
6" (15.24 cm)
6" (15.24 cm)
21" (53.34 cm)
GPG 81-370
6" (15.24 cm)
6" (15.24 cm)
6" (15.24 cm)
24" (60.96 cm)
is to reduce the standby heat loss encountered with storage
tank heaters. The water heaters covered by this manual meet
or exceed the Energy Policy Act standards with respect to
insulation and standby heat loss requirements, making an
insulation blanket unnecessary.
Should you choose to apply an insulation blanket to this
heater, you should follow these instructions. See the
Features and Components section of this manual for
identification of components mentioned below. Failure to
follow these instructions can restrict the air flow required for
proper combustion, potentially resulting in fire, asphyxiation,
serious personal injury or death.
•
•
•
•
•
•
DO NOT apply insulation to the top of the water heater, as
this will interfere with safe operation of the draft control.
DO NOT cover the gas control valve, thermostat or the
Temperature-Pressure Relief Valve.
DO NOT allow insulation to come within 2” (5 cm) of the
burners, to prevent blockage of combustion air flow to the
burners.
DO NOT cover the instruction manual. Keep it on the side of
the water heater or nearby for future reference.
DO obtain new warning and instruction labels from the
manufacturer for placement on the blanket directly over the
existing labels.
DO inspect the insulation blanket frequently to make certain
it does not sag, thereby obstructing combustion air flow.
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 the Maintenance Section in this manual for sediment and
lime scale removal procedures.
Figure 7.
INSULATION BLANKET
Circulation pumps
A circulating pump is used when a system requires a circulating
loop or there is a storage tank used in conjunction with the water
heater. See Water Piping Diagrams in this manual for installation
location of circulating pumps.
Breathing Hazard - Carbon Monoxide Gas
Do not obstruct water heater air intake
with insulating blanket.
See the Circulation Pump Wiring Diagrams in this manual for
electrical hookup information. Install in accordance with the
current edition of the National Electrical Code, NFPA 70 or the
Canadian Electrical Code, CSA C22.1.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
All-bronze circulating pumps are recommended for used with
commercial water heaters.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Some circulating pumps are manufactured with sealed bearings
and do not require further lubrication. Some circulating pumps
must be periodically oiled. Refer to the pump manufacturer’s
instructions for lubrication requirements.
Insulation blankets are available to the general public for
external use on gas water heaters but are not necessary
with these products. The purpose of an insulation blanket
11
CIRCULATING PUMP WIRING DIAGRAM
DISHWASHER LOOP WITH TOGGLE SWITCH
CIRCULATING PUMP WIRING DIAGRAM
STORAGE TANK OR BUILDING RECIRCULATION
FIELD SUPPLIED TEMPERATURE CONTROL
INSTALLED IN THE STORAGE TANK
OR CIRCULATING LOOP RETURN LINE
DISHWASHER
FIELD SUPPLIED TEMPERATURE
SWITCH
CIRCULATING LOOP RETURN LINE
BreathingTOGGLE
Hazard - Carbon
Gas
CONTROL Monoxide
INSTALLED IN THE
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH WATER HEATER AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
Under no circumstances should
NOTE: USE SEPARATE 120 VAC POWER
the input exceed the rate shown
SUPPLY FOR PUMP CIRCUIT. DO NOT SHARE
POWER WITH WATER HEATER AS THIS MAY on the water heater’s rating label.
CAUSE ELECTRICAL LINE NOISE AND LEAD
TO ERRATIC CONTROL SYSTEM OPERATION.
L1 HOT
Overfiring could result in damage to
the water heater and sooting.
L1 HOT
120 VAC
POWER
CIRC
PUMP
MOTOR
120 VAC
POWER
MOTOR
L2 NEUTRAL
Breathing carbon monoxide can cause brain damage or
L2 NEUTRAL
death. Always read and understand instruction manual.
FIGURE 8.
CIRCULATING PUMP WIRING DIAGRAM
DISHWASHER LOOP WITH TOGGLE SWITCH
ONTROL
DISHWASHER
TOGGLE
SWITCH
NE
Gas and carbon monoxide
detectors
CIRC
are available.
PUMP
Installations above 2000 feet (610 meters) require
replacement of burner orifices in accordance with current
edition of the National Fuel Gas Code (ansi z223.1). For
Canadian installations consult Canadian Installations Code
can/csa b149.1. Failure to replace orifices will result in
improper and inefficient operation of the water heater resulting
in the production of increased levels of carbon monoxide gas
in excess of safe limits which could result in serious personal
injury or death.
FIELD SUPPLIED TEMPERATURE
CONTROL INSTALLED IN THE
CIRCULATING LOOP RETURN LINE
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT SHARE
POWER WITH WATER HEATER AS THIS MAY
CAUSE ELECTRICAL LINE NOISE AND LEAD
TO ERRATIC CONTROL SYSTEM OPERATION.
L1 HOT
120 VAC
POWER
You should contact your gas supplier for any specific changes
which may be required in your area.
CIRC
PUMP
MOTOR
As the elevation above sea level is increased, there is less
oxygen per cubic foot of air. Therefore, the heater input rate
should be reduced at high altitudes for satisfactory operation
with the reduced oxygen supply. Failure to make this reduction
would result in an over firing of the heater causing sooting,
poor combustion and/or unsatisfactory heater performance.
L2 NEUTRAL
FIGURE 9.
HIGH ALTITUDE INSTALLATIONS
Ratings specified by manufacturers for most appliances apply
for elevations up to 2000 feet (610m). For elevations above
2000 feet (610), ratings must be reduced at the rate of 4%
for each 1000 feet (305m) above sea level. For example, if a
heater is rated at 78,000 Btuh (22.9 Kwh) at sea level, to rate
the heater at 4000 feet (1219m), you subtract 4 (once for each
thousand feet) x.04 (4% input reduction) x 78,000 (original
rating) from the original rating.
Fire and Explosion Hazard
Under no circumstances should the
input exceed the rate shown on the
water heater’s rating label.
Overfiring could result in fire or
explosion.
Gas and carbon monoxide detectors are
available.
Therefore, to calculate the input rating at 4,000 feet (1219m):
4 x .04 x 78,000 = 12,480 Btuh (3.7 Kwh), 78,000 (22.9 Kwh) 12,480 (3.7 Kwh) = 65,520 Btuh (19.2 Kwh). At 6000 feet (1829m)
the correct input rating should be 59,280 Btuh (17.4 Kwh).
12
Installation Requirements
4. When installing multiple water heaters in the same gas supply
system it is recommended that individual positive lock-up gas
pressure regulators be installed at each unit.
Gas supply Systems
Low pressure building gas supply systems are defined as those
systems that cannot under any circumstances exceed 14”
W.C. (1/2 PSI Gauge). These systems do not require pressure
regulation. Measurements should be taken to insure that gas
pressures are stable and fall within the requirements stated on
the water heater rating plate. Readings should be taken with
all gas burning equipment off (static pressure) and with all gas
burning equipment running at maximum rate (dynamic pressure).
The gas supply pressure must be stable within 1.5” W.C.
from static to dynamic pressure to provide good performance.
Pressure drops that exceed 1.5” W.C. may cause rough starting,
noisy combustion or nuisance outages. Increases or spikes
in static pressure during off cycles may cause failure to ignite
or in severe cases damage to appliance gas valves. If your
low pressure system does NOT meet these requirements, the
installer is responsible for the corrections.
Power Supply
The water heaters covered in this manual require a 120 VAC,
1Ø (single phase), 60Hz, 15 amp power supply and must also
be electrically grounded in accordance with local codes or, in the
absence of local codes, with the National Electrical Code, ANSI/
NFPA 70 or the Canadian Electrical Code, CSA C22.1.
WATER TEMPERATURE CONTROL AND Mixing Valves
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
High Pressure building supply systems use pressures that exceed
14” W.C. (1/2 PSI Gauge). These systems must use field supplied
regulators to lower the gas pressure to less than 14” W.C. (1/2
PSI Gauge). Water heaters require gas regulators that are properly
sized for the water heater input and deliver the rating plate specified
pressures. Gas supply systems where pressure exceeds 5 PSI
often require multiple regulators to achieve desired pressures.
Systems in excess of 5 PSI building pressure should be designed
by gas delivery professionals for best performance. Water heaters
connected to gas supply systems that exceed 14” W.C. (1/2 PSI
Gauge) at any time must be equipped with a gas supply regulator.
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.
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).
All models require a minimum gas supply pressure of 4.5" W.C.
for natural gas and propane gas. The minimum supply pressure
is measured while gas is flowing (dynamic pressure). The supply
pressure should never fall below 4.5" W.C. for natural gas and
propane gas. The supply pressure should be measured with all
gas fired appliances connected to the common main firing at full
capacity. If the supply pressure drops more than 1.5” W.C. as gas
begins to flow to the water heater then the supply gas system
including the gas line and/or the gas regulator may be restricted
or undersized. See Supply Gas Regulator section and Gas Piping
section of this manual. The gas valve on all models has a maximum
gas supply pressure limit of 14” W.C. The maximum supply pressure
is measured while gas is not flowing (static pressure).
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 5 shows 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.
In addition to using the lowest possible temperature setting that
satisfies the demand of the application a Mixing Valve should be
installed at the water heater (see Figure 10) or at the hot water taps
to further reduce system water temperature.
SUPPLY GAS REGULATOR
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.
The maximum allowable gas supply pressure for this water heater is
14" W.C. (3.48 kPa). Install a positive lock-up gas pressure regulator
in the gas supply line if inlet gas pressure can exceed 14" W.C.
(3.48 kPa) at any time. Regulators must be sized/used according to
manufacturer’s specifications. Supply gas regulators shall have inlet
and outlet connections not less than the minimum supply gas line
size for the water heater they supply.
If a positive lock-up regulator is required follow these instructions:
1. Positive lock-up gas pressure regulators must be rated at or above
the input Btu/hr rating of the water heater they supply.
2. Positive lock-up gas pressure regulator(s) should be installed no closer
than 3 equivalent feet (1 meter) and no farther than 8 equivalent
feet (2.4 meters) from water heater’s inlet gas connection.
3. After installing the positive lock-up gas pressure regulator(s), an
initial nominal supply pressure setting of 7" W.C. (1.74 kPa) while
water heater is operating is recommended and will generally
provide good water heater operation. Some additional adjustment
maybe required later to maintain a steady gas supply pressure.
Table 5.
Water Temperature °F
Time for 1st Degree Burn
(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)
45 minutes
5 minutes
25 seconds
5 seconds
2 seconds
1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978)
13
A properly sized thermal expansion tank must be installed on
all closed systems to control the harmful effects of thermal
expansion. Contact a local plumbing service agency to have a
thermal expansion tank installed.
HOT WATER
OUTLET
See Water Line Connections on page 19 and the Water Piping
Diagrams beginning on page 35.
12” TO 15”
(30-38 cm)
TEMPERED WATER
OUTLET
Temperature-pressure relief valve
CHECK
VALVE
COLD
WATER
INLET
CHECK
VALVE
Explosion Hazard
MIXING
VALVE
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
TO TANK
INLET
Properly sized temperaturepressure relief valve must be
installed in opening provided.
FIGURE 10.
Dishwashing Machines
Can result in overheating and
excessive tank pressure.
All dishwashing machines meeting the National Sanitation
Foundation requirements are designed to operate with water
flow pressures between 15 and 25 pounds per square inch
(103 kPa and 173 kPa). Flow pressures above 25 pounds
per square inch (173 kPa), or below 15 pounds per square
inch (103 kPa), will result in improperly sanitized dishes.
Where pressures are high, a water pressure reducing or flow
regulating control valve should be used in the 180°F (82°C)
line to the dishwashing machine and should be adjusted to
deliver water pressure between these limits.
Can cause serious injury or death.
This water heater is provided with a properly rated/sized and certified
combination Temperature-Pressure Relief Valve (T&P valve) by
the manufacturer. The valve is certified by a nationally recognized
testing laboratory that maintains periodic inspection of production
of listed equipment of materials as meeting the requirements for
Pressure Relief Valves for Hot Water Supply Systems, ANSI Z21.22
• CSA 4.4, and the code requirements of ASME.
The National Sanitation Foundation also recommends
circulation of 180°F (82°C) water. The circulation flow rate
should be just enough to provide 180°F (82°C) water at the
point of take-off to the dishwashing machine.
If replaced, the new T&P valve must meet the requirements
of local codes, but not less than a combination TemperaturePressure Relief Valve rated/sized and certified as indicated in
the above paragraph. The new valve must be marked with a
maximum set pressure not to exceed the marked hydrostatic
working pressure of the water heater (150 psi = 1,035 kPa) and
a discharge capacity not less than the water heater Btu/hr or kW
input rate as shown on the water heater’s model rating label.
Adjust flow by throttling a full port ball valve installed in
the circulating line on the outlet side of the pump. Never
throttle flow on the suction side of a pump. See Water Piping
Diagrams in this manual.
Closed Water Systems
NOTE: In addition to the factory installed Temperature-Pressure
Relief Valve on the water heater, each remote storage tank that
may be installed and piped to a water heating appliance must also
have its own properly sized, rated and approved TemperaturePressure Relief Valve installed. Call the toll free technical
support phone number listed on the back cover of this manual
for technical assistance in sizing a Temperature-Pressure Relief
Valve for remote storage tanks.
Water supply systems may, because of code requirements or
such conditions as high line pressure, among others, have
installed devices such as pressure reducing valves, check
valves, and back flow preventers. Devices such as these
cause the water system to be a closed system.
Thermal Expansion
For safe operation of the water heater, the Temperature-Pressure
Relief Valve must not be removed from its designated opening
nor plugged. The Temperature-Pressure Relief Valve must be
installed directly into the fitting of the water heater designed for
the pressure relief valve . Install discharge piping so that any
discharge will exit the pipe within 6 inches (15.2 cm) above an
adequate floor drain, or external to the building. In cold climates
it is recommended that it be terminated at an adequate drain
inside the building. Be certain that no contact is made with any
live electrical part. The discharge opening must not be blocked
or reduced in size under any circumstances. Excessive length,
over 30 feet (9.14 m), or use of more than four elbows can cause
restriction and reduce the discharge capacity of the valve.
As water is heated, it expands (thermal expansion). In a
closed system the volume of water will grow when it is heated.
As the volume of water grows 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 TemperaturePressure Relief Valve operation: water discharged from the
valve due to excessive pressure build up. This condition is
not covered under the limited warranty. The TemperaturePressure Relief Valve is not intended for the constant relief
of thermal expansion.
14
Contaminated Air
No valve or other obstruction is to be placed between the
Temperature-Pressure Relief Valve and the tank. Do not connect
discharge piping directly to the drain unless a 6” (15.2 cm)
air gap is provided. To prevent bodily injury, hazard to life, or
property damage, the relief valve must be allowed to discharge
water in adequate quantities should circumstances demand. If
the discharge pipe is not connected to a drain or other suitable
means, the water flow may cause property damage.
Breathing Hazard - Carbon Monoxide Gas
Install water heater in accordance with
the Instruction Manual and NFPA 54 or
CAN/CSA-B149.1.
To avoid injury, combustion and ventilation
air must be taken from outdoors.
Do not place chemical vapor emitting
products near water heater.
CAUTION
Water Damage Hazard
• Temperature-Pressure Relief Valve discharge
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
pipe must terminate at adequate drain.
Corrosion of the flue ways and vent system may occur if air for
combustion contains certain chemical vapors. Such corrosion
may result in failure and risk of asphyxiation.
T&P Valve Discharge Pipe Requirements:
• Shall not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both
the Temperature-Pressure Relief Valve and the discharge
pipe.
• Must terminate a maximum of six inches above a floor
drain or external to the building. In cold climates, it is
recommended that the discharge pipe be terminated at an
adequate drain inside the building.
• Shall not have any valve or other obstruction between the
pressure relief valve and the drain.
Combustion air that is contaminated can greatly diminish the life
span of the water heater and water heater components such as
hot surface igniters and burners. Propellants of aerosol sprays,
beauty shop supplies, water softener chemicals and chemicals
used in dry cleaning processes that are present in the combustion,
ventilation or ambient air can cause such damage.
Do not store products of this sort near the water heater. Air which
is brought in contact with the water heater should not contain any
of these chemicals. If necessary, uncontaminated air should be
obtained from remote or outdoor sources. The limited warranty
is voided when failure of water heater is due to a corrosive
atmosphere. (See limited warranty for complete terms and
conditions).
Air requirements
Burn hazard.
Hot water discharge.
Breathing Hazard - Carbon Monoxide Gas
Install water heater in accordance with
the Instruction Manual and NFPA 54 or
CAN/CSA-B149.1.
To avoid injury, combustion and ventilation
air must be taken from outdoors.
Do not place chemical vapor emitting
products near water heater.
Keep clear of TemperaturePressure Relief Valve
discharge outlet.
The Temperature-Pressure Relief Valve must be manually operated
at least twice a year. Caution should be taken to ensure that (1) no
one is in front of or around the outlet of the Temperature-Pressure
Relief Valve discharge line, and (2) the water manually discharged
will not cause any bodily injury or property damage because
the water may be extremely hot. If after manually operating the
valve, it fails to completely reset and continues to release water,
immediately close the cold water inlet to the water heater, follow the
draining instructions in this manual, and replace the TemperaturePressure Relief Valve with a properly rated/sized new one.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
For safe operation an adequate supply of fresh uncontaminated
air for combustion and ventilation must be provided.
An insufficient supply of air can cause recirculation of combustion
products resulting in contamination that may be hazardous to
life. Such a condition often will result in a yellow, luminous burner
flame, causing sooting of the combustion chamber, burners and
flue tubes and creates a risk of asphyxiation.
NOTE: The purpose of a Temperature-Pressure Relief Valve is to
prevent excessive temperatures and pressures in the storage tank.
The T&P valve is not intended for the constant relief of thermal
expansion. A properly sized thermal expansion tank must be
installed on all closed systems to control thermal expansion, see
Closed Water Systems and Thermal Expansion on page 14.
Do not install the water heater in a confined space unless an
adequate supply of air for combustion and ventilation is brought
in to that space using the methods described in the Confined
Space section that follows.
If you do not understand these instructions or have any questions
regarding the Temperature-Pressure Relief Valve call the toll
free number listed on the back cover of this manual for technical
assistance.
Never obstruct the flow of ventilation air. If you have any doubts
or questions at all, call your gas supplier. Failure to provide the
proper amount of combustion air can result in a fire or explosion
and cause property damage, serious bodily injury or death.
15
Unconfined Space
Direct Vent Appliances
An Unconfined Space is one whose volume IS NOT LESS THAN
50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the
total input rating of all appliances installed in the space. Rooms
communicating directly with the space, in which the appliances
are installed, through openings not furnished with doors, are
considered a part of the unconfined space.
Appliances installed in a Direct Vent configuration that derive all
air for combustion from the outdoor atmosphere through sealed
intake air piping are not factored in the total appliance input Btu/
hr calculations used to determine the size of openings providing
fresh air into confined spaces.
Makeup air requirements for the operation of exhaust fans,
kitchen ventilation systems, clothes dryers and fireplaces shall
also be considered in determining the adequacy of a space to
provide combustion, ventilation and dilution air.
Where exhaust fans are installed, additional air shall be provided
to replace the exhausted air. When an exhaust fan is installed
in the same space with a water heater, sufficient openings to
provide fresh air must be provided that accommodate the
requirements for all appliances in the room and the exhaust fan.
Undersized openings will cause air to be drawn into the room
through the water heater’s vent system causing poor combustion.
Sooting, serious damage to the water heater and the risk of fire
or explosion may result. It can also create a risk of asphyxiation.
Exhaust Fans
Unusually Tight Construction
In unconfined spaces in buildings, infiltration may be adequate
to provide air for combustion, ventilation and dilution of flue
gases. However, in buildings of unusually tight construction (for
example, weather stripping, heavily insulated, caulked, vapor
barrier, etc.) additional air must be provided using the methods
described in the Confined Space section that follows.
Louvers and Grilles
The free areas of the fresh air openings in the instructions that
follow do not take in to account the presence of louvers, grilles or
screens in the openings.
Confined Space
The required size of openings for combustion, ventilation and
dilution air shall be based on the “net free area” of each opening.
Where the free area through a design of louver or grille or screen
is known, it shall be used in calculating the size of opening
required to provide the free area specified. Where the louver and
grille design and free area are not known, it shall be assumed
that wood louvers will have 25% free area and metal louvers and
grilles will have 75% free area. Non motorized louvers and grilles
shall be fixed in the open position.
A Confined Space is one whose volume is less than 50 cubic
feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input
rating of all appliances installed in the space.
Openings must be installed to provide fresh air for combustion,
ventilation and dilution in confined spaces. The required size for
the openings is dependent on the method used to provide fresh
air to the confined space and the total Btu/hr input rating of all
appliances installed in the space.
VENTING INSTALLATION
venting
to face in direction needed. The assembly must be fitted to the
jacket cover such that it is plumb and level to the ground. Fasten
the draft control assembly to the top cover using sheet metal
screws at three locations, or more, as required.
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.
Dampers or other obstructions must not be installed between the
heater and the barometric draft control assembly.
Heater must be protected from freezing downdrafts.
Do not adjust settings on gate. Counterweight washers are factory
adjusted and should result in breeching pressure measurements
at the combustion test hole (Figure 11) within the range shown
in Table 9.
Remove all soot or other obstructions from the chimney that will
retard a free draft.
Type B venting is recommended with these heaters.
NOTE: A negative draft must be maintained in the vent piping.
When installed, the damper gate must pivot freely in the ring
guides. This gate will automatically adjust to regulate the chimney
draft imposed on the heater.
This water heater must be vented in compliance with all local
codes, the current revision of the National Fuel Gas Code
(ANSI-Z223.1) and with the Category I Venting Tables.
If any part of the vent system is exposed to ambient temperatures
below 40°F (4.4°C) it must be insulated to prevent condensation.
• Do not connect the heater to a common vent or chimney with
solid fuel burning equipment. This practice is prohibited by
many local building codes as is the practice of venting gas
fired equipment to the duct work of ventilation systems.
• Where a separate vent connection is not available and the vent
pipe from the heater must be connected to a common vent with
an oil burning furnace, the vent pipe should enter the smaller
common vent or chimney at a point above the large vent pipe.
BAROMETRIC DRAFT CONTROL ASSEMBLY
A double-acting barometric draft control assembly is provided
with each unit. The draft control assembly must be installed
without alteration. This assembly is factory adjusted for horizontal
application only and must be attached to the heater as shown in
Figure 11. The outlet of the draft control assembly may be rotated
PROPER DRAFT CONTROLLER AND
VENT PIPE INSTALLATION
FIGURE 11.
16
Fresh Air Openings For Confined Spaces
Alternatively a single permanent opening, commencing
within 12 inches (300 mm) of the top of the enclosure,
shall be provided. See Figure 12. The water heater shall
have clearances of at least 1 inch (25 mm) from the sides
and back and 6 inches (l50 mm) from the front of the
water heater. The opening shall directly communicate
with the outdoors or shall communicate through a vertical
or horizontal duct to the outdoors or spaces that freely
communicate with the outdoors and shall have a minimum
free area of the following:
The following instructions shall be used to calculate the size,
number and placement of openings providing fresh air for
combustion, ventilation and dilution in confined spaces. The
illustrations shown in this section of the manual are a reference
for the openings that provide fresh air into confined spaces
only. DO NOT refer to these illustrations for the purpose of vent
installation. See Venting Installation on page 16 for complete
venting installation instructions.
1. 1 square inch per 3000 Btu/hr (733 mm 2 per kW) of
the total input rating of all appliances located in the
enclosure, and
Outdoor Air Through Two Openings
2. Not less than the sum of the areas of all vent connectors
in the space.
Outdoor Air Through Two Horizontal Ducts
Figure 12.
The confined space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. The openings shall communicate directly with the
outdoors. See Figure 12.
Each opening shall have a minimum free area of 1 square inch
per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating
of all appliances installed in the enclosure. Each opening shall
not be less than 100 square inches (645 cm2).
Figure 14.
The confined space shall be provided with two permanent
horizontal ducts, one commencing within 12 inches (300
mm) of the top and one commencing within 12 inches
(300 mm) of the bottom of the enclosure. The horizontal
ducts shall communicate directly with the outdoors. See
Figure 14.
Outdoor Air Through One Opening
Each duct opening shall have a minimum free area of
1 square inch per 2,000 Btu/hr (1100 mm2 per kW) of
the aggregate input rating of all appliances installed in
the enclosure.
When ducts are used, they shall be of the same cross
sectional area as the free area of the openings to which
they connect. The minimum dimension of rectangular air
ducts shall be not less than 3 inches.
Figure 13.
17
Outdoor Air Through Two Vertical Ducts
When ducts are used, they shall be of the same cross sectional
area as the free area of the openings to which they connect.
The minimum dimension of rectangular air ducts shall be not less
than 3" (76.2 mm).
The illustrations shown in this section of the manual are a
reference for the openings that provide fresh air into confined
spaces only.
Air From Other Indoor Spaces
Do not refer to these illustrations for the purpose of vent
installation. See Venting Installation on page 14 for complete
venting installation instructions.
Figure 16.
The confined space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. See Figure 16.
Figure 15.
The confined space shall be provided with two permanent vertical
ducts, one commencing within 12 inches (300 mm) of the top and
one commencing within 12 inches (300 mm) of the bottom of the
enclosure. The vertical ducts shall communicate directly with the
outdoors. See Figure 15.
Each opening shall communicate directly with an additional
room(s) of sufficient volume so that the combined volume of all
spaces meets the criteria for an Unconfined Space.
Each opening shall have a minimum free area of 1 square inch
per 1,000 Btu/hr (2200 mm2 per kW) of the aggregate input rating
of all appliances installed in the enclosure. Each opening shall
not be less than 100 square inches (645 cm2).
Each duct opening shall have a minimum free area of 1 square
inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input
rating of all appliances installed in the enclosure.
18
VENT CONNECTION
Where an existing chimney or vent is to be used, be sure
that the chimney or vent has adequate capacity for the
number and sizes of gas appliances being vented through
it. Inspect the chimney or vent and remove all soot or other
obstructions which will retard free draft.
Vent connections must be made to an adequate stack
or chimney. Refer to the National Fuel Gas Code (current
edition) or to the vent pipe manufacturer’s gas vent and
chimney sizing table to properly design and size the venting
system. Refer to Table 6 for the vent pipe size required for
installation to the barometric draft control assembly outlet.
Vent connectors making horizontal runs must have a minimum
upward slope toward the chimney or vent of 1/4 inch per foot.
Vent connector length should be kept as short as possible.
Be sure that the vent pipe does not extend beyond the inside
wall of a chimney.
Table 6. BAROMETRIC DRAFT CONTROL
ASSEMBLY OUTLET SIZE
MODEL
DRAFT CONTROL
OUTLET DIAMETER
GPG 81-140
6”
GPG 81-199
6”
GPG 81-270
8”
GPG 81-370
8”
In venting systems where a continuous or intermittent
back (positive) draft is found to exist, the cause must
be determined and corrected. In some cases, a special
vent cap may be required. Do not install this unit on the
positive draft side of a venting system being served by a
power exhauster.
water heater installation
Water Line Connections
Water Piping Diagrams
This manual provides detailed water piping diagrams for typical
methods of application for the water heaters, see Water Piping
Diagrams beginning on page 35.
The water piping installation must conform to these instructions
and to all local code authority having jurisdiction. Good practice
requires that all heavy piping be supported.
The water heater may be installed by itself, or with a separate
storage tank. When used with a separate storage tank, the
circulation may be either by gravity or by means of circulating
pump. Adjust flow by throttling a full port ball valve installed in the
circulating line on the outlet side of the pump. Never throttle flow
on the suction side of a pump. See the Water Piping Diagrams
beginning on page 35.
Read and observe all requirements in the following sections
before installation of the water piping begins:
1. Water Temperature Control and Mixing Valves on page 13.
2. Dishwashing Machines on page 14.
3. Temperature-Pressure Relief Valve on page 14-15.
4. Closed Systems and Thermal Expansion on page 14.
Note: In addition to the factory installed Temperature-Pressure
Relief Valve (T&P valve) on the water heater, each remote
storage tank that may be installed and piped to a water heating
appliance must also have its own properly sized, rated and
approved Temperature-Pressure Relief Valve installed.
5. For multiple water heater installations see Water Piping
Diagrams beginning on page 35.
Water (potable) Heating And Space Heating
Call the toll free technical support phone number listed on the
back cover of this manual for further assistance in sizing a T&P
valve for remote storage tanks.
1. All piping components connected to this unit for space
heating applications shall be suitable for use with potable
water.
T&P Valve Discharge Pipe
2. Toxic chemicals, such as those used for boiler treatment,
shall NEVER be introduced into this system.
3. This unit may NEVER be connected to any existing heating
system or component(s) previously used with a non-potable
water heating appliance.
Explosion Hazard
4. When the system requires water for space heating at
temperatures higher than required for domestic water
purposes, a tempering valve must be installed. Please
refer to installation diagrams beginning on page 35 of this
manual for suggested piping arrangements.
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
5. These water heaters cannot be used in space heating
applications only
Properly sized temperaturepressure relief valve must be
installed in opening provided.
Thermometers (not Supplied)
Can result in overheating and
excessive tank pressure.
Thermometers should be obtained and field installed as shown
in the installation diagrams.
Can cause serious injury or death.
Thermometers are installed in the system as a means of
detecting the temperature of the outlet water supply.
19
Tube Inlet Installation
This water heater is provided with a properly rated/sized and
certified combination temperature - pressure (T&P) relief valve
by the manufacturer. See Temperature-Pressure Relief Valve
on pages 14-15 for information on replacement and other
requirements.
CAUTION
Water Damage Hazard
Figure 17.
• Temperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
BURNER INSTALLATION
Remove the factory-installed insulation covering the combustion
chamber opening. (A utility knife is useful for cutting out the
insulation). Cut the insulation back even with the jacket opening.
Install the flange gasket (which is usually taped to the heater jacket)
over the three bolts protruding from the tank at the combustion
chamber opening.
Install a discharge pipe between the T&P valve discharge
opening and a suitable floor drain. Do not connect discharge
piping directly to the drain unless a 6” (15.2 cm) air gap is
provided. To prevent bodily injury, hazard to life, or property
damage, the relief valve must be allowed to discharge water
in adequate quantities should circumstances demand. If the
discharge pipe is not connected to a drain or other suitable
means, the water flow may cause property damage.
Remove hardware (3 hex nuts, 3 flat washers, and 3 lock washers)
from the shipping bag attached to the heater’s electrical conduit.
Begin assembling the power burner to the tank by placing the power
burner nozzle in the combustion chamber opening. Slide the nozzle
into the tank and rotate the mounting flange to engage the mounting
bolts, refer to Figure 18. Then, place the flat washers followed by
the lock washers, and finally the hex nuts on the mounting bolts.
Hand tighten the nuts. Then gradually tighten each nut alternating
between the 3 mounting bolts. Do not over tighten as damage to
the flange gasket or to the tank may result. Refer to Figure 18.
T&P Valve Discharge Pipe Requirements:
• Shall not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both
Temperature-Pressure Relief Valve and the discharge pipe.
• Must terminate a maximum of six inches above a floor
drain or external to the building. In cold climates, it is
recommended that the discharge pipe be terminated at an
adequate drain inside the building.
• Shall not have any valve or other obstruction between the
relief valve and the drain.
Installation Diagrams - Top Inlet/Outlet Usage
Use of the top inlet water connection requires an inlet dip tube
(refer to Figure 17). The tube is supplied in the heater. Follow
caution labels if applying heat to this fitting. Do not allow pipe
dope to contact the plastic tube during installation.
POWER BURNER INSTALLATION
FIGURE 18.
20
heater wiring
All electrical work must be installed in accordance with the current edition of the National Electrical Code ANSI/NFPA No. 70 or Canadian Electrical
Code CSA C22.1 and 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 water heater must be replaced, use only type 105°C thermoplastic or equivalent 2500C type F must be
used for the flame sensor and igniter leads.
The controls of this water heater are polarity sensitive. Be certain to properly wire the hot and neutral connections.
Figure 19.
21
GAS PIPING
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.
Contact your local gas service company to ensure that adequate
gas service is available and to review applicable installation codes
for your area.
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.
Size the main gas line in accordance with Table 7. The figures shown
are for straight lengths of pipe at 0.5 in. W.C. pressure drop, which is
considered normal for low pressure systems. Note: Fittings such as
elbows, tees and line regulators will add to the pipe pressure drop.
Also refer to the latest version of the National Fuel Gas Code.
GAS PIPING AND SEDIMENT TRAP INSTALLATION
Schedule 40 Steel or Wrought Iron Pipe is the preferred material
for the gas line of this water heater. It is imperative to follow the
sizing recommendations in the latest version of the National Fuel
Gas Code if Corrugated Stainless Steel Tubing (CSST) is used as
the gas line for this water heater.
The heater is not intended for operation at higher than 14.0" W.C.natural gas, (1/2 pound per square inch gage) supply gas pressure.
Exposure to higher supply pressure may cause damage to the
gas valve which could result in fire or explosion. If overpressure
has occurred such as through improper testing of gas lines or
emergency malfunction of the supply system, the gas valve must be
checked for safe operation. Make sure that the outside vents on the
supply regulators and the safety vent valves are protected against
blockage. These are parts of the gas supply system, not the heater.
Vent blockage may occur during ice storms.
Figure 20.
Table 7. MAXIMUM CAPACITY OF PIPE IN
CUBIC FEET OF GAS PER HOUR
(Based upon a Pressure Drop of 0.5 inch Water Column and
0.6 Specific Gravity Gas and max. gas pressure of .5 psig)
Gas Line Leak Testing
NOMINAL IRON PIPE SIZE (INCHES)
LENGTH
IN FEET
1/2
3/4
1
10
175
360
680
20
120
250
465
30
97
200
40
82
170
1 1/4 1 1/2
2
2 1/2
3
4
Fire and Explosion Hazard
1,400 2,100 3,950 6,300 11,000 23,000
950
1,460 2,750 4,350
7,700
375
770
1,180 2,200 3,520
6.250
12.800
320
660
5,300
10,900
990
1,900 3,000
Use joint compound or Teflon tape
compatible with propane gas.
Leak test before placing the water
heater in operation.
Disconnect gas piping and main gas
shutoff valve before leak testing.
Install sediment trap in accordance
with NFPA 54.
15,800
50
73
151
285
580
900
1,680 2,650
4,750
9,700
60
66
138
260
530
810
1,520 2,400
4,300
8,800
70
61
125
240
490
750
1,400 2,250
3,900
8,100
80
57
118
220
460
690
1,300 2,050
3,700
7,500
90
53
110
205
430
650
1,220 1,950
3,450
7,200
100
50
103
195
400
620
1,150 1,850 3,250
6,700
125
44
93
175
360
550
1,020 1,650 2,950
6,000
150
40
84
160
325
500
950
1,500
2,650
5,500
175
37
77
145
300
460
850
1,370
2,450
5,000
200
35
72
135
280
430
800
1,280
2,280
4,600
Any time work is done on the gas supply system perform a leak test
to avoid the possibility of fire or explosion.
1.For test pressures exceeding 1/2 psi (3.45 kPa) disconnect the
water heater and its Main Gas Shutoff Valve from the gas supply
piping system during testing, see Figure 20. The gas supply line
must be capped when disconnected from the water heater.
2.For test pressures of 1/2 psi (3.45 kpa) or less, the water heater
need not be disconnected, but must be isolated from the supply
gas line by closing the Main Gas Shutoff Valve during testing.
It is important to guard against gas valve fouling from contaminants in
gas ways. Such fouling may cause improper operation, fire or explosion.
3.Coat all supply gas line joints and connections upstream of the
water heater with a non-corrosive soap and water solution to
test for leaks. Bubbles indicate a gas leak. Do not use matches,
candles, flame or other sources of ignition for this purpose.
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.
4.Repair any leaks before placing the water heater in operation.
To trap any dirt or foreign material in the gas supply line, a sediment
trap must be incorporated in the piping (see Figure 20). 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 latest version of the National Fuel Gas Code.
Purging
Gas line purging is required with new piping or systems in which air
has entered.
To prevent damage, care must be taken not to apply too much torque
when attaching gas supply pipe to gas valve inlet.
Purging should be performed per the current edition of NFPA 54 the
National Fuel Gas Code.
22
START-UP and OPERATION
• Attach a gas pressure gauge or manometer to upstream side
of main gas cock and a gas pressure gauge or manometer to
the manifold pressure tapping.
• Check voltage at disconnect switch to make certain that it
matches that shown on the burner label.
• Apply a few drops of No. 20 SAE non-detergent oil to the
motor bearings.
• Drill max. 5/16" hole in breeching as close as possible to flue
connection on heater to install stack thermometer and
combustion analyzing equipment. (See Figure 11).
•You are now ready to begin the burner start up procedure.
Fire or Explosion Hazard
Gas line purging is required with new piping or systems in
which air has entered.
To avoid risk of fire or explosion purge discharge must not
enter into confined areas or spaces where ignition can occur.
The area must be well ventilated and all sources of ignition
must be deactivated or removed.
Installation and start up of this water heater requires abilities and
skills equivalent to that of a licensed tradesman in the field involved,
see Qualifications on page 6.
Do not place the water heater in operation 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.
Read instruction manual before
installing, using or servicing
water heater.
Light the water heater in accordance with the Lighting and Operation
Instruction label on the water heater and in this manual on pages 25.
Prior to Start Up
Before attempting start up, thoroughly study and know the exact
Sequence Of Operation. See written Sequence Of Operation on
page 23 and Sequence Of Operation Flow Chart on page 24.
This product requires a formal Start-Up by an authorized service/
start-up provider that has been approved by the manufacturer for
this specific product. Call 1-800-527-1953 to locate the nearest
authorized start-up provider and arrange a factory start-up. Please
provide as much notice as possible, preferably 2 weeks. Please
have the model and serial number ready when you call.
This start-up is required to activate the warranty and ensure safe,
efficient operation.
Warranty on this product is limited and could be void in the event
the unit is not installed per the instructions in this manual and/or not
started up by an authorized factory trained service/start-up provider.
The following test equipment should be on hand: (all test equipment
must be acclimated to ambient temperature before calibration and use.)
1. CO2 indicator (Fyrite or similar) or O2 analyzer
2. CO indicator (Monoxor or similar)
3. Stack thermometer
4. Draft Gauge or inclined manometer
5. Two U-tube manometers or calibrated 0-10" and 0-35" w.c.
pressure gauges.
6. Combination volt/ammeter.
Be certain that the water heater is full of water, that air is purged from
the gas and water lines and that there are no leaks in the gas and
water lines. Ensure all inlet water valves are open.
Filling The Water Heater
Follow these steps to fill the water heater prior to start up.
1. Close the heater drain valve.
2. Open a nearby hot water faucet to permit air in system to escape.
3. Fully open the cold water inlet valve allowing the piping and
water heater to fill with water.
4. Close hot water faucet opened in Step 2 as water starts to flow.
Read SEQUENCE OF OPERATION section of this manual prior
to lighting and operating this water heater.
With above conditions satisfied, start the unit in accordance with the
instructions on the operating label attached to the heater. For your
convenience a copy of the instructions are shown on pages 25.
SEQUENCE OF OPERATION
7.
The following information will describe the Sequence of Operation
for this water heater.
1. Switch power on to unit.
2. Thermostat calls for heat.
3.
On a call for heat, 24V is applied to motor start relay and air
switch. Once the fan motor reaches operating rpm combustion
air pressure is sensed by the air proving switch and closes the
switch contacts energizing the S89 ignition module. The ignition
module performs diagnostic self check on system components.
If the Ignition Control does not sense the flame during the
4 second ignition trial period, the Ignition Control shuts the Gas
Valve and turns off the Spark Igniter. The control is locked out,
the power to the unit must be cycled to restart the Ignition
Control.
8. If the ignition control senses flame during the 4 seconds trial for
ignition period, the gas control remains open and the burner on
until the call for heat ends.
9. The Ignition Control monitors the Flame Sensor during the
heating cycle. If the flame signal is lost, the Ignition Control shuts
the Main Gas Valve and re-starts the ignition process at
step 4.
4. The Ignition Control begins the trial for ignition after 30 seconds
prepurge is completed.
5. The Ignition Control turns on the Spark Igniter and opens the Pilot
Gas Valve.
10.Once the unit is satisfied, the Ignition Control will shut off the
Main Gas Valve and the unit will be in standby mode until another
call for heat is initiated by the thermostat.
6. The Ignition Control monitors the Flame Sensor during the ignition
trial period.
See the flow chart on page 24 for more information.
23
SEQUENCE OF OPERATION FLOW CHART
Description of this flow chart can be found in the “SEQUENCE OF OPERATION” section found on page 25.
START
THERMOSTAT
CALLS FOR HEAT.
SAFE
START
CHECK
POWER INTERUPTION.
SYSTEM SHUTS OFF. RESTARTS
WHEN POWER IS RESTORED.
SAFE START
CHECK
IF FLAME SIMULATION
CONDITION IS PRESENT,
SYSTEM WILL NOT START.
VALVE-ON DELAY
(S89F ONLY)
TRIAL FOR
IGNITION
BURNER
OPERATION
END
VALVE-ON DELAY
30S PREPURGE
COMBUSTION
AIR BLOWER STARTS.
SPARK GENERATOR
POWERED, IGNITION
BEGINS AND GAS
CONTROL OPENS.
IF NO SPARK, S89 LOCKS OUT
AND SHUTS DOWN SYSTEM.
MUST BE RESET.
BURNER LIGHTS.
IGNITION STOPS
AND FLAME
CURRENT IS
SENSED.
IF FLAME CURRENT IS ABSENT,
WEAK, OR UNSTEADY, S89
LOCKS OUT AND SHUTS DOWN
SYSTEM. MUST BE RESET.
BURNER RUNS
S89 MONITORS
FLAME CURRENT.
IF FLAME IS LOST, S89 CLOSES
GAS CONTROL, THEN RESTARTS
SAFE START CHECK AND TRIAL
FOR IGNITION.
THERMOSTAT
SATISFIED. GAS
CONTROL CLOSES,
BURNER GOES OFF.
FLOWCHART 1.
24
LIGHTING & OPERATION LABEL
Figure 21. Label for Natural AND LP Gas Models
25
Adjustments
time required for the heater to consume 5 cubic feet of gas. The
actual rate may then be estimated by using the formula below:
1. Check gas line pressure and manifold pressure (Table 9) and
adjust as required.
(3600/T) x H = Btuh
2. Check barometric damper for proper operation. Parts must
move freely.
T = Time in seconds to burn one cubic foot of gas.
3. Allow the unit to operate for 15 minutes. Drain hot water from
the heater or storage tank to continue main burner operation.
H = Btu’s per cubic foot of gas.
Btuh = Actual heater input.
4. Determine heat input rate (see CHECKING THE INPUT
section below).
Example:
CHECKING VENTING
T = 15.1 seconds
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.
H = 1050 Btu
Btuh = ?
(3600/15.1) x 1050 = 250,000
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
Z223.1or the CAN/CGA B149 Installation Codes and
these instructions. Determine that there is no blockage or
restriction, leakage, corrosion and other deficiencies which
could cause an unsafe condition.
The input may be adjusted by adjusting the pressure regulator.
Remove the top cap to expose the adjustment screw. Turning
the screw in increases the gas pressure and backing the
screw out decreases the pressure. Do not turn the adjusting
screw in past the point where no further increase in pressure
is noted.
3. So far as is practical, close all building doors and windows
and all doors between the space in which the water
heater(s) connected to the venting system are located and
other spaces of the building. Turn on all appliances not
connected to the venting system. Turn on all exhaust fans,
such as range hoods and bathroom exhausts, so they shall
operate at maximum speed. Close fireplace dampers.
The manifold pressure is measured at the Line Pressure Tap,
see Figure 22, and should be used as a reference point for
making pressure regulator adjustments. Table 9 gives the
design manifold pressures for each model. Increase or reduce
the pressure as required to obtain the rated input.
If an acceptable rate cannot be achieved by adjusting the
pressure regulator (manifold pressure), first check to be
certain that the gas supply pressure to the unit is adequate.
If the supply pressure is inadequate, a different burner orifice
may be required. Obtain from the utility the heating value and
specific gravity of the gas at the site. Provide this information
and the altitude of the site to obtain a larger orifice size.
4. Follow the lighting instruction. Place the water heater in
operation. Adjust thermostat so water heater shall operate
continuously.
5. After it has been determined that each appliance connected
to the venting system properly vents when tested as outlined
above, return doors, windows, exhaust fans, fireplace
dampers and any other gas burning appliance to their
previous conditions of use.
UNDER NO CIRCUMSTANCES SHOULD THE GAS INPUT
EXCEED THE INPUT SHOWN ON THE HEATER MODEL AND
RATING PLATE. OVERFIRING COULD RESULT IN DAMAGE
OR SOOTING OF THE HEATER.
6. If improper venting is observed during any of the above
tests, the venting system must be corrected.
FAILURE TO CORRECT BACK DRAFTS MAY CAUSE AIR
CONTAMINATION AND UNSAFE CONDITIONS.
Table 8.
APPROXIMATE TIME REQUIRED TO CONSUME
1 CU. FT. OF GAS AT FULL CAPACITY
• If the back draft cannot be corrected by the normal method
or if a suitable draft cannot be obtained, a blower type flue
gas exhauster must be employed to assure proper venting
and correct combustion.
INPUT
RATE
(BTUH)
INPUT
BTUH
PER
CU. FT.
TIMES
(for Natural
gas in Sec.)
TIMES
(for LP gas
in Sec.)
GPG 81-140
140000
1050
2500
27. 2
64.7
GPG 81-199
199000
1050
2500
19.0
45.2
The input rate can be estimated by timing the meter, if no other
appliances are operating.
GPG 81-270
270000
1050
2500
14.0
33.3
With a stopwatch, or a wristwatch, which can display the time
in seconds, read the gas meter and measure the amount of
GPG 81-370
370000
1050
2500
10.2.
24.3
CHECKING THE INPUT
For installation locations with elevations above 2000 feet, refer
to HIGH ALTITUDE INSTALLATIONS section of this manual
for input reduction procedure.
26
SETTING BURNER OPERATION
Table 9.
NOMINAL START-UP SPECIFICATIONS
Make combustion measurements and corresponding air
shutter adjustments per Table 9. Combustion results from
Table 9 are for natural gas models.
MODEL
GPG 81-140 GPG 81-199 GPG 81-270 GPG 81-370
Max. Gas Line Press.(W.C.) Nat. Gas - 10.5” W.C./Prop. Gas -13.0”
Manifold Press. (W.C.)
Natural Gas
3.5
3.5
3.5
3.5
Propane Gas
3.5
3.5
3.5
3.5
Orifice
Natural Gas
0.24
0.308
0.386
0.532
Propane Gas
0.209
0.257
0.302
0.368
Air Shutter Setting No.
Natural Gas
2.5
5.75
4
3
Propane Gas
4.5
10
4
8.5
CO%
9.2%
9.8%
7.5%
8.0%
CO Parts Per Million
<200
<200
<200
<200
Gross Stack Temp. (°F)
305
338
405
488
Ranges from - 0.02 to - 0.07 Inches Water Column
Breeching Press.(inches W.C.)
• Proceed with CO2 test of the flue gases with an Orsat or
other similar combustion test equipment. If the CO2 content
is within range (see Table 9) no adjustment of the air shutter
is required. Flue gas temperature and CO2 measurements
should be repeated 3 times to ensure accurate readings.
• Check the flue gas temperature ahead of the barometric
damper. See Table 9 (net temp. = gross temp. = ambient temp.)
• Check breeching pressure and the barometric damper control
to make sure it operates freely and there is no discharge of
flue products into the room.
• Check main burner operation by cycling on and off the
thermostat dial several times. Wait 1 minute between cycles
for regulators and sequencing to reset.
When all adjustments are satisfactory:
• Fill in part no. 196793 “Start-up” form.
• Adjust thermostat temperature dial to deliver desired water
temperature at point of use.
• For subsequent normal starting and shutoff procedure, see
LIGHTING and OPERATION LABEL on page 25.
Figure 22.
27
mAINTENANCE
venting system and BAROMETRIC DRAFT CONTROL
heater where the thermostat senses the drop in water temperature
and activates main burner operation of the water heater.
The heater is equipped with a double acting barometric draft
control. This control assembly is factory adjusted to automatically
regulate the chimney draft imposed on the unit. The damper gate
must pivot freely in the ring guides. See Figure 23.
If the storage tank temperature control is out of calibration, replace
with new control.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL
TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE
TO THE Water heater.
temperature-Pressure relief Valve test
Burn hazard.
Hot water discharge.
keep clear of TemperaturePressure Relief Valve
discharge outlet.
BAROMETRIC DRAFT CONTROL
FIGURE 23.
Examine the venting system every six months for obstructions
and/or deterioration of the vent piping.
Remove all soot or other obstructions from chimney which will
retard free draft.
It is recommended that the Temperature-Pressure Relief Valve should
be checked to ensure that it is in operating condition every 6 months.
GENERAL
When checking the Temperature-Pressure Relief Valve operation,
make sure that (1) no one is in front of or around outlet of TemperaturePressure Relief Valve discharge line, and (2) that water discharge
will not cause any property damage, as water may be extremely hot.
Use care when operating valve as valve may be hot.
Water heater maintenance includes periodic tank flushing and
cleaning, and removal of lime scale. The power burner should be
inspected and adjusted to maintain proper combustion. Refer to
Table 9. A periodic inspection of the venting system and barometric
damper should be made. Where used, the water heating system
circulating pump should be oiled per manufacturer's instructions.
To check the pressure relief valve, lift lever at the end of valve several
times, see Figure 24. The valve should seat properly and operate freely.
If after manually operating the valve, it fails to completely reset and
continues to release water, immediately close the cold water inlet to
the water heater and drain the water heater, see Draining And Flushing
on page 32. Replace the Temperature-Pressure Relief
Following are the instructions for performing some of the
recommended maintenance. Power burner inspection and
adjustment should be performed by a competent technician.
Table 10.
Valve with a properly rated/sized new one, see Temperature-Pressure
Relief Valve on pages 12-13 for instructions on replacement.
RECOMMENDED MAINTENANCE SCHEDULE
FOR THE GPG HEATER
COMPONENTS
OPERATION
INTERNAL
Flushing
Monthly
Tank
Sediments
Removal
Semi-Annually
Lime Scale
Removal
As Required
REQUIRED
Un»l_ime
Delimer
Relief Valve
Inspect
Semi-Annually
Circulating Pump
and Power
Burner Motor(1)
Oiling
Quarterly
SAE No. 20
Non-Detergent
Motor Oil
Power Burner
and Ignition
Device (2)
Inspection
and Adjustment
Semi-Annually
Combustion Test
Kit and Test
Specifications
Main Burner
Vent System and
Inspect
Semi-Annually
Barometric
Damper
Inspect
Semi-Annually
Anode(s)
Inspect
Annually
Figure 24.
If the Temperature-Pressure Relief Valve on water heater weeps
or discharges periodically, this may be due to thermal expansion.
NOTE: Excessive water pressure is the most common cause of
Temperature-Pressure Relief Valve leakage. Excessive water system
pressure is most often caused by "thermal expansion" in a "closed
system." See Closed Water Systems and Thermal Expansion on
page 12. The Temperature-Pressure Relief Valve is not intended for
the constant relief of thermal expansion.
Draft Gauge
remote storage tank temperature control
Water temperature in remote storage tank (if used) is controlled by the
storage tank temperature control. The sensing element is mounted
in the hot water storage tank, see Water Piping Diagram section.
Temperature-Pressure Relief Valve leakage due to pressure build
up in a closed system that does not have a thermal expansion
tank installed is not covered under the limited warranty. Thermal
expansion tanks must be installed on all closed water systems.
A change in water temperature in the storage tank lower than the
tank temperature control setting will cause the sensor to activate the
circulating pump. The pump then circulates the water through the
DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF
VALVE OPENING. THIS CAN CAUSE PROPERTY DAMAGE,
SERIOUS INJURY OR DEATH.
28
It is recommended that the water heater storage tank be drained
and flushed every 6 months to reduce sediment buildup. The
water heater should be drained if being shut down during freezing
temperatures. See Features And Components in this manual for
the location of the water heater components described below.
TO DRAIN THE WATER HEATER STORAGE TANK:
1. Turn off the electrical supply to the water heater.
2. Turn off the gas supply at the Main Gas Shutoff Valve if the
water heater is going to be shut down for an extended period.
3. Ensure the cold water inlet valve is open.
4. Open a nearby hot water faucet and let the water run until the
water is no longer hot.
5. Close the cold water inlet valve to the water heater.
6. Connect a hose to the water heater drain valve and terminate
it to an adequate drain.
7. Open the water heater drain valve and allow all the water to
drain from the storage tank.
8. Close the water heater drain valve when all water in the
storage tank has drained.
9. Close the hot water faucet opened in Step 4.
10.If the water heater is going to be shut down for an extended
period, the drain valve should be left open.
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
Properly sized temperaturepressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
anode rod inspection
CAUTION
Property Damage Hazard
TO FLUSH THE WATER HEATER STORAGE TANK:
1. Turn off the electrical supply to the water heater.
2. Ensure the cold water inlet valve is open.
3. Open a nearby hot water faucet and let the water run until the
water is no longer hot. Then close the hot water faucet.
4. Connect a hose to the drain valve and terminate it to an
adequate drain.
5. Ensure the drain hose is secured before and during the entire
flushing procedure. Flushing is performed with system water
pressure applied to the water heater.
6. Open the water heater drain valve to flush the storage tank.
7. Flush the water heater storage tank to remove sediment and
allow the water to flow until it runs clean.
8. Close the water heater drain valve when flushing is completed.
9. Remove the drain hose.
10.Fill the water heater - see Filling The Water Heater in this manual.
11. Turn on electrical supply to place water heater back in operation.
12.Allow the water heater to complete several heating cycles to
ensure it is operating properly.
• Avoid water heater damage.
• Inspection and replacement of anode rod required.
The anode rod is used to protect the tank from corrosion. Most
hot water tanks are equipped with an anode rod. The submerged
rod sacrifices itself to protect the tank. Instead of corroding tank,
water ions attack and eat away the anode rod. This does not affect
water’s taste or color. The rod must be maintained to keep tank in
operating condition.
Anode rod deterioration depends on water conductivity, not
necessarily water condition. A corroded or pitted anode rod indicates
high water conductivity and should be checked and/or replaced more
often than an anode rod that appears to be intact. Replacement
of a depleted anode rod can extend the life of your water heater.
Inspection should be conducted by a qualified technician, and at a
minimum should be checked annually after warranty period.
Artificially softened water is exceedingly corrosive because the
process substitutes sodium ions for magnesium and calcium ions.
Use of a water softener may decrease the life of water heater tank.
recommended procedure for periodic
removal of lime deposits from tank type
commercial water heaters
The anode rod should be inspected after a maximum of three
years and annually thereafter until condition of anode rod dictates
its replacement. Anode replacement is not covered by warranty.
NOTE: artificially softened water requires the anode rod to be
inspected annually.
The amount of calcium carbonate (lime) released from water is
in direct proportion to water temperature and usage, see chart.
The higher the water temperature or water usage, the more lime
deposits are dropped out of the water. This is the lime scale which
forms in pipes, heaters and on cooking utensils.
Lime accumulation not only reduces the life of equipment but also
reduces efficiency of the heater and increases fuel consumption.
The usage of water softening equipment greatly reduces the
hardness of the water. However, this equipment does not always
remove all of the hardness (lime). For this reason it is recommended
that a regular schedule for deliming be maintained.
The time between cleaning will vary from weeks to months
depending upon water conditions and usage.
The depth of lime buildup should be measured periodically. Heaters
equipped with cleanouts will have about 2" of lime buildup when
the level of lime has reached the bottom of the cleanout opening. A
schedule for deliming should then be set up,based on the amount
of time it would take for a 1" buildup of lime. It is recommended that
the water heater initially be inspected after 6 months.
Example 1:
Initial inspection after 6 months shows 1/2" of lime accumulation.
Therefore, the heater should be delimed once a year.
Example 2:
Initial inspection after 6 months shows 2" of lime accumulation.
Therefore, the heater should be delimed every 3 months.
Draining and flushing
Burn harzard.
Hot water discharge.
Keep hands clear of drain
valve discharge.
29
Prepare the Water Heater
To delime the water heater using the Flo-Jug method, first
prepare the heater for deliming.
Explosion Hazard
Flammable hydrogen gases
may be present.
Keep all ignition sources away
from faucet when turning on
hot water.
Do not smoke or have open flame or sparks in vicinity of heater.
Do not mix UN•LIME with other chemicals. Do not allow contact
with magnesium, aluminum or galvanized metals.
Figure 25.
Chemical Hazard
deliming solvents
UN•LIME is recommended for deliming. UN•LIME is a patented
food grade acid which is safe to handle and does not create the
harmful fumes which are associated with other products.
• Product contains phosphoric acid.
• Keep out of reach of children.
UN•LIME may be obtained from your dealer, distributor or
water heater manufacturer. Order Part Number 9005416105,
1 gallon, packed 4 gallons per case or Part Number 9005417105,
5 gallon container.
• Use rubber or neoprene gloves.
Contains phosphoric acid. In case of external contact, flush with
cool water. If irritation persists, get medical attention. If swallowed,
give 1 or 2 glasses of water or milk and call physician.
NOTE: Un•Lime is not available for use in Canada.
Hydrochloric base acids are not recommended for use on glass
lined tanks.
Get immediate medical attention for eyes. Keep out of reach
of children.
Observe handling instructions on label of product being used.
NOTE: THE USE OF RUBBER OR NEOPRENE GLOVES IS
RECOMMENDED, ESPECIALLY IF YOU HAVE ANY OPEN
SORES OR CUTS TO AVOID UNNECESSARY IRRITATION OR
DISCOMFORT.
tank Cleanout Procedure
The following practices will ensure longer life and enable the
unit to operate at its designed efficiency:
1. Once a month the heater should be flushed. Open drain valve
and allow two gallons of water to drain from heater. Inlet water
valve should remain open to maintain pressure in tank.
2. A cleanout opening is provided for periodic cleaning of the tank.
Gas must be shut off and heater drained before opening cleanout.
1. Turn off fuel and/or power supply to heater. Also, turn off power
to any electrical device or equipment, which is attached, or part
of the system.
2. Open hot water side of faucet closest to heater and allow water
to run until it is cool enough to handle safely.
3. Close cold water inlet valve to heater.
4. Connect hose to drain valve at bottom of heater and start draining
heater into suitable floor drain area.
5. Remove pressure relief valve while heater is draining. NOTE:
Do not replace pressure relief valve until deliming is completed.
Pressure relief valve opening will also act as a vent in case of
possible contact between the delimer and the anode rod(s),
which may produce flammable hydrogen-air mixtures.
6. If pressure relief valve appears to be limed-up, place it in a clean
glass or plastic container adequate in size so that you can pour
enough UN•LIME® into container to cover the valve and allow
space for foaming. When foaming stops, run fresh cool water into
the container and rinse the pressure relief valve for a few minutes.
7. If heater does not drain completely after a reasonable length
of time, turn off the main water supply valve to stop water from
entering the tank due to a by-pass problem or defective cold
water inlet valve. Also, check for clogged drain valve opening.
Heater must be completely drained before introducing UN•LIME.
8. Remove the cleanout cover and place a clean plastic bucket
next to the cleanout opening.
Partially open the cold water inlet valve to allow time to
accomplish the following and then close the valve.
To clean heater through cleanout opening, proceed as follows:
3. Drain heater.
4. Remove outer cover plate from lower side of heater jacket.
5. Remove six (6) hex head screws securing tank cleanout plate
and remove plate.
6. Remove lime, scale, or sediment using care not to damage
the glass lining.
7. Inspect cleanout plate gasket, if new gasket is required,
replace with part no. 9004099215.
8. Install cleanout plate. Be sure to draw plate up tight by
tightening screws securely.
9. Replace outer jacket cover plate.
In some water areas the sediment might not be removed by this
method and may result in the water heater making rumbling or
boiling noises. To dissolve and remove these more stubborn
mineral deposits, UN•LIME Professional Delimer should be used.
DELIMING USING FLO-JUG METHOD
UN•LIME in the 5 gallon size is recommended for deliming of all
models. Contact your local dealer, distributor or, water heater
manufacturer:
30
While the water is being run through the tank, insert a
stiff wire, copper tube flattened at one end or an opened
wire coat hanger through the cleanout opening and
scrape out any loose deposits of scale or sediment. This
is an economical way to avoid unnecessary usage of the
deliming solution.
Normally, lime removal will be completed within one hour.
Severe build-up of lime may take longer than an hour to complete
descaling.
Note: To check UN•LIME for continued use, place some scale
or white chalk in a glass with a small amount of UN•LIME. If
the material is vigorously dissolved by the UN•LIME, it can be
reused; if not, the UN•LIME should be replaced.
Repeat the opening and closing of the cold water inlet valve
as necessary but be sure the heater is completely drained
when ready to introduce the UN•LIME.
Upon completion, reinstall the cleanout cover and use a new
cleanout cover gasket (part number 9004099215).
Remove the drain valve.
9. Install the long plastic male adapter insert fitting into the drain
valve opening of heater after applying Teflon tape or paste to
threads. Tighten firmly by hand and use wrench or adjustable
pliers to check for secure connection. Do not over tighten to
avoid damage to threads and fittings.
Prepare the Up-N-Down Transfer Kit
The next step is the preparation on the Up-N-Down Transfer Kit,
if you have not already done so:
1. With the 5 gallon Up-N-Down container in the vertical
position, unscrew the plastic vent cap in the handle and
pierce the plastic membrane over the vent boss under the
cap to allow the container to vent.
Figure 26.
power Burner
Keep the area around the burner clear and free of combustible
materials, gasoline or other flammable liquids or vapors.
Do not obstruct burner air openings or ventilation grilles for
combustion air.
Note: If your container does not have the vent cap and vent
boss, drill a 3/16” hole in the handle. When you have finished
deliming you will be able to plug this drilled vent with the
stainless steel screw that is supplied with the kit.
2. Remove the container’s cap and cut the plastic membrane
located in the 3/4” IPT opening in the cap. Take care to not
damage the threads.
3. Find the 3/4” male adapter, apply teflon tape to the threaded
end and screw it into the 3/4” IPT opening in the cap.
4. Put cap with male adapter back on the container and slide
3/4” hose over end of male adapter and fasten in place using
hose clamp provided.
Delime using Flo-Jug Method
5. Slide the hose clamp over end of hose and slide hose over
the male adapter in the water heater drain opening and
secure in place using hose clamp.
TYPICAL MAIN BURNER FLAME
FIGURE 27.
The main burner flames (Figure 27) should be visually checked
once a year for proper operation. This can be observed through
the observation port on the burner housing. Burner flame should
be blue. DO NOT use the observation port on the side of the tank
to inspect the burner flame.
6. Lift container to the “Pour” Position, see Figure 26, being
careful to keep the vent in the handle above the liquid level
and pour the UN•LIME into the heater.
7. Lower container, you may have to place the container on its
empty carton to prevent the UN•LIME from flowing back into
the container.
1. Add a few drops of no. 20 non-detergent oil (GPG 81-140 Thru
81-370) into the oil tubes once every three months.
2. At least annually, contact a qualified service agency for a burner
readjustment, cleaning and other than routine maintenance.
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.
8. Let UN•LIME remain in the heater for 5 minutes and then
lower the container to the “Drain” Position, see Figure 26.
9. Deliming activity is indicated by foaming on the surface of the
UN•LIME. If there is deliming activity, repeat steps 6 thru 8.
31
Gas Control Valve
Figure 30 shows the combination gas control valves used on
these heaters.
If gas control valve becomes defective, repairs should not
be attempted. A new valve should be installed in place of
defective one.
Figure 30.
SERVICE
ELECTRICAL SERVICING
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 a qualified service technician or
qualified agencies, using appropriate test equipment, be allowed
to service the heater.
As preliminary step, check wiring against diagram, check for
grounded, broken or loose wires. Check all wire ends to be sure
that they are making good contact.
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND
DANGEROUS OPERATION.
VERIFY PROPER OPERATION AFTER SERVICING.
32
Troubleshooting checklist
COMPLAINT
Water not hot enough.
Insufficient hot water
CAUSE
USER
REMEDY
QUALIFIED SERVICE AGENCY
Thermostat set too low.
Set thermostat dial to a higher
temperature.
Upper and/or lower temperature
probe out of calibration.
Call qualified service agency.
Thermostat set too low.
Set thermostat dial to a higher
temperature.
Upper and/or lower temperature
probe out of calibration.
Call qualified service agency.
Main manual gas shutoff valve
partially closed.
Open main manual gas shutoff
valve to fullest extent.
Heater too small for demand.
Space usage to give heater time
to restore water temperature.
Heater recovery is slower.
Call qualified service agency.
Water temperature too hot.
Thermostat set too high.
Set thermostat to a lower setting.
Heater makes sounds: sizzling.
Condensation on outside of
tank - normal.
Rumbling.
Sediment accumulation on
bottom of tank.
Ticking or metallic sounds.
Expansion and contractionnormal.
Pounding / water hammer.
Air chambers in piping have
become waterlogged. Thermal
expansion tank damaged,
improperly charged, or
improperly sized.
Combustion noises.
Too much primary air.
Overtired heater. Incorrect
burners or orifice for types of
gas used.
Water leaks.
Gas odors.
Check continuity and resistance
(Ohms) of upper and lower
thermostat probes. Replace probes
if out of specification.
Check continuity and resistance
(Ohms) of upper and lower
thermostat probes. Replace probes
if out of specification..
Check gas input. If incorrect, adjust
gas pressure or replace main burner
orifice.
Drain a quantity of water through
drain valve. If rumbling persists,
call a qualified service agency.
Delime heater.
Drain piping system and refill.
Heater must be off while this
is being done. Check thermal
expansion tank charge pressure
when the water system pressure
is zero.
Follow the manufacturer's
instructions for proper charging
of the thermal expansion tank.
Call qualified service agency.
Call qualified service agency.
Check and correct as necessary.
Drain valve not closed tightly.
If drain valve cannot be closed
tightly, replace.
If leakage source cannot be
corrected or identified, call
qualified service agency.
Shut off gas supply to heater
and close cold water inlet valve to
heater.
Repair or in case of suspected tank
leakage, be certain to confirm before
replacing heater.
Heater is over fired.
Shut off gas supply to heater and
call qualified service agency.
Check for sooted flue passage.
Check for obstructed vent line.
Check backdraft or lack of draft.
Draft hood may be improperly
installed or not sized properly.
Possible gas leaks.
Shut off gas supply to heater and
call gas company at once.
33
For Your Information
c. A sulfate reducing bacteria which has accumulated
within the water heater (this harmless bacteria is
nontoxic to humans).
start up conditions
SMOKE/ODOR
d. An excess of active hydrogen in the tank. This is caused
by the corrosion protective action of the anode rod.
It is not uncommon to experience a small amount of smoke and
odor during the initial start-up. This is due to burning off of oil
from metal parts, and will disappear in a short while.
Smelly water may be eliminated or reduced in some water
heater models by replacing the anode rod(s) with one of less
active material, and then chlorinating water heater tank and all
water lines.
STRANGE SOUNDS
Possible noises due to expansion and contraction of some metal
parts during periods of heat-up and cool-down do not necessarily
represent harmful or dangerous conditions.
Contact the local water heater supplier or service agency for
further information concerning an Anode Rod Replacement Kit
and this chlorination treatment.
Condensation causes sizzling and popping within the burner area
during heating and cooling periods and should be considered
normal. See “Condensation" section in this manual.
If smelly water persists after anode rod replacement and chlorination
treatment, we can only suggest that chlorination or aeration of the
water supply be considered to eliminate the water problem.
CONDENSATION
Whenever the water heater is filled with cold water, some
condensate will form while the burner is on. A water heater may
appear to be leaking when in fact the water is condensation.
This usually happens when:
Do not remove the anode rod leaving the tank unprotected. By
doing so, all warranty on the water heater tank is voided.
“AIR” IN HOT WATER FAUCETS
HYDROGEN GAS: Hydrogen gas can be produced in a hot
water system that has not been used for a long period of time
(generally two weeks or more). Hydrogen gas is extremely
flammable and explosive. To prevent the possibility of injury under
these conditions, we recommend the hot water faucet, located
farthest away, be opened for several minutes before any electrical
appliances which are connected to the hot water system are
used (such as a dishwasher or washing machine). If hydrogen
gas is present, there will probably be an unusual sound similar to
air escaping through the pipe as the hot water faucet is opened.
There must be no smoking or open flame near the faucet at the
time it is open.
a. A new water heater is filled with cold water for the first time.
b. Burning gas produces water vapor in water heaters,
particularly high efficiency models where flue temperatures
are lower.
c. Large amounts of hot water are used in a short time and the
refill water in the tank is very cold.
Moisture from the products of combustion condense on the cooler
tank surfaces and form drops of water which may fall onto the
burner or other hot surfaces to produce a “sizzling” or “frying” noise.
operational conditions
HIGH WATER TEMPERATURE SHUT OFF SYSTEM
HOT WATER ODOR
This water heater is equipped with a manual reset type high limit
(Energy Cutout) switch. The high limit switch interrupts the main
burner gas flow should water temperature reach 203°F (95°C).
In each water heater there is installed at least one anode rod for
corrosion protection of the tank. Certain water conditions will
cause a reaction between this rod and the water. The most
common complaint associated with the anode rod is one of a
“rotten egg smell” in the hot water. The smell is a result of four
factors which must all be present for the odor to develop:
In the event of high limit switch operation, the water heater
cannot be restarted unless the water temperature is reduced
to approximately 120F (49C). The high limit reset button on the
front of the thermostat then needs to be depressed. See Figure 2
for the location of the reset button.
a. A concentration of sulfate in the supply water.
b. Little or no dissolved oxygen in the water.
34
35
ALT. COLD WATER
CONNECTION
HOT WATER
TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (1 UNIT) WITH VERTICAL STORAGE TANK
COLD WATER
SUPPLY
EXPANSION
TANK
DRAIN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
HOT WATER RETURN
FROM FIXTURES
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
water Piping Diagrams
36
HOT WATER TO FIXTURES
ALTERNATE
LOCATION
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (1 UNIT) WITH HORIZONTAL STORAGE TANK
DRAIN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
RETURN FROM
FIXTURES
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
37
HOT
WATER
RETURN
TEMPERED
WATER
OUTLET
COLD
HOT
HOT
WATER
OUTLET
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
EXPANSION
TANK
COLD WATER
SUPPLY
TEMPERED
WATER
RETURN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (1 UNIT) WITH MIXING VALVE TWO TEMPERATURE
DRAIN
PIPE T&P TO
OPEN DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
38
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
PIPE T&P TO
OPEN DRAIN
HOT WATER
TO FIXTURES
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (2 UNITS)
COLD WATER
SUPPLY
EXPANSION
TANK
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
HOT WATER
RETURN
LEGEND
39
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (2 UNITS) WITH VERTICAL STORAGE TANK
ALTERNATE
COLD WATER
CONNECTION
HOT WATER
TO FIXTURES
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
COLD WATER
SUPPLY
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
EXPANSION
TANK
LEGEND
40
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (2 UNITS) WITH VERTICAL STORAGE TANK
ALTERNATE
COLD WATER
CONNECTION
HOT WATER
TO FIXTURES
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
COLD WATER
SUPPLY
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
EXPANSION
TANK
LEGEND
41
PIPE T&P TO
OPEN DRAIN
HOT WATER TO FIXTURES
DRAIN
EXPANSION
TANK
COLD WATER
SUPPLY
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
ALTERNATE
LOCATION
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (2 UNITS) WITH HORIZONTAL STORAGE TANK
LEGEND
HOT WATER
RETURN FROM
FIXTURES
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
42
EXPANSION TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
HOT WATER
TO FIXTURES
PRE-HEATED
WATER TO
BOOSTER
DRAIN
BOOSTER
HEATER
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
BOOSTER WATER RETURN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
BOOSTER WATER
TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
1st HEATER
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE (2 UNITS) TWO TEMPERATURE
LEGEND
43
PRE-HEATER
PRE-HEATER
MUST BE IDENTICAL HEATERS
PIPE T&P TO
OPEN DRAIN
DRAIN
BOOSTER RETURN
(IF USED)
EXPANSION
TANK
COLD WATER
SUPPLY
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
HOT OUTLET
AT STORED
TEMPERATURE
BOOSTED
WATER
OUTLET
TYPICAL
BOOSTER
HEATER
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE (2 UNITS) WITH BOOSTER TWO TEMPERATURE
LEGEND
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
44
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
PIPE T&P TO
OPEN DRAIN
HOT WATER
TO FIXTURES
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI-FLUE (3 UNITS)
DRAIN
EXPANSION
TANK
COLD WATER
SUPPLY
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
45
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
ALT. COLD WATER
CONNECTION
EXPANSION TANK
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
COLD WATER
SUPPLY
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
HOT WATER TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
HEATER
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI-FLUE (3 UNITS) WITH VERTICAL STORAGE TANK
STORAGE TANK
46
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
STORAGE TANK
HOT WATER TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI-FLUE (3 UNITS) WITH HORIZONTAL STORAGE TANK
ALTERNATE
LOCATION
PIPE T&P TO
OPEN DRAIN
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
EXPANSION TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
47
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
FINISHED FLOOR
HOT WATER
TO FIXTURES
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE FLUE (4 UNITS)
PIPE T&P TO
OPEN DRAIN
DRAIN
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
COLD WATER
SUPPLY
EXPANSION
TANK
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
48
HEATER
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI-FLUE (4 UNITS) WITH VERTICAL STORAGE TANK
STORAGE TANK
ALT. COLD
WATER
CONNECTION
HOT WATER
TO FIXTURES
DRAIN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
49
HEATER
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
DRAIN
STORAGE TANK
ALTERNATE
LOCATION
PIPE T&P TO
OPEN DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
HOT WATER
TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI-FLUE (4 UNITS) WITH HORIZONTAL STORAGE TANK
LEGEND
EXPANSION TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
manifold kits
Dimensions shown are for minimum space occupied by the water heaters
assemblies.
Space for the barometric draft control assemblies, combustion clearances
and servicing must be added.
PRIOR TO START UP
IMPORTANT
Factory Start-Up is required for activating warranty and assuring maximum
operating performance. Contact your local sales representatives or
Authorized Start-Up Agent to arrange a FREE Certified Start-Up.
50
COMMERCIAL GAS
Glass Lined Tank Type Water Heater
REPLACEMENT PARTS LIST
MAIN BURNER ORIFICE CHART
Natural Gas Propane Gas
BurnerWayne C.S.Wayne C.S.
ModelsNumber Part No. (Decimal) Part No. (Decimal)
GPG 81-140 HSG-200 62459-001
0.24
62459-001
0.209
GPG 81-199 HSG-200 62459-001
0.38
62459-001
0.257
GPG 81-270 HSG-400 62459-002
0.368
62459-002
0.302
GPG 81-370 HSG-400 62459-002
0.532
62459-002
0.386
51
ItemDescriptionGPG 81-140GPG 81-199GPG 81-270GPG 81-370
1..... Anode........................................................9003892005(2)........ 9003892005(2).......9003892005(2)...........9003892005(2)
2..... Baffle, Flue.................................................9005293205(7)........ 9005293205(7).......9005293205(7)...........9005293205(7)
3..... Barometric Draft Control w Tee Assy.........9500007199............ 9500007199............9500007200...............9500007200
Cleanout Assembly:
4..... Gasket.......................................................9004099215............ 9004099215............9004099215...............9004099215
5..... Pressure Plate...........................................9005797205............ 9005797205............9005797205...............9005797205
6..... Screw, Self Tapping (Req’d)......................9004100215............ 9004100215............9004100215...............9004100215
7..... Cover, Cleanout Opening..........................181260.................... 181260....................181260.......................181260
8..... Thermostat with ECO................................9004529005............ 9004529005............9004529005...............9004529005
9..... Valve, Drain...............................................9003906015............ 9003906015............9003906015...............9003906015
10.... Valve, T & P...............................................9005903205............ 9005903205............9005903205...............9005903205
11.... Reducer, Flue............................................76707-0................... 76707-0...................76707-4......................76707-4
* Items not illustrated. ( ) Reflects quantities.
All information such as model and series number, type of gas and specifications must tobe supplied to State
Water Heaters.
52
notes
53
notes
54
Model GPG Limited Warranty
Factory Start-Up is required for activating warranty and assuring maximum operating performance. Contact your local sales representatives or Authorized StartUp Agent to arrange a FREE Certified Start-Up.
State Water Heaters, the warrantor, extends the following LIMITED WARRANTY to the owner of this water heater.
1.THE TANK
If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable water therein,
during the first THREE years after initial installation, the warrantor will supply a complete new State water heater of equivalent size and current model.
Some government agencies are requiring energy efficient standards for water heaters. In the event regulations prohibit sale of a model of equivalent size
and construction, State will provide a model which complies with the regulations of your area, in which case the consumer will be charged the difference in
price between the like replacement and the energy efficient model required. The warranty on the replacement water heater will be limited to the unexpired
term of the original warranty.
2.ALL OTHER PARTS
If within ONE year after initial installation of this water heater, any part or portion shall prove upon examination by the warrantor to be defective in material
or workmanship, the warrantor will repair or replace such part or portion at its option.
3.CONDITIONS AND EXCEPTIONS
This warranty shall apply only when the water heater is installed in accordance with local plumbing and building codes, ordinances and regulations, the
printed instructions provided with it and good industry practices. In addition, a temperature and pressure relief valve, certified by A.G.A. and approved by
the American Society of Mechanical Engineers, must have been installed.
a. This warranty shall apply only when the heater is used:
(1) at temperatures not exceeding the maximum setting of its thermostat;
(2) at water pressure not exceeding the working pressure shown on the water heater;
(3) when operated free of the damaging effects of uncontrolled water hammer;
(4) when filled with potable water, free to circulate at all times;
(5) in a non-corrosive and non-contaminated atmosphere;
(6) in its original installation location;
(7) with factory approved anode(s) installed;
(8) in the United States, its territories or possessions, and Canada.
b. Any accident to the water heater, any misuse, abuse (including freezing) or alteration of it, any operation of it in a modified form, or any attempt to repair
tank leaks will void this warranty.
c. This warranty is void if a device acting as a backflow prevention device (check valves etc.) is installed in the cold water supply the heater is connected
to, unless an effective method of controlling thermal expansion is also installed at the heater(s) and operational at all times. The relief valve installed on
the heater is not an acceptable method.
4.SERVICE AND REPAIR EXPENSES
Under the limited warranty the warrantor will provide only a replacement water heater or part thereof. The owner is responsible for all other costs. Such
costs may include but are not limited to:
a.Labor charges for service removal, repair or reinstallation of the water heater or any component part;
b. Shipping, delivery, handling, and administrative charges for forwarding the new heater or replacement part from the nearest distributor and returning the
claimed defective heater or part to such distributor.
c. All cost necessary or incidental for any material and/or permits required for installation of the replacement heater or part.
5.LIMITATIONS ON IMPLIED WARRANTIES
Implied warranties, including the warranty of merchantability imposed on the sale of this heater under state law are limited to one (1) year duration for the
heater or any of its parts. Some states do not allow limitation on how long an implied warranty lasts, so the above limitation may not apply to you.
6.CLAIM PROCEDURE
Any claim under the warranty should be initiated with the dealer who sold the heater, or with any other dealer handling the warrantor’s products. If this is
not practicable, the owner should contact:
State Water Heaters
500 Tennessee Waltz Pkwy
Ashland City, TN 37015
a. The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by the warrantor.
b. Dealer replacements are made subject to in-warranty validation by warrantor.
7.DISCLAIMERS
NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE HEATER OR THE
INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF THE HEATER. THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPERTY OR OTHER CONSEQUENTIAL DAMAGE.
THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY,
WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR IN TORT.
a. Some states do not allow the exclusion or limitation of the incidental or consequential damage, so the above limitations or exclusions may not apply to
you.
b. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Fill in the following for your own reference. Keep it. Registration is not a condition of warranty. The model and serial number are found on the heater’s rating plate.
Model No.______________________ Serial No.________________________________________________ Date Installed___________________________
Dealer’s Name_________________________________________________________________________________________________________________
Dealer’s Address______________________________________________________________________________ Phone No._________________________
City and State__________________________________________________________________________________ Zip____________________________
KEEP THIS WARRANTY POSTED ADJACENT TO THE HEATER FOR FUTURE REFERENCE.
55
500 Tennessee Waltz Parkway, Ashland City, TN 37015
Technical Support: 800-365-8170 • Parts: 800-821-2017
www.statewaterheaters.com
Copyright © 2013 State Industries, Inc., All rights reserved.
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