Page 1
STAINLESS STEEL
NDIRECT-FIRED
I
WATER HEATER
A Spanish language version of these instructions is available by contacting the manufacturer
listed on the rating plate.
La version Espanola de estas instruccions se puede obtener al escribirle a la fábrica cuyo
nombre aparece in la placa de especificaciones.
INSTALLATION/OPERATING MANUAL
WITH PARTS LISTING AND TROUBLESHOOTING GUIDE
WARNING
To avoid damage or injury, there
must be no materials stored
against the indirect water heater
and proper care must be taken to
avoid unnecessary contact
(especially by children) with the
indirect water heater.
Do not store or use
gasoline or other
flammable liquids in
the vicinity of this
water heater or any
other appliance.
For your family’s comfort, safety, and convenience, we
recommend this water heater be installed and serviced by a
plumbing professional.
238-46392-00H REV 6/16
Page 2
CONGRATULATIONS!
You have just purchased one of the finest water heaters
on the market today!
This installation, operation, and instruction manual will
explain in detail the installation and maintenance of your
new Indirect Water Heater. We strongly recommend that
you contact a plumbing professional for the installation of
this water heater.
We require that you carefully read this manual, as well as
the enclosed warranty, and refer to it if questions arise. If
you have any specific questions concerning your
warranty, please consult the plumbing professional from
whom your water heater was purchased. For your
records we recommend that you write the model, serial
number and installation date of your water heater in the
back of this manual.
This manual should be kept with the water heater.
We’re committed to providing you with the finest water
heater made.
2
Page 3
SECTION I
IMPORTANT INFORMATION
-READ CAREFULLY-
CAUTION
The maximum boiler water supply temperature to the indirect
heat exchanger must not exceed 240°F (115°C).
Improper water quality will reduce the expected life of the water
heater. Hard water, sediment, high or low PH and high levels of
chlorides in the domestic water should be avoided. Be sure that
PH value falls between 6 and 8 and dissolved chlorides are less
than 100 ppm. A filter must be used where sediment is greater
than 5 microns in size that is present in the water. A water
softening system is recommended for areas with hard water. In
areas where water quality is unknown, a qualified water
treatment expert should be consulted.
NOTICE: Damage to tanks caused by improper water quality is not
covered under warranty.
NOTICE
Insulation blankets are not required for this water heater. This
water heater meets or exceeds the ASHRAE/IES 90.1b standards
with respect to insulation and standby loss requirements.
TABLE OF CONTENTS
I- IMPORTANT INFORMATION…………….….. 3
II- SPECIFICATIONS………………………………. 8
III- GENERAL INFORMATION……………………. 12
IV- PRE-INSTALLATION…………………………… 15
V- WATER CONNECTIONS……………………….. 19
VI- ELECTRICAL CONNECTIONS……………….. 24
VII- OPERATING INSTRUCTIONS………………… 26
VIII- MAINTENANCE…………………………………. 30
IX- TROUBLESHOOTING GUIDE………………… 32
X- PARTS LIST……………………………………… 34
3
Page 4
Important Information continued-
The equipment must be installed in accordance with those
installation regulations required in the area where the installation is
to be made. These regulations must be carefully followed in all
cases. Authorities having jurisdiction must be consulted before
installations are made.
All wiring on water heaters installed in the USA must be in
accordance with the National Electrical Code (latest edition) and/or
local regulations; or in Canada, installed in accordance with the
Canadian Electrical Code (latest edition) and/or local regulations.
The following terms are used throughout this manual to bring
attention to the presence of hazards of various risk levels, or to
important information concerning product life.
DANGER
Indicates an imminently
hazardous situation, which,
if not avoided, will result in
death, serious injury, or
substantial property
damage.
WARNING
Indicates a potentially
hazardous situation, which,
if not avoided, could result
in death, serious injury, or
substantial property
damage.
Indicates a potentially
hazardous situation, which,
if not avoided, may result
in moderate, or minor
injury or property damage.
Indicates special
instructions on installation,
operation or maintenance,
which are important but
not related to personal
injury hazards.
CAUTION
NOTICE
4
Page 5
Important Information continued-
DANGER
DO NOT store or use gasoline or other flammable,
combustible, or corrosive vapors and/or liquids in the vicinity
of this or any other appliance.
IF YOU SMELL GAS:
DO NOT try to light any appliance.
DO NOT touch any electric switch; do not use any
telephone in your building.
Immediately call your gas supplier from a telephone in
another building. Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the fire
department.
DO NOT OPERATE THE APPLIANCE UNTIL THE
LEAKAGE IS CORRECTED!
Liquefied petroleum gas/propane gas is heavier than air and
will remain at floor level if there is a leak. Basements, crawl
spaces, closets, and areas below ground level will serve as
pockets for accumulation of leaking gas.
This water heater is supplied with an adjustable thermostat
to control water temperature. Hot water temperatures
required for automatic dishwasher and laundry use can
cause scald burns resulting in serious personal injury and/or
death. The temperature at which injury occurs varies with
the person’s age and the time of exposure. The slower
response time of disabled persons increases the hazards to
them. NEVER allow small children to use a hot water tap or
to draw their own bath water. NEVER leave a child or
disabled person unattended in a bathtub or shower.
To comply with NSF requirements this water heater is to be:
a) Sealed to the floor with sealant, in a smooth and easily
cleanable way, or
b) Installed with an optional leg kit that includes legs
and/or extensions that provide a minimum clearance of
6” beneath the water heater.
5
Page 6
Important Information continued-
WARNING
Installation is not complete unless a properly sized/capacity
temperature and pressure relief valve is installed into the top of
the water heater. See the General Information section of this
manual for details.
This water heater contains very hot water under high pressure.
Do not unscrew any pipe fittings or attempt to disconnect any
components of this water heater without positively assuring the
water is cool and has no pressure. Always wear protective
clothing and equipment when installing, starting up, or
servicing this water heater to prevent scald injuries. Do not rely
on pressure and temperature gauges to determine the
temperature and pressure of the water heater. This water
heater contains components that become very hot. Do not touch
any components unless they are cool.
Improper installation, adjustments, alteration, service or
maintenance can cause property damage, personal injury or
loss of life. Failure to follow all instructions in the proper order
can cause personal injury or death. Read and understand all
instructions, including all those contained in component
manufacturer’s manuals, which are provided with the
appliance before installing, starting-up, operating, maintaining,
or servicing this appliance. Keep this manual and literature in
legible condition and posted near the appliance for reference by
owner and service technician.
This water heater requires regular maintenance and service to
operate safely. Follow the instructions contained in this
manual.
Installation, maintenance, and service must be performed only
by an experienced, skilled, and knowledgeable installer or
service agency.
6
Page 7
Important Information continued-
WARNING
It is the responsibility of the installing contractor to see that all
controls are correctly installed and are operating properly
when the installation is complete.
DO NOT operate the water heater with jumpered or absent
controls or safety devices.
DO NOT tamper with or alter the water heater and/or controls.
DO NOT operate the water heater if any external part has been
under water. Immediately call a qualified service technician to
inspect the appliance and to replace any part of the control
system that was under water.
This water heater is suitable for installation on combustible
flooring. DO NOT install this water heater on carpeting.
DO NOT operate this water heater without first being certain it
is filled with water.
Flammable items, pressurized containers, or any other potential
fire hazardous articles must never be placed on or adjacent to
the heater. Containers of flammable gases should not be stored
or used in the same room with this water heater.
7
Page 8
SECTION II
SPECIFICATIONS
Figure 1 – Heater Layout (40, 52, 75 single exchanger models)
Table 1: Water Heater Dimension (Inches)
MODEL A B C D E F G
40-Gal. 24 5 9-1/2 19 24-5/8 35-1/4 35-1/2
52-Gal. 24 5 9-1/2 19 28-3/8 45-5/8 45-7/8
75-Gal. 24 5 9-1/2 19 28-1/4 63-7/8 64-1/8
8
Page 9
Specifications continued-
Figure 2 – Tank Layout (120 gallon model)
9
Page 10
Specifications continued-
Table 2: Water Heater Capacities
MODEL
Tank Cap.
(Gal)
Coil Cap.
(Gal)
Dry Weight
(Lbs)
Wet Weight
(Lbs)
40-Gal. 40 1.2 90 415
52-Gal. 52 1.6 100 525
75-Gal. 75 1.6 125 745
120-Gal. 119 4.6 270 1257
Table 3: AHRI Certified Water Heater Ratings
MODEL
First
Hour
Rating
(Gal/Hr)
Continuous
Draw
Rating
(Gal/Hr)
Standby
Heat
Loss
Rating
(°F/Hr)
Minimum
Output of
Heat Source
(BTU/Hr)
Minimum
Source
Flow Rate
(Gal/Min)
40-Gal. 158 133 0.9 87,500 8.0
52-Gal. 200 165 0.7 113,000 8.0
75-Gal. 225 165 0.5 113,000 8.0
120-Gal. 360 280 0.6 195,000 11.0
NOTE: These certified ratings were obtained with a heat source
output and flow rate as specified in Table 3 and a 180°F boiler water
supply temperature. Other results will be obtained under different
conditions.
Table 4: Water Heater Performance
MODEL
Maximum First
140 °F 115 °F
Hour Rating
(Gal/Hr) @
Continuous
Draw Rating
(Gal/Min) @
140 °F 115 °F
Approximate
Boiler Output
Needed For
Ratings
(BTU/hr)
40-Gal. 209 279 3.0 4.2 136,000
52-Gal. 276 369 4.0 5.5 180,000
75-Gal. 293 385 4.0 5.5 180,000
120-Gal. 517 683 7.2 10.0 325,000
NOTE: Based on 200°F boiler water temperature and 50°F potable
water inlet temperature.
Heat
10
Page 11
Specifications continued-
Table 5: Water Heater Performance
MODEL
40-Gal. 7.3 7.6 6.0 @ 8 gpm
52-Gal. 9.7 10.0 6.2 @ 8 gpm
75-Gal. 14.3 10.0 6.2 @ 8 gpm
120-Gal 23.8 21.3 8.5 @ 11 gpm
Hot Water
Availability
(Minutes)
Coil Heat
Transfer
Area (Sq Ft)
Pressure Drop
(Feet of Head)
NOTICE
If the boiler takes longer to heat up from a cold start than the
water availability as noted above, hot water shortage may
occur.
Hot water availability is based on drawing 80% of the heated
tank volume at 4 gallons per minute flow rate.
The maximum heat transfer through the coil (heat input) of
the water heater at 240°F boiler water supply temperature
and 210°F potable water temperature is below 77,500 Btu/hr
for the 40, 52 and 75 gallon single heat exchanger models.
Heat transfer is below 139,500 Btu/hr for the 120 gallon
models. Potable water temperature is limited to below 210°F
and nominal water-containing capacity is below 120 gallons
for all indirect-fired models.
Accordingly, per Part HLW-101.2, Section IV of the ASME
Boiler and Pressure Vessel Code, all indirect-fired products
listed are exempted from compliance with the code.
11
Page 12
SECTION III
GENERAL INFORMATION
FEATURES
This water heater contains the following features:
HEAT EXCHANGER -- The heat exchanger (coil) has 3/4” NPT
female fittings.
These water heaters with stainless steel single-wall heat
exchangers meet the Uniform Plumbing Code for installation in
all potable water systems provided that:
The boiler water (including additives) is practically non-
toxic, having toxicity rating of class of 1 as listed in
Clinical Toxicology of Commercial Products.
The boiler water pressure is limited to maximum 30 psig
by approved relief valve.
The heat transfer medium is potable water or contains only
substances that are recognized as safe by the U.S. Food
and Drug Administration (FDA).
The pressure of the heat transfer medium is maintained
less than the normal minimum operating pressure of the
potable water system.
ADJUSTABLE THERMOSTAT – The temperature may be
adjusted from approximately 80°F (27°C) to approximately
160°F(72°C). The aquastat (thermostat) is factory set at
120°F(49°C). It is recommended that lower temperatures be used
to avoid the risk of scalding. Refer to the Section VII of this
manual. It is further recommended, in all cases, that the water
temperature be set for the lowest temperature that satisfies your
hot water needs. This will also provide the most energy efficient
operation of the water heater and minimizes scale formation.
Setting the water heater temperature at 120°F(49°C) will reduce
the risk of scalds. Some locations require settings to specific
lower temperatures.
12
Page 13
General Information continued-
TEMPERATURE AND PRESSURE RELIEF VALVE
WARNING
Keep clear of the combination temperature and pressure relief
valve discharge line outlet. The discharge may be hot enough to
cause scald injury. The water is under pressure and may splash.
For protection against excessive temperatures and pressure, install
temperature and pressure protective equipment required by local
codes, but not less than a combination temperature and pressure
relief valve certified by a nationally recognized testing laboratory
that maintains periodic inspection of production of listed equipment
or materials as meeting the requirements of the Standard for Relief
Valves and Automatic Gas Shutoff Devices for Hot Water Supply
Systems, ANSI Z21.22 and the Standard CAN1-4.4 Temperature,
Pressure, Temperature and Pressure Relief Valves and Vacuum
Relief Valves. The combination temperature and pressure relief
valve must be marked with a maximum set pressure not to exceed
the maximum working pressure of the water heater. The
combination temperature and pressure relief valve must also have
an hourly rated temperature steam BTU discharge capacity not less
than the hourly rating of the water heater. The supplied
combination temperature and pressure relief valve, when properly
installed and unrestricted, will discharge the maximum input
produced by a 240°F (115°C) boiler supply temperature. A lower
boiler supply temperature will reduce the input required to be
discharged in the event of excessive potable water temperatures.
Install the combination temperature and pressure relief valve into
the opening provided and marked for this purpose on the water
heater.
Some models may already be equipped or supplied with a
temperature and pressure relief valve. Verify that the combination
temperature and pressure relief valve complies with local codes. If
the temperature and pressure relief valve does not comply with
local codes, replace it with one that does.
13
Page 14
General Information continued-
WARNING
Install a discharge line so that water discharged from the
temperature and pressure relief valve will exit within six (6) inches
above, or any distance below, the structural floor and cannot
contact any live electrical part. The discharge line is to be installed
to allow for complete drainage of both the temperature and pressure
relief valve and the discharge line. The discharge opening must not
be subjected to blockage or freezing. DO NOT thread, plug, or cap
the discharge line. It is recommended that a minimum clearance of
four (4) inches be provided on the side of the water heater for
servicing and maintenance of the combination temperature and
pressure relief valve.
Do not place a valve between the combination temperature and
pressure relief valve and the tank!
A sacrificial anode is used to extend tank life. The removal of this
anode, except for inspection and/or replacement, will nullify the
warranty. In areas where water is unusually active, an odor may occur at
the hot water faucet due to a reaction between the sacrificial anode and
the impurities in the water. If this should happen, an alternative anode
may be purchased from the supplier that installed this water heater. This
will minimize the odor while protecting the tank. Additionally, the
water heater should be flushed with appropriate dissolvers to eliminate
any bacteria.
WARNING
This product contains one or more chemicals known to the State of
California to cause cancer, birth defects, or reproductive harm.
14
Page 15
SECTION IV
PRE-INSTALLATION
UNPACKING
INSPECT SHIPMENT carefully for any signs of damage. If
damage is noted, do not install the product. Contact the shipper or
manufacturer. All equipment is carefully manufactured,
inspected, and packed. Our responsibility ceases upon delivery of
the packaged water heater to the carrier in good condition.
NOTE: Any claims for damage or shortage in shipment must
be filed immediately against the carrier by the consignee.
This water heater MUST be installed indoors out of the wind
and weather.
IMPORTANT DECISIONS REQUIRED
BEFORE INSTALLATION
SIZING
1. Boiler DOE Heating Capacity – The indirect-fired
water heater will provide the rated performance only if
used in conjunction with a heat source with a DOE
heating capacity (Heat Output) at least as much as the
minimum noted in Table 3. If the heat source has less
capacity, the output of the tank will be reduced. To
determine the approximate reduction in output from the
tank use the following formula:
New Rating = (maximum continuous draw rating) x
Actual Output of Heat Source
Minimum Output of Heat Source
For example, what would the continuous draw rating be if
a 52-gallon indirect-fired water heater were installed with
a heat source having a DOE heating capacity of 85,000
BTU/h?
Answer:
New Rating
= 165 gal/hr x (85,000 BTU/h)/(113,000 BTU/h)
= 165 gal/hr x 0.752 = 124 gal/hr
15
Page 16
Pre-installation continued-
NOTICE
Increasing the boiler DOE heating capacity above the
values listed in Table 3 will not increase the rating of
the water heater.
2. Circulator Sizing – Refer to Table 5 for the
corresponding pressure drop through the coil for the
given model. Calculate the pressure drop of all straight
pipe and fittings on the supply and return of the water
heater at the selected flow rate. Add the piping/fitting
pressure drop to the pressure drop through the water
heater coil.
Select a circulator that will provide an appropriate flow rate
at the combined pressure drop.
SYSTEM ZONE CONTROL
The indirect-fired water heater must be installed as a zone
separate from the space heating system. The domestic hot water
zone’s piping and circulator must be sized for a minimum flow
rate with all zones in use and a maximum flow rate with only the
water heater in use. For this reason, the preferred method of zone
control is with circulators.
1. Circulators – With space heating zones using
circulators, the indirect-fired heater should be added as
an additional zone with a circulator.
2. Zone Valves – Select a valve with a low-pressure drop to
assure adequate flow through the water heater.
3. Hybrid – The space heating zone can be zoned using
zone valves and the indirect-fired heater zoned with a
circulator.
DOMESTIC HOT WATER PRIORITY
Two options are available, Priority and Non-Priority.
1. Priority – Demand for space heating is interrupted or
postponed until the domestic hot water demand is
satisfied. This option provides maximum delivery of
domestic hot water. Priority is recommended when:
16
Page 17
Pre-installation continued-
a) Boiler DOE heating capacity is 100,000 Btu per
hour or less, or
b) When boiler output required to satisfy domestic hot
water demand is at least 50% of the boiler output
required to satisfy space heating demand, or
c) When an interruption in space heating can be
tolerated during a long domestic hot water draw.
2. Non-Priority – Boiler output is divided between space
heating and domestic hot water heating. Delivery of
domestic hot water can be reduced during simultaneous
space and domestic hot water heating operations,
depending on such factors as boiler output, boiler oversizing, number of space heating zones calling for heat,
and the ratio of domestic hot water load to space heating
load.
CAUTION
This water heater must be located in an area where leakage of
the tank, water line connections, or the temperature and pressure
relief valve will not result in damage to the area adjacent to the
water heater or to lower floors of the structure. When such
locations cannot be avoided, a suitable drain pan must be
installed under the water heater. The drain pan depth must be
suitable for draining and collecting water. The drain pan can be
purchased from your plumbing professional. The drain pan must
be piped to an adequate drain. The piping must be at least 3/4
inch in diameter and pitched for proper drainage.
Component Location
Minimum Clearance from Combustible Materials
Top Sides Front Rear
0” 0” 0” 0”
Table 6 – Minimum Combustible Material Clearances
Recommended Service Clearances
Non-Piping
Side
6”(15.2cm) 30”(76.2cm) 1”(2.5cm) 12”(30.5cm)
Front
(Aquastat)
Table 7 – Service Clearances
17
Rear
Top
Page 18
Pre-installation continued-
CAUTION
Do not drop water heater. Do not bump water heater jacket against
floor.
Appliance Location
1. Boiler Location – Locate the indirect-fired water heater as
close to the boiler as practical.
2. Fixture Locations – For fastest delivery of hot water, place
the indirect-fired water heater close to points of use.
Additional Recommended Components
1. Shut-off Valves – Allows isolation of water heater from
domestic water system and/or boiler system during service.
2. Unions – Allows water heater movement during service if
adequate clearance cannot be provided.
3. Thermal Expansion Tank – If the water heater is installed
in a closed water supply system, such as one having a back-
flow preventer in the cold water line, provide thermal
expansion control. Contact the water supplier or local
plumbing inspector for additional information.
WARNING
Do not plug the inlet and outlet tappings of tankless heater left
installed in the boiler.
MOVE THE WATER HEATER TO A PERMANENT
POSITION BY SLIDING OR WALKING.
NOTICE
For California installation 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 Office of the State
Architect, 400 P Street, Sacramento, CA 95814.
18
Page 19
SECTION V
WATER CONNECTIONS
WARNING
FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED
TEMPERATURE AND PRESSURE RELIEF VALVE WILL
RELEASE THE MANUFACTURER FROM ANY CLAIM
WHICH MIGHT RESULT FROM EXCESSIVE
TEMPERATURE AND PRESSURES.
Keep clear of the temperature and pressure relief valve discharge
line outlet. The discharge may be hot enough to cause scald injury.
The water is under pressure and may splash.
CAUTION
This Stainless Steel tank requires a premium grade of thread
sealant, Loctite 565, to ensure leaks do not occur from the tank
fittings after installation.
INSTALL TEMPERATURE AND PRESSURE RELIEF
VALVE (if not factory installed)
WARNING
Temperature and pressure relief valve discharge piping must be piped
near the floor to eliminate potential of severe burns. Do not pipe in any
area where freezing could occur. Do not install any shut-off valves,
plugs or caps to the temperature and pressure relief valve or piping.
INSTRUCTIONS FOR POTABLE CONNECTIONS
1. BEFORE PROCEEDING WITH THE INSTALLATION,
CLOSE THE MAIN WATER SUPPLY VALVE. After
shutting off the main water supply, open a faucet to relieve
the water line pressure to prevent any water from leaking
out of the pipes while making the water connections to the
water heater. After the pressure has been relieved, close the
faucet. The DRAIN/COLD water inlet and HOT water
19
Page 20
Water Connections continued-
outlet are identified on the side and top of the water heater,
respectively. Make the proper plumbing connections
between the water heater and the plumbing system to the
house. Install a shut-off valve in the cold water supply line.
2. If this water heater is installed in a closed water supply
system, such as one having a back-flow preventer in the
cold water supply, provisions must be made to control
thermal expansion. DO NOT operate this water heater in a
closed system without provisions for controlling thermal
expansion. Warranties do not cover damages from thermal
expansions such as pressure bulges and/or deformities. A
properly sized expansion tank will alleviate most problems.
Your water supplier or local plumbing inspector should be
contacted on how to control this situation.
3. After installation of the water lines, open the main water
supply valve and fill the water heater. While the water
heater is filling, open several hot water faucets to allow air
to escape from the water system. When steady
streams of water flow through the faucets, close them and
check all water connections for possible leaks.
4. NEVER OPERATE THE WATER HEATER
WITHOUT FIRST BEING CERTAIN THAT IT IS
FILLED WITH WATER.
INSTRUCTIONS FOR BOILER CONNECTIONS
The indirect-fired heater connection labeled “To Boiler Return”
should be piped to the boiler return piping as close to the boiler as
possible and especially after any flow control or check valves in
the space heating return piping. The use of a union and a shut-off
valve is recommended. The use of a flow control or check valve
is required to prevent back flow through the water heater during
operation of the space heating system. Pipe and fittings between
the boiler and indirect-fired water heater should be ¾” diameter
or larger.
CAUTION
Maximum boiler water supply temperature to the indirect heat
exchanger must not exceed 240°F (116°C).
20
Page 21
Water Connections continued-
CONNECT WATER BOILER SUPPLY PIPING
1. For a space heating system that utilizes ZONE VALVES, refer
to Figure 3. The indirect-fired water heater connection labeled
“FROM BOILER SUPPLY” should be piped to the boiler
supply piping. Mount the circulator making sure the flow
arrow points toward the water heater. The use of shut-off
valves and unions are recommended for future service
convenience. The use of an air separator and vent is
recommended to eliminate air in the system. Pipe and fittings
between the boiler and indirect-fired water heater must be ¾”
diameter or larger.
Figure 3 - Water Boiler Piping with Zone Valves
2. For a space heating system that utilizes CIRCULATORS, refer
to Figure 4. The indirect-fired water heater connection labeled
“FROM BOILER SUPPLY” should be piped to the boiler
supply piping. Mount the circulator making sure the flow
arrow points toward the water heater. The use of shut-off
valves and unions are recommended for future service
convenience. The use of an air separator and vent is
recommended to eliminate air in the system. Pipe and fittings
between the boiler and indirect-fired water heater must be ¾”
diameter or larger.
21
Page 22
Water Connections continued-
Figure 4 - Water Boiler Piping with Circulators
CONNECT STEAM BOILER SUPPLY PIPING
Figure 5 represents a typical steam boiler connection diagram.
Refer to the boiler installation manual or contact the boiler
manufacturer for an appropriate piping diagram. The use of a
union, shut-off valves, and a drain valve is recommended for
future service convenience. The use of an in-line “Y”-style
strainer is required to prevent accumulation of sludge in the water
heater’s coil.
Figure 5 – Typical Steam Boiler Connections (connections available
below the water line)
22
Page 23
Water Connections continued-
NOTICE
Typical steam boiler without connections available below the water line
is not recommended due to insufficient water temperature, especially
during warmer months when the space heating system is not
operational. Boiler water temperature at the bottom of a steam boiler
can be 50°F lower than the boiler’s water temperature limit setting
during such periods.
FILL BOILER SYSTEM
1. On new boiler installations, do not purge the boiler or space
heating system through the water heater. During any boiler or
space heating system flushing, cleaning, or purging, the water
heater should be isolated to avoid possible attack on the coil
by chemical additives.
2. Purge air from boiler/water heater piping.
3. Check system for leaks. Repair as necessary.
23
Page 24
SECTION VI
ELECTRICAL CONNECTIONS
Install electric wiring in accordance with National Electric Code
or the Canadian Electrical Code and local regulations. See the
boiler’s installation manual for wiring diagrams.
DANGER
Positively assure all electrical connections are unpowered before
attempting installation or service of electrical components or
connections of the water heater or building. Lock out all
electrical boxes with padlock once power is turned off.
WARNING
When installed, the water heater must be electrically grounded in
accordance with local codes or, in the absence of local codes,
with the National Electrical Code, ANSI/NFPA 70, and /or the
CSA C22.1 Electric Code (latest editions).
Failure to properly wire electrical connections to the water heater
may result in serious physical harm.
Electrical power may be from more than one source. Make sure
all power is off before attempting any electrical work.
This indirect-fired water heater is supplied with an aquastat
temperature control. This aquastat must be properly installed in
the aquastat well location of the water heater. Refer to Figure 6.
Remove the cover and loosen the clamping screws. Insert the
aquastat capillary bulb to the well bottom as shown and screw the
aquastat clamp securely in the well groove. The aquastat acts as a
thermostat for zone control and should be wired accordingly.
Refer to the boiler or zone control manufacturer’s instructions if
any additional wiring is required. The control is factory set at
120°F (49°C) and care should be made to not rotate this dial
while wiring the control. Once electrical connections are
complete, secure the aquastat cover back in place.
24
Page 25
Electrical Connections continued-
AT NO TIME SHOULD WATER HEATER OPERATION
TAKE PLACE WITHOUT THE COVER ON THE
CONTROL.
Figure 6 - Aquastat Control
25
Page 26
SECTION VII
OPERATING INSTRUCTIONS
WARNING
Water heaters are heat-producing appliances. To avoid damage
or injury there must be no materials stored against the water
heater, and proper care must be taken to avoid unnecessary
contact (especially by children) with the water heater.
UNDER NO CIRCUMSTANCES SHALL FLAMMABLE
MATERIALS, SUCH AS GASOLINE OR PAINT THINNER
BE USED OR STORED IN THE VICINITY OF THE WATER
HEATER OR IN ANY LOCATION FROM WHICH FUMES
COULD REACH THE WATER HEATER.
Installation or service of this water heater requires ability
equivalent to that of a licensed tradesman in the field
involved. Plumbing and electrical work are required.
SYSTEM START-UP
Follow boiler installation instructions to place boiler in operation.
SEQUENCE OF OPERATIONS
1. Aquastat senses stored water temperature below desired
setpoint.
a. Domestic hot water priority only: Normally closed
contacts open to interrupt space heating.
b. Normally open contact closes, energizing the domestic
hot water circulator.
2. Aquastat senses stored water temperature at desired setpoint.
a. Aquastat contacts open, turning off domestic hot water
circulator and de-energizing relay.
b. Normally open contacts open, stopping boiler operation.
c. Domestic hot water priority only: Normally closed
contacts close, returning boiler control to space heating.
26
Page 27
Operating Instructions continued-
WATER TEMPERATURE ADJUSTMENT
WARNING
SCALDING
This water heater can deliver scalding temperature water at any
faucet in the system. Be careful whenever using hot water to
avoid scalding injury. By setting the thermostat on this water
heater to obtain an increased water temperature, you may create
the potential for scald injury. To protect against injury, you
should install an ASSE approved mixing valve (a device to limit
the temperature of water to protect against scald injury via
mixing hot and cold water supply) in the water system. This valve
will reduce point of discharge temperature in branch supply lines.
Such valves are available from the manufacturer of this water
heater or a local plumbing supplier. Please consult with a
plumbing professional.
Table 8 details the approximate relationship of water temperature
and time with regard to scald injury and may be used as a guide in
determining the safest water temperature for your applications.
Water temperature over 125°F
can cause severe burns
instantly or death from scalds.
Children, disabled and elderly
are at highest risk of being
scalded.
Review this instruction manual
before setting temperature
at water heater.
Feel water before bathing or
showering.
Temperature limiting valves are
available.
Figure 7 - Scald Warning
RELATIONSHIPS IN SCALDS
120°F (49°C)
125°F (52°C)
130°F (54°C)
135°F (57°C)
140°F (60°C)
145°F (63°C)
150°F (66°C)
155°F (68°C)
APPROXIMATE
TIME/TEMPERATURE
ORE THAN 5
M
MINUTES
1 ½ to 2 minutes
About 30 seconds
About 10 seconds
Less than 5 seconds
Less than 3 seconds
BOUT 1 ½ SECONDS
A
About 1 second
Table 8 – Scald Relationships
27
Page 28
Operating Instructions continued-
CAUTION
Before adjusting the aquastat, turn off all power supplied to the
indirect-fired water heater.
For the most energy efficient operation, adjust the aquastat for
the minimum water temperature necessary to meet domestic hot
water needs. Refer to Figure 8. Use a small flat screwdriver to
rotate the temperature dial through the hole directly below the
temperature indication window. The temperature setting is
aligned with the notch in this window. IT IS NOT
NECESSARY TO REMOVE THE COVER TO ADJUST
THE TEMPERATURE SETTING. THE AQUASTAT
COVER SHOULD NEVER BE REMOVED WITHOUT
ELECTRICITY BEING FIRST DISCONNECTED.
Figure 8 - Aquastat Control
After the indirect-fired water heater completes a heat-up cycle,
check the water temperature at a faucet. Allow enough water to
flow to ensure that the water temperature reflects the tank
temperature. Adjust the water heater’s temperature setting as
necessary.
28
Page 29
Operating Instructions continued-
Adjusting to a lower temperature setting will not immediately
affect water temperature. Draw sufficient water or allow the
water heater to remain idle until a heat-up cycle is initiated.
After the heater’s heat-up cycle is complete, check the water
temperature at a faucet to determine if further adjustment is
necessary.
Adjusting to a higher temperature may not immediately affect
water temperature. If a heat-up cycle begins, allow the heat-up
cycle to complete before checking the water temperature. If a
heat-up cycle does not begin, draw sufficient water or allow the
water heater to remain idle until a heat-up cycle is initiated.
After the heater’s heat-up cycle is complete, check the water
temperature at a faucet to determine if further adjustment is
necessary.
29
Page 30
SECTION VIII
MAINTENANCE
This indirect-fired water heater is intended to provide a service
life of many years. Components that require service, however,
may be subject to failure. Failure to use the correct procedures or
parts in these circumstances may make the water heater unsafe.
The owner should arrange to have the following inspections and
simple maintenance procedure performed by qualified service
personnel at the frequencies suggested.
1. Boiler and Domestic Water Piping (Annual) – Check all
piping for signs of leakage at joints, unions, and shut-off
valves. Repair as needed.
2. Temperature and Pressure Relief Valve (Annual) – The
temperature and pressure relief valve should be checked to
ensure that it is in operating condition. To check the relief
valve, lift the lever at the end of the valve several times. The
valve should seat properly and operate freely. If water does
not flow, remove and inspect for obstructions or corrosion.
Replace with a new valve of the recommended capacity as
necessary. Do not attempt to repair the valve, as this could
result in improper operation and a tank explosion. In areas
with poor water conditions, it may be necessary to inspect
the temperature and pressure relief valve more often than
once a year.
CAUTION
Before manually operating the valve, make sure that a drain
line has been attached to the valve to direct the discharge to
an open drain. Failure to take this precaution could mean
contact with extremely hot water discharging from the valve
during this checking operation.
30
Page 31
Maintenance continued-
If the temperature and pressure relief valve on the heater
discharges periodically or continuously, it may be due to
thermal expansion of water in a closed water supply
system, or it may be due to a faulty relief valve.
Thermal expansion is the normal response of water when it
is heated. In a closed system, thermal expansion will cause
the system pressure to build until the relief valve actuation
pressure is equaled. Then the relief valve will open,
allowing some water to escape, slightly lowering the
pressure. Contact your water supplier or local plumbing
inspector on how to control this situation.
ABOVE ALL, DO NOT PLUG THE TEMPERATURE
AND PRESSURE RELIEF VALVE. THIS IS NOT A
SOLUTION AND CAN CREATE A HAZARDOUS
SITUATION.
3. Sediment (Annual, but harsh water quality may dictate
more frequent service) – Depending on water conditions,
a varying amount of sediment may collect in the tank.
Levels requiring service are indicated by a small
temperature difference in the supply and return lines (See
also “Scale” below). Repeated flushing usually clears such
material. As a preventive measure, water should be drawn
from the tank at the drain valve until it runs clear.
4. Scale (Annual) – Hard water may cause scale to build-up
on the outside of the heat exchanger coil. A water softener
will prevent this problem (See also “Sediment” above).
Symptoms would be reduced recovery capacity or reduced
temperature differential between boiler supply and return
lines. Repeated flushing should resolve the problem.
31
Page 32
SECTION IX
TROUBLE SHOOTING GUIDE
PROBLEM CAUSE SOLUTION
No hot water
at faucet
Boiler does not
operate
Refer to boiler installation
instructions
Check main service
switch
Check fused disconnect
Circulator does not
operate
Improper aquastat
setting or
Check power supply
Replace as necessary
Turn tank aquastat to
appropriate setting
calibration
Zone valve does
not open (if used)
Electrical problem
(relay, wiring, etc.)
Check power supply
Replace as necessary
Check fuse and replace
Check circuit breaker and
reset (if applicable)
Check power supply
Scale build-up If boiler, circulator, and
tank are operating
satisfactorily, coil may
have scale coating. See
Section VIII:
Maintenance
Water at faucet
too hot
Clogged cold water
filter or boiler
supply strainer (if
used)
Improper system
plumbing
Improper system
wiring
Aquastat set too
high
32
Clean or replace filter or
strainer
Compare plumbing to
Section V
Compare wiring to
Section VI
Lower aquastat setting.
See Section VII
Page 33
Trouble Shooting Guide continued-
PROBLEM CAUSE SOLUTION
Insufficient hot
water
Boiler cycles
more than 5
times per day
in summer
Aquastat setting
too low
Undersized boiler
Adjust aquastat to higher
setting. See Section VII
Rewire for priority
with no priority to
domestic hot water
Peak use of hot
water is greater
than tank storage
Determine peak usage
and compare to tank
capacity
capacity
Faulty tank
Replace aquastat
aquastat
Excessive demand Reduce demand or
consider larger tank
Faulty aquastat Replace aquastat
Boiler high limit
set too low
Increase boiler high limit
setting
33
Page 34
SECTION X
PARTS LIST
PART NAME & DESCRIPTION
1. Temperature and Pressure
Relief Valve
2. Aquastat Well 5. Drain/Return Valve
3. Aquastat 6. Anode
4. Nipple ¾ NPT x 2”
34
Page 35
Contact your supplier or plumbing professional for replacement
parts or contact the company at the address given on the rating
plate of the water heater.
Provide the part name, model, and serial numbers of the water
heater when ordering parts.
READ THE WARRANTY FOR A FULL EXPLANATION OF THE
LENGTH OF TIME THAT PARTS AND THE WATER HEATER ARE
WARRANTED.
Manufactured under one or more of the following U.S. Patents: RE.34,534; B1
5,341,770; 4,416,222; 4,628,184; 4,669,448; 4,672,919; 4,808,356; 4,829,983;
4,861,968; 4,904,428; 5,000,893; 5,023,031; 5,052,346; 5,081,696; 5,092,519;
5,115,767; 5,199,385; 5,277,171; 5,372,185; 5,485,879; 5,574,822; 5,596,952;
5,660,165; 5,682,666; 5,761,379; 5,943,984; 5,954,492; 5,988,117; 6,142,216;
6,684,821; 7,063,132; 7,007,748; Other U.S. and Foreign patent applications
pending. Current Canadian Patents: 1,272,914; 1,280,043; 1,289,832;
2,045,862; 2,092,105; 2,107,012; 2,108,186; 2,112,515
Complete the following information and retain for future reference:
Model No:
Serial No:
Service Phone
Days: Nights:
Address:
Supplier:
Supplier Phone No:
35
Page 36
NOTES:
36
Loading...