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SUPER HIGH EFFICIENCY WATER HEATERS
SUPPLEMENT TO INSTRUCTION MANUAL
P/N 238-44219-00
(Replaces pg. 2 in instruction manual.)
You have just purchased one of the finest water heaters on the market today!
CONGRATULATIONS!
This installation, operation and instruction manual will explain in detail the installation
and maintenance of your new High Efficiency Flammable Vapor Ignition Resistant Gas
Water Heater. We strongly recommend that you contact a plumbing professional for
the installation of this water heater.
We require that you carefully read this manual, as well as the enclosed warranty, and
refer to it when questions arise. If you have any specific questions concerning your
warranty, please consult the plumbing professional from whom your water heater was
purchased. For your records, we recommend that you write the model, serial number
and installation date of your water heater in the maintenance section in the back of this
manual.
Special Flammable Vapor Ignition Resistant System:
This water heater is equipped with a Flammable Vapor Ignition Resistant System. In
the event of improper usage or storage of gasoline or other flammable materials in the
location where the water heater is installed, the technology will resist ignition of the
flammable vapors outside the confines of the water heater.
The Flammable Vapor Ignition Resistant System Features:
Advanced Flame Arrestor Design
Re-settable Thermal Switch to prevent burner/pilot operation with restricted
airflow
Flammable Vapor Sensor
Automatic Ignition Device
Sight Window to observe operation of pilot and burner
FOR YOUR SAFETY: Activation of the Flammable Vapor Ignition Resistant System
occurs when flammable vapors are drawn into the water heater and are combusted. If
flammable vapors are detected:
Do not try to light any appliance.
Do not touch any electrical switch; do not use any phone in your building.
Leave the premises and immediately call the fire department from a
neighbor’s phone. Follow the fire department’s instructions.
Once the flammable vapor has been evacuated, contact your plumbing professional or
the manufacturer for further instructions. Replacement of a Flammable Vapor Ignition
Resistant System equipped water heater due to a flammable vapor shutdown is not
covered under the terms of the limited warranty.
238-48703-00B 12/12
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Minimum Clearances
(Replaces pg. 9 in instruction manual.)
WARNING
Failure to adhere to these installation and operating instructions may create a hazard to
life and property and will nullify the warranty.
This installation must allow access to the front of the water heater and adequate
clearance must be provided for servicing and operating this water heater. The water
heater may be installed on either a combustible or non-combustible floor. If the water
heater is to be installed directly on carpeting, it must be installed on top of a metal or
wood panel (or equivalent) extending beyond the full width and depth of the water
heater by at least 3 in. (7.6 cm) in any direction or, if the appliance is to be installed in
an alcove or closet, the entire floor must be covered by the panel. If the rating plate or
the label on the front of the heater specifies minimum clearances less than those listed
below, the water heater must be installed in accordance with the minimum clearances
listed on the rating plate or the label on the front of the heater.
If it is necessary to install this water heater in an alcove, use the clearances listed in
Figure 1.
Figure 1. Minimum Clearances for an Alcove Installation.
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Venting
(Replaces pg. 10 in instruction manual.)
WARNING
The venting system must be installed properly following all local codes or in the
absence of local codes, the latest edition of the National Fuel Gas Code (ANSI Z223.1latest edition), or in Canada, The Natural Gas and Propane Installation Code (B149.100 latest edition). Failure to properly install the venting system could result in property
damage, personal injury, or death.
WARNING
Carefully inspect the venting system of a replacement water heater installation before
connecting to the venting system. All joints in the vent connector must be securely
fastened with screws and fit tightly together. Inspect the venting system for signs of
deterioration (rust and perforation) and replace any sections that are not in good
condition.
The chimney must be lined and in good condition. Check to make sure the venting
system is properly sized for the water heater. If the venting system was previously
sized for another gas appliance that has been removed, the venting system may now
be too large. Refer to the latest edition of the National Fuel Gas Code (ANSI Z223.1latest edition), or in Canada, the Natural Gas and Propane Installation Code (B149.100 latest edition) for the correct sizing of venting systems and common venting with
another gas appliance.
Do not vent this water heater into the venting system of another gas appliance
designed to vent under positive pressure.
The water heater should be installed as close as practical to the venting system to
minimize the vent connector length required. Refer to local codes for the distance
limitations on vent connector lengths.
At the completion of the water heater installation, the burner and venting system must
be checked for proper operation with all other commonly vented appliances in
operation. Check for spillage of flue products around the outside relief opening of the
draft hood after several minutes of operation. The flame from a match should be drawn
into the draft hood. Do not use the water heater or connected equipment if spillage is
detected until the problem is corrected. Refer to the latest edition of the National Fuel
Gas Code, or in Canada, the Natural Gas and Propane Installation Code for complete
details on the “Procedure to Be Followed to Place Equipment in Operation”.
This water heater has been shipped with a draft hood for which it was designed with
reference to the horizontal and vertical planes. If removed, the draft hood must be
replaced in the same position and secured to the blower draft hood bracket.
NOTICE
This water heater is equipped with a draft hood. This water heater can be vented using
single wall or double wall vent connector pipe. This water heater may be vented into
Type B vent or a masonry chimney. This water heater can use either 3” or 4” venting.
Refer to the National Fuel Gas Code (latest edition) vent tables, using “NAT” columns
to determine appropriate vent configuration.
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Lighting and Shutdown Instructions
(Replaces pg. 18-19 in instruction manual.)
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THERMOSTAT ADJUSTMENT
(Replaces pg. 20-21 in instruction manual.)
The thermostat dial is adjusted to its lowest setting when shipped from the factory.
When adjusting the thermostat, it should be remembered that lower temperature
settings are more energy efficient. To adjust the thermostat, turn the dial clockwise until
the minimum acceptable temperature is set. It is suggested that the starting point
setting not exceed the 120°F (49°C) or “HOT” setting on the thermostat.
Figure 2. Gas Valve.
The thermostat dial is set to its lowest temperature setting when shipped from the
factory. Remember that lower temperature settings are more energy efficient. Adjust
the temperature by turning the thermostat dial. It is suggested that the starting point
setting not be greater than the “Hot” mark on the thermostat dial (approximately 120°F
[48.9°C]). Rotate the thermostat dial counter-clockwise
temperature setting. Rotate the thermostat dial clockwise
temperature setting. Adjust the dial until the minimum acceptable temperature is
achieved.
to decrease the
to increase the
DANGER
Hotter water increases the risk of scald injury. Scalding may occur within five (5)
seconds at a temperature setting of 140F (60
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.
Note: This water heater is equipped with an energy cut out device to prevent
overheating. Should overheating occur or the gas supply fails to shut off, turn off the
manual gas control valve to the water heater, and call a qualified service technician.
Note: Whenever the water heater is filled with cold water, condensate will form on the
cool tank surface and drops of water 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.
C). To protect against hot water injury,
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BURNER FLAME CHECK
(Replaces pg. 22 in instruction manual.)
Steel Burner: These models are equipped with self adjusting air mixture and do not
have an adjustable air shutter (See Figure 3). At periodic intervals, a visual check of
the main burner and pilot flames should be made to determine if they are burning
properly. The main burner flame should light smoothly from the pilot.
Figure 3. Burner and Pilot Assembly Used.
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TROUBLESHOOTING CHART
g)
p
)
(
)
g
p
p
g
(Replaces pg. 26-27 in instruction manual.)
LED St atus Control Status Probable Cause
None (LED not on
or flashin
One short f lash
every f our
seconds
Alt ernates bright
and dim
heart beat
Short f lash once
every second
Tw o flashes,
three second
pause
Three flashes,
three second
pause
Four flashes,
three second
ause
Fiv e f lash es ,
three second
ause
Six flashes, one
flash, three
second pause
(Soft Lockout)
Electrical power not
resent
Stand-by mode,
Thermost at is sat isfied (no
faults
Thermost at calling for
heat (no fault )
Weak pilot signal on last
call for heat
Pressure switch not
w orking - closed position
Pressure switch or
temperat ure sw it ch not
w orking - open position
Excessive t ank
temperature, sy st em must
be reset
False pilot f lame present Pilot valve stuck in open position
Failed to light pilot ,
syst em reset s after (5)
minutes
1. Control pow er sw itch in " OFF" position
2. Supply voltage interrupted
Temperature demand is satisfied (no call for
heat)
Tank temperature below setpoint of
t herm ost at
1. Unstable pilot
2. Pilot t ube block or restricted
3. Oxidation build-up on pilot electrode
4. Wire damage to pilot assembly or bad
connection at
1. Pressure swit ch t ubing kinked or blocked
2. Blocked pressure tap on switch
3. Faulty pressure sw itc h
1. Vent blockage or improper vent
configuration
2. Pressure swit ch t ubing kinked or blocked
3. Blow er not spinning t o speed
4. Faulty pressure sw itc h
1. Thermal w ell sensor out of calibration
2. Faulty gas valve
1. Unstable pilot
2. Pilot t ube block or restricted
3. Oxidation build-up on pilot electrode
4. Wire damage to pilot assembly or bad
connection at
as valve
as valve
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Troubleshooting continued-
Six flashes, three
flashes, t hree
second pause
(Soft Lockout)
Six flashes, four
flashes, t hree
second pause
Seven flashes,
three second
pause
Pilot f lame extinguished,
system auto resets after
(5) minut es
Undesired false pilot flame
sensed, sy stem auto
resets
Flammable vapor sensor or
resettable thermal switch
fault det ected, see
w arning label
1. Unstable pilot
2. Pilot tube block or restrict ed
3. Oxidation build-up on pilot electrode
4. Wire damage to pilot assembly or bad
connection at gas valve
5. Insufficient combustion air
Pilot valve stuck in open position
1. Flammable vapor present
2. Flammable vapor sensor exposed to
excessive moisture
3. Flammable vapor sensor exposed to
ext reme ambient t emperature
4. Re-settable thermal switch open
Eight f lashes, one
flash, three
second pause
Eight f lashes,
two flashes,
three second
pause
Eight f lashes,
three f lashes,
three second
pause
Eight f lashes,
four flashes,
three second
pause
Flammable vapor sensor
out of specification,
possible short
Temperat ure sensor f ault
Gas valv e elec tronics f ault
detect ed
Gas valve fault detected
Fault Probable Cause
Re-settable Thermal Switch Tripped (Open)
1. Flammable vapor sensor out of
specification
2. Possible short in f lammable vapor sensor
or re-sett able thermal sw itch w iring
1. Damage to thermal w ell wires
2. Thermal well sensor resistance out of
range
3. Replace thermal w ell
1. Verify control is not w et or physically
damaged
2. Reset control on/off switch
3. Replace electronic module if 8-3 error
persists
1. Verify control is not w et or physically
damaged
2. Reset control on/off switch
3. Replace gas control if 8-4 error persists
1. Insufficient combustion air
2. Flammable vapors present
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Troubleshooting continued-
Control Sequence of Operation
Start up Sequence
Upon powering up, the control checks for the presence of the flammable vapors, if the
resistance is in the expected range the control will begin normal operation after 5 to 8
seconds.
Normal Heating Sequence
1. The thermostat senses a call for heat.
2. The control checks the pressure switch condition.
3. If the pressure switch is open, the control sends power to the blower motor.
4. The blower starts moving combustion air through the combustion system.
5. The pressure switch closes.
6. The control senses the closed pressure switch and starts the ignition process by
providing a spark at the pilot electrode and allowing gas to flow to the pilot.
7. When the pilot is lit, the gas control senses the pilot flame and opens the main gas
valve.
8. The main burner is lit.
9. The main burner and blower continue to operate until the thermostat is satisfied.
10. The blower operates for a short post purge period before shutting down.
11. The water heater remains in the stand-by mode until the next call for heat.
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INSTALLATION FOR POTABLE WATER
(Replaces pg. 28 in instruction manual.)
Figure 4
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PARTS LIST DRAWING
(Replaces pg. 29 in instruction manual.)
Figure 5
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PARTS LIST
(Replaces pg. 30 in instruction manual.)
PART NAME AND DESCRIPTION
1. Draft hood 15. Right side inner door
2. Jacket head 15A. Re-settable Thermal Switch
3. Jacket 16. Left side inner door
4. High Efficiency Blower 17. Blower harness
5. Heat trap (outlet) 18. Main burner feedline
6. Anode Outlet Device 19. Gas control
7. Heat trap (inlet) 20. FV sensor / RTS wire harness
8. Baffle 21. FV sensor clip
9. Diptube 22. FV sensor
10. T&P valve 23. Outer door
11. Tank 24. Burner
12. Combustion chamber 25. Orifice
13. Pedestal base 26. Pilot assembly
14. Drain valve
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THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION
OF: GAS WATER HEATERS SUITABLE FOR WATER
(POTABLE) HEATING AND SPACE HEATING
(Replaces pg. 31 in instruction manual.)
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.
1. Toxic chemicals, such as those used for boiler treatment, must not be introduced
into potable water used for space heating.
2. This water heater must not be connected to an existing heating system or
component(s) previously used with a non-potable water heating appliance.
3. When the system requires water for space heating at temperatures higher than
required for other means, such as an ASSE approved mixing valve must be
installed to temper the water for those uses in order to reduce the scald hazard
potential.
Please refer to Figure 6 for suggested piping arrangements.
Figure 6
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(In addition to the instruction manual.)
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Electrical Connections
(In addition to the instruction manual.)
All electrical wiring and connections must be in accordance with the National Electric
Code ANSI/NFPA No. 70-Latest Edition, or the Canadian Electrical Code C22.1-Latest
Edition, and any local codes which may apply. The water heater must be electrically
grounded.
If a flexible line cord and plug is permitted by local code, then provide a (3) three wire
grounding type receptacle within 6 ft. (1.9 m) of the water heater and use the flexible
cord provided. Do not plug the line cord into a receptacle that can have its power
supply interrupted by a switch that is used to turn on and off lights.
Turn off the water heater gas control and disconnect power to the water heater. If
wiring in conduit is required, cut the flexible line cord at least 6 in. (15.2 cm) from the
bushing. Unscrew and remove the blower junction box assembly. Pull the cord into
the junction box assembly housing. Cut the three wires from the line cord at the
bushing inside of the housing. Enlarge the hole in the back of the blower junction box
assembly to receive a 1” electrical conduit connector. Wire the power supply into the
circuit at the appropriate locations.
Replace the blower junction box assembly and re-install the screws previously
removed. Connect power to the water heater. Turn the water heater gas control back
on.
CAUTION
Turn off or disconnect the electrical power supply to the water heater before servicing.
Label all wires prior to disconnection when servicing controls. Wiring errors can cause
improper and dangerous operation. Verify proper operation after servicing.
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Wiring Diagram
(In addition to the instruction manual.)
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