AHRI 154 User Manual

Page 1

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 condence in our products.

Thank you for buying this energy efcient 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

BY THIS WATER HEATER.

100322746 2000573801 (Rev B)

Page 2

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

Qualications ..................................................................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 Conned 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

Efkal 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

Page 3

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

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.

Page 4

GENERAL SAFETY INFORMATION

PRECAUTIONS

DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN

EXPOSED TO FLOODING OR WATER DAMAGE. Immediately call a qualied 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 qualied 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.

Page 5

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.

Page 6

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 Qualied Agency (as dened 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 qualied (as dened by ANSI above) and licensed or certied 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.

“Qualied 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 Ofce 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.

Page 7

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 signicantly 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

Page 8

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.

Page 9

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

71 cm

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

Efciency%

°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

21 3 Kg

Propane

Gas

Page 10

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, bafes, 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)

(RIGHT SIDE)B(LEFT SIDE)C(BACK)

(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

Page 11

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 identication 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

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

Page 12

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 orices with ones suitable for your area. Failure to replace orices will result in improper and inefcient 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 specic 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 specied 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).

Page 13

INSTALLATION REQUIREMENTS

GAS SUPPLY SYSTEMS

Low pressure building gas supply systems are dened 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 specied 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

Page 14

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 inrm 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 satises 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 Qualied 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.

Page 15

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 certied combination Temperature-Pressure Relief Valve (T&P valve) by the manufacturer. The valve is certied 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 certied 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.

Page 16

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 conned 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 Unconned 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 unconned 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 unconned spaces in buildings, inltration 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 conned 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 insufcient 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 conned spaces. The required size for the openings is dependent on the method used to provide fresh air to the conned space AND the total Btu/hr input rating of all appliances installed in the space.

Page 17

DIRECT VENT APPLIANCES

Appliances installed in a Direct Vent conguration 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 conned 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, sufcient 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 specied. 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.

Page 18

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.

Page 19

MULTIPLE HEATER MANIFOLD

Table 6

(page 21) should be used for horizontally manifolding

two or more heaters.

Figure 13. Common Venting Multiple Water Heaters

FRESH AIR OPENINGS FOR CONFINED SPACES

The following instructions shall be used to calculate the size, number and placement of openings providing fresh air for combustion, ventilation and dilution in conned spaces. The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into conned spaces only. DO NOT refer to these illustrations for the purpose of vent installation.

See

Venting Installation

OUTDOOR AIR THROUGH TWO OPENINGS

for venting installation instructions.

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).

OUTDOOR AIR THROUGH ONE OPENING

Figure 15. Outdoor Air Through One Opening

Alternatively a single permanent opening, commencing within 12 inches (300 mm) of the top of the enclosure, shall be provided.

See

Figure 15

. The water heater shall have clearances of at least 1 inch (25 mm) from the sides and back and 6 inches (150 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:

Figure 14. Outdoor Air Through Two Openings

The conned 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 14

1. One square inch per 3000 Btu/hr (733 mm2 per kW) of the

total input rating of all appliances located in the enclosure

2. Not less than the sum of the areas of all vent connectors in

the space

OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS

Figure 16. Two Horizontal Ducts

Page 20

The conned 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 16

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.

OUTDOOR AIR THROUGH TWO VERTICAL DUCTS

The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into conned spaces only.

DO NOT refer to these illustrations for the purpose of vent installation. See

Venting Installation

(page 18) for venting

installation instructions.

of the enclosure. The vertical ducts shall communicate directly with the outdoors. See

Figure 17

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.

AIR FROM OTHER INDOOR SPACES

Figure 17. Two Vertical Ducts

The conned 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

Figure 18. Two Permanent Openings

The conned 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 18

Each opening shall communicate directly with an additional room(s) of sufcient volume so that the combined volume of all spaces meets the criteria for an Unconned 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).

Page 21

Table 6. Technical Data Venting

TYPE B GAS VENT Multiple Gas Fired Tank-Type Heaters

When venting multiple tank type heaters using Type B vent pipe, follow the installation diagram (gure 13) and tables below which give sizing and data based upon

54/ANSI Z223. 1992

MODEL 120

Input: 120,000 Btuh Total Vent Height (Feet)

Draft Hood: 5” 6 8 10 15 20 30 50 100

Number of Heaters

MODEL 154 Input: 154,000 Btuh Total Vent Height (Feet) Draft Hood: 6” 6 8 10 15 20 30 50 100

Numbers of Heaters

Input Btuh Rise

120,000 1 Ft. 7 7 7 6 6 6 6 6 120,000 2 Ft. 6 6 6 6 6 6 6 5 120,000 3 Ft. 6 6 6 6 6 5 5 5

Combined Input in

Thousands of Btuh

2 240 10 8 8 7 7 7 6 7 3 360 10 10 10 10 8 8 7 7 4 480 12 12 12 10 10 10 8 8

Input Btuh Rise Vent Connector Diameter (in inches)

154,000 1 Ft. 8 8 7 7 7 7 7 7 154,000 2 Ft. 7 7 7 7 7 6 6 6

154,000 3 Ft. 7 7 7 6 6 6 6 6

Combined Input in

Thousands of Btuh

2 308 10 10 10 8 8 7 7 7 3 462 12 12 12 10 10 10 8 8 4 616 14 14 12 12 12 10 1 10

NFPA

Vent Connector Diameter (inches)

Manifold and Common Vent Diameter (In inches)

Manifold and Common Vent Diameter (in inches)

MODEL 180, 197, 199, 200 Input: 180,000, 199,000 Btuh Total Vent Height (Feet)

Number of Heaters

Draft Hood: 6” 6 8 10 15 20 30 50 100

Input Btuh Rise Vent Connector Diameter (in inches)

180,000 1 Ft. 8 8 8 8 8 7 7 7 199,000 - - 8 8 8 8 8 7 180,000 2 Ft. 8 8 7 7 7 7 7 7 199,000 8 8 8 8 7 7 7 7 180,000 3 Ft. 7 7 7 7 7 7 6 6 199,000 8 8 7 7 7 7 7 6

Combined Input in

Thousands of Btuh

360 10 10 10 10 8 8 7 7 398 12 10 10 10 10 8 8 7 540 14 12 12 12 10 10 10 8 597 14 14 12 12 12 10 10 10 720 14 14 14 12 12 12 10 10 796 16 14 14 14 12 12 12 10

Manifold & Common Vent Diameter

Page 22

Table 6. Technical Data Venting

MODEL 250, 251 Input: 250,000/251,000 Btuh Total Vent Height (Feet) Draft Hood: 6” 6 8 10 15 20 30 50 100

Number of Heaters

2 500/502 14 12 12 10 10 10 10 8 3 750/753 16 14 14 14 12 12 10 10 4 1000/1004 18 16 16 14 14 14 12 12

MODEL 275 Input: 275,000 Btuh Total Vent Height (Feet) Draft Hood: 6” 6 8 10 15 20 30 50 100

Number of Heaters

2 500/502 14 12 12 10 10 10 10 8 3 750/753 16 14 14 14 12 12 10 10 4 1000/1004 18 16 16 14 14 14 12 12

MODEL 305 Input: 305,000 Btuh Total Vent Height (Feet) Draft Hood: 8” 6 8 10 15 20 30 50 100

Number of Heaters

2 610 14 14 12 12 12 10 10 10 3 915 16 16 16 14 14 12 12 12 4 1220 18 18 16 16 16 14 14 12

MODEL 365, 400 Input: 365,000, 399,000 Btuh Total Vent Height (Feet) Draft Hood: 8” 6 8 10 15 20 30 50 100

Number of Heaters

2 730 14 14 14 12 12 12 10 10

3 1095 18 18 16

4 1460

Input Btuh Rise Vent Connector Diameter (inches)

250/251,000 1 Ft. - - - - - - 8 8 250/251,000 2 Ft. - - - 8 8 8 8 8 250/251,000 3 Ft. - 8 8 8 8 8 7 7

Combined Input in

Thousands of Btuh

Input Btuh Rise Vent Connector Diameter (inches)

275,000 2 Ft. - - - - - 8 8 8 275,000 3 Ft. - - - 8 8 8 8 8

Combined Input in

Thousands of Btuh

Input Btuh Rise Vent Connector Diameter (inches)

305,000 1 Ft. - - 10 10 10 10 10 10 305,000 2 Ft. 10 10 10 10 10 10 8 8 305,000 3 Ft. 10 10 10 10 10 8 8 8

Combined Input in

Thousands of Btuh

Input Btuh Rise Vent Connector Diameter (inches)

365,000 1 Ft. - - - - - 10 10 10 399,000 - - - - - - 10 10 365,000 2 Ft. 12 12 10 10 10 10 10 10 399,000 12 12 12 12 10 10 10 10 365,000 3 Ft. 10 10 10 10 10 10 10 10 399,000 12 10 10 10 10 10 10 10

Combined Input in

Thousands of Btuh

798 16 14 14 14 12 12 10 10

1197

1596 22 20 20

Manifold and Common Vent Diameter (In inches)

16 18 18 20 20

18 18

14 14 12 12 16 14

18 16

18 16 14 14

14 14

12 12

MECHANICAL VENTING

SINGLE UNIT INSTALLATION

When mechanical venting of this heater is desired, the following kit is available.

A. O. Smith part number 100110445

Where an approved power venter is to be installed to operate in conjunction with the water heater thermostat, the following codes must be adhered to. Field wiring should conform to the current edition of the

National Electrical Code NFPA 70

and/or local codes.

VENT INSTALLATION

Seal all joints between the power venter and the vent termination. This is to prevent leakage of exhaust products into the room(s) due to positive pressure of blower.

The “Sequence of Operation” description will be the same with mechanical venting except;

• When the water heater thermostat calls for heat:

Thermostat contacts “Close” and the power venter blower (120 VAC) is energized. Sufcient draft must be established for the “Draft Prover Switch (N.O.)” to “Close”. When the draft prover switch “Closes” the relay coil of the ue damper is energized.

MULTIPLE UNIT INSTALLATION

For multiple unit installations, contact A. O. Smith, Technical Support Center at 1-800-527-1953.

Page 23

WATER HEATER INSTALLATION

WATER LINE CONNECTIONS

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.

Read and observe all requirements in the following sections before installation of the water piping begins:

•

Water Temperature Control and Mixing Valves

•

Dish-washing Machines

•

Temperature-Pressure Relief Valve

•

Closed Water Systems

• For multiple water heater installations, see

Diagrams

WATER (POTABLE) HEATING AND SPACE HEATING

All piping components connected to this unit for space heating applications shall be suitable for use with potable water.

Toxic chemicals, such as those used for boiler treatment, shall NEVER be introduced into this system.

This unit may NEVER be connected to any existing heating system or component(s) previously used with a non-potable water heating appliance.

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

43) for suggested piping arrangements.

(page 43).

(page 14).

and

(page 15).

Thermal Expansion

(page 14).

Water Piping

Water Piping Diagrams

(page

T&P VALVE DISCHARGE PIPE

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 certied combination temperature - pressure (T&P) relief valve by the manufacturer. See

15) for information on replacement and other requirements.

Temperature-Pressure Relief Valve

(page

CAUTION

Water Damage Hazard

These water heaters cannot be used in space heating applications only

THERMOMETERS (NOT SUPPLIED)

Thermometers should be obtained and eld installed as shown in the installation diagrams.

Thermometers are installed in the system as a means of detecting the temperature of the outlet water supply.

WATER PIPING DIAGRAMS

This manual provides detailed water piping diagrams for typical methods of application for the water heaters. See

Diagrams

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 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

(page 43).

Note: In addition to the factory installed Temperature-Pressure

(page 43) .

Water Piping Diagrams

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.

Water Piping

Temperature-Pressure Relief Valve discharge

•

pipe must terminate at adequate drain.

Install a discharge pipe between the T&P valve discharge opening and a suitable oor 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 ow may cause property damage.

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 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.

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.

Page 24

INSTALLATION DIAGRAMS - TOP INLET/OUTLET USAGE

Use of the top inlet water connection requires an inlet dip tube (refer to gure 19). The tube is supplied in the heater. Follow caution labels if applying heat to this tting. Do not allow pipe dope to contact the plastic tube during installation.

WATER HEATER WIRING

Figure 19. Tube Inlet Installation

All electrical work must be installed in accordance with the current edition of the

National Electrical Code ANSI/NFPA No. 70

and

must conform to all local code authority having jurisdiction. AN

ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF ELECTRICAL SHOCK OR POSSIBLE ELECTROCUTION.

24 VAC TO IGNITION CONTROL

24 VAC

DRIVE

LOWER PROBE

UPPER PROBE/ECO

BLK

DAMPER

DAMPER DRIVE

24 NEUTRAL

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 ame sensor and igniter leads.

The controls of this water heater are polarity sensitive. Be certain to properly wire the hot and neutral connections.

11E79

LINE IN

BLK

ON/OFF SWITCH

BLK

120 vac

NEUTRAL

GND

PROPANE GAS VALV E

MV/PV

BLK

MV/PV

24 V GND

SPARKER

LEGEND: W--WHITE BLK--BLACK BL--BLUE R--RED Y--YELLOW

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED MUST BE REPLACED, USE ONLY TYPE 105O C THERMOPLASTIC OR EQUIVALENT. FLAME SENSOR IGNITION CABLE MUST BE 250O C TYPE F.

24 V

GND-BURNER

HONEYWELL IGNITION

NATURAL GAS VALV E

FACTORY WIRED

BY INSTALLER

330548-000 REV 00

Figure 20. Wiring Diagram

Page 25

SUPPLY GAS LINE INSTALLATION

Contact your local gas service company to ensure that adequate gas service is available and to review applicable installation codes for your area.

Size the main gas line in accordance with

Table 7

. The gures 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

Fuel Gas Code ANSI Z223.1 / NFPA 54

National

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

Gas Code

if Corrugated Stainless Steel Tubing (CSST) is used as

National Fuel

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 re 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.

If copper supply lines are used they must be internally tinned and certied for gas service. Before attaching the gas line, be sure that all gas pipe is clean on the inside.

To trap any dirt or foreign material in the gas supply line, a sediment trap must be incorporated in the piping (see

Figure 21

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

Fuel Gas Code ANSI Z223.1 / NFPA 54

National

To prevent damage, care must be taken not to apply too much torque when attaching gas supply pipe to gas valve inlet.

Apply joint compounds (pipe dope) sparingly and only to the male threads of pipe joints. Do not apply compounds to the rst two threads. Use compounds resistant to the action of liqueed petroleum gases.

GAS METER SIZE – NATURAL GASES ONLY

Be sure the gas meter has sufcient capacity to supply the full rated gas input of the water heater as well as the requirements of all other gas red equipment supplied by the meter. If gas meter is too small, ask the gas company to install a larger meter having adequate capacity.

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.

Table 7. Gas Supply Pipe Lengths (in feet)

(Maximum Equivalent Pipe Length - Natural Gas Only)

Input rate

(BTU/hr)

154,000 10 40 150 200 200

Fitting

Type*

45°Ell 0.7 1.0 1.2 1.6 1.9 90°Ell 1.6 2.1 2.6 3.5 4.0

Tee 3.1 4.1 5.2 6.9 8.0

*Screwed Fittings Natural Gas 0.60 Specic Gravity, 0.50" W.C. Pressure Drop

Schedule 40 Steel or Wrought Iron Pipe

1/2" 3/4" 1" 1 1/4" 1 1/2"

Equivalent length in feet

It is important to guard against gas valve fouling from contaminants in gas ways. Such fouling may cause improper operation, re or explosion.

Figure 21. Gas Piping And Sediment Trap Installation

Gas Line Leak Testing

Any time work is done on the gas supply system perform a leak test to avoid the possibility of re or explosion.

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.

Page 26

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 21

. 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.

3. Paint all supply gas line joints and connections upstream of the water heater with a rich soap and water solution to test for leaks. Bubbles indicate a gas leak. Do not use matches, candles, ame or other sources of ignition for this purpose.

4. Repair any leaks before placing the water heater in operation.

PURGING

Gas line purging is required with new piping or systems.

Purging should be performed per the current edition of

the

National Fuel Gas Code

NFPA 54

Page 27

Fire or Explosion Hazard

OPERATION

The water heaters covered by this manual are equipped with an electronic control system that automatically sequences the Igniter, the 24 VAC Gas Valve, the Burner ignition, and ame sensing.

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.

Read instruction manual before

installing, using or servicing

water heater.

PRIOR TO START UP

Installation and start up of this water heater requires abilities and skills equivalent to that of a licensed tradesman in the eld involved. See

Do not place the water heater in operation if any part has been under water. Immediately call a qualied 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.

Light the water heater in accordance with the

Label

(page 29) on the water heater and in this manual.

Qualifications

(page 6).

Lighting & Operation

Before attempting start up, thoroughly study and know the exact

Sequence of Operation

Sequence Of Operation Flow Chart,

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 ll 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 ll with water.

4. Close hot water faucet opened in Step 2 as water starts to ow.

Read

Sequence of Operation

and operating this water heater.

With above conditions satised, start the unit in accordance with the instructions on the

heater. See

Lighting & Operation Label

. See written

section of this manual prior to lighting

Lighting & Operation Label

Sequence of Operation

Figure 22

(page 29).

(page 28).

attached to the

and the

SEQUENCE OF OPERATION

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. Ignition Control performs diagnostic self check on system

components.

4. The Ignition Control begins the trial for ignition.

5. The Ignition Control turns on the Spark Igniter and opens the

Pilot Gas Valve.

6. The Ignition Control monitors the Flame Sensor during the ignition trial period.

7. If the Ignition Control does not sense the pilot ame during the ignition trial period, the Ignition Control shuts the Pilot Gas Valve and turns off the Spark Igniter. Depending on the water heater model, the Ignition Control will either retry the ignition trial at step 4 or lockout the ignition sequence. If the ignition

sequence is locked out, the power to the unit must be cycled to restart the Ignition Control.

8. If the pilot ame is proved during the ignition trial period, the Ignition Control turns off the Spark Ignitor and opens the Main Gas Valve.

9. The Ignition Control allows a 2 second pilot ame stabilization period to insure that the pilot ame is not extinguished by the main burner light-off process.

10. The Ignition Control monitors the Flame Sensor during the heating cycle. If the ame signal is lost, the Ignition Control shuts the Main Gas Valve and Pilot Gas Valve and re-starts the ignition process at step 4.

11. Once the unit is satised, the Ignition Control will shut off the Main Gas Valve and the Pilot Gas Valve and the unit will be in standby mode until another call for heat is initiated by the thermostat.

See the ow chart,

Figure 22

(page 28), for more information.

Page 28

IDLE

(NOT POWERED)

“CALL FOR HEAT” RECEIVED FROM

THERMOSTAT

POWER TO

MODULE AND

SELF CHECK

TRIAL FOR

IGNITION

(TIMER STARTED)

FLAME

PROVED?

(BEFORE TRIAL FOR IGNITION TIMER EXPIRES)

YES

SPARK ON

CLOSE PILOT

GAS VALV E

OPEN PILOT GAS

VALV E

SPARK OFF

RETRY DELAY

(5 MINUTES)

RETRY

RETRY OR

LOCKOUT

MODEL?

WAIT FOR “CALL FOR HEAT” TO BE REMOVED

ACTIVATE ALARM

CONTACT(S)

(OPTIONAL)

LOCKOUT

SPARK OFF

OPEN MAIN GAS

VALV E

FLAME

STABILIZATION

(2 SECONDS)

“CALL

RUN

FOR HEAT”

ENDS?

YES

CLOSE MAIN GAS VALVE AND PILOT

GAS VALV E

Description of this ow chart can be found in

Figure 22. Sequence Of Operation Flow Chart

FLAME

LOST?

Sequence of Operation

CLOSE MAIN GAS

YES

VALV E AND PILOT

(page 27).

GAS VALV E

Page 29

LIGHTING & OPERATION LABEL

FOR YOUR SAFETY READ BEFORE OPERATING

OPERATING INSTRUCTIONS

TO TURN OFF GAS APPLIANCE

Page 30

FOR YOUR SAFETY READ BEFORE OPERATING

OPERATING INSTRUCTIONS

TO TURN OFF GAS APPLIANCE

Page 31

ADJUSTMENTS

CHECKING THE VENTING

ON INITIAL STARTUP, SOME ADJUSTMENTS MAY BE

NECESSARY.

Check Manifold and inlet gas pressures. See

Gas Supply Systems

(page 13) and (page 31).

Check Pilot Burner. See

Pilot Burner

(page 36).)

TESTING DAMPER OPERATION

With the Service Switch in the AUTOMATIC OPERATION position, check the operation of the ue damper three (3) times with the water operating controls for proper operating sequence:

• The damper disc must be open (in the vertical position) before the ignition and combustion process begins.

• The damper disc must be in the open position when the main burner is ring.

• The gas control valve must close and the main burner must have ceased ring before the damper disc begins its return to the closed (horizontal) position.

If during testing of the operation of the damper you nd that there is a problem with the operation of the water heater when the Service Switch is in the AUTOMATIC OPERATION position: Reset the Service Switch to the HOLD OPEN DAMPER position and check operation again.

If the water heater does operate when placed in the HOLD OPEN DAMPER position:

• Refer to the

Guide

(page 40).

Effikal RVGP-KSF-Series Flue Damper Trouble Shooting

• If the water heater does not operate with the Service Switch in either position:

• Refer to

Checklist

Troubleshooting

(page 41).

(page 39) and

Table 11. Troubleshooting

The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in

operation.

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal pitch,

as required in the

National Fuel Gas Code, ANSI Z223.1

and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deciencies which could cause an unsafe condition.

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 replace dampers.

4. Follow the lighting instruction. Place the water heater being inspected in operation. Adjust thermostat so water heater shall operate continuously.

5. Test for draft hood spillage at the relief opening after 5 minutes of main burner operation.

6. 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.

7. 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.

• If the back draft cannot be corrected by the normal method

or if a suitable draft cannot be obtained, a blower type ue gas exhauster must be employed to assure proper venting and correct combustion.

Page 32

CHECKING THE INPUT

For installation locations with elevations above 2000 feet, refer to HIGH ALTITUDE INSTALLATIONS section of this manual for input reduction procedure.

1. Attach a pressure gauge or a manometer to the manifold pressure tap on the gas control valve and refer to

Table 8

, for

correct manifold pressure.

2. Use this formula to “clock” the meter. Be sure that other gas consuming appliances are not operating during this interval.

(3600/T) x H = Btuh

T = Time in seconds to burn one cubic foot of gas.

H = Btu’s per cubic foot of gas.

Btuh = Actual heater input.

Example: (Using 250 heater)

T = 15.1 seconds

H = 1050 Btu

Btuh = ?

(3600/15.1) x 1050 = 250,000 (Compare with 250 model and rating.)

Table 8. Approximate Time Required To Consume 1 Cu. Ft. Of Gas

Input

Rate

(BTUH)

154,000

at Full Capacity

Type

Gas

NATURAL

PROPANE

BTUH

Per

Cu. Ft.

1050 2500

Time Req’d to

Consume 1 Cu. Ft.

Of Gas

24.5 SEC.

58.4 SEC.

Should it be necessary to adjust the gas pressure to the burners to obtain the full input rate, the steps below should be followed:

3. Remove the regulator adjustment sealing cap and adjust the pressure by turning the adjusting screw with a screwdriver.

• Clockwise to increase gas pressure and input rate.

• Counterclockwise to decrease gas pressure and

input rate.

4. “Clock” the meter as in step 2 above.

5. Repeat steps 3 and 4 until the specied input rate is achieved.

6. Turn the gas control knob to PILOT. Remove the pressure

gauge and replace the sealing cap and the Allen wrench set screw in the pressure tap opening.

UNDER NO CIRCUMSTANCES SHOULD THE GAS INPUT EXCEED THE INPUT SHOWN ON THE HEATER MODEL AND

RATING PLATE. OVER-FIRING COULD RESULT IN DAMAGE

OR SOOTING OF THE HEATER.

Page 33

MAINTENANCE

VENTING SYSTEM

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.

REMOTE STORAGE TANK TEMPERATURE CONTROL

The water temperature in the 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

Diagrams

(page 43).

Water Piping

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 heater where the thermostat senses the drop in water temperature and activates main burner operation of the water heater.

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.

Valve with a properly rated/sized new one. See

Pressure Relief Valve

Figure 23. Temperature-Pressure Relief Valve.

(page 15) for instructions on replacement.

Temperature-

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

Water Systems

and

Thermal Expansion

(page 14). The

Closed

Temperature-Pressure Relief Valve is not intended for the constant relief of thermal expansion.

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.

DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF

VALVE OPENING. THIS CAN CAUSE PROPERTY DAMAGE,

SERIOUS INJURY OR DEATH.

Hot water discharge.

Keep clear of TemperaturePressure Relief Valve discharge outlet.

It is recommended that the Temperature-Pressure Relief Valve should be checked to ensure that it is in operating condition every 6 months.

When checking the Temperature-Pressure Relief Valve operation, make sure that (1) no one is in front of or around the outlet of the Temperature-Pressure Relief Valve discharge line, and (2) that the water discharge will not cause any property damage, as the water may be extremely hot. Use care when operating valve as the valve may be hot.

To check the pressure relief valve , lift the lever at the end of the valve several times. See

Figure 23

. 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

and flushing

(page 34). Replace the Temperature-Pressure

Draining

Relief

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

The anode rod is used to protect the tank from corrosion. Most hot water tanks are equipped with an anode rod. The submerged rod sacrices 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.

Page 34

Property Damage Hazard

CAUTION

Burn harzard.

Hot water discharge.

Keep hands clear of drain valve discharge.

Avoid water heater damage.

•

Inspection and replacement of anode rod required.

•

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 qualied technician, and at a minimum should be checked annually after the warranty period.

Articially softened water is exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions.

The use of a water softener may decrease the life of the water

heater tank.

The anode rod should be inspected after a maximum of three years and annually thereafter until the condition of the anode rod dictates its replacement. Anode replacement is not covered by warranty. NOTE: articially softened water requires the anode rod to be inspected annually.

DRAINING AND FLUSHING

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.

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 ushing procedure. Flushing is performed with system water pressure applied to the water heater.

6. Open the water heater drain valve to ush the storage tank.

7. Flush the water heater storage tank to remove sediment and

allow the water to ow until it runs clean.

8. Close the water heater drain valve when ushing is completed.

9. Remove the drain hose.

10. Fill the water heater - see

11. Turn on the electrical supply to place the water heater back in operation.

12. Allow the water heater to complete several heating cycles to

ensure it is operating properly.

REMOVING LIME DEPOSITS FROM TANK TYPE COMMERCIAL WATER HEATERS

Filling the Water Heater

(page 27).

It is recommended that the water heater storage tank be drained and ushed every 6 months to reduce sediment buildup. The water heater should be drained if being shut down during freezing temperatures. See 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.

Features and Components

(page 7)

The amount of calcium carbonate (lime) released from water is in direct proportion to water temperature and usage. See

. 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 efciency 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.

Figure

Page 35

EXAMPLE 2:

Initial inspection after 6 months shows 2" of lime accumulation. Therefore, the heater should be delimed every 3 months.

Figure 24. Lime Accumulation after Six Months

5. Inspect cleanout plate gasket, if new gasket is required,

replace with part no. 100109686.

6. Install cleanout plate. Be sure to draw plate up tight by

tightening screws securely.

7. 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:

Telephone: (800) 433-2545

Fax: (800) 433-2515

Website: www.hotwater.com/parts

PREPARE THE WATER HEATER

To delime the water heater using the Flo-Jug method, rst prepare the heater for deliming.

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.

UN•LIME may be obtained from your dealer, distributor or water heater manufacturer. Order Part Number 100110459,1 gallon, packed 4 gallons per case or Part Number 100110460, 5 gallon container.

Hydrochloric base acids are not recommended for use on glass lined tanks.

Observe handling instructions on label of product being used.

TANK CLEANOUT PROCEDURE

The following practices will ensure longer life and enable the unit to operate at its designed efciency:

1. Once a month the heater should be ushed. Open the drain valve and allow two gallons of water to drain from the 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.

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 ame or sparks in vicinity of heater. Do not mix UN•LIME with other chemicals. Do not allow contact with magnesium, aluminum or galvanized metals.

Chemical Hazard

• Product contains phosphoric acid.

• Keep out of reach of children.

• Use rubber or neoprene gloves.

Contains phosphoric acid. In case of external contact, ush with cool water. If irritation persists, get medical attention. If swallowed, give 1 or 2 glasses of water or milk and call physician.

To clean heater through cleanout opening, proceed as follows:

1. Drain heater.

2. Remove outer cover plate from lower side of heater jacket.

3. Remove six (6) hex head screws securing tank cleanout plate

and remove plate.

4. Remove lime, scale, or sediment using care not to damage the glass lining.

Get immediate medical attention for eyes. Keep out of reach of children.

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.

Page 36

DELIME THE WATER HEATER

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 oor 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 ammable 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.

While the water is being run through the tank, insert a stiff wire, copper tube attened 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.

Note: If your container does not have the vent cap and

vent boss, drill a 3/16” hole in the handle. When you have nished 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 teon 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

1. 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.

2. Lift container to the “Pour” Position (see

Figure 25)

, being

careful to keep the vent in the handle above the liquid level and pour the UN•LIME into the heater.

3. Lower container, you may have to place the container on its empty carton to prevent the UN•LIME from owing back into the container.

4. Let UN•LIME remain in the heater for 5 minutes and then lower the container to the “Drain” Position. See

Figure 25

5. Deliming activity is indicated by foaming on the surface of the

UN•LIME. If there is deliming activity, repeat steps 2 thru 4.

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 100109686).

Remove the drain valve.

9. Install the long plastic male adapter insert tting into the drain valve opening of heater after applying Teon tape or paste to threads. Tighten rmly by hand and use wrench or adjustable pliers to check for secure connection. Do not over tighten to avoid damage to threads and ttings.

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 25. Flo-Jug Deliming Method

PILOT BURNER

At least once a year, check the pilot burner ( main burner,

Figure 28

, for proper operation. See

Figure 26)

Figure 27

and the

for the

location of the Pilot Burner and the Main Burners. For access to pilot, unfasten two screws to burner cover and remove. Locate

Page 37

the burner with pilot and remove screw holding burner to manifold. Unfasten pilot tubing from valve and slide out burner and pilot.

Servicing of the pilot burner includes keeping pilot free of lint, cleaning the burner head, the primary air opening and the orice of the pilot burner.

Figure 26. Checking the Pilot Burner

• Give reasonably quiet operation during ignition, burning and extinction.

• Cause no excessive lifting of ame from burner ports.

If the preceding burner characteristics are not evident, check for accumulation of lint or other foreign material that restricts or other foreign material that restricts or blocks air openings to

burner or heater.

To clean main burners:

1. Remove main burners from unit.

2. Check that burner venturi and ports are free of foreign matter.

3. Clean burners with bristle brush and/or vacuum cleaner

• DO NOT distort burner ports or pilot location.

4. Reinstall burners in unit. Make sure front and rear of

burners are installed correctly in burner support brackets.

Also check for good ow of combustion and ventilating air to

the unit.

Figure 27. Locating the Pilot and Main Burners

The pilot burner ame is affected by the following:

1. Low gas pressure.

• Adjust pilot ame by means of the pilot gas adjustment

located on the gas control valve. See

Figure 29

and

Figure 30

• The pilot ame should envelop sensing device with 5/8” (1.6cm) ame. See cover screw shown in

Figure 28

Figure 29

. Remove pilot adjustment

and

Figure 30

. Turn

inner adjustment screw clockwise to decrease, or counterclockwise to increase pilot flame. Be sure to replace cover screw on gas control valve after adjustment to prevent possible gas leakage.

2. Clogged pilot burner orice.

• Clean or replace orice. A clogged orice will restrict gas

ow.

Pilot sensing device must sense a ame before sparking will stop.

Loose wires or a draft may cause intermittent or abnormal sparking. To eliminate this condition, rst correct loose wiring condition, and then, if necessary, increase pilot ame.

Figure 28. Typical Pilot and Main Burner Flames

GAS CONTROL VALVE

Figure 29

and

Figure 30

show the two types of combination gas

control valves used on this heater.

If gas control valve becomes defective, repairs should not be attempted. A new valve should be installed in place of defective

one.

Figure 29. LP Gas Valve

MAIN BURNER

The main burner shown in

Figure 28

, should display the following

characteristics:

• Cause rapid ignition and carry over of ame across entire

burner.

Figure 30. Natural Gas Valve

Page 38

SERVICE

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 qualied service technician or qualied 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.

ELECTRICAL SERVICING

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION.

VERIFY PROPER OPERATION AFTER SERVICING.

Page 39

TROUBLESHOOTING

IGNITION MODULE

Before calling your service agent, the following checklist should be examined to eliminate obvious problems from those requiring replacement or servicing.

• Check that “main manual gas shut-off valve” is fully open and that gas service has not been interrupted.

• Check that after following the water

Operating Instructions

, the

• Is the water temperature in tank below the thermostat dial

setting on the thermostat (calling for heat)?

• It is possible that the high limit (E.C.O.) has functioned to shut off the water heater. See FEATURES - Water Temperature Control in the

Operating Instructions

for reset procedure. Contact

your serviceman if limit continues to function to shut off water

heater.

“Top Knob” of the gas control valve is in “ON” position.

• Check electrical supply to the water heater for possible blown (or tripped) fusing or power interruption.

Table 9. Troubleshooting Flash Codes

Green LED

Flash Code

OFF No "Call for Heat Not applicable None

Flash Fast Power up - internal check Not applicable None

Heartbeat Normal startup - ignition sequence

4 Secons ON the "x" ashes

A Flash Code Descriptions:

- Flash Fast: rapid blinking.

- Heartbeat: constant 1/2 second bright, 1/2 second dim cycles.

- 4 second solid on pulse followed by "x" 1 second flashes indicates flame current to the nearest μA

- A single flash code number signifies that the LED flashes X times at 2 Hz, remains off for two seconds, and them repeats the sequence.

started (including prepurge

Device in run mode. "x" = Flame current to the nearest μA.

2 5 minute Retry Delay - Pilot ame

not detected during trial for ignition

3 Recycle - Flame failed during run Initiate new trial for ignition. Flash

4 Flame sensed out of sequence If situation self-corrects within 10

6 Control Internal Error Control remains in wait mode. When

7 Flame rod shorted to ground Control remains in wait mode. When

8 Low secondary voltage supply Control remains in wait mode. When

Indicates Next System Action Recommended Service Action

Not applicable None

Initiate new trial for ignition after retry delay completed.

code will remain through the ignition trial until ame is proved.

seconds, control returns to normal sequence. If ame out of sequence remains longer than 10 seconds, control will resume normal operation 1 hour after error is corrected.

the fault corrects, control resumes normal operation.

If system fails to light on next trial for ignition, check gas supply, pilot burner, spark- and ame-sense wiring, ame-rod contaminated or out of position, burner ground connection.

If system fails to light on next trial for ignition, check gas supply, pilot burner, ame-sense wiring, contamination of ame rod, burner ground connection.

Check for pilot ame. Replace gas valve if pilot ame present. If no pilot ame, cycle "Call for Heat." If error repeats, replace control.

Cycle "Call for Heat." If error repeats, replace control.

Check ame-sense lead wire for damage or shorting. Check that ame rod is in proper position Check ame rod ceramic for cracks, damage or tracking.

Check transformer and AC line for proper input voltage to the control. Check with full system load on the transformer.

FLUE DAMPER

Do not turn damper open manually or motor damage will result, use the service switch. All readings are taken from harness

receptacle. Do not push meter leads into harness receptacle. This opens the pins and will create connection problems. See the following

Guide

(page 40).

Effikal RVGP-KSF-Series Flue Damper Trouble Shooting

Page 40

EFFIKAL RVGP-KSF-SERIES FLUE DAMPER TROUBLE SHOOTING GUIDE

Do not turn damper open manually or motor damage will result, use the service switch. All readings are taken from harness

Figure 31. Damper Disc Shown in Open Position

24 V.A.C. NORMAL SEQUENCE OF OPERATION

receptacle. Do not push meter leads into harness receptacle. This opens the pins and will create connection problems.

Table 10. Efkal Damper Pinouts & Wire Colors

Efkal Wires Function Adapter Wire Colors In*

1. Brown 24 VAC HOT Black

2. Orange Signal In Yellow

3. Yellow Signal Out Red

4. Black 24 VAC Common White

A. FLUE DAMPER OPEN OR OPENING (Unit is calling for heat and damper disc should be in vertical position)

VOLTAGE ACROSS:

4 & 1 All Times that High Limit is closed

4 & 2 Calling for Heat Open or Opening

Do not negate the action

WARNING

of any existing safety

or operational controls.

4 & 3 During Combustion Damper Open+

B. FLUE DAMPER CLOSED (Unit is not calling for heat and damper disc should be in horizontal position)

NOTE: POSITION 4 IS COMMON AND POSITION 3 IS HOT 24 VAC VOLTAGE ACROSS:

4 & 1 All Times that High Limit is closed

NO VOLTAGE ACROSS:

4 & 3 or 4 & 2 1. Thermostat not calling for heat.

ABNORMAL OPERATION

A. NOTHING WORKING; NO VOLTAGE

ACROSS: 4 & 1; 4 & 2; 4 & 3:

1. High Limit has tripped and is OPEN. Determine reason for tripping of high limit

2. Bad Transformer

3. Loose or broken connections

4. Blown fuse or circuit breaker

5. Disconnect switch off

6. Harness not plugged into water heater receptacle

B. DAMPER HAS OPENED, NO

COMBUSTION VOLTAGE ACROSS

1. Check for power at ignition module terminals. If 24VAC power is present damper

is working properly.

2. Defective component in water heater after the ue damper.

3. If 24 VAC is not present at the ignition module, look for loose or broken

connections between damper and ignition module.

4. If the connections from damper to ignition module seem proper, replace damper assembly. If a damper assembly is not available, place the service switch in the hold open position. This should keep the damper in the open position and allow the customer to have automatic heat, until a replacement damper can be installed.

C. DAMPER ROTATES CONTINUOUSLY

D. DAMPER STICKS

1. Change the entire damper assembly

1. Make sure no screws obstruct the damper blade.

2. Make sure damper pipe assembly is not egg shaped.

3. Make sure damper rod is not rubbing on pipe assembly.

See gure on front page of this insert sheet

Important: DAMPER MUST BE OPEN BEFORE

A.O. Smith Technical Center at 1-800-527-1953. COMBUSTION TAKES PLACE. If all steps have been tried and damper problems persists call

Page 41

COMPLAINT CAUSE

Water not hot enough.

Insufcient hot water

Table 11. Troubleshooting Checklist

Thermostat set too low.

Upper and/or lower temperature probe out of calibration.

Thermostat set too low.

Upper and/or lower temperature probe out of calibration.

Main manual gas shutoff valve partially closed.

Heater too small for demand.

REMEDY

USER QUALIFIED SERVICE AGENCY

Set thermostat dial to a higher temperature.

Call qualied service agency.

Set thermostat dial to a higher temperature.

Call qualied service agency.

Open main manual gas shutoff valve to fullest extent.

Space usage to give heater time to restore water temperature.

Check continuity and resistance (Ohms) of upper and lower thermostat probes. Replace probes if out of specication.

Check continuity and resistance (Ohms) of upper and lower thermostat probes. Replace probes if out of specication..

Heater recovery is slower. Call qualied service agency.

Draft hood not installed or one or more bafes.

Water temperature too hot. Thermostat set too high. Set thermostat to a lower setting.

Heater makes sounds: sizzling.

Rumbling.

Ticking or metallic sounds.

Pounding / water hammer.

Combustion noises.

Water leaks.

Gas odors.

Condensation on outside of tank

- normal.

Sediment accumulation on bottom of tank.

Expansion and contractionnormal.

Air chambers in piping have become waterlogged. Thermal expansion tank damaged, improperly charged, or improperly sized.

Too much primary air. Adjust shutters.

Overtired heater. Incorrect burners or orice for types of gas used.

Drain valve not closed tightly.

If leakage source cannot be corrected or identied, call qualied service agency.

Heater is overtired.

Call qualied service agency.

Drain a quantity of water through drain valve. If rumbling persists, call a qualied service agency.

Drain piping system and rell. Heater must be off while this is being done. Check thermal expansion tank charge pressure when the water system pressure is zero.

Call qualied service agency. Check and correct as necessary.

If drain valve cannot be closed tightly, replace.

Shut off gas supply to heater and close cold water inlet valve to

heater.

Shut off gas supply to heater and call qualied service agency.

Check gas input. If incorrect, adjust gas pressure or replace main burner orice.

Install draft hood or bafes as furnished with unit.

Delime heater.

Follow the manufacturer's instructions for proper charging of the thermal expansion tank.

Repair or in case of suspected tank leakage, be certain to conrm before replacing heater.

Check for sooted ue 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.

Page 42

FOR YOUR INFORMATION

START UP CONDITIONS

SMOKE/ODOR

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.

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.

Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal. See

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:

• A new water heater is lled with cold water for the rst time.

• Burning gas produces water vapor in water heaters,

particularly high efciency models where ue temperatures are lower.

• Large amounts of hot water are used in a short time and the rell 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

HOT WATER ODOR

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:

• A concentration of sulfate in the supply water.

• Little or no dissolved oxygen in the water.

Condensation

next in this manual.

• A sulfate reducing bacteria which has accumulated within the water heater (this harmless bacteria is nontoxic to humans).

• An excess of active hydrogen in the tank. This is caused by the corrosion protective action of the anode rod.

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.

Contact the local water heater supplier or service agency for further information concerning an Anode Rod Replacement Kit and this chlorination treatment.

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.

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 ammable 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 ame near the faucet at the time it is open.

HIGH WATER TEMPERATURE SHUT OFF SYSTEM

This water heater is equipped with a manual reset type high limit (Energy Cutout) switch. The high limit switch interrupts the main burner gas ow should 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 120F (49C). The high limit reset button on the front of the thermostat then needs to be depressed. See for the location of the reset button.

Figure 2

Page 43

WATER PIPING DIAGRAMS

FINISHED

FLOOR

HOT WATER

TO FIXTURES

COLD WATER

SUPPLY

EXPANSION

TANK

ALT. COLD WATER

CONNECTION

HOT WATER RETURN

FROM FIXTURES

PIPE T&P TO

OPEN DRAIN

FULL PORT BALL VALV

CHECK VALVE

TEMPERATURE GAGE

WATER FLOW SWITCH

LEGEND

TEMPERATURE & PRESSURE

RELIEF VALVE

PRESSURE RELIEF VALVE

CIRCULATING PUMP

TANK TEMPERATURE CONTROL

DRAIN

MULTI FLUE - (1 UNIT) WITH VERTICAL STORAGE TANK

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

FOR ADDITIONAL REQUIREMENTS.

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.

Page 44

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.

FULL PORT BALL VALV

FINISHED

FLOOR

HOT WATER TO FIXTURES

COLD WATER

SUPPLY

HOT WATER

RETURN FROM

FIXTURES

ALTERNATE

LOCATION

CIRCULATING PUMP

EXPANSION

TANK

PIPE T&P TO

OPEN DRAIN

CHECK VALVE

TEMPERATURE GAGE

WATER FLOW SWITCH

LEGEND

TEMPERATURE & PRESSURE

RELIEF VALVE

PRESSURE RELIEF VALVE

CIRCULATING PUMP

TANK TEMPERATURE CONTROL

DRAIN

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

MULTI FLUE - (1 UNIT) WITH HORIZONTAL STORAGE TANK

FOR ADDITIONAL REQUIREMENTS.

Page 45

FULL PORT BALL VALV

HOT WATER

TO FIXTURES

COLD WATER

SUPPLY

HOT WATER

RETURN

EXPANSION

TANK

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

CHECK VALVE

LEGEND

TEMPERATURE & PRESSURE

RELIEF VALVE

PRESSURE RELIEF VALVE

TEMPERATURE GAGE

CIRCULATING PUMP

WATER FLOW SWITCH

DRAIN

TANK TEMPERATURE CONTROL

MULTI FLUE - (2 UNITS)

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

FOR ADDITIONAL REQUIREMENTS.

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).

Page 46

FULL PORT BALL VALV

FINISHED

FLOOR

COLD WATER

SUPPLY

HOT WATER

TO FIXTURES

ALTERNATE

COLD WATER

CONNECTION

HOT WATER

RETURN

EXPANSION

TANK

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

CHECK VALVE

LEGEND

TEMPERATURE & PRESSURE

RELIEF VALVE

PRESSURE RELIEF VALVE

TEMPERATURE GAGE

CIRCULATING PUMP

WATER FLOW SWITCH

TANK TEMPERATURE CONTROL

DRAIN

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

MULTI FLUE - (2 UNITS) WITH VERTICAL STORAGE TANK

FOR ADDITIONAL REQUIREMENTS.

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.

Page 47

FULL PORT BALL VALV

FINISHED

FLOOR

HOT WATER TO FIXTURES

COLD WATER

SUPPLY

HOT WATER

RETURN FROM

FIXTURES

ALTERNATE

LOCATION

EXPANSION

TANK

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

CHECK VALVE

TEMPERATURE GAGE

WATER FLOW SWITCH

LEGEND

TEMPERATURE & PRESSURE

RELIEF VALVE

PRESSURE RELIEF VALVE

CIRCULATING PUMP

TANK TEMPERATURE CONTROL

DRAIN

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

MULTI FLUE - (2 UNITS) WITH HORIZONTAL STORAGE TANK

FOR ADDITIONAL REQUIREMENTS.

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.

Page 48

FULL PORT BALL VALV

BOOSTER WATER

CHECK VALVE

TEMPERATURE GAGE

WATER FLOW SWITCH

LEGEND

BOOSTER WATER RETUR

TEMPERATURE & PRESSURE

RELIEF VALVE

PRESSURE RELIEF VALVE

CIRCULATING PUMP

TANK TEMPERATURE CONTROL

DRAIN

HEATER

BOOSTER

TO FIXTURES

PRE-HEATED

WATER TO

BOOSTER

COLD WATER

SUPPLY

HOT WATER

TO FIXTURES

RETURN

EXPANSION TANK

1st HEATER

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

MULTI FLUE (2 UNITS) TWO TEMPERATURE

FOR ADDITIONAL REQUIREMENTS.

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.

Page 49

FULL PORT BALL VALV

FINISHED FLOOR

HOT OUTLET

CHECK VALVE

LEGEND

TEMPERATURE & PRESSURE

RELIEF VALVE

PRESSURE RELIEF VALVE

TEMPERATURE GAGE

WATER FLOW SWITCH

CIRCULATING PUMP

TANK TEMPERATURE CONTROL

DRAIN

AT STORED

TEMPERATURE

HOT WATE

RETURN

BOOSTER RETURN

(IF USED)

BOOSTED

WATER

OUTLET

COLD WATER

SUPPLY

TYPICAL

BOOSTER

EXPANSION

TANK

HEATER

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

PRE-HEATER

MUST BE IDENTICAL HEATERS

PRE-HEATER

MULTI FLUE (2 UNITS) WITH BOOSTER TWO TEMPERATURE

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

FOR ADDITIONAL REQUIREMENTS.

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.

Page 50

FULL PORT BALL VALV

HOT WATER

CHECK VALVE

LEGEND

TEMPERATURE & PRESSURE

RELIEF VALVE

PRESSURE RELIEF VALVE

TEMPERATURE GAGE

WATER FLOW SWITCH

CIRCULATING PUMP

TANK TEMPERATURE CONTROL

DRAIN

HOT WATE

RETURN

COLD WATER

SUPPLY

EXPANSION

TANK

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

TO FIXTURES

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

MULTI-FLUE (3 UNITS)

FOR ADDITIONAL REQUIREMENTS.

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.

Page 51

TO FIXTURES

HOT WATE

HOT WATER

FINISHED FLOOR

RETURN

FULL PORT BALL VALV

CHECK VALVE

TEMPERATURE GAGE

WATER FLOW SWITCH

COLD WATER

SUPPLY

EXPANSION TANK

LEGEND

ALT. COLD WATER

CONNECTION

TEMPERATURE & PRESSURE

RELIEF VALVE

PRESSURE RELIEF VALVE

CIRCULATING PUMP

TANK TEMPERATURE CONTROL

DRAIN

AOS

STORAGE TANK

PIPE T&P TO

OPEN DRAIN

HEATERHEATERHEATER

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

MULTI-FLUE (3 UNITS) WITH VERTICAL STORAGE TANK

FOR ADDITIONAL REQUIREMENTS.

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.

Page 52

FULL PORT BALL VALV

FINISHED FLOOR

EXPANSION TANK

CHECK VALVE

LEGEND

TEMPERATURE GAGE

WATER FLOW SWITCH

HOT WATER

RETURN

COLD WATER

SUPPLY

TEMPERATURE & PRESSURE

RELIEF VALVE

PRESSURE RELIEF VALVE

CIRCULATING PUMP

TANK TEMPERATURE CONTROL

DRAIN

PIPE T&P TO

HOT WATER TO FIXTURES

OPEN DRAIN

HEATERHEATERHEATER

ALTERNATE

LOCATION

AOS

STORAGE TANK

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

MULTI-FLUE (3 UNITS) WITH HORIZONTAL STORAGE TANK

FOR ADDITIONAL REQUIREMENTS.

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.

Page 53

HOT WATER

FINISHED FLOOR

HOT WATE

FULL PORT BALL VALV

CHECK VALVE

TEMPERATURE GAGE

WATER FLOW SWITCH

RETURN

COLD WATER

SUPPLY

EXPANSION

TANK

LEGEND

TEMPERATURE & PRESSURE

RELIEF VALVE

PRESSURE RELIEF VALVE

CIRCULATING PUMP

TANK TEMPERATURE CONTROL

DRAIN

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

TO FIXTURES

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

MULTI FLUE FLUE (4 UNITS)

FOR ADDITIONAL REQUIREMENTS.

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.

Page 54

Page 55

FULL PORT BALL VALV

HOT WATER

CHECK VALVE

TEMPERATURE GAGE

WATER FLOW SWITCH

HOT WATER

RETURN

COLD WATER

SUPPLY

EXPANSION

TANK

LEGEND

ALT. COLD

WATER

CONNECTION

TO FIXTURES

TEMPERATURE & PRESSURE

RELIEF VALVE

PRESSURE RELIEF VALVE

CIRCULATING PUMP

TANK TEMPERATURE CONTROL

DRAIN

AOS

STORAGE TANK

PIPE T&P TO

OPEN DRAIN

HEATERHEATERHEATERHEATER

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

MULTI-FLUE (4 UNITS) WITH VERTICAL STORAGE TANK

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

FOR ADDITIONAL REQUIREMENTS.

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.

Page 56

FULL PORT BALL VALV

EXPANSION TANK

CHECK VALVE

LEGEND

TEMPERATURE & PRESSURE

RELIEF VALVE

PRESSURE RELIEF VALVE

TEMPERATURE GAGE

WATER FLOW SWITCH

CIRCULATING PUMP

TANK TEMPERATURE CONTROL

DRAIN

HOT WATER

RETURN

PIPE T&P TO

OPEN DRAIN

COLD WATER

ALTERNATE

LOCATION

AOS

SUPPLY

HOT WATER

TO FIXTURES

HEATERHEATERHEATERHEATER

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

STORAGE TANK

MULTI-FLUE (4 UNITS) WITH HORIZONTAL STORAGE TANK

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

FOR ADDITIONAL REQUIREMENTS.

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.

Page 57

Page 58

Figure 32. Vacuum Relief Valve

MANIFOLD KITS

Figure 33. Two-Unit Manifold Kit (100109228)

Table 12. Rough-In Dimensions

Dimensions "A" Inches (cm)

Models

154 67.50” (171cm)

Low Prole Vertical Hood "A"

Figure 34. Three-Unit Manifold Kit (100109229)

Figure 35. Four-Unit Manifold Kit (100109230)

Page 59

NOTES

Page 60