Bradford White D-80T-180-3N, D-100S-250-3NA, D-100T-250-3NA, D-38T-155-3N+, D-100S-199-3N Installation Manual

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Page 1

a plumbing prof essional.

personal injury or death.

GAS-FIRED COMMERCIAL WATER HEATER

- Do not st ore or use gasoline or ot her

- WHA T T O DO IF Y OU SMELL GAS

- For your family ’s com f ort, saf et y and

W A RNI N G: I f the informa t ion in

t hese inst r uct ions is not followed exact ly, a f ire or explosion may result ca using propert y dam age,

f lammable vapors and liquids in t he vic inity of t his or any ot her appliance.

• Do not t r y to light any appliance.

• Do not t ouc h any elect ric al switch; do

not use any phone in your building.

• Immediately call y our gas supplier f rom a neighbor’ s phone. Follow the gas supplier’ s instructions.

• If y ou cannot reach your gas supplier, cal l th e fi r e d epar tmen t.

conv enience, it is recomm ended this water h eater b e i ns tal l ed and ser vi c ed b y

INSTALLATION/OPERATION MANUAL

PLACE THESE INSTRUCTIONS ADJACENT TO WATER HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE

WITH TROUBLESHOOTING GUIDE

238-47675-00F 8/18

Page 2

SECTION I: IM P O RTANT INFORMATION

Thi s water h eater h as a l im i t ed warr anty. The warr an t y for thi s water h eater i s v al id o nl y if th e water h eater

any damage, injury, or loss of lif e resulting f rom alteration and/or f ailure to com ply wit h these instruct ions.

IMPORTANT-Before proceeding, please inspect the water heater and components for possible damage. DO NOT purchased or the manufacturer listed on the rating plate for replacement parts.

NOTICE

IMPORTANT INFORMATION..........................2

VIII

ELECTRICAL CONNECTIONS.....................21

SPECIFICATIONS............................................5

OPERATING INSTRUCTIONS......................23

III

GENERAL INFORMATION..............................8

MAINTENANCE.............................................32

DIAGNOSTIC AND TROUBLESHOOTING

GUIDE............................................................34

VENTING........................................................15

XII

PARTS LIST...................................................54

INSTALLATION FOR POTABLE

WATER AND SPACE HEATING...................55

VII

GAS CONNECTIONS....................................19

XIV

NOTES………………………………………….56

TA BLE OF CONTENTS

This gas-fired water heater is design certified by CSA International under the American National Standard,

READ CAREF ULLY

Indicates special instruc t ions on installation,

Indicates a pot entially hazardous sit uation, which,

WARNING

Indicates potent ially hazardous situat ion, which, if injury or property damage.

CAUTION

Indicat es an imminent ly hazardous sit uation, injury or substant ial property damage.

DANGER

Z21.10.3 and CAN/CGA 4.3-M (as indicated on the rating plate). These st andards are available from CSA Standards Association, 5060 Spectrum Way Mississauga, Ontario L4W 5N6 CANADA. This w ater heater must be installed in accordance w ith loc al codes. In the absence of local codes, it must be installed in compliance w it h t he National Fuel Gas Code (ANSI Z223 . 1-Latest Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B14 9.2 Propane Instal lat ion Co de (Lat est Edition).

The follow ing terms are used throughout t his manual to bring at t ention t o the presence of hazards at various risk levels, or t o import ant inf ormat ion concerning product lif e.

w hic h, if not avoided, will result in death, serious

not avoided, may result in moderate or minor

NOTICE

if not avoided, could result in death, serious injury or substantial property damage.

has been installed, maintained and operated in accordance w it h these instructions. The warranty does not cover damage or injury caused by t he use of any energy-saving devices (other than t hose aut horized by t he manufact urer) in conjunct ion wit h t his wat er heater. The use of unaut horized energy-sav i ng d ev ic es m ay dec reas e t h e l ife o f t he water heater and endanger life and/or property. The manufact urer will not be liable for

install damaged components. If damage is evident, please contact the supplier where the water heater was

operation or m aintenance, w hic h are import ant but not related to personal injury hazards.

IV INSTALLATION INSTRUCTIONS..................10 XI

VI WATER CONNECTIONS……………………..17 XIII

Page 3

DANGER

DO NOT store or use gas oline or other f lammable, combustible, or corrosive vapors and/or liquids in the vicinity of this or any other appliance.

This water heater is equipped with an adjustable thermostat to control water temperature. Hot water temperatures

The slower

or to draw their own bath water. NEVER leave a child or disabled person unattended in a bathtub or shower.

Toxic chemic al, such as those used for boiler treatment, must not be introduced into potable water used for spac e heating.

This water heater must not be connected to an existing heating system or c omponent(s) pr eviously used with a nonpotable water heating appliance.

All piping components connected to this water heater for space heating applications must be suitable for use with

WARNING

Improper installation, adjustments, alteration, service or maintenance can cause property damage, personal injury or

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 a qualified, skilled and knowledgeable installer or service provider.

Installation is not complete unless a temperature and pressure relief valve is installed into the proper location at the top of this water heater.

It is the responsibility of the installing contractor to see that all controls are correctly installed and are properly operating when the installation is complete.

DO NOT operate this water heater without first being certain it is filled with water.

DO NOT tamper with or alter the water heater and/or controls.

DO NOT operate water heater with jumpered or absent controls or safety devices.

DO NOT operate water heater if any external part has been under water. Immediately call a qualified service

been under water.

DO NOT attempt to use this water heater with any gas other than the type listed on the rating plate. Do not attempt to

gas company if there are any questions.

For installations in high altitude regions, this water heater must be ordered from the supplier to the manufacturer’s constructed water heaters.

Incorrect operation of this appliance may create a hazard to life and property and will nullify the warranty.

DO NOT operate this water heater if the input rate exceeds the rate shown on the water heater rating plate.

This water heater contains very hot water under high pressure. Do not unscrew any pi pe fittings nor attempt to

unless they are cool.

This water heater must be properly vented and connected to an approved vent system in good condition. DO NOT

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. response time of disabled pers ons incr eases the hazards to them . NEVER allow small children to use a hot water tap,

potable water.

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 provided with the appliance before installing, starting-up, operating, maintaining or servicing this appliance. Keep this manual and literature in legible condition with this water heater for

technician to inspect the appliance and to replace any part of the control system including gas controls, which has

convert this water heater for use with a gas other than the type for which it is equipped. Failure to use the proper gas can create an unsafe condition resulting in property damage, bodily injury, or death. Consult your local gas supplier or

specifications for that particular altitude. Contact the company listed on the rating plate when ordering high altitude

disconnect any components of this water heater without positively assuring the water is cool and is not under pressure. Always wear protective clothing and equipment when installing, starting up or servicing this water heater to prevent scald injuries. Do not rely on the temperature gauges to determine the temperature. Do not touch any components

operate water heater with the absence of an approved vent system. A clean and unobstructed vent system is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the water heater’s efficiency.

Page 4

WARNING

This water heater needs fresh air for safe operation and must be installed so there are provisions for adequate

burners, and flue tubes and creates a risk of asphyxiation.

Water heater materials of construction, products of combustion and the fuel contain carbon monoxide, nitrogen oxides,

respirators and equipment when servicing or working nearby this water heater.

Flammable items, pressurized containers or any other potential fire hazardous articles must never be placed on or with this water heater.

Insulation blankets are not required for this water heater. This water heater meet s or exceeds the ASHRAE/IES 90.1b (latest edition) standards with respect to insulation and standby loss requirements.

Set t ing t he w at er t emperature t o t he maximum set point c an result in scalding hot water deliv er ed to th e

r a long

faucet at the time it is open.

Liquefied petroleum gases/propane gas is heavier than air and will remain at floor level if there is a leak.

D O NO T O PERATE THE APPL I AN CE U NTI L T HE LEAK A G E IS C O R REC TED !

WARNING

Prior to connecting the gas supply line to a gas fired water heater, ensure that the gas supply line does not have

WARNING

combustion and ventilation air. Insufficient air supply will cause a recirculation of combustion products resulting in contamination that may be hazardous to life. This will result in carboning or sooting of the combustion chamber,

aldehydes and/or other toxic or harmful substanc es which can cause death or serious injur y and which are known to the state of California to cause canc er, birth defects and other reproductive harm . Always use proper safety clothing,

adjacent to the water heater. Open containers of flamm able material should not be stored or us ed in the same room

faucets. It is highly recommended that t he maximum setpoint be adjusted t o t he lowest t emperature possible f or t he needs of t he installation. See f ollowing section in t his Inst allat ion/Operat ion Manual t o c hange the maximum set point limit (max setpoint ). M ak e su re th e wat er heater c on tro l di sp lay i s no t i n a p ub l ic ar ea t h at can result in t he t emperature sett ings being improperly adjusted.

Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank fo period of time (generally two weeks or more) . Hydrogen gas is extremely flammable. To prevent the possibility of injury under these conditions, we recomm end the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance, which is connect to the hot water system. If hydrogen is present, there will be unusual sounds such as air escaping through the pipes as hot water begins to f low. Do not smoke or have open flame near the

moisture/water or dirt/scale inside the gas line. Commonly this check is done at the lowest point in the gas distribution system prior to gas burning appliances.

Do not use this appliance if any external part to the tank has been submerged in water. You should contact a qualified service technician to inspect the appliance and to replace any part of the control system including the combination gas control which has been submerged in water. See the Gas Connections section of this manual before servicing or replacing a water heater that has had any external part to the tank submerged in water.

Basement s, craw l spaces, closets and areas below ground level w ill serve as pockets for accumulat ion of leak in g gas. Before lighting, smell all around the appliance area for gas. Be sure to smell next to t he f loor.

I F Y O U S MELL GA S :

• DO NOT try to light any appliance.

• DO NOT touch any elect ric sw itch; do not use any t elephone in your building.

• Immediately call your gas supplier from a telephone in another building. Follow the gas supplier’s

instructions.

• If y ou cannot reach your gas supplier, call t he fire department.

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.

Page 5

Model Description

Capacity

(GAL)

Input (BTU/hr)

Nat.

100

199,999

75.00

64.75

56.50

4.63

23 6 100

250,000

75.00

64.75

56.50

4.63

23 6 100

270,000

N/A

75.00

64.75

56.50

4.63

23 6 100

300,000

75.44

64.75

56.50

4.63

23 7 80

399,999

375,000

71.50

60.25

51.50

10.25

N/A 8 80

450,000

425,000

69.00

60.25

51.50

10.25

N/A

505,000

475,000

69.00

60.25

51.50

10.25

N/A

10 Model Description

Input (kW/hr)

(Litres)

Nat.

378.5

58.6

191

164

144

11.8

58.4

15.2

378.5

73.2

191

164

144

11.8

58.4

15.2

378.5

79.1

N/A

191

164

144

11.8

58.4

15.2

378.5

87.9

192

166

144

11.8

58.4

17.8

302.8

117.2

109.9

181

153

131

26.0

N/A

20.3

302.8

131.8

124.5

175

153

131

26.0

N/A

25.4

302.8

148.0

139.2

175

153

131

26.0

N/A

25.4

Model Description

Capacity

(GAL)

Input

(BTU/hr)

370,000

71.38

64.75

54.13

399,999

(NAT ONLY)

300,000

72.00

65.75

54.13

425,000

81.00

75.50

64.50

505,000

81.00

75.50

64.50

10 Model Description

Capacity

(Litres)

Input

(kW/hr)

246.1

108.4

181

164

137

20.3

117.2

(NAT ONLY)

283.9

87.9

183

167

137

17.8

302.8

124.5

206

192

164

25.4

302.8

148.0

206

192

164

25.4

Model Description

Capacity

(GAL)

Input

(BTU/hr)

370,000

73.25

64.75

54.50

399,999

(NAT ONLY)

300,000

75.88

65.75

54.13 7 80

425,000

82.75

75.50

64.50

505,000

82.75

75.50

64.50

10 Model Description

Capacity

(Litres)

Input

(kW/hr)

246.1

108.4

186

165

138

20.3

117.2

(NAT ONLY)

283.9

87.9

193

167

138

17.8

302.8

124.5

210

192

164

25.4

302.8

148.0

210

192

164

25.4

Figure 1

Figure 2

SECTION II: SPECIFICATIONS

Non-Flue Damper Models and Flue Damper Models (Figure 1)

(in) B (in) C (in) D (in) E (in) F (in)

Capacity

(cm)

1. N/A - Denotes not available.

Non-Flue Damper Models (Figure 2)

(in.) B (in.) C (in.) D (in.)

246.1

71.38 64.75 54.13 8

(cm) B (cm) C (cm) D (cm)

181 164 137 20.3

Flue Damper Models (Figure 2)

(in.) B (in.) C (in.) D (in.)

246.1

73.25 64.75 54.50 8

(cm) B (cm) C (cm) D (cm)

186 165 138 20.3

Page 6

Model Description

Capacity

(GAL)

Input

(BTU/hr)

155,000

51.00

43.50

35.00

33.75

6 Model Description

Capacity

(Litres)

Input

(kW/hr)

143.9

45.4

130

110

15.2

Model Description

Cap.

(GAL)

Input

(BTU/hr)

180,000

70.13

66.25

64.50

56.00

19.50

55.13

199,999

70.13

66.25

64.50

56.00

19.50

55.13

250,000

(235,000 LP)

199,999

81.13

77.25

75.50

67.00

19.50

66.13

250,000

(235,000 LP)

100

199,999

75.50

69.88

61.88

60.38

20.75

56.88

100

250,000

75.50

69.88

61.88

60.38

20.75

56.88

Model Description

Cap.

(GAL)

Input

(BTU/HR)

180,000

71.88

66.25

64.50

56.00

19.50

55.13

199,999

71.88

66.25

64.50

56.00

19.50

55.13

250,000

(235,000 LP)

199,999

83.38

77.25

75.50

67.00

19.50

66.13

250,000

(235,000 LP)

100

199,999

76.75

70.00

67.88

60.38

20.75

56.88

100

250,000

76.75

70.00

67.88

60.38

20.75

56.88

Model Description

Cap.

(Liters)

Input

(kW/hr)

302.8

52.8

178

169

164

142

49.5

140

302.8

58.7

178

169

164

142

49.5

140

73.3

(68.9 LP)

371.0

58.7

206

196

192

170

49.5

168

73.3

(68.9 LP)

378.5

58.7

192

177

157

153

52.7

144

378.5

73.3

192

177

157

153

52.7

144

Model Description

Cap.

(Liters)

Input

(kW/hr)

302.8

52.8

183

169

164

142

49.5

1.40

302.8

58.7

183

169

164

142

49.5

1.40

73.3

(68.9 LP)

371.0

58.7

224

196

192

170

49.5

1.68

73.3

(68.9 LP)

378.5

58.7

192

177

157

153

52.7

1.44

378.5

73.3

192

177

157

153

52.7

1.44

Figure 3

Figure 4

Flue Damper Models and Non-Flue Damper Models (Figure 3)

(in.) B (in.) C (in.) D (in.)

(cm) B (cm) C (cm) D (cm) E (cm)

Non-Flue Da mper Models (Figure 4 )

(in.) B (in.) C (in.) D (in.) E (in.) F (in.)

(in.)

302.8

371.0

70.13 66.25 64.50 56.00 19.50 55.13

82.88 77.25 75.50 67.00 19.50 66.13

(cm) B (cm) C (cm) D (cm) E (cm) F (cm)

178 169 164 142 49.5 140

211 196 192 170 49.5 168

Flue Damper Models (Figure 4)

(in.) B (in.) C (in.) D (in.) E (in.) F (in.)

71.88 66.25 64.50 56.00 19.50 55.13

88.38 77.25 75.50 67.00 19.50 66.13

302.8

371.0

(cm) B (cm) C (cm) D (cm) E (cm) F (cm)

183 169 164 142 49.5 1.40

224 196 192 170 49.5 1.68

Page 7

160,000

(155,000

LP)

46.9

160,000

(155,000

LP)

(Liters)

(kW/hr)

Figure 5

Non-Flue Damper Models (Figure 5)

Model Description

Capacity

(GAL)

Model Description

Capacity

(Liters)

283.9

Input

(BTU/hr)

Input

(kW/hr)

(45.4 LP)

(in.) B (in.) C (in.) D (in.) E (in.)

70.13 67.13 65.00 54.50 6

(cm) B (cm) C (cm) D (cm) E (cm)

178 171 165 138 15.2

Flue Damper Models (Figure 5)

Model Description

Capacity

(GAL)

Model Description

Capacity

283.9 36.6 183 171 165 138 12.7

283.9

Input

(BTU/hr)

75 125,000 72.25 67.13 65.00 54.50 5

Input

46.9

(45.4 LP)

(in.) B (in.) C (in.) D (in.) E (in.)

72.25 67.13 65.00 54.50 6

(cm) B (cm) C (cm) D (cm) E (cm)

184 171 165 138 15.2

The following notes apply to the tables accompanying Figures 1 - 5.

1. All models with flue dampers and/or above 400,000 BTU per hour input employ a “spark to pilot” (IID) ignition system and requires 120 volt AC electric supply.

2. Model number may have a suffix “N” for natural gas or “X” for liquefied petroleum (LP) gases. Some models may have “A” as a suffix for ASME. Check the rating plate on front of the water heater for model number verification.

Page 8

Keep clear of combination temperature and pressure relief valve discharge line outlet. The discharge may be

WARNING

SECTION III: GENERAL INFORMATION

FEATURES

1. Porcelain enamel lined tank provides corrosion protection with a tough glass lining on the interior of the tank.

2. Magnesium anodes provide an extra measure of protection and extends tank life.

3. Flue Damper on 24 volt ignition models reduces standby losses on the burner off cycle saving fuel.

4. Hand Hole Cleanout allows inspection of tank interior and allows the removal of lime and sediment deposits.

5. Honeywell Integrated Water Heater Control on 24 volt models having the following features:

• Attractive digital water heater display on control panel for precisely setting and displaying the temperature setpoint. Pressing temperature up and down buttons changes the temperature setpoint. Temperature format may be displayed in degrees F or degrees C.

• Single control board with plug in wiring controls temperature, ignition, and flue damper operation.

• Reduced number of parts for servicing and wiring.

• Plug in wiring reduces chance of miswiring.

• Water heater display will show diagnostic codes in the event the water heater needs servicing. Aids in diagnosing

and servicing the water heater. Temperature of the tank sensors can be monitored in the Service Mode.

• Water heater display can show up to 10 previous error codes to further aid in servicing the water heater.

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, ANS 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.

Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose on the water heater.

Note: Some models may already be equipped or supplied with a combination temperature and pressure relief valve. Verify that the combination temperature and pressure relief valve complies with local codes. If the combination temperature and pressure relief valve does not comply with local codes, replace it with one that does. Follow the installation instructions above on this page.

Install a discharge line so that water discharged from the combination temperature and pressure relief valve will exit within six (6) inches (15.2 cm) 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 combination 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 (10.2 cm) 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.

Page 9

WARNING

This product contains one or more chemicals known to the State of California to cause c ancer, birth defects, or reproductive harm.

DISHWASHING MACHINE RE QUIREMENTS

All dishwashing machines meeting the National Sanitation Foundation requirem ents are designed to operate with water flow pressures between 15 and 25 pounds per square inch. Flow pressures above 25 pounds per square inch, or below 15 pounds per square inch, will result in improperly sanitized dishes.

The National Sanitation Foundation also recommends circulation of 180°F water. Where this is done, the circulation should be very gentle so that it does not cause any unnecessary turbulence inside the water heater. The circulation should be just enough to provide 180°F water at the point of take-off to the dishwashing machine. Adj ust flow by means of the valve in the circulation line.

A sacrificial anode is used to ex tend tank life. The removal of this anode, ex cept 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.

Page 10

INSTALLATION OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED

he gas supplier

UNDER NO CIRCUMSTANCES SHALL FLAM MABLE MATERIALS, SUCH

NE OR PAINT THINNER BE USED OR STORED IN T HE VICINITY OF THIS WATER HEATER, V ENT AIR INTAKE SYSTEM OR IN ANY LOCATION FROM W HICH FUMES COULD REACH THE W ATER HEAT ER OR VENT-A IR IN TAK E S YS TEM .

SECTION IV: INSTALLATION INSTRUCTIONS

WARNING

TRADESM AN IN THE FIELD INVOLVED. PLU M BI N G, A I R S U PPLY , V ENTING, GAS SUPPLY A N D ELEC T R I CAL WO RK A RE REQ U I RED .

DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE FOLLOWING:

• Liquefied petroleum gases/propane gas and natural gas have an odorant added by t t hat aids in detect ion of t he gas.

• Most people recognize this odor as a ‘‘sulfur’’ or ‘‘rot t en egg’’ smell.

• Other conditions, such as ‘‘odorant fade’’ can cause the odorant t o diminish in intensity, or ‘‘fade’’,

and no t be as read il y detec tab l e.

• If you have a diminished sense of smell, or are in any way unsure of t he presence of gas, immediately cont act your gas supplier from a t elephone in another building.

• Gas detec tor s ar e av ail abl e. Contact your gas supplier or plumbing professional for more inf ormation.

Liquefied petroleum gases/propane gas is heavier than air and w ill remain at floor level if there is a leak. Basement s, craw l spaces, closets and areas below ground level w ill serve as pockets for accumulat ion of leak in g gas. Before lighting, smell all ar ou nd th e app li anc e ar ea fo r g as. Be sure to smell next t o the floor.

I F Y O U S MELL GA S :

• Do not try t o light any appliance.

• Do not touch any electric sw it c h; do not use any t elephone in your building.

• Immediately call your gas supplier from a telephone in another building. Follow the gas supplier’s

instructions.

• If y ou cannot reach your gas supplier, call t he fire department.

D O NO T O PERATE THE APPL I AN CE U NTI L T HE LEAK A G E IS C O R REC TED !

This water heater must be located in an area w here leakage of the tank, water line connections, or the co mb inati on t emp erat ur e and pres sure r elief val ve wil l n ot resu lt i n dam age t o t he ar ea adjac ent to t he w at er heat er or to low er f loors of the struct ure. When such locations cannot be avoided, a suitable drain pan must be inst alled under t he w at er heat er. The drain pan depth must be suitable for draining and collecting w ater, and have a minimum length and w idth of at least f our (4) inches (10 .0 c m) measured from t he jacket of the w ater heater. The drain pan, as described above, can be purchased from your plumbing professional. The drain pan must be piped to an adequate drain. The piping must be at least ¾ inch (2 .0 cm) in diameter and pit ched f or proper drainage.

Water heaters are heat producing appliances. To avoid damage or injury there must be no materials stored agai nst t h e w at er heat er and p rop er c are must be t aken to avoid unnecessary cont act (especially by children) w ith the water heater components.

AS GASOLI

Page 11

DAMAGE TO THE WATER HEATER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY STORE ANY POTENTIALLY CORROSIVE COMPOUNDS IN THE VICINITY OF THE WATER HEATER.

NOTICE

The N ational Fuel Gas Code (A N SI Z 23 3.1- lat est e dit ion) or in Canada The Natural Gas or Propane

If t he buildings cold w at er supply has a back-flo w pr ev en t er , c h ec k v alv e o r w ater m et er with c hec k v al v e,

CAUTION

IF COMBUSTIBLE FLOORING IS USED, A THERMAL BREAK LEG KIT MUST BE INSTALLED BEFORE SETTING

WARNING

Minimum Clearances

Inst allat ion Code CAN/CGA (B149.1, B149.2- la t e st e dit ion) , e xpressly prohibit s the f ollowing:

a. Inst allation of a w at er heater in a bathroom, bedroom, or any occupied room normally kept c losed. b. Installation of a w at er heat er in a garage, unless the unit is installed so that t he burner and ignit ion

dev i c es are at least ei gh teen (1 8) i nc h es (45.8 cm) above floor level and protect ed t o avoid damage by a moving vehicle.

The location of this water heater is of the utmost importance. Before installing this water heater, you should read the Installation section of these instructions. After reading these Installation and Operating Instructions, select a location for the water heater where the floor is level and is easily accessible to water lines, gas supply (type identified on the rating plate), an adequate open drain, and a chimney or exhaust gas vent. DO NOT locate the water heater where water lines

could be subjected to free zing temperatures. Make sure the cold water pipes are not located directly above the gas control box or any other electrical control so that condensate dur ing humid weather does not drip on the controls.

WATER HEATER IN PLACE. THE APPROPRIATE LEG KIT HAS BEEN INCLUDED WITH THIS WATER HEATER.

This installation must allow access to the front of the water heater and adequate clearanc e must be provided for servicing and operating this water heater. The water heater m ay be installed on either a combus tible or non-c om bustible f loor. If the water heater is to be installed directly on carpeting, it must be installed on top of a m etal or wood panel (or equivalent) extending beyond the full width and depth of the appliance by at least three (3) inches (7.6 cm) in any direction or, if the appliance is to be installed in an alcove or closet, the entire f loor must be covered by the panel. The minimum clearances to combustibles for this water heater are given on the following pages. A minim um of 24 inches front clearance must be provided for inspection and servicing. Adequate clearances must be provided for easy access to controls by service personnel to enable proper cleaning, servicing, and operation of the water heater. Under no circumstances is the f ront of the water heater to be placed in a position where the burner tray assembly cannot slide out for removal when servicing.

This water heater MUST be installed indoors out of the wind and weather. Note: For California ins tallation this water heater mu st be braced, anchored, or strapped to avoid falling or

moving during an earthquake. See instructions for correct installation procedures. Instructions may be obtained from DSA Headquarters Office, 1102 Q Street, Suite 5100, Sacramento, California 95811.

Water heater corrosion and component failure can be caused by the heating and breakdown of airborne chemical vapors. Examples of some typical compounds that are potentially corrosive are: spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes and process chemicals. These materials are corrosive at very low concentration levels with little or no odor to reveal their presence.

THE WARRANTY. DO NOT OPERATE THE WATER HEATER IF EXPOSURE HAS OR WILL OCCUR. DO NOT

Page 12

UNPACKING INSPECT SHIPMENT carefully for any signs of damage.

1. All equipment is carefully manufactured, inspected and packed.

2. Any claims for damage or shortage in shipment must be filed imm ediately with the manufacturer noted on the rating plate label.

LOCATE WATER HEATER in front of final position before removing crate.

1. LOCATE so that venting connections will be short and direct.

2. THIS WATER HEATER IS SUITABLE FOR INSTALLATION ON CO MBUSTIBLE FLOOR . The thermal break leg kit supplied with the water heater must be used.

3. Proper venting practices must be considered when selecting a location for this water heater. For exact venting specifications, please consult the Venting section of these Installation and Operating Instructions.

4. It is recommended that a minimum clearance of four (4) inches (10.2 cm) be provided on the side of the water heater for servicing and maintenance of the combination temperature and pressure relief valve.

5. Increase distances to provide clearance for servicing.

Input

Less than or equal to 300,000 BTUH 2 in. (5.1 CM)

Greater than 300,000 BTUH 6 in (15.2 CM)

Front, sides

and Rear “A”

Page 13

IMPORTANT-The flow of combustion and ventilating air must not be obstructed.

WARNING

The draft diverter relief opening of the water heater and combustion air inlet must be in the same atmospheric

CAUTION

REMOVE CRATE

1. Remove all banding and pry off crate sides carefully so as not to damage the water heater.

2. Carefully roll/lift the water heater from the crate base.

MOVE WATER HEATER TO PERMANENT POSITION by sliding or walking. Place drain pan underneath water heater INSTALL TEMPERATURE AND PRESSURE RELIEF VALVE (if not already installed).

This water heater must be located in an area where the general public does not have access to set temperatures.

AIR REQUIREMENTS

1. Do not obstruct the flow of ventilating air.

2. For s afe operation, adequate air is needed for com bustion and ventilation. Sooting may result in serious damage

to the water heater and risk of fir e or ex plosion. It can also create a risk of asphyxiation. Such a condition often will result in a yellow, luminous burner flame, causing carboning or sooting of the combustion chamber, burner and flue tubes.

MECHANICAL EXHAUSTING OF ROOM AIR - Where an exhaust fan is installed in the same room with this

water heater and combustion air is drawn from inside the room, sufficient openings for air must be provided in the walls. UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE WATER HEATER’S VENTING SYSTEM, CAUSING POOR COMBUSTION THAT MAY BE HAZARDOUS TO LIFE. SOOTING MAY RESULT IN SERIOUS DAMAGE TO THE WATER HEATER AND RISK OF FIRE OR EXPLOSION, WHICH CAN ALSO CREATE A RISK OF ASPHYXIATION. Refer to local codes and /or National Fuel Gas Code (ANSI Z223.1-Latest Edit ion), or in Canada CAN/CGA B149 . 1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B149 . 2 Propane Inst allat ion Code (Latest Edition) for proper air opening sizing.

CONFINED SPACES

If the water heater is installed in a confined space (volume is less than 50 ft.

/1000 BTU (15 m3/0.29 kW) per hour of the total input rating of all gas appliances in that space), air must be supplied through two permanent openings. One opening must be within 12 inches (30.5 cm) from the top of the enclosure and one within 12 inches (30.5 cm) of the bottom. The openings must be protected by metal louvers or 1/4” (6.4 mm) min. mesh metal screen. The size of the openings are as follows:

pressure zone. Large exhaust fans in kitchens and other locations can lower the air pressure inside an enclosure and interfere with the proper operation and venting of the water heater. In these cases, the water heater should be installed in a separate room with the combustion and ventilation air supplied directly from outdoors as previously described.

1. If the openings communicate directly with an additional room(s) of sufficient volume, each opening must have a

minimum free area opening of 1 in. appliances in the confined space, but not less than 100 in.

/1000 BTU (2.54cm2/0.29kW) per hour of the total input rating of all gas

(254 cm2).

2. If the openings communicate with the outdoors through horizontal ducts, each opening must have a minimum free

area of 1 in.

3. If the openings communicate directly with the outdoors or through vertical ducts with the outdoors, each opening must

have a minimum free area of 1 in.

/2000 BTU (2.54cm2/0.59kW) per hour of the total rating of all gas appliances in the enclosure.

/4000 BTU (2.54cm2/1.18kW) per hour of the total rating of all gas appliances in

the enclosure.

Page 14

ALL A IR FROM INSIDE THE BUILDING: The confined space must be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space must be considered in making this determination. Each opening must have a minimum free area of 1 in.

(2.54cm 100 square inches (254cm

/0.29kW) per hour of the total input rating of all gas utilization equipment in the confined space, but not less than

). One opening must be within 12 inches (30.5 cm) of the top and one within 12 inches (30.5

cm) of the bottom of the enclosure.

UNCONFINED SPACES In unconfined spaces in buildings, infiltration may be adequate to provide air for combustion, ventilation and dilution of flue gases. However, in buildings of tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), additional air may need to be provided using the methods described above under CONFINED SPACES: All Air From Outdoors or SPECIALLY ENGINEERED INSTALLATIONS.

SPECIALLY ENGINEERED INSTALLATIONS The requirements noted under CONFINED SPACES above must not necessarily govern when special engineering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion, ventilation, and dilution of flue gases.

/1000 BTU

Page 15

Do not t urn on elect rical pow er t o wat er heater unt il f lue damper is inst alled and w at er heater is filled w it h

CAUTION

The venting syst em must be installed properly f ollowing all local codes or in t he absence of local codes, the

in Operation’’.

SECTION V: VENTING

latest ed iti on o f th e Nati on al Fuel Gas Code (ANSI Z223.1- l atest edi ti on ), o r i n Canad a, Th e Natu ral Gas and Propane Installation Code (B149 . 1 -0 0 l atest ed iti on ). Failure to properly install t he venting syst em could result in property damage, personal injury, or death.

Careful ly in sp ec t th e v ent ing syst em of a replacement wat er heater installation bef ore connecting t o the vent ing system. All joint s in the vent connect or must be securely f astened w it h screw s and fit tight ly together. Inspect the venting syst em f or signs of det eriorat ion (rust and perforation) and replace any sect ions t hat are not in good condition. The chimney must be lined and in good condit ion. Check t o make sure the venting syst em is properly sized f o r th e wat er h eat er . If t he vent ing syst em w as previously sized for another gas appl ian c e th at h as b een removed, t he venting syst em may now be t oo large. Refer t o th e latest ed i t i o n o f the N at i o nal Fuel Gas Cod e (ANSI Z223.1-latest edition), or in Canada, t he Nat ural Gas and Propane Installation Code (B1 4 9 . 1-00 l atest edition) f or t he correct sizing of v ent ing systems and common vent ing wit h anot her gas appliance. Do not vent t his w at er heater int o t he vent ing system of anot her gas appliance designed to vent under positive pressure. The w ater heater sh ou ld be i n stall ed as c lo se as p ract ical t o t he vent ing system t o minim ize t he vent connect or length required. Refer to local codes for t he distance limit ations on vent connect or lengt hs. A t t he complet ion of t he w at er heater installation, t he burner and vent ing system must be checked for proper operation wit h all other commonly vent ed appliances in operat ion. Check f or spillage of f lue product s around t he outside relief opening of t he draft hood af t er several minutes of operation. The flame f rom a match should be draw n int o the draft hood. Do not use the w at er heater or connect ed equipment if spillage is detect ed unt il t he problem is corrected. Refer to th e l at es t ed i t i on o f the N at i o nal Fuel Gas Cod e, o r i n Can ada, the N at u r al Gas and Propane Installat ion Code f or complet e details on the ‘‘Procedure to Be Followed t o Place Equipment

This water heater has been shipped with a draft diverter for which it was designed with reference to the horizontal and vertical planes, its certified category I, per latest ANSI Z 21.10.3-2015.CSA 4.3-2015 revision. Refer to the latest edition of the National Fuel Gas Code (ANSI Z223.1-latest edition), or in Canada, the Natural Gas and Propane installation Code (B149.1-00 latest edition). If removed, the draft diverter must be replaced in the same position and secured to the jacket top by the screws with which it was installed.

This water heater must be connected to a lined masonry chimney or venting system approved by local codes or ordinances. The vent connector used to attach the draft diverter outlet to the chimney or approved vent must be of the same diameter as the draft diverter outlet or larger. For proper venting in certain installations, a larger vent connector may be needed. Consult venting tables in ANSI standard (Z223.1- latest edition), National Fuel Gas Code and CAN/CGA (B149.1 or B149.2-latest editions) Natural Gas and Propane Installation Code, or local code officials for proper application for your area.

FLUE DAMPER Refer to Figure 6 and follow these instructions:

WARNING

water.

1. Remove the damper from the accompanying box shipped within the crate.

2. Locate the collector outlet on top of the water heater. Place the damper over the collector outlet and rotate as

necessary to a position in which the damper wiring plug can be fully engaged with the connector on the side of the water heater.

Page 16

Modif ic ation t o the f lue damper or the draft div erter may result in personal injury, property damage or deat h. instructions w it hout modif ic ation.

CAUTION

3. Secure the flue damper to the jacket top with sheet metal screws.

4. Connect the damper wiring plug to the damper wire harness connector on the side of the water heater. Note: The plug

and connector can only be engaged one way (polarized).

5. The Lighting and Operating instructions are outlined in this manual. The damper must be in the open position when

the water heater main burner is operating (the arrow on the damper plate is in the “up” position when open. Be certain

the arrow is in a visible position when installed). DRAFT DIVERTER This water heater has been shipped with a draft diverter for which it was designed. Remove the bag containing the legs

and instructions from the draft diverter. Attach the legs to the draft diverter and attach the draft diverter to the water heater per the instructions in the bag.

The fl u e dam p er an d d raft d i v erter are to b e pl ac ed i n p o siti on an d o per ate ex ac tl y as stated in these

Figure 6

Page 17

A PPR O XI MA TE TIME/TEM PERATURE REL A TIO NS HI PS I N S C AL D S

120°F (49°C)

More t han 5 minut es

125°F (52°C)

1½ t o 2 minut es

130°F (54°C)

About 3 0 seconds

135°F (57°C)

About 1 0 seconds

140°F (60°C)

Less than 5 seconds

145°F (63°C)

Less than 3 seconds

150°F (66°C)

About 1 ½ seconds

155°F (68°C)

About 1 second

If sweat fittings are to be used, DO NOT apply heat to the nipples on top or side of the water heater. Sweat the tubing nipples containing a plastic liner.

CAUTION

FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED TEMPERATURE AND PRESSURE RELIEF VALVE TEMPERATURE AND PRESSURES.

WARNING

If this water heater is installed in a closed water supply system, such as the one having a back-flow preventer in the

contacted on how to control this situation.

NOTICE

SECTION VI: WATER CONNECTIONS

NOTE: 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 COLD water inlet and HOT water outlet are identified on the top and front of the water heater. Make sure the diptube is in place before making the cold water connection. 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.

to the adapter before fitting the adapter to the water heater connections. It is imperative that heat is not applied to the

WILL RELEASE THE MANUFACTURER FROM ANY CLAIM WHICH MIGHT RESULT FROM EXCESSIVE

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. Your water supplier or local plumbing inspector should be

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 a steady stream of water flows through the faucets, close them and check all water connections for possible leaks. NEVER OPERATE THE WATER

HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER.

Page 18

Keep clear of combination temperature and pressure relief valve discharge line outlet. The discharge may be

WARNING

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

Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose on the water heater.

pressure relief valve. Do not place a valve between the combination temperature and pressure relief valve and the tank.

Hydrogen gas can be p roduced in an operating water heater that has not had water drawn from the tank for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the possibility of injury under these conditio ns, we recommend the hot water faucet to be o p en for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system. If hydrogen is present, there will be an unusual s o un d such as air escapi ng through the pipes as hot water begins to flow. Do not smoke or have open flame near the faucet at the time it is open.

This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water. By setting the thermostat on this water heater to obtain the increased temperature water required by these appliances, you may create the potential for scald injury. To protect against injury , you should install an ASSE approved mixing valve in the water system. This valve will reduce point of discharge temperature by mixing cold and hot water 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. For information regarding space heating water connections and plumbing arrangements, refer to the section at the end of this manual.

Page 19

The manufacturer of this water heater will not be liable for any damage or injury caused as a result of a cracked gas

WARNING

The water heater and individual shutoff valve must be disconnected from the gas supply piping system during any

CAUTION

SECTION VII: GAS CONNECTIONS

The gas supply lines must meet all requirements of the National Fuel Gas Code (ANSI Z223.1-Latest Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.2 Propane Installation Code (Latest Edition).

The minimum permissible gas supply pressure for the purpose of input adjustment is one (1.0) inch (0.25 kPa) water column above the operating manifold pressure. See the rating plate and gas valve for the manifold pressure and gas type. The maximum permissible gas supply pressure is fourteen (14.0) inches (3.5 kPa) water column for natural gas and liquefied petroleum gases/propane gas.

1. Connect this water heater only to the type of gas (Natural or Propane gas) as shown on the rating plate. Use clean

black iron pipe or equivalent material approved by local codes and ordinances. (Dirt and scale from the pipe can enter the gas valve and cause it to malfunction). The inlet gas line must have a minimum length of three (3) inches (7.6 cm) drip leg (sediment trap) installed as close to the water heater’s gas valve as possible. A ground joint union must be installed as close to the water heater as possible in the gas supply line feeding the water heater to permit servicing of the water heater. Compounds used on the threaded joints of the gas piping must be resistant to the action of liquefied petroleum gases/propane gas. DO NOT apply pipe dope to the gas valve inlet and make certain that no pipe dope has become lodged in the inlet screen of the gas valve. Extreme care must be taken to ensure no pipe dope enters the gas valve. Avoid excessive torque when tightening the gas supply line to the gas valve. Excessive torque may result in cracking of the gas valve housing and could create a gas leak. The suggested maximum torque is 31.5 ft. lbs. (4.4 kg- m).

inlet as a result of excessive torque.

2. This water heater and its gas connection must be leak tested before placing the water heater in operation. Check for

gas leaks with a soap and water solution and a brush or a commercial leak detector fluid. NEVER USE A MATCH OR OPEN FLAME FOR TESTING!

pressure testing of the system at test pressures in excess of 1/2 psi (3.5 kPa). The water heater must be isolated from the gas supply piping system by closing its manual shutoff valve during any pressure testing of the gas supply system at test pressures equal to or less than 1/2 psi (3.5 kPa). The supply line must be capped when not connected to the water heater.

3. While checking for leaks care must be taken to prevent solution from contacting the electrical connections at the

control. If electrical connections at the control become wet, they must be thoroughly dried before attempting to operate the water heater.

Page 20

WARNING

Water heater s are heat-producing appliances. To avoid damage or injury there must be no m aterials stored against

CIRCUMSTANCES SHOULD FLAMMABLE

MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS 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, air supply, venting, gas supply and electrical work are required.

Light the unit in accordance with the operating instructions label attached to the water heater.

Under no circumstanc es should the input r ate ex ceed the input r ate s hown on the water heater r ating plate. O ver f iring could result in damage or sooting of the water heater.

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

5. Sooting

NEVER OPERATE THE WATER HEATER WIT HOUT FIRST BEING CERTAIN IT IS FIL LED WITH W ATER AND A

F THE

WATER HEATER.

the water heater or direc t vent system, and proper care m ust be taken to avoid unnecessary contact (especially by children) with the water heater and direct vent system. UNDER NO

factory authorized independent service contractor or qualified service professional.

1. Flooding to or above the level of the burner or controls

2. External firing

3. Damage

4. Firing without water

TEMPERATURE AND PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE OPENING O

TO FILL THE WATER HEATER

1. Close the water heater drain valve by turning the knob clockwise. If alternative water connections are provided but not

used, make certain they are plugged (i.e. rear connections).

2. Open the cold water supply shut-off valve.

3. Open several hot water faucets to allow air to escape from the system.

4. When a steady stream of water flows from the faucets, the water heater is filled. Close the faucets and check for water

leaks at the water heater drain valve, combination temperature and pressure relief valve and the hot and cold water connections.

5. To restore operation of water heater refer to operating instruction label on the water heater. TO DRAIN THE WATER HEATER

Should it become necessary to completely drain the water heater, make sure you follow the steps below:

1. Reduce the thermostat setpoint to the lowest setting. On water heater models having 24 volt controls, depress the

control panel rocker switch on the top of the control box to the “OFF” position and disconnect the power to the water heater.

2. Rotate and partially depress gas control knob clockwise to the “OFF” position.

3. Shut off the gas supply to the water heater.

4. Close the cold water supply shut-off valve.

5. Open the drain valve on the water heater by turning the knob counter-clockwise. The drain valve has threads on the

end that will allow the connection of a standard hose coupling.

6. Open a hot water faucet to allow air to enter the system. To refill the water heater, refer to “To Fill the Water Heater.”

Page 21

WARNING

Turn off or disconnect the electrical power supply to the water heater before servicing. Label all wires prior to

Verify proper

This water heater must be wired on a separate circuit. Failure to wire on a separate circuit may cause improper

water heater.

Do not energize the electric circuit before the water heater tank is filled with water.

Standing pilot

SECTION VIII: ELECTRICAL CONNECTIONS

Standing Pilot Wiring Diagram

Robertshaw Gas Valve Honeyw el l Gas Valve

Spark to Pilot (IID) igni t i on system.

disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. operation after servicing.

All electrical wiring must be installed and grounded in accordance with local codes, or in the absence of local codes, the National Electrical Code, ANSI/NFPA 70 and/or CSA C22.2 Electrical Code. In Canada, follow t he latest edition of th e Canad ian Electr ic al Cod e (Part 1, CSA -C22 . 1 ) and all applicable local codes.

The water heater must be wired to a 115 volt, 60 Hz, AC power supply. The water heater must be wired on a separate circuit and breaker. If a flexible line cord and plug is permitted by local code, then provide a three wire grounding type receptacle within reach of the line cord provided on the control box. Do not plug the line cord into a receptacle that can have the power supply interrupted by a switch that is used to control lights or another appliance.

If wiring in conduit is required, cut the line cord close to the control board and make the appropriate wiring connections.

CAUTION

operation or failure of the electrical components of the water heater. Refer to the “Electrical Connections” section of the Installation and Operating Instructions Manual for complete instructions on electrical wiring and connections to the

Page 22

Spark to Pilot Ignition (IID) Wiring Diagram

Page 23

SECTION IX: OPERATING INSTRUCTIONS

Lighting And Shutdown Instructions

Standing Pilot Models

Page 24

Lighting and Shutdown Instructions

Spark to Pilot Ignition (IID) Models

Page 25

A PPR O XI MA TE TIME/TEM PERATURE RELATIONSHIPS IN SCALDS

120°F (49°C)

More t han 5 minut es

125°F (52°C)

1½ t o 2 minut es

130°F (54°C)

About 3 0 seconds

135°F (57°C)

About 1 0 seconds

140°F (60°C)

Less than 5 seconds

145°F (63°C)

Less than 3 seconds

150°F (66°C)

About 1 ½ seconds

155°F (68° C)

About 1 second

Thi s water heater, when set at a low er t emperature sett ing, is not c apable of producing hot wat er of

CAUTION

Whenever the water heater is filled with cold water, condensate will form on the cool tank surface and drops of water

NOTICE

Hotter water increases the risk of scald injury. Scalding may occur within five (5) seconds at a temperature setting of

DANGER

TEMPERATURE ADJUSTMENT

140°F (60°C). To protect against hot water injury, install an ASSE approved mixing valve in the water system. This valve will reduce point of discharge temperature by mixing cold and hot water in branch water lines. A licensed plumbing professional or local plumbing authority should be consulted.

This water heater is equipped with an energy cut out device to prevent overheating. Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance and call a qualified service technician.

suff ic ient t emperature f or sanitizing purposes.

will fall on the hot burner and combustion chamber surfaces producing a “sizzling” noise. Condensation is normal and does not indicate a leak. It will disappear when the tank becomes heated.

The l o wer th e t em p eratu re s et ti ng, t he greater t he energy efficiency, bot h t o heat t he wat er and to maintain t h e sto rag e t em p eratu r e du ri ng stan db y p eri od s. Lo wer water tem p eratu res also ex ten d tan k li fe. Remem ber , no water h eat i n g sy s t em wil l pr ov i de exac t tem per atur es at al l ti mes . A l low a f ew days of operation at t his sett ing t o det ermine the correct t emperature set t ing consistent wit h the requirements for the installation.

Condensation does not mean your tank is leaking. Over 40% of reported tank leaks on installation are proven to be condensation. To avoid unnecessary expense and inconvenience, make sure the tank is leaking before calling a service person.

The temperature selector knob of the thermostat has been adjusted to its lowest setting when shipped from the factory.

The marking on the thermostat temperature scale (shown at left) is the preferred starting point for setting the temperature control. For energy-efficient operation of your water heater, the suggested initial temperature setting is approximately 120°F (49°C). Households with small children or invalids may require a 120°F (49°C) or lower temperature setting to reduce the risk

of scald injury. Some states require a lower temperature setting. Full counterclockwise rotation of the temperature selector dial is the minimum temperature setting. Full clockwise

rotation of the temperature selector dial is the maximum temperature setting. NOTE: The lower the temperature setting, the greater the energy efficiency, both to heat the w ater and to maintain its temperature during standby periods. Lower water temperatures also extend tank life. Remember, no water heating system will provide exact temperatures at all times. Allow a few days of operation at this setting to determine the correct temperature setting consistent with

Page 26

SELECT

SET

Status

Set button

Select button

Temperature

Down Button

Temperature

Up Button

°F

idle

setpoint

Operational

Sequence of

operation Indicator

Reads "Idle” or “Heating"

Status Indicator

Read "Operational"

or "Service Needed"

Shown flashing

in display only when

temp is adjusted

Temperature Setpoint

in Degrees F or Degrees C

Range 70 - Max °F

Range 21 - Max ° C

Water Heater Display and Control Buttons

If t he wat er heater display does not show ‘‘Operational’’ in the ‘‘Status’’ indicat or, there may be an operating

WARNING

When the maximum setpoint is reached, the display will show ‘‘Max Setpoint ’’ w ithout the setpoint value. The default t emperature setpoint f rom t he f act ory i s 7 0 ˚F (21˚C).

NOTICE

your needs. NOTE: This water heater, when set at a lower temperature setting, is not capable of producing hot water of sufficient temperature for sanitizing purposes.

During the winter season or any cold period, you may desire a higher temperature setting to adjust for the colder incoming water. This adjustment, however, may cause additional condensation to form on the cooler tank surface. This does not mean the tank is leaking. During summer months, the warmer incoming water temperatures will benefit the performance of your water heater and reduce the amount of condensation developed.

TEMPERATURE ADJUSTMENT (24V CONTROL SYSTEM)

The water heater temperature setting is adjusted by using the control display mounted to the front of the control panel of the water heater. The water heater thermostat is set at the lowest setpoint of 70°F when shipped from the factory. The control display shows the temperature setpoint in degrees Fahrenheit (°F) or degrees Celsius (°C), and the status of the water heater (“Idle” or “Heating”). If the water heater is functioning normally, the display will also show “Operational”.

For energy efficient operation of your water heater, the suggested initial temperature setting is 120°F (49°C). During the winter season, or any cold period, you may desire a higher temperature setting to adjust for the colder incoming water. This adjustment, however, may cause additional condensation to form on the cooler tank surface. This does not mean the tank is leaking. During summer months, the warmer incoming water temperatures will benefit the performance of your water heater and reduce the amount of condensation developed.

malfunc t ion wit h t he wat er heater. If t his is the case, a numeric code w ill be displayed. Ref er to th e lab el n ex t t o t he display f or t he definit ion of the error code and call your plumbing prof essional or service agent to serv i c e t h e water h eater. Do no t try to r eset th e water h eat er with ou t h av in g a q u ali fied ser v ic e p erso n t o diagnose and correct t he problem. If t he display is blank or does not show an error code, make sure there is po wer to t h e wat er h eat er .

Set t ing t he w at er t emperature t o t he maximum set point c an result in scalding hot water delivered to the f aucets. It is highly recommended that t he maximum setpoint be adjust ed to t he lowest t emperature possible f or t he needs of t he installation. See following sect ion t o change the maximum setpoint limit (max setpoint ).

The maximum set t ing is equal to approximat ely 1 80 ˚F (82˚C).

Page 27

Step 1: Depress and hold “Temperature Up” button until desired setpoint temperature appears in the display.

Step 2: “Setpoint” indicator begins flashing in the display after pressing “Temperature Up” button.

Step 3: Press “SET” button for new setting to take effect immediately. “Setpoint” will stop flashing. If the “SET” button is not

SELECT

SET

Status

°F

idle

Operational



Step 1

SELECT

SET

Status

°F

idle

setpoint

Operational



Step 2

"Setpoint"

flashes

SELECT

SET

Status

°F

idle

setpoint

Operational



Press SET Button for sett ing to

to take eff ect im m ediat ely

Step 3

"Setpoint" flashes

for 10 seconds

To I ncrease Setpoint T emperat ure

pressed, the new temperature setting will take effect in approximately 10 seconds.

Page 28

Step 1: Depress and hold “Temperature Down” button until desired setpoint temperature appears in the display.

Step 2: “Setpoint” indicator begins flashing in the display after pressing “Temperature Down” button.

Step 3: Press “SET” button for new setting to take effect immediately. The setpoint will stop flashing. If the “SET” button is

SELECT

SET

Status

°F

idle

Operational



Step 1

SELECT

SET

Status

°F

idle

setpoint

Operational

"Setpoint"

flashes

Step 2



SELECT

SET

Status

°F

idl

setpoint

Operational

"Setpoint" flashes

for 10 seconds



Press SET for se tting to

take effect im m ediat ely

Step 3

To Decrease Setpoint Temperature

not pressed, the new temperature setting will take effect in approximately 10 seconds.

Page 29

Step 1: Press “SELECT” button until °F/°C is displayed.

Step 2: Press “SET” button to change temperature format. Symbol °F/°C will flash.

Step 3a: Press “Temperature Up” button to change temperature format to °C.

SELECT

SET

Status

°C

idle

Operational



Step 3a

°F/°C

°F/°C Flashes

Changes to "°C"

SELECT

SET

Status

idle

Operational

Press select

Step 1

°F

°F/°C

SELECT

SET

Status

idle

Operational

Step 2

°F/°C Flashes

°F

°F/°C

To Change Temperature Format in Display from °F to °C or ˚C to ˚F:

Page 30

Step 3b: Press “Temperature Down” button to change temperature format to °F.

Step 4: Press “SET” button to confirm ˚F or ˚C format. °F/°C will stop flashing. Setpoint display will appear in the format Step 5: Pressing “SELECT” button will return display to setpoint in format selected (˚F or ˚C) immediately.

SELECT

SET

Status

°F

idle

Operational

Step 4

Press Set

°F/°C

Symbol "°F/°C" Stops Flashing

SELECT

SET

Status

°F

idle

Operational



Step 3b

°F/°C

°F/°C Flashes

Changes to "°F"

SELECT

SET

Status

°F

idle

Operational



Press select

Step 5

Setpoint shown in °F

selected (˚F or ˚C) in 10 seconds.

Page 31

WARNING

WATER HEATER OR VENT SYSTEM.

Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long

WARNING

IMPORTANT- In the event of an emergency, turn off the gas and electric (if applicable) to the appliance.

damaged or if any joi n t is found not sealed

NOTICE

An automatic gas shut-off device (ECO) is incorporated in the sensor and control board which will shut off all gas supply to the burner and pilot if the water heater temperature exceeds 200°F (93°C). Should the ECO function (open), the water temperature should be reduced to approximately 120°F (49°C) and follow applicable Lighting Instructions to place the water heater in operation. The water heater must have the problem corrected by a qualified service person before putting the water heater back in operation. It is recommended that all service work be performed by a qualified service agency.

If the water heater is to remain idle for 30 days or more or is subjected to freezing temperatures while shut off, the water heater and piping should be fully drained (See “To Drain the Water Heater”) and the drain valve should be left fully open.

period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the possibility of injury under these conditions, we recommend the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system. If hydrogen is present, there will be an unusual sound such as air escaping through the pipes as hot water begins to flow. Do not smoke or have open flame near the faucet at the time it is open.

Burner Flame Check

At the time of installation and at periodic intervals (about every 3 months), a visual check of the pilot and burner flames should be made to determine if they are burning properly. No adjustment to the air shutter should be required for this heater. The burner flames should be blue with yellow tips. A blue-orange flame is characteristic of operation on liquefied petroleum (LP) gas. If the burner flame does not appear as described, an air shutter adjustment may be required. The burner tube flames should light smoothly from the pilot.

IMPORTANT- The water heater should be inspected at a minimum annually by a qualified service technician for damaged components and/or joints not sealed. DO NOT operate th is water heater if any p art is found

Figure 8

WARNING

Do not run out of propane gas. Damage to the water heater may occur.

Water heaters are heat producing appliances. To avoid damage or injury there must be no materials stored against the water heater or vent system, and proper care must be taken to avoid unnecessary contact (especially by children) with the water heater and vent system. UNDER NO CIRCUMSTANCES SHALL FLAMMABLE

MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER, VENT SYSTEM OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE

Page 32

IMPORTANT- If the combination temperature and pressure relief valve on the appliance discharges periodically, this inspector on how to correct this situation. Do not plug the combination temperature and pressure relief valve outlet.

NOTICE

FOR YOUR SAFETY, DO NOT ATTEMPT REPAIR OF COMBINATION GAS CONTROL, BURNERS OR GAS

CAUTION

When lifting lever of the combinati o n temperature and pressure relief valve, hot water will be released under

WARNING

SECTION X: MAINTENANCE

The following maintenance should be performed by a qualified service technician at the minimum periodic intervals suggested below. In some installations, the maintenance interval may be more frequent depending on the amount of use and the operating conditions of the water heater. Regular inspection and maintenance of the water heater will help to insure safe and reliable operation.

1. Annual checks of the ignition systems (millivolt and electronic), temperature controls and any other water heater controls are necessary to ensure proper operation. Also, all safety shut-off valves must be checked to verify proper operation and tightness.

2. The flow of combustion and ventilation air MUST NOT be restricted. Clear the combustion air openings of any dirt, dust, or other restrictions. WARNING! The combustion ventilation system may be HOT.

3. At all times keep the water heater area clear and free from combustible materials, gasoline and other flammable vapors and liquids.

4. Bi-annually conduct a visual check of the pilot and burner flames to determine that they are burning properly. See “Burner Flame

Check” section for example of proper burner flame pattern.

5. Annually remove the main burner rack assembly to clean orifices and related parts of any dirt or other foreign material. Inspect

the burner ports for obstructions or debris and clean with a wire brush, vacuum, or use a mild detergent solution to clean as needed. NOTE: It is imperative for proper operation of the water heater that the main burner rack be replaced in the original location

pressure. Be careful that any released water does not result in bodily injury or property damage. Keep clear of the combination temperature and pressure relief valve discharge line outlet. The d i sc har ge m ay

be hot enough t o cause scald injury. The wat er i s un der p ressu re an d may spl ash .

WARNING

Do not run out of propane gas. Damage to the water heater may occur.

6. At least once a year, check the combination temperature and pressure relief valve to insure that the valve has not become encrusted with lime. Lift the lever at the top of the valve several times until the valve seats properly without leaking and operates freely.

may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing

7. Monthly drain off a gallon of water to remove silt and sediment. WARNING! This water may be HOT.

8. All models are equipped with a cleanout opening to aid in removal of hard water deposits from the tank bottom. If this water heater operates under hard water conditions, the following should be performed at least every 3 months: Drain the water heater. Remove the cleanout jacket cover and tank cover. When cleaning the tank, care must be taken to avoid trying to break deposits loose as this could damage the glass lining and shorten the life of the water heater. After cleaning, replace the cleanout tank cover and jacket cover, and refill with water.

9. A sacrificial anode rod has been installed to extend tank life. The anode rod should be inspected annually (every year) and

replaced when necessary to prolong tank life. Water conditions in your area will influence the time interval for inspection and replacement of the anode rod. Contact the plumbing professional who installed the water heater or the manufacturer listed on the rating plate for anode replacement information. The use of a water softener may increase the speed of anode consumption. More frequent inspection of the anode is needed when using softened (or phosphate treated) water.

10. The venting system must be inspected at least once a year to ensure against leakage of exhaust products.

PIPING. REFER REPAIRS TO A QUALIFIED SERVICE TECHNICIAN.

Page 33

Manufactured under one or more of the following U.S. Patents: 5,277,171; 5,341,770; 5,372,185; 5,485,879;

2,476,685; 2,504,824; 2,548,958

Contact your supplier, plumbing professional or contact the company at the address given on the rating plate of the water heater for replacement parts.

Provide the part name as well as the model and serial number(s) of the water heater(s) when ordering parts.

READ THE WARRANTY FOR A FULL EXPLANATION OF THE LENGTH OF TIME THAT PARTS AND THE WATER HEATER ARE WARRANTED.

5,574,822; 5,596,952; 5,660,165; 5,682,666; 5,761,379; 5,943,984; 5,954,492; 5,988,117; 6,056,542; 6,142,216; 6,442,178; 6,684,821; 6,935,280; 7,063,132; 7,063,133; 7,007,748; 7,270,087; 7,334,419; 7,337,517; 7,409,925; 7,458,341; 7,559,293; 7,621,238; 7,634,976; 7,650,859; 7,665,210; 7,665,211; 7,699,026; 7,866,168; 7,900,589; 7,971,560; 7,992,526 8,082,888; 8,146,772; Other U.S. and Foreign patent applications pending. Current Canadian Patents: 2,092,105; 2,107,012; 2,108,186; 2,112,515; 2,143,031; 2,239,007; 2,262,174; 2,314,845; 2,409,271;

Complete the following information and retain for future reference:

Model No:

Serial No:

Service Phone Days: Nights:

Address:

Supplier:

Supplier Phone No:

TYPICAL INSTALLATION

Page 34

SECTION XI: DIAGNOSTIC AND TROUBLESHOOTING GUIDE

OPERATING AND TROUBLESHOOTING GUIDE-SEQUENCE OF OPERATION (STANDING PILOT WITH MILLI-VOLT CONTROL)

1. With the pilot lit, the pilot burner assembly power pile generates milli-voltage to energize the magnet coil in the gas valve permitting gas flow through pilot and to the main gas ports of the valve. Simultaneously, milli-voltage is also directed to the ECO (energy cut off) switches located in the thermostat.

2. Set the control knob on the gas valve to “ON” position.

3. Set the adjustable thermostat to desired water temperature.

4. As the water temperature decreases below the thermostat setting in the tank, the contacts in the thermostat will close, thereby energizing the circuit to the main valve permitting the flow of gas to the main burner.

5. A slow opening feature of the gas valve will cause the burners to light slowly at a reduced manifold pressure. After a few seconds (allowing the combustion system to stabilize), the manifold pressure will increase to the maximum setting of the gas valve.

6. The burners will continue to fire until the thermostat becomes satisfied, where upon the contacts will open, deenergize the main valve circuit, and the burners will extinguish.

7. If the temperature rises above fixed ECO (energy cut off) setting, the ECO contacts will open simultaneously deenergizing pilot and main valve circuits, and the burners will be extinguished.

DIAGNOSTIC GUIDE FOR HONEYWELL INTEGRATED CONTROL SYSTEM FOR FLUE DAMPER MODELS-SEQUENCE OF OPERATION

1. W hen the tank temperature drops below the tem perature setpoint on the display, the control opens the flue dam per to start the ignition sequence.

2. W hen the flue damper reac hes the full open position, the end switch in the damper closes, com pleting the 24 volt circuit to the control.

3. After the end switch closes, the control sends 24 volt power to the pilot valve “PV” terminals on the gas valve allowing pilot gas to flow to the pilot. T he control also s ends high voltage through the pilot electrode to spark to the pilot hood and ignite the pilot gas. If the pilot does not ignite within 90 seconds, the pilot valve is denergized and the sparking stops for 65 seconds, and will attempt to ignite the pilot two more times. If the pilot does not light on the 3 attempt, the control will go into “soft lockout” for 1 hour and then will repeat the 3 ignition attempts.

4. W hen the pilot is lit, the flame is sensed by the flame s ense rod. The flame sense signal received by the control board causes the sparking to s top and the main gas valve to open. The m ain burner s ignite fr om the pilot flame. The pilot is continually monitored by the flame sensing circuit. If for any reason, the pilot flam e is not sens ed by the flam e sensing circuit, the gas valves close. After a 65 second delay, the pilot valve opens and the pilot electrode sparks to relight the pilot. The same sequence will occur in the event of a power supply or gas supply interruption.

5. T he main burners continue to operate until the water temperature in the tank increas es past the control setpoint, which will cause the gas valve to close. T he flue damper c loses shortly after the gas valve closes . The water heater remains in the standby mode until the temperature drops below the setpoint and initiates another heating cycle.

6. If for some reason, the tank temperature should reach or exceed 200˚F, then the control closes the gas valve and goes into a “hard loc kout” state and will not operate until reset by a qualified service person. The display will read “error code 65”, which indicates the tank high lim it temperature has been ex ceeded. No attempt should be made to reset the control until a service person has cor rected the cause of the high limit condition. Refer to the diagnostic service section at the end of this Installation and Operating Instructions Manual.

Page 35

Step 1: Press “Select” and “Temperature Up” buttons together and hold for 3 seconds until “Max Setpoint” is shown in the

Step 2: Pressing “Select” button will change display to next mode

SELECT

SET

Status

°F

idle

Operational

Water

Temp

SELECT

SET

Status

idle

Operational



"Max Setpoint"

next to Temperature

Setpoint value

Max

Setpoint

The following procedure is for service and installation personnel only. Resetting lockout conditions without correcting the malfunction can result in a hazardous condition.

WARNING

30 Seconds after the last button press, the display will automatically return to the “User Mode”. Simultaneously

NOTICE

ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY (FOR SERVICE PERSONNEL ONLY)

The display has a “service mode” for changing the maximum setpoint and accessing information in aiding servicing of the water heater. This procedure is for service and installation personnel only. To enter the Service Mode, follow the steps illustrated below:

display.

pressing the “Select” and “Temperature Up” buttons will switch the display immediately to the “User Mode”.

Page 36

Error Code Number (Display/Reset). This is only shown if there is an operating error in the “User Mode”.

1. Max Setpoint (Display/Change)

2a. Water Temperature Average (Displays average if there are two sensors – sensor temperature displayed if single

SELECT

SET

Status

°F

idle

Water Tem p

Operational

SELECT

Lockout RESET

Status

Service Needed

Error Code Shown

in Water Heat er Display

SELECT

SET

Status

°F

idle

Operational

Max Setpoint value in

Water Heat er Display

Max

Setpoint

The following is the sequence of modes available in “Service Mode” by pressing the “Select” button:

sensor is used).

Page 37

2b. Water Temperature - Upper Sensor (Displays if there is an upper sensor – some models)

2c. Water Temperature - Lower Sensor (Displays if there are two sensors)

3. Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle)

SELECT

SET

Status

Heating

Operational

Flame Current

µA

SELECT

SET

Status

°F

idle

Operational

Upper

Sensor

SELECT

SET

Status

°F

idle

Operational

Lower Sensor

Page 38

4. Setpoint (Display/Change)

5. ˚F/˚C (Display/Change)

6. Differential (Display only – shows the differential of the thermostat)

SELECT

SET

Status

°F

idle

Differential

Operational

SELECT

SET

Status

°F/C°

idle

Operational

°F

SELECT

SET

Status

°F

idle

setpoin

Operational

Page 39

7. Software Version (Display only)

8. Error Code History (Displays if there are present error codes or up to 10 previous error codes). Water Heater Display Step 1: In service mode press the “Select” button until “Max Setpoint” is displayed.

SELECT

SET

Status

idle

Operational

Soft

SELECT

SET

Status

°F

idle

Max

Operational

Setpoint

SELECT

SET

Status

idle

Operational

No current error codes

Set t ing t he w at er t emperature t o t he maximum set point c an result in scalding hot water delivered to the

being improperly adjusted. See previous w arning on scalds and an ASSE approved mixing valve.

WARNING

will show -- if there are no error codes.

To change the Maximum Setpoint Limit (Max Setpoint) for the temperature setpoint:

f aucets. It is highly recommended that t he maximum setpoint be adjust ed to t he lowest tem p eratu r e po ssi bl e f or t he needs of t he installation. See following sect ion t o change the maximum setpoint limit (max setpoint ). M ak e sur e th e water h eat er c on tr ol di sp lay i s n ot i n a p ub l ic ar ea t h at c an resu lt i n t h e tem per atur e setti ng s

Page 40

Step 2: Press “Set” button to enter setting mode. “Max Setpoint” will flash to indicate setting mode. Step 3: Press the “UP” or “DOWN” buttons to change the maximum setpoint value. This will limit the maximum setpoint the

Step 4: Press “Set” button to confirm new “Max Setpoint” value and stop setting mode.

SELECT

SET

Status

°F

idle

Operational

Max

Setpoint

"Max Setpoint" Flashes

SELECT

SET

Status

°F

idle

Operational

Max

Setpoint

"Max Setpoint" continues to flash

while making adjustments

SELECT

SET

Status

°F

idle

Operational

Max

Setpoint

"Max Setpoint" stops flashing

user can select. Note: The maximum setpoint is approximately 180˚F.

Page 41

Step 5: 30 Seconds after the last button press, the Water Heater Display will go back to “User Mode”. It will read “Max

Step 1: In Service Mode, Press the “Select” button until “Water Temp” is displayed in the upper right section of the water

SELECT

SET

Status

idle

Operational

Max

Setpoint



Exiting Service Mode

SELECT

SET

Status

°F

idle

Operational

Water

Temp

Setpoint” without showing a temperature value if the temperature setpoint is at the maximum setting. The Water Heater Display can be set back to the “User Mode” immediately by pressing both the “Temperature Up” and “Select” buttons together for 3 seconds.

Display of Water Temperature:

heater display. For water heaters using two temperature sensors in the tank, this will be the average reading between the two sensors. For water heaters using a single sensor, this is the reading for the sensor.

Page 42

Step 2: For water heaters using two temperature sensors, pressing the “Select” button again displays the Upper Sensor

Step 3: For water heaters using two temperature sensors, pressing the “Select” button again displays the Lower Sensor

The pilot flame sense current is available only when the burners are in operation. Step 1: Make sure the status displays

SELECT

SET

Status

°F

idle

Operational

Lower Sensor SELECT

SET

Status

Operational

Flame

Current

Heating

µA

SELECT

SET

Status

°F

idle

Operational

Upper Sensor

temperature reading. “Upper Sensor” will be displayed in the lower right side of the status window of the water heater display.

temperature reading. “Lower Sensor” will be displayed in the lower left side of the status window of the water heater display.

To Display Flame Sense Current of the Pilot Fla m e Sensor:

“Heating” or draw enough hot water to start the burners. Step 2: Enter the “Service Mode” described previously. Step 3: Press the “Select” button until a number value is displayed with “Flame Current” to the right of the number. The value displayed is in microamps (µA).

Page 43

Step 1: In “Service Mode” press the “Select” button until “Setpoint” is shown in the water heater display.

Step 2: Press the “Set” button to enter the setting mode. “Setpoint” will flash in the water heater display.

Step 3: To raise the temperature setpoint, press the “Temperature Up” button until the desired temperature is shown on the

SELECT

SET

Status

°F

idle

setpoint

Operational

SELECT

SET

Status

°F

idle

setpoint

Operational

"Setpoint" Flashes

SELECT

SET

Status

°F

idle

setpoint

Operational



"Setpoint" Flashes

Note: The maximum temperature that can be set in the Water Heater Display is limited to the “Max Setpoint”

NOTICE

To Display and Change Temperature Setpoint:

water heater display.

described previously. To change the “Max Setpoint”, refer to the procedure “To Change the Maximum Setpoint Limit…” described previously under “Accessing the Service Mode on the Water Heater Display”.

Page 44

Step 4: To lower the temperature setpoint, press the “Temperature Down” button until the desired temperature is shown on

Step 5: When the desired setpoint is reached on the water heater display, press the “Set” button to confirm the new

To Display and Change Temperature Format (˚F/˚C):

SELECT

SET

Status

°F

idle

setpoint

Operational

"Setpoint" Flashes

SELECT

SET

Status

°F

idle

setpoint

Operational

"Setpoint" Stops Flashing

SELECT

SET

Status

idle

Operational

°F

°F/C°

the water heater display.

setpoint. “Setpoint” stops flashing in the water heater display.

To Change Temperature Format in Display from ˚F to ˚C or ˚C to ˚F:

Step 1: While in “Service Mode”, press “Select” button until “˚F/˚C” is shown in the upper right portion of the water heater display.

Page 45

Step 2: Press “Set” button to change temperature format. “˚F/˚C” symbol will flash in the water heater display.

Step 3a: Press “Temperature Up” button to change temperature format to ˚C. Step 3b: Press “Temperature Down” button to change temperature format to ˚F.

SELECT

SET

Status

idle

Operational

°F

°F/C°

"°F/°C" Flashes

SELECT

SET

Status

idle

Operational

°C

Changes to "°C"



°F/C°

"°F/°C" Flashes

SELECT

SET

Status

idle

Operational

°F

Changes to "°F"

°F/C°

"°F/°C" Flashes

Page 46

Step 4: Press “Set” button to confirm ˚F or ˚C format. ˚F/˚C will stop flashing.

Step 5: Pressing “Select” button will return display to setpoint in format selected (˚F or ˚C) immediately.

SELECT

SET

Status

°F

idle

Operational

Lower Sensor

Setpoint shown in °F

SELECT

SET

Status

°F

idle

Operational

°F

°F/C°

"°F/°C" Symbol Stops Flashing

Page 47

Lockout RESET

SELECT

Status

Service needed

Error Code Shown in

Water Heat er Display

Press for 2 seconds

SELECT

SET

Status

Service Needed



SELECT

Lockout RESET

Status

Service Needed

Error Code Shown in

Water Heater Display

Step 1: Press for 3 seconds

to enter service mode.

Step 2: Press for 3 seconds to

reset control in service mode.

Resetting Error Codes in Hard Lockout Condition

The following procedure is for service and installation personnel only. Resetting lockout conditions without correcting

WARNING

How to reset the control from Lockout Conditions:

the malfunction can result in a hazardous condition

If an error code is displayed (except for #4, low flame sense current), the water heater will be in a “lockout condition” with the water heater display showing the error code number and “Service Needed” in the status section of the display window. Error codes 62 (maximum number of retries detected) and 63 (maximum number if ignition recycles detected) are “Soft Lockouts” in which the control can be reset in the “User Mode” by pressing the lower right button under “Lockout Reset” shown in the lower right portion of the display. The control will also go through 3 attempts to relight the burners every hour in the soft lockout condition.

Resetting Error Codes in Soft Lockout Condition

All other error codes will put the water heater into a “Hard Lockout” condition, in which the water heater will not operate and cannot be reset in the “User Mode”. To reset a hard lockout, first enter the “Service Mode” described earlier by pressing both the “Temperature Up” and “Select Buttons” at the same time for 3 seconds. Then press the lower right button under “Lockout Reset” in the water heater display and hold for 3 seconds.

Page 48

Error Codes and Error History Display:

Step 1:

SELECT

SET

idle

Service Needed

SELECT

SET

Status

°F

idle

Operational

No Current Error Code

If there is an operating problem with the water heater, an error code number will appear on the water heater display with “Service Needed” to the right of the “Status” indicator. The error code label is located below the water heater display and the following section in this Installation and Operating Instruction Manual explains the error codes with corrective actions to repair the water heater.

Example of Error Code in the Display:

Error Code History:

In “Service Mode” pressing the “Select” button after the “Software Version” (item 8 in the previously described sequence of service modes) will show an error code history, if there have been any previous operating problems with the water heater. If the display shows --, there is not a current error code. The Water Heater Display will provide up to 10 previous error codes. The oldest error code will be stored in code index #1 and the most recent in code index #10 (if there are 10 error codes).

To view previous error codes:

In “Service Mode” press the “Select” button until the next display after the “Software Version”. If there are no current error codes, the display will show -- .

Page 49

Step 2:

Step 3:

SELECT

SET

Status

idle

Operational

Error Code Index

SELECT

SET

Status

idle

Operational

No Error Code Shown

for Code Index 10

Press the “Temperature Down” button to select the error code index, starting with the most recent error code “10”.

Press the “Select” button to view the error code for “code 10”. If there is a number displayed, note what the number is. The label next to the water heater display will identify the code number. If no number is displayed with only a “--“ in the water heater display, then there has not been an error code for error code index 10.

Page 50

Step 4:

Step 5:

SELECT

SET

Status

idle

Operational

Error Code Index

SELECT

SET

Status

idle

Operational

Stored Error Code

For Code Index #9

Press the “Temperature Down” button to change to the previous code index, code #9.

Press the “Select” button for code index #9 to view if there are any code numbers.

Page 51

Step 6:

Step 7: 10 seconds after the last button press, the Water Heater Display will revert back to the current error code display.

Error

Code

Determine flame sense current in the Service Mode with the water heater

pilot.

Check to see if flue damper has fully opened. If not, disconnect damper

replace flue damper.

Check to see if flue damper has fully closed. If not, disconnect damper

is continuity, the end switch is stuck closed. Replace flue damper.

SELECT

SET

Status

°F

idle

setpoint

Operational



Exiting Service Mode

Continue pressing the “Temperature Down” button to change to the next error code index and press “Select” to view the error code number, if any , for that index number. Continue on to index #1, the oldest error code index. The water heater display will store up to 10 error codes with the oldest code starting in code index #1 with the most recent code in code index #10.

To exit Service Mode, either wait 30 seconds or press Temperature Up button and Select Button for 3 seconds.

DIAGNOSTIC ERROR CODES AND TROUBLESHOOTING PROCEDURES FOR HONEYWELL INTEGRATED CONTROLS (24 VOLT FLUE DAMPER MODEL SERIES)

Definition of Code Cause of Problem and Actions Taken to Correct

Low Flame Sense Current

Damper End Switch Failed to Close (Stuck Open)

Damper End Switch Failed to Open (Stuck Closed)

operating. If less than 1.0 microamps, check pilot flame sense rod and wire. Clean flame sense rod with emery cloth. If problem is not solved, replace

harness at damper plug connection and check for 24 volts between pins on red and white wires. If no voltage, check wire harness or measure output on control board (pins 1&4). If there is no voltage at the control board, replace control. Replace wire harness if voltage does not pass to the pin terminals from the control. If there is 24 volts at flue damper connection, replace flue damper. If damper is open, disconnect harness and check continuity between pins from black and yellow wires on flue damper. If no continuity,

harness at damper plug connection and check for 24 volts between pins on red and white wires. If no voltage, check wire harness or measure voltage output on control board (pins 1&4). If there is no voltage at the control board, replace control. Replace wire harness if voltage does not pass to the pin terminals from the control. If there is 24 volts at flue damper connection, replace flue damper. If damper is closed, disconnect harness and check continuity between pins from black and yellow wires on flue damper. If there

Page 52

Error

Code

Flame Sensed Out of

Gas Valve)

Check to make sure gas valve has closed. No voltage should be present at harness are correct. If gas valve is stuck open, replace.

Flame Detected After Completes

Check to make sure gas valve has closed. No voltage should be present at harness are correct. If gas valve is stuck open, replace.

Upper Sensor Readings Faulty

Resistance of upper sensor out of operating range. Check continuity of wire harness to upper sensor, and if O.K., replace upper sensor.

Lower Sensor Readings Faulty

Resistance of lower sensor out of operating range. Check continuity of wire harness to lower sensor, and if O.K., replace lower sensor.

Pilot flame sensor rod is shorted to ground. Check to see if flame sensor wire

or flame rod is bent.

AC Line Frequency

Incorrect

Check line voltage to the water heater. Determine cause of low or high separate line.

Check line voltage to the water heater for erratic readings. Also check wiring control board.

Pilot is either not lighting or not staying lit during the ignition cycle. Check

damaged or electrode is damaged.

Pilot flame is lost during run cycle, then reestablished on ignition cycle.

flame sensor, or electrode is damaged.

Electronics Failure

Replace control board.

Water temperature in tank has exceeded 200˚F. Check lower sensor. Make

replace control board.

Definition of Code Cause of Problem and Actions Taken to Correct

31 32

Normal Sequence (Before Opening Gas Valve or After Closing

Flame Detected Before Ignition

Heating Cycle

Flame Rod Shorted to Ground

Error – Signal Too Noisy or Frequency

Line Voltage Too Low or High

Check to make sure gas valve has closed. No voltage should be present at the gas valve before or after ignition cycle. Make sure wire positions on the wire harness are correct. If gas valve is stuck open, replace.

the gas valve before the ignition cycle. Make sure wire positions on the wire

has bare spots touching metal parts of if flame sensor rod is touching the pilot shield or other metal parts. Replace pilot if flame sense wire is damaged

Check line voltage frequency to the water heater. Determine if there are wide fluctuations. Call an electrician if the problem persists. The water heater should be on a separate line.

voltage. Call an electrician or your utility. The water heater should be on a

DC Output Voltage Unstable

Maximum Number of Retries Detected

Maximum Number of Ignition Recycles Detected

High Water Temperature (Over 200˚F)

to make sure there are no shorts. If power supply and wiring is O.K., replace

inlet gas pressure for minimum pressure on rating label. Is pilot electrode sparking? Check gas valve wire harness for broken wires or shorts. If 24 volts is present between PV and PV/MV terminals at the gas valve, replace gas valve. Check for voltage output to the yellow and red gas valve wires on the control board pins. If during the ignition trial period, there is no voltage present at the control board pin terminal for the red and yellow wires leading to the gas valve, then replace the control board. Replace pilot if wires are

Check inlet gas pressure. Is gas pressure dropping below the minimum operating pressure on the rating label after the main gas valve opens? Is the gas pipe size to the water heater adequate? Check the pilot shield position and condition of the burners. Clean or replace as needed. Check the pilot flame and observe the microamp output on the run cycle. Check the pilot tubing to the pilot and replace if crimped or damaged. Replace pilot if wires,

sure sensor is fully inserted into the well (clip on sensor wire secures sensor in place). Check lower and upper (where used) sensor readings. If not within specifications, replace sensor. If sensor and wire harnesses check O.K.,

Page 53

In Degrees F

°F 0 1 2 3 4 5 6 7 8 9

26109

25400

24712

24045

23399

22771

22163

21573

21000

20445

19906

19383

18876

18383

17905

17440

16990

16553

16128

15715

15314

14925

14548

14180

13823

13477

13140

12812

12494

12185

11884

11592

11308

11032

10763

10502

10248

10000

9760

9526

9299

9078

8862

8653

8449

8250

8057

7869

7685

7507

7333

7165

7000

6839

6683

6531

6383

6238

6098

5961

100

5827

5697

5570

5446

5326

5208

5094

4982

4873

4767

110

4663

4562

4464

4368

4274

4183

4094

4006

3922

3839

120

3758

3679

3602

3527

3453

3382

3312

3244

3177

3112

130

3048

2986

2925

2866

2808

2752

3697

3643

2590

2538

140

2488

2439

2391

2344

2298

2253

2209

2166

2124

2083

150

2043

2004

1966

1928

1891

1856

1820

1786

1753

1720

160

1688

1656

1625

1595

1566

1567

1509

1481

1454

1427

170

1402

1376

1351

1327

1303

1280

1257

1235

1213

1191

180

1170

1150

1129

1110

1090

1071

1053

1035

1017

999

190

982

965

949

933

917

901

886

871

857

842

200

828

814

801

788

775

762

749

737

725

713

In Degrees C

°C 0 1 2 3 4 5 6 7 8 9 0 32648

31026

29495

28049

26682

25389

24166

23010

21915

20879

19898

18968

18088

17253

16461

15710

14998

14322

13680

13071

12492

11942

11419

10922

10450

10000

9572

9165

8778

8409

8057

7722

7403

7099

6808

8532

6268

6016

5775

5546

5327

5117

4917

4726

4543

4368

4201

4042

3889

3742

3602

3468

3340

3217

3099

2986

2878

2774

2675

2579

2488

2400

2316

2235

2157

2083

2011

1942

1876

1813

1752

1693

1637

1582

1530

1480

1432

1385

1340

1297

1256

1216

1177

1140

1105

1070

1037

1005

974

944

916

888

861

835

810

786

763

741

719

698

Procedure for Checking Thermostat Sensors

Set the thermostat above water temperature (See temperature adjustment section) and observe system through one (1) complete cycle. Make sure system operates as desired.

To check the upper sensor or lower sensor assembly, compare the resistance of the sensor terminals (blue leads for upper sensor, yellow and black lead for lower sensor) as measured by an ohmmeter to the water temperature as measured by an accurate thermometer. Thermistor resistance increases as the temperature decreases. The tables below show the correct sensor resistance at various temperatures. Replace the sensor if the ohm reading in the chart does not approximate the reading from the sensor at the temperature measured in the tank.

Page 54

Spark To Pilot Ignition Parts List.

* Denotes emergency shut-off devices.

PART NAME AND DESCRIPTION

1. Drafthood

17. Integrated Control Board

2. Diptube

18. Pilot Shield

3. Flue Baffle

19. Control Box

4. Cleanout Access (Jacket) Cover

5. Drain Valve

21. Utility Cover

22. Wire Harness-Damper/ Upper Sensor

6a. Cleanout Cover O-Ring (Not Pictured)

6b. Cleanout Cover Gasket A.S.M.E. (Not Pic)

7. Heat Shield

25. Tank Leg Thermal Break

8. Main Burner Tube(s)

26. Lower Temp Sensor

27. Wire Harness-Lower Sensor

10. Pilot Burner Assembly

28. T&P Valve

11. Pilot Supply Tube

29. Nylon Cable Clamp

12. Main Burner Manifold

30. Self Tapping Screw

13. Gas Valve *

31. Control display *

14. Main Burner Orifice

32. Upper Temp Sensor

15. Control Box Cover

33. Outlet Nipple

16. Transformer

34. Collector Head

Standing Pilot Parts List

* Denotes emergency shut-off devices.

PART NAME AND DESCRIPTION

1. Drafthood

2. Diptube

3. Flue Baffle

4. Cleanout Access (J acket) Cover

5. Drain Valve

6. Cleanout Cover

6a. Cleanout Cover O-Ring (Not Pictured)

6b. Cleanout Cover Gasket A.S. M. E . (Not Pic)

7. Heat Shield

8. Main Burner Tube(s)

9. Burner Tray

10. Pilot Burner Assembly

11. Pilot Supply Tube

12. Main Burner Manifold

13. Gas Valve *

14. Main Burner Orifice

15. Pilot Shield

16. Utility Cover

17. Anode Rod

18. Tank Leg Thermal Break

19. Wire Harness

20. T&P Valve

21. Outlet Nipple

22. Collector Head

23. Thermostat *

SECTION XII: PARTS LIST

REPLACEMENT PARTS LISTS

Contact your supplier, plumbing professional or the company listed on the rating plate of the water heater for replacement parts. Provide the part name as well as the model and serial number(s) of the water heater(s) when ordering parts. When applicable, the

following information must be provided: type of gas, voltage and amperage, item number (from the following list) and description (from the following list).

20. Power Switch

6. Cleanout Cover

23. Flue Damper

24. Anode Rod

9. Burner Tray

Page 55

SECTION XIII: INSTALLATION FOR POTABLE WATER AND SPACE HEATING

THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION OF:

GAS WATER HEATERS SUITABLE FOR WATER (POTABLE) HEATING AND SPACE HEATING

1. All piping components connected to this water heater for space heating applications must be suitable for use with potable water. In Massachusetts, space heating piping length must not exceed 50 feet.

2. Toxic chemicals, such as those used for boiler treatment, must not be introduced into potable water used for space heating.

3. This water heater must not be connected to an existing heating system or component(s) previously used with a non-potable water heating appliance.

4. When the system requires water for space heating at temperatures higher than required for other uses, a means such as an ASSE approved mixing valve shall be installed to temper the water for those uses in order to reduce scald hazard potential.

Please refer to the illustrations below and on the following pages for suggested piping arrangements.

Page 56

SECTION XIV: NOTES

Bradford White D-80T-180-3N, D-100S-250-3NA, D-100T-250-3NA, D-38T-155-3N+, D-100S-199-3N Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

WITH TROUBLESHOOTING GUIDE

Non-Flue Damper Models (Figure 2)

Flue Damper Models and Non-Flue Damper Models (Figure 3)

Non-Flue Da mper Models (Figure 4 )

Input

Less than or equal to 300,000 BTUH 2 in. (5.1 CM)

Greater than 300,000 BTUH 6 in (15.2 CM)

IMPORTANT-The flow of combustion and ventilating air must not be obstructed.

AIR REQUIREMENTS

Spark to Pilot Ignition (IID) Wiring Diagram

ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY (FOR SERVICE PERSONNEL ONLY)

Procedure for Checking Thermostat Sensors