John Wood SERIES 100 User Manual
MODELS (A)JWSH100150 THRU (A)JWSH100250
SERIES 100 AND 101
COMMERCIAL GAS WATER HEATER
GAS-FIRED POWER BURNER
FOR DOMESTIC HOT WATER
• INSTALLATION • OPERATION • SERVICE • MAINTENANCE • LIMITED WARRANTY
WARNING: If the information in these
instructions is not followed exactly, a re
or explosion may result causing property
damage, personal injury or death.
– Do not store or use gasoline or other
ammable vapors and liquids in the
vicinity of this or any other appliance.
– WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch;
do not use any phone in your
building.
• Immediately call your gas supplier
from a neighbor's phone. Follow the
gas supplier's instructions.
• If you cannot reach your gas supplier,
call the re department.
– Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
CAUTION
TEXT PRINTED OR UNDERLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY. PLEASE
READ THOROUGHLY BEFORE INSTALLING AND USING
THIS APPLIANCE.
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND
NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED 0809 316792-000
1
599 Hill Street West
Fergus, ON Canada N1M 2X1
MODELS (A)JWSH100150 THRU (A)JWSH100250 ROUGH-IN-DIMENSIONS
GAS VALVE PIPING
(A)JWSH100150, (A)JWSH100199, &
(A)JWSH100250
3/4" NPT
Table 1. RECOVERY CAPACITIES - NATURAL GAS / L.P.
Model
(A)JWSH100150 150,000 nat/lp 100 576 432 345 288 247 216 192 173 157 144 133 123
(A)JWSH100199 199,900 nat/lp 100 767 575 460 384 329 288 256 230 209 192 177 164
(A)JWSH100250 250,000 nat/lp 100 960 720 576 480 411 360 320 288 262 240 221 206
Model
(A)JWSH100150 44 nat/lp 379 2179 1635 1308 1090 934 817 726 654 594 545 503 467
(A)JWSH100199 58 nat/lp 379 2904 2178 1743 1452 1245 1089 968 871 792 726 670 622
(A)JWSH100250 73 nat/lp 379 3632 2724 2179 1816 1557 1362 1211 1090 991 908 838 778
Recovery capacities are based on 95% thermal efciency.
Input
BTU/Hr.
Gas
kW-Hr
Usage
Liter
Usage
Gas
Approx.
Gallon
Capacity
Approx.
Capacity
30 40 50 60 70 80 90 100 110 120 130 140
17 22 28 33 39 44 50 56 61 67 72 78
TEMPERATURE RISE - DEGREES F - GALLONS PER HOUR
TEMPERATURE RISE - DEGREES C - LITERS PER HOUR
FOREWORD
These designs comply with the current version of the Standard for Gas Water
Heaters, Volume III, ANSI Z21.10.3 / CSA 4.3 as automatic circulating tank water
heaters, and automatic storage water heaters.
Detailed installation diagrams are found in this manual. These diagrams will
serve to provide the installer with a reference for the materials and methods
of piping necessary. It is highly essential that all water, gas piping and wiring
be installed as shown on the diagrams.
Particular attention should be given to the installation of thermometers at the
locations indicated on the diagrams as these are necessary for checking the
proper functioning of the heater.
In addition to these instructions, the equipment shall be installed in
accordance with those installation regulations in force in the local area
where the installation is to be made. These shall be carefully followed
in all cases. Authorities having jurisdiction should be consulted before
installations are made.
In the absence of local codes, the installation must comply with the current
editions of the CAN/CSA-B149.1, the Natural Gas and Propane Installation
Code and CSA C22.1, the Canadian Electrical Code. All documents are
available from the Canadian Standards Association, 5060 Spectrum Way,
Mississauga, Ontario, Canada, L.
2
PAGE
ROUGH-IN DIMENSIONS ................................................................. 2
FOREWORD ..................................................................................... 2
FEATURES ........................................................................................ 3,4
Water Temperature Control ........................................................... 3
High Limit Switch (E.C.O.) ............................................................ 4
Dishwashing Machine Requirement .............................................. 4
Circulating Pump ........................................................................... 5
INSTALLATION INSTRUCTIONS ..................................................... 4
Required Ability ............................................................................. 4
Insulation Blankets ........................................................................ 4
Locating The Heater ...................................................................... 5
Clearances .................................................................................... 5
Hard Water .................................................................................... 6
Air Requirements .......................................................................... 6
Mechanical Exhausting of Room Air ............................................. 6
Unconned Space ......................................................................... 6
Conned Space ............................................................................. 6
Chemical Vapor Corrosion ............................................................ 6
Venting .......................................................................................... 6
Vent Pipe Termination ................................................................... 6
Installation Requirements for the
Direct Venting ................................................................................ 8
Direct Vent Terminal Installation (Sidewall) ................................... 8
Vertical Vent Terminal Installation ................................................. 9
Installation Sequence .................................................................... 9
Installation of Vent System ............................................................ 10
Vent Pipe Preparation ................................................................... 10
CONTROL AND SWITCHES ............................................................. 11
Blower Prover Switch .................................................................... 11
Blocked Outlet Prover Switch ........................................................ 11
Blocked Inlet Prover Switch .......................................................... 11
Low Gas Pressure Switch ............................................................. 11
On/Off Switch ................................................................................ 11
Hot Surface Igniter ........................................................................ 11
GAS PIPING ...................................................................................... 11
Connection of Gas Pipe ................................................................ 12
Purging .......................................................................................... 13
Gas Meter Size - City Gases Only ................................................ 13
Gas Pressure Regulation .............................................................. 13
Gas Valves .................................................................................... 13
SYSTEM CONNECTIONS ................................................................ 13
TABLE OF CONTENTS
PAGE
Thermometers ............................................................................... 13
Relief Valve ................................................................................... 13
Water Line Connections ............................................................... 13
Heater Wiring ............................................................................... 14
USING THE ELECTRONIC CONTROLLER .................................... 15
Overview ...................................................................................... 15
Operating States .......................................................................... 15
Adjusting the Operating Set Point ................................................ 16
Changing the Display Units .......................................................... 17
Fault and Warning Conditions ...................................................... 17
Access to the Current Fault or Warning ....................................... 17
Viewing the Fault History ............................................................. 18
PRIOR TO START-UP ...................................................................... 18
Required Ability ............................................................................ 18
OPERATING INSTRUCTIONS ......................................................... 19
Adjustment Procedure (Initial Start-Up) 120 and 150 Models ...... 19
Adjustment Procedure (Initial Start-Up) 199 and 250 Models ...... 19
Cathodic Protection ...................................................................... 20
Precautions .................................................................................. 20
GENERAL INFORMATION ............................................................... 20
Power Burner ............................................................................... 20
High Limit ..................................................................................... 20
High Altitude Installations ............................................................. 20
MAINTENANCE ............................................................................... 20
General ........................................................................................ 20
Maintenance Schedule ................................................................ 20
Flushing ........................................................................................ 23
Draining ........................................................................................ 23
Sediment Removal ....................................................................... 23
Lime Scale Removal .................................................................... 23
Anode Inspection and Replacement ............................................ 23,24
Drain Valve and Access Panels ................................................... 24
Relief Valve .................................................................................. 24
Circulating Pump .......................................................................... 24
Vent System ................................................................................. 24
INSTALLATION DIAGRAMS ............................................................ 25-29
Manifold Kits ................................................................................. 30
CHECKLIST AND SERVICE INFORMATION .................................. 31
TROUBLE-SHOOTING .................................................................... 31
LIMITED WARRANTY ...................................................................... 33
FEATURES
IMPORTANT
IT IS REQUIRED THAT A QUALIFIED SERVICE TECHNICIAN PERFORM
THE INITIAL FIRING OF THE HEATER. AT THIS TIME THE USER SHOULD
NOT HESITATE TO ASK THE TECHNICIAN ANY QUESTIONS WHICH HE
MAY HAVE IN REGARD TO THE OPERATION AND MAINTENANCE OF
THE UNIT.
A CHECKLIST AND SERVICE INFORMATION section are included at the rear
of this manual. By using this checklist the user may be able to make minor
operational adjustments and save himself unnecessary service calls. However,
the user should not attempt repairs which are not listed in this section.
WATER TEMPERATURE CONTROL
TH IS WATER HEATER IS EQU IPP ED WITH AN ADJUSTAB LE
DANGER
THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT WATER
TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHER AND
LAUNDRY USE CAN CAUSE SCALD BURNS RESULTING IN SERIOUS
PERSONAL INJURY AND/OR DEATH. THE TEMPERATURE AT WHICH
INJURY OCCURS VARIES WITH THE PERSON’S AGE AND THE TIME
OF THE EXPOSURE. THE SLOWER RESPONSE TIME OF CHILDREN,
AGED OR DISABLED PERSONS INCREASES THE HAZARDS TO THEM.
NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER TAP, OR TO
DRAW THEIR OWN BATH WATER. NEVER LEAVE A CHILD OR DISABLED
PERSON UNATTENDED IN A BATHTUB OR SHOWER.
THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE THE
GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET TEMPERATURES.
The water temperature is controlled using the Temperature Control Button
on the Display at the front of the unit (See Figure 1). This control utilizes
two temperature probes to determine the tank temperature. The primary
temperature probe is located at the top of the tank and the other is near
the water inlet.
The temperature may be adjusted from 90°F/32°C to 180°F/82°C. The
thermostat was adjusted to 120°F/49°C before the heater was shipped from
the factory. It is recommended that lower water temperature be used to avoid
the risk of scalding. It is further recommended, in all cases, that the water
3
temperature be set for the lowest temperature which satises your hot water
needs. This will also provide the most energy efcient operation of the water
heater and minimize scale formation.
SETTING THE WATER HEATER TEMPERATURE AT 120°F/49°C WILL
REDUCE THE RISK OF SCALDS.
Figure 1 shows the approximate time-to-burn relationship for normal adult
skin. Short repeated heating cycles caused by small hot water uses can
cause temperatures at the point of use to exceed the thermostat setting by
up to 20°F/11°C. If you experience this type of use, you should consider
using lower temperature settings to reduce scald hazards.
DISHWASHING MACHINE REQUIREMENT
All dishwashing machines meeting the National Sanitation Foundation
requirements are designed to operate with water ow pressures between
15 and 25 pounds per square inch (103 Kpa and 173 Kpa). Flow pressures
above 25 pounds per square inch (173 Kpa), or below 15 pounds per square
inch (103 Kpa), will result in improperly sanitized dishes. Where pressures
are high, a water pressure reducing or ow regulating control valve should
be used in the 180°F (82°C) line to the dishwashing machine, and should
be adjusted to deliver water between these limits.
Water Time to Produce 2nd & 3rd
Temperature Degree Burns on Adult Skin
180°F / 82°C Nearly instantaneous
170°F / 77°C Nearly instantaneous
160°F / 71°C About 1/2 second
150°F / 66°C About 1-1/2 seconds
140°F / 60°C Less than 5 seconds
130°F / 54°C About 30 seconds
120°F / 49°C More than 5 minutes
FIGURE 1.
Valves for reducing point-of-use temperature by mixing cold and hot water are
available (see Figure 2). Also available are inexpensive devices that attach
to faucets to limit hot water temperatures. Contact a licensed plumber or the
local plumbing authority.
The National Sanitation Foundation also recommends circulation of 180°F
(82°C) water. Where this is done, the circulation should be very gentle so
that it does not cause any unnecessary turbulence inside the water heater.
The circulation should be just enough to provide 180°F (82°C) water at the
point of take-off to the dishwashing machine. Adjust ow by means of the
plug cock in the circulating line. (See installation diagrams.)
CIRCULATING PUMP
A circulating pump is used when a system requires a circulating
loop or there is a storage tank used in conjunction with the heater.
Refer to the piping diagrams at rear of manual for electrical hookup
information and install in accordance with the current edition of the
National Electrical Code, NFPA 70 or the Canadian Electrical Code,
CSA C22.1.
All bronze circulating pumps are recommended for used with
commercial water heaters.
Although circulating pumps are oiled and operated by the
manufacturer some circulating pumps must be oiled again before
operated. Please refer to manufacturer's instructions.
INSTALLATION INSTRUCTIONS
REQUIRED ABILITY
FIGURE 2.
HIGH LIMIT SWITCH (E.C.O.)
The top immersion well of the dual bulb controller also contains the high limit
(energy cutoff) sensor. The high limit switch interrupts the main burner gas
ow should the water temperature reach approximately 202°F/94°C.
Should the high limit switch activate, the control system will automatically reset
the unit once the water temperature in the tank falls below 140°F/60°C. If the
unit is manually shut down and restarted, as long as the temperature in the
tank is lower than 160°F/71°C, the unit will reset and initiate operation.
High limit switch operation is the likely cause when higher than normal water
temperatures occur with a recurring need to restart the water heater. This
could be due to a malfunctioning thermostat allowing the gas valve to remain
open and the burner to continue ring even after water temperature in the
tank has already reached the set point. Contact your dealer or servicer if
continued high limit switch operation occurs.
INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES
ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE
FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, GAS SUPPLY
AND ELECTRICAL WORK ARE REQUIRED.
INSULATION BLANKETS
Insulation blankets available to the general public for external use
on gas water heaters are not approved for use on your water heater.
The purpose of an insulation blanket is to reduce the standby heat
loss encountered with storage tank water heaters. Your water heater
meets or exceeds the ASHRAE/IES 90.1 1999 standards with respect
to insulation and standby loss requirements, making an insulation
blanket unnecessary.
WARNING
Should you choose to apply an insulation blanket to this heater, you should
follow these instructions. Failure to follow these instructions can result in
re, asphyxiation, serious personal injury or death.
• Do not apply insulation to the top, or the upper 15" (38 cm) of the water
heater, as this will interfere with safe operation.
• Do not cover the temperature & pressure relief valve.
• Do not cover the instruction manual. Keep it on the side of the water
heater or nearby for future reference.
• Do obtain new labels from John Wood for placement on the blanket
directly over the existing labels.
4
LOCATING THE HEATER
WARNING
THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH AS
GAS WATER HEATERS IN ROOMS, GARAGES OR OTHER AREAS
WHERE GASOLINE, OTHER FLAMMABLE LIQUIDS OR ENGINE
DRIVEN EQUIPMENT OR VEHICLES ARE STORED, OPERATED OR
REPAIRED. FLAMMABLE VAPORS ARE HEAVY AND TRAVEL ALONG
THE FLOOR AND MAY BE IGNITED BY THE HEATER’S IGNITER OR
MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION. SOME LOCAL
CODES PERMIT OPERATION OF GAS APPLIANCES IF INSTALLED 18
INCHES (46 cm) OR MORE ABOVE THE FLOOR. THIS MAY REDUCE
THE RISK IF LOCATION IN SUCH AN AREA CANNOT BE AVOIDED.
THE HEATER SHALL BE LOCATED OR PROTECTED SO IT IS NOT
SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE.
DO NOT LOCATE THE HEATER WHERE NOISE FROM THE EXHAUST
OR INTAKE WILL BE OBJECTIONABLE. THIS INCLUDES LOCATIONS
CLOSE TO OR ACROSS FROM WINDOWS AND DOORS. AVOID
ANCHORING THE VENT AND INTAKE PIPES DIRECTLY TO FRAMED
WALLS, FLOORS OF CEILINGS UNLESS RUBBER ISOLATION PIPE
HANGERS ARE USED. THIS PREVENTS ANY VIBRATIONS FROM
BEING TRANSMITTED INTO THE LIVING SPACES.
WARNING
THIS WATER HEATER IS A CONDENSING UNIT AND REQUIRES A DRAIN
TO BE LOCATED IN CLOSE PROXIMITY TO ALLOW THE CONDENSATE
TO DRAIN SAFELY. THE CONDENSATE DRAINS FROM THE UNIT AT
THE EXHAUST ELBOW LOCATED AT THE BOTTOM OF THE UNIT. NOTE:
IT IS IMPORTANT THAT THE CONDENSATE HOSE NOT BE ELEVATED
ABOVE THE EXHAUST ELBOW (SEE FIGURE 3). THE CONDENSATE
BUILD-UP WILL BLOCK THE EXHAUST OUTLET, WHICH WILL CAUSE
IMPROPER OPERATION.
FIGURE 3.
WARNING
FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY OTHER
POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON
OR ADJACENT TO THE HEATER. OPEN CONTAINERS OF FLAMMABLE
MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM
WITH THE HEATER.
When installing the heater, consideration must be given to proper location.
Location selected should be as close to the intake and exhaust termination
points as practicable, with adequate air supply and as centralized with the
piping system as possible.
THE HEATER MUST NOT BE LOCATED IN AN AREA WHERE IT WILL BE
SUBJECT TO FREEZING.
LOCATE IT NEAR A FLOOR DRAIN. THE HEATER SHOULD BE LOCATED
IN AN AREA WHERE LEAKAGE FROM THE HEATER OR CONNECTIONS
WILL NOT RESULT IN DAMAGE TO THE ADJACENT AREA OR TO LOWER
FLOORS OF THE STRUCTURE.
When such locations cannot be avoided, it is recommended that a suitable
drain pan, adequately drained, be installed under the appliance.
Water heater life depends upon water quality, water pressure and the
environment in which the water heater is installed. Water heaters are
sometimes installed in locations where leakage may result in property
damage, even with the use of a drain pan piped to a drain. However,
unanticipated damage can be reduced or prevented by a leak detector or
water shut-off device used in conjunction with a piped drain pan. These
devices are available from some plumbing supply wholesalers and retailers,
and detect and react to leakage in various ways:
WARNING
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER.
IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT
THE APPLIANCE AND TO REPLACE ANY PART OF THE CONTROL
SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER.
CLEARANCES
These heaters are approved for installation on combustible ooring in an
alcove when the minimum clearances from any combustion construction are
followed as indicated in Figure 4.
In all installations the minimum combustible clearances from any vent piping
shall be 0". Vent piping passing through a combustible wall or ceiling must
be a continuous run (no joints).
A service clearance of 24" (61 cm) should be maintained from serviceable
parts such as relief valves, ue bafes, ue damper devices, thermostats,
cleanout openings or drain valves.
Always disconnect electrical power before servicing the unit.
• Sensors mounted in the drain pan that trigger an alarm or turn off the
incoming water to the water heater when leakage is detected.
• Sensors mounted in the drain pan that turn off the water supply to the entire
home when water is detected in the drain pan.
• Water supply shut-off devices that activate based on the water pressure
differential between the cold water and hot water pipes connected to the
water heater.
• Devices that will turn off the gas supply to a gas water heater while at the
same time shutting off its water supply.
FIGURE 4.
*ILLUSTRATION OF MINIMUM COMBUSTIBLE CLEARANCES IN AN
ALCOVE.
5
HARD WATER
Where hard water conditions exist, water softening or the threshold type of
water treatment is recommended. This will protect the dishwashers, coffee
urns, water heaters, water piping and other equipment.
See MAINTENANCE section for details of tank cleanout procedure.
AIR REQUIREMENTS
KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE MATERIALS,
GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATING AIR.
WARNING
FOR SAFE OPERATION PROVIDE ADEQUATE AIR FOR COMBUSTION
AND VENTILATION. AN INSUFFICIENT SUPPLY OF AIR WILL CAUSE
RECIRCULATION OF COMBUSTION PRODUCTS RESULTING IN
CONTAMINATION THAT MAY BE HAZARDOUS TO LIFE. SUCH A CONDITION
OFTEN WILL RESULT IN A YELLOW, LUMINOUS BURNER FLAME, CAUSING
CARBONING OR SOOTING OF THE COMBUSTION CHAMBER, BURNERS
AND FLUE TUBES AND CREATES A RISK OF ASPHYXIATION.
MECHANICAL EXHAUSTING OF ROOM AIR
Where an exhaust fan is installed in the same room with a heater, sufcient
openings for air must be provided in the walls. UNDERSIZED OPENINGS WILL
CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE HEATER’S
VENTING SYSTEM, CAUSING POOR COMBUSTION. SOOTING MAY
RESULT IN SERIOUS DAMAGE TO THE HEATER AND RISK OF FIRE OR
EXPLOSION. IT CAN ALSO CREATE A RISK OF ASPHYXIATION.
If the conned space is within a building of tight construction, air for combustion
and ventilation must be obtained from outdoors. When directly communicating
with the outdoors through vertical ducts, two permanent openings, located
in the above manner, shall be provided. Each opening shall have a free
area of not less than one square inch (6.5 cm²) per 4000 Btuh of the total
input of all appliances in the enclosure. If horizontal ducts are used, each
opening shall have a free area of not less than one square inch (6.5 cm²) per
2000 Btuh of the total input of all appliances in the enclosure.
CHEMICAL VAPOR CORROSION
WARNING
CORROSION OF THE FLUE WAYS AND VENT SYSTEM MAY OCCUR IF
AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS. SUCH
CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION.
Spray can propellants, cleaning solvents, refrigerator and air conditioning
refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes, and
process chemicals are typical compounds which are potentially corrosive.
PRODUCTS OF THIS SORT SHOULD NOT BE STORED NEAR THE
HEATER. ALSO, AIR WHICH IS BROUGHT IN CONTACT WITH THE
HEATER SHOULD NOT CONTAIN ANY OF THESE CHEMICALS. IF
NECESSARY, UNCONTAMINATED AIR SHOULD BE OBTAINED FROM
REMOTE OR OUTSIDE SOURCES.
VENTING
WARNING
THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST BE
FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULATION
OF FLUE GASES. SUCH CONDITIONS CAUSE SOOTING OR RISKS OF
FIRE AND ASPHYXIATION.
UNCONFINED SPACE
In buildings of conventional frame, brick or stone construction, unconned
spaces may provide adequate air for combustion and ventilation.
If the unconfined space is within a building of tight constructi on
(buildings using the following construction: weather stripping, heavy
insulation, caulking, vapor barrier, etc.), air for combustion and ventilation
must be obtained from outdoors. The installation instructions for conned
spaces in tightly constructed buildings must be followed to ensure adequate
air supply.
CONFINED SPACE
When drawing combustion air from inside a conventionally constructed
building to a conned space, such a space shall be provided with two
permanent openings, ONE IN OR WITHIN 12" (31 cm) OF THE ENCLOSURE
TOP AND ONE IN OR WITHIN 12" (31 cm) OF THE ENCLOSURE BOTTOM.
Each opening shall have a free area of at least one square inch (6.5 cm²)
per 1000 Btuh appliances in the enclosure, but not less than 100 square
inches (645 cm²).
Heater must be protected from freezing downdrafts during shutdown periods.
WARNING
NEVER OPERATE THE HEATER UNLESS IT IS VENTED TO THE
OUTDOORS AND HAS ADEQUATE AIR SUPPLY TO AVOID RISKS OF
IMPROPER OPERATION, FIRE, EXPLOSION OR ASPHYXIATION.
VENT PIPE TERMINATION
NOTE: Before installing venting, determine place of vent pipe termination.
See Figures 5a & b and 6a & b before proceeding.
CAUTION
DO NOT TERMINATE THE VENTING WHERE NOISE FROM THE
EXHAUST OR INTAKE WILL BE OBJECTIONABLE. THIS INCLUDES
LOCATIONS CLOSE TO OR ACROSS FROM WINDOWS AND DOORS.
AVOID ANCHORING THE VENT AND INTAKE PIPES DIRECTLY TO
FRAMED WALLS, FLOORS OR CEILINGS UNLESS RUBBER ISOLATION
PIPE HANGERS ARE USED. THIS PREVENTS ANY VIBRATIONS FROM
BEING TRANSMITTED INTO THE LIVING SPACES.
6
CAUTION
TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE
IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN
THESE TWO TERMINALS IS RECOMMENDED.
CANADIAN POWER VENT
FIGURE 5.
CANADIAN DIRECT VENT
FIGURE 6.
7
IMPORTANT
The vent system must terminate so that proper clearances are maintained
as cited in local codes or the current editions of the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 or the Natural Gas and Propane Installation Code,
CAN/CSA-B149.1.
Installation of this water heater must comply with CAN/CSA B149.1
- Natural Gas and Propane Installation Code which requires the vent
system components be certied to ULC S636.
Do not terminate the exhaust vent terminal over public area where condensate
or vapor can cause nuisance or hazard.
Plan the vent system layout so that proper clearances are maintained from
plumbing and wiring.
Vent pipes serving power vented appliances are classied by building codes
as "vent connectors". Required clearances from combustible materials must
be provided in accordance with information in this manual under LOCATION
OF HEATER and CLEARANCES, and with National Fuel Gas Code and
local Codes.
NOTE: TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING
TO THE AIR INTA KE IN WINDY/COLD AREA S, THE M AXI MUM
PR ACTICAL DISTANCE BET WEEN THESE TWO TERMINALS IS
RECOMMENDED.
FOR ALL
MODELS
FIGURE 8.
IMPORTANT
Plan the layout of the vent system backwards from the vent termination to
the appliance.
WARNING
USE ONLY THE VENT TERMINALS SUPPLIED WITH THIS UNIT.
TERMINATION OF A VENT SYSTEM WITH A DEVICE OTHER THAN
THE SUPPLI ED VEN T TERMINATIONS WILL AFF ECT SYSTEM
PERFORMANCE AND RESULT IN A SAFETY HAZARD.
DIRECT VENTING
The intake vent terminals provided on the unit contains a mesh screen (see
Figure 7) to prevent large particles from entering the unit.
FIGURE 7.
IMPORTANT
WHEN LOCATING THE TERMINALS ON A SIDEWALL, THE FOLLOWING
SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE
FOLLOWED.
1. The air intake terminal and the exhaust vent terminal must terminate on
the same exterior wall.
2. The vertical centerline of the air intake terminal must be located at a
minimum of 24" (61 cm).
3. The horizontal centerline of the air intake terminal may not be located
below the horizontal centerline of the exhaust vent terminal.
CAUTION
Vent terminals supplied with the heater must be used.
NOTE: BEFORE BEGINNING INSTALLATION OF ANY VENT PIPE READ
THE VENT PIPE MANUFACTURER'S INSTALLATION INSTRUCTIONS.
1. After the points of termination have been determined, use the cover plates
as templates to mark the holes for the vent pipes to be inserted through
the wall. BEWARE OF CONCEALED WIRING AND PIPING INSIDE OF
WALL.
2. If the vent terminals are being installed on the outside of a nished wall, it
may be easier to mark both the inside and outside wall. Align the holes by
drilling a hole through the center of the template from the inside through
to the outside. The template can now be positioned on the outside wall
using the drilled holes as a centering point for the template.
WHEN THE UNIT IS TO BE SETUP AS A DIRECT VENT, THE MESH SCREEN
WARNING
MUST BE REMOVED. THE INLET VENT PIPE MAY THEN BE GLUED TO
THE INTAKE VENT TERMINALS (see Figure 8) PROVIDED ON THE UNIT.
DIRECT VENT TERMINAL INSTALLATION
IMPORTANT
THIS UNIT CONSISTS OF TWO VENT TERMINALS - AN INTAKE VENT
TERMINAL AND AN EXHAUST VENT TERMINAL. THE INTAKE VENT
TERMINAL IS A 3" 45° PVC ELBOW WITH A DOME MESH WIRE SCREEN
AND THE EXHAUST VENT TERMINAL IS A 3" 45°PVC ELBOW WITH A
MESH WIRE SCREEN.
3. A) MASONRY SIDE WALLS
Chisel an opening approximately 1/2" (1.3 cm) larger than the marked
circle.
B) WOODEN SIDE WALLS
Drill a pilot hole approximately one quarter inch outside of the marked
circle. This pilot hole is used as a starting point for a saws-all or sabre saw
blade. Cut around the marked circle staying approximately one quarter
inch outside of the line. (This will allow the vent pipe to easily slide through
the opening. The resulting gap will be covered by the vent terminal cover
plates.) Repeat this step on the inside wall if necessary.
4. Cut a length of 3" PVC pipe about 3.5" (8.9 cm) longer than the wall
thickness at the opening.
8
5. Glue the intake vent terminal to the section of the pipe.
VERTICAL VENT TERMINAL INSTALLATION
6. Slide the wall plate over the pipe to stop against intake vent terminal.
7. Place a bead of caulking (not supplied) around the gap between the pipe
and the wall. Place some of the caulking on the back of the plate to hold
it against the wall after installation.
8. If the vent pipe is installed up to the wall, with a coupling on the
end against the wall opening, the pipe with the vent terminal can be
prepared for gluing before inserting through the wall. Slide the pipe
through the wall and insert into coupling on the other side of the wall,
making sure that the vent terminal ends up pointed in the correct position
(See Figure 9).
IMPORTANT
WH EN TER MIN ATIN G THROUGH A ROOF, THE FOL LOW ING
SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE
FOLLOWED.
1. Proper support must be provided for all pipe protruding through the roof.
2. The vertical roof terminations should be sealed with a plumbing roof boot
or equivalent ashing.
3. The intake vent termination and the exhaust vent termination must
penetrate the same side of roof.
4. The center line of the intake vent termination and the center line of the
exhaust vent termination must be no closer than 24" (61cm).
5. The intake vent terminal and the exhaust vent terminal must be oriented
facing downward and the same direction.
The specications are displayed in Figure 10 & 11.
NOTE: Exhaust vent terminal is installed using the same procedure.
INSTALLATION SEQUENCE
NOTE: BEFORE BEGINNING INSTALLATION OF ANY VENT PIPE, READ
“VENT PIPE PREPARATION” SECTION ON PAGE 12.
FIGURE 9.
1. After the points of termination have been determined, use the cover plates
as templates to mark the holes for the vent pipes to be inserted through
the roof.
2. Drill a pilot hole approximately 1/4" (6 mm) outside of the marked
circle. This pilot hole is used as a starting point for a saws-all or sabre
saw blade. Cut around the marked circle staying approximately one
quarter inch outside the line. (This will allow the vent pipe to easily slide
through the opening). The resulting gap will be covered by the roof
boot/ashing.
3. Suspend the pipe through the center of the hole using proper support.
4. Slide roof boot or equivalent ashing over pipe and secure roof boot
equivalent ashing to roof.
5. Seal around ashing.
6. Terminate intake terminal and exhaust vent terminal facing down as
shown in Figure 11.
FIGURE 10.
FIGURE 11.
9
INSTALLATION OF VENT SYSTEM
WARNING
THE OPTIONAL INTAKE VENTING ARRANGEMENT AND THE
EXHAUST VENTING ARRANGEMENT MUST BE INSTALLED TO
RUN DIRECTLY TO THE OUTDOORS AND NOT IN ANY WAY BE
CONNECTED TO ANOTHER VENTING SYSTEM (I.E. FURNACE,
DRYERS OR SPACE HEATERS). IT IS CRUCIAL THAT THE VENTING
ARRANGEMENT BE KEPT SEPARATE FROM OTHER VENTING
SYSTEMS. IF THIS WARNING IS IGNORED, AND THE SYSTEM IS
VENTED INCORRECTLY, IT MAY CAUSE IMPROPER OPERATION,
FIRE, EXPLOSION, OR ASPHYXIATION.
1. Plan the route of the vent system from the vent termination to the planned
location of the appliance. Layout the total vent system to use the minimum
of vent pipe and elbows possible.
NOTE: for Water Heaters in locations with high ambient temperatures (above
100°F or 38°C) and/or insufcient dilution air, it is recommended that CPVC
pipe and ttings marked ULC S636 compliant (MUST USE SUPPLIED VENT
TERMINAL) be used.
4. It is important that condensate not be allowed to buildup in the exhaust
vent pipe. To prevent this from happening the pipe should be installed
with a slight, 1/8" (3mm) per 5' (152 cm) of pipe maximum downward
(toward terminal) slope.
5. The vent system should be supported every 5' (152 cm) of vertical run
and every 3' (91cm) of horizontal run of vent pipe length.
NOTE: Stress levels in the pipe and ttings can be signicantly increased
by improper installation. If rigid pipe clamps are used to hold the pipe in
place, or if the pipe cannot move freely through a wall penetration, the
pipe may be directly stressed, or high thermal stresses may be formed
when the pipe heats up and expands. Install accordingly to minimize
such stresses.
2. The installer may add up to a MAXIMUM OF FIFTY (50) EQUIVALENT
FEET (15.2 m) of 3" pipe to the exhaust venting arrangement. This
addition of FIFTY (50) EQUIVALENT FEET (15.2 m) of pipe on both
the intake venting arrangement and exhaust venting arrangement must
include any 3" PVC elbows which equals (5) EQUIVALENT FEET (1.5
m) of pipe.
Table 2. VENT LENGTH TABLE
Number 3" 3" 4"
of 90° Minimum Maximum Maximum
Elbows Pipe (Ft./M.) Pipe (Ft./M.) Pipe (Ft./M.)
ONE (1) 7/2 45/13.7 115/35
TWO (2) 7/2 40/12.2 110/33.5
THREE (3) 7/2 35/10.7 105/32
FOUR (4) 7/2 30/9.1 100/30.5
FIVE (5) 7/2 --- 95/29
SIX (6) 7/2 --- 90/27.4
4" PVC may be used for a MAXIMUM intake of ONE HUNDRED TWENTY
(120) EQUIVALENT FEET (36.6m) and a MAXIMUM exhaust of ONE
HUNDRED TWENTY (120) EQUIVALENT FEET (36.6m). The maximum
number of 90° elbows with the 4" venting is six (6) on the intake and six (6)
on the exhaust. A 90° elbow is equal to ve (5) equivalent feet (1.5m) of pipe.
One (1) 90° elbow is equal to two (2) 45° elbows. Any venting conguration
using less than 50 equivalent feet should use 3" venting. See Table 2. For
either vent diameter, the maximum vent lengths in Table 2 are EXCLUSIVE
of the factory-installed vent component and prescribed terminations. That
is, the equivalent vent lengths associated with the 90° elbow (installed on
the unit) and the 45° termination elbow should NOT be considered part of
the vent lengths referred to in Table 2.
The 3 " vent i ng ter m inal s (pro v ided ) must b e used w i th the
3" vent pipe. Two, approved 4" vent terminals (not provided) must be used
with 4" vent pipe. See replacement parts list for terminals.
IMPORTANT
When multiple units are direct vented through a wall (3" or 4" venting), no
intake air terminal should be lower than the highest exhaust vent terminal.
VENT PIPE PREPARATION
1. INITIAL PREPARATION
A. Make sure the solvent cement you are planning to use is designed
for the specic application you are attempting.
B. Know the physical and chemical characteristics and limitations of
the PVC or CPVC piping materials that you are about to use.
C. Know the reputation of your pipe and cement manufacturer and
their products.
D. Know your own qualications or those of your contractor. The solvent
welding technique of joining PVC or CPVC pipe is a specialized skill
just as any other pipe tting technique.
E. Closely supervise the installation and inspect the nished job before
start-up.
F. Contact the manufacturer, supplier, or competent consulting agency
if you have any questions about the application or installation of
PVC or CPVC pipe.
G. Take the time and effort to do a professional job. Shortcuts will only
cause you problems and delays in start-up. The majority of failures
in these systems are the result of shortcuts and/or improper joining
techniques.
2. SELECTION OF MATERIALS
PRIMER
It is recommended that Tetrahydrofuran (THF) be used to prepare the surfaces
of pipe and ttings for solvent welding. Do not use water, rags, gasoline or
any other substitutes for cleaning PVC or CPVC surfaces. A chemical cleaner
such as MEK may be used.
CEMENT
The only cement approved for this system is IPEX System 636 CPVC Cement
Product for use on marked PVC and CPVC ULC S636 pipe and ttings.
NOTE: This water heater can only be vented with PVC pipe certied and
marked as complying with ULC S636 and glued with IPEX System 636
CPVC Cement Product .
SAFETY PRECAUTION: PRIMERS AND CEMENTS ARE EXTREMELY
FLAMMABLE AND MUST NOT BE STORED OR USED NEAR HEAT OR
OPEN FLAME. ALSO, USE ONLY IN A WELL-VENTILATED AREA.
10
CONTROLS AND SWITCHES
All models are provided with four pressure switches. These switches are
essential to the safe and proper operation of the unit. All switches are wired
in series. The controller is set up to shut the unit down whenever there is a
failure of any of the switches. It is important to understand the purpose of
each switch.
LOW GAS PRESSURE SWITCH
(SEE FIGURE 12)
The Low Gas Switch (LGS) is a single-pole, normally open pressure switch
that will close its contacts when a rising pressure of 5.0 in. (1.25Kpa) W.C.
is encountered. The contacts will open when the pressure falls below the
xed set point of 4.8"WC (1.18Kpa) for natural gas models and 8.5"WC
(2.08Kpa) for propane models. The LGS monitors the gas supply pressure
to the heater. If the gas supply falls below 5.0 in. (1.25Kpa) W.C., the main
burner is extinguished (if heater is running) or the heater will not start up.
ON/OFF SWITCH
The ON/OFF Switch is a single-pole, single-throw rocker switch. This switch
provides 120V from the line source to the heater.
FIGURE 12.
BLOWER PROVER SWITCH
(SEE FIGURE 12)
The Blower Prover Switch is provided on the heater to verify that the fan
is operating. It is a positive pressure switch whose electrical contacts are
normally open. When the fan increases the pressure in the burner, the
pressure switch will allow the electrical contacts to close. The pressure switch
is connected to the burner tap by a piece of tygon tubing. This tubing must
be connected in order for the switch to change the electrical contacts. The
controller requires that the electrical contacts on this air ow switch be open
before it will allow the blower to come on.
THE WATER HEATER IS POLARITY SENSITIVE. BEFORE APPLYING
CAUTION
ELECTRICITY TO THIS HEATER BE CERTAIN THAT SUPPLY NEUTRAL
WIRE TO GROUND CHECK INDICATES ZERO VOLTAGE.
HOT SURFACE IGNITER
The Hot Surface Igniter is a device that ignites the main burner by high
temperature (>1800°F or >982°C). When 120VAC is applied to the igniter,
sufcient heat is generated to ignite the main burner. Although improvements
have been made to strengthen the igniter, it is still fragile and care must be
taken when handling the igniter to prevent breakage.
GAS PIPING
Contact your local gas service company to ensure that adequate gas service
is available and to review applicable installation codes for your area.
Size the main gas line in accordance with Table 3. The gures shown are
for straight lengths of pipe at 0.5" (125Pa) W.C. pressure drop, which is
considered normal for low pressure systems Note that ttings such as elbows
and tees will add to the pipe pressure drop.
CAUTION
DO NOT USE FLEXIBLE GAS PIPING.
TABLE 3. MAXIMUM CAPACITY OF PIPE IN CUBIC FEET
OF GAS PER HOUR
(Based upon a Pressure Drop of 0.5") Water Column and 0.6 Specic
Gravity Gas and max. gas pressure of 0.5 psig)
BLOCKED OUTLET PROVER SWITCH
(SEE FIGURE 12)
The Blocked Outlet Prover Switch is set up to shut the unit off when a build-up
of positive pressure in the exhaust vent pipe occurs. This switch is a positive
pressure switch that requires an increase in pressure to change the electrical
contacts from normally closed to open. When this switch prevents the unit
from igniting, most likely the exhaust is blocked by some means Check to
see if the condensate is allowed to ow freely from the exhaust elbow and
for obstructions in the exhaust venting and exhaust vent terminal. Also verify
that there is no more than fty equivalent feet (15.2 m) of three inch PVC
vent pipe on the exhaust.
BLOCKED INLET PROVER SWITCH
(SEE FIGURE 12)
The Blocked Inlet Prover Switch is set up to shut the unit off when a build-up
of negative pressure in the intake vent pipe occurs. This switch is a negative
pressure switch that requires an increase in negative pressure to change the
electrical contacts from normally closed to open. The switch is connected
to the pressure tap on the PVC ange connected to the inlet of the blower.
When this switch prevents the unit from igniting, most likely the intake is
blocked by some means. Check to see if there is no more than fty equivalent
feet (15.2 m) of three inch PVC vent pipe on the intake. Also verify that the
intake and intake vent terminal is free of obstructions that may prevent air
from entering the unit.
LENGTH NORMAL IRON PIPE SIZES (INCHES)
IN INPUT IN THOUSANDS BTU/HR
FEET 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4"
10 175 360 680 1400 2100 3960 6300 11000 23000
20 120 250 485 950 1460 2750 4360 7700 15800
30 97 200 375 770 1180 2200 3520 6250 12800
40 82 170 320 660 990 1900 3000 5300 10900
50 73 151 285 580 900 1680 2650 4750 9700
60 66 138 260 530 810 1520 2400 4300 8800
70 61 125 240 490 750 1400 2250 3900 8100
80 57 118 220 460 690 1300 2050 3700 7500
90 53 110 205 430 650 1220 1950 3450 7200
100 50 103 195 400 620 1150 1850 3250 6700
125 44 93 175 360 550 1020 1650 2950 6000
150 40 84 160 325 500 950 1500 2650 5500
175 37 77 145 300 460 850 1370 2450 5000
200 35 72 135 280 430 800 1280 2280 4600
LENGTH NORMAL IRON PIPE SIZES (INCHES)
IN INPUT IN KW
METERS 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4"
3.0 51 105 199 410 615 1160 1845 3221 6735
6.1 35 73 142 278 428 805 1277 2255 4626
9.1 28 59 110 225 346 644 1031 1830 3748
12.2 24 50 94 193 290 556 878 1552 3192
15.2 21 44 83 170 264 492 776 1391 2840
18.3 19 40 76 155 237 445 703 1259 2577
21.3 18 37 70 143 220 410 659 1142 2372
24.4 17 35 64 135 202 381 600 1083 2196
27.4 16 32 60 126 190 357 571 1010 2108
30.5 15 30 57 117 182 337 542 952 1962
38.1 13 27 51 105 161 299 483 864 1757
45.7 12 25 47 95 146 278 439 776 1610
53.3 11 23 42 88 135 249 401 717 1464
61.0 10 21 40 82 126 234 375 688 1347
11
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