Lochinvar Ultra Low NOx Gas, RGU-I Service Manual

INSTALLATION & SERVICE MANUAL

For Flammable Vapor Ignition Resistant System

Equipped Water Heater

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GAS-FIRED WATER HEATER

WARNING

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

FOR YOUR SAFETY Do not store or use gasoline or other flammable, combustible, or corrosive 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 telephone in your building.

• Immediately call your gas supplier from a neighbor’s telephone. 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.

For your family’s comfort, safety and convenience, we recommend this water heater be installed and serviced by a plumbing professional.

TABLE OF CONTENTS

GENERAL INFORMATION .......................................................... 1

INSTALLATION.................................................................... 2

Locating The Water Heater ............................................ 2

Minimum Clearances ...................................................... 3

Venting ........................................................................ 3

Combustion Air Supply .................................................. 3

Water Connections ....................................................... 4

Gas Connections ........................................................... 5

GENERAL OPERATION .............................................................. 6

Lighting and Shutdown Instructions............................... 6

Thermostat Adjustment ................................................. 7

Burner Flame Check ....................................................... 7

MAINTENANCE ........................................................................ 7

INSTALLATION DRAWING FOR POTABLE WATER .......................... 9

INSTALLATION INSTRUCTIONS FOR POTABLE WATER AND

SPACE HEATING .................................................................... 10

GENERAL INFORMATION

This gas-fired water heater is design certified by CSA International under the applicable American National Standard, Z21.10.1 or CSA 4.1-(as indicated on the rating plate), available from CSA International, 8501 East Pleasant Valley Road, Cleveland, OH U.S.A. 44131-5575.

Special Flammable Vapor Ignition Resistant System:

This water heater is equipped with a Flammable Vapor Ignition Resistant System. In the event of improper usage or storage of gasoline or other flammable materials in the location where the water heater is installed, the technology will resist ignition of the flammable vapors outside the confines of the water heater.

The Flammable Vapor Ignition Resistant System features:

• Advanced Flame Arrestor Design.

• Intelligent Diagnostic Control to prevent burner/pilot operation with restricted airflow.

• Spark Igniter

• Sight Window to observe operation of pilot and burner.

FOR YOUR SAFETY: Activation of the Flammable Vapor Ignition Resistant System occurs when flammable vapors are drawn into the water heater and are combusted. If flammable vapors are detected:

• Do not try to light any appliance.

• Do not touch any electrical switch; Do not use any phone in your building.

• Leave the premises and immediately call the fire department from a neighbor’s phone. Follow the fire department’s instructions.

Once the flammable vapor has been evacuated, contact your plumbing professional or the manufacturer for further instructions. Replacement of a Flammable Vapor Ignition Resistant System equipped water heater due to a flammable vapor shutdown is not covered under the terms of the limited

warranty.

This water heater must be installed in accordance with local codes. In the absence of local codes, it must be installed in compliance with the National Fuel Gas Code (ANSI Z223.1-Latest Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.2 Propane Installation Code (Latest Edition). The warranty for this water heater is in effect only when the water heater is installed, adjusted, and operated in accordance with these Installation and Operating Instructions. The manufacturer will not be liable for any damage resulting from alteration and/or failure to comply with these instructions.

This water heater is not design certified for installation in a mobile home. Such an installation may create a hazardous condition and will nullify the warranty.

This water heater has been designed and certified for the purpose of heating potable water. The installation and use of this water heater for any purpose other than the heating of potable water may cause damage to the water heater, create a hazardous condition, and nullify the warranty.

CAUTION

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

Do not use this appliance if any part has been submerged in 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. Depending upon the individual circumstances, it may be necessary to replace the entire water heater.

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DANGER

Do not store or use gasoline or other flammable, combustible, or corrosive vapors and liquids in the vicinity of this or any other appliance.

IMPORTANT

Before proceeding, please inspect the water heater and components for possible damage. DO NOT install any damaged components. If damage is evident then please contact the supplier where the water heater was purchased or the manufacturer listed on the rating plate for replacement parts

This water heater has been manufactured for operation at altitudes from sea level to 2000 feet (610m) (unless otherwise specified on the water heater rating plate). For use of this appliance at an elevation greater than 2000 feet (610m), contact the dealer or manufacturer listed on the rating plate for information on any necessary modification. Uncorrected operation of this appliance may create a hazard to life and property.

Make sure that you check the rating plate and combination gas control on the water heater to be certain that the type of gas being supplied corresponds with the marking on the rating plate and combination gas control.

A sacrificial anode is used to extend tank life. The removal of this anode, for any reason, will nullify the warranty. In areas where water is unusually active, an odor may occur at the hot water faucet due to a reaction between the sacrificial anode and the impurities in the water. If this should happen, an alternative anode may be purchased from the supplier that installed this water heater. This will minimize the odor while protecting the tank. Additionally, the water heater should be flushed with appropriate dissolvers to eliminate any bacteria.

INSTALLATION

Locating The Water Heater

WARNING

Water heaters are heat producing appliances. To avoid damage or injury there shall be no materials stored against the water heater or vent-air intake system and proper care shall be taken to avoid unnecessary contact (especially by children) with the water heater and vent-air intake components.UNDER NO

CIRCUMSTANCES SHALL FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER, VENT-AIR INTAKE SYSTEM OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER OR VENT-AIR INTAKE SYSTEM.

This water heater MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present, unless the installation is such to eliminate the probable ignition of gasoline or flammable vapors.

Water heaters in residential garages must be installed and located, or protected, to avoid physical damage. For other installations refer to local codes. In the absence of local codes, the water heater must be installed in compliance with the National Fuel Gas Code, (ANSI Z223.1- Latest Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.2 Propane Installation Code (Latest Edition).

The location of this water heater is of the utmost importance. Before installing this water heater read the Installation section of these instructions. After reading these Installation and Operating Instructions, select a location for the water heater where the floor is level and is easily accessible to gas and water supply lines. DO NOT locate the water heater where water lines could

be subjected to freezing temperatures. Make sure the cold water pipes are not located directly above the gas control so that condensate during humid weather does not drip on the controls.

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

EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY THE WARRANTY. DO NOT OPERATE THE WATER HEATER IF EXPOSURE HAS OR WILL OCCUR. DO NOT STORE ANY POTENTIALLY CORROSIVE COMPOUNDS IN THE VICINITY OF THE WATER HEATER.

WARNING

Liquefied petroleum gases/propane gas are heavier than air and will remain at floor level if there is a leak. Basements, crawl spaces, closets and areas below ground level will serve as pockets for accumulation of leaking gas. Before lighting, smell all around the appliance area for gas. Be sure to smell next to the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any telephone in your building.

• Immediately call your gas supplier from a neighbor’s telephone. Follow the gas supplier’s instructions.

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

DO NOT OPERATE APPLIANCE UNTIL LEAKAGE IS CORRECTED!

WARNING

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

• Liquefied petroleum gases/propane gas and natural gas have an odorant added by the gas supplier that aids in detection of the gas.

• Most people recognize this odor as a “sulfur” or “rotten egg” smell.

• Other conditions, such as “odorant fade” can cause the odorant to diminish in intensity, or “fade”, and not be as readily detectable.

• If you have a diminished sense of smell, or are in any way unsure of the presence of gas, immediately contact your gas supplier from a neighbor’s telephone.

• Gas detectors are available. Contact your gas supplier or plumbing professional for more information.

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

This water heater must be located in an area where leakage of the tank, water line connections, or the combination temperature and pressure relief valve will not result in damage to the area adjacent to the water heater or to lower floors of the structure. When such locations cannot be avoided, a suitable drain pan

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must be installed under the water heater. The drain pan must be no greater than 1-½ inches (3.8 cm) deep and have a minimum length and width of at least four (4) inches (10.2 cm) measured from the jacket of the water heater. The drain pan, as described above, can be purchased from your plumbing professional. The drain pan must be piped to an adequate drain. The piping must be at least 3/4 inch (1.9 cm) in diameter and pitched for proper drainage.

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

MINIMUM CLEARANCES

WARNING

Failure to adhere to these installation and operating instructions may create a hazard to life and property and will nullify the warranty.

This installation shall allow access to the front of the water heater and adequate clearance shall be provided for servicing and operating this water heater. The water heater may be installed on either a combustible or non-combustible floor. If the water heater is to be installed directly on carpeting, it shall be installed on top of a metal or wood panel (or equivalent) extending beyond the full width and depth of the appliance by at least three (3) inches (7.6 cm) in any direction or, if the appliance is to be installed in an alcove or closet, the entire floor shall be covered by the panel. If the rating plate or the label on the

front of the heater specifies minimum clearances less than those listed in the below table, the water heater may be installed in accordance with the minimum clearances listed on the rating plate or the label on the front of the heater.

Vent piping must be attached to the draft diverter outlet to connect the water heater to the gas vent or chimney. The following minimum clearances must be followed when connecting vent piping:

a) The vent connector must be the same nominal size as the draft

diverter.

b) The vent connector should not exceed 15 feet (4.5m) in length (for

power vent appliances, refer to supplemental instructions), must not project into the chimney beyond the inner wall and should contain the least possible number of bends.

c) All horizontal runs should have a minimum rise of ¼ inch(2.1cm/m)

per foot of run.

d) Joints of vent connectors shall be securely fastened by sheet metal

screws or other approved methods.

e) All single wall vent connectors must be at least 6" (15cm) from

combustible surfaces.

f) Vent connectors made of single-wall metal pipe shall not pass through

any attic, inside wall, concealed space, or any floor. When a single-wall metal pipe passes through an exterior wall constructed of combustible material, it shall be guarded at the point of passage by a ventilated metal thimble at least 4" (10cm) larger in diameter than the connector. (Consult National Fuel Gas Code, ANSI Z223.1and/or CAN/CGA B149, Installation Codes).

A separate vent for each application is strongly recommended. If combined venting of multiple appliances is necessary or if an unusual situation arises, consult the National Fuel Gas Code, ANSI Z223.1and/or CAN/CGA B149, Installation Codes (latest editions), for sizing and installation information.

COMBUSTION AIR SUPPLY

If it is necessary to install this water heater in an alcove, use the clearances listed in Figure 1.

Figure 1

VENTING

WARNING

The vent system must be installed properly. Failure to properly install the vent system could result in property damage, personal injury, or death.

Place the draft diverter over the flue opening at the top of the water heater by inserting the tips of the draft diverter legs into the four (4) holes provided in the water heater top. On some models, line up the holes in the draft diverter legs with the holes provided on top of the water heater. Secure the draft diverter to the water heater with sheet metal screw. (See Figure 5)

WARNING

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any telephone in your building.

• Immediately call your gas supplier from a neighbor’s telephone. Follow the gas supplier’s instructions.

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

DO NOT OPERATE APPLIANCE UNTIL LEAKAGE IS CORRECTED!

IMPORTANT

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

• Do not block or in any way restrict jacket air inlet slots located the bottom front of the water heater.

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, causing carboning or sooting of the combustion chamber, burners and flue tubes with possible damage to the water heater.

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When an exhaust fan is installed in the same room with a heater, sufficient openings for air must be provided in the walls. Undersized openings will cause air to be drawn into the room through the chimney, causing recirculation of combustion products.

Unconfined Spaces

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

WATER CONNECTIONS

Note:

BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN WATER SUPPLY VALVE.

After shutting off the main water supply, open a faucet to relieve the water line pressure to prevent any water from leaking out of the pipes while making the water connections to the water heater. After the pressure has been relieved, close the faucet. The COLD water inlet and HOT water outlet are identified on the top of the water heater. The fittings at the cold water inlet and hot water outlet are dielectric waterway fittings with 3/4" NPT male thread. Make the proper plumbing connections between the water heater and the plumbing system to the house. Install a shut-off valve in the cold water supply line.

Confined Spaces

Confined spaces are spaces defined as having less than 50 ft.

of space per

1,000 BTU (15m3/.29kw) per hour of input.

All Air From Inside the Building: The confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each opening shall have a minimum free area of 1 square inch per 1000 BTU (2.54cm2/.29kw) per hour of the total input rating of all gas utilization equipment in the confined space, but not less than 100 square inches (254cm2). One opening shall be within 12 inches (31cm) of the top and one within 12 inches (31cm) of the bottom of the enclosure.

All Air From Outdoors: The confined space shall be provided with two permanent openings, one commencing within 12 inches (31cm) of the top and one commencing within 12 inches (31cm) 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.

1. When directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4000 BTU (2.54cm2/1.2kw) per hour of total input rating of all equipment in the enclosure.

2. When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4000 BTU (2.54cm2/

1.2kw) per hour of total input rating of all equipment in the enclosure.

If sweat fittings are to be used, DO NOT apply heat to the nipples on top of the

CAUTION

water heater. Sweat the tubing to the adapter before fitting the adapter to the water connections. It is imperative that heat is not applied to the nipples containing a plastic liner.

WARNING

FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED ¾” X ¾” TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE MANUFACTURER FROM ANY CLAIM WHICH MIGHT RESULT FROM EXCESSIVE TEMPERATURE AND PRESSURES.

If this water heater is installed in a closed water supply system, such as the one having a back-flow preventer in the cold water supply, provisions shall be Made to control thermal expansion. DO NOT operate this water heater in a closed system without provisions for controlling thermal expansion. Your water supplier or local plumbing inspector should be contacted on how to control this situation.

After installation of the water lines, open the main water supply valve and fill the water heater. While the water heater is filling, open several hot water faucets to allow air to escape from the water system. When a steady stream of water flows through the faucets, close them and check all water connections for possible leaks. NEVER OPERATE THE WATER HEATER WITHOUT

FIRST BEING CERTAIN IT IS FILLED WITH WATER.

3. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2000 BTU (2.54cm2/.6kw) per hour of total input rating of all equipment in the enclosure.

4. 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 dimension of rectangular air ducts shall be not less than 3 inches (7.5cm)

Specially Engineered Installations

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

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