Giant PV1, UG40-40LFPV1-N2U, UG40-38LFPV1-P2U, UG50-40LFPV1-N2U, UG50-38LFPV1-P2U Owner's Manual

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Page 1

RESIDENTIAL POWER VENT GAS-FIRED WATER HEATERS

WARNING

ISO 9001

ENREGISTRÉ

(EQUIPPED WITH FVIR TECHNOLOGY)

OWNER’S MANUAL

INSTALLATION AND OPERATING INSTRUCTIONS

PV1 Model only

This water heater IS NOT design certified for installation in a manufactured (mobile) home or for installation outdoors.

If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

DO NOT store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• DO NOT try to light any appliance.

• DO NOT touch any electrical switch.

• DO NOT use any phone in your building.

• From a neighbour’s phone, immediately

call your gas supplier. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by

a qualified installer, service agency or the gas supplier.

IMPORTANT

READ THESE INSTRUCTIONS CAREFULLY BEFORE BEGINNING THE INSTALLATION. PROPER INSTALLATION WILL PROVIDE SAFE AND EFFICIENT SERVICE AND AVOID NEEDLESS EXPENSE NOT COVERED BY THE WARRANTY. READ THE PRODUCT WARRANTY CONTAINED IN THIS MANUAL AND REMEMBER TO FILL OUT AND RETURN TO THE MANUFACTURER ALL RELEVANT WARRANTY CARDS AND CERTIFICATES. SHOULD YOU HAVE ANY QUESTIONS, PLEASE CONTACT YOUR LOCAL DEALER OR REFER TO THE

SAVE THIS MANUAL FOR FUTURE REFERENCES.

GETTING SERVICE FOR YOUR WATER HEATER SECTION OF THIS MANUAL.

For your records, write the model and serial number here:

Model # ________________________________

Serial # ________________________________

54000030

ISO 9001

REGISTRED

Page 2

TABLE OF CONTENTS

Safety Information ............. 3

Installation Instructions .......... 4

Altitude...................4

Location ................. 4

Minimum Clearances ........... 4

Combustion and Ventilation Air Supply ... 4 Requirements for Unconfined Spaces ... 5

Requirements for Confined Spaces .... 5

Louvers and Grilles ............ 6

Corrosive Atmospheres .......... 6

Venting ................. 7

Termination Screen .............7

Through-the-Wall Venting Installation ... 8 Through-the-Roof Venting Installation ... 8

Condensation in the Venting System .... 8

CPVC Adaptor ...............8

Water Piping ............... 9

Temperature and Pressure-Relief Valve .. 9 Pressure Build-up in a Water System ... 10

Filling the Water Heater .......... 12

Gas Connections ............. 12

Installation Instructions for Water Heaters Approved for Space Heating

and Potable Water Heating ....... 13

Wiring .................. 14

Installation Checklist ........... 15

Operating Instructions ........... 16

Lighting the Water Heater ......... 16

Water Temperature Regulation ...... 17

Out of Fuel ............... 18

General Maintenance ........... 18

Housekeeping . . . . . . . . . . . . . . 18

Safety System .............. 18

Condensation .............. 18

Burner Ignitor Assembly .......... 19

Water Heater Tank ............ 19

Temperature and Pressure-Relief Valve... 19

Venting System Inspection......... 19

Anode .................. 19

Draining the Water Heater ......... 19

Vacation ................. 20

Getting Service for your Water Heater ... 20

Replacement Parts ............. 21

Troubleshooting Guide ........... 22

Warranty .................. 26

FVIR technology equipped with a flammable vapour sensor and the flame arrestor.

WARNING

Flammable Vapour Sensor

Do not remove the protective cover. Do not spray water or leak detector products on this sensor. Do not expose this sensor to bleach or other liquid cleaning products. Avoid humid environments and freezing temperatures.

If the sensor detects the presence of flammable vapour, the gas control will switch to lock out mode and the water heater will shut down. Do not try and restart the water heater. Have the water heater inspected immediately by a qualified service technician or the gas supplier.

This water heater is equipped with FVIR technology. Activation of the FVIR technology occurs when flammable vapours are drawn into the water heater. If the flammable vapour sensor detects the presence of flammable vapours when the water heater is operating, the gas control will switch to lock out mode and the water heater will shut down. If the water heater is not operating when the flammable vapours are detected, the control will switch to lock out mode and prevent the water heater from lighting. If the flammable vapours enter the combustion chamber and ignite, the flame arrestor will prevent these combustible vapours from igniting outside of the water heater.

If flammable vapours are detected:

•DO NOT try to light any appliance. • DO NOT touch any electrical switch. DO NOT use any phone in your building. •

From a neighbour’s phone, immediately call your gas supplier.

•Ifyoucannotreachyourgassupplier,callthefiredepartment.

Follow the gas supplier’s instructions.

After the flammable vapours have been evacuated, contact a qualified service technician or the gas supplier to have the water heater inspected immediately.

to a flammable vapour shutdown is not covered under the terms of the Standard Basic Limited Warranty.

Replacement of an FVIR technology equipped water heater due

Page 3

SAFETY INFORMATION

WARNING

Your safety and the safety of others is extremely important during the installation, operation and servicing of this water heater. Many safety-related messages have been provided in this manual and on your water heater. Always read and abide by all safety messages. These messages will point out the potential hazard, tell you how to reduce the risk of injury and tell you what will happen if the instructions are not followed.

This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others. All safety messages will follow the safety alert symbol and either the word “DANGER” or “WARNING”.

DANGER

WARNING

Serious injury or death can occur if you do not follow the instructions immediately.

Serious injury or death can occur if you do not follow the instructions.

DO NOT use this water heater if any part has been under water. Immediately call a qualified service technician to inspect the water heater and to replace any part of the

control system and any gas control which has been under water. Failure to follow this instruction can result in property damage, personal injury or death.

Page 4

INSTALLATION INSTRUCTIONS

IMPORTANT

These instructions have been written as a guide for the proper installation and operation of your water heater and the manufacturer of this water heater will not accept any liability where these instructions have not been followed. However, for your safety and to avoid damage caused by improper installation, this water heater must be installed by a Certified Licensed Professional and meet all local codes or, in the absence of local codes, CAN/ CSA B149.1, Natural Gas and Propane Gas Installation Code, in Canada and/or the National Fuel Gas Code, ANSI Z223.1/NFPA 54, in the United States.

Before proceeding with the installation instructions:

1) Inspect the water heater and its component parts for possible damage. DO NOT install or attempt to

repair any damaged component parts. If you detect any damage, contact the dealer where the water heater was purchased or the manufacturer listed on the warranty card.

2) Verify that the type of gas being supplied corresponds to what is marked on the rating plate and gas control valve of the water heater.

Altitude

This water heater is approved for altitudes up to 5,000 feet (1,524 m).

Location

This water heater should be located close enough to the outside wall so that it is within the venting requirements listed in these installation instructions and as close as possible to the main use of hot water. This location must not be subject to freezing temperatures. The water heater should be positioned, so that there is easy access to the burner, gas control valve and drain valve. It must be located close to a suitable free-flowing floor drain. Where a floor drain is not adjacent to the water heater, a suitable drain pan must be installed under the water heater (see Figure 12). This drain pan should be at least four (4) inches (10.2 cm) larger than the diameter of the water heater and at least one (1) inch (2.5 cm) deep, providing access to the drain valve. This pan must not restrict the flow of ventilation and combustion air. This pan must be piped to a suitable drain to prevent damage to property in the event of a water leak from the piping, the relief valve or the water heater.

Minimum Clearances

The minimum clearances from combustible material for this water heater are: Two (2) inches (5.1 cm) from the sides and rear, four (4) inches (10.2 cm) from the front and eighteen (18) inches (45.7 cm) from the top (see Figure 1).

Figure 1

18''

min.

2'' min.

4'' min.

2'' min.

Sooner or later, all water heaters leak. The manufacturer, based on national building codes, has given the necessary instructions to prevent damage to the building. Under no circumstances is the manufacturer to be held liable for any water damage in connection with this water heater.

This water heater is approved for installation on either a combustible or non-combustible floor. However, should this water heater be installed directly on carpeting, the carpeting must be protected by a wood or metal panel beneath the water heater. This panel must extend at least three (3) inches (7.6 cm) beyond the width and depth of the water heater. Should the water heater be installed in an alcove or closet, the entire floor area must be covered by the panel.

Combustion and Ventilation Air Supply

In order for the water heater to operate properly, it must be supplied with an uninterrupted flow of clean combustion and ventilation air. The area around the water heater must always be kept clear and the combustion air intake holes at the bottom of the water heater must never be blocked. An inadequate supply of air to the water heater will produce a bright yellow burner flame causing sooting in the combustion chamber, on the burner and in the flue tube. This can result in damage to the water heater and serious bodily injury, if not corrected.

Combustion and ventilation air requirements are determined by where the water heater is to be located. Water heaters are installed in either open

Page 5

INSTALLATION INSTRUCTIONS

Confined Space

Inlet air duct

18''

24''

(unconfined) spaces or smaller (confined) spaces, such as closets or small rooms.

Requirements for Unconfined Spaces

An unconfined space is an area with at least 50 cubic feet for each 1,000 BTUH (4.8 m3/kW) of the total input rating for all gas appliances installed in that space. Water heaters installed in unconfined spaces do not usually require outdoor air to function properly. However, in buildings with tight construction (heavy insulation, vapour barriers, weather stripping, etc.) and particularly in modern buildings, additional fresh air may need to be provided. For instructions on obtaining additional air supply, see the requirements below for confined spaces.

Requirements for Confined Spaces

A confined space is an area where the volume is less than 50 cubic feet for each 1,000 BTUH (4.8 m3/kW)

of the total input rating for all gas appliances installed in that space. Water heaters installed in confined spaces require additional air. This can be provided in two ways:

In Canada (refer to CAN/CSA B149.1)

1) All Air From Inside the Building (see Figure 2):

The confined space shall be provided with

one opening of one (1) square inch per 1,000 BTUH (22.0 cm2/kW) communicating directly with one or more rooms of sufficient volume, so that the combined volume of all spaces meets the criteria for an unconfined space for all the appliances installed in that confined space.

Figure 2

1 foot above and within 2 feet horizontally from the burner level of the appliance having the largest input.

Figure 3

Confined Space

Inlet air duct

18''

24''

In U.S.A. (refer to ANSI Z223.1/NFPA 54)

1) All Air From Inside the Building (see Figure 4):

The confined space shall be provided with two

permanent openings communicating directly with one or more rooms of sufficient volume, so that the combined volume of all spaces meets the criteria for an unconfined space. The total input rating of all gas appliances installed in the combined space shall be considered in making this determination.

Each opening shall have a minimum free area of one (1) square inch per 1,000 BTUH (22.0 cm2/ kW) of the total input rating of all gas appliances in the confined space, but not less than 100 square inches (645.16 cm2). One opening shall commence within 6 inches (15.2 cm) of the top and one within 6 inches (15.2 cm) of the bottom of the enclosure.

Confined Space

2) All Air From Outdoors: (see Figure 3): An air-supply shall be provided with one open-

ing that communicates directly with the outdoors by means of a duct. This duct shall be sized according to CAN/CSA B149.1 and terminate within

Permanent Opening

-------------1 square inches /

1000 BTUH

2) All Air From Outdoors: The confined space shall be provided with two

permanent openings, one commencing within six

Figure 4

Page 6

INSTALLATION INSTRUCTIONS

(6) inches (15.2 cm) of the top and one commencing

within six (6) inches (15.2 cm) from the bottom of the enclosure. The openings shall communicate directly or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

A) When communicating directly with the outdoors,

each opening shall have a minimum free area of one (1) square inch per 4,000 BTUH (5.5 cm2/kW) of the total input rating of all gas appliances in the enclosure (see Figure 5).

B) When communicating with the outdoors through

vertical ducts, each opening shall have a minimum free area of one (1) square inch per 4,000 BTUH (5.5 cm2/kW) of the total input rating of all gas appliances in the enclosure (see Figure 6).

C) When communicating with the outdoors through

horizontal ducts, each opening shall have a minimum free area of one (1) square inch per 2,000 BTUH (11.0 cm2/kW) of the total input rating of all gas appliances in the enclosure (see Figure 7).

Figure 5

Figure 6

When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect. The minimum short side dimension of rectangular air ducts shall not be less than three (3) inches (7.62 cm).

Louvers and Grilles

In calculating free area for ventilation and combustion air supply openings, consideration must be given to the blocking effect of louvers, grilles or screens protecting the openings. Screens must not be smaller than 1/4 inch (6.4 mm) mesh. If the free area through a particular design of louver or grille is known, it should be used in calculating the size of opening required to provide the free area specified. If the design and free area is not known, it may be assumed that wood louvers and grilles will allow 20-25% free area and metal louvers and grilles will allow 60-75% free area. Louvers and grilles must be installed in the open position or interconnected with the water heater so that they are opened automatically during water heater operation.

Figure 7

Corrosive Atmospheres

If this water heater is to be installed in a beauty shop, barber shop, photo processing lab, dry cleaning establishment, a building with an indoor pool or near a chemical storage area, it is imperative that the combustion and ventilation air be drawn from outside these areas. These particular environments

contain products such as aerosol sprays, detergents, bleaches, cleaning solvents, refrige rants and other volatile compounds that, in addition to being highly flammable, become highly corrosive acid compounds when burned. Exposure to such compounds can be hazardous and lead to premature product failure.

Page 7

INSTALLATION INSTRUCTIONS

WARNING

DANGER

Should the water heater fail, due to exposure to such a corrosive atmosphere, the warranty is void.

Venting

When installing the venting system, make sure to follow all local codes or, in the absence of local codes, CAN/CSA B149.1, Natural Gas and Propane Gas Installation Code, in Canada and/ or the National Fuel Gas Code, ANSI Z223.1/ NFPA 54, in the United States. Never operate the water heater unless it is properly ventilated to the outdoors and has adequate air supply for proper operation. Failure to properly install the venting system could result in property damage, personal injury or death.

Before installing the vent piping, make sure that the vent system layout has been properly planned. Verify that the location of the water heater respects all clearances from combustible material, all venting requirements (see Table 1) and that the vent terminal will be installed as specified by all local codes or, in the absence of local codes, CAN/CSA B149.1, Natural Gas and Propane Installation Code, in Canada and/or the National Fuel Gas Code, ANSI Z223.1/NFPA 54, in the United States (see Figure 11).

According to the CAN/CSA-B149, Natural Gas and Propane Installation Code, plastic vent systems installed in Canada must be certified to the STANDARD FOR TYPE BH GAS VENTING SYSTEMS, ULC S636. Components of the certified vent system must not be interchanged with other vent systems or unlisted pipe/ fittings. Plastic components and specified primers and glues of the certified vent system must be from a single vent system manufacturer and not intermixed with other vent system manufacturer’s vent system parts unless those are certified to be used with this system. Plastic vent systems shall also be installed such that the first three (3) feet (91 cm) of pipe from the water heater outlet is readily accessible for visual inspection.

Termination screen

A restrictor screen (see Figure 9) is provided with the following Energy Star models (see Table 2). The two (2) inch (5.1 cm) restrictor screen must be installed and glued, and the wire mesh shall be removed from the vent termination elbow when total equivalent length is thirty (30) feet (9.1 m) or less of two inch vent pipe, otherwise a standard wire mesh screen shall be installed. When using three (3) inch vent pipe a standard wire mesh must be installed in all cases (see Table 3).

Figure 8

This water heater is equipped with a power venter that evacuates the products of combustion to the outdoors. All models are shipped from the factory with the power venter already installed.

This water heater must be vented directly to the outdoors, either horizontally through the wall or vertically through the roof. The venting must not be attached to an existing chimney or in common with any other appliance and must not be insulated. Only two (2) inch (5.1 cm) or three (3) inch (7.6 cm) schedule 40 PVC or CPVC pipe and fittings may be used to vent this water heater. The pipe and all the fittings must be permanently joined using the appropriate primer and solvent-based cement. Horizontal runs of vent pipe must be supported every three (3) feet (91 cm) and vertical runs of vent pipe must be supported every five (5) feet (1.5 m).

Table 1

PV1 Models only UG40, UG50 and UG60

VENT PIPE DIAMETER 2 inches 3 inches Maximum equivalent length*

Minimum equivalent length* One 45˚ elbow is equivalent, in straight pipe, to One 90˚ elbow is equivalent, in straight pipe, to

* Note: Outdoor termination elbow not to be counted when determining total length.

MAXIMUM EQUIVALENT LENGTH OF VENT PIPE - DO NOT EXCEED

50,0 feet (15,2 m)

7,5 feet (2,3 m) 3,0 feet (0,9 m) 5,0 feet (1,5 m)

140,0 feet (42,7 m)

9,5 feet (2,9 m) 4,0 feet (1,2 m) 7,0 feet (2,1 m)

Page 8

INSTALLATION INSTRUCTIONS

WARNING

Through-the-Wall Venting Installation

Cut or drill a hole through the exterior wall, slightly larger than the diameter of the vent pipe selected. The larger hole will allow for final alignment with the water heater. Extend a section of the pipe through the hole to the outside and attach the terminating elbow to the exterior end of the pipe. Connect and

Figure 9

Table 2

Natural Gas Propane Gas UG40-40LFPV1-N2U UG40-38LFPV1-P2U UG50-40LFPV1-N2U UG50-38LFPV1-P2U

UG60-40MFPV1-N2U UG60-38MFPV1-P2U

secure all piping and elbows from the power venter to the wall. Make sure that all horizontal runs have a minimum rise of Figure 8). When the installation is completed, the vent terminal must be at two (2) inches (5.1 cm) from the exterior surface of the wall (see Figure 8). Make sure that all piping is properly braced. If the venting will pass through an enclosed area, make sure to leave at least one (1) inch (2.5 cm) clearance around the piping for air circulation.

Through-the-Roof Venting Installation

Cut or drill a hole through the roof and ceiling, slightly larger than the diameter of the vent pipe selected. The larger hole will allow for the final alignment with the water heater. Construct the vent terminal assembly. Extend a section of pipe through the hole in the roof to the outside and attach the terminal assembly to the exterior end of the pipe. Connect and secure all piping and elbows from the power venter to the roof. Make sure that all horizontal runs have a minimum rise of inch per foot (21 mm/m) of run (see Figure 8).

/4 inch per foot (21 mm/m) of run (see

When the installation is completed, the vent terminal must be a minimum of eighteen (18) inches (45.7 cm) from the exterior surface of the roof (see Figure 8). Make sure that all piping is properly braced. If the venting will pass through an enclosed area, make sure to leave at least one (1) inch (2.5 cm) clearance around the piping for air circulation.

Condensation in the Venting System

In some installations, condensation will form in the horizontal runs of vent piping. To prevent condensation from flowing back into the power venter, install a condensate trap to the drain outlet of the rubber transition fitting. Make sure that the condensate removal tube flows to a suitable free-flowing drain.

CPVC Adaptor

A CPVC vent system adaptor should be installed when using PVC pipes for venting this water heater (see Figure 10). The vent system adaptor consists of a PVC coupling glued to a CPVC pipe. The CPVC pipe must be inserted into the rubber transition fitting on the outlet of the blower assembly (see Figure 10).

INSTALLATION The PVC coupling on the vent system adaptor must be

attached to the PVC vent system using the proper primer, cleaner and cement.

ALWAYS read and abide by all safety messages printed on the primer, cleaner and cement containers. Primer, cleaner and cements are extremely flammable. DO NOT store these products near heat, sparks or flames. They are harmful or fatal if swallowed. Their vapours are also harmful. They may irritate eyes and can be absorbed through the skin. Failure to follow these instructions can result in property damage, personal injury or death.

1) Adjust the vent pipe length to properly fit the vent system adaptor on the blower assembly outlet.

2) Cut pipe ends squarely, removing all burrs and dirt.

3) Dry fit the pipe/fitting to be connected to make sure they fit properly.

4) Clean the pipe/fitting with the proper primer or cleaner.

Table 3

VENT DIAMETER

2” (5.1 cm)

VENT DIAMETER

3” (7.6 cm)

TERMINATION

45˚ ELBOW

TERMINATION

45˚ ELBOW

0’ - 30’ 30’ - 50’

0’ - 30’ 30’ - 140’

Page 9

WARNING

INSTALLATION INSTRUCTIONS

WARNING

5) Apply a thin coat of cement to the fitting, avoiding puddling inside.

6) Apply a liberal coat of cement to the vent pipe, leaving no voids.

7) QUICKLY assemble parts while cement is fluid! If you wait too long, re-coat pipe/fitting.

8) Push the vent pipe completely into the PVC coupling, turning as it goes until it bottoms out.

9) Hold pipe and fitting together for 30 seconds. Then carefully clean off any excess material with a cloth. Allow connections a sufficient time to cure before disturbing.

10) Loosen the upper hose clamp on the rubber transition fitting and fully insert the CPVC pipe of the vent system adaptor (1” [2.5 cm] deep). Do not apply cement to the rubber transition fitting.

11) Tighten the upper hose clamp to ensure the vent pipe is firmly secured and gas tight.

12) Make sure that the lower hose clamp is firmly seated, secured and gas tight. Gently move the vent pipe side to side and vertically to ensure that it is securely in place and that there is no slippage.

Note: If you are using CPVC pipes for the venting system, the use of the vent system adaptor is not necessary.

When the installation is complete, visually inspect the venting system to make sure that all joints are properly connected and all instructions have been followed. Failure to properly install the venting system could result in property damage, personal injury or death.

Water Piping

Refer to Figure 11 for a typical installation. Use of this layout should provide a trouble-free installation for the life of the water heater. Before making the plumbing connections, locate the COLD water inlet and the HOT water outlet. These fittings are both 3/4” N.P.T. male thread. Make sure that the dip-tube is installed in the cold water inlet. Install a shut-off valve close to the water heater in the cold water line. It is recommended that unions be installed in the cold and hot water lines so that the water heater can be easily disconnected, if servicing is required.

When assembling the hot and cold piping, use a good food grade of pipe joint compound and ensure all fittings are tight. It is imperative that open flame is not applied to the inlet and outlet fittings, as heat will damage or destroy the plastic-lined fittings. This will

result in premature failure of the fittings, which is not covered by the warranty.

Temperature and Pressure-Relief Valve

DO NOT plug the temperature and pressurerelief valve or its discharge line. DO NOT remove the relief valve. Make sure the relief valve is properly sized for the water heater. If the relief valve continuously discharges water, call a qualified service technician to correct the problem. Failure to follow these instructions can result in property damage, personal injury or death.

Figure 10

Vent System Adaptor

Drain Outlet

Blower Assembly Outlet

Connection to a 2 inch vent system Connection to a 3 inch vent system

The blower assembly must always have the two (2) inch rubber transition fitting. A reducing coupling 2” X 3” is necessary for a three (3) inch venting system. This coupling must be installed as close as possible after the rubber transition fitting and in every case, before the first elbow.

Rubber

transition tting

Vent System Adaptor

Drain Outlet

Blower Assembly Outlet

Rubber

transition tting

Page 10

INSTALLATION INSTRUCTIONS

Figure 11

Minimum Slope

1/4”/foot (21mm/m)

1) Vent pipe

2) Power vent assembly

3) Union

4) Cold water manual shut-off valve

5) Cold water inlet

6) Expansion tank

7) Temperature and pressure-relief valve

8) Overflow tube

9) Drain valve

10) Combustion air intake holes

11) Drain pan

12) Free-flowing floor drain

13) Sight glass

14) Resettable Thermal Switch

15) Outer access door

16) Inner access door

17) Flammable vapour sensor

18) Cap

19) Drip leg (Sediment trap)

20) Gas supply manual shut-off valve

21) Union

22) Gas control valve

23) Rating plate

24) Dip-tube

25) 12’ Power cord (3,86 m)

26) Hot water outlet

27) Union

28) Flame sensor

29) Ignitor

30) Burner orifice

31) Burner

To protect from excessive pressure and/or temperature, the manufacturer has installed a temperature and pressure-relief valve that meets the requirements of the Standard for Relief Valves and Automatic Gas Shut-Off Devices for Hot Water Supply Systems, CSA 4.4, in Canada and ANSI Z21.22, in the United States. This relief valve has a maximum set pressure that does not exceed the hydrostatic working pressure of the water heater (150 psi = 1,035 kPa) and a BTU/h rating equal to or greater than the input rating, as shown on the water heater rating plate. It should never be plugged or removed from the opening marked for it on the water heater.

If this relief valve should need to be replaced, use only a new temperature and pressure-relief valve. Never install an old or existing relief valve, as it may be damaged or inadequate for the working requirements of the new water heater. This new relief valve must meet all local codes or, at a minimum, the requirements listed above. Never install any other type of valve between the relief valve and the water heater.

A discharge line must be installed into the relief valve. The discharge line:

• Mustnotbesmallerthanthe outletpipesizeofthe

relief valve.

• Must not terminate less than six (6) inches (15.2

cm) and not more than twelve (12) inches (30.5 cm) above a floor drain.

• Mustnotberestrictedinanyway.Donotthread,cap

or in any way restrict the end of this outlet.

• Mustbeofamaterialcapableofwithstanding210

(99oC) without distortion.

• Mustbeinstalledtoallowcompletedrainageofthe

relief valve and discharge line.

• Mustterminateatanadequatefree-flowingdrain.

Pressure Build-up in a Water System

When the water heater operates, the heated water expands creating a pressure build-up. This is a natural function and is one of the reasons for installing a temperature and pressure-relief valve. If the cold water

Page 11

Figure 12

INSTALLATION INSTRUCTIONS

The Vent Termination must have a :

A) Clearance above grade, veranda, porch, deck or balcony. 12 inches (30 cm) 12 inches (30 cm)

B) Clearance to window or door that may be opened.

C) Clearance to outside corner.

D) Clearance to inside corner.

E) Clearance to service regulator vent outlet.. 3 feet (91 cm) 6 feet (1,82 m)

F) Clearance to each side of center line extended above

meter/regulator assembly.

G) Clearance to non-mechanical air supply inlet to building or

the combustion air inlet to any other appliance..

H) Clearance to a mechanical air supply inlet.

I) Clearance above paved sidewalk or paved driveway

located on public property.

•

Clearance under veranda, porch, deck or balcony.**

•

Clearance to permanently closed window.* Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61 cm) from

•

the center line of the terminal.* Clearance to unventilated soffit.*

•

Canadian Installations U.S.A. Installations)

12 inches (30 cm)

* *

3 feet (91 cm) within a

height 15 feet (4.57 m)

above the meter/regulator

assembly

12 inches (30 cm)

6 feet (1.82 m)

7 feet (2.13 m) 7 feet (2.13 m)

12 inches (30 cm) Shall not

3 feet (91 cm) within a

height 15 feet (4.57 m)

above the meter/regulator

* * *

3 feet (91 cm)

assembly

* * *

* * * *

Clearance in accordance with local installation codes and the requirements of the gas supplier.

For Canadian and U.S.A. installations, the vent shall not terminate above a paved driveway that is located between two single family dwellings and serves both

dwellings.

** The veranda, porch or deck is fully open on a minimum of two sides beneath the floor.

***The vent terminal must terminate at least four (4) feet (1.22m) below, four (4) feet (1.22m) horizontally from or one (1) foot (30 cm) above any door, window

and gravity air inlet to the building.

**** The vent terminal must terminate at least three (3) feet (91cm) above any forced air inlet duct located within ten (10) feet (3.05m).

Page 12

INSTALLATION INSTRUCTIONS

WARNING

supply line has a built-in water meter, check valve or pressure-reducing valve, a suitable expansion tank must be installed to prevent pressure build-up or water hammer effect. Otherwise, the warranty is void (see Figure 11). An indication of pressure build-up is frequent discharges of water from the relief valve. If the relief valve discharges water on a continuous basis, it may indicate a malfunction of the relief valve and a qualified service technician must be called to have the system checked and the problem corrected.

Filling the Water Heater

NEVER operate the water heater unless it is completely filled with water.

this instruction can result in premature failure of the water heater that is not covered by the warranty.

Check that all of the water piping connections have been made. To fill the water heater:

1) Make sure that the water heater drain valve is closed by inserting a flat head screwdriver into the slot on the head of the drain valve and turning the knob clockwise

2) Open the cold water supply manual shut-off valve. This valve must remain open, as long as the water heater is in use. NEVER operate the water heater with the cold water supply manual shut-off valve closed.

3) To make sure the water heater is completely full of water, open all of the hot water faucets in the house to let the air out of the water heater and plumbing system. Leave the faucets open until a constant flow of water is obtained.

4) Check all of the plumbing connections to make sure there are no leaks.

Gas Connections

DO NOT attempt to use this water heater with any gas other than the type of gas shown on the water heater rating plate. Failure to follow this instruction can result in property damage, personal injury or death.

The gas piping must be installed as indicated in Figure 11. For the correct size of piping for this water heater, consult CAN/CSA B149.1, National Gas and Propane Installation Codes (in Canada) and/or the National Fuel Gas Code, ANSI Z223.1/NFPA 54,

Failure to follow

in the United States. Only new piping with cleanly cut threads may be used, together with a suitable sealing compound that is approved for natural and propane gases. It is mandatory that a readily accessible manual shut-off valve be installed in the gas supply line. The gas supply manual shut-off valve must be close to the water heater. A drip leg (sediment trap) must be installed in the gas line ahead of the gas control valve to prevent dirt from entering it. A union must be installed between the gas control valve and the gas supply manual shut-off valve for easy maintenance of the water heater.

NEVER use an open flame to test for gas leaks. A fire or explosion could occur resulting in property damage, personal injury or death.

The water heater and its gas connection must be leak tested before placing the appliance into operation. To leak test the system:

1) Turn on the manual gas shut-off valve near the water heater.

2) Use a soapy water solution to test all connections and fittings for leaks. Bubbles indicate a gas leak.

3) Correct all leaks.

Make sure that the inlet pressure to the water heater

does not exceed propane gases. Pressures in excess of can damage the gas control valve, resulting in a fire or explosion from leaking gas. For purposes of adjustment, the minimum inlet pressure is indicated on the water heater rating plate.

If any pressure testing of the gas line is undertaken at test pressures in excess of water heater and its gas supply manual shut-off valve must be disconnected from the gas supply piping system and the end of the pipe sealed with a female cap. If the testing is to be undertaken at a test pressure less than manual shut-off valve must be closed.

U.L. and CSA recognized fuel gas and Carbon Monoxide (Co) detectors are recommended in all applications and should be installed using the manufacturer’s instructions and local codes, rules or regulations.

/2 psi (3.5 kPa) for both natural and

/2 psi (3.5 kPa)

/2 psi (3.5 kPa), the

/2 psi (3.5 kPa), the gas supply

Page 13

INSTALLATION INSTRUCTIONS

Installation Instructions for Water Heaters Approved for Space Heating and Potable Water Heating (see Figure 13)

When using a water heater for space and potable water heating, the instructions provided in this manual and with the air-handling unit must be respected and, in particular, the following:

1) All piping and components that are used in the system must be of a nonferrous type suitable for potable water. This also applies to any sealant used.

2) When used as a dual purpose water heater, it must not be connected to any system that has been previously used for non-potable water heating. This includes any piping because, in all probability, existing piping would have been, in the past, treated with chemicals for cleaning or sealing the system.

3) If this water heater is to be used for space heating, make sure that all safety codes are respected. Pay special attention to safety valve pressure and expansion tanks.

4) Do not use toxic chemicals to clean the potable water heating system.

5) Where water temperature in excess of 140

C) is required for a space heating application, a

(60

mixing valve must be installed in the potable side of the system. This will temper the water and reduce the risk of scalding.

6) If the incoming water line to the heater is equipped with a check valve, water meter or pressure-reducing valve, an expansion tank must be installed in the system. This will prevent weeping from the water heater relief valve and premature failure of the heater due to expansion of the water during the heating cycle.

7) Before acquisition of a water heater for space heating application, it is necessary to have the area of intended use sized by a qualified technician. This will ensure that an adequate water heating capacity will be available for both heating and potable water supply and that the application will meet all local codes and public utility requirements.

Note: It is good practice to oversize the water heater, to ensure that all of the potential hot water requirements are available.

Figure 13

Hot water to house

Water heater

Cold water supply

to water heater

Check Valve

Circulation Pump

Air handler

Page 14

INSTALLATION INSTRUCTIONS

WARNING

Wiring

This water heater uses an external electrical source for power. It must be electrically grounded in accordance with all local codes or, in the absence of local codes, CSA C22.1 Canadian Electrical Code, in Canada and/or the National Electrical Code, ANSI/ NFPA 70, in the United States. Failure to properly ground this water heater can result in property damage, personal injury or death.

Wiring Diagram for Models UG40, UG50, UG60

Figure 14

Blower Unit

High Limit Switch

Yellow

Before lighting your water heater, check that all of the wires have been installed correctly (see Figure 14). Make sure that none of the wires are grounded, have split or are broken. Verify that all wiring connections are properly secured, as there is a possibility that they have become loose during transportation. If any of the original wiring needs replacing, use only 18AWGtype or greater wire that is approved for 221oF (105oC).

High Limit Switch

(Access Door)

Gas Control

Vacuum Switch (N.O.)

Blue White

Green Black

Red

Yellow

Black White Green

Power Cord

Red

Yellow

Blue

White

Black Green

Hot Surface Igniter

Flame Sensor

Flammable Vapor Sensor

Page 15

INSTALLATION INSTRUCTIONS

Installation Checklist

Location

 • Isthewaterheaterlocatedwithintheventingrequirementsandclosetothemainuseofhotwater? ......

 • Isthewaterheaterprotectedfromfreezingtemperatures? .......................................L

 • Hasadrainpanbeeninstalledandpipedtoafree-flowingdrain?.................................L

 • Isthegascontrolvalveaccessibleforservicing? ..............................................L

 • Haveclearancesfromcombustiblematerialsbeenobserved? ....................................L

Combustion and Ventilation Air Supply

 • Istheareaaroundthewaterheatercleanandproperlyventilated? ................................

 • Isthefreshairsupplyfreeofcorrosiveelementsandflammablevapours? ..........................L

 • Doesthewaterheaterhaveaccesstoenoughfreshcombustionair? ..............................L

 • Havethefreshairopeningsbeensizedcorrectlyand

 hasconsiderationbeengiventotheblockingeffectoflouversandgrilles? ..........................

Venting

 •Isthefluebaffleinstalledinthefluetube?....................................................

 •Hasthewaterheaterbeenventedseparatelyfromallotherappliances?............................L

 •HaveonlyPVCorCPVCpipeandfittingsbeenusedtoassembletheventpiping? ...................L

 •Haveallhorizontalrunsofventpipebeeninstalledwithaminimumriseof

/4inchperfoot(21mm/m)ofrun? .........................................................L

 •Hasalltheventpipingbeensecuredwiththeappropriateprimerandsolvent-basedcement? ...........L

 •Hastheventingbeensupportedattheproperintervals? ........................................L

 •Haveprecautionsbeentakenagainstcondensationflowingintothepowerventer? ...................L

Water Piping

 •Isthedip-tubeinstalledinthecoldwaterinlet? ................................................

 •Hasatemperatureandpressure-reliefvalvebeeninstalled? .....................................L

 •Doesthisvalvehaveadischargelineinstalledandisitpipedtoafree-flowingdrain? .................L

 •Havealltheplumbingconnectionsbeenproperlyinstalledandaretheyleak-free?....................L

 •Isthewaterheaterfullofwater? ...........................................................L

Gas Connections

 •Isthegassuppliedtothewaterheaterthesametypeasindicatedonthewaterheaterratingplate? .....

 •Hasthegaslinebeeninstalledwithamanualshut-offvalve,unionanddripleg? .....................L

 •Isthegaspipinglargeenoughandmadeofanapprovedmaterial?................................L

 •Haveallconnectionsbeenmadewithanapprovedjointcompound?...............................L

 •Hasthegaspipingbeentestedforleakswithasoapandwatersolution?...........................L

Wiring

 •Hasthewiringbeenproperlyinstalled? ......................................................

 •Havetheelectricalconnectionsbeencheckedandaretheysecure?...............................L

 •Isthewaterheaterelectricallygrounded? ....................................................L

 •Doesthe120Vwallreceptaclehavetheproperpolarity? ........................................L

Page 16

WARNING

OPERATING INSTRUCTIONS

Lighting the Water Heater

Before lighting or re-lighting your water heater, make sure that you have read and understood all of the instructions and warnings in this manual and on your water heater. If you

have any questions about lighting your water heater, immediately contact a qualified installer, service agency or the gas supplier.

Lighting Instructions

DO NOT light this water heater if:

• Itisnotfullofwater.

• The gas supplied does not match the type

listed on the rating plate.

• Gasoline or other flammable vapours and liquids have been stored in the vicinity of the water heater.

Failure to follow these instructions can result in property damage, personal injury or death.

Page 17

OPERATING INSTRUCTIONS

CLIGNOTANT

TEMPÉRATURE

APPROXIMATIVE

˚F (˚C)

70 (21)

(Vacances)

110 (43)

115 (46)

120 (49)

125 (52)

130 (54)

135 (57)

140 (60)

145 (63)

150 (66)

160 (71)

TEMPS

NÉCESSAIRE POUR CAUSER UNE BRÛLURE

S/O

5 minutes

30 secondes

5 secondes

1,5 seconde

moins d'une

seconde

AFFICHAGE

WARNING

Water Temperature Regulation

The higher the setting, the greater the risk of scalding. Hot water can cause third degree burns

in under one (1) second at 160

F (71oC), in five (5) seconds at 140oF (60oC) and in thirty (30) seconds at 130oF (54oC). In households where there are children, physically challenged individuals or elderly persons, mixing valves for point of use are necessary as means of reducing the scalding potential of hot water.

The gas control valve is factory-adjusted to its lowest temperature, approximately 70

F (21oC). When the water heater is plugged in for the first time, the gas control valve will start to heat the water to this temperature. To avoid any unintentional changes in the water temperature settings, the gas control valve has a tamper resistant feature included for changing the temperature setting. If you want to change this setting for either cooler or warmer water, the following steps are necessary:

2. If this is the first time that the control has been used, the leftmost green indicator will be illuminated, indicating the water temperature setting of approximately 70°F (21°C). If the control has been in operation for some time, the water temperature setting may indicate a diffe rent temperature. See Figure 15 for an explanation of what each of the temperature indicators mean.

To decrease the temperature, press and release

the COOLER button once. The temperature indicators will now display the new temperature setting. Press and release the COOLER button until you have reached the desired setting.

HOLDING DOWN THE BUTTON WILL NOT CONTINUE TO LOWER THE SETTING. The

button must be pressed and released for each temperature change desired.

Figure 15

DISPLAY

FLASHING

1) “Wake up” the temperature indicators by holding down both the COOLER and HOTTER temperature adjustment buttons at the same time for one second (see Lighting Instructions). One or two of the temperature indicators will light up. These indicators will only remain on for 30 seconds, if no further buttons are pressed. After 30 seconds, the control will go back to “Sleep” mode and both buttons will again have to be pressed to see the water temperature setting. Release both of the temperature adjustment buttons.

APPROXIMATE

TEMPERATURE

˚F (˚C)

70 (21)

(Vacation)

110 (43)

115 (46)

120 (49)

125 (52)

130 (54)

135 (57)

140 (60)

145 (63)

150 (66)

160 (71)

APPROXIMATE

TIME TO

CAUSE INJURY

N/A

5 Minutes

30 Seconds

5 Seconds

1.5 Seconds

Under 1 Second

To increase the temperature, press and release

the HOTTER button once. The temperature indicators will now display the new temperature setting. Press and release the HOTTER button until you have reached the desired setting.

HOLDING DOWN THE BUTTON WILL NOT CONTINUE TO RAISE THE SETTING. The

button must be pressed and released for each temperature change desired.

To maximize the efficiency of this water heater and

reduce the risk of scalding, it is recommended that the gas control valve be set at the setting below the large triangle

(«m»)

, which represents approximately

120°F (49°C).

3. When you have completed setting the control, wait 30 seconds to see that the temperature indicators go off and the control enters “Sleep” mode. ALL OF THE TEMPERATURE

INDICATORS WILL BE OFF DURING NORMAL OPERATION. If at any time you see the indicators

on, there may be a system error and you should consult the Troubleshooting Guide of this document or contact a trained service professional.

When hot water is drawn from the tank in frequent short bursts, a condition known as “stacking” is created. “Stacking” is the result of increased cycling of the burner and can produce very hot water temperatures at the hot water outlet. Always remember to check the hot water coming out of any faucet with your hand before use. This will reduce the risk of scalding-related injury.

Page 18

WARNING

GENERAL MAINTENANCE

The gas control valve pictured in this manual is equipped with a single-use type automatic high temperature cutoff. Should the temperature of the water exceed 193 cutoff will automatically shut off the gas supply to the water heater. If this situation occurs, the gas control valve must be replaced immediately by a qualified service technician.

Should overheating occur or the gas supply fail to shut off, close the gas supply manual shut-off valve. Failure to follow this instruction can result in property damage, personal injury or death.

Out of Fuel

If your water heater should run out of gas, proceed as follows:

1) Unplug the power cord from the wall socket.

2) Close the gas supply manual shut-off valve.

3) Once the gas supply has been re-established, proceed to the Lighting Instructions.

Housekeeping

Keep the area around the water heater clean and free of dust, lint and dirt. Verify the combustion air intake holes, at the bottom of the water heater, at least once every six (6) months and vacuum up any dirt, as required. Make sure that all of the minimum clearances to combustible materials are being maintained.

DO NOT store or use gasoline or other flammable vapours and liquids around the water heater. DO NOT block or, in any way, restrict the flow of fresh air through the combustion air intake holes at the bottom of the water heater. DO NOT put or store any objects on the top of the water heater.

Failure to follow these instructions can result in property damage, personal injury or death.

Safety System

This water heater is equipped with a safety system that will shut it down in the event of a flammable vapour incident. It is a safety feature that may prevent property damage, personal injury or death.

The safety system is comprised of two parts, a flammable vapour (FV) sensor and the flame arrestor. The FV sensor is located on the front left bottom of the exterior casing of the water heater. The FV sensor is protected from shock and contaminants by a robust plastic cover. The function of the FV sensor is to detect the presence of flammable vapours before

F (90oC), the high temperature

they enter the combustion chamber and ignite. If the FV sensor detects the presence of flammable vapours while the water heater is operating, the gas control will switch to lock out mode and the water heater will shut down. If the water heater is not operating when the flammable vapours are detected, the control will switch to lock out mode and prevent the water heater from lighting.

It is unlikely that there will ever be a flammable vapour ignition in the combustion chamber as the flammable vapours will have been detected by the FV sensor. However, if flammable vapours manage to enter the combustion chamber during main burner operation and ignite, the flame arrestor technology will prevent ignition of the vapours outside the combustion chamber.

After a flammable vapour incident has occurred and the flammable vapours have dissipated, the FV sensor is designed to automatically reset itself. The Intelli-Vent gas control, however, will have gone into lock out mode and will need to be manually reset. A qualified service technician must be called to determine if flammable vapours entered the combustion chamber and ignited. In most instances, there will not have been ignition of flammable vapours inside the combustion chamber because the FV sensor will have detected these vapours and shut down the water heater. In this case, the Intelli-Vent control can be reset and the water heater may resume normal operation. On the other hand, if the flammable vapours ignited inside the combustion chamber, the water heater may need to be replaced. The technician will be able to determine whether or not the water heater needs to be replaced based on the amount of flammable vapours that entered the combustion chamber and the damage to the water heater from the resulting fire.

Condensation

As moisture from the products of combustion comes into contact with the cold surface of the inner tank, it may condense. This situation will usually occur:

1) When the water heater is filled with cold water for the first time.

2) If the water heater has been undersized.

3) When large amounts of hot water are drawn from the water heater in a short period of time and the refill water is very cold.

Due to the high-efficiency rating of this gas-fired water heater, it may produce more condensation than older models. Condensation forming on the flue tube will drop on the burner making a “sizzling” sound. This condition is not uncommon and must never be misinterpreted as a leaking tank. It will disappear once the water becomes heated.

gas

Page 19

GENERAL MAINTENANCE

WARNING

Because of the large amounts of water that can condense, it is very important that a drain pan be installed under the water heater (refer to Figure

11). Under no circumstances is the manufacturer to be held liable for any water damage, in connection with this water heater. If the problem

does not go away and water continues to drip after the water heater has heated up, check all of the plumbing connections to make sure they are not leaking.

Burner Ignitor Assembly

Every three (3) months, check the burner and ignitor assembly. Remove the outer access door and look through the sight glass to examine the flames. A soft blue flame indicates proper gas combustion. A yellow tipped flame indicates poor combustion. With a vacuum cleaner, remove any dust, lint and dirt accumulation on or around the combustion chamber and in the combustion air intake holes.

Water Heater Tank

Drain a pail of water through the drain valve at least once a year. This will remove excess sediment from the bottom of the tank. This sediment, if allowed to

accumulate, will reduce the efficiency and the life of

the tank.

can be obtained from the manufacturer.

The life expectancy of the water heater is reduced where a water softener is introduced to fight hard water, because the sodium salts added by a softener make this water extremely conductive. In these conditions, the anode is consumed more rapidly and should be verified every year.

In certain water conditions, the anode will react with the water, producing discoloured or smelly water. The most common complaint is hot water that smells like rotten eggs. This phenomenon is the result of the reaction between the anode and hydrogen sulfide gas dissolved in the water, which occurs frequently in well systems. This problem can usually be eliminated or reduced by changing the anode to a type more suitable for these conditions (aluminum anode) and by chlorinating the water heater and plumbing system. If the problem persists, special filtration equipment may be required. Under no circumstances is the anode to be removed from the water heater on a permanent basis. Removal of the anode will lead

to premature failure of the water heater and void the warranty.

Temperature and Pressure-Relief Valve

Manually operate the temperature and pressure-relief valve at least once a year, standing clear of the outlet to avoid being burned. Lift and release the operating lever on the valve to make it operate freely. If, after manually operating the valve, it fails to completely reset itself and continues to discharge water, replace it with a new one.

Venting System Inspection

The venting system must be thoroughly inspected once a year. Check the area where the water heater is located to make sure that there is enough clean combustion and ventilation air. Remove any possible obstructions that would prevent proper air circulation and venting. Check the venting system to make sure that all of the connections are securely fastened and that all of the joints are properly sealed. If any part of the venting system is damaged, it must be replaced by a qualified service technician.

Anode

This water heater is equipped with an anode that is designed to prolong the life of the glass-lined tank. The anode is slowly consumed, protecting the glass-lined tank from corrosion. The anode should be checked every two (2) years. If more than half of the anode has been consumed, it should be replaced. Instructions on how to change the anode

Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally two [2] weeks or more). HYDROGEN GAS IS EXTREMELY FLAMMABLE. It is highly recommended to open the hot water faucet in the kitchen for several minutes before you use any electrical appliances connected to the hot water system, such as a dishwasher or washing machine. If hydrogen gas is present, there will be an unusual sound, such as air escaping through the pipe, as the hot water faucet is opened. DO NOT smoke or introduce an open flame near the faucet when it is opened.

Draining the Water Heater

To completely drain the water heater:

1) Unplug the power cord from the wall socket.

2) Close the gas supply manual shut-off valve.

3) Close the cold water supply manual shut-off valve.

4) Connect one end of a garden hose to the water heater drain valve and put the other next to a freeflowing drain.

5) Open the drain valve by inserting a flat head screwdriver into the slot on the head of the drain valve and turning the knob counterclockwise .

6) Open a hot water faucet to allow air into the system.

Page 20

GENERAL MAINTENANCE

Vacation

If you are planning a vacation or other prolonged absence, it is highly recommended to shut off the gas supply and the cold water supply to the water heater. This will save energy, protect against property damage in the event the water heater leaks and prevent the build-up of hydrogen gas. If the water heater and piping are exposed to freezing temperatures, they should both be drained.

Remember to check the water heater thoroughly after it has been shut off for an extended period of time before putting it back in operation. Make sure that the water heater is completely full of water and that the cold water supply manual shut-off valve is open, before lighting the burner.

Getting Service for your Water Heater

If you are experiencing problems with your water heater, follow these three easy steps:

1) Consult the Troubleshooting Guide contained in this manual (see Page 22). It lists the most common problems experienced with your gas-fired water heater. The solutions you find listed may provide a quick and simple solution to your problem and save you time and money.

2) If the solution listed in the Troubleshooting Guide does not solve the problem or if your particular problem is not listed in the guide, contact the installer of the water heater or the local gas utility.

3) If you still cannot solve the problem, contact the manufacturer’s Customer Service Department by e-mail at gemco@gemcoinc.com or by phone at 1-800-363-9354. To help serve you in a quick and efficient manner, always have the

following information ready:

a) Model number. b) Serial number. c) Date of installation. d) Where the water heater was purchased. e) Complete address where the water heater is installed. f) A description of the problem.

Page 21

Complete blower assembly for model UG50-65(-59)

REPLACEMENT PARTS

Complete blower assembly for PV1 model UG40/UG50/UG60

ID No. Description

1 Gas control valve 2 Flammable vapour sensor 3 Protective Cover 4 Ignitor assembly 5 Complete burner assembly 6 Inner access door kit 7 Outer access door 8 Resettable thermal switch 9 Drain valve 10 Overflow tube 11 Dip-tube 12 Magnesium anode 13 Temperature & pressure-relief valve 14 Flue baffle 15 Complete blower assembly 16 High limit switch 17 Rubber transition fitting 18 Vacuum switch 19 Plastic-lined di-electric galvanized nipple

Complete

burner assembly

Page 22

TROUBLESHOOTING GUIDE

WARNING

Disconnect the electrical power before servicing the water heater. Service should only be performed by a qualified service technician. Failure to follow these instructions can result in personal injury or death.

CONDITION (code#) CAUSE REMEDY

An open earth ground circuit to the igni-

tion.

A wiring error or a high resistance to earth

ground.

1) Check that the earth ground conductor is properly connected at the fuse box or breaker panel and the water heater.

2) Check that the grounding conductors on the water heater are properly connected and secure.

1) Check for proper connection of the line neutral and line hot wires.

2) Check that the water heater is securely connected to earth ground.

The pressure switch remained closed

longer than 5 seconds after the call for heat began.

The pressure switch remained open

longer than 5 seconds after the power venter was energized.

(see note at the bottom of the page)

The self diagnostic test has detected an

error in the hot surface ignitor circuit..

The maximum number of ignition retries

or recycles has been reached and the system is in lockout .

The gas valve driver circuit. 1) Turn off the power to the water heater for 10 seconds and then back on.

The internal microcomputer. 1) Turn off the power to the water heater for 10 seconds and then back on.

The internal circuit.. 1) Turn off the power to the water heater for 10 seconds and then back on

Flame signal sensed out of proper

sequence.

1) The pressure switch wiring is incorrect.

2) The pressure switch is defective and must be replaced.

1) The pressure switch wiring is incorrect.

2) The pressure switch tubing is not connected correctly.

3) There are obstructions or restrictions in the water heater air intake or exhaust flue.

1) Check the wiring is correct and secure.

2) Disconnect the ignitor connector and measure the ignitor resistance with an accurate ohmmeter between pins 1 and 2. Resistance should be between 11.5 and 18.8 ohms. If the reading is incorrect, replace the hot surface ignitor.

3) If the above checks are good, replace the gas control valve.

1) Check if the gas supply is off or too low to operate.

2) Check the flame sensor rod to see that it is located properly and free from contamination. Reposition the flame sensor rod or lightly clean it with an abrasive cloth.

3) The hot surface ignitor may not be positioned correctly. Reposition as necessary.

4) Check that the hot surface ignitor and flame sensor rod are wired correctly and in good working condition.

5) Low voltage to the water heater. Check and repair.

2) If the above step did not clear the error, replace the gas control valve.

1) Replace the gas control valve..

The high temperature thermal cut-off is

open.

One of the temperature adjust buttons is

stuck closed.

The water temperature sensor is either

open or short-circuited.

The self-diagnostic test found a problem

with the flammable vapour sensor.

The control detected the presence of

flammable vapours near the appliance and entered lockout.

Note: Since the high limit switch on the blower is in series with the pressure switch, the problem could be that the high limit switch tripped.

1) Replace the gas control valve..

1) Make sure that there are no objects leaning against the front of the control.

2) Lightly press and release each of the buttons once.

3) If the above actions do not clear the error, the control will continue to regulate the water temperature at the last setting, but you will not be able to change settings unless you replace the gas control valve.

1) Check that all of the wiring is correct and that there are no open or shorted circuits.

2) If no wiring problems are found, the gas control valve must be replaced.

1) Check that all wiring is correct and that there are no open or shorted circuits.

2) If no wiring problems are found, the flammable vapour sensor must be replaced.

1) Identify the source of the flammable vapours and remove it from the area surrounding the water heater

2) Contact a qualified service technician or the gas supplier to have the water heater inspected immediately.

Page 23

TROUBLESHOOTING GUIDE

CONDITION CAUSE REMEDY

The burner will not ignite. No gas. Check with gas utility company.

Dirt in gas line. Notify utility company. Install drip leg in gas line.

Combustion air intake holes blocked. With a vacuum cleaner, remove dirt, dust and lint.

Main burner line clogged. Clean. Check for source of trouble and correct.

Defective flame sensor. Replace with new flame sensor.

Defective gas control valve. Replace with new gas control valve.

Gas control valve set too low. Turn temperature dial to desired temperature.

Heater installed in a confined area. Provide fresh air ventilation.

The burner flame floats and lifts off ports.

Vacuum switch located in the blower assembly remain open.

The burner flame is yellow and lazy.

The burner flame is too high. Insufficient secondary air. Provide fresh air ventilation.

The flame burns at the orifice.Low gas pressure. Check with gas utility company.

High operating costs. Gas control valve set too high. Turn temperature dial to desired temperature.

Insufficient hot water. Low gas pressure. Check with gas utility company.

Slow hot water recovery. Insufficient secondary air. Provide fresh air ventilation.

High gas pressure. Check with gas utility company. Orifice too large. Replace with correct orifice. Flue clogged. Clean. Check for source of trouble and correct. Combustion air intake holes blocked. With a vacuum cleaner, remove dirt, dust and lint. Heater installed in a confined area. Provide fresh air ventilation. Cold drafts (downdraft). Locate source and correct. One of the potential causes is excessive

dirt, dust and other debris accumulation on the flame arrestor and on the blower impeller.

Insufficient secondary air. Provide fresh air ventilation. Flue clogged. Clean. Check for source of trouble and correct. Combustion air intake holes blocked. With a vacuum cleaner, remove dirt, dust and lint. Main burner line clogged. Clean. Check for source of trouble and correct. Heater installed in a confined area. Provide fresh air ventilation.

Orifice too large. Replace with correct orifice. Defective gas control valve. Replace with new gas control valve.

Defective gas control valve. Replace with new gas control valve.

Sediment or lime in tank. Drain. Check to see if water treatment is necessary. Water heater is undersized. Install size of water heater that meets demand. Wrong piping connections. Correct piping, dip tube must be in cold inlet. Leaking faucets. Repair faucets. Gas leaks. Check with gas utility company. Repair at once. Wasted hot water. Advise consumer. Long runs or exposed piping. Insulate piping. Hot water piping on outside wall. Insulate piping.

Wrong piping connections. Correct piping, dip tube must be in cold inlet. Sediment or lime in tank. Drain. Check to see if water treatment is necessary. Water heater is undersized. Install the size of water heater that meets the demand. Gas control valve set too low. Turn temperature knob to desired temperature. Leaking faucets. Repair faucets. Wasted hot water. Advise consumer. Long runs or exposed piping. Insulate piping. Hot water piping on outside wall. Insulate piping.

Low gas pressure. Check with gas utility company. Gas control valve set too low. Turn temperature dial to desired temperature. Improper calibration. Replace gas control valve. Flue clogged. Clean. Check for source of trouble and correct. Water heater is undersized. Install size of water heater that meets demand. Wrong piping connection. Correct piping, dip tube must be in cold inlet. Wasted hot water. Advise consumer.

Clean the flame arrestor in the combustion chamber using a stiff brush, compressed air and/or a vacuum cleaner. In no circumstances, the blower assembly should be removed for cleaning or replaced without contacting the manufacturer.

Page 24

TROUBLESHOOTING GUIDE

CONDITION CAUSE REMEDY

Leaking water. Poorly sealed, hot or cold water connec-

tions, gas control valve threads, relief valve or drain valve.

Leakage from plumbing system or other appliances.

Condensation. Refer to Condensation.

Water drips from the relief valve.

The gas control valve fails to shut-off.

Condensation. Water heater filled for the first time. Let water heater warm up. Problem should go away. If it

Combustion odours. Insufficient secondary air. Provide fresh air ventilation.

Smoking and carbon formation (sooting).

Smelly water. High sulfate or mineral content in water. Change magnesium anode to an aluminum anode and

The access door temperature high limit switch is tripping.

Heater stacking. Lower gas control valve setting. Excessive water pressure. Install a pressure-reducing valve. Thermal expansion in a closed water sys-

tem. Improperly seated valve. Check relief valve works properly and replace, if neces-

Defective gas control valve. Replace with new gas control valve. Improper calibration. Replace gas control valve.

Heavy draws of hot water with Let water heater warm up. Problem should go away. very cold refill water. If it persists, check all plumbing connections for leaks. Water heater is undersized. Install size of water heater that meets demand.

Heater installed in a confined area. Provide fresh air ventilation.

Flue clogged. Clean. Check for source of trouble and correct. Insufficient secondary air. Provide fresh air ventilation. Low gas pressure. Check with gas utility company. Burner flame yellow, lazy. Refer to The burner flame is yellow and lazy. Flue clogged. Clean. Check for source of trouble and correct. Defective gas control valve. Replace with new gas control valve. Heater installed in a confined area. Provide fresh air ventilation.

Not enough draft from the venting system.

Not enough fresh air for the combustion. Supply make-up air. Refer to installation instructions pro-

Ambiant air temperature is too high. Reduce ambiant air temperature. Excessive dirt, dust or other debris accu-

mulation on the flame arrestor.

Tighten threaded connections.

Inspect plumbing system and other appliances.

Install an expansion tank.

sary.

persists, check all plumbing connections for leaks.

bleach tank. Check for any obstruction in the chimney. Ensure that the

chimney is sized and installed according to installation instructions provided in this manual.

vided in this manual.

Clean the flame arrestor in the combustion chamber using a stiff brush, compressed air and/or a vacuum cleaner.

Page 25

NOTES : _________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________

Page 26

turer from whom they purchased the heater. If this procedure cannot

be followed, contact any other local contractor, wholesaler or retailer

handling our water heaters. Also, for warranty information you may

call the manufacturer’s customer service department at (514) 645-

8893 or 1-800-363-9354, option 1. We suggest that prior to calling

the factory, that you make sure to have the model number and serial

number that is to be found on the outside casing of the heater. Proof

of purchase showing the date, name and place of the business from

whom the water heater was purchased is essential to settle any

warranty claim dispute over the length of the period of installation.

If an exact replacement is not available, a current model water

heater or component part with comparable operating features will be

provided by the manufacturer. If government regulations or industry

standards require the replacement model water heater or compo-

nent part to have features not found on the defective model water

heater or component part, you will be charged the difference in price

associated with these required features. If you pay the difference in

price for these required features, you will receive a complete new

Standard Basic Limited Warranty for the replacement water heater.

MISCELLANEOUS

No one is authorized to make any other warranties on the manu-

facturer’s behalf. Any implied warranties of any nature offered

by a third party other than what is stated in this Standard Basic

March 2011

Limited Warranty will not be honoured. No claims for incidental or

consequential damages (including damages from leakage) will be

accepted. If you do not return the warranty card, a proof of purchase

showing the name, date and location of the original source of pur-

chase is a necessity to process a warranty claim. Failure to produce

this documentation will result in the lesser or the warranty periods

being offered. In order to avoid any confusion and/or disputes, we

suggest that the warranty card be completed and mailed back no

later than forty-five (45) days after installation.

EXTENDED WARRANTIES

For information on some premium quality residential gas and electric

water heaters, contact your local licensed plumber or look for them

at selected retailers.

ON RESIDENTIAL GAS WATER HEATERS

ing in dry firing of the heating elements.

junction with any other energy saving device or other source(s)

of energy not approved by the manufacturer; or for other than

use with potable water without any additives such as salt, chlo-

To any damage or failure caused by operating the heater with an

empty or partially empty inner tank or sediment build-up result

To any damage or failure caused by utilizing the heater in con

rine or chemicals other than those added for the purpose of

all times. All anodes must be checked at least once every two

rendering the water fit to drink.

years and replaced, if necessary

To any damage or failure caused by the removal of the anode

and/or by not assuring that there is a working anode in the tank

any damage caused by not having the water heater installed

the heater is operated at water temperatures exceeding the

adjacent to a free flowing drain in the event of water leakage.

maximum setting of the operating and/or high limit control or the

heater is not supplied with potable water, free to circulate at all

To any damages or failure caused by having affixed to the

heater any non-factory made or factory approved replacement

part(s) such as elements, controls, dip-tubes, relief valves, etc.

times.

10)

STANDARD BASIC LIMITED WARRANTY

GENERAL

The manufacturer warrants that, subject to verification of a warranty

claim within the warranty period as described below, it will take the

necessary corrective action to either repair or replace a water heater

or component part which is determined to be defective in material

or workmanship subject to the terms and conditions outlined in this

document. Further, any replacement water heater or component part

supplied under warranty will carry only the unexpired portion of the

original water heater’s warranty. The number of replacement water

heaters is limited to one (1) per original unit purchased. If due to

some extremely unusual circumstance, a replacement water heater

or component part is found by our inspection and testing department

to be defective, another heater or component part will be supplied to

fulfill the obligation of the warranty of the original heater.

THE INNER TANK

If the inner tank fails within *SIX (6) years after the date of the

original installation, a replacement water heater will be provided to

the party from whom the unit was originally purchased. If the water

heater is installed in other than a single family dwelling, the tank

warranty is limited to ONE (1) year. If an exact replacement is not

available, the manufacturer reserves the right to furnish a compa-

rable model water heater; however, a surcharge will be applied for

If the heater has experienced the effect of thermal expansion

due to excessive pressure (exceeding 300PSI). The result of

excessive pressure usually reverses the bottom of the inner tank

and can occur with the addition of a pressure reducing valve

and/or a check valve in the municipal water supply system in a

single family dwelling.

If the heater is installed outside of Canada or the United States.

SERVICE LABOUR RESPONSIBILITY

This warranty does not cover any labour expense for service,

removal or re-installation of a replacement heater. All such expenses

are your responsibility.

SHIPPING COSTS

If a water heater or component part is deemed to be replaced, the

manufacturer will pay the transportation costs of the replacement

unit to a convenient authorized distributor or retailer as selected by

us. You must pay any local cartage including the cost of returning

the replaced item to the authorized distributor or retailer from whom

the replacement is coming from.

HOW TO MAKE A CLAIM

Any claim for warranty service should be made to your contractor,

11)

any additional component(s) incorporated in the replacement water

heater. The warranty reply card must be completed and sent back to

the manufacturer within forty-five (45) days of the installation date. If

12)

ed instructions.

as well as any applicable national or local building codes.

install, operate or maintain the unit in accordance with the print-

said warranty card is not returned, the date indicated on the model

serial plate will prevail.

COMPONENT PARTS

If any component part is found to be defective within ONE (1) year

from the date of original installation, provided said defective part is

an in-house factory made piece or an original factory approved OEM

piece, the manufacturer will furnish a replacement part after the

receipt and testing of the part claimed to be defective.

THIS WARRANTY WILL NOT APPLY

1) To defects or malfunctions resulting from failure to properly

2) If the installation does not conform to CSA and/or ETL Standards

3) To any damage or failure caused by abuse, accident, fire, floods,

wholesaler or retailer from whom the water heater was purchased. In

an approved pressure and temperature relief valve having been

installed.

freezing or other acts of God.

4) To any damage or failure caused by operating the heater without

turn, said contractor, wholesaler or retailer will contact the manufac-

Giant PV1, UG40-40LFPV1-N2U, UG40-38LFPV1-P2U, UG50-40LFPV1-N2U, UG50-38LFPV1-P2U Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual