A.O. Smith BPD-80 Installation Manual

0 (0)

Installation and Operating Manual

COMMERCIAL GAS WATER HEATERS

POWER DIRECT VENT GAS MODELS

WITH HOT SURFACE IGNITION

NOT FOR USE IN MANUFACTURED (MOBILE) HOMES

MODELS BPD-80 SERIES 210, 211

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.

• For Your Safety •

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE CONTACT THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.

KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE

WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

1502 331603-000

TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE . . . . . . . . . . .3 GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Qualiﬁ ed Installer Or Service Agency . . . . . . . . . . . . 6 Preparing For The Installation. . . . . . . . . . . . . . . . . . 6

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS . . . . . . . . . . . 7 TYPICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 9

Get To Know Your Water Heater - Gas Models

(List Referencing Figures 1-5). . . . . . . . . . . . . . . . . . 9 Replacement Parts And Deliming Products . . . . . . 10 Combo Heating Inlet And Outlet Side Taps . . . . . . . 10 Water Piping - Mixing Valve Usage . . . . . . . . . . . . . .11

Mixing Valves

Water Heater Operation . . . . . . . . . . . . . . . . . . . . . 12 Electrical Requirements & Wiring Diagram . . . . . . . 13

SAFETY LOCKOUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

High Limit Controls (Energy Cut Off). . . . . . . . . . . . 14

Thermostat/Water Temperature Blower High Limit Switch

Blower Air Pressure Switches . . . . . . . . . . . . . . . . . 14

LOCATING THE NEW WATER HEATER. . . . . . . . . . . . . 15

Facts To Consider About The Location . . . . . . . . . . 15

Clearances To Combustibles Floors With Carpeting Clearances For Servicing Important Notes and Warnings

Insulation Blankets . . . . . . . . . . . . . . . . . . . . . . . . . 17 Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 17

INSTALLING THE NEW WATER HEATER . . . . . . . . . . . 18

Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Space Heating And Potable Water Systems . . . . . . 18 Combo Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

System Requirements Installation

Closed Water Systems . . . . . . . . . . . . . . . . . . . . . . 20 Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . 20 Temperature-Pressure Relief Valve. . . . . . . . . . . . . 20

T&P Valve Discharge Pipe Requirements: Temperature-Pressure Relief Valve And

Pipe Insulation

High Altitude Installation . . . . . . . . . . . . . . . . . . . . . 22 Gas Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Sediment Traps. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Filling The Water Heater . . . . . . . . . . . . . . . . . . . . . 24 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Termination Clearances (Sidewall) . . . . . . . . . . . . . 26

Side Wall Vent Terminal Installation Roof Vent Terminal Installation Concentric Vent Termination Kit Installation Multiple Concentric Vent Installations Vent Pipe Length Vent Pipe Termination Venting Terminations And Sizing Vent Screen Installation Vent Pipe Material

Vent Pipe Preparation . . . . . . . . . . . . . . . . . . . . . . . 30

Vent Pipe Installation Vent Pipe Runs Vent Terminal Installations

Blower Assembly Installation. . . . . . . . . . . . . . . . . . 33

Vent/Intake Pipe Connections To Blower/Air Duct Coupling Installations According To Vent Sizes

Sound Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . 35 Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . 36

LIGHTING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . 37 OPERATING THE TEMPERATURE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Gas Control Valve/Thermostat . . . . . . . . . . . . . . . . 39

FOR YOUR INFORMATION. . . . . . . . . . . . . . . . . . . . . . . 40

Start Up Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 40

Condensate Smoke/Odor Strange Sounds

Operational Conditions . . . . . . . . . . . . . . . . . . . . . . 40

Smelly Water

“Air” In Hot-Water Faucets . . . . . . . . . . . . . . . . . . . 40

PERIODIC MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 41

General Upkeep . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Venting System Inspection . . . . . . . . . . . . . . . . . . . 41 Burner Operation And Inspection . . . . . . . . . . . . . . 41 Combustion Chamber And Burner Cleaning. . . . . . 42 Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Temperature-Pressure Relief Valve Test . . . . . . . . . 42 Draining And Flushing. . . . . . . . . . . . . . . . . . . . . . . 43

To Drain The Water Heater Storage Tank: To Flush The Water Heater Storage Tank:

Anode Rod Maintenance. . . . . . . . . . . . . . . . . . . . . 44

LEAKAGE CHECKPOINTS . . . . . . . . . . . . . . . . . . . . . . . 45

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

REFERENCE PARTS LISTING . . . . . . . . . . . . . . . . . . . . 46 TROUBLESHOOTING GUIDELINES. . . . . . . . . . . . . . . . 48

Resetting The Heater Control . . . . . . . . . . . . . . . . . 48 Lockouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Soft Lockout Hard Lockout

Ignition State And Timing . . . . . . . . . . . . . . . . . . . . 48 System Status And Error Codes . . . . . . . . . . . . . . . 49 Reading The LED Flash Sequence. . . . . . . . . . . . . 49 Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Other Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

SAFE INSTALLATION, USE AND SERVICE

Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very

important that the meaning of each safety message is understood by you and others who install, use or service this water heater.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates an imminently

DANGER

WARNING

CAUTION

hazardous situation which, if not avoided, will result in death or injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.

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

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.

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.

This product is certiﬁ ed to comply with a maximum weighted average of 0.25% lead content as required in some areas.

IMPORTANT DEFINITIONS

Qualiﬁ ed Installer: A qualiﬁ ed installer must have ability equivalent to a licensed tradesman in the ﬁ elds of plumbing, air supply, venting and gas supply, including a thorough understanding of the requirements of the “National Fuel Gas Code”, ANSI Z223.1/NFPA 54 as it relates to the installation of gas ﬁ red water heaters. The qualiﬁ ed installer must also be familiar with the design features and use of ﬂ ammable vapor ignition resistant water heaters and have a thorough understanding of this Installation and Operating manual.

Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the ﬁ elds of plumbing, air supply, venting and gas supply, including a thorough understanding of the requirements of the “National Fuel Gas Code”, ANSI Z223.1/NFPA 54 as it relates to the installation of gas ﬁ red water heaters. The service agency must also have a thorough understanding of this Installation and Operating manual, and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer.

Gas Supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances within this application. The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the Natural Gas meter or Propane storage tank of a building. Many gas suppliers also offer service and inspection of appliances within the building.

DANGER

GENERAL SAFETY

Water temperature over 125°F can cause severe burns instantly resulting in severe injury or death.

HOT

BURN

Children, the elderly and the disabled and are at highest risk of scald injury.

Feel water before bathing or showering.

Temperature limiting valves are available.

Read instruction manual for safe temperature setting.

WARNING

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 control to excessive

gas pressure.

• Use only gas shown on rating plate.

• Maintain required clearances to combustibles.

• Keep ignition sources away from faucets after

extended period of non-use.

Read instruction manual before

installing, using or servicing

water heater.

GENERAL SAFETY

WARNING

Breathing Hazard - Carbon Monoxide Gas

• Install vent system in accordance with codes.

• Do not operate water heater if flood damaged.

• For operation above 10,100’, a high altitude orifice must be installed.

• Do not operate if soot buildup is present.

• Do not obstruct water heater air intake with insulating jacket.

• Do not obstruct blower air intake.

• Do not place chemical vapor emitting products near water heater.

• Gas and carbon monoxide detectors are available.

• No vent damper installation is compatible with this power vented water heater.

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

DANGER

FLAMMBLE

Vapors from flammable liquids may explode and catch fire causing death or severe burns.

Do not use or store flammable products such as gasoline, solvents or adhesives in the same room or area near the water heater.

Keep flammable products:

1. far away from heater,

2. in approved containers,

3. tightly closed and

4. out of children's reach.

Installation: Do not install the water heater where flammable products will be stored or used.

Flammable Vapors

Water heater has a main burner and hot surface igniter. The hot surface igniter:

1. can be triggered at any time and

2. the hot surface will ignite flammable vapors.

Vapors:

1. cannot be seen,

2. are heavier than air,

3. go a long way on the floor and

4. can be carried from other rooms to the the electodes by air currents.

INTRODUCTION

Thank You for purchasing this water heater. Properly

installed and maintained, it should give you years of trouble free service.

Abbreviations found in this Installation and Operating manual:

• CSA - Canadian Standards Association

• ANSI - American National Standards Institute

• NFPA - National Fire Protection Association

• ASME - American Society of Mechanical Engineers

• UL - Underwriters Laboratories Inc.

• AHRI - Air Conditioning, Heating and Refrigeration

Institute.

This gas-ﬁ red water heater is design certiﬁ ed by CSA International, under Water Heater Standard ANSI

Z21.10.3 • CSA 4.3 (current edition), as applicable.

QUALIFIED INSTALLER OR SERVICE AGENCY

Installation and service of this water heater requires ability equivalent to that of a Qualiﬁ ed Agency (as deﬁ ned by ANSI below) in the ﬁ 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 2006 Sec. 3.3.83: “Qualiﬁ ed Agency” - “Any individual, ﬁ rm, corporation or company that either in person or through a representative is engaged in and is responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair or servicing of appliances and equipment; that is experienced in such work; that is familiar with all precautions required and that has complied with all the requirements of the authority having jurisdiction.”

If you are not qualiﬁ ed (as deﬁ ned by ANSI above) and licensed or certified as required by 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.

PREPARING FOR THE INSTALLATION

1. Read the “General Safety” section of this manual ﬁ rst and then entire manual carefully. If you don’t follow safety rules, the water heater will not operate properly. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE. This manual contains instructions for installation, operation, and maintenance of the gas-ﬁ red water heater. It also contains warnings throughout the manual that you must read and be aware of. All warnings and instructions are essential to proper operation of the water heater and your safety. Since we cannot put

everything on the ﬁ rst few pages, READ ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER. The installation must conform with these instructions and local code authority having jurisdiction. In absence of local codes, installation must comply with current editions of the

“National Fuel Gas Code”, ANSI Z223.1/NFPA 54 and “National Electrical Code”, NFPA 70. All

documents are available from:

CSA International, 8501 East Pleasant Valley Road, Cleveland, Ohio, United States 44131-5575.

NFPA documents are also available from: National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

2. The water heater, when installed, must be electrically grounded in accordance with the local codes or in the absence of local codes: current edition of the “National Electrical Code”, NFPA 70.

3. If after reading this manual you have any questions or do not understand any portion of the instructions, call the local gas utility or the manufacturer whose name appears on the rating plate.

4. Carefully plan the place where you are going to put the water heater. Correct combustion, vent action, and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and ﬁ res (see Figure 12). Examine the location to ensure the water heater complies with the “Locating The New Water Heater” section in this manual.

5. For installation in areas subject to earthquakes, this water heater must be braced, anchored, or strapped to avoid falling or moving during an earthquake. See instructions for correct installation procedures. Instructions may be obtained from:

California Ofﬁ ce of the State Architect, 400 P Street, Sacramento, CA 95814.

6. Massachusetts Code requires this water heater to be installed In accordance with Massachusetts 248-CMR

2.00: State Plumbing Code and 248-CMR 5.00.

7. Complies with California Health and Safety code 116875 (known as AB-1953) and with weighted average maximum of 0.25% lead.

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS

COMMONWEALTH OF MASSACHUSETTS For all side wall terminated, horizontally vented power vent, direct vent and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above ﬁ nished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisﬁ ed:

INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasﬁ tter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the ﬂ oor level where the gas equipment is to be installed. In addition, the installing plumber or gasﬁ tter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualiﬁ ed licensed professionals for the installation of hard wired carbon monoxide detectors. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent ﬂ oor level. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/ UL 2034 listed and CSA certiﬁ ed.

SIGNAGE A metal or plastic identiﬁ cation plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one- half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”

INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

EXEMPTIONS The following equipment is exempt from 248 CMR 5.08(2) (a) 1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building, or structure used in whole or in part for residential purposes.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the ﬂ ue gases, but identiﬁ es “special venting systems,” the following requirements shall be satisﬁ ed by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

INSTALLATION GRAPHIC: GAS-FIRED POTABLE WATER HEATING/SPACE HEATING SYSTEM

• If your water heater will be installed in the Commonwealth of Massachusetts, refer to the following

graphic during installation and during modifications to the water supply system.

COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM

TEMPERED WATER TO FIXTURES (MUST MEET TEMPS LISTED IN MASS. CODE 248 CMR

MUST BE VERTICAL TO REMOVE A

MIXING VALVE (MUST BE INSTALLED BELOW TOP OF WATER HEATER AS PER MANUFACTURER’S RECOMMENDATIONS)

WATER HEATER ACCEPTED BY THE BOARD FOR INSTALLATION IN MASSACHUSETTS.

MASSACHUSETTS INSTALLATION REQUIREMENTS:

1.) CONNECT ELECTRONICALLY-CONTROLLED TIMER TO AN ALL-BRONZE PUMP. PUMP MUST ACTIVATE EVERY 6 HOURS

2.) ALL WATER PIPING MUST BE INSTALLED AND INSULATED IN ACCORDANCE WITH MASSACHUSETTS CODE (248 CMR

3.) PIPING LOOP BETWEEN WATER HEATER AND AIR HANDLER MUST BE INSTALLED IN COMPLIANCE WITH 248 CMR.

† REQUIRED FOR MASSACHUSETTS.

‡ PIPING FROM THE TOP OF THE WATER HEATER WITH TEES IS ACCEPTABLE.

IR BUBBLES

FOR 60 SECONDS. TURN PUMP TIMER OFF BEFORE CLOSING PIPING LOOP SHUT-OFF VALVE.

& 780 CMR).

†

)

†

TYPICAL MIXING VALVE INSTALLATION

EXPANSION TANK

CHECK

VALVE

UNION

HOT

WATER

OUT

VACUUM

†

RELIEF VALVE

UNION

TEMP/ PRESSURE RELIEF VALV E

SEE NOTE ‡

100’-0” MAXIMUM DISTANCE FROM WATER HEATER TO FAN COIL AND BACK. (DEVELOPED LENGTH) NOT INCLUDING COIL

CHECK VALVE

(1/8” HOLE

DRILLED IN CLAPPER)

PUMP

AIR

HANDLER

SHUT-OFF

VALV E

IN HEATING UNIT

COLD WATER INLET

†

FLOW CONTROL

OUT

COIL

AIR

HANDLER

†

SHUT-OFF

VALVE

TYPICAL INSTALLATION

GET TO KNOW YOUR WATER HEATER - GAS MODELS (LIST REFERENCING FIGURES 1-5)

1 Termination Elbow with Rodent

Screen 2 *Vent Pipe 3 *Coupling (if required) 4 CPVC Vent Pipe ( 5 ft. supplied) 5 *Vent Pipe Elbow (long radius) 6 *CPVC Vent Pipe Elbow 7 *Union (Di-electric water connection) 8 Cold-Water Inlet Nipple/Diptube 9 **Combo Heating System Supply

Outlet (Optional) 10 T&P Valve 11 * Discharge Pipe 12 **Combo Heating System Return

Inlet (Optional) 13 Gas Control Valve/Thermostat

(Honeywell) 14 Gas Valve Electronic Control Module

And Cover (Honeywell) 15 Drain Valve 16 Outer Gas Door 17 Manifold Door Assembly (behind

outer door) (see Figure 3)

3 4

18 *Metal Drain Pan 19 *Floor Drain 20 Flexible Manifold Tube (see

Figure 3) 21 ***Control Harness 22 *Sediment Trap 23 *Ground Joint Union (gas

connection) 24 *Main Manual Gas Shut-off Valve 25 *Gas Supply* 26 Anode (under cap) 27 Bafﬂ e Assembly 28 Hot-Water Outlet Nipple/Anode 29 Sound Suppressor (Tee ﬁ tting) 30 *Inlet Water Shut-off Valve 31 ****Rubber Coupling (see Figure 4) 32 Gear Clamp (see Figure 4) 33 ***Blower with Power Cord (see

Figure 4) 34 Air Duct Adapter 35 Air Inlet Snorkel 36 Air Duct 37 *Thermal Expansion Tank (see

“Closed Water Systems” and

“Thermal Expansion” sections) 38 Flame Sensor Rod (see Figure 3) 39 Sheet Metal Burner (see Figure 3)

40 Gas Oriﬁ ce (see Figure 3) 41 Gas Manifold (see Figure 3) 42 Hot-Surface Igniter (see Figure 3) 43 Manifold Door Gasket (see

Figure 3) 44 Manifold Door (see Figure 3) 45 Two Piece Grommet With Clip (see

Figure 3) 46 Viewport (see Figure 3) 47 Air Tubing (Intake) (see Figure 4) 48 Blower High Limit Switch (see

Figure 4) 49 Intake Air Pressure Switch (NC)

(inside box) (see Figure 4) 50 Capacitor (see Figure 4) 51 Air Tubing (Exhaust) (see Figure 4) 52 Exhaust Air Pressure Switch (NO)

(inside box) (see Figure 4) *, **, ***, **** see notes on following

page

AIR INLET PIPING

EXHAUST OUTLET

PIPING

13 14

16 17

Front View

Figure 1 Figure 2

1920

Rear View

Natural gas and Propane (LP) main burner with igniter assembly. NG burner shown. LP burner similar but with drain hole (item 17 in Figure 1).

Flare Nut

††

Figure 3

REPLACEMENT PARTS AND DELIMING PRODUCTS

Replacement parts and recommended delimer may be ordered through authorized servicers or distributors. When ordering parts, provide complete model and serial numbers (see rating plate), quantity and name of part desired. Standard hardware items may be purchased locally.

COMBO HEATING INLET AND OUTLET SIDE TAPS

Models equipped with Combo Heating capabilities are shipped with the two side plumbing taps OPEN (item 9 and item 12 in Figure 1 and see also Figure 6 & Figure 19). If the heater is to be operated without using the side taps these openings must be plugged with the two pipe plugs supplied with the heaters.

Shown with Junction Box Cover removed for clarity.

Vacuum relief valve install per local codes (not supplied with heater).

Figure 4

Figure 5

Notes:

* Items not supplied with the water heater. ** The side recirculation loop connections may not be

used as the primary water inlet and outlet connections. See “Combo Heating Inlet And Outlet Side Taps”

below. *** Caution harness has 120 VAC In operation. **** See “Vent Pipe Installation” for more information.

WATER PIPING - MIXING VALVE USAGE

Mixing Valves

Water temperature over

DANGER

125°F can cause severe burns instantly resulting in severe injury or death.

Children, the elderly and the disabled and are at highest risk of scald injury.

Feel water before bathing or showering.

Temperature limiting devices

HOT

such as mixing must be installed when required by codes and to ensure safe

BURN

temperatures at fixtures.

Water heated to a temperature which satisﬁ es space heating, 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 a temperature increase of the hot water by 20F° higher than the heater’s temperature settings.

TEMPERED POTABLE WATER

MIXING

VALV E

TEMPERATUREPRESSURE RELIEF VALVE

SUGGESTED PIPING ARRANGEMENT

FOR TOP CONNECTIONS

SHUT-OFF

VALV E

COLD-WATER

INLET

This appliance has been design certiﬁ ed as complying with ANSI/CSA Standard for water heaters and is considered suitable for combination Water (Potable) Heating and Space Heating but not space heating only applications.

The water supply pressure should not exceed 80 psi. If this occurs, a pressure reducing valve with a bypass should be installed in the cold water inlet line. This should be placed on the supply to the entire house in order to maintain equal hot and cold water pressures.

TEMPERED

POTABLE WATER

NON-TEMPERED

WATER SUPPLY

SUGGESTED PIPING

ARRANGEMENT FOR

TOP CONNECTIONS

TEMPERATUREPRESSURE RELIEF VALVE

DISCHARGE PIPE (DO NOT CAP OR PLUG)

* NOTE: THE

T&P VALVE

DISCHARGE PIPE

SHALL BE PIPED

DIRECTLY TO

THE DRAIN OR

EXTERNAL TO

THE BUILDING

SHUT-OFF

VALV E

COLD-WATER

INLET

NON-TEMPERED

WATER RETURN

MIXING VALVE

METAL DRAIN

PAN 1.75 in.

MAX. DEPTH.

AT LEAST 2

in. GREATER

THAN THE

DIAMETER OF

THE WATER

HEATER.

DISCHARGE PIPE (DO NOT CAP OR PLUG)

* NOTE: THE

T&P VALVE

DISCHARGE

PIPE SHALL

BE PIPED

DIRECTLY TO

THE DRAIN

OR EXTERNAL

TO THE

BUILDING

DRAIN VALV E

MASSACHUSETTS: INSTALL A VACUUM RELIEF IN COLD WATER LINE PER SECTION 19 MGL 142.

CERTAIN MODELS

ARE EQUIPPED WITH

SIDE PLUMBING

CONNECTIONS FOR

SPACE HEATING.

METAL DRAIN PAN

1.75 in. MAX. DEPTH. AT LEAST 2 in.

GREATER THAN THE

DIAMETER OF THE

WATER HEATER.

6 in. MAX. AIR GAP*

Figure 6

DRAIN VALV E

6 in. MAX. AIR GAP*

MASSACHUSETTS: INSTALL A VACUUM RELIEF IN COLD WATER LINE PER SECTION 19 MGL 142.

Figure 7

TEMPERED

POTABLE

WATER

NON-

TEMPERED

WATER

SUPPLY

TO HOT

OUTLET

SHUT-OFF

MIXING

VALV E

NON-

TEMPERED

WATER

RETURN

TO COLD

Figure 8

COLD-

WATER

SUPPLY

INLET

Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the inﬁ rm and the physically/mentally disabled. Table 1 (published by U.S. Government Memorandum,

1978) shows the approximate time-to-burn relationship for normal adult skin. If anyone using hot water provided by the water heater being installed ﬁ 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.

Water

Temperature

°F

Time for 1st

Degree Burns

(Less Severe Burns)

110 (normal shower temp.)

116 (pain threshold)

116 35 minutes 45 minutes

122 1 minute 5 minutes

131 5 seconds 25 seconds

140 2 seconds 5 seconds

149 1 second 2 seconds

154 instantaneous 1 seconds

(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978)

Time for Permanent

Burns 2nd & 3rd

Degree (Most

Severe Burns)

Table 1

In addition to using lowest possible temperature setting that satisﬁ es demand of application, a mixing valve should be installed at water heater (see Figure 6 & Figure 7) or at hot-water taps to further reduce system water temperature. Mixing valves are available at plumbing supply stores. Consult a Qualiﬁ ed Installer or Service Agency. Follow mixing valve manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the “Operating The Temperature Control System” section in this manual.

WATER HEATER OPERATION

Figure 9 shows the water heater’s sequence of operation when a call for heat is initiated. The ignition control module will attempt to light the burner three times. If the ignition control does not detect ignition it will enter lockout mode and ﬂ ash the corresponding error code.

HEATER

THERMOSTAT

CALLS FOR

HEAT

HEATER CONTROL

CHECKS TO ENSURE

BLOWER EXHAUST

PRESSURE SWITCH IS

OPEN

BLOWER IS

ENERGIZED

CONTROL CHECKS

TO ENSURE: EXHAUST PRESSURE SWITCH CLOSES AND

INTAKE PRESSURE

SWITCH REMAINS

CLOSED INDICATING

BLOWER IS

OPERATING AND

THERE ARE NO

BLOCKAGES (INTAKE

OR EXHAUST)

TEMPERATURE

SWITCH REMAINS CLOSED INDICATING VENT TEMPERATURE

IS NOT ABOVE THE

ALLOWABLE LIMIT

IGNITER IS ENERGIZED

AND GAS VALVE IS

OPENED

BURNER COMES ON

AND THE FLAME IS

SENSED BY CONTROL

BURNER CONTINUES

UNTILL THE WATER IN

THE TANK REACHES

THERMOSTAT SETTING

GAS VALVE IS CLOSED

AND BURNER SHUTS

OFF

BLOWER CONTINUES

FOR A POST PURGE

TIME

HEATER

REMAINS ON STANDBY UNTIL NEXT CALL FOR

HEAT

Figure 9

ELECTRICAL REQUIREMENTS & WIRING DIAGRAM

WARNING

Electric Shock Hazard

Disconnect power before servicing.

Replace all parts and panels before operating.

Failure to do so can result in death or electrical shock.

Before plugging in the water heater, always make sure:

• The voltage and frequency correspond to that

speciﬁ ed on the water heater wiring diagram.

• The electrical outlet has the proper overload fuse or

breaker protection.

1. The unit must be connected to a 120VAC power supply. A dedicated power circuit is preferred.

2. The water heater must be properly grounded.

3. This water heater is a polarity sensitive appliance and will not operate if the power supply polarity is reversed.

Note: Always reference the wiring diagram for the correct electrical connections.

After making all electrical connections, completely ﬁ ll the tank with water and check all connections for leaks. Open the nearest hot-water faucet and let it run for 3 minutes to purge the water lines of air and sediment and to ensure complete ﬁ lling of the tank. The electrical power may then be turned on. Verify proper operation after servicing. See also “Installation Checklist”.

CAUTION:

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING. POWER VENT WIRING SCHEMATIC.

NOTE: REFER TO THE “Installation Checklist” BEFORE OPERATING THIS HEATER.

EARTH GND

CAPACITOR

BLOWER

FLAME SENSOR

HOT SURFACE IGNITER

PRESSURE SWITCH (CLOSED)

PRESSURE SWITCH (OPEN)

PRESSURE SWITCH (CLOSED)

HIGH LIMIT SWITCH (CLOSED)

Circled numbers indicate sequence of operation.

Figure 11

IF WIRING HAS TO BE REPLACED IN THE FIELD, USE ONLY TYPE TEW 105°C WIRE.

ELECTRICAL RATING 120V, 5A, 60 HZ.

HONEYWELL GAS VALVE

YELLOW

WHITE

BLUE

BLACK

GREEN

IGNITER - FLAME ROD ASSEMBLY

PRESSURE

SWITCH

YELLOW

BLUE

(NO)

BLACK SMOOTH - LINE

BLACK RIBBED - NEUTRAL

BLACK MIDDLE - GND

JUNCTION BOX

PRESSURE

SWITCH

(NC)

CAPACITOR

HIGH LIMIT

BLACK

BLACK WHITE

GREEN

120Vac/60Hz Wall Plug

SWITCH

BLOWER

Figure 10

SAFETY LOCKOUTS

This water heater has several lockout features designed to prevent the heater from operating in unsafe conditions.

HIGH LIMIT CONTROLS (ENERGY CUT OFF)

Thermostat/Water Temperature

This feature is a part of the gas control valve/thermostat (see Figure 1, item 12) and limits the maximum water temperature. In the event of the water overheating, this safety feature shuts off the fuel supply to the burner.

Blower High Limit Switch

This device is located on the blower (see Figure 4, item

48) and limits the maximum temperature of the blower. If the blower temperature rises above the temperature setting, the switch opens causing the heater to shut down. The switch will auto reset once the temperature drops sufﬁ ciently.

BLOWER AIR PRESSURE SWITCHES

The blower/heater is equipped with two air pressure switches located in the junction box (see Figure 4, item 49 and item 52). These devices are connected in series and monitor the air pressure produced by the blower. In the event that the exhaust venting becomes blocked or sufﬁ ciently restricted, the normally open (NO) air pressure switch will shut down the heater. In the event that the intake pipe becomes sufﬁ ciently blocked or restricted, the normally closed (NC) air pressure switch will shut down the heater.

LOCATING THE NEW WATER HEATER

FACTS TO CONSIDER ABOUT THE LOCATION

Carefully choose an indoor location for the new water heater because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance. This water heater is not for use in manufactured (mobile) homes or outdoor installation. Whether replacing an old water heater or putting the water heater in a new location, the following critical points must be observed:

1. Select a location indoors as close as practical to the vent termination or location to which the water heater vent piping is going to be connected, and as centralized with the water piping system as possible.

2. Selected location must provide adequate clearances for servicing and proper operation of the water heater.

3. Avoid locations that could cause the water heater to freeze from outside air.

4. Selected location must provide access to a properly grounded electrical branch circuit. A dedicated circuit is preferred. Do not use a GFI outlet.

5. Avoid locations that expose the water heater to direct sunlight.

6. Keep combustibles such as boxes, magazines, clothes, etc., away from the water heater area.

Important: Do not use an extension cord to connect the water heater to an electrical outlet.

CAUTION

• Sensors mounted in the metal drain pan that trigger an

alarm or turn off the incoming water to the water heater when leakage is detected.

• Sensors mounted in the metal drain pan that turn off

the water supply to the entire building when water is detected in the metal drain pan.

• Water supply shut-off devices that activate based on

the water pressure differential between the cold-water and hot-water pipes connected to the water heater.

• Devices that will turn off the gas supply to a gas water

heater while at the same time shutting off its water supply.

WARNING

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 control to excessive gas

pressure.

• Use only gas shown on rating plate.

• Maintain required clearances to combustibles.

• Keep ignition sources away from faucets after extended

period of non-use.

Read instruction manual before

installing, using or servicing

water heater.

Property Damage Hazard

• All water heaters eventually leak.

• Do not install without adequate drainage.

Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak, the ﬂ ow of water will not cause damage to the structure. For this reason it is not advisable to install the water heater in an attic or upper ﬂ oor. In all cases, a metal drain pan should be installed under the water heater. Metal drain pans are available at your local hardware store. Such a metal drain pan must have a clearance of at least 1 in. greater than any point on the water heater’s outer jacket and must be piped to an adequate drain. The pan must have a maximum depth of 1.75 in. . Water heater life depends upon water quality, water pressure and the environment in which the water heater is installed. Water heaters are sometimes installed in locations where leakage may result in property damage, even with the use of a metal drain pan piped to a drain. However, unanticipated damage can be reduced or prevented by a leak detector or water shut-off device used in conjunction with a piped metal drain pan. These devices are available from some plumbing supply wholesalers and retailers, and detect and react to leakage in various ways:

WARNING

FLAMMABLES

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Storage or use of gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or death.

Flammable Vapors

WARNING

Fire Hazard

For continued protection against risk of fire:

• Do not install water heater on carpeted floor.

• Do not operate water heater if flood damaged.

Clearances To Combustibles

Minimum clearances between water heater and combustibles are 0 in. at the sides and rear, 5.5 in. from the front and 12 in. from top (standard clearance.) If clearances stated on the heater differ from standard clearances, install water heater according to clearances stated on the heater (see Figure 12).

Floors With Carpeting

This water heater must not be installed directly on carpeting. Carpeting must be protected by a metal or wood panel beneath the appliance extending beyond the full width and depth of the appliance by at least 3 in. in every direction, or if the appliance is installed in an alcove or closet, the entire ﬂ oor must be covered by the panel. Failure to heed this warning may result in a ﬁ re hazard.

Clearances For Servicing

When installing the heater, consideration must be given to proper location. Location selected should be as close to the wall as practicable and as centralized with the water piping system as possible.

Servicing this appliance, such as changing the anodes, etc. requires clearances for accessibility and replacement of parts. The anode could be as long as 35 in. .

WARNING

Breathing Hazard - Carbon Monoxide Gas

• Flue gases may escape if vent pipe is deformed, broken, or not properly connected.

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

Refer to the current edition of the “National Fuel Gas Code”, ANSI Z223.1/NFPA 54 for detailed requirements.

0in. MIN.

TOP VIEW

OF CLOSET

WITHOUT DOOR

0 in.

MIN.

5.5 in. MIN.

TOP VIEW OF

CLOSET WITH

DOOR

0 in. MIN.

Figure 12

WARNING

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.

Important Notes and Warnings

• This heater is certiﬁ ed to be installed using Schedule

40 PVC or CPVC or polypropylene plastic vent material. Only use approved material. All venting material and components must be joined with the approved primer/ cleaner and solvent cement or mechanical seals. To join PVC and CPVC materials, use ATSM F-493 compliant cement.

• Do not common vent this heater with any other

appliance.

• During operation the plastic piping will expand as it

heats up and contract as it cools down. This is normal for this type of venting. Rigidly fastening the vent piping can cause undue stress that may result in the cracking or fracturing the vent piping material. A fracture of the venting pipe may pose a serious safety hazard. To prevent stressing of the vent system, all hangers and supports must allow the vent piping freedom to move.

• Use long sweep elbows wherever possible. Closely

coupled elbows and short radius elbows can reduce the venting capacity.

• All power vented water heaters generate a certain

amount of operational noise. In order to minimize noise transmission to the support structure, it is recommended to use isolation pads between the pipe hangers and the vent pipe.

• Most power vent installations develop some

condensation in the vent piping. When using long runs of venting or when the venting passes through cold or unheated areas, considerable amounts of condensate from the ﬂ ue gases can develop. Provision must be made for the condensate to drain freely from the system or to be collected in a condensate trap(s) that can be drained. Damage or fracture of the vent piping may occur if the condensate is allowed to collect and freeze. Pooling of condensate can restrict airﬂ ow and can cause nuisance failures of the system.

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 ﬂ ow.

WARNING

Breathing Hazard - Carbon Monoxide Gas

• Do not obstruct water heater air intake(s) with insulating jacket.

• Gas and carbcn monoxide detectors are available.

• Install water heater in accordance with the instruction manual and NFPA54.

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

AIR REQUIREMENTS

For safe operation an adequate supply of fresh, uncontaminated air for combustion, dilution and ventilation must be provided. Note: Contaminated or dusty air may cause build-up on the blower wheel resulting in nuisance shut downs.

INSULATION BLANKETS

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 standby heat loss encountered with storage tank heaters. Your water heater meets or exceeds the current standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary. Should you choose to apply an insulation blanket to this heater, you should follow these instructions (For identification of components mentioned below, see Figure 1 thru Figure 5). Failure to follow these instructions will restrict the air ﬂ ow required for proper combustion and dilution, potentially resulting in ﬁ re, asphyxiation, serious personal injury or death.

• Do not apply insulation to the top of the water heater,

as this will interfere with safe operation of the blower assembly.

• Do not cover the outer door, thermostat or T&P relief

valve.

• Do not cover the “Installation And Operating manual”.

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