AHRI 154 User Manual
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; do
not use any phone in your building.
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.
•
•
•
•
Instruction Manual
COMMERCIAL GAS WATER HEATERS
MODEL 154
SERIES 120/121
INSTALLATION - OPERATION
- SERVICE - MAINTENANCE
We appreciate your condence in our products.
Thank you for buying this energy efcient water heater.
PRINTED 0819
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
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.
• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
1
BY THIS WATER HEATER.
100322746 2000573801 (Rev B)
CONTENTS
SAFE INSTALLATION, USE, AND SERVICE..................... 3
APPROVALS ...................................................................... 3
GENERAL SAFETY INFORMATION .................................. 4
Precautions ....................................................................4
Grounding Instructions ...................................................4
Hydrogen Gas Flammable .............................................4
INTRODUCTION ................................................................ 6
Abbreviations Used ........................................................6
Qualications ..................................................................6
Preparing for the Installation ..........................................6
FEATURES AND COMPONENTS ..................................... 7
The Eliminator (self-cleaning system) ............................7
INSTALLATION CONSIDERATIONS ................................. 9
Rough-In Dimensions .....................................................9
Locating the Water Heater .............................................10
NSF Leg Kit ................................................................... 11
Insulation Blanket .......................................................... 11
High Altitude Installations ..............................................12
INSTALLATION REQUIREMENTS .................................. 13
Gas Supply Systems .....................................................13
Supply Gas Regulator ...................................................13
Power Supply ................................................................13
Water Temperature Control and Mixing Valves .............14
Dish-washing Machines ................................................14
Closed Water Systems ..................................................14
Thermal Expansion .......................................................14
Temperature-Pressure Relief Valve ............................... 15
Contaminated Air ...........................................................16
Air Requirements ...........................................................16
VENTING INSTALLATION ............................................... 18
Fresh Air Openings For Conned Spaces .....................19
Outdoor Air Through One Opening ...............................19
Mechanical venting ........................................................22
WATER HEATER INSTALLATION .................................... 23
Water Line Connections ................................................23
T&P Valve Discharge Pipe ............................................23
Installation Diagrams - Top Inlet/Outlet Usage ..............24
Water Heater Wiring ......................................................24
Supply Gas Line Installation ..........................................25
OPERATION ..................................................................... 27
Prior to Start Up .............................................................27
SEQUENCE OF OPERATION ......................................... 27
Lighting & Operation Label ............................................29
Adjustments ...................................................................31
Checking the Venting ....................................................31
Checking the Input ........................................................32
MAINTENANCE ............................................................... 33
Venting System .............................................................33
Remote Storage Tank Temperature Control ..................33
Temperature-Pressure Relief Valve Test .......................33
Anode Rod Inspection ...................................................33
Draining and ushing .....................................................34
Removing Lime Deposits from Tank Type
Commercial Water Heaters ...........................................34
Deliming Solvents ..........................................................35
Tank Cleanout Procedure ..............................................35
Deliming Using Flo-Jug Method ....................................35
Pilot Burner ....................................................................36
Main Burner ...................................................................37
Gas Control Valve..........................................................37
SERVICE .......................................................................... 38
Electrical Servicing ........................................................38
TROUBLESHOOTING ..................................................... 39
Ignition Module ..............................................................39
Flue Damper ..................................................................39
Efkal RVGP-KSF-Series Flue Damper Trouble Shooting
Guide .............................................................................40
FOR YOUR INFORMATION ............................................. 42
Start Up Conditions .......................................................42
Operational Conditions ..................................................42
WATER PIPING DIAGRAMS ............................................ 43
MANIFOLD KITS .............................................................. 58
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
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 indicates an imminently
DANGER
WARNING
CAUTION
CAUTION
hazardous situation which, if not avoided,
will result in injury or death.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
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.
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.
APPROVALS
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.
Note: ASME construction is optional on the water heaters
covered in this manual.
3
GENERAL SAFETY INFORMATION
PRECAUTIONS
DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN
EXPOSED TO FLOODING OR WATER DAMAGE. Immediately
call a qualied service agency to inspect the water heater and
to make a determination on what steps should be taken next.
If the unit is exposed to the following, do not operate heater until
all corrective steps have been made by a qualied service agency.
1. External re.
2. Damage.
3. Firing without water.
GROUNDING INSTRUCTIONS
This water heater must be grounded in accordance with the
National Electrical Code
and/or local codes. These codes must be
followed in all cases. Failure to ground this water heater properly
may also cause erratic control system operation.
This water heater must be connected to a grounded metal,
permanent wiring system; or an equipment grounding conductor
must be run with the circuit conductors and connected to the
equipment grounding terminal or lead on the water heater.
HYDROGEN GAS FLAMMABLE
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
ammable. 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 ow. THERE
SHOULD BE NO SMOKING OR OPEN FLAME NEAR THE
FAUCET AT THE TIME IT IS OPEN.
Explosion Hazard
Flammable hydrogen gases
may be present.
Keep all ignition sources away
from faucet when turning on
hot water.
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.
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.
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.
Explosion Hazard
Overheated water can cause
water tank explosion.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
CAUTION
Improper installation, use and service may result
in property damage.
Do not operate water heater if exposed to flooding or
•
water damage.
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.
4
Fire or Explosion Hazard
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
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.
Breathing Hazard - Carbon Monoxide Gas
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
CAUTION
Property Damage Hazard
All water heaters eventually leak.
•
Fire Hazard
For continued protection against
risk of fire:
Do not install water heater on
carpeted floor.
Do not operate water heater if
exposed to flooding or water
damage.
Fire and Explosion Hazard
Use joint compound or Teflon tape
compatible with propane gas.
Leak test gas connections before
placing water heater in operation.
Disconnect gas piping at main
gas shutoff valve before leak
testing heater.
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.
Do not install without adequate drainage.
•
Electrical Shock Hazard
Turn off power at the branch circuit
•
breaker serving 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.
•
Failure to follow these instructions can
•
result in personal injury or death.
Jumping out control circuits or components can
result in property damage, personal injury or death.
Service should only be performed by a qualified service
•
technician 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.
Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the appliance warranty.
5
INTRODUCTION
Thank You for purchasing this water heater. Properly installed
and maintained, it should give you years of trouble free service.
ABBREVIATIONS USED
Abbreviations found in this Instruction Manual include :
• 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
QUALIFICATIONS
QUALIFIED INSTALLER OR SERVICE AGENCY
Installation and service of this water heater requires ability
equivalent to that of a Qualied Agency (as dened by ANSI
below) in the eld 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.
ANSI Z223.1:
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.”
If you are not qualied (as dened by ANSI above) and licensed or
certied 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.
“Qualied Agency” - “Any individual, rm, corporation
PREPARING FOR THE INSTALLATION
1. Read the entire manual before attempting to install or operate
the water heater. Pay close attention to the
Information
water heater may not operate safely. It could cause property
damage, injury and/or death.
This manual contains instructions for the installation,
operation, and maintenance of the 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.
2. Be sure to turn off power when working on or near the electrical
system of the water heater. Never touch electrical components
with wet hands or when standing in water.
3. The installation must conform to all instructions contained in
this manual and the local code authority having jurisdiction.
These shall be carefully followed in all cases. Authorities
having jurisdiction should be consulted before installation
begins if there are any questions regarding compliance with
local, state or national codes.
4. After reading this manual, if you have any questions or do
not understand any portion of the instructions, call the toll
free number on the back cover of this manual for technical
assistance. In order to expedite your request, please have the
full Model, Serial and Series numbers of the water heater you
are working with available for the technician. This information
is located on the water heater’s rating label.
5. Carefully plan the placement of the water heater. Correct
combustion, vent action, and vent pipe installation are very
important in preventing death from possible carbon monoxide
poisoning and res.
Examine the location to ensure that it complies with the
requirements in
the Water Heater
(page 4). If you don’t follow the safety rules, the
Rough-In Dimensions
(page 10).
(page 9) and
General Safety
Locating
6. For installation in California this water heater must be braced or
anchored to avoid falling or moving during an earthquake. See
instructions for correct installation procedures. Instructions
may be obtained from California Ofce of the State Architect,
1102 Q Street, Suite 5100, Sacramento, CA 95811.
7. 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.
6
FEATURES AND COMPONENTS
THE ELIMINATOR (SELF-CLEANING SYSTEM)
These units include The Eliminator (Self-Cleaning System)
installed in the front water inlet. See
Figure 1
. The Eliminator
inlet tube can only be used in the front water inlet connection.
Do not install the Eliminator inlet tube in either the top or back
inlet water connection.
The Eliminator must be oriented correctly for proper function.
There is a marked range on pipe nipple portion of the Eliminator,
that must be aligned with top of inlet spud. A label above the
jacket hole has an arrow that will point to marked portion of
pipe nipple if the orientation is correct. If the arrow does not
point within the marked range on pipe nipple, adjust the pipe
nipple to correct. A pipe union is supplied with the Eliminator to
reduce probability of misaligning the Eliminator accidentally while
tightening the connection to inlet water supply line. Improper
orientation of the Eliminator can cause poor performance of
heater and can signicantly reduce outlet water temperatures
during heavy draws.
Figure 1. Eliminator Self Cleaning System
Contact your dealer or service agent if continued high limit switch
operation occurs.
Figure 2. Digital Thermostat
ELECTRONIC IGNITION CONTROL
Each heater is equipped with a Honeywell ignition module. The
solid state ignition control ignites the pilot burner gas by creating
a spark at the pilot assembly. See
Figure 3
. Pilot gas is ignited
and burns during each running cycle. The main burner and pilot
gases are cut off during the OFF cycle. Pilot gas ignition is proven
by the pilot sensor. Main burner ignition will not occur if the pilot
sensor does not rst sense pilot ignition.
Note: The Eliminator may have 1, 3 or 7 cross tubes.
HIGH LIMIT SWITCH
The digital thermostat (
Figure 2)
contains the high limit (energy
cutout) switch. The high limit switch interrupts main burner gas
ow should the water temperature reach 203°F (95°C).
In the event of high limit switch operation, the water heater
cannot be restarted unless the water temperature is reduced to
approximately 120°F (49°C). The high limit reset button on the
front of the control then needs to be 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.
Figure 3. Honeywell Ignition Module
7
AUTOMATIC FLUE DAMPER
This unit is equipped with an automatic ue damper that reduces
heat loss during the OFF cycles. The automatic ue damper
drive assembly is a eld replaceable part and may be obtained
by contacting A. O. Smith Corporation at 500 Tennessee Waltz
Parkway, Ashland City, TN 37015, 1-800-433-2545.
Each automatic ue damper drive assembly is equipped with a
“Service Switch”, as shown in
Figure 4
The “Service Switch” has 2 positions: AUTOMATIC OPERATION
and HOLD OPEN DAMPER. For normal operation the switch
should be in the AUTOMATIC OPERATION position.
If there is a problem with the damper the “Service Switch” can be
placed in the HOLD OPEN DAMPER position. When the switch
is placed in the HOLD OPEN DAMPER position the damper
disc will rotate to the open position and the heater may be used
until vent assembly is repaired or replaced. DO NOT turn the
damper disc manually; damage will occur to the drive assembly
if operated manually. Refer to TESTING DAMPER OPERATION
section of this manual for additional information.
Figure 4. Flue Damper
UNCRATING
The heater is shipped with the ue damper already installed. The
wiring conduit runs from the thermostat to the damper drive cover.
Before turning unit on, check to make sure the wiring conduit is
securely plugged into damper drive.
8
ROUGH-IN DIMENSIONS
INSTALLATION CONSIDERATIONS
Figure 5. Rough-In Dimensions
Table 1. Rough-In Dimensions
Connections
Model
154
Input Rate
BTU/Hr.
154,000 BTU/Hr
45 Kw/Hr
Approx
Tank
Cap. A B C D E F
81 Gal
67-1/2”
4-1/2”
62”
53-5/8”
307 L
171 cm
12 cm
157 cm
136 cm
20-1/2”
52 cm
21”
53 cm
Gas
Inlet
G H
1/2”
1/2”
Vent
Dia
I J
54-5/8”
139 cm6”15 cm
Top Front Back Top Front Back Std. Asme
27-3/4”
1-1/2" NPT
1-1/2" NPT
71 cm
1-1/2" NPT
1-1/2" NPT
1-1/2" NPT
1-1/2" NPT
1-1/2" NPT
1-1/2" NPT
1-1/2" NPT
1-1/2" NPT
1-1/2" NPT
1-1/2" NPT
Table 2. Gas Pressure Requirements
Model
All 3.5" W.C. (0.87 kPa) 10.0" WC (2.49 kPa) 4.5" W.C. (1.12 kPa) 11.0" W.C. 2.74 kPa) 14” W. C. (3.48 kPa) 14” W. C. (3.48 kPa) 120/60 120/60 <5 <5
*Manifold Pressure Minimum Supply Pressure Maximum Supply Pressure Volts/ Hz Amperes
Natural
Natural Gas Propane Gas Natural Gas Propane Gas Natural Gas Propane Gas
Gas
Propane
Gas
Natural
Table 3. Recovery Capacities 120-400/A Models
Input
Model
Btu/hr kW
154 154,000 45
APPROX.
GAL.
CAP.
81 Gal
306 L
Thermal
Efciency%
80
°F 30°F 40°F 50°F 60°F 70°F 80°F 90°F 100°F 110°F 120°F 130°F 140°F
°C 17°C 22°C 28°C 33°C 39°C 44°C 50°C 56°C 61°C 67°C 72°C 78°C
GPH 498 373 299 249 213 187 166 149 136 124 115 107
LPH 1885 1412 1132 943 806 708 628 564 515 469 435 405
U. S. Gallons/hr & liters/hr at temperature rise indicated
Gas
Approximate
Ship. WeightInlet Outlet
470 Lbs
NA
21 3 Kg
Propane
Gas
9
LOCATING THE WATER HEATER
When installing the heater, consideration must be given to
proper location. Location selected should be as close to the
stack or chimney as practicable, with adequate air supply and
as centralized with the piping system as possible.
The heater must not be located in an area where it will be subject
to freezing.
Locate it near a oor 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 oors of the structure.
CAUTION
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
Fire or Explosion Hazard
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
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.
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 ow.
CLEARANCES
This heater is approved for installation on combustible ooring
in an alcove when the minimum clearance from combustion or
non-combustible construction is followed as indicated in
(page 10) and
Table 4
.
Figure 6
In all installations the minimum combustible clearances from
draft hood 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.
A service clearance of 24” (610mm) should be maintained from
serviceable parts, such as relief valves, bafes, thermostats,
cleanout openings or drain valves.
Table 4. Installation Clearances
Model
154 1” (2.54 cm) 1” (2.54 cm) 1” (2.54 cm) 12” (30.48 cm)
A
(RIGHT SIDE)B(LEFT SIDE)C(BACK)
D
(CEILING)
There is a risk in using fuel burning appliances such as gas water
heaters in rooms, garages or other areas where gasoline, other
ammable liquids or engine driven equipment or vehicles are
stored, operated or repaired. Flammable vapors are heavy and
travel along the oor and may be ignited by the heater’s igniter
or main burner ames causing re or explosion. Some local
codes permit operation of gas appliances in such areas if they
are installed 18” or more above the oor. This may reduce the
risk if location in such an area cannot be avoided.
Do not install this water heater directly on a carpeted oor. A re
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 oor shall be covered by the panel.
Also, see the DRAINING requirements in
Maintenance
(page 33).
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
re hazardous articles must never be placed on or adjacent to
the heater. Open containers or ammable material should not
be stored or used in the same room with the heater.
Figure 6. Minimum Clearances to Combustible Materials
10
NSF LEG KIT
CIRCULATING PUMP WIRING DIAGRAM
STORAGE TANK OR BUILDING RECIRCULATION
CIRCULATING PUMP WIRING DIAGRAM
DISHWASHER LOOP WITH TOGGLE SWITCH
FIELD SUPPLIED TEMPERATURE
CONTROL INSTALLED IN THE
CIRCULATING LOOP RETURN LINE
DISHWASHER
TOGGLE
SWITCH
CIRC
PUMP
MOTOR
L1 HOT
L2 NEUTRAL
120 VAC
POWER
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.
The NSF Leg Kit (part number 100109227) is needed only
for applications that must conform to NSF/ANSI Standard 5.
Installation of the NSF leg kit will increase the height of the unit
and all connection points by 3 inches. See
Figure 7
.
Follow these steps to install the Leg Kit:
1. Unit needs to be lifted in a way not to damage unit or laid on it’s
side to access the bottom of the legs.
2. Slide leg extension under leg and the bolt up through the bottom
hole located in the bottom of the leg.
3. Once in place, screw nut down and secure.
4. Front of leg should line up with front of leg extension as shown
to make sure weight of unit is distributed through the leg
extension.
• DO NOT apply insulation to the top of the water heater, as this
will interfere with safe operation of the draft hood.
• 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 ow to the
burners.
• DO NOT allow insulation to come within 9 inches (23 cm)
of oor, (within 2 inches (5 cm) of bottom cover) to prevent
blockage of combustion air ow 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 ow.
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.
Figure 7. NSF Leg Kit
INSULATION BLANKET
Breathing Hazard - Carbon Monoxide Gas
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
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 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
Components
section of this manual for identication of components
mentioned below. Failure to follow these instructions can restrict
the air ow required for proper combustion, potentially resulting
in re, asphyxiation, serious personal injury or death.
Features and
See the Maintenance Section in this manual for sediment and
lime scale removal procedures.
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
(page 43) in this manual for
installation location of circulating pumps.
See the circulation pump wiring diagrams,
Figure 8
and
for electrical hookup information. Install in accordance with the
current edition of the
National Electrical Code, NFPA 70
.
All-bronze circulating pumps are recommended for used with
commercial water heaters.
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.
FIELD SUPPLIED TEMPERATURE CONTROL
INSTALLED IN THE STORAGE TANK
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
11
OPERATION.
L1 HOT
L2 NEUTRAL
Figure 8. Circulating Pump Wiring Diagram - Storage Tank or
120 VAC
POWER
OR CIRCULATING LOOP RETURN LINE
CIRC
PUMP
MOTOR
Figure 9
,
Building Recirculation
CIRCULATING PUMP WIRING DIAGRAM
DISHWASHER LOOP WITH TOGGLE SWITCH
DISHWASHER
TOGGLE
SWITCH
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
L2 NEUTRAL
Figure 9. Circulating Diagram - Dishwasher Loop
FIELD SUPPLIED TEMPERATURE
CONTROL INSTALLED IN THE
CIRCULATING LOOP RETURN LINE
CIRC
PUMP
MOTOR
HIGH ALTITUDE INSTALLATIONS
Installations above 2000 feet (610 meters) require replacement
of burner orices with ones suitable for your area. Failure to
replace orices will result in improper and inefcient 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.
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.
Breathing Hazard - Carbon Monoxide Gas
Under no circumstances should
the input exceed the rate shown
on the water heater’s rating label.
Overfiring could result in damage to
the water heater and sooting.
Gas and carbon monoxide detectors
are available.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
You should contact your gas supplier for any specic requirements
in your area.
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 ring of the heater causing sooting, poor
combustion and/or unsatisfactory heater performance.
Ratings specied 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.
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
GAS SUPPLY SYSTEMS
Low pressure building gas supply systems are dened 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 ensure 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.
High Pressure building supply systems use pressures that
exceed 14” W.C. (1/2 PSI Gauge). These systems must use eld
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 specied 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.
All models require a minimum gas supply pressure of 3.5" W.C. for
natural gas and 8.5" W.C. for propane gas. The minimum supply
pressure is measured while gas is owing (dynamic pressure).
The supply pressure should never fall below 3.5" W.C. for natural
gas and 8.5" W.C. for propane gas. The supply pressure should
be measured with all gas red appliances connected to the
common main ring at full capacity. If the supply pressure drops
more than 1.5” W.C. as gas begins to ow to the water heater
then the supply gas system including the gas line and/or the gas
regulator may be restricted or undersized. See
(page 13). 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 owing (static pressure).
SUPPLY GAS REGULATOR
The maximum allowable gas supply pressure for this water heater
is 14.0 inches W.C. (3.49 kPa) for natural and propane gas. Install
a positive lock-up gas pressure regulator in the gas supply line
if inlet gas pressure can exceed these pressures at any time.
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 7.0” W.C.
while the water heater is operating is recommended and
will generally provide good water heater operation. Some
addition adjustment maybe required later to maintain a
steady gas supply pressure.
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.
POWER SUPPLY
The water heater 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
National Electrical Code, ANSI/NFPA 70
Supply Gas Regulator
.
13
WATER TEMPERATURE CONTROL AND MIXING VALVES
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).
HOT WATER
OUTLET
TEMPERED WATER
OUTLET
12” TO 15”
(30-38 cm)
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.
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.
Some people are more likely to be permanently injured by
hot water than others. These include the elderly, children, the
inrm and the physically/mentally disabled.
Table 5
shows the
approximate time-to-burn relationship for normal adult skin.
If anyone using hot water provided by the water heater being
installed ts 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
satises the demand of the application, a mixing valve should
be installed at the water heater or at the hot water taps to further
reduce system water temperature. See
Figure 10
(page 14).
Mixing valves are available at plumbing supply stores. Consult
a Qualied Installer or Service Agency. Follow mixing valve
manufacturer’s instructions for installation of the valves.
Table 5. BURN TIME AT VARIOUS TEMPERATURES
Time for Permanent
Water Temperature
°F (°C)
110 (43) (normal shower temp.)
116 (47) (pain threshold)
116 (47) 35 minutes 45 minutes
122 (50) 1 minute 5 minutes
131 (55) 5 seconds 25 seconds
140 (60) 2 seconds 5 seconds
149 (65) 1 second 2 seconds
154 (68) instantaneous 1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,
1978)
Time for 1st Degree Burn
(Less Severe Burns)
Burns
2nd & 3rd Degree
(Most Severe Burns)
DISH-WASHING MACHINES
COLD
WATER
INLET
CHECK
VALV E
TO TANK
INLET
Figure 10. Mixing Valve
CHECK
VALV E
MIXING
VALV E
The National Sanitation Foundation also recommends circulation
of 180°F (82°C) water. The circulation should be just enough to
provide 180°F (82°C) water at the point of take-off to the dishwashing machine.
Adjust ow by throttling a full port ball valve installed in the
circulating line on the outlet side of the pump. Never throttle
ow on the suction side of a pump. See the
Water Piping Diagrams
(page 43).
Note: These water heaters meet the NSF Standard 5 for
sanitary installations when used with the leg kit part
number 100109227.
CLOSED WATER SYSTEMS
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 ow preventers. Devices such as these cause the water
system to be a closed system.
THERMAL EXPANSION
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 Temperature-Pressure Relief Valve operation:
water discharged from the valve due to excessive pressure build
up. This condition is not covered under the limited warranty.
All dish-washing machines meeting the National Sanitation
Foundation requirements are designed to operate with water ow
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 ow regulating control valve should
be used in the 180°F (82°C) line to the dish-washing machine and
should be adjusted to deliver water pressure between these limits.
The Temperature-Pressure Relief Valve is not intended for the
constant relief of thermal expansion.
A properly sized and pressurized 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.
14
See
Water Line Connections
(page 23) and the
Water Piping Diagrams
(page 43).
TEMPERATURE-PRESSURE RELIEF VALVE
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.
This water heater is provided with a properly rated/sized and
certied combination Temperature-Pressure Relief Valve (T&P
valve) by the manufacturer. The valve is certied by a nationally
recognized testing laboratory that maintains periodic inspection
of production of listed equipment of materials as meeting the
requirements for
•
CSA 4.4
, and the code requirements of
Relief Valves for Hot Water Supply Systems, ANSI Z21.22
ASME
.
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 certied 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.
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 Temperature-Pressure
Relief Valve installed. Contact your local distributor or
contact Technical Support for assistance in sizing a
Temperature-Pressure Relief Valve for remote storage
tanks. See the contact information label on the water
heater.
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 tting of the water heater designed for the
relief valve. Install discharge piping so that any discharge will exit
the pipe within six inches (15.2 cm) above an adequate oor 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.
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 six inches (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 if circumstances demand. If the
discharge pipe is not connected to a drain or other suitable
means, the water ow may cause property damage.
CAUTION
Water Damage Hazard
Temperature-Pressure Relief Valve discharge
•
pipe must terminate at adequate drain.
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 (15.2 cm) above a
oor 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.
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.
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.
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 Temperature-Pressure Relief Valve with
a properly rated/sized new one.
15
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
Expansion
and
Closed Water Systems
(page 14).
Thermal
If you do not understand these instructions or have any questions
regarding the Temperature-Pressure Relief Valve. Contact your
local distributer or contact Technical Support for assistance. See
the contact information label on the water heater.
CONTAMINATED AIR
Breathing Hazard - Carbon Monoxide Gas
Install water heater in accordance with
the Instruction Manual and NFPA 54.
To avoid injury, combustion and ventilation
air must be taken from outdoors.
Do not place chemical vapor emitting
products near water heater.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Corrosion of the ue ways and vent system may occur if air for
combustion contains certain chemical vapors. Such corrosion
may result in failure and risk of asphyxiation.
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.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Combustion air that is contaminated can greatly diminish the life
span of the water heater and water heater components such as
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.
AIR REQUIREMENTS
For safe operation an adequate supply of fresh uncontaminated
air for combustion and ventilation must be provided.
Do not install the water heater in a conned space unless an
adequate supply of air for combustion and ventilation is brought
in to that space using the methods described in
Confined Space
(page 16).
Never obstruct the ow 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 re or explosion
and cause property damage, serious bodily injury or death.
UNCONFINED SPACE
An Unconned 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 unconned space.
Makeup air requirements for the operation of exhaust fans,
kitchen ventilation systems, clothes dryers and replaces shall
also be considered in determining the adequacy of a space to
provide combustion, ventilation and dilution air.
UNUSUALLY TIGHT CONSTRUCTION
In unconned spaces in buildings, inltration may be adequate to
provide air for combustion, ventilation and dilution of ue 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
Confined Space
CONFINED SPACE
(page 16).
A conned space is one whose volume IS LESS THAN 50 cubic
feet per 1,000 Btu/hr (4.8 cm per kW) of the total input rating of
all appliances installed in the space.
An insufcient 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
ame, causing sooting of the combustion chamber, burners and
ue tubes and creates a risk of asphyxiation.
Openings must be installed to provide fresh air for combustion,
ventilation and dilution in conned spaces. The required size for
the openings is dependent on the method used to provide fresh
air to the conned space AND the total Btu/hr input rating of all
appliances installed in the space.
16
DIRECT VENT APPLIANCES
Appliances installed in a Direct Vent conguration 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 conned spaces.
EXHAUST FANS
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, sufcient 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 re or
explosion may result. It can also create a risk of asphyxiation.
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.
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 specied. 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 xed in the open position.
17
VENTING INSTALLATION
VENTING
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.
Heater must be protected from freezing downdrafts.
Remove all soot or other obstructions from the chimney that will
retard a free draft.
Water heaters covered by these instructions are Category I,
Natural Draft appliances. Type B venting is recommended with
this heater. For typical venting application see
This water heater must be vented in compliance with all local
codes, the current revision of the
and with the
If any part of the vent system are exposed to ambient temperatures
below 40°F 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
red equipment to the duct work of ventilation systems.
Category I Natural Draft Venting Tables
National Fuel Gas Code (ANSI-Z223.1)
Table 6
.
(page 21).
The venting must comply with the current editions of the
Fuel Gas Code, ANSI Z223.1/NFPA 54
Figure 11. Correct Vent Pipe Installation
Figure 12. Incorrect Vent Pipe Installation
.
National
• 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.
18
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