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RPD-I
Service Manual
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Lochinvar RPD-I, Power Direct Vent Gas Service Manual

INSTALLATION & SERVICE MANUAL
RPD-I&S
POWER DIRECT VENT 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 ..................................................................... 1
Locating The Water Heater .............................................. 1
Minimum Clearances ....................................................... 2
Venting ...................................................................... 2-6
Water Connections ......................................................... 7
Gas Connections............................................................. 8
Electrical Connections...................................................... 8
Wiring Diagram.............................................................. 9
GENERAL OPERATION .............................................................. 8
Lighting and Shutdown Instructions .............................. 10
Thermostat Adjustment ................................................. 10
Burner Flame Check ....................................................... 10
MAINTENANCE ...................................................................... 11
INSTALLATION INSTRUCTIONS FOR POTABLE WATER AND
SPACE HEATING .................................................................... 12
VENT PIPE PREPARATION AND JOINING .................................. 12
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 held 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.
CAUTION
Incorrect operation of this appliance may create a hazard to life and property and will nullify the warranty.
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.
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
GENERAL INFORMATION
This gas-fired water heater’s design is certified by CSA International under the
American National Standard Z21.10.1 - (as indicated on the rating plate) and CSA 4.1-M - (as indicated on the rating plate).
This water heater must be installed in accordance with local codes or, in the absence of local codes, the National Fuel Gas Code, ANSI Z223.1-Latest Edition) and/or in Canada CAN/CGA B149 Installation Codes (Latest Editions). The
Water heaters are heat producing appliances. To avoid damage or injury there
WARNING
shall be no materials stored against the water heater or vent-air intake system. Use proper care 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.
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Locating The Water Heater
DO NOT install the water heater in any location where gasoline or flammable vapors are likely to be present.
CAUTION
The National Fuel Gas Code (ANSI Z233.1-or latest edition) and CAN/CGA (B149.1-or latest edition), expressly prohibits the installation of a water heater in a garage, unless the unit is installed so that the burner and ignition devices are at least eighteen (18) inches (46 cm) above floor level and
protected to avoid damage by a moving vehicle.
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.
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!
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT
WARNING
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.
The water heater must be located close enough to the outside wall to keep the venting distance within the maximum distance described in the installation instructions. Read the venting section in this installation instruction manual before locating the water heater.
This water heater must be located in an area where leakage of the tank or water line connections and 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 adequately piped for proper drainage, 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 must allow access to the front of the water heater and adequate clearance must be provided for servicing and operating this water heater. The water heater may be installed on either a combustible or non-combustible floor. If the water heater is to be installed directly on carpeting, it must be installed on top of a metal or wood panel 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 must be covered by the panel. The minimum clearances to combustibles for this water heater is: zero (0) inches (0 cm) from the sides and rear, five (5) inches (12.7 cm) from the front of the jacket, zero (0) inches (0 cm) from the vent connector and fifteen (15) inches (38.1 cm) from the jacket top.
VENTING
The Nation Fuel Gas Code ANSI Z223.1-(Latest Edition), CGA/CAN B149 Installation Code, and local codes have specific requirements for the location of the vent terminals on vertical walls. The guide lines listed below are from the National
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Fuel Gas Code. Consult the local codes, and/or National Fuel Gas Code ANSI Z223.1-(Latest Edition), or CGA/CAN B149 Installation Code to determine if there are any additions or changes to the following specifications.
(A) The vent terminals must terminate at least 3 feet (.91 m) above any
forced air inlet duct located within 10 feet (3 m). Exception: This provision shall not apply to the combustion air intake of a direct vent appliance.
(B) The vent terminals must terminate at least 1 foot (1.2m) below, 1
foot (1.2 m) horizontally from, or 1 foot (.31 m) above any door, window, gravity air inlet into the building.
(C) The bottom of the vent terminals must be located at least 1 foot
(.31 m) above grade and above the anticipated snow level.
(D) The vent terminals must not terminate over a public walkway or over
an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valve, or other equipment.
(E) The water heater location must provide easy access for the entire
length of the vent connector.
(F) The vent system must be inspected at least once a year to ensure
against leakage of exhaust products.
Exceptions For Installations in Canada:
(A) The vent terminals must be located at least 1 foot (.31 m) from any
window or door which can be opened in any building, any non-mechanical air supply inlet to any building, or the combustion air inlet to any other appliance.
(B) The vent terminals must be located at least 6 feet (1.8 m) from any
mechanical air supply inlet to the building.
(C) The vent terminals must not terminate above a meter/regulator
assembly or within 3 feet (.91 m) horizontally of the vertical center line of the regulator and must be at least 6 feet (1.8 m) from any gas service regulator vent outlet.
(D) The vent terminals must be at least 7 feet (2.1 m) above a paved
sidewalk or a paved driveway located on public property.
(E) The vent terminals must not terminate above a paved sidewalk or a
paved driveway which is located on adjacent private property.
7. After securing the Vertical Pipe to the Jacket Head with the Support Bracket, tighten the clamps on the Rubber Intake Elbow.
8. Using the RTV sealant provided, place a bead of RTV around the Vertical Pipe at the Metal Boot location, and at the Intake Tee location. Smooth out the RTV to provide a seal at both locations.
9. Two 90° end terminal elbows are supplied. These must be installed at the extreme ends of the intake and exhaust venting outside the building. The end terminal with the external screen must be installed on the intake vent as shown in Figure 7.
10.Proceed as necessary to complete the venting installation as described in the venting section of this manual.
Figure 1
Vent Assembly Illustration
“This End up” Label
Intake Tee
Apply RTV Sealant Here
Support Bracket
Vertical Pipe
Apply RTV Sealant Here
Metal Boot
Curve Faces Upward
Rubber Intake Elbow
Blower Intake Collar
Jacket Head
Gas Control
Venting Installation Instructions For Supplied Intake Venting:
1. Refer to Figure 1, “Vent Assembly Illustration” to install intake venting as described below.
2. Insert one end of the Vertical Pipe into Metal Boot on the lower backside of the water heater.
3. Slide the Support Bracket over the Vertical Pipe, but do not fasten to the Jacket Head.
4. Position the Intake Tee on top of the Vertical Pipe so that the short straight section of the tee faces the Blower Intake Collar, and the curve of the tee faces upward. Proper orientation of the
curved section of the tee is critical. Be sure it is facing upward. Refer to “This End Up” label on Intake Tee.
5. Slide the Rubber Intake Elbow over the Blower Intake Collar and over the short straight section of the Intake Tee.
6. Using a level to ensure that the Vertical Pipe is straight up and down, secure the Vertical Pipe to the Jacket Head using the Support Bracket and three (3) self-drilling screws provided. NOTE:
Correct vertical positioning of the Vertical Pipe is Important.
Venting System Condensation
Condensate formation does not occur in all installations of power vented heaters, but should be protected against on installations where condensation can form in the venting system.
Formation of condensation in the venting system of Power Vented water heaters is dependent upon installation conditions including, but not limited to:
ambient temperature and humidity of installation location;
ambient temperature and humidity of venting space;
vent distance and slope;
and product usage.
In order to effectively control condensate from adversely affecting the mechanical components of the water heater several methods may be employed:
1. For horizontal installations the vent pipe can be installed with a downward slope (not less than 1/8" nor greater than ½” per foot maximum) and away from the blower motor.
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2. In order to prevent condensate from draining back into the blower (vertical or horizontal runs), a fitting and drain hose is available as a condensate trap kit (see Table 1 for service part numbers). The all rubber fitting with drain outlet mounts directly to the blower motor outlet and is secured with two hose clamps (one to the blower motor outlet and the other to the vent connector). The plastic tubing is provided to drain any accumulated condensate away from the water heater and to a suitable drain. The kit comes complete with instructions for proper installation of the fitting.
Table 1
Model Service Part
2” (5.1 cm) Blower Outlet (exhaust) DRV1200 3” (7.6 cm) Blower Outlet (exhaust) DRV1201
3. In order to prevent condensate from draining back into the blower (vertical or horizontal runs), a drain tee and condensate trap can be installed in the horizontal vent as close as practical to the blower vent connection (see Figure 2). The condensate disposal tube should be installed to drain any accumulated condensate away from the water heater and to a suitable drain. The drain tee and condensate hose are available through your local distributor.
CONDENSATE “T”
ELBOW
Figure 2
ELBOW
BLOWER
To calculate total equivalent feet
Add up the total number of 90° elbows on the intake and the exhaust, and multiply by 5 feet (1.5 m) (each 90° elbow is equivalent to 5 feet (1.5 m) of straight pipe). To this number add the total number of feet of straight pipe on the intake and the exhaust. This sum (total of all 90° elbows at 5 feet (1.5 m) each, plus total number of feet of straight pipe) must not exceed 80 feet (24.4 m). All elbows must be included in the calculation except those on the extreme ends of the intake and exhaust. 45° elbows may also be used. When using 45° elbows, take the total number of 45° elbows on the intake and exhaust and multiply by 2-1/2 feet (.76 m) (each 45° elbow is equivalent to 2-1/2 feet (.76 m) of straight pipe).
Total equivalent feet= (# of 90° elbows x 5) + (# of 45° elbows x 2-1/2) + (total feet of straight pipe)
Total equivalent meters= (# of 90° elbows x 1.5) + (# of 45° elbows x .76) + (total meters of straight pipe)
EXAMPLE: The exhaust has two 90° elbows and the intake has four 90° elbows. The total feet of straight pipe on the exhaust is 15 ft. (4.6 m) and the total feet of straight pipe on the intake is 20 ft (6.1 m).
six 90° elbows x 5 ft. each = 30 ft
Total straight pipe = 11 ft+3 ft+1 ft+3 ft+9 ft+6 ft+2 ft= 35 ft
Total equivalent feet = 65 ft
LOOP
DRAIN TUBE
TO DRAIN
This water heater is a power direct vented appliance and is designed to intake and exhaust its products of combustion through 3" (7.6 cm) or 4" (10.2 cm) diameter Schedule 40 PVC pipe to the outdoors. This water heater may intake and exhaust either through the wall or vertically through the roof. Use a 3" (7.6
cm) to 4" (10.2 cm) reducer to connect to the intake and outlet when using 4" (10.2 cm) PVC. Table 2 lists the maximum intake and exhaust lengths for this
water heater using 3" (7.6 cm) PVC. If possible, locate the water heater so that the venting length and number of elbows are kept to the minimum distance necessary to reach the outside. If the installation requires venting lengths that exceed the lengths listed for 3" (7.6 cm) PVC in Table 2, then use 4" (10.2 cm) PVC for the vent connector. Table 3 lists the venting distances allowed with 4"
(10.2 cm) diameter PVC pipe. When venting with 4" (10.2 cm) PVC, use a 4" (10.2 cm) to 3" (7.6 cm) reducer to exit through the building wall with 3" (7.6 cm) PVC. Use the 3" (7.6 cm) vent terminal supplied with the water heater to
terminate on the outside of the building. If the length of the 3" (7.6 cm) PVC needed to go through the wall is greater than 14" (35.5 cm), use 4" (10.2 cm) PVC to go through the wall and reduce to 3" (7.6 cm) PVC immediately after exiting the outside wall. Refer to the venting illustrations on the following pages. Make sure the vent pipe terminal elbow fittings are at least 1" (2.5 cm) away from the edge of the wall.
Total six 90° elbows x 1.5 m each = 9.0m straight pipe=3.4m+.91m+.31m+.91m+2.7m+1.8m+.61m = 10.6m
Total equivalent meters = 19.6m
1 FT
(0.31 M)
EXHAUST
3 FT
(0.91 M)
BLOWER ASSEMBLY
9 FT
(2.7 M)
INTAKE
11 FT
(3.4 M)
6 FT
(1.8 M)
ELBOWS NOT INCLUDED
IN CALCULATION
WALL
2 FT
(0.6 M)
ELBOWS INCLUDED
3 FT
(0.91 M)
IN CALCUALTION
Figure 3
IMPORTANT
For 3" (7.6 cm) vent piping, the total equivalent feet of venting (intake plus exhaust) must not exceed 80 feet (24.4 m) and the total equivalent feet of venting (intake or exhaust) must not exceed 40 feet (12.2 m). The total equivalent feet of intake must be within 20 feet (6.1 m) of the total equivalent feet of exhaust. See Table 2 for common 3" (7.6 cm) vent lengths.
For 4" (10.2 cm) vent piping, the total equivalent feet of venting (intake plus exhaust) must not exceed 150 feet (45.7 m) and the total equivalent feet of venting (intake or exhaust) must not exceed 75 feet (22.9 m). The total equivalent feet of intake must be within 20 feet (6.1 m) of the total equivalent feet of exhaust. See Table 3 common 4" (10. cm) vent lengths.
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