A.O. Smith GSP 100, GSP 130, GSP 150, GTP 130, GTP 150 Installation Manual
...
Instruction Manual
CONTENT
RESIDENTIAL GAS WATER HEATERS
POWER DIRECT VENT GAS MODELS
WITH DIRECT SPARK IGNITION
MODELS
PG10/GHX/GSP/GTP
Series 200, 201
NATURAL GAS & PROPANE
LOW LEAD
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.
Thank you for buying this energy efcient water heater.
We appreciate your condence in our products.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, CALL THE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
PRINTED 0517 100286999_2000536191_Rev C
1
• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE.................................3
APPROVALS .................................................................................3
GENERAL SAFETY INFORMATION .............................................4
Precautions ..............................................................................4
Grounding Instructions .............................................................4
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH
OF MASSACHUSETTS .................................................................7
INTRODUCTION ...........................................................................8
Abbreviations Used ..................................................................8
Qualications ............................................................................8
Preparing For The Installation ..................................................8
MODEL CHARACTERISTICS .......................................................9
FEATURES AND COMPONENTS
Controls And Switches ...........................................................13
INSTALLATION CONSIDERATIONS ..........................................14
Locating The Water Heater ....................................................14
Insulation Blankets .................................................................15
Combustion Air And Ventilation ..............................................15
Corrosion and Water Quality ..................................................15
INSTALLATION REQUIREMENTS .............................................16
Gas Supply Systems ..............................................................16
Supply Gas Regulator ............................................................16
Power Supply .........................................................................16
Mixing Valves..........................................................................17
Circulation Pumps ..................................................................17
Space Heating And Potable Water System ............................18
Storage Tank Installation ........................................................18
Solar Installation .....................................................................18
Closed Water Systems ...........................................................18
Thermal Expansion ................................................................18
Temperature-Pressure Relief Valve ........................................19
Condensate DRAIN ................................................................20
VENTING INSTALLATION ..........................................................21
Vent Installation Considerations .............................................21
General Venting Instructions ..................................................21
Approved Vent/Intake Material ...............................................21
Polypropylene Installations .....................................................22
Vent Pipe Termination.............................................................22
Planning The Vent System .....................................................22
Integrated Filter Installation ....................................................23
Direct Vent Air Intake Moisture Protection ..............................24
Horizontal Vent Terminal Installation ......................................24
Vertical Vent Terminal Installation ...........................................25
Termination Clearances Sidewall Direct Vent .........................26
Direct Vent Installation Diagrams ...........................................27
Concentric Vent Installation ....................................................28
Venting Multiple Units .............................................................29
WATER HEATER INSTALLATION ..............................................30
CONDENSATE DRAIN INSTALLATION ................................30
Supply Gas Line Installation ...................................................30
Gas Line Leak Testing ............................................................31
Purging ...................................................................................31
Electrical Wiring ......................................................................32
Water Line Connections .........................................................32
TEMPERATURE REGULATION .................................................34
HIGH TEMPERATURE LIMIT CONTROL (ECO) ...................34
Thermostat Control .................................................................34
CONTROL SYSTEM OPERATION .............................................35
Overview ................................................................................35
Control System Navigation .....................................................35
User Settings & Control System Menus .................................38
..............................................10
START UP
TROUBLESHOOTING ................................................................47
LEAKAGE CHECKPOINTS .........................................................52
PERIODIC MAINTENANCE ........................................................53
DIAGRAMS .................................................................................55
NOTES ........................................................................................60
NOTES ........................................................................................61
...................................................................................43
Start Up Conditions ................................................................43
Prior To Start up......................................................................43
Filling The Water Heater .........................................................43
Initial Start Up .........................................................................44
Lighting & Operation Labels ...................................................45
Checking The Firing Rate .......................................................46
Gas Input Rate .......................................................................46
High Altitude Installations .......................................................46
Installation Checklist ...............................................................47
Sequence Of Operation ..........................................................47
Sequence Of Operation Flow Chart
Operational Problems .............................................................49
Fault And Alert Conditions ......................................................50
Venting System Inspection .....................................................53
Integrated Filter Preventative Maintenance ............................53
Temperature-Pressure Relief Valve Test ................................53
Draining and Flushing ............................................................54
Service ...................................................................................54
CCB - Central Control Board Layout ......................................55
Wiring Diagram .......................................................................56
Piping Diagrams .....................................................................58
.......................................48
2
SAFE INSTALLATION, USE AND SERVICE
CONTENT
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER 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
CAUTION
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.
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
APPROVALS
LOW LEAD
3
CAUTION
GENERAL SAFETY INFORMATION
PRECAUTIONS
DO NOT USE THIS WATER HEATER IF ANY PART HAS
BEEN EXPOSED TO FLOODING OR WATER DAMAGE.
Immediately call a qualified service technician to inspect
the water heater and to make a determination on what steps
should be taken next.
If the unit is exposed to the following, do not operate heater
until all corrective steps have been made by a qualied service
technician.
1. External re.
2. Damage.
3. Firing without water.
Verify the power to the water heater is turned off before performing any service procedures.
The Enable/Disable switch at the base of the water heater disables the 24 volt gas control valve.
Electrical supply must be turned off at circuit breaker serving water heater.
GROUNDING INSTRUCTIONS
This water heater must be grounded in accordance with the National
Electrical Code and/or local codes. These must be followed in all
cases. Failure to ground this water heater properly may also cause
erratic control system operation.
This water heater must be connected to a grounded permanent
wiring system; or an equipment grounding conductor must be
run with the circuit conductors and connected to the equipment
grounding terminal or lead on the water heater.
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 Te mperaturePressure Relief Valve must be
installed in the opening provided.
Improper installation, use and service may result
in property damage.
Do not operate water heater if exposed to flooding or water
•
damage.
Install in location with drainage.
•
Fill tank with water before operation.
•
Properly sized thermal expansion tanks are required on all
•
closed water systems.
Refer to this manual for installation and service.
4
GENERAL SAFETY INFORMATION
5
Fire or Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Avoid all ignition sources if you smell gas.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating plate.
Keep ignition sources away from faucets after extended
periods of non-use.
Maintain required clearances to combustibles.
Do not expose gas control valve/thermostat to excessive
gas pressure.
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.
Breathing Hazard - Carbon Monoxide Gas
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
CAUTION
GENERAL SAFETY INFORMATION
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 the water heater in
operation.
Disconnect gas piping at main
gas shutoff valve before leak
testing.
Install sediment trap in accordance
with NFPA 54.
Electrical Shock Hazard
Turn off power to the water heater
•
before performing any service.
Label all wires prior to disconnecting
•
when performing service. Wiring errors
can cause improper and dangerous
operation.
Verify proper operation after servicing.
•
Failure to follow these instructions can
•
result in personal injury or death.
Fire and Explosion Hazard
Do not use water heater with any gas
other than the gas shown on the rating
plate.
Excessive gas pressure to gas control
valve can cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
technician for installation and service.
6
INSTALLATION REQUIREMENTS FOR THE 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 nished grade in the
area of the venting, including but not limited to decks and porches, the following requirements should be satised:
INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas
fueled equipment, the installing plumber or gastter should observe that a hard wired carbon monoxide detector with an alarm
and battery back-up is installed on the oor level where the gas equipment is to be installed. In addition, the installing plumber
or gastter should 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 should
be the responsibility of the property owner to secure the services of qualied 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 oor level.
In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner should
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 should be installed.
APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above
provisions should comply with NFPA 720 and be ANSI/UL 2034 listed and CSA certied.
SIGNAGE A metal or plastic identication plate should 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 should 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 should 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 should
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 a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the
flue gases, but identifies special venting systems, the following requirements should be satisfied by the manufacturer:
1. The referenced special venting system instructions should be included with the appliance or equipment installation
instructions; and
2. The special venting systems should be Product Approved by the Board, and the instructions for that system should 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 should remain with the appliance or
equipment at the completion of the installation.
7
INTRODUCTION
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
ABBREVIATIONS USED
Abbreviations found in this Instruction Manual include :
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• AHRI - Air-Conditioning, Heating and Refrigeration Institute
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• UL - Underwriters Laboratory
• CSA - Canadian Standards Association
QUALIFICATIONS
QUALIFIED INSTALLER OR SERVICE AGENCY
Installation and service of this water heater requires ability
equivalent to that of a Qualied Agency (as dened by ANSI below)
in the eld involved. Installation skills such as plumbing, air supply,
venting, gas supply and electrical supply are required in addition to
electrical testing skills when performing service.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualied Agency” - “Any
individual, 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.”
is essential that all venting, water piping, gas piping and wiring
be installed as shown.
Particular attention should be given to the installation of
thermometers at the locations indicated in the piping diagrams
as these are necessary for checking the operation of the water
heater.
The principal components of the water heater are identied in
Features and Components beginning on Page 10 in this manual.
Use this reference to locate and identify various components on
the water heater.
See the Installation Checklist and Troubleshooting on page
47. By using this checklist the user may be able to make
minor operational adjustments and avoid unnecessary service
calls. However, service and diagnostic procedures should only
be performed by a Qualied Service Agency.
NOTE: Costs to correct installation errors are not covered
under the limited warranty.
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.
If you are not qualied (as dened by ANSI above) and licensed or
certied as required by the authority having jurisdiction to perform
a given task do not attempt to perform any of the procedures
described in this manual. If you do not understand the instructions
given in this manual do not attempt to perform any procedures
outlined in this manual.
PREPARING FOR THE INSTALLATION
1. Read the entire manual before attempting to install or operate
the water heater. Pay close attention to the General Safety
Information on Page 4 through Page 6. If you don’t follow the
safety rules, the 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. Detailed
installation diagrams are also found in this manual. These
diagrams will serve to provide the installer with a reference. It
In the absence of local codes, the installation must comply
with the current editions of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and the National Electrical Code, NFPA 70.
All documents are available from the Canadian Standards
Association, 8501 East Pleasant Valley Road, Cleveland, OH
44131. NFPA documents are also available from the National
Fire Protection Association, 1 Batterymarch Park, Quincy, MA
02269.
4. If after reading this manual 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 number of the water heater you
are working with available for the technician. This information is
located on the water heater’s rating plate.
5. Carefully plan the placement of the water heater. Examine the
location to ensure that it complies with the requirements in
Locating The Water Heater on Page 14.
8
MODEL CHARACTERISTICS
Table 1 – GAS AND ELECTRICAL CHARACTERISTICS
*Manifold Pressure Electrical Characteristics
Gas Type “WC kPA Volts/Hz Amperes
Nat./LP 0 0 120/60 <7
* The manifold pressure is the factory setting and is not adjustable. A negative pressure will be seen with just the blower running without
the Gas Control Valve open.
All models - Maximum Supply Pressure: 14 inches W.C. (3.48kPa)
Minimum Supply Pressure for Natural Gas: 3.50” (.87kPa)
Minimum Supply Pressure for Propane Gas: 8.00” (1.99kPa)
Minimum pressure must be maintained under both load and no load (dynamic and static) conditions.
Table 2 – RECOVERY CAPACITIES
Input Recovery Capacities
Rating
(Btu/hr)
100,000 29.3
130,000 38.1
150,000 44.0
175,000 51.3
199,000 58.3
Rating
(kW)
Temp.
Rise
F 30 40 50 60 70 80 90 100 110 120 130 140
C 17 22 28 33 39 44 50 56 61 67 72 78
GPH 381 286 229 190 163 143 127 114 104 95 88 82
LPH 1442 1082 865 721 618 541 481 433 393 361 333 309
GPH 495 371 297 248 212 186 165 149 135 124 114 106
LPH 1875 1406 1125 937 803 703 625 562 511 469 433 402
GPH 571 429 343 286 245 214 190 171 156 143 132 122
LPH 2163 1622 1298 1082 927 8 11 721 649 590 541 499 464
GPH 667 500 400 333 286 250 222 200 182 167 154 143
LPH
GPH 758 569 455 379 325 284 253 227 207 190 175 162
LPH 2870 2152 1722 1435 1230 1076 957 861 783 717 662 615
2524 1893 1514 1262 1082 946 841 757 688 631 582 541
Recovery capacity based on 95% thermal efciency.
9
FEATURES AND COMPONENTS
34 GALLON NOMINAL CAPACITY UNIT
**11
**34
**25
32
24
27
31
17
14
20
21, 22
9
10
**12
15
33
30
23
11
5
6
7
4
8
28
32
**33
15
16
26
29
13
* CAUTION HARNESS HAS 120 VAC. IN OPERATION.
** See Venting Installation and Condensate Piping for more information.
17
19
**11
**12
18
VACUUM RELIEF
VALV E
*INSTALL PER
LOCAL CODES
1
2
3
This is a view of the area
at the bottom of
heater behind the
Access Doors.
Figure 1. 34 GALLON NOMINAL CAPACITY UNIT
10
FEATURES AND COMPONENTS (CONT.)
50 GALLON NOMINAL CAPACITY UNIT
**11
**34
**25
32
31
17
14
20
9
10
**12
15
33
30
23
11
5
6
7
4
8
24
27
28
32
**33
15
16
26
29
13
* CAUTION HARNESS HAS 120 VAC. IN OPERATION.
** See Venting Installation and Condensate Piping for more information.
21, 22
18
17
19
**11
**12
VACUUM RELIEF VALVE
*INSTALL PER
LOCAL CODES
1
2
3
This is a view of the area
at the bottom of
heater behind the
Access Doors.
Figure 2. 50 GALLON NOMINAL CAPACITY UNIT
11
FEATURES AND COMPONENTS (CONT.)
1: Control Assembly
2: Blocked Intake Switch
3: Blocked Outlet Switch
4: Blower Assembly
5: Burner Assembly
6: Flame Sensor
7: Igniter Assembly
8: Gas Control Valve Assembly
9: Display Board
10: Display Enclosure
** 11: Exhaust Elbow Assembly
** 12: Condensate Drain Outlet
13: Enable / Disable Switch
14: Hot Water Outlet
15: Gas Supply
16: Main Manual Gas Shutoff Valve
17: Union
18: Inlet Water Shutoff Valve
19: Cold Water Inlet
20: T & P Relief Valve
21: Rating Plate
22: Labels
23: Drain Valve
24. Upper Temperature Probe (ECO)
** 25: Exhaust Vent Terminal
26: Drain Pan
27: Insulation
28: Lower Temperature Probe
29: Access Door
30: Spark Module
31. Air Intake Pipe
32. Additional Side Taps
33. Intake Air Connection
**34. Intake Vent Terminal
12
CONTROLS AND SWITCHES
Switch
Switch
This model is provided with two pressure switches. These switches
are essential to the safe and proper operation of the unit. All switches
are wired in series. The controller is set up to shut the unit down
whenever there is a failure of any of the switches. It is important to
understand the purpose of each switch.
Blocked Outlet
Switch
Blocked Intake
34 GALLON NOMINAL CAPACITY UNIT
Blocked Outlet
Switch
BLOCKED OUTLET SWITCH
The Blocked Outlet Switch is set up to shut the unit off when a buildup of positive pressure in the exhaust vent pipe occurs. This switch
is a positive pressure switch that requires an increase in pressure to
change the electrical contacts from normally closed to open. When
this switch prevents the unit from igniting, most likely the exhaust is
blocked by some means. Check to see if the condensate is allowed
to ow freely from the exhaust elbow and for obstructions in the
exhaust venting and exhaust vent terminal. Also verify that the vent
length does not exceed the maximum allowed as shown in Planning
the Vent System beginning on page 22.
BLOCKED INTAKE SWITCH
The Blocked Intake Switch is set up to shut the unit off when a buildup of negative pressure in the intake air pipe occurs. This switch
is a negative pressure switch that requires an increase in negative
pressure to change the electrical contacts from normally closed to
open. The switch is connected to the pressure tap on the PVC pipe
connected to the inlet of the blower. When this switch prevents the
unit from igniting, most likely the intake is blocked. Verify that the
integrated lter on the intake air connection, the intake air pipe,
and the intake air termination are free of obstructions that may
prevent air from entering the unit. Also Verify the intake air pipe
length does not exceed the maximum allowed in Planning the Vent
System beginning on page 22.
WATER HEATING ENABLE/DISABLE SWITCH
IMPORTANT: The Enable/Disable switch listed in this manual is
NOT an “on/off” switch and does not disconnect 120 volt power to
the CCB and other heater components.
When in the “Disabled” position the switch removes electrical power
from the gas control valve so that water heating is disabled. The
display, CCB, and other electrical components will still be energized
and the display will read “Water Heating Disabled”.
Blocked Intake
50 GALLON NOMINAL CAPACITY UNIT
Figure 3
SPARK IGNITER
The Spark Igniter is a device that ignites the main burner by spark.
When high voltage is applied to the igniter, spark is generated to
ignite the main burner.
CONFIGURATION KEY
The configuration key is located inside the control box. It
provides for the ability of the heater to retain information
collected over its lifetime, even if the control board is replaced
because of failure.
The conguration key should stay with the heater.
13
CAUTION
INSTALLATION CONSIDERATIONS
LOCATING THE WATER HEATER
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
Carefully choose a location for the new water heater. The placement
is a very important consideration for the safety of the occupants in
the building and for the most economical use of the water heater.
Whether replacing an existing water heater or installing the water
heater in a new location observe the following critical points:
1. The water heater must be located indoors.
2. The water heater must not be located in an area where it will
be subject to freezing temperatures.
3. Locate the water heater so it is protected and not subject to
physical damage by a moving vehicle. In garage installation
avoid damage to your water heater by installing a vehicle
stop as shown in Figure 4. Check state and local codes for
requirements prior to installation.
4. Locate the water heater on a level surface.
5. Locate the water heater near a oor drain. The water heater
should be located in an area where leakage of the tank or
connections will not result in damage to the area adjacent
to the water heater or to lower oors of the structure. When
such locations cannot be avoided, it is recommended that a
metal drain pan, piped to adequate drain, be installed under
the water heater. Drain pan should be fabricated with sides
at least 1-3/4” deep with diameter at least 2” greater than
diameter of heater. Pan must not restrict combustion air ow.
6. Locate the water heater close to the point of major hot
water usage.
7. Locate the water heater close to a 120 VAC power supply.
See Power Supply on Page 16 for requirements.
8. Locate the water heater where an adequate supply of fresh
air for combustion and ventilation can be obtained. See
Combustion Air and Ventilation on Page 15.
9. Locate the water heater where the vent and intake air piping,
when installed, will remain within the maximum equivalent
lengths allowed. See Planning the Vent System on page 22.
11. Do not locate the water heater where the subsequent
installation of the vent (exhaust) or intake air terminations
would be objectionable due to noise at the termination(s).
This includes locations close to or across from windows and
doors. See Venting Installation beginning on page 21.
Do not locate water heater areas where ammable liquids (vapors)
are likely to be present or stored (garages, storage and utility
areas, etc.): Flammable liquids (such as gasoline, solvents,
propane (LP or butane, etc.) and other substances (such as
adhesives, etc.) emit ammable vapors which can be ignited by
a gas water heater’s ignition device or main burner. The resulting
ashback and re can cause death or serious burns to anyone
in the area.
Figure 4. GARAGE INSTALLATION
10. Do not locate the water heater where noise (such as
the Combustion Blower) during normal operation will be
objectionable in adjacent areas.
When the water heater is installed directly on carpeting, the water
heater shall be installed on a metal or wood panel extending beyond
the full width and depth of the water heater by at least 3″ (7.62 cm) in
any direction or, if the water heater is installed in an alcove or closet,
the entire oor shall be covered by the panel. The panel must be
strong enough to carry the weight of the heater when full of water.
14
Minimum clearances from combustible materials are stated on the data
plate located on the front of the water heater. Standard clearances
are 0” (0 cm) at the sides and rear, 0” (0 cm) from the front, and 0” (0
cm) from the top. If the clearances from combustible material stated
on the water heater differ from the standard clearances, install the
water heater according to the clearances stated on the water heater.
Adequate clearance for inspection and service should be considered
before installation. A minimum of 24” (61 cm) of front clearance and 4”
(10.2 cm) on each side should be provided for access to replaceable
and/or serviceable parts such as thermostats, drain valve, condensate
drain, temperature-pressure relief valve, and the vent connection
(exhaust elbow).
Figure 5 may be used as a reference guide to locate the specic
clearance locations. When installing the water heater, consideration
must be given to proper location. The location selected should be
as close to the wall as practicable and as centralized with the water
piping system as possible.
CEILING
LEFT
WALL
FRONT VIEW
*For service access
0"
RIGHT
WALL
WITHOUT DOOR
MIN.
TOP VIEW
OF CLOSET
WATER
HEATER
0" MIN.
*4" MIN.
TOP VIEW
OF CLOSET
WITHOUT DOOR
WATER
HEATER
0" MIN.
*24" MIN. (61 cm)
0" MIN.
Figure 5: MINIMUM CLEARANCE LOCATIONS
INSULATION BLANKETS
• 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.
COMBUSTION AIR AND VENTILATION
A gas water heater cannot operate properly without the correct
amount of air for combustion. 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 death, serious bodily injury, or
property damage.
Figure 6: COMBUSTION AIR AND VENTILATION
It is imperative that the water heater(s) be installed direct vent so
that all air for combustion and ventilation is taken from outdoors.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorine based chemicals, refrigerants, etc.) in addition to being
highly ammable in many cases, will also react to form corrosive
acids when exposed to the combustion products of the water heater.
The results can be hazardous, and also cause product failure. Air
for combustion and ventilation must not come from a corrosive
atmosphere. Any failure due to corrosive elements in the atmosphere
is excluded from warranty coverage.
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. Your water heater meets or
exceeds the Energy Policy Act 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 identication of components
mentioned below. See Figures 1, 2, and 3. Failure to follow these
instructions can restrict the air ow required for proper combustion,
potentially resulting in re, asphyxiation, serious personal injury or death.
• Do not cover the control system LCD on top of the water heater.
• Do not cover the outer door, thermostat or temperature-pressure
relief valve.
• Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
CORROSION AND WATER QUALITY
Water quality will vary from location to location and may contain
contaminates that may reduce the life or performance of the water heater.
Contaminates which can reduce the life or performance of the water
heater if present in high quantities include those which contribute to
hardness (dissolved minerals such as sodium, calcium and magnesium);
plus chlorides and sulfates. Additionally, water that is too acidic or basic
(measured as pH) can reduce the life of the water heater. Water treatment
systems (such as water softeners for hardness) should be used and
maintained properly if the contaminate levels exceed the following:
Warranty is void in applications which exceed the
water quality requirements listed below.
Total Hardness: 12 grains per gal. (205 mg/liter) max.
Chloride: 200 mg/liter max.
pH: 6.5-8.0
Alkalinity: 200 mg/liter max.
15
INSTALLATION REQUIREMENTS
GAS SUPPLY SYSTEMS
Low pressure building gas supply systems are dened as those
systems that cannot under any circumstances exceed 14”
W.C. (1/2 PSI Gauge). These systems do not require pressure
regulation. Measurements should be taken to insure that gas
pressures are stable and fall within the requirements stated on
the water heater rating plate. Readings should be taken with
all gas burning equipment off (static pressure) and with all gas
burning equipment running at maximum rate (dynamic pressure).
The gas supply pressure must be stable within 1.5” W.C.
from static to dynamic pressure to provide good performance.
Pressure drops that exceed 1.5” W.C. may cause rough starting,
noisy combustion or nuisance outages. Increases or spikes in
static pressure during off cycles may cause failure to ignite or in
severe cases damage to water heater gas control valves. If your
low pressure system does NOT meet these requirements, the
installer is responsible for the corrections.
High pressure building supply systems use pressures that exceed
14” W.C. (1/2 PSI Gauge). These systems must use eld supplied
regulators to lower the gas pressure to less than 14” W.C. (1/2
PSI Gauge). Water heaters require gas regulators that are properly
sized for the water heater input and deliver the rating plate specied
pressures. Gas supply systems where pressure exceeds 5 PSI
often require multiple regulators to achieve desired pressures.
Systems in excess of 5 PSI building pressure should be designed
by gas delivery professionals for best performance. Water heaters
connected to gas supply systems that exceed 14” W.C. (1/2 PSI
Gauge) at any time must be equipped with a gas supply regulator.
All models require a minimum gas supply pressure of 3.5”
W.C.(0.87 kPa) for natural gas and 8.0” W.C. (1.99 kPa) for
propane. The minimum supply pressure is measured while gas
is not owing (static pressure) AND while gas is owing (dynamic
pressure). The supply pressure (static and dynamic) should never
fall below 3.5” W.C.(0.87 kPa) for natural gas or 8.0” W.C. (1.99
kPa) for propane. The supply pressure should be measured with
all gas red water heaters connected to the common main ring
at full capacity. If the supply pressure drops more than 1.5” W.C.
(0.37 kPa) 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 Supply Gas Regulator on page
16 and Supply Gas Line Installation on page 30. The gas control
valve on all models has a maximum gas supply pressure limit of
14” W.C.(3.48 kPa) The maximum supply pressure is measured
while gas is not owing (static pressure) AND while gas is owing
(dynamic pressure).
SUPPLY GAS REGULATOR
The maximum allowable gas supply pressure for this water heater
is 14 inches W.C. (3.5 kPa). Install a positive lock-up gas pressure
regulator in the gas supply line if inlet gas pressure can exceed 14
inches W.C. (3.5 kPa) at any time. Regulators must be sized/used
according to manufacturer’s specications.
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. Supply gas regulators shall have inlet and outlet connections not
less than the minimum supply gas line size for the water heater
they supply
3. Positive lock-up gas pressure regulator(s) should be installed
no closer than 3 feet (1 meter) and no farther than 8 feet (2.4
meters) from the water heater’s inlet gas connection.
4. After installing the positive lock-up gas pressure regulator(s) an
initial nominal supply pressure setting of 7.0” W.C.(1.74 kPa) for
Natural Gas and 11.0” W.C. (2.74 kPa) for Propane (LP) while
the water heater is operating is recommended and will generally
provide good water heater operation. Some additional adjustment
may be required later to maintain a steady gas supply pressure.
5. 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.
All gas piping must comply with local codes and ordinances or
with current editions of the National Fuel Gas Code (ANSI Z223.1/
NFPA-54). Copper or brass tubing and ttings (except tin lined
copper tubing) shall not be used.
If the gas control valve is subjected to pressures exceeding 1/2 psi
(3.5 kPa), the damage to the gas control valve could result in a re
or explosion from leaking gas.
If the main gas line Shut-off serving all gas water heaters is used,
also turn off the gas at each water heater. Leave all gas appliances
shut off until the water heater installation is complete.
A gas line of sufcient size must be run to the water heater. Consult
the current edition of the National Fuel Gas Code (ANSI Z223.1/
NFPA 54) and your gas supplier concerning pipe size.
There must be:
• A readily accessible manual shut off valve in the gas supply
line serving the water heater, and
• A sediment trap ahead of the gas control valve to help prevent
dirt and foreign materials from entering the gas control valve.
• A ground joint union of proper size between the manual shut
off valve and gas control valve to permit servicing of the unit.
Be sure to check all the gas piping for leaks before lighting the
water heater. Use a soapy water solution, not a match or open
ame. Rinse off soapy solution and wipe dr y.
POWER SUPPLY
The water heaters covered in this manual require a 120 VAC,
1Ø (single phase), 60Hz, 7 amp power supply and must also be
electrically grounded in accordance with local codes or, in the
absence of local codes, with the National Electrical Code, ANSI/
NFPA 70.
If any of the original wire as supplied with the water heater must
be replaced, it must be replaced with 105°C rated wiring or its
equivalent, except in the burner housing. In this case 200°C
rated wire must be used.
DEDICATED POWER WIRING AND BREAKERS
Dedicated power supply wires, ground wiring and dedicated
circuit breakers often prevent electrical line noise and
should be considered when installing the water heater.
POWER FLUCTUATIONS AND ELECTRICAL NOISE
The water heater’s control system requires a source of stable
clean electricity for proper operation. Connecting the water heater
to a branch circuit that is subject to uctuations in voltage level
16
or electrical line noise such as EMI (electro magnetic interference)
or RFI (radio frequency interference) may cause erratic control
system operation and malfunction.
A high quality power supply lter/suppressor must be installed
if the above conditions exist. Call the technical support phone
number for more information.
NOTE: Malfunctions caused by the power supply and the costs
to install the power supply filters are not covered under the
limited warranty.
MIXING VALVES
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Water heated to a temperature which will satisfy clothes washing,
dish washing, and other sanitizing needs can scald and cause
permanent injury upon contact. Short repeated heating cycles
caused by small hot water uses can cause temperatures at the point
of use to exceed the water heater’s temperature setting by up to
20°F (11°C).
Some people are more likely to be permanently injured by hot water
than others. These include the elderly, children, the inrm and the
physically/mentally disabled. Table 3 shows the approximate timeto-burn relationship for normal adult skin. If anyone using hot water
provided by the water heater being installed ts into one of these
groups or if there is a local code or state law requiring a certain water
temperature at the point of use, then special precautions must be taken.
In addition to using the lowest possible temperature setting that
satises the demand of the application a Mixing Valve should be
installed at the water heater or at the hot water taps to further
reduce system water temperature. See Figure 7 below and Figures
51 through 53 in Piping Diagrams beginning on Page 58.
HOT WATER
OUTLET
12” TO 15”
(30-38 cm)
TEMPERED WATER
OUTLET
TO TANK
INLET
MIXING
VALVE
CHECK
VALVE
COLD
WATER
INLET
CHECK
VALVE
Figure 7
Mixing valves are available at plumbing supply stores. Consult a
Qua lie d Inst alle r or Se r v ice Agenc y. Fol l ow mi xing val ve ma nufa c ture r ’s
instructions for installation of the valves.
In all cases, the following burn table must be used.
Table 3
Water Temperature
°F (°C)
Time for 1st Degree Burn
(Less Severe Burns)
110 (43.3) (normal shower temp.)
116 (46.7) (pain threshold)
116 (46.7) 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 (67.8) instantaneous 1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)
Time for Permanent
Burns
2nd & 3rd Degree
(Most Severe Burns)
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. The
tank is provided with a 1” NPT recirculation loop return connection. See
the Piping Diagrams section beginning on Page 58 for the installation
location of circulating pumps.
See Circulation Pump Wiring Diagrams on page 57 for electrical hookup
information. Install in accordance with the current edition of the National
Electrical Code, NFPA 70.
Re f e r to th e circula t i n g pump ma nufactu r e r ’s i n s t r uctions fo r its o p e r a tion,
lubrication and maintenance instructions.
17
SPACE HEATING AND POTABLE WATER SYSTEM
ater
Hot
W
O
Your water heater is equipped with additional side taps for use in
space heating applications. See Features and Components on
Page 10 for locations. If this water heater is to be used to supply
both space heating and potable (drinking) water, the instructions
listed below must be followed:
• Be sure to follow the manual(s) shipped with the air handler
or other type heating system.
• Thi s water he a ter cann o t be used in spac e he a ting ap p l icati o n s
only.
• This water heater is not to be used as a replacement for an
existing boiler installation.
• Do not use with piping that has been treated with chromates,
boiler seal or other chemicals and do not add any chemicals
to the water heater piping
• If the space heating system requires water temperatures in
excess of 120°F, a mixing valve must be installed per the
manufacturer’s instructions in the potable hot water supply to
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. The
temperature-pressure relief valve is not intended for the constant
relief of thermal expansion.
A properly sized thermal expansion tank should 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.
limit the risk of scald injury. See Mixing Valves on Page 17.
• Pumps, valves, piping and fittings must be compatible with
potable water.
• A properly installed ow control valve is required to prevent
thermosiphoning. Thermosiphoning is the result of a continuous
ow of water through the air handler circuit during the off cycle.
Weeping (blow off) of the temperature-pressure relief valve (T &
P relief valve) or higher than normal water temperatures are the
rst signs of thermosiphoning.
• The hot water line from the water heater should be vertical past
any mixing valve or supply line to the heating system to remove
air bubbles from the system. Do not connect the water heater to
any system or components previously used with non-potable water
NOTE: To protect against untimely corrosion of hot and cold
water fittings, it is strongly recommended that di-electric unions
or couplings be installed on this water heater (see Figure 8) when
connected to copper pipe.
heating appliances when used to supply potable water.
STORAGE TANK INSTALLATION
When installing the water heater with a storage tank, see Figure
ater
utlet
Union
Sweat
Fittings
52 on page 59 in Piping Diagrams for suggestions.
NOTE: If ta nk temperatur e is set ab o v e 120°F and wat e r is su p p l i e d
for domestic use (hand washing, showering, etc.) a mixing valve
should be installed in the hot water line to domestic xtures.
Installation must conform to local code requirements. If a check
valve is installed in the cold water supply line, an expansion tank
must be installed between the check valve and the water heater’s
Temperature-
Pressure
Relief Valve
cold water inlet. Set storage tank temperature ve degrees lower
than the water heater’s temperature setting. Using the plug valve,
adjust the ow in the recirculating line to ve gallons per minute.
Sweat
SOLAR INSTALLATION
If this water heater is used as a solar storage heater or as a
backup for the solar system, the water supply temperatures to the
water heater tank may be in excess of 120°F (48.9°C). A mixing
valve must be installed in the water supply line to limit the supply
temperature to 120°F (48.9°C).
Fittings
Shutoff
Valve
Union
Cold
W
Inlet
NOTE: Solar water heating systems can often supply water with
temperatures exceeding 180°F (82.2°C) and may result in water
heater malfunction.
CLOSED WATER SYSTEMS
Water supply systems may, because of code requirements or such
Figure 8 also shows the typical attachment of the water piping
to the water heater. The water heater is equipped with 1” NPT
Figure 8
conditions as high line pressure, among others, have installed
18
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