Lochinvar CG150, CG200 User Manual

MODELS CG(N,L)150 & CG(N,L)200

COMMERCIAL GAS, GLASS-LINED, TANK-TYPE WATER HEATER

 •INSTALLATION •OPERATION •MAINTENANCE•LIMITEDWARRANTY

Thank you for buying this energy efcient water heater. We
appreciate your condence in our products.

CAUTION

TEXT IN BLACK BOLD TYPE OR UNDERLINED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ
THOROUGHLY BEFORE INSTALLING AND USING THIS
APPLIANCE.

300 Maddox Simpson Parkway

Phone: [phone] • Fax: [phone]

Technical Service email: [e-mail]

PLACE THESE INSTRUCTIONS ADJACENT TO HEATER

AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.

Printed in U.S.A. 1011 322880-000

1

Lebanon, TN 37090

www.Lochinvar.com

ROUGH-IN-DIMENSIONS

FIGURE 1

TABLE 1 - HEATER PERFORMANCE DATA

Input Approx. RECOVERY RATING CAPACITIES (GPH) AT TEMPERATURE RISE SHOWN
Rate Tank Approx. F 20°F 30°F 40°F 50°F 60°F 70°F 80°F 90°F 100°F 110°F 120°F 130°F 140°F
Model Btuh Cap. Eff. % C 11°C 17°C 22°C 28°C 33°C 39°C 44°C 50°C 56°C 61°C 67°C 72°C 78°C

CGN150032 150,000 NAT 32 Gal 80 GPH 727 485 364 291 242 208 182 162 145 132 121 112 104

44 kW/Hr. NAT 121 Litres LPH 2752 1836 1378 1102 916 787 689 613 549 500 458 424 394

CGL150032 150,000 LP 32 Gal 80 GPH 727 485 364 291 242 208 182 162 145 132 121 112 104

44 kW/Hr. LP 121 Litres LPH 2752 1836 1378 1102 916 787 689 613 549 500 458 424 394

CGN200032 199,900 NAT 32 Gal 80 GPH 969 646 485 388 323 277 242 215 194 176 162 149 139

59 kW/Hr. NAT 121 Litres LPH 3668 2445 1836 1469 1223 1049 916 814 734 666 613 564 526

CGL200032 182,000 LP 32 Gal 80 GPH 882 588 441 353 294 252 221 196 177 160 147 136 126

53 kW/Hr. LP 121 Litres LPH 3339 2226 1669 1336 1113 954 837 742 670 606 557 515 477

FOREWORD

These designs comply with ANSI Z21.10.3 as a Booster type
water heater.

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.

These heaters may be installed on combustible oors.

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.

The installation must conform to these instructions and the
local code authority having jurisdiction. In the absence of local
codes, the installation must comply with the latest editions of
the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and the
National Electrical Code, NFPA 70, documents are available from
the National Fire Protection Association, 1 Batterymarch Park,
Quincy, MA 02269.

2

TABLE OF CONTENTS

Page

ROUGH-IN-DIMENSIONS ......................................................2

FOREWORD ...........................................................................2

GENERAL SAFETY INFORMATION .......................................3

Precautions .........................................................................3

Grounding Instructions ........................................................3

Chemical Vapor Corrosion...................................................3

Improper Combustion ........................................................ 3-4

Extended Non-Use ..............................................................4

Insulation Blankets ..............................................................4

High Altitude Installation ......................................................4

FEATURES ..............................................................................4

The Eliminator™ (Self-Cleaning System) .......................... 4-5

High Limit Switch ................................................................5

Electronic Ignition Control ...................................................5

Exhaust Inducer (Blower Assy.) ...........................................5

Circulating Pump .................................................................5

Dishwashing Machine Requirement ....................................5

INSTALLATION INSTRUCTIONS ...........................................6

Required Ability ...................................................................6

Uncrating .............................................................................6

Locating The Heater ............................................................6

Levelling ..............................................................................6

Clearances ..........................................................................6

Hard Water ..........................................................................6

Air Requirements ............................................................... 6-7

Venting ..............................................................................7-8

Multiple Heater Manifold ......................................................8

Water Line Connections ......................................................8

Water (Potable) Heating and Space Heating ......................8

Thermometers (Not Supplied) .............................................8

Relief Valve ..........................................................................8

Gas Piping ...........................................................................9

Purging ................................................................................9

Gas Pressure Regulator ................................................... 9-10

Heater Wiring .....................................................................10

Page

INSTALLATION DIAGRAMS .............................................. 11-17

OPERATION ..........................................................................18

General ..............................................................................18

SEQUENCE OF OPERATION ..............................................18

Lighting and Operation ......................................................19

Water Temperature Control ...............................................20

PREVENTIVE MAINTENANCE .............................................20

Check The Ignitor Assembly ..............................................20

Ignitor Assembly ................................................................20

Main Burner .................................................................... 20-21

Gas Valves ........................................................................21

Checking The Input ...........................................................21

Venting System .................................................................21

Remote Storage Tank Temperature Control ......................21

Relief Valve ........................................................................22

Hot Water Odor .................................................................22

Anode Rod Inspection .......................................................22

Flushing .............................................................................22

Draining .............................................................................22

Recommended Procedure For Periodic
Removal of Lime Deposits From Tank Type

Commercial Water Heaters ............................................ 22-23

Deliming Solvents ..............................................................23

Tank Cleanout Procedures ............................................. 23-24

Ignition Module System .....................................................24

System Diagnostics ...........................................................24

SERVICE ...............................................................................24

Electrical Servicing ............................................................24

Replacement Parts ............................................................24

Sequence of Operation Flow Chart ...................................25

Operational Checklist ........................................................26

Limited Warranty ...............................................................27

GENERAL SAFETY INFORMATION

PRECAUTIONS

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN
UNDER WATER. Immediately call a qualied service technician
to inspect the appliance and to replace any part of the control
system and any gas control which has been under water.

IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO NOT
OPERATE HEATER UNTIL ALL CORRECTIVE STEPS HAVE
BEEN MADE BY A QUALIFIED SERVICEMAN.

1. EXTERNAL FIRE.

2. DAMAGE.

3. FIRING WITHOUT WATER.

4. SOOTING

GROUNDING INSTRUCTIONS

This water heater must be grounded in accordance with the
National Electric Code and/or local codes. These must be followed
in all cases.

This water heater must be connected to a grounded metal,
permanent wiring system; or an equipment grounding conductor
must be run with the circuit conductors and connected to the
equipment grounding terminal or lead on the water heater, see
Figure 9.

CHEMICAL VAPOR CORROSION

WARNING

CORROSION OF THE FLUEWAYS 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 (water softener salt), waxes, and process
chemicals and typical compounds which are potentially corrosive.
Do not store products of this sort near the heater. Also, air which
is brought in contact with a the heater should not contain any of
these chemicals. If necessary, uncontaminated air should be
obtained from remote or outside sources. The limited warranty
is voided when failure of water heater is due to a corrosive
atmosphere. (Refer to the limited warranty for complete terms
and conditions.

IMPROPER COMBUSTION

WARNING

ATTIC AND/OR EXHAUST FANS OPERATING ON THE
PREMISES WITH A WATER HEATER CAN RESULT IN CARBON
MONOXIDE POISONING AND DEATH.

3

OPERATION OF THESE FANS CAN PRODUCE A NEGATIVE
DRAFT IN THE AREA OF THE WATER HEATER PREVENTING
THE PRODUCTS OF COMBUSTION FROM EXHAUSTING
THROUGH THE CHIMNEY OR VENT PIPE.

The venting of the water heater should be inspected by a qualied
service technician at the time of installation and periodically
thereafter to ensure a down-draft condition does not exist.

DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND
VENTILATING AIR. ADEQUATE AIR FOR COMBUSTION AND
VENTILATION MUST BE PROVIDED FOR SAFE OPERATION.

EXTENDED NON-USE PERIODS

WARNING

HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER
SYSTEM SERVED BY THIS HEATER THAT HAS NOT BEEN
USED FOR A LONG PERIOD OF TIME (GENERALLY TWO
WEEKS OR MORE). HYDROGEN GAS IS EXTREMELY
FLAMMABLE. To reduce the risk of injury under these conditions,

it is recommended that the hot water faucet be opened for several
minutes at the kitchen sink before using any electrical appliance
connected to the hot water system. If hydrogen is present, there will
probably be an unusual sound such as air escaping through the pipe
as the water begins to ow. THERE SHOULD BE NO SMOKING

OR OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.

INSULATION BLANKETS

Insulation blankets available to the general public for external
use on gas water heaters are not approved for use on your
Lochinvar water heater. The purpose of an insulation blanket is to
reduce the standby heat loss encountered with storage tank water
heaters. Your Lochinvar water heater meets or exceeds the the
current edition of ASHRAE/IES 90.1 standards with respect to
insulation and standby loss requirement 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 of the water heater, as
this will interfere with safe operation of drafthood.

• 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 Lochinvar for placement on the
blanket directly over the existing labels.

HIGH ALTITUDE INSTALLATIONS

As elevation above sea level is increased, there is less oxygen
per cubic foot of air. Therefore, the heater input rate should be
reduced at high altitudes for satisfactory operation with the reduced
oxygen supply. Failure to make this reduction would result in an
overring of the heater causing sooting, poor combustion and/or
unsatisfactory heater performance.

REQUIREMENTS

Ratings specied by manufacturers for most appliances apply
for elevations up to 2000 feet. For elevations above 2000
feet, ratings must be reduced at the rate of 4% for each 1000
feet above sea level. For example, if a heater is rated at
120,000 Btuh at sea level, to rate the heater at 4000 feet, you
subtract 4 (once for each thousand feet) x.04 (4% input reduction)
x 120,000 Btuh (original rating) from the original rating. Therefore,
to calculate the input rating at 4,000 feet: 4 x .04 x 120,000 =19,200
Btuh, 120,000 - 19,200 = 100,800 Btuh. At 6000 feet the correct

input rating should be 91,200 Btuh.

The input reduction is primarily achieved by reducing the
size of the main burner orices. To do this, the main burner
orices require replacement with orices sized for the particular
installation elevation. Correct orice sizing and parts may be
obtained from Lochinvar. When ordering, be sure to state the
model number and the altitude of the location where the water
heater is being installed.

Upon completion of derating of the heater, adjustment to the
gas pressure regulator may be required. See CHECKING
THE INPUT section in this manual for inlet and manifold
pressure requirements.

Also due to the input rating reduction required at high altitudes,
the output rating of the appliance is also reduced and should be
compensated for in the sizing of the equipment for application.

FEATURES

THE ELIMINATOR™ (SELF-CLEANING SYSTEM)

These units include The Eliminator (Self-Cleaning System)
installed in the front water inlet, see Figure 2. The Eliminator
must be oriented correctly for proper function. There is a marked
range on the pipe nipple portion of the Eliminator, that must be
aligned with the top of the inlet spud. A label above the jacket
hole has an arrow that will point to the marked portion of the pipe
nipple if the orientation is correct. If the arrow does not point
within the marked range on the pipe nipple, adjust the pipe nipple
to correct. A pipe union is supplied with the Eliminator to reduce
the probability of misaligning the Eliminator accidentally while
tightening the connection to the inlet water supply line. Improper
orientation of the Eliminator can cause poor performance of the
heater and can signicantly reduce outlet water temperatures
during heavy draws.

WARNING

INSTALLATIONS ABOVE 2000 FEET (610 METERS) REQUIRE
REPLACEMENT OF THE BURNER ORIFICE IN ACCORDANCE
WITH SECTION 8.1.2 OF THE NATIONAL FUEL GAS CODE
(ANSI Z223.1). FAILURE TO REPLACE THE ORIFICE WILL
RESULT IN IMPROPER AND INEFFICIENT OPERATION
OF THE APPLIANCE RESULTING IN THE PRODUCTION
OF INCREASED LEVELS OF CARBON MONOXIDE GAS
IN EXCESS OF SAFE LIMITS WHICH COULD RESULT IN
SERIOUS PERSONAL INJURY OR DEATH.

You should contact your gas supplier for any specic changes
which may be required in your area.

Note: The inlet tube may have 1, 3 or 7 cross tubes.

FIGURE 2

For proper function, the Eliminator must be oriented correctly.
There is a marked range on the pipe nipple that must be aligned
with the top of the inlet spud (check for label on the appliance)
to assure proper operation. Please check to conrm that the
marked range is in alignment with the top of the spud. A pipe
union is supplied with the Eliminator to help eliminate the

4

possibility of changing the orientation by accidentally overtightening
the inlet supply. Improper orientation of the Eliminator may cause
temperature buildup issues or spells of colder than usual water

temperatures.

HIGH LIMIT SWITCH

The digital thermostat (see Figure 3) contains the high limit
(energy cutoff) sensor. The high limit switch interrupts
main burner gas ow should the water temperature reach
20 3°F(19 5°C).

In the event of high limit switch operation, the appliance cannot be
restarted unless the water temperature is reduced to approximately
120°F (49°C). The high limit reset button on the front of the control

then needs to be depressed.

Continued manual resetting of high limit control, preceded by
higher than usual water temperature is evidence of high limit
switch operation. The following is a possible reason for high limit
switch operation.

A malfunction in the thermostatic controls would allow the gas
valve to remain open causing water temperature to exceed the
thermostat setting. The water temperature would continue to rise
until high limit switch operation.

Contact your dealer or service agent if continued high limit
switch operation occurs.

EXHAUST INDUCER (BLOWER ASSEMBLY)

All units are equipped with a exhaust inducer. The inducer
assists in drawing in fresh air to the unit for combustion and then
assists in dispensing the combustion by-products into the venting
leading outside.

The exhaust inducer is equipped with a gravity controlled damper
to reduce the amount of heat loss through the ue, improving
efciency.

FIGURE 5 - EXHAUST INDUCER

FIGURE 3 - DIGITAL THERMOSTAT

ELECTRONIC IGNITION CONTROL

Each heater is equipped with a ignition module. The solid state
ignition control (see Figure 4), ignites the main burner by utilizing
a silicone nitride ignitor. The silicone nitride ignitor shuts off during
the heating cycle and the main burner ame is sensed through a
remote ame sensor integral to the silicone nitride ignitor assembly.
The ignition control will try to ignite the main burner three times
before lockout. Then it waits one hour before trying again to ignite
the main burners. This is a continuous cycle.

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 latest version of the
National Electric Code ANSI/NFPA No. 70.

Only all bronze circulators are used with commercial water

heaters.

Although circulators are oiled and operated by the manufacturer
some circulators must be oiled again before operating. Please
refer to manufacturer’s instructions.

DISHWASHING MACHINE REQUIREMENT

These appliances meet the National Sanitation Foundation
Standard for sanitary installations when used with the following
leg kit part number 9003425205.

All dishwashing machines meeting the National Sanitation
Foundation requirements are designed to operate with water
ow pressures between 15 and 25 psi. Flow pressures above
25 psi, or below 15 psi, will result in improperly sanitized dishes.
Where pressures are high, a water pressure reducing or ow
regulating control valve should be used in 180°F (82°C) line to
the dishwashing machine, and should be adjusted to deliver water
between these limits.

FIGURE 4 - IGNITION CONTROL BOARD

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.

5

INSTALLATION INSTRUCTIONS

REQUIRED ABILITY

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.

WARNING

FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT
IN SERIOUS PERSONAL INJURY OR DEATH.

UNCRATING

The heater is shipped with the inducer already installed. The wiring
conduit runs from the thermostat to the inducer. Before turning unit on,
check to make sure wiring conduit is securely plugged into the inducer.

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 PILOT OR MAIN BURNER FLAMES CAUSING FIRE
OR EXPLOSION. SOME LOCAL CODES PERMIT OPERATION OF
GAS APPLIANCES IN SUCH AREAS IF THEY ARE INSTALLED
18” OR MORE ABOVE THE FLOOR. THIS MAY REDUCE THE
RISK IF LOCATION IN SUCH AN AREA CANNOT BE AVOIDED.

DO NOT INSTALL THIS WATER HEATER DIRECTLY ON A
CARPETED FLOOR. A FIRE HAZARD MAY RESULT. Instead the

water heater must be placed on a metal or wood panel extending
beyond the full width and depth by at least 3 inches in any direction.
If the heater is installed in a carpeted alcove, the entire oor shall
be covered by the panel. Also, see the DRAINING requirements
in MAINTENANCE Section.

THE HEATER SHALL BE LOCATED OR PROTECTED SO IT IS
NOT SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE.

WARNING

FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY
OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST
NEVER BE PLACED ON OR ADJACENT TO THE HEATER. OPEN
CONTAINERS OR 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
stack or chimney 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, A SUITABLE
DRAIN PAN SHOULD BE INSTALLED UNDER THE HEATER. Such

pans should be fabricated with sides at least 2” deep, with length and
width at least 2” greater than the diameter of the heater and must be
piped to an adequate drain. The pan must not restrict combustion air ow.

For appliance installation locations with elevations above
20 0 0 feet (610 m), refer to HIGH ALTITU DE INSTALL ATIO NS
section of this manual for input reduction procedure.

LEVELING

If the unit is not level, insert the bolts which were used in crating
into the legs to correct this condition.

CLEARANCES

These heaters are approved for installation on combustible ooring
in an alcove when the minimum clearance from any combustion
construction are followed as indicated in gure 6.

In all installations the minimum combustible clearances from vent
piping shall be 6”. Vent piping passing through a combustible wall
or ceiling must be a continuous run (no joints) and retain the 6”
clearance unless an approved reducing thimble is used.

A service clearance of 24” should be maintained from serviceable
parts, such as relief valves, ue bafes, thermostats, cleanout
openings or drain valves.

The units are approved for installation with side, rear and ceiling
clearances.

HARD WATER

Where hard water conditions exist, water softening or threshold type
of water treatment is recommended. This will protect dishwashers,
coffee urns, water heaters, water piping and other equipment.

See MAINTENANCE section for details of tank cleanout procedure.

CLOSED WATER SYSTEMS

Water supply systems may, because of code requirements
or such conditions as high line pressure, among others, have
installed devices such as pressure reducing valves, check
valves, and back ow preventers. Devices such as these cause
the water system to be a closed system.

THERMAL EXPANSION

As water is heated, it expands (thermal expansion). In a closed
system the volume of water will grow when it is heated. As the
volume of water grows there will be a corresponding increase
in water pressure due to thermal expansion. Thermal expansion
can cause premature tank failure (leakage). This type of failure
is not covered under the limited warranty. Thermal expansion
can also cause intermittent Temperature-Pressure Relief Valve
operation: water discharged from the valve due to excessive
pressure build up. This condition is not covered under the limited
warranty. The Temperature-Pressure Relief Valve is not intended
for the constant relief of thermal expansion.

A properly sized thermal expansion tank must be installed on
all closed systems to control the harmful effects of thermal
expansion. Contact a local plumbing service agency to have a
thermal expansion tank installed.

AIR REQUIREMENTS

REFER TO THE LATEST EDITION OF THE “NATIONAL FUEL
GAS CODE” ANSI Z223.1/NFPA 54.

KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE
MATERIALS, GASOLINE AND OTHER FLAMMABLES,
VAPORS AND LIQUIDS.

DO NOT OBSTRUCT THE FLOW OF COMBUSTION OR
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 AIR CONTAMINATION THAT
MAY BE HAZARDOUS TO LIFE. SUCH A CONDITION OFTEN
WILL RESULT IN A YELLOW, LUMINOUS BURNER FLAME,

6

FIGURE 6 - ILLUSTRATION OF MINIMUM COMBUSTIBLE CLEARANCES IN AN ALCOVE

CAUSING CARBONING OR SOOTING OF THE COMBUSTION
CHAMBER, BURNERS AND FLUE TUBES AND CREATES A
RISK OF ASPHYXIATION.

Where an exhaust fan is supplied in the same room with a
heater, sufcient openings for air must be provided in the walls.

UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN
INTO THE ROOM THROUGH THE CHIMNEY, CAUSING POOR
COMBUSTION. SOOTING MAY RESULT IN SERIOUS DAMAGE

TO THE HEATER AND RISK OF FIRE OR EXPLOSION.

UNCONFINED SPACE

In buildings of conventional frame, brick, or stone construction,
unconned spaces may provide adequate air for combustion,
ventilation and draft hood dilution.

If the unconned space is within a building of tight construction
(buildings using the following construction: weather stripping,
heavy insulation, caulking, vapor barrier, etc.), air for combustion,
ventilation and draft hood dilution must be obtained from outdoors.
The installation instructions for confined spaces in tightly
constructed buildings must be followed to ensure adequate air
supply.

CONFINED SPACE

When drawing combustion and dilution air from inside a
conventionally constructed building to a conned space, such a
space shall be provided with two permanent openings, ONE IN
OR WITHIN 12 INCHES OF THE ENCLOSURE TOP AND ONE
IN OR WITHIN 12 INCHES OF THE ENCLOSURE BOTTOM.
Each opening shall have a free area of at least one square inch
per 1000 Btuh of the total input of all appliances in the enclosure,
but not less than 100 square inches.

If the conned space is within a building of tight construction,
air for combustion, ventilation, must be obtained from outdoors.
When directly communicating with the outdoors or 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 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 per
2000 Btuh of the total input of all appliances in the enclosure.

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.

Heater must be protected from freezing downdrafts.

Remove all soot or other obstructions from the chimney that will

retard a free draft.

Type B venting is recommended with these heaters.

This water heater must be vented in compliance with all local
codes, the current revision of the National Fuel Gas Code
(ANSI-Z223.1) and with the Category I Venting Tables.

If any part of the vent system are exposed to ambient
temperatures below 40°F (4°C) it must be insulated to
prevent condensation.

The following steps shall be followed with each appliance
connected to the venting system placed in operation, while
any other appliances connected to the venting system are not

in operation.

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal pitch,
as required in the National Fuel Gas Code, ANSI Z223.1.
Determine that there is no blockage or restriction, leakage,
corrosion and other deciencies which could cause an unsafe
condition.

3. So far as is practical, close all building doors and windows
and all doors between the space in which the water heater(s)
connected to the venting system are located and other spaces
of the building. Turn on all appliances not connected to the
venting system. Turn on all exhaust fans, such as range hoods
and bathroom exhausts, so they shall operate at maximum
speed. Close replace dampers.

4. Follow the lighting instruction. Place the water heater being
inspected in operation. Adjust thermostat so appliance shall
operate continuously.

5. After it has been determined that each appliance connected
to the venting system properly vents when tested as outlined
above, return doors, windows, exhaust fans, replace dampers
and any other gas burning appliance to their previous conditions

of use.

6. If improper venting is observed during any of the above tests,
the venting system must be corrected.

WARNING

FAILURE TO CORRECT BACK DRAFTS MAY CAUSE AIR
CONTAMINATION AND UNSAFE CONDITIONS.

• If the back draft cannot be corrected by the normal method or
if a suitable draft cannot be obtained, a blower type ue gas
exhauster must be employed to assure proper venting and
correct combustion.

• Do not connect the heater to a common vent or chimney with
solid fuel burning equipment. This practice is prohibited by
many local building codes as is the practice of venting gas
red equipment to the duct work of ventilation systems.

7

FIGURE 7

• Where a separate vent connection is not available and the vent
pipe from the heater must be connected to a common vent with
an oil burning furnace, the vent pipe should enter the smaller
common vent or chimney at a point above the large vent pipe.

CAUTION

A closed system will exist if a check valve (without bypass),
pressure reducing valve (without bypass), or a water meter
(without bypass) is installed in the cold water line between
the water heater and street main (or well).

Excessive pressure may develop in such closed systems,
causing premature tank failure or intermittent relief valve
operation. This is not a warranty failure. An expansion tank
or a similar device may be required in the inlet supply line
between the appliance and the meter or valve to compensate
for the thermal expansion of the water.

MULTIPLE HEATER MANIFOLD

When horizontally manifolding two or more heaters vent as
shown in Figure 8. Refer to NFPA 54/ANSI Z223.1 for venting
multiple heaters.

FIGURE 8

WATER LINE CONNECTIONS

This manual provides detailed installation diagrams (see pages
12 thru 17 of this manual) for typical methods of application for
the water heaters.

The water heater may be installed by itself, or with a separate
storage tank, on both single and two-temperature systems. When
used with a separate storage tank, the circulation may be either
by gravity or by means of a circulating pump. When a circulating
pump is used it is important to note that the ow rate should be
slow so that there will be a minimum of turbulence inside the heater.

If a water heater is installed in a closed water system, contact the water
supplier or local plumbing inspector on how to control this situation.

WATER (POTABLE) HEATING

AND SPACE HEATING

1. All piping components connected to this unit for space heating

applications shall be suitable for use with potable water.

2. Toxic chemicals, such as those used for boiler treatment, shall
NEVER be introduced into this system.

3. This unit may NEVER be connected to any existing heating
system or component(s) previously used with a non-potable

water heating appliance.

4. When the system requires water for space heating at
temperatures higher than required for domestic water purposes,
a tempering valve must be installed. Please refer to installation
diagrams on pages 12 thru 17 of this manual for suggested

piping arrangements.

5. These water heaters cannot be used in space heating
applications only.

SYSTEM CONNECTIONS

The system installation must conform to these instructions and to
the local code authority having jurisdiction. Good practice requires
that all heavy piping be supported.

THERMOMETERS (Not Supplied)

Thermometers should be obtained and eld installed as shown in
the installation diagrams.

Thermometers are installed in the system as a means of detecting
the temperature of the outlet water supply.

RELIEF VALVE

This water heater is equipped with a combination
temperature-pressure relief valve that complies with the standard
for relief valves and automatic gas shutoff devices for hot water
supply system, ANSI Z21.22. FOR SAFE OPERATION OF

THE WATER HEATER, THE RELIEF VALVE(S) MUST NOT BE
REMOVED OR PLUGGED.

ASME ratings cover pressure relief capacities. CSA ratings cover
release rate with temperature actuation.

In addition to the appliance relief valve, each remote storage tank
which may be used in conjunction with this appliance shall also be
installed with a properly sized, rated and approved combination
temperature (ANSI) and pressure (ASME) relief valve(s).

WARNING

THE PURPOSE OF RELIEF VALVE IS TO AVOID EXCESSIVE
PRESSURE OR TEMPERATURE INTO THE STEAM RANGE,
WHICH MAY CAUSE SCALDING AT FIXTURES, TANK
EXPLOSION, SYSTEM OR HEATER DAMAGE. NO VALVE IS
TO BE PLACED BETWEEN THE RELIEF VALVE AND TANK.

Your local code authority may have other specic relief valve
requirements.

A DRAIN LINE MUST BE CONNECTED TO THE RELIEF VALVE
TO DIRECT DISCHARGE TO A SAFE LOCATION TO AVOID
SCALDING OR WATER DAMAGE. THIS LINE MUST NOT BE
REDUCED FROM THE SIZE OF THE VALVE OUTLET AND
MUST NOT CONTAIN VALVES, RESTRICTIONS NOR SHOULD
IT BE LOCATED IN FREEZING AREAS. DO NOT THREAD OR
CAP THE END OF THIS LINE. RESTRICTED OR BLOCKED
DISCHARGE WILL DEFEAT THE PURPOSE OF THE VALVE
AND IS UNSAFE. DISCHARGE LINE SHALL BE INSTALLED TO
ALLOW COMPLETE DRAINAGE OF BOTH THE VALVE AND LINE.

See SERVICE INFORMATION section for procedure and
precautions.

8

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 2. The gures
shown are for straight lengths of pipe at 0.5 in. W.C. pressure
drop, which is considered normal for low pressure systems. Note:
Fittings such as elbows, tees and line regulators will add to the
pipe pressure drop. Also refer to the latest version of the National
Fuel Gas Code.

To prevent damage, care must be taken not to apply too much
torque when attaching gas supply pipe to gas valve inlet.

Apply joint compounds (pipe dope) sparingly and only to the
male threads of pipe joints. Do not apply compounds to the rst
two threads. Use compounds resistant to the action of liqueed
petroleum gases.

BEFORE PLACING THE HEATER IN OPERATION, CHECK FOR
GAS LEAKAGE. Use soap and water solution or other material
acceptable for the purpose in locating the leaks. DO NOT USE
MATCHES, CANDLES, FLAME OR OTHER SOURCES OF
IGNITION FOR THIS PURPOSE.

WARNING

THE HEATER IS NOT INTENDED FOR OPERATION AT
HIGHER THAN 14.0” W.C.(3.48 kPa) - NATURAL GAS, 14.0”
W.C.(3.48kPa) EXPOSURE TO HIGHER SUPPLY PRESSURE
MAY CAUSE DAMAGE TO THE GAS VALVE WHICH COULD
RESULT IN FIRE OR EXPLOSION. IF OVERPRESSURE HAS
OCCURRED SUCH AS THROUGH IMPROPER TESTING OF
GAS LINES OR EMERGENCY MALFUNCTION OF THE SUPPLY
SYSTEM, THE GAS VALVE MUST BE CHECKED FOR SAFE
OPERATION. MAKE SURE THAT THE OUTSIDE VENTS ON
THE SUPPLY REGULATORS AND THE SAFETY VENT VALVES
ARE PROTECTED AGAINST BLOCKAGE. THESE ARE PARTS
OF THE GAS SUPPLY SYSTEM, NOT THE HEATER. VENT
BLOCKAGE MAY OCCUR DURING ICE STORMS.

TABLE 2 - GAS SUPPLY LINE SIZES (IN INCHES)*

MAXIMUM CAPACITY OF PIPE IN CUBIC FEET PER HOUR

(Based upon a Pressure Drop of 0.5 inch Water Column and

0.6specicGravityGasandmax.gaspressureof0.5psig)

LENGTH NOMINAL IRON PIPE SIZES (INCHES)

IN 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
20 120 250 465 950 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

IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING
FROM CONTAMINANTS IN THE GAS WAYS. SUCH FOULING
MAY CAUSE IMPROPER OPERATION, FIRE OR EXPLOSION.

IF COPPER SUPPLY LINES ARE USED THEY MUST BE
INTERNALLY TINNED AND CERTIFIED FOR GAS SERVICE.
BEFORE ATTACHING THE GAS LINE, BE SURE THAT ALL
GAS PIPE IS CLEAN ON THE INSIDE.

TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS
SUPPLY LINE, A DIRT LEG (SOMETIMES CALLED SEDIMENT
TRAP OR DRIP LEG) MUST BE INCORPORATED IN THE PIPING
(SEE FIG. 9). THE DIRT LEG MUST BE READILY ACCESSIBLE
AND NOT SUBJECT TO FREEZING CONDITIONS. INSTALL
IN ACCORDANCE WITH RECOMMENDATIONS OF SERVING
GAS SUPPLIERS. REFER TO THE LATEST VERSION OF THE
NATIONAL FUEL GAS CODE.

DISCONNECT THE HEATER AND ITS MANUAL GAS SHUTOFF
VALVE FROM THE GAS SUPPLY PIPING SYSTEM DURING
ANY SUPPLY PRESSURE TESTING EXCEEDING 1/2 PSIG.
GAS SUPPLY LINE MUST BE CAPPED WHEN DISCONNECTED
FROM THE HEATER FOR TEST PRESSURES OF 1/2 PSIG OR
LESS. THE APPLIANCE NEED NOT BE DISCONNECTED, BUT
MUST BE ISOLATED FROM THE SUPPLY PRESSURE TEST
BY CLOSING THE MANUAL GAS SHUTOFF VALVE.

GAS PIPING AND DIRT LEG INSTALLATION

FIGURE 9

PURGING

Gas line purging is required with new piping or systems in which

air has entered.

CAUTION

PURGING SHOULD BE PERFORMED BY PERSONS
EXPERIENCED IN THIS TYPE GAS SERVICE. TO AVOID RISK
OF FIRE OR EXPLOSION, PURGE DISCHARGE MUST NOT
ENTER CONFINED AREAS OR SPACES WHERE IGNITION CAN
OCCUR. THE AREA MUST BE WELL VENTILATED AND ALL
SOURCES OF IGNITION MUST BE INACTIVATED OR REMOVED.

GAS METER SIZE — NATURAL GASES ONLY

Be sure the gas meter has sufcient capacity to supply the full
rated gas input of the water heater as well as the requirements of
all other gas red equipment supplied by the meter. If gas meter
is too small, ask the gas company to install a larger meter having
adequate capacity.

GAS PRESSURE REGULATOR

The gas pressure regulator is built into the gas valve and is
equipped to operate on the gas specied on model and rating
plate. The regulator is factory adjusted to deliver gas to burner
at correct water column pressure allowing for a nominal pressure
drop through the controls.

The minimum gas supply pressure for input adjustment must not
be less than 4.5” w.c. for natural gas.

9