A.O. Smith 225M, 160M, 200M, HW-120M User Manual

MODELS HW-120M, 160M, 200M, 225M

COMMERCIAL GAS COPPER HEAT EXCHANGER WATER HEATER

BURKAY UP-FLOW MODELS

Including Models with Intermittent Pilot Ignition (I.I.D.)

• Installation • Operation • Maintenance • Limited Warranty

WARNING: If the information in these instructions are 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.

CAUTION

TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY . PLEASE READ THOROUGHLY BEFORE USING APPLIANCE.

A DIVISION OF A.O. SMITH CORPORATION

McBEE, SOUTH CAROLINA, USA

RENTON, WA, USA

STRATFORD, ONT ARIO, CANADA

VELDHOVEN, THE NETHERLANDS

ww w.hotwater.com

PLACE THESE INSTRUCTIONS ADJACENT TO HEATER

AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE

PRINTED IN U.S.A. 0905 SUPERSEDES PART NO. 192011-000 REV.4

PART NO. 212626-000

ROUGH-IN-DIMENSIONS

TABLE 1 - ROUGH-IN DIMENSIONS

Models HW-120M HW-160M HW-200M HW-200M

Dimensions Inches mm Inches mm Inches mm Inches mm

A 49 3/8 1254 50 1/8 1273 53 1/4 1353 60 1524 B 30 3/8 772 30 3/8 772 33 1/8 84 1 33 1/8 841 C 23 5/8 600 23 5/8 600 27 1/8 68 9 27 1/8 689 D 20 3/4 527 20 3/4 527 20 3/4 52 7 20 3/4 527 E 5 1/2 140 5 1/2 140 5 1/2 140 5 1/2 140 F 10 254 10 254 10 254 10 254 G 11 13/16 300 11 13/16 300 11 13/16 300 11 13/16 300 H 6 152 7 178 7 178 7 178 J 26 11/16 678 26 11/16 678 26 11/16 678 26 11/16 678 K 20 3/4 527 20 3/4 527 20 3/4 52 7 20 3/4 527

L 1 1/4 NPT 1 1/4 NPT 1 1/4 NPT 1 1/4 NPT M 1 NPT 1 NPT 1 NPT 1 NPT N 1/2 NPT 1/2 NPT 1/2 NPT 1/2 NPT W 1 3/4 44 1 3/4 44 1 3/4 44 1 3/4 44

Approx.

Shipping 120 lbs. 54 Kg. 155 lbs. 70 Kg. 165 Lbs. 75 Kg. 175 lbs. 79 Kg.

Weight

HEA TER PERFORMANCE DA T A

NOTE: To compensate for the effects of high altitude areas above 2000 feet, input rating, and therefore recovery ratings, should be reduced approximately 4% for each 1000 feet above sea level.

TABLE 2 - RECOVER Y CAPACITIES

U.S. Gallons/Hrs. and Litres/Hr. at TEMPERATURE RISE INDICATED

Input F° 20F° 30F° 36F° 40F° 50F° 54F° 60F° 70F° 72F° 80F° 90F° 100F° 108F° 110F° 120F° 126F° 130F° 140F°

Model Btuh KW C° 11.1C° 16.6C° 20C° 22.2C° 27.7C° 30C° 33.3C° 38.8C° 40C° 44.4° 50C° 55.5C° 60C° 61.1C° 66.6C° 70C° 72.2C° 77.7C°

HW-120M

HW-160M

HW-200M

HW-2250M

120,000 GPH 605 403 336 303 242 224 202 173 168 151 134 121 112 110 101 96 93 86

35 LPH 2290 1527 1272 1145 916 848 763 654 636 573 509 458 242 416 382 364 352 327

160,000 GPH 777 518 432 388 311 288 259 222 216 194 173 155 144 141 129 123 120 11 1

47 LPH 2941 1961 1634 1471 1176 1089 980 840 817 735 654 588 545 535 490 467 452 420

199,000 GPH 987 658 548 494 395 366 329 282 274 247 219 197 183 179 165 157 152 141

58 LPH 3737 2491 2076 1869 1495 1384 1246 1068 1038 934 830 747 692 679 623 593 575 534

225,000 GPH 1096 731 609 548 438 406 365 313 304 274 244 219 203 199 183 174 169 157

66 LPH 4149 2766 2305 2074 1659 1537 1383 1185 1152 1037 922 830 768 754 691 659 638 593

Recovery rating of models shown in chart above are obtained by actual efficiency test data by recognized Certification Agency. NOTE: Recovery rate shown on each models rating plate is based on the requirements of ANSI Standard Z21.10.3, which stipulates

the data to be based on energy efficiency of 75%.

TABLE 3 - CAPACITY AND GAS AND ELECTRIC CHARACTERISTICS

Manifold Pressure Maximum Supply Pressure Electrical Characteristics

Model Type of Gas Inches W.C. kPa Inches W.C. kPa Volts/Hz Amperes

HW-120M thru 225M NATURAL 3.5 0.87 10.5 2.61 120/60 <5 HW-120M thru 200M PROPANE 10 2.49 13.0 3.23 120/60 <5

Minimum Supply Pressure, Natural Gas: 4.5 inches W.C. (1.12 kPa) Minimum Supply Pressure, Propane Gas: 11.0 inches W.C. (1.74 kPa) Minimum Pressure must be maintained under both load and no load (static and dynamic) conditions.

FOREWORD

This design complies with the latest edition of the ANSI Standard Z21.10.3 for gas water heaters Vol. III Storage Water Heaters with input ratings above 75,000 BTU per hour Circulating and Instantaneous.

Detailed installation diagrams are in this manual. These diagrams will serve to provide the installer with a reference for the materials and method of piping suggested. IT IS ESSENTIAL THAT ALL WATER AND GAS PIPING AND THE ELECTRICAL WIRING BE INSTALLED AND CONNECTED AS SHOWN IN THE DIAGRAMS.

You should thoroughly read and understand this manual before installation and operation of this unit.

CHECK THE DIAGRAMS THOROUGHLY BEFORE STARTING INSTALLATION TO AVOID POSSIBLE ERRORS AND TO MINIMIZE TIME AND MATERIALS COST.

Particular attention should be given to the installation of thermometers at the locations indicated in the diagrams as these are necessary for checking the operation of the heater.

MAKE SURE THE GAS ON WHICH THE HEATER WILL OPERA TE IS THE SAME AS THAT SPECIFIED ON THE HEATER MODEL AND RATING PLATE.

TABLE OF CONTENTS

PAGE

ROUGH-IN DIMENSIONS .................................................................. 2

FOREWORD....................................................................................... 3

GENERAL SAFETY INFORMATION .................................................. 3

Precautions .................................................................................... 3-4

Grounding Instructions ................................................................... 4

Chemical V apor Corrosion ............................................................. 4

Liquid Petroleum Models................................................................ 4

High Altitude Installations ............................................................... 4

FEATURES......................................................................................... 5

Automatic Gas Shutoff Control ....................................................... 5

Protector Switch (Coil High Limit)................................................... 5

Thermal Balancer........................................................................... 5

Intermittent Ignition Control Module ................................................ 5-6

Circulating Pump............................................................................ 6

Tank Temperature Control (Not Supplied) ...................................... 6

Safety Flow Switch (Not Supplied) ................................................. 6-7

Drain Valve (Not Supplied)............................................................. 7

Thermometers (Not Supplied) ........................................................ 7

INSTALLATION INSTRUCTIONS ....................................................... 8

Important ........................................................................................ 8

Required Ability .............................................................................. 8

Location ......................................................................................... 8

Installation Clearances ................................................................... 8

Levelling......................................................................................... 8

Air Requirements ........................................................................... 8-9

Venting........................................................................................... 9

Relief Valve.................................................................................... 9-10

Hard Water..................................................................................... 10

Closed Water System .................................................................... 10

Water Line Connections ................................................................ 10

Water (Potable) Heating ................................................................ 10

The factory warranty will be void if the unit(s) have been improperly installed or operated.

In addition to these instructions, the boiler(s) shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.

In absence of local codes, the installation must comply with the latest editions.

n the United States: The National Fuel Gas Code, ANSI Z223.1 and the National Electric Code, NFPA 70.

In Canada: The Installation Code CAN/CGA B149.1 and .2 (latest edition) and the Canadian Electric Code, CSA C22.1.

These are available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131, USA, or , Canadian Gas Association Laboratories, 55 Scarsdale Road, Don Mills, Ontario M3B 2R3, Canada.

PAGE

PIPING DIAGRAMS ............................................................................ 11-13

Gas Connections ........................................................................... 14-15

Electrical Information ..................................................................... 15-16

OPERATION........................................................................................ 17

Important ....................................................................................... 17

General........................................................................................... 17

Filling.............................................................................................. 17

Purging Of Gas Line ...................................................................... 17

Operating Instructions For I.I.D Models. ....................................... 18

Checking And Adjusting The Input................................................. 19

SERVICE INFORMATION .................................................................. 20

Pilot And Main Burner Maintenance ............................................... 20

I.I.D. Pilot Burner ........................................................................... 20-21

Protector Switch (Coil High Limit-All Heaters) ............................... 21

T ank Temperature Control .............................................................. 21

Automatic Gas Shutoff Control ..................................................... 21

Thermal Balancer ........................................................................... 21

Inspecting The Heat Exchanger And Venting System .................. 21-22

Gas Pressure Regulator ................................................................ 22

Relief Valve ................................................................................... 22

Circulating Pump............................................................................ 22

Electrical Service ........................................................................... 22

Replacement Parts ........................................................................ 22

PREVENTIVE MAINTENANCE ........................................................... 22

Recommended Procedure For Periodic Removal Of Lime

Deposits From Coil Type Commercial Water Heaters ................. 22-23

Deliming Solvents .......................................................................... 23

Removing Light Deposits .............................................................. 23

Heavy Lime Deposits ................................................................... 23-24

CHECKOUT ........................................................................................ 24-27

LIMITED WARRANTY ........................................................................ 28

GENERAL SAFETY INFORMATION

PRECAUTIONS

If the unit is exposed to the following, do not operate heater until all corrective steps have been made by a qualified serviceman:

1. FLOODING TO LEVEL OF BURNER OR CONTROLS OR HIGHER.

2. EXPOSURE TO FIRE.

3. IF DAMAGED.

4. FIRING WITHOUT WATER.

5. SOOTING.

KEEP THE HEATER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS. AREA AROUND HEA TER MUST NOT CONTAIN OBSTRUCTING MATERIAL TO THE FLOW OF COMBUSTION AND VENTILATING AIR.

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE.

Heater must be protected from freezing downdrafts during shutdown periods.

GROUNDING INSTRUCTIONS

This water heater must be grounded in accordance with the National Electric Code and/or local codes. These must be followed in all cases.

This water heater must be connected to a grounded metal, permanent wiring system; or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the water heater.

CHEMICAL V APOR CORROSION

WARNING

CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS. SUCH CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION.

Spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride (water softener salt), waxes, and process chemicals are typical compounds which are potentially corrosive. Do not store products of this sort near the heater . Also, air which is brought in contact with the heater should not contain any of these chemicals. If necessary, uncontaminated air should be obtained from remote or outside sources. The limited warranty is voided when failure of water heater is due to a corrosive atmosphere. (Refer to the limited warranty for complete terms and conditions.)

LIQUID PETROLEUM MODELS

Water heaters for propane or liquefied petroleum gas (LPG) are different from natural gas models. A natural gas heater will not function safely on LP gas and no attempt should be made to convert a heater from natural to LP gas.

LP gas must be used with great caution. It is highly explosive and heavier than air. It collects first in low areas making odor difficult to detect at nose level. If LP gas is present or even suspected, do not attempt to find the cause yourself. Go to a neighbor’s house, leaving your doors open to ventilate the house, then call your gas supplier or service agent. Keep area clear until a service call has been made.

At times you may not be able to smell an LP gas leak. One cause is odor fade, which is a loss of the chemical odorant that gives LP gas its distinctive smell. Another cause can be your physical condition, such as having a cold or diminishing sense of smell with age. For these reasons, the use of a propane gas detector is recommended.

IF YOU EXPERIENCE AN OUT-OF-GAS SITUATION, DO NOT TRY TO RELIGHT APPLIANCES YOURSELF. Only trained LP professionals should conduct the required safety checks in accordance with industry standards.

HIGH AL TITUDE INSTALLA TIONS

WARNING

INSTALLA TIONS ABOVE 2000 FEET REQUIRE REPLACEMENT OF THE BURNER ORIFICE IN ACCORDANCE WITH SECTION

8.1.2 OF THE NA TIONAL FUEL GAS CODE (ANSI Z223.1). FOR CANADIAN INSTALLATIONS CONSULT CANADIAN INSTALLATION CODES AND CAN/CGA B149. FAILURE TO REPLACE THE ORIFICES WILL RESULT IN IMPROPER AND INEFFICIENT OPERATION OF THE APPLIANCE 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.

You should contact your gas supplier for any specific changes which may be required in your area.

As elevation above sea level is increased, there is less oxygen per cubic foot of gas. Therefore, the heater input rate should be reduced at high altitudes for satisfactory operation with the reduced oxygen supply. Failure to make this reduction could result in an overfiring of the heater, causing sooting, poor combustion and/or unsatisfactory heater performance.

U.S. REQUIREMENTS

Ratings specified by manufacturers for most appliances apply for elevations up to 2000 feet (610m). For elevations above 2000 feet (610m), 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 120,000 Btuh (35 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 120,000 (original rating) from the original rating. Therefore, to calculate the input rating at 4,000 feet (121.9m): 4 x .04 x 120,000=19,200 Btuh (5.6 Kwh), 120,000 (35 Kwh) - 19,200 (5.6Kwh)=100,000 Btuh (29.4 Kwh). At 6000 feet (1829m) the correct input rating should be 91,200 Btuh (26.7 Kwh).

CANADIAN REQUIREMENTS

Appliances with inputs up to and including 400,000 BTU (117.2 Kw) must be factory equipped with orifices for operation at specific elevations. Standard (sea level) orifices permit operation up to 2000’ (610m) elevation. For operation between 2000’ (610m) and 4500’ (1370m) specify “HIGH AL TITUDE OPERA TION” when ordering the heater(s). For operation above 4500’ (2370m) consult factory before ordering.

Field conversion for operation at altitudes other than that specified on the heater rating plate is not permitted.

The input reduction is primarily achieved by reducing the size of the main burner orifice. T o do this, the main burner orifices require replacement with orifices sized for the particular installation elevation. Correct orifice sizing and parts may be obtained from A.O. Smith Water Products Company. When ordering, be sure to state the model number and the altitude of the location where the water heater is being installed.

Upon completion of derating of the heater, adjustment to the gas pressure regulator may be required. See CHECKING THE INPUT section in this manual for inlet and manifold pressure requirements.

Also due to the input rating reduction required at high altitudes, the output rating of the appliance is reduced and should be compensated for in the sizing of the equipment for the application.

FEATURES

T ABLE 4.

Control Device Factory Setting Field Adjustment

Heater Automatic Gas Shutoff Control Fixed 1900F (87.7°C) cut in temp. Non-adjustable

Heater Protector Switch Fixed 2000F (93.3°C) cut in temp. Non-adjustable Tank Temperature Control Field Supplied and Installed Adjust to Requirements Safety Flow Switch See Table 1 Field Adjustable

AUTOMA TIC GAS SHUT OFF CONTROL

The automatic gas shutoff control, fig. 1, is an automatic safety device which activates at a water temperature of approximately 1950F (90.5°C). This limits the water outlet temperature to a maximum of 200

F (87.7°C).

F (90.5°C) cut out temp.

195

2500F (121°C) cut out temp.

The device is wired in series with the gas valve. The control will automatically reset when the water temperature cools to approximately 190

F (87.7°C).

Should the automatic gas shutoff control activate during a heating cycle, the heater’s gas valve will close; extinguishing the main burners. The pilot burner will also be extinguished. The circulating pump will continue operating as long as the storage tank thermostat continues to “call for heat”. When the water temperature in the heater drops to 1800F (82.2°C) or below the control module will begin an ignition cycle which will relight the pilot burner and main burners. Re-ignition of the main burners will occur if the storage tank thermostat continues to call for heat. Otherwise, the normal operating cycle will resume on the thermostat’s next call for heat.

AUTOMA TIC GAS SHUT OFF CONTROL

FIGURE 1

FIGURE 2

DO NOT RESET THIS SWITCH WITHOUT PERFORMING THE SYSTEM CHECKS OUTLINED UNDER PROTECTOR SWITCH IN THE SERVICE INFORMA TION SECTION. ALSO, SEE CHART ONE UNDER THE CHECKOUT SECTION. IF NECESSARY, CALL A QUALIFIED SERVICEMAN. Once the cause of the protector switch activation has been determined and corrected, it will be necessary to restart the heater following the LIGHTING AND OPERATING instructions.

THERMAL BALANCER

The thermal balancer (standard on Models HW-200M and HW-225M, optional on Models HW-120M and HW-160M) is a snap-acting single-pole thermal relay used only on Cer-Temp 80 Recovery systems. It gives immediate pump start but delay of pump shutoff for approximately 2 minutes. Residual heat in the heat exchanger is then recovered after shutdown. This improves efficiency and balances heater temperature with tank temperature at shutdown.

INTERMITTENT IGNITION CONTROL MODULE

PROTECTOR SWITCH

(Coil High Limit)

This heater is equipped with a manually reset protector switch, Figure 2, located under the small cover on the side of the jacket. This device provides positive shutdown of the heater in the event of heater or system malfunction. Should the surface temperature of the copper tubing heat exchanger reach 2500F (121.1°C), the protector switch will activate. The gas valve will close, and the pilot and main burners will be extinguished. To resume heater operation, the protector switch must be manually reset (remove the protector switch cover and push the reset button) after the coil surface temperature cools to less than 2000F(93.3°C).

The Honeywell S-8600 control module contain the electronic components of the system and also serve as a central wiring system for the controls mounted on the heater. The control module performs the following functions:

1. Checks for safe-start by sensing for a flame or false flame condition on start-up.

2. Generates a potential of 15,000 volts for spark ignition of the pilot burner.

3. Opens the pilot valve.

4. Discontinues ignition spark when the pilot flame is established. The S-8600 control used on propane gas models provides safety lockout if the pilot fails to ignite within the pilot flame establishing period. The S-8600 control used on natural gas models continues trial for ignition until pilot flame is established.

5. After proof-of-pilot flame, opens the main valve.

6. On a power loss, shuts the heater down. When power is restored it will begin a new ignition cycle.

7. On a loss of flame, shuts off main gas and starts trial for pilot ignition.

INTERMITTENT IGNITION CONTROL MODULE (I.I.D.)

FIGURE 3

Follow the same oiling procedure if a replacement circulator is installed into the system.

T ANK TEMPERA TURE CONTROL

(Not Supplied)

DANGER

USE ANTI-SCALD VALVE(S) in the hot water system to reduce the risks of scalds at points of use such as lavatories, sinks and bathing facilities.

The tank temperature control is located in the lower portion of the hot water storage tank, see PIPING DIAGRAMS. It is the primary operating control of the system and regulates the water temperature in the tank.

The storage tank thermostat should have contact ratings that exceed the maximum electrical requirements of the system. Typically, the thermostat should have motor full load and locked rotor current ratings which exceed the total amount of current required to drive the pump(s) controlled by the thermostat.

The thermostat should have a temperature range of 100 (37.7°C) to 180 for the storage tank thermostat is 1200F (48.8°C). However, for normal use, the thermostat should be adjusted to the lowest setting which produces an acceptable hot water supply temperature. This will always give the most energy efficient operation. Do not adjust the thermostat to achieve a storage temperature of 190oF (87.7°C) or above. This action may cause the automatic gas shutoff control to activate shutting down the heater.

F (82.2°C) or more. The preferred initial setting

CIRCULA TING PUMP

Constant circulating pump operation of the heater voids the warranty. Constant water flow through the unit will “wash” away the copper’s natural protective coating. This is called velocity erosion. This erosion is not as great a problem when intermittent circulating operation is used per the recommended installation procedure. Constant circulation of water between the storage tank and the building is permissible as long as the water does not constantly flow through the heater.

Only all bronze circulators are used with commercial water heaters. Although circulators are oiled and operated by the manufacturer,

THEY MUST BE OILED AGAIN BEFORE OPERATED. Oil the three oil cups (2 on the motor, 1 on the pump) as instructed by manufacturer. See fig. 4.

Thereafter, lubricate the three oil cups at least once every 4 months.

TYPICAL CIRCULA TING PUMP

FIGURE 4

Use 2 or 3 teaspoonsful in bearing oil cups, and 10 or 12 drops in the motor oil cups. Use no. 20 non-detergent motor oil.

Intermittent ignition device and circulator start and stop simultaneously as the tank thermostat contacts open and close. This basic action, water flowing whenever the burner operates, must not be altered.

SAFETY FLOW SWITCH

(Not Supplied)

The safety flow switch is a safety device installed at the water outlet of the unit to prevent main burner operation in the event of inadequate water flow through the unit.

An accessory package A.O.S. No. 211480 containing a safety flow switch is available for this application.

This switch may be mounted in a horizontal pipe line or a vertical pipe line with upward water flow. Do not install the switch where the water flow is downward.

For proper performance mount the switch in a section of pipe where there is a straight run of at least 5 pipe diameters on each side of the flow switch (i.e. do not locate adjacent to valves, elbows, orifices, etc.).

The flow switch shall be mounted in a standard 1" x 1" x 1" tee for a 1" pipe application. For larger pipe sizes use a reducing tee in order to keep the switch as close to the pipe as possible. Install the flow switch in the branch (top) opening of the reducing tee and provide adequate paddle length in the flow stream. For example in a 2" pipe installation use a 2" x 2" x 1" reducing tee. For 1", 2" or 3" pipe use the paddle segments as supplied. For other pipe sizes (i.e. 1 1/4", 1 1/2", and 2 1/2") trim the paddle to the proper pipe size, see fig. 5. If a standard tee is used, install a face or hex bushing in the top opening. The paddle must be adjusted or trimmed to the size of the pipe in which it will be installed.

CAUTION: The paddle must be trimmed at the dotted arc. It must not touch the pipe or any restrictions when installed.

FIGURE 5

CAUTION

Any part of the paddle must not touch the pipe or any restrictions in the pipe. Screw the flow switch in position so the flat of the paddle is at right angles to the flow. The arrow on the side case must point in the direction of the flow.

The safety flow switch may be field adjusted to obtain higher minimum flow rates than those shown in Table 5.

To adjust the flow rate setting:

1. Remove the flow switch cover.

2. For higher flow rate—turn the range adjusting screw clockwise.

3. For lower flow rate—turn the range adjusting screw counterclockwise.

CAUTION

The switch is factory set at approximately the minimum flow rate, see Table 5. It must not be set lower than the factory setting as this may result in the switch failing to return at a “no flow” condition.

4. Replace the flow switch cover.

TABLE 5 - SAFETY FLOW SWITCH SETTINGS

Minimum Flow Rate (GPM)

Contacts Close Contacts Close Pkg.

Model GPM LP M GPM LP M No.

HW-120M,160M 0.6 2.3 0.3 1.1 211480

HW-200M 4.2 15.9 2 .5 9.5 211480 HW-225M 5.8 22.0 3 .7 14.0 211480

The installer is cautioned to follow the manufacturer’s instructions exactly when inserting this switch into a pipe tee. This is necessary in order to assure positive action of the switch with water flow. Once the minimum flow rate (Table 5) through the heater is reached, the safety flow switch contacts close and consequently , main burner operation is achieved.

DRAIN V ALVE (Not Supplied)

A drain valve must be obtained and installed on each heater and tank for draining purposes, see installation diagrams in this manual.

THERMOMETERS (Not Supplied)

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

Thermometers are installed in the system as a means of detecting a possible liming condition in the heater. An increase of 5 the normal temperature rise through the heater is an indication that lime is present. The term “temperature rise” designates the difference between the heater inlet and outlet water temperatures.

An increase of 5

F (3°C) above the recorded temperature rise may signify a liming condition in the coils or heat exchanger. Refer to PREVENTIVE MAINTENANCE section of this manual for deliming instructions.

Record temperature rise at initial start-up for future reference.

F over

INST ALLA TION INSTRUCTIONS

IMPORTANT

Strict adherence to installation wiring diagrams shown in this manual is required to prevent constant pump operation when the system temperature control is satisfied, otherwise the warranty is void as stipulated under item 2a (6) of the LIMITED WARRANTY.

REQUIRED ABILITY

INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, GAS SUPPLY AND ELECTRICAL WORK ARE REQUIRED.

LOCATION

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 piping system as possible.

THE HEATER SHOULD NOT BE LOCA TED IN AN AREA WHERE IT WILL BE SUBJECT TO FREEZING.

LOCATE IT NEAR A FLOOR DRAIN. THE HEATER SHOULD BE LOCATED IN AN AREA WHERE LEAKAGE FROM THE HEA TER OR CONNECTIONS WILL NOT RESUL T IN DAMAGE TO THE ADJACENT AREA OR TO LOWER FLOORS OF THE STRUCTURE.

WHEN SUCH LOCATIONS CANNOT BE A VOIDED, A SUIT ABLE DRAIN PAN SHOULD BE INSTALLED UNDER THE HEATER. Such pans should be fabricated with sides at least 2" (50.8mm) deep, with length and width at least 2" (50.8mm) greater than the diameter of the heater and must be piped to an adequate drain. The pan must not restrict combustion air flow.

Should the heater be installed in a garage, the heater must be located, or protected, so it is not subject to physical damage by a moving vehicle.

WARNING

THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH AS HEATERS IN ROOMS OR AREAS WHERE GASOLINE, OTHER FLAMMABLE LIQUIDS OR ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED, OPERATED OR REPAIRED. FLAMMABLE VAPORS ARE HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE IGNITED BY THE IGNITER OR MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION. SOME LOCAL CODES PERMIT OPERA TION OF GAS APPLIANCES IN SUCH AREAS IF THEY ARE INSTALLED 18 INCHES OR MORE ABOVE THE FLOOR. THIS MA Y REDUCE THE RISK IF LOCA TION IN SUCH

AN AREA CANNOT BE AVOIDED.

For appliance installation in locations with elevations above 2,000 feet (600M), refer to HIGH ALTITUDE INSTALLATIONS section of this manual for input reduction procedure.

INST ALLA TION CLEARANCES

These units are approved for installation in an alcove having minimum clearances from combustible construction of 44" (1,118mm) from top of the jacket, 6" (152.4mm) from sides, and 6" (152.4mm) from rear and vent connections.

All models may be installed on combustible flooring.

DO NOT INSTALL THIS WATER HEATER DIRECTLY ON A CARPETED FLOOR. A FIRE HAZARD MAY RESULT.

the water heater must be placed on a metal or wood panel extending beyond the full width and depth by at least 3 inches (76.2mm) in any direction. If the heater is installed in a carpeted alcove, the entire floor shall be covered by the panel. Also, see the DRAIN REQUIREMENTS.

It is recommended that at least 24" (610mm) be provided on the left side and front of the unit for accessibility and proper servicing. In a utility room installation, the door shall be wide enough to allow the heater to enter or to permit the replacement of another appliance.

Instead

LEVELLING

Each unit should be checked after installation to be certain that it is level.

If the unit is not level, obtain and insert metal shims under the base ring of the unit to correct this condition.

AIR REQUIREMENTS

WARNING

FOR SAFE OPERA TION AN AMPLE SUPPLY OF AIR MUST BE PROVIDED FOR PROPER COMBUSTION AND VENTILA TION. AN INSUFFICIENT SUPPLY OF AIR WILL RESULT IN A YELLOW/LUMINOUS BURNER FLAME, CAUSING CARBONING OR SOOTING OF THE FINNED HEAT EXCHANGER AND CREATING A RISK OF ASPHYXIATION. DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATION AIR.

UNCONFINED SPACE

In buildings of conventional frame, brick, or stone construction, unconfined spaces may provide adequate air for combustion, ventilation and draft hood dilution.

WARNING

FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON OR ADJACENT TO THE HEATER. OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM WITH THE HEATER.

If the unconfined space is within a building of tight construction (buildings using the following construction: weather stripping, heavy insulation, caulking, vapor barrier , etc.), air for combustion, ventilation, and draft hood dilution must be obtained from outdoors. The installation instructions for confined spaces in tightly constructed buildings must be followed to ensure adequate air supply.

CONFINED SPACE

When drawing combustion and dilution air from inside a conventionally constructed building to a confined space, such a space shall be provided with two permanent openings, ONE IN OR WITHIN 12 INCHES (30.5cm) OF THE ENCLOSURE BOTTOM. Each opening shall have a free area of at least one square inch per 1000 Btuh (2,225mm

/Kw)of the total input of all appliances in the enclosure, but not less than 100 square inches (645 square cm).

Do not install without draft hood and do not install any damper in flueway. Be sure that the vent pipe does not extend beyond the inside wall of the chimney.

2. Where a continuous or intermittent back draft is found to exist, the cause must be determined and corrected. A special vent cap may be required.

FAILURE TO CORRECT BACK DRAFTS MAY CAUSE AIR CONTAMINATION AND UNSAFE CONDITIONS.

If the confined space is within a building of tight construction, air for combustion, ventilation and draft hood dilution must be obtained from outdoors. When directly communicating with the outdoors or communicating with the outdoors through vertical ducts, two permanent openings, located in the above manner, shall be provided. Each opening shall have a free area of not less than one square inch per 4000 Btuh (8,900mm

/Kw) of the total input of all appliances in the enclosure. If horizontal ducts are used, each opening shall have a free area of not less than one square inch per 2000 Btuh (4,450mm

/Kw) of the total input of all appliances in the enclosure. For Canadian installations consult CAN/CGA B149.

Where an exhaust fan is installed in the same room with a heater , sufficient openings for air must be provided in the walls.

UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE CHIMNEY, CAUSING POOR COMBUSTION. SOOTING MAY RESULT AND RISK OF ASPHYXIATION WILL OCCUR.

VENTING

WARNING

THE INSTRUCTIONS IN THIS SECTION ON VENTING THE HEATER MUST BE FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULA TION OF FLUE GASES. SUCH CONDITIONS CAUSE SOOTING OR RISKS OF FIRE AND ASPHYXIATION.

In the United States: Vent sizing, installation and termination shall be in accordance with the NATIONAL FUEL GAS CODE. ANSI Z223.1-1999 or most recent edition.

In Canada: With Canadian Installation Code CAN/CGA B149 (latest edition) Type B venting may be used with these heaters. All local and utility regulations on venting should be followed.

Remove all soot or other obstructions from chimney which will retard free draft.

1. Install and size the vent pipe as necessary. The connection

from the heater to the chimney should be run full size and should have a minimum pitch upward to the chimney of one quarter inch per foot length.

• If the back draft cannot be corrected by the normal methods or if a suitable draft cannot be obtained, ablower type flue gas exhauster must be employed to assure proper venting and correct combustion.

3. Do not connect the heater to a common flue or chimney with solid fuel burning equipment. This practice is prohibited by many local building codes as is the practice of venting gas fired equipment to the duct work of ventilation systems.

• Where a separate vent connection is not available and the vent pipe from the heater must be connected to a common flue with an oil burning furnace, the vent pipe should enter the common flue or chimney at a point above the flue pipe from oil furnace.

4. Where two or more appliances vent into a common vent connector or manifold, the area of the common vent should at least equal the area of the largest flue or vent connector plus 50% of the areas of the additional draft hood outlets.

5. Refer to the

National Fuel Gas Code for information pertaining to multiple heater venting. The ASHRAE HVAC SYSTEMS & EQUIPMENT HANDBOOK 2000, as well as many manufacturers’ gas vent and chimney sizing handbooks contain information on multiple heater manifold venting.

RELIEF V AL VE

An ASME-rated pressure relief valve (Supplied) must be installed in the hot water outlet line as near to the heater as possible. This pressure relief valve is rated in accordance with and comply with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”), 1989 edition (or latest edition).

A C.S.A design-certified and ASME-rated temperature and pressure relief valve (Not Supplied) must be installed on each and every water storage tank. This relief valve shall comply with the Standard for Relief V alves and Automatic Gas Shutoff Devices for Hot Water Supply systems, “ANSI Z21.22-1986 or latest edition”. This relief valve should have a temperature rating of 2100F (98.8°C), a pressure rating not exceeding the lowest rated working pressure of any system component and a discharge capacity exceeding the total input of the water heaters supplying water to the storage tank.

PROPER VENT PIPE INST ALLATION

FIGURE 6

Select a relief valve with a discharge capacity exceeding the maximum heater input rating and a pressure rating not exceeding the working pressure shown on the rating plate of the heater.

Locate the T & P relief valve in the top of the tank, or in the side of the tank on centerline within the upper 6 inches from the top of the tank. See installation diagrams. Tapping shall be threaded in accordance with the latest version of the Standard for Pipe Threads, General Purpose (inch), ANSI/ASME B1.20.1. Mark location with a Class III label. See ANSI Z21.10.1, Part 1, MARKING.

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