Instruction Manual
CONTENT
COMMERCIAL GAS WATER HEATERS
POWER DIRECT VENT GAS MODELS
WITH DIRECT SPARK IGNITION
MODELS
PGC/SPC/BSS/BTS
Series 200, 201
NATURAL GAS & PROPANE
LOW LEAD
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
Do not store or use gasoline or other
flammable 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 fire department.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
Thank you for buying this energy efcient water heater.
We appreciate your condence in our products.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, CALL THE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
PRINTED 1216 100277192
• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
1
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE.................................3
APPROVALS .................................................................................3
GENERAL SAFETY INFORMATION .............................................4
Precautions ..............................................................................4
Grounding Instructions .............................................................4
INSTALLATION REQUIREMENTS FOR MASSACHUSETTS
INTRODUCTION ...........................................................................8
Abbreviations Used ..................................................................8
Qualications ............................................................................8
Preparing For The Installation ..................................................8
DIMENSIONS AND CAPACITY DATA ...........................................9
Rough In Dimensions: All Models .............................................9
FEATURES AND COMPONENTS ..............................................11
34 Gallon Unit .........................................................................11
50 Gallon Unit .........................................................................12
Controls And Switches ...........................................................14
INSTALLATION CONSIDERATIONS ..........................................15
Locating The Water Heater ....................................................15
Insulation Blankets .................................................................16
Combustion Air And Ventilation ..............................................16
Corrosion and Water Quality ..................................................16
INSTALLATION REQUIREMENTS .............................................17
Gas Supply Systems ..............................................................17
Supply Gas Regulator ............................................................17
Power Supply .........................................................................17
Mixing Valves..........................................................................18
Circulation Pumps ..................................................................18
Dishwashing Machines ...........................................................18
Space Heating And Potable Water System ............................19
Storage Tank Installation ........................................................19
Solar Installation .....................................................................19
Closed Water Systems ...........................................................19
Thermal Expansion ................................................................19
Temperature-Pressure Relief Valve ........................................20
Condensate Drain ..................................................................21
VENTING INSTALLATION ..........................................................22
Vent Installation Considerations .............................................22
General Venting Instructions ..................................................22
Approved Vent/Intake Material ...............................................22
Polypropylene Installations .....................................................23
Vent Pipe Termination.............................................................23
Planning The Vent System .....................................................23
Integrated Filter Installation ....................................................24
Direct Vent Air Intake Moisture Protection ..............................25
Horizontal Vent Terminal Installation ......................................25
Vertical Vent Terminal Installation ...........................................26
Termination Clearances Sidewall Direct Vent .........................27
.........7
Direct Vent Installation Diagrams ...........................................28
Concentric Vent Installation ....................................................29
Venting Multiple Units .............................................................30
WATER HEATER INSTALLATION ...............................................31
Condensate Drain Installation ................................................31
Supply Gas Line Installation ...................................................31
Gas Line Leak Testing ............................................................32
Purging ...................................................................................32
Electrical Wiring ......................................................................33
Water Line Connections .........................................................33
T&P Valve Discharge Pipe .....................................................34
TEMPERATURE REGULATION .................................................35
High Temperature Limit Control (ECO)...................................35
Thermostat Control .................................................................35
CONTROL SYSTEM OPERATION .............................................36
Overview ................................................................................36
Control System Navigation .....................................................36
User Settings & Control System Menus .................................39
START UP ...................................................................................44
Start Up Conditions ................................................................44
Prior to Start Up ......................................................................44
Filling the Water Heater ..........................................................44
Initial Start Up .........................................................................45
LIGHTING THE WATER HEATER ..............................................46
Lighting & Operation Labels ...................................................46
Checking the Firing Rate ........................................................47
Gas Input Rate .......................................................................47
High Altitude Installations .......................................................47
TROUBLESHOOTING ................................................................48
Installation Checklist ...............................................................48
Sequence Of Operation ..........................................................48
Sequence Of Operation Flow Chart .......................................49
Operational Problems .............................................................50
Fault And Alert Conditions ......................................................51
LEAKAGE CHECKPOINTS .........................................................53
PERIODIC MAINTENANCE ........................................................54
Venting System Inspection .....................................................54
Ingegrated Filter Preventative Maintenance ...........................54
Temperature-Pressure Relief Valve Test ................................54
Draining and Flushing ............................................................55
Service ...................................................................................55
DIAGRAMS .................................................................................56
CCB-Central Control Board Layout ........................................56
Wiring Diagram .......................................................................57
Circulation Pump Wiring Diagrams ........................................58
Piping Diagrams .....................................................................59
NOTES ........................................................................................61
2
SAFE INSTALLATION, USE AND SERVICE
CONTENT
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER indicates an imminently
DANGER
WARNING
CAUTION
hazardous situation which, if not avoided,
will result in injury or death.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION used without the safety alert
CAUTION
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and
how to avoid the risk of injury.
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
APPROVALS
LOW LEAD
3
CAUTION
GENERAL SAFETY INFORMATION
PRECAUTIONS
DO NOT USE THIS W ATER HE ATER IF ANY PART HAS
BEEN EXPOSED TO FLOODING OR WATER DAMAGE.
Immediately call a qualified service technician to inspect
the water heater and to make a determination on what steps
should be taken next.
If the unit is exposed to the following, do not operate heater
until all corrective steps have been made by a qualied service
technician.
1. External re.
2. Damage.
3. Firing without water.
Verify the power to the water heater is turned off before performing any service procedures.
The Enable/Disable switch at the base of the water heater disables the 24 volt gas control valve.
Electrical supply must be turned off at circuit breaker serving water heater.
GROUNDING INSTRUCTIONS
This water heater must be grounded in accordance with the National
Electrical Code and/or local codes. These must be followed in all
cases. Failure to ground this water heater properly may also cause
erratic control system operation.
This water heater must be connected to a grounded 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.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Explosion Hazard
Overheated water can cause
water tank explosion.
Properly sized Te mperaturePressure Relief Valve must be
installed in the opening provided.
Improper installation, use and service may result
in property damage.
Do not operate water heater if exposed to flooding or water
•
damage.
Install in location with drainage.
•
Fill tank with water before operation.
•
Properly sized thermal expansion tanks are required on all
•
closed water systems.
Refer to this manual for installation and service.
4
GENERAL SAFETY INFORMATION
5
Fire or Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Avoid all ignition sources if you smell gas.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating plate.
Keep ignition sources away from faucets after extended
periods of non-use.
Maintain required clearances to combustibles.
Do not expose gas control valve/thermostat to excessive
gas pressure.
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Breathing Hazard - Carbon Monoxide Gas
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
CAUTION
GENERAL SAFETY INFORMATION
Fire Hazard
For continued protection against
risk of fire:
Do not install water heater on
carpeted floor.
Do not operate water heater if
exposed to flooding or water
damage.
Fire and Explosion Hazard
Use joint compound or Teflon tape
compatible with propane gas.
Leak test gas connections
before placing the water heater in
operation.
Disconnect gas piping at main
gas shutoff valve before leak
testing.
Install sediment trap in accordance
with NFPA 54 or CAN/CSA B149.1.
Electrical Shock Hazard
Turn off power to the water heater
•
before performing any service.
Label all wires prior to disconnecting
•
when performing service. Wiring errors
can cause improper and dangerous
operation.
Verify proper operation after servicing.
•
Failure to follow these instructions can
•
result in personal injury or death.
Fire and Explosion Hazard
Do not use water heater with any gas
other than the gas shown on the rating
plate.
Excessive gas pressure to gas control
valve can cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
technician for installation and service.
6
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS
For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed
in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by
the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above nished grade in the
area of the venting, including but not limited to decks and porches, the following requirements should be satised:
INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas
fueled equipment, the installing plumber or gastter should observe that a hard wired carbon monoxide detector with an alarm
and battery back-up is installed on the oor level where the gas equipment is to be installed. In addition, the installing plumber
or gastter should observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each
additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It should
be the responsibility of the property owner to secure the services of qualied licensed professionals for the installation of hard
wired carbon monoxide detectors.
In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired
carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent oor level.
In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner should
have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a battery
operated carbon monoxide detector with an alarm should be installed.
APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above
provisions should comply with NFPA 720 and be ANSI/UL 2034 listed and CSA certied.
SIGNAGE A metal or plastic identication plate should be permanently mounted to the exterior of the building at a minimum
height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating
appliance or equipment. The sign should read, in print size no less than one-half (1/2) inch in size, GAS VENT DIRECTLY
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.
INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment should not approve the
installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance
with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA
54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the
dwelling, building, or structure used in whole or in part for residential purposes.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product
Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with
the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system should
include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer
of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the
flue gases, but identifies special venting systems, the following requirements should be satisfied by the manufacturer:
1. The referenced special venting system instructions should be included with the appliance or equipment installation
instructions; and
2. The special venting systems should be Product Approved by the Board, and the instructions for that system should include a
parts list and detailed installation instructions.
A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting
instructions, all parts lists for venting instructions, and/or all venting design instructions should remain with the appliance or
equipment at the completion of the installation.
7
INTRODUCTION
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
ABBREVIATIONS USED
Abbreviations found in this Instruction Manual include :
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• AHRI - Air-Conditioning, Heating and Refrigeration Institute
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• UL - Underwriters Laboratory
• CSA - Canadian Standards Association
QUALIFICATIONS
QUALIFIED INSTALLER OR SERVICE AGENCY
Installation and service of this water heater requires ability
equivalent to that of a Qualied Agency (as dened by ANSI below)
in the eld involved. Installation skills such as plumbing, air supply,
venting, gas supply and electrical supply are required in addition to
electrical testing skills when performing service.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualied Agency” - “Any
individual, rm, corporation or company that either in person or
through a representative is engaged in and is responsible for (a)
the installation, testing or replacement of gas piping or (b) the
connection, installation, testing, repair or servicing of appliances
and equipment; that is experienced in such work; that is familiar
with all precautions required; and that has complied with all the
requirements of the authority having jurisdiction.”
is essential that all venting, water piping, gas piping and wiring
be installed as shown.
Particular attention should be given to the installation of
thermometers at the locations indicated in the piping diagrams
as these are necessary for checking the operation of the water
heater.
The principal components of the water heater are identied in
Features and Components beginning on Page 11 in this manual.
Use this reference to locate and identify various components on
the water heater.
See the Installation Checklist and Troubleshooting on page
48. By using this checklist the user may be able to make
minor operational adjustments and avoid unnecessary service
calls. However, service and diagnostic procedures should only
be performed by a Qualied Service Agency.
NOTE: Costs to correct installation errors are not covered
under the limited warranty.
2. Be sure to turn off power when working on or near the electrical
system of the water heater. Never touch electrical components
with wet hands or when standing in water.
3. The installation must conform to all instructions contained in
this manual and the local code authority having jurisdiction.
These shall be carefully followed in all cases. Authorities having
jurisdiction should be consulted before installation begins if
there are any questions regarding compliance with local, state
or national codes.
If you are not qualied (as dened by ANSI above) and licensed or
certied as required by the authority having jurisdiction to perform
a given task do not attempt to perform any of the procedures
described in this manual. If you do not understand the instructions
given in this manual do not attempt to perform any procedures
outlined in this manual.
PREPARING FOR THE INSTALLATION
1. Read the entire manual before attempting to install or operate
the water heater. Pay close attention to the General Safety
Information on Page 4 through Page 6. If you don’t follow the
safety rules, the water heater may not operate safely. It could
cause property damage, injury and/or death.
This manual contains instructions for the installation, operation,
and maintenance of the water heater. It also contains warnings
throughout the manual that you must read and be aware of.
All warnings and all instructions are essential to the proper
operation of the water heater and your safety. Detailed
installation diagrams are also found in this manual. These
diagrams will serve to provide the installer with a reference. It
In the absence of local codes, the installation must comply with
the current editions of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54 and the National Electrical Code, NFPA 70 or 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, 8501
East Pleasant Valley Road, Cleveland, OH 44131. NFPA
documents are also available from the National Fire Protection
Association, 1 Batterymarch Park, Quincy, MA 02269.
4. If after reading this manual you have any questions or do
not understand any portion of the instructions, call the toll
free number on the back cover of this manual for technical
assistance. In order to expedite your request, please have the
full Model, Serial and Series number of the water heater you
are working with available for the technician. This information is
located on the water heater’s rating plate.
5. Carefully plan the placement of the water heater. Examine
the location to ensure that it complies with the requirements
in Locating The Water Heater on Page 15 and the Rough In
Dimensions on Page 9.
8
DIMENSIONS AND CAPACITY DATA
ROUGH IN DIMENSIONS: ALL MODELS
All Models
Additional
Side Taps
Figure 1 . DIMENSIONS FOR ALL MODELS
Air Inlet
U.S.
GALLONS
34 130
34 150
50 130
50 150
50 175
50 199
INPUT
(KBTU/HR)
UNITS
Inches
Inches
Inches
Inches
Inches
Inches
Top Outlet: 1” NPT
Side Inlet: 1” NPT
Gas Inlet: 1/2” NPT
Condensate drain outlet: 1/2” NPT
U.S. GALLONS
34 130 2 OR 3 150
34 150 2 OR 3 150
50 130 2 OR 3 176
50 150 2 OR 3 180
50 175 3 180
50 199 3 180
cm
cm
cm
cm
cm
cm
Table 1A - ROUGH-IN-DIMENSIONS
EXTERIOR WATER CONNECTIONS
T&P
HOT
A B C D E F G H
48-1/2 22 15-3/4 40-1/2 41 6-3/8 5-1/2 6-5/8
123.19 55.88 40 102.87 104.14 16.19 13.97 16.82
48-1/2 22 15-3/4 40-1/2 41 6-3/8 5-1/2 6-5/8
123.19 55.88 40 102.87 104.14 16.19 13.97 16.82
62-3/8 22 15-3/4 54-1/2 55 6-3/8 5-1/2 6-5/8
165.7 55.88 40 138.43 139.7 16.19 13.97 16.82
63-3/4 22 15-3/4 55-3/4 56-1/4 6-3/8 5-1/2 6-5/8
161.925 55.88 40 141.605 142.875 16.19 13.97 16.82
63-3/4 22 15-3/4 55-3/4 56-1/4 6-3/8 5-1/2 6-5/8
161.925 55.88 40 141.605 142.875 16.19 13.97 16.82
63-3/4 22 15-3/4 55-3/4 56-1/4 6-3/8 5-1/2 6-5/8
161.925 55.88 40 141.605 142.875 16.19 13.97 16.82
GAS
SUPPLY
AIR INLET/EXHAUST
Table 1B - ROUGH-IN-DIMENSIONS
INPUT
(KBTU/HR)
VENT
DIAMETER
(in.)
APPROX SHIP. WEIGHT
(lbs.)
9
DIMENSIONS AND CAPACITY DATA
Table 2 – CAPACITY, GAS AND ELECTRICAL CHARACTERISTICS
Approximate Capacity *Manifold Pressure Electrical Characteristics
U.S. Gals. Liters Gas Type “WC kPA Volts/Hz Amperes
34 129 Nat./LP 0 0 120/60 <7
50 189 Nat/LP 0 0 120/60 <7
* The manifold pressure is the factory setting and is not adjustable. A negative pressure will be seen with just the blower running without
the Gas Control Valve open.
All models - Maximum Supply Pressure: 14 inches W.C. (3.48kPa)
Minimum Supply Pressure for Natural Gas: 3.50” (.87kPa)
Minimum Supply Pressure for Propane Gas: 8.00” (1.99kPa)
Minimum pressure must be maintained under both load and no load (dynamic and static) conditions.
Table 3 – RECOVERY CAPACITIES
Input Recovery Capacities
Rating
(Btu/hr)
130000 38.1
150000 44.0
175000 51.3
199000 58.3
Rating
(kW)
Temp.
Rise
F 30 40 50 60 70 80 90 100 110 120 130 140
C 17 22 28 33 39 44 50 56 61 67 72 78
GPH 495 371 297 248 212 186 165 149 135 124 114 106
LPH 1875 1406 1125 937 803 703 625 562 511 469 433 402
GPH 571 429 343 286 245 214 190 171 156 143 132 122
LPH 2163 1622 1298 1082 927 811 721 649 590 541 499 464
GPH 667 500 400 333 286 250 222 200 182 167 154 143
LPH 2524 1893 1514 1262 1082 946 841 757 688 631 582 541
GPH 758 569 455 379 325 284 253 227 207 190 175 162
LPH 2870 2152 1722 1435 1230 1076 957 861 783 717 662 615
Recovery capacity based on 95% thermal efciency.
10
FEATURES AND COMPONENTS
34 GALLON UNIT
**11
**34
**25
32
24
27
31
17
14
20
21, 22
9
10
**12
15
33
30
23
11
5
6
7
4
8
28
32
**33
15
16
26
29
13
* CAUTION HARNESS HAS 120 VAC. IN OPERATION.
** See Venting Installation and Condensate Piping for more information.
17
19
**11
**12
18
VACUUM RELIEF
VALV E
*INSTALL PER
LOCAL CODES
1
2
3
This is a view of the area
at the bottom of
heater behind the
Access Doors.
Figure 2. 34 GALLON UNIT
11
FEATURES AND COMPONENTS (CONT.)
50 GALLON UNIT
**11
**34
**25
32
31
17
14
20
9
10
**12
15
33
30
23
11
5
6
7
4
8
24
27
28
32
**33
15
16
26
29
13
* CAUTION HARNESS HAS 120 VAC. IN OPERATION.
** See Venting Installation and Condensate Piping for more information.
21, 22
18
17
19
**11
**12
VACUUM RELIEF VALVE
*INSTALL PER
LOCAL CODES
1
2
3
This is a view of the area
at the bottom of
heater behind the
Access Doors.
Figure 3. 50 GALLON UNIT
12
FEATURES AND COMPONENTS (CONT.)
1: Control Assembly
2: Blocked Intake Switch
3: Blocked Outlet Switch
4: Blower Assembly
5: Burner Assembly
6: Flame Sensor
7: Igniter Assembly
8: Gas Control Valve Assembly
9: Display Board
10: Display Enclosure
** 11: Exhaust Elbow Assembly
** 12: Condensate Drain Outlet
13: Enable / Disable Switch
14: Hot Water Outlet
15: Gas Supply
16: Main Manual Gas Shutoff Valve
17: Union
18: Inlet Water Shutoff Valve
19: Cold Water Inlet
20: T & P Relief Valve
21: Rating Plate
22: Labels
23: Drain Valve
24. Upper Temperature Probe (ECO)
** 25: Exhaust Vent Terminal
26: Drain Pan
27: Insulation
28: Lower Temperature Probe
29: Access Door
30: Spark Module
31. Air Intake Pipe
32. Additional Side Taps
33. Intake Air Connection
**34. Intake Vent Terminal
13
CONTROLS AND SWITCHES
Switch
Switch
This model is provided with two 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.
Blocked Outlet
Switch
Blocked Intake
34 GALLON UNIT
Blocked Outlet
Switch
BLOCKED OUTLET SWITCH
The Blocked Outlet Switch is set up to shut the unit off when a buildup 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 the vent
length does not exceed the maximum allowed as shown in Planning
the Vent System beginning on page 23.
BLOCKED INTAKE SWITCH
The Blocked Intake Switch is set up to shut the unit off when a buildup of negative pressure in the intake air 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 pipe
connected to the inlet of the blower. When this switch prevents the
unit from igniting, most likely the intake is blocked. Verify that the
integrated lter on the intake air connection, the intake air pipe,
and the intake air termination are free of obstructions that may
prevent air from entering the unit. Also Verify the intake air pipe
length does not exceed the maximum allowed in Planning the Vent
System beginning on page 23.
WATER HEATING ENABLE/DISABLE SWITCH
IMPORTANT: The Enable/Disable switch listed in this manual is
NOT an “on/off” switch and does not disconnect 120 volt power to
the CCB and other heater components.
When in the “Disabled” position the switch removes electrical power
from the gas control valve so that water heating is disabled. The
display, CCB, and other electrical components will still be energized
and the display will read “Water Heating Disabled”.
Blocked Intake
50 GALLON UNIT
Figure 4
SPARK IGNITER
The Spark Igniter is a device that ignites the main burner by spark.
When high voltage is applied to the igniter, spark is generated to
ignite the main burner.
CONFIGURATION KEY
The configuration key is located inside the control box. It
provides for the ability of the heater to retain information
collected over its lifetime, even if the control board is replaced
because of failure.
The conguration key should stay with the heater.
14
CAUTION
INSTALLATION CONSIDERATIONS
LOCATING THE WATER HEATER
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
Carefully choose a location for the new water heater. The placement
is a very important consideration for the safety of the occupants in
the building and for the most economical use of the water heater.
Whether replacing an existing water heater or installing the water
heater in a new location observe the following critical points:
1. The water heater must be located indoors.
2. The water heater must not be located in an area where it will
be subject to freezing temperatures.
3. Locate the water heater so it is protected and not subject to
physical damage by a moving vehicle. In garage installation
avoid damage to your water heater by installing a vehicle
stop as shown in Figure 5. Check state and local codes for
requirements prior to installation.
4. Locate the water heater on a level surface.
5. Locate the water heater near a oor drain. The water heater
should be located in an area where leakage of the tank or
connections will not result in damage to the area adjacent
to the water heater or to lower oors of the structure. When
such locations cannot be avoided, it is recommended that a
metal drain pan, piped to adequate drain, be installed under
the water heater. Drain pan should be fabricated with sides
at least 1-3/4” deep with diameter at least 2” greater than
diameter of heater. Pan must not restrict combustion air ow.
6. Locate the water heater close to the point of major hot
water usage.
7. Locate the water heater close to a 120 VAC power supply.
See Power Supply on Page 18 for requirements.
8. Locate the water heater where an adequate supply of fresh
air for combustion and ventilation can be obtained. See
Combustion Air and Ventilation on Page 16.
9. Locate the water heater where the vent and intake air piping,
when installed, will remain within the maximum equivalent
lengths allowed. See Planning the Vent System on page 24.
11. Do not locate the water heater where the subsequent
installation of the vent (exhaust) or intake air terminations
would be objectionable due to noise at the termination(s).
This includes locations close to or across from windows and
doors. See Venting Installation beginning on page 22.
Do not locate water heater areas where ammable liquids (vapors)
are likely to be present or stored (garages, storage and utility
areas, etc.): Flammable liquids (such as gasoline, solvents,
propane (LP or butane, etc.) and other substances (such as
adhesives, etc.) emit ammable vapors which can be ignited by
a gas water heater’s ignition device or main burner. The resulting
ashback and re can cause death or serious burns to anyone
in the area.
10. Do not locate the water heater where noise (such as
the Combustion Blower) during normal operation will be
objectionable in adjacent areas.
Figure 5. GARAGE INSTALLATION
When the water heater is installed directly on carpeting, the water
heater shall be installed on a metal or wood panel extending beyond
the full width and depth of the water heater by at least 3″ (7.62 cm) in
any direction or, if the water heater is installed in an alcove or closet,
the entire oor shall be covered by the panel. The panel must be
strong enough to carry the weight of the heater when full of water.
15
Minimum clearances from combustible materials are stated on the data
plate located on the front of the water heater. Standard clearances
are 0” (0 cm) at the sides and rear, 0” (0 cm) from the front, and 0” (0
cm) from the top. If the clearances from combustible material stated
on the water heater differ from the standard clearances, install the
water heater according to the clearances stated on the water heater.
Adequate clearance for inspection and service should be considered
before installation. A minimum of 24” (61 cm) of front clearance and 4”
(10.2 cm) on each side should be provided for access to replaceable
and/or serviceable parts such as thermostats, drain valve, condensate
drain, temperature-pressure relief valve, and the vent connection
(exhaust elbow).
Figure 6 may be used as a reference guide to locate the specic
clearance locations. When installing the water heater, consideration
must be given to proper location. The location selected should be
as close to the wall as practicable and as centralized with the water
piping system as possible.
CEILING
LEFT
WALL
FRONT VIEW
*For service access
0"
RIGHT
WALL
WITHOUT DOOR
MIN.
TOP VIEW
OF CLOSET
WATER
HEATER
0" MIN.
*4" MIN.
TOP VIEW
OF CLOSET
WITHOUT DOOR
WATER
HEATER
0" MIN.
*24" MIN. (61 c m)
0" MIN.
Figure 6: MINIMUM CLEARANCE LOCATIONS
INSULATION BLANKETS
• Do obtain new warning and instruction labels from the manufacturer
for placement on the blanket directly over the existing labels.
• Do inspect the insulation blanket frequently to make certain it
does not sag, thereby obstructing combustion air ow.
COMBUSTION AIR AND VENTILATION
A gas water heater cannot operate properly without the correct
amount of air for combustion. Never obstruct the ow of ventilation
air. If you have any doubts or questions at all, call your gas supplier.
Failure to provide the proper amount of combustion air can result
in a re or explosion and cause death, serious bodily injury, or
property damage.
Figure 7: COMBUSTION AIR AND VENTILATION
It is imperative that the water heater(s) be installed direct vent so
that all air for combustion and ventilation is taken from outdoors.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorine based chemicals, refrigerants, etc.) in addition to being
highly ammable in many cases, will also react to form corrosive
acids when exposed to the combustion products of the water heater.
The results can be hazardous, and also cause product failure. Air
for combustion and ventilation must not come from a corrosive
atmosphere. Any failure due to corrosive elements in the atmosphere
is excluded from warranty coverage.
Insulation blankets are available to the general public for external use
on gas water heaters but are not necessary with these products. The
purpose of an insulation blanket is to reduce the standby heat loss
encountered with storage tank heaters. Your water heater meets or
exceeds the Energy Policy Act standards with respect to insulation and
standby loss requirements, making an insulation blanket unnecessary.
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions (For identication of components
mentioned below. See Figures 1, 2, 3 and 4. Failure to follow these
instructions can restrict the air ow required for proper combustion,
potentially resulting in re, asphyxiation, serious personal injury or death.
• Do not cover the control system LCD on top of the water heater.
• Do not cover the outer door, thermostat or temperature-pressure
relief valve.
• Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
CORROSION AND WATER QUALITY
Water quality will vary from location to location and may contain
contaminates that may reduce the life or performance of the water heater.
Contaminates which can reduce the life or performance of the water
heater if present in high quantities include those which contribute to
hardness (dissolved minerals such as sodium, calcium and magnesium);
plus chlorides and sulfates. Additionally, water that is too acidic or basic
(measured as pH) can reduce the life of the water heater. Water treatment
systems (such as water softeners for hardness) should be used and
maintained properly if the contaminate levels exceed the following:
Warranty is void in applications which exceed the
water quality requirements listed below.
Total Hardness: 12 grains per gal. (205 mg/liter) max.
Chloride: 200 mg/liter max.
pH: 6.5-8.0
Alkalinity: 200 mg/liter max.
16
INSTALLATION REQUIREMENTS
GAS SUPPLY SYSTEMS
Low pressure building gas supply systems are dened as those
systems that cannot under any circumstances exceed 14”
W.C. (1/2 PSI Gauge). These systems do not require pressure
regulation. Measurements should be taken to insure that gas
pressures are stable and fall within the requirements stated on
the water heater rating plate. Readings should be taken with
all gas burning equipment off (static pressure) and with all gas
burning equipment running at maximum rate (dynamic pressure).
The gas supply pressure must be stable within 1.5” W.C.
from static to dynamic pressure to provide good performance.
Pressure drops that exceed 1.5” W.C. may cause rough starting,
noisy combustion or nuisance outages. Increases or spikes in
static pressure during off cycles may cause failure to ignite or in
severe cases damage to water heater gas control valves. If your
low pressure system does NOT meet these requirements, the
installer is responsible for the corrections.
High pressure building supply systems use pressures that exceed
14” W.C. (1/2 PSI Gauge). These systems must use eld supplied
regulators to lower the gas pressure to less than 14” W.C. (1/2
PSI Gauge). Water heaters require gas regulators that are properly
sized for the water heater input and deliver the rating plate specied
pressures. Gas supply systems where pressure exceeds 5 PSI
often require multiple regulators to achieve desired pressures.
Systems in excess of 5 PSI building pressure should be designed
by gas delivery professionals for best performance. Water heaters
connected to gas supply systems that exceed 14” W.C. (1/2 PSI
Gauge) at any time must be equipped with a gas supply regulator.
All models require a minimum gas supply pressure of 3.5”
W.C.(0.87 kPa) for natural gas and 8.0” W.C. (1.99 kPa) for
propane. The minimum supply pressure is measured while gas
is not owing (static pressure) AND while gas is owing (dynamic
pressure). The supply pressure (static and dynamic) should never
fall below 3.5” W.C.(0.87 kPa) for natural gas or 8.0” W.C. (1.99
kPa) for propane. The supply pressure should be measured with
all gas red water heaters connected to the common main ring
at full capacity. If the supply pressure drops more than 1.5” W.C.
(0.37 kPa) as gas begins to ow to the water heater then the supply
gas system including the gas line and/or the gas regulator may
be restricted or undersized. See Supply Gas Regulator on page
17 and Supply Gas Line Installation on page 31. The gas control
valve on all models has a maximum gas supply pressure limit of
14” W.C.(3.48 kPa) The maximum supply pressure is measured
while gas is not owing (static pressure) AND while gas is owing
(dynamic pressure).
SUPPLY GAS REGULATOR
The maximum allowable gas supply pressure for this water heater
is 14 inches W.C. (3.5 kPa). Install a positive lock-up gas pressure
regulator in the gas supply line if inlet gas pressure can exceed 14
inches W.C. (3.5 kPa) at any time. Regulators must be sized/used
according to manufacturer’s specications.
If a positive lock-up regulator is required follow these instructions:
1. Positive lock-up gas pressure regulators must be rated at or
above the input Btu/hr rating of the water heater they supply.
2. Supply gas regulators shall have inlet and outlet connections not
less than the minimum supply gas line size for the water heater
they supply
3. Positive lock-up gas pressure regulator(s) should be installed
no closer than 3 feet (1 meter) and no farther than 8 feet (2.4
meters) from the water heater’s inlet gas connection.
4. After installing the positive lock-up gas pressure regulator(s) an
initial nominal supply pressure setting of 7.0” W.C.(1.74 kPa) for
Natural Gas and 11.0” W.C. (2.74 kPa) for Propane (LP) while
the water heater is operating is recommended and will generally
provide good water heater operation. Some additional adjustment
may be required later to maintain a steady gas supply pressure.
5. When installing multiple water heaters in the same gas supply
system it is recommended that individual positive lock-up gas
pressure regulators be installed at each unit.
All gas piping must comply with local codes and ordinances or with
the current editions National Fuel Gas Code (ANSI Z223.1/ NFPA-
54) or the Natural Gas and Propane Installation Code (CAN/CSA
B149.1) whichever applies. Copper or brass tubing and ttings
(except tin lined copper tubing) shall not be used.
If the gas control valve is subjected to pressures exceeding 1/2 psi
(3.5 kPa), the damage to the gas control valve could result in a re
or explosion from leaking gas.
If the main gas line Shut-off serving all gas water heaters is used,
also turn off the gas at each water heater. Leave all gas appliances
shut off until the water heater installation is complete.
A gas line of sufcient size must be run to the water heater. Consult
the current edition of National Fuel Gas Code (ANSI Z223.1/NFPA
54) or the Natural Gas and Propane Installation Code (CAN/CSA
B149.1) and your gas supplier concerning pipe size.
There must be:
• A readily accessible manual shut off valve in the gas supply
line serving the water heater, and
• A sediment trap ahead of the gas control valve to help prevent
dirt and foreign materials from entering the gas control valve.
• A ground joint union of proper size between the manual shut
off valve and gas control valve to permit servicing of the unit.
Be sure to check all the gas piping for leaks before lighting the
water heater. Use a soapy water solution, not a match or open
ame. Rinse off soapy solution and wipe dr y.
POWER SUPPLY
The water heaters covered in this manual require a 120 VAC,
1Ø (single phase), 60Hz, 7 amp power supply and must also be
electrically grounded in accordance with local codes or, in the
absence of local codes, with the National Electrical Code, ANSI/
NFPA 70 or the Canadian Electrical Code, CSA C22.1.
If any of the original wire as supplied with the water heater must
be replaced, it must be replaced with 105°C rated wiring or its
equivalent, except in the burner housing. In this case 200°C
rated wire must be used.
DEDICATED POWER WIRING AND BREAKERS
Dedicated power supply wires, ground wiring and dedicated
circuit breakers often prevent electrical line noise and
should be considered when installing the water heater.
POWER FLUCTUATIONS AND ELECTRICAL NOISE
The water heater’s control system requires a source of stable
clean electricity for proper operation. Connecting the water heater
to a branch circuit that is subject to uctuations in voltage level or
17
electrical line noise such as EMI (electro magnetic interference) or
RFI (radio frequency interference) may cause erratic control system
operation and malfunction.
A high quality power supply lter/suppressor must be installed if the
above conditions exist. Call the technical support phone number for
more information.
NOTE: Malfunctions caused by the power supply and the costs
to install power supply lters are not covered under the limited
warranty.
MIXING VALVES
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
CIRCULATION PUMPS
A circulating pump is used when a system requires a circulating loop or
there is a storage tank used in conjunction with the water heater. The tank
is provided with a 1” NPT recirculation loop return connection. See the
Piping Diagrams section beginning on Page 59 for the installation location
of circulating pumps.
See Circulation Pump Wiring Diagrams on page 58 for electrical hookup
information. Install in accordance with the current edition of the National
Electrical Code, NFPA 70 or the Canadian Electrical Code, CSA C22.1.
Stainless Steel circulating pumps are recommended for use with
commercial water heaters.
Re f e r to th e circula t i n g pump ma nufactu r e r ’s in s t r u c t i ons fo r it s opera t i o n ,
lubrication and maintenance instructions.
DISHWASHING MACHINES
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 pressure between these limits.
See Figure 8.
Water heated to a temperature which will satisfy clothes washing,
dish washing, and other sanitizing needs can scald and cause
permanent injury upon contact. Short repeated heating cycles
caused by small hot water uses can cause temperatures at the point
of use to exceed the water heater’s temperature setting by up to
20°F (11°C).
Some people are more likely to be permanently injured by hot water
than others. These include the elderly, children, the inrm and the
physically/mentally disabled. Table 4 shows the approximate timeto-burn relationship for normal adult skin. If anyone using hot water
provided by the water heater being installed ts into one of these
groups or if there is a local code or state law requiring a certain water
temperature at the point of use, then special precautions must be taken.
In addition to using the lowest possible temperature setting that
satises the demand of the application a Mixing Valve should be
installed at the water heater or at the hot water taps to further
reduce system water temperature. See Figure 8 in Dishwashing
Machines and Figures 52 through 54 in Piping Diagrams beginning
on Page 59.
Mixing valves are available at plumbing supply stores. Consult
a Qualied Installer or Service Agency. Follow mixing valve
manufacturer’s instructions for installation of the valves.
In all cases, the following burn table must be used.
Table 4
Water Temperature
°F (°C)
Time for 1st Degree Burn
(Less Severe Burns)
110 (43.3) (normal shower temp.)
116 (46.7) (pain threshold)
116 (46.7) 35 minutes 45 minutes
122 (50) 1 minute 5 minutes
131 (55) 5 seconds 25 seconds
140 (60) 2 seconds 5 seconds
149 (65) 1 second 2 seconds
154 (67.8) instantaneous 1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)
Time for Permanent
Burns
2nd & 3rd Degree
(Most Severe Burns)
HOT WATER
OUTLET
12” TO 15”
(30-38 cm)
TEMPERED WATER
OUTLET
TO TANK
INLET
MIXING
VALVE
CHECK
VALVE
COLD
WATER
INLET
CHECK
VALVE
Figure 8
The National Sanitation Foundation also recommends circulation of
180°F (82°C) water. The circulation should be just enough to provide
180°F (82°C) water at the point of take-off to dishwashing machine.
Adjust ow by throttling a full port ball valve installed in the circulating
line on the outlet side of the pump. Never throttle ow on the suction
side of a pump.
NOTE: To comply with NSF Standard 5 installation requirements the
bottom of the water heater must be sealed to the oor with a silicone
based sealant or elevated 6 inches above the oor.
18
SPACE HEATING AND POTABLE WATER SYSTEM
ater
Hot
W
O
Your water heater is equipped with additional side taps for use in
space heating applications. See Features and Components on
Page 11 for locations. If this water heater is to be used to supply
both space heating and potable (drinking) water, the instructions
listed below must be followed:
• Be sure to follow the manual(s) shipped with the air handler
or other type heating system.
• Th i s water he a ter cann o t be used in spa c e he ating ap p licat i o ns
only.
• This water heater is not to be used as a replacement for an
existing boiler installation.
• Do not use with piping that has been treated with chromates,
boiler seal or other chemicals and do not add any chemicals
to the water heater piping
• If the space heating system requires water temperatures in
excess of 120°F, a mixing valve must be installed per the
manufacturer’s instructions in the potable hot water supply to
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 should 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.
limit the risk of scald injury. See Mixing Valves on Page 18.
• Pumps, valves, piping and fittings must be compatible with
potable water.
• A properly installed ow control valve is required to prevent
thermosiphoning. Thermosiphoning is the result of a continuous
ow of water through the air handler circuit during the off cycle.
Weeping (blow off) of the temperature-pressure relief valve (T &
P relief valve) or higher than normal water temperatures are the
rst signs of thermosiphoning.
• The hot water line from the water heater should be vertical past
any mixing valve or supply line to the heating system to remove
air bubbles from the system. Do not connect the water heater to
any system or components previously used with non-potable water
NOTE: To protect against untimely corrosion of hot and cold
water fittings, it is strongly recommended that di-electric unions
or couplings be installed on this water heater (see Figure 9) when
connected to copper pipe.
heating appliances when used to supply potable water.
STORAGE TANK INSTALLATION
When installing the water heater with a storage tank, see Figure
ater
utlet
Union
Sweat
Fittings
55 on page 60 in Piping Diagrams for suggestions.
NOTE: If ta nk temperatur e is set ab o v e 120°F and wat e r is su p p l i e d
for domestic use (hand washing, showering, etc.) a mixing valve
should be installed in the hot water line to domestic xtures.
Installation must conform to local code requirements. If a check
valve is installed in the cold water supply line, an expansion tank
must be installed between the check valve and the water heater’s
Temperature-
Pressure
Relief Valve
cold water inlet. Set storage tank temperature ve degrees lower
than the water heater’s temperature setting. Using the plug valve,
adjust the ow in the recirculating line to ve gallons per minute.
Sweat
SOLAR INSTALLATION
If this water heater is used as a solar storage heater or as a
backup for the solar system, the water supply temperatures to the
water heater tank may be in excess of 120°F (48.9°C). A mixing
valve must be installed in the water supply line to limit the supply
temperature to 120°F (48.9°C).
Fittings
Shutoff
Valve
Union
Cold
W
Inlet
NOTE: Solar water heating systems can often supply water with
temperatures exceeding 180°F (82.2°C) and may result in water
heater malfunction.
Figure 9
CLOSED WATER SYSTEMS
Water supply systems may, because of code requirements or such
conditions as high line pressure, among others, have installed
19
Figure 9 also shows the typical attachment of the water piping
CAUTION
to the water heater. The water heater is equipped with 1” NPT
connections for all models.
NOTE: If using copper tubing, solder tubing to an adapter before
attaching the adapter to the water heater connections. Do not
solder the water lines directly to the water heater connections. It
will damage the tank, T & P Valve and Pipe Insulation (if supplied).
Fit pipe insulation over the incoming cold water line and the hot
water line. Make sure that the insulation is against the top cover
of the heater. Fit T & P valve insulation over valve. Make sure that
the insulation does not interfere with the lever of the T & P valve.
Secure all insulation using tape.
TEMPERATURE-PRESSURE RELIEF VALVE
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
Properly sized temperaturepressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
Properly sized temperaturepressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
This water heater is provided with a properly rated/sized and
certied combination Temperature-Pressure Relief Valve (T&P
relief valve) by the manufacturer. The valve is certied by a
nationally recognized testing laboratory that maintains periodic
inspection of production of listed equipment of materials as
meeting the requirements for Relief Valves for Hot Water Supply
Systems, ANSI Z21.22 • CSA 4.4, and the code requirements
of ASME.
If replaced, the new T&P valve must meet the requirements
of local codes, but not less than a combination TemperaturePressure Relief Valve rated/sized and certied as indicated in
the previous paragraph. The new valve must be marked with a
maximum set pressure not to exceed the marked hydrostatic
working pressure of the water heater (150 psi = 1,035 kPa) and
a discharge capacity not less than the water heater Btu/hr or
kW inp ut rate as sh o wn on the wate r he ate r ’s mode l ra t ing pla te.
NOTE: In addition to the factory installed Temperature-Pressure
Relief Valve on the water heater, each remote storage tank
that may be installed and piped to a water heating appliance
must also have its own properly sized, rated and approved
Temperature-Pressure Relief Valve installed.
For safe operation of the water heater, the Temperature-Pressure
Relief Valve must not be removed from its designated opening
nor plugged. The Temperature-Pressure Relief Valve must be
installed directly into the tting of the water heater designed for the
Temperature-Pressure Relief Valve. Install discharge piping so that
any discharge will exit the pipe within 6 inches (15.2 cm) above an
adequate oor drain, or external to the building. In cold climates it is
recommended that it be terminated at an adequate drain inside the
building. Be certain that no contact is made with any live electrical
part. The discharge opening must not be blocked or reduced in size
under any circumstances. Excessive length, over 30 feet (9.14 m),
or use of more than four elbows can cause restriction and reduce
the discharge capacity of the valve.
No valve or other obstruction is to be placed between the
Temperature-Pressure Relief Valve and the tank. Do not connect
discharge piping directly to the drain unless a 6” (15.2 cm) air gap
is provided. To prevent bodily injury, hazard to life, or property
damage, the temperature-pressure relief valve must be allowed
to discharge water in adequate quantities should circumstances
demand. If the discharge pipe is not connected to a drain or other
suitable means, the water ow may cause property damage.
Water Damage Hazard
Temperature-Pressure Relief Valve discharge
•
pipe must terminate at adequate drain.
T&P VALVE DISCHARGE PIPE REQUIREMENTS:
• Shall not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
20
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both
the Temperature-Pressure Relief Valve and the discharge
pipe.
• Must terminate a maximum of six inches (15.2 cm) above a
oor drain or external to the building. In cold climates, it is
recommended that the discharge pipe be terminated at an
adequate drain inside the building.
• Shall not have any valve or other obstruction between the
temperature-pressure relief valve and the drain.
Burn hazard.
Hot water discharge.
Keep clear of TemperaturePressure Relief Valve
discharge outlet.
The Temperature-Pressure Relief Valve must be manually
operated at least twice a year. Caution should be taken to ensure
that (1) no one is in front of or around the outlet of the TemperaturePressure Relief Valve discharge line, and (2) the water manually
discharged will not cause any bodily injury or property damage
because the water may be extremely hot. If after manually
operating the valve, it fails to completely reset and continues to
release water, immediately close the cold water inlet to the water
heater, follow the draining instructions in this manual, and replace
the Temperature-Pressure Relief Valve with a properly rated/sized
new one.
NOTE: The purpose of a Temperature-Pressure Relief Valve
is to prevent excessive temperatures and pressures in the
storage tank. The T&P 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 thermal
expansion, see Closed Water Systems and Thermal Expansion
on Page 19.
If you do not understand these instructions or have any
questions regarding the Temperature-Pressure Relief Valve call
the toll free number listed on the back cover of this manual for
technical assistance.
CONDENSATE DRAIN
The water heaters covered in this manual are condensing water
heaters and require a building drain to be located in close proximity
to allow the condensate to drain safely.
Condensate drains from the water heater at the exhaust elbow
located at the bottom. The eld installed condensate drain line
must not be elevated above the condensate drain connection on
the condensate trap, see Figure 10. If the condensate does not
drain properly it will build up in the exhaust (vent) elbow. This will
restrict the ow of ue gases and cause the Blocked Exhaust
pressure switch to open its contacts. The control system monitors
all pressure switches, if the Blocked Exhaust Switch contacts are
open the control system will lock out and disable heating operation.
The “Blocked Exhaust” Fault message will be displayed on the
control system’s LCD.
The Condensate Cleanout Cap must be on and tight when unit is
in operation.
NOTE: If the “Blocked Exhaust “ Fault message is ever displayed
on the control system LCD, check the condensate drain rst and
ensure it is not blocked.
Old trap piping is not compatible with
new trap piping.
EXHAUST (VENT)
ELBOW
CONDENSATE
DRAIN LINE
CONNECTION
DRAIN LINE TO TERMINATE NO
MORE THAN 6 INCHES (15.2cm)
CONDENSATE
CLEANOUT CAP
CONDENSATE DRAIN
LINE - FIELD INSTALLED
BUILDING
DRAIN
Figure 10
DO NOT remove the factory installed exhaust/condensate elbow
for any reason, see Figure 10. The water heater’s vent pipe is
under a slight positive pressure while unit is in operation. The
water trap inside of the exhaust/condensate elbow prevents ue
gases from escaping into the installed space.
Do not install any external condensate trap. The exhaust elbow
assembly has an internal condensate trap.
Installation must conform with these instructions and local
building codes.
Field supplied materials required for installation include:
• Approved PVC cement and PVC primer.
• 1/2 inch PVC pipe - minimum length to equal the distance
between the water heater and a suitable building drain.
• 1/2 inch PVC ttings (elbows, couplings, and adapters)
necessary to install a condensate drain line between the
Exhaust/Condensate Elbow Assembly and a suitable
building drain.
• Floor mounted standoffs to brace the drain line.
NOTES:
1. The condensate drains from the water heater’s covered by
this instruction have PH levels between 4.3 and 5.0. Install
a commercially available neutralizing kit if required by local
codes. Lower PH levels are acidic. Do not connect a metal
condensate drain line, such as copper pipe, to the water
heater for this reason.
2. The eld installed condensate drain line must not be less than
1/2 inch PVC in size.
3. DO NOT remove, modify or alter the factory condensate trap.
THIS SIDE VIEW
OF EXHAUST
ELBOW AND
ARROW INDICATE
THE LOCATION OF
THE PRESSURE
PORT
ABOVE DRAIN
21
VENTING INSTALLATION
VENT INSTALLATION CONSIDERATIONS
This water heater has a direct vent system in which all air for
combustion is taken from the outside atmosphere and all
combustion products are discharged to the outdoors.
This water heater must be properly vented for removal of exhaust
gases to the outside atmosphere. Correct Installation of the vent
pipe system is mandatory for the safe and efcient operation of
this water heater and is an important factor in the life of the unit.
Vent pipe installation must be performed in accordance with state
and local codes, or in the absence of such, the National Fuel
Gas Code, NFPA 54, ANSI Z223.1-current edition. Canadian
installations must be performed in accordance with CAN/CSAB149.1-current edition.
Either 2 inch or 3 inch pipe may be used on the vent termination
for 130,000 & 150,000 Btu/hr models. When concentric venting
130,000 & 150,000 Btu/hr, use only 2 inch concentric vent on the
vent termination. When concentric venting 130,000 & 150,000
Btu/hr models, 3 inch pipe must be reduced to 2 inch concentric
vent at the termination. Use only 3 inch pipe or 3 inch concentric
vent on the vent termination for 175,000 & 199,000 Btu/hr models.
When replacing an existing Polaris unit, it is recommended
that the venting system be reviewed for compliance with the
requirements contained in this instruction manual. If the venting
is not in compliance, it is recommended that the appropriate
changes be made to bring it into compliance. Never operate the
water heater unless it is vented to the outdoors.
Note: It is important that the factory-installed air inlet lter be
inspected periodically and cleaned if necessary. See Integrated
Filter Preventative Maintenance on Page 54 in the Periodic
Maintenance section.
Note: If vent system is not in compliance with the current installation
manual, the manufacturer reserves the right to evaluate installation
prior to granting any warranty on service claims.
Important: Check to make sure the vent pipe is not blocked in
any way.
Note: Do not common vent this water heater with any other
appliance. Do not install in the same chase or chimney with
a metal or high-temperature plastic from another gas or fuel
burning appliance.
In cold climates any water vapor remaining in the ue gases
will condense into a cloud of vapor at the point where the vent
system exits the building. Special consideration is recommended,
before locating the vent termination near walkways, windows and
building entrances.
Direct venting into dead spaces such as alleys, atriums, and
inside corners can cause recirculation of ue gases. Recirculation
of ue gases will cause sooting, and icing of the combustion air
intake during severe cold weather. To prevent the recirculation
of ue gases, maintain as much distance as possible between
the combustion air intake and the exhaust vent terminal. Refer
to Horizontal Vent Terminal Installation on Page 25 and Vertical
Vent Terminal Installation on Page 26.
GENERAL VENTING INSTRUCTIONS
The following guidelines should be followed when installing the
air inlet and exhaust outlet piping:
• Venting should be as direct as possible with a minimum
number of pipe ttings.
• Vent diameter must not be reduced unless specically noted in
the installation instructions.
• All 2” horizontal inlet vent piping must be sloped downward
1/4 inch per foot (3” Piping must slope downward 1/8” per foot)
toward the water heater so that moisture in the inlet air will exit
through the air intake moisture drain trap.
• All 2” horizontal exhaust vent piping must be sloped upward
1/4 inch per foot (3” Piping must slope upward at 1/8” per foot)
so that condensate will run back to the heater and exit through
the condensate trap.
• Support all horizontal pipe runs every four feet and and all
vertical pipe runs every six feet or according to local codes.
• All venting systems (except Polypropylene vent systems)
run through unconditioned spaces where below freezing
temperatures are expected should be properly insulated
to prevent freezing. For horizontal runs, wrap the vent pipe
with nationally recognized/listed heat tape and/or approved
insulation for freeze protection. Install per the manufacturer’s
instructions.
• An air intake lter is included with the unit and must be installed
according to the installation instructions supplied with the lter.
• It is important to select the proper pipe cement for the type
of plastic pipe being used. All joints in the vent system piping
(except Polypropylene vent systems) must be properly
cemented. Polypropylene vent systems do not use cement to
connect the pipe and elbow sections but use a push together
gasket seal method. Do not attempt to connect Polypropylene
with sealant cement.
• Piping must be sized and cut before cementing. Cut the pipe
end square and remove all ragged edges and burrs. Make sure
the inside of the pipe is clean and free of cuttings and loose dirt.
Chamfer the end and apply primer to the tting and pipe. Apply
a moderate even coat of pipe cement inside the tting. Apply
a liberal amount of cement to the outside of the pipe to socket
depth. Assemble the parts quickly while cement is still wet. Twist
the pipe 1/4 turn during insertion and hold for 30 seconds.
• All pipe, ttings, pipe cement, primers and procedures must
conform to American National Standard Institute and American
Society for Testing and Materials (ANSI/ASTM) standards in
the United States. This water heater has been design certied
by the Canadian Standards Association for use with the
specied (CSA) listed plastic vent pipe.
APPROVED VENT/INTAKE MATERIAL
Approved vent and intake air pipe materials that may be used in
the United States:
PVC pipe materials:
• DWV ASTM-D2665 or CSA B181.2
• Schedule 40, 80, 120 ASTM-D1785 or CSA B137.3
• SDR Series ASTM-2241 or CSA B137.3
22
CPVC pipe materials:
• CPVC 41 ASTM-D2846 or CSA B137.6
• Schedule 40, 80 ASTM-F441 or CSA B137.6
• SDR Series ASTM-F442
Polypropylene - See Polypropylene Installations.
• M & G Duravent PolyPro vent system
• Centrotherm InnoFlue vent system
Approved vent pipe materials that must be used in Canada:
• ULC S636 PVC / CPVC
• ULC S636 Polypropylene - See Polypropylene Installations.
Approved intake air pipe materials that must be used in Canada:
PVC pipe materials:
• DWV ASTM-D2665 or CSA B181.2
• Schedule 40, 80, 120 ASTM-D1785 or CSA B137.3
• SDR Series ASTM-D2241 or CSA B137.3
CPVC pipe materials:
• CPVC 41 ASTM-D2846 or CSA B137.6
• Schedule 40, 80 ASTM-F441 or CSA B137.6
• SDR Series ASTM-F442
Polypropylene - See Polypropylene Installations.
• M & G Duravent PolyPro vent system
• Centrotherm InnoFlue vent system
NOTE: The use of cellular core PVC (ASTM F891), cellular core
CPVC, or Radel® (polyphenolsulfone) in non-metallic venting
systems is prohibited. Covering non-metallic vent pipe and ttings
with thermal insulation is prohibited. If the water heater is being
installed as a replacement for an existing power vented heater
in pre-existing venting, a thorough inspection of existing venting
system must be performed prior to any installation work. Verify
that correct material as detailed above has been used, and that
the minimum or maximum vent lengths and terminal location as
detailed in this manual have been met. Carefully inspect the entire
venting system for any signs of cracks or fractures, particularly at
joints between elbows and other ttings and straight runs of vent
pipe. Check system for signs of sagging or other stresses in joints
as a result of misalignment of any components in the system.
If any of these conditions are found, they must be corrected in
accordance with the venting instructions in this manual before
completing installation and putting the water heater into service.
NOTE: For water heaters in locations with high ambient
temperatures above 100°F (38°C) it is recommended that CPVC
or Polypropylene pipe and ttings be used.
NOTE: Use only solid (not foam core) piping. Plastic pipe and
ttings are available through most plumbing suppliers. Always
check the marking on the pipe to make sure you are using the
correct material.
POLYPROPYLENE INSTALLATIONS
The water heater has been approved to be installed with
Polypropylene vent material as shown in Table 5 and Table
6. The approved application of single wall, non-exible, nonconcentric Polypropylene vent material is offered by two specic
manufacturers (Centrotherm ECO Systems and DuraVent
Polypropylene). These listed products must be installed by following
the vent manufacturer’s instructions. Refer to Table 7 in Planning
the Vent System on Page 24 to determine the maximum pipe length
and number of elbows that can be used.
Insulation should not be used on Polypropylene venting materials.
The use of insulation will cause increased vent wall temperatures,
which could result in vent pipe failure.
Use only the adapters and vent system listed in Tables 5 and 6.
DO NOT mix vent systems of different types or manufacturers.
Failure to comply could result in severe personal injury, death, or
substantial property damage.
Installations must comply with applicable national, state, and
local codes. For Canadian installation, Polypropylene vent must
be listed as a ULC-S636 approved system. If Polypropylene vent
is not required by your local code, you may use either PVC or
CPVC pipes for your water heater that allows non-metallic venting
material installations.
Polypropylene vent systems do not use cement to connect the pipe
and elbow sections but use a push together gasket seal method.
Do not attempt to connect Polypropylene with sealant cement. All
vent connections MUST be secured by the vent manufacturer’s
joint connector. The installer must use a specic vent starter
adapter at the ue connection. The adapter is supplied by the vent
manufacturer to adapt to its vent system.
In order to be in full compliance with UL 1738 or ULC-S636 and
to meet the requirements of the water heater manufacturer, you
must use the metal joint connector rings, available from the
Polypropylene vent manufacturer, to stiffen the joints of 2”, and
3” diameter pipes.
VENT PIPE TERMINATION
The rst step is to determine where the inlet and exhaust vent
pipes will terminate. The combustion air inlet and exhaust outlet
piping and terminations may be installed in one of the following
termination types:
1. Standard Horizontal (2 Pipe) - See Figure 24
2. Alternate Horizontal (2 Pipe) - See Figure 20
3. Vertical (2 Pipe) - See Figures 21, 22, & 25
4. Concentric Vent Through the Wall - See Figure 30
5. Concentric Vent Through the Roof - See Figure 29
When venting one water heater, locate the inlet and exhaust
terminations according to Figure 11 below. When installing more
than one water heater, see Venting Multiple Units on Page 30.
3" Max.
4"
Max.
Termination Dimensions: 2" Pipe
4" Max.
5"
Max.
Termination Dimensions: 3" Pipe
Figure 11.
The vent system must terminate so that proper clearances are
maintained as cited in local codes or the current edition of the
National Fuel Gas Code, (ANSI Z223.1, 12.9.1 through 12.9.4) or
the Natural Gas and Propane Installation Code (CAN/CSA-B149.1).
See Figure 23.
Instructions on proper installation through a sidewall are provided in
Figure 18 and Figure 19. Plan the vent system layout so that proper
clearances are maintained from plumbing and wiring.
Vent pipes serving power vented water heaters are classied by
building codes as vent connectors. Required clearances from
combustible materials must be provided in accordance with
information in this manual under Locating The Water Heater on Page
15 and Installation Requirements starting on Page 17, and with the
National Fuel Gas Code and local codes.
PLANNING THE VENT SYSTEM
For water heater installations at elevations up to 2000 ft (610 m),
size the exhaust and combustion air inlet pipes as specied in
Table 7A. For water heater installations at elevations from 2000
ft (610 m) to 7,700 ft (2,347 m), size the exhaust and combustion
air inlet pipes as specied in Table 7B. Tables 7A and 7B list
the maximum allowable length in feet of the exhaust outlet and
combustion air inlet pipes as related to the number of required
elbows and the termination type. The specied maximum lengths
are for the separate inlet and exhaust pipe systems and not the
combined length of both systems. The minimum pipe length is 6
feet with one elbow per side.
.
23
Table 5. M & G Duravent PolyPro
Nominal Pipe
Diameter
2” 2PPS-AD PPS-PAC 2PPS-LB 2PPS-E90 2PPS
3” 3PPS-AD PPS-PAC 3PPS-LB 3PPS-E90 3PPS
Flue Outlet
Adapter
Adapter
Connector
Ring
Connector
90 Degree
Elbow
Table 6. Centrotherm InnoFlue SW
Nominal Pipe
Diameter
2”
3”
Flue Outlet
Adapter
ISAGL
0202
ISAGL
0303
Adapter
Connector
Ring
Connector
90 Degree
Elbow
IAFC02 IANS02 ISELL0287 ISVL02
IAFC03 IANS03 ISELL0387 ISVL03
Vent Material Terminal(s)
2PPS & 2PPS-BG for Exhaust;
2PPS-E90 & 2PPS-BG for Intake (Direct Vent only)
3PPS & 3PPS-BG for Exhaust;
3PPS-E90 & 3PPS-BG for Intake (Direct Vent only)
Vent Material Terminal(s)
ISVL02 & IASPP02 for Exhaust;
ISELL0287 & IASPP02 for Intake (Direct Vent only)
ISVL03 & IASPP03 for Exhaust;
ISELL0387 & IASPP03 for Intake (Direct Vent only)
Table 7A. Elevations up to 2000 Ft.
Table 7B. Elevations from 2000 Ft. to 7,700 Ft.
Correct Fittings Incorrect Fittings
90° Long Sweep
Elbow
45° Sweep Elbow
90° Short
Sweep
Elbow
45° Vent
Elbow
90° Vent
Elbow
Figure 12. Correct and Incorrect Pipe Fittings
INTEGRATED FILTER INSTALLATION
The air intake filter included with the unit must be installed
according to the installation instructions supplied with the lter.
Installation steps are shown in Figures 13-16.
When installing the adaptor rubber boot, note the following:
• Re mov e and di s c a r d the pl a s t i c cap f r o m th e outer cl a m s h e l l
housing. See Figure 13.
• To connect heater to the air inlet, use the vent adaptor
rubber boot provided in the base skirt. The adaptor rubber
boot is designed for 3” venting (Figure 14).
NOTE: if there is a need for 2” venting, then use plastic pipe
ttings to transition down.
• Loosen the hose clamp at the adaptor rubber boot and slide
the plastic piping into the adaptor rubber boot. With piping in
place, tighten the hose clamp. Install a 3” x 3” x 2” drain/waste/
vent tting to trap airborne particulates. See Figure 15.
NOTE: If piping has been previously cut with a saw, be sure to
remove all burrs and plastic shavings from the piping before installing.
NOTE: The heater must never be operated without the lter
media installed.
1. Determine termination type and pipe size.
2. Determine number of elbows in exhaust pipe. Do not include the
elbows in the termination or the condensate trap. Corresponding
number in Table 7 indicates the maximum length of exhaust pipe.
3. Determine number of elbows in inlet pipe. Do not include the
elbows in the termination. The corresponding number in Table 7
indicates the maximum length of inlet pipe.
NOTE: Use Table 7A at elevations up to 2000 ft (610 m) and use
Table 7B at elevations from 2000 ft (610 m) to 7,700 ft (2,347 m).
IMPORTANT: Do not use vent elbows in this vent pipe installation.
See Figure 12.
24
Outer Clamshell
Housing With Filter
Remove
Plastic Cap
Figure 13. Remove Plastic Cap
Adaptor Rubber
Figure 14. Adapter Rubber Boot
Boot
Gas Piping
Push On &
Tighten Clamp
Outer Clamshell
Housing
Base Skirt
Hose Clamp
Filter Media shown insid
the Outer Clamshell Housing
INTAKE AIR CONDENSAT E TEE INSTALLATION
Piped To
External Air
Supply
3" x 3" x 2"
DWV Fitting
3" Plastic Pipe
Adaptor Rubber Boot
Outer Clamshell Housing
Figure 15. Air Inlet Piping
e
NOTE: if found difficult to
reattach the outer clamshell
Adaptor
Rubber Boot
Outer Clamshell
Housing
Remove
Filter Media
housing to the internal clamshell
housing - apply a thin layer of silicone
grease to the surface of the black rubber
support of the Filter Media.
Figure 16. Filter Media
DIRECT VENT AIR INTAKE MOISTURE PROTECTION
The air intake piping in a direct vent system will normally not
ha ve any moi s ture accu m ulat i o n in it . Ho wev er, in ce r t a i n ca ses,
moi s t ure may bu i ld up and need s to be dr ained . Typ i c al situa t i ons
include, but are not limited to:
• Cold outdoor temperature, particularly if the air inlet is short,
• Heater being used mostly for space heating,
• Air inlet pipe has vertical rise near the heater and,
• High outdoor humidity.
In s t allat i o ns with any of th e s e co n diti o n s ar e requir e d to pr ovid e
a moisture drain with a trap that ows to a waste drain. See
Figure 17. Install a drain tee assembly and a trap in the inlet
ve nt as cl ose to the wat er heate r as po s sible . Th is is to drain an y
water that may be in the combustion air pipe and prevent it from
entering the blower. The drain tubing in any installation should
have a loop trap and ow to an appropriate waste drain. The air
intake drain line must be entirely separate from the exhaust vent
outlet condensate line.
INSTALL TEE FITTING AS CLOSE TO
WATER HEATER INTAKE AIR
CONNECTION AS POSSIBLE
RUN DRAIN HOSE
TO SUITABLE FLOOR
DRAIN SEPARATELY FROM
OTHER CONDENSATE DRAINS
FACTORY
INTAKE AIR
CONNECTION
FIELD SUPPLIED
3"x3"x1/2" TEE
WITH HOSE BARB
FITTING INSTALLED
CONNECT FIELD
SUPPLIED FLEXIBLE
DRAIN HOSE TO BARB
FITTING AND FORM A
LOOP WATER TRAP IN
DRAIN HOSE
HORIZONTAL VENT TERMINAL INSTALLATION
NOTE: If you are installing your system so that it vents through the
roof, please refer to Vertical Vent Terminal Installation on Page 26.
1. After the points of termination have been
determined (see Vent Pipe Termination on page 23)
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. 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.
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.
2. Cut a length of pipe about 3.5” (8.9 cm) longer than the
wall thickness at the opening.
3. Glue the air intake terminal to the section of the pipe.
4. Slide the wall plate over pipe to stop against air intake terminal.
5. 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.
6. If the air intake pipe is installed up to the wall, with a coupling on the
end against the wall opening, the pipe with the air intake 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. See Figure 18 and Figure 19.
7.
Refer to Figure 11 in “Vent Pipe Termination” for standard and
alternate vent termination dimensions.
8. Refer to Figure 20 below for the Alternate Horizontal Termination
installation.
Figure 18
INTAKE
AIR
PIPING
Figure 17
Figure 19
25
*Refer to Figure 11 for Inlet/Outlet Location Dimensions
Alternate Horizontal Termination
Figure 20
VERTICAL VENT TERMINAL INSTALLATION
The vertical inlet air termination requires a return bend or two
short or long sweep radius 90 elbows to keep the inlet downward
and prevent entry of rain. These elbows are considered part of
the termination and should not be included when calculating
the maximum allowable vent pipe length. Refer to Figures 21
and 22 for the proper location of the air inlet with respect to
the exhaust outlet termination. The air inlet and exhaust outlet
terminations must be at least 12 inches above the roof line or
anticipated snow levels.
WHEN TERMINATING THROUGH A ROOF, THE FOLLOWING
SPECIFICATIONS PERTAINING TO TERMINAL LOCATION
MUST BE FOLLOWED.
1. Support horizontal pipe every four feet. Support vertiocal
pipe every six feet.
2. Increase the 12 inch minimum above grade to keep terminal
openings above anticipated snow levels.
FL AT RO O F IN STALL AT I ON
On at roof installations the air intake and the exhaust vent
terminations must be a minimum of 24 inches (60 cm) above
any parapet, vertical wall or structure within 10 feet (3 m)
horizontally.
Flashing
12" Min.
See Note 2.
Exhaust
Vent
Roof Line
See Note 3
12” Min.
See Note 2
Anticipated
Snow Level
Notes:
1. Support Horizontal Pipe Every
Four Feet. Support Vertical Pipe
Every Six Feet.
2. Increase The 12 Inch Minimum
Above Grade To Keep Terminal
Openings Above Anticipated
Snow Levels.
3. See Figure 11 from "Vent Pipe
Te rmination" on page 23 to properly
locate the inlet and exhaust
terminals.
PITCHED ROOF INSTALLATION (ALL MODELS)
Figure 21
See Note 3.
1. Support Horizontal Pipe Every
Four Feet. Support Vertical Pipe
Every Six Feet.
2. Increase The 12 Inch Minimum
Above Grade To Keep Te rminal
Openings Above Anticipated
Snow Levels.
3. See Figure 11 from "Vent Pipe
Te rmination" on page 23 to properly
locate the inlet and exhaust
terminals.
FLAT ROOF INSTALLATION (ALL MODELS)
Combustion Air Termination and Exhaust Air Termination
Must Be Located in the Same Pressure Zones.
Figure 22
26
TERMINATION CLEARANCES SIDEWALL DIRECT VENT
EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION
D
E
B
L
(using outdoor air for combustion)
G
B
C
B
F
B
B
H
H
B
M
J
I
K
Figure 23
Vent terminal clearances for “Direct Vent” installations. Direct Vent congurations use outdoor air for combustion.
DIRECT VENT
Clearance above grade,
veranda, porch, deck or
A
balcony
CANADIAN INSTALLATIONS 1US INSTALLATIONS
12 inches (30 cm) 12 inches (30 cm)
2
Clearance to each side
of center line extended
H
above meter/regulator
assembly
CANADIAN INSTALLATIONS
Clearance in accordance with
local installation codes and the
requirements of the gas supplier.
1
US INSTALLATIONS
Clearance in accordance
with local installation codes
and the requirements of the
gas supplier.
2
6 in (15 cm) for
appliances ≤ 10,000
Btuh (3 kW), 9 in (23
cm) for appliances
> 10,000 Btuh (3 kW)
and ≤ 50,000 Btuh (15
kW), 12 in (30 cm) for
appliances > 50,000
Btuh (15 kW)
Clearance to service
I
regulator vent outlet
Clearance to a non
mechanical air supply
inlet into building or
J
combustion air inlet to
any other appliance
Clearance to a
mechanical air supply
K
inlet
Clearance above
paved sidewalk or
L
paved driveway located
on public property
Clearance under
veranda, porch, deck,
M
or balcony
Above a regulator within 3 ft (91
cm) horizontally of the vertical
center line of the regulator vent
outlet to a maximum vertical
distance of 15 ft (4.5 m)
6 in (15 cm) for appliances
≤ 10,000 Btuh (3 kW), 12 in
(30 cm) for appliances > 10,000
Btuh (3 kW) and ≤ 100,000 Btuh
(30 kW), 36 in (91 cm) for appliances
>100,000 Btuh (30 kW)
6 feet (1.83 m)
7 feet (2.13 m)† 7 feet (2.13 m)†*
12 inches (30 cm) ‡ 12 inches (30 cm) ‡*
Clearance in accordance
with local installation codes
and the requirements of the
gas supplier
6 in (15 cm) for appliances
≤ 10,000 Btuh (3 kW), 9 in
(23 cm) for appliances
> 10,000 Btuh (3 kW) and
≤ 50,000 Btuh (15 kW), 12 in
(30 cm) for appliances
> 50,000 Btuh (15 kW)
3 feet (91 cm) above if within
10 feet (3 m) horizontally
Clearance to window or
B
door that may be opened
Clearance to
permanently closed
C
window
Vertical clearance to
ventilated soft located
above the terminal within
D
a horizontal distance of
2 feet (61 cm) from the
center line of the terminal
Clearance to unventilated
E
soft
Clearance to outside
F
corner
Clearance to inside
G
corner
6 in (15 cm) for appliances
≤ 10,000 Btuh (3 kW), 12 in
(30 cm) for appliances > 10,000
Btuh (3 kW) and ≤ 100,000 Btuh
(30 kW), 36 in (91 cm) for
appliances >100,000 Btuh (30 kW)
6 inches (15 cm)* 6 inches (15 cm)*
12 inches (30 cm)* 12 inches (30 cm)*
12 inches (30 cm)* 12 inches (30 cm)*
2 feet (60 cm)* 2 feet (60 cm)*
18 inches (45 cm)* 18 inches (45 cm)*
1 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code.
2 In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
Where it may cause hazardous frost or ice accumulations on adjacent property surfaces.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the oor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.
27
DIRECT VENT INSTALLATION DIAGRAMS
Notes:
1. Support Horizontal Pipe Every
Four Feet. Support Vertical
Pipe Every Six Feet.
2. Increase the 12" minimum
above grade to keep terminal
openings above anticipated snow
levels.
3. Slope all piping 1/8" per foot down
toward water heater.
4.
When venting with 2" pipe, a sufficient
length of 3" pipe (6" minimum) must be
inserted into the exhaust and inlet elbow
assembly before transitioning down to 2" pipe
with a 3" x 2" reducer.
5. For units with inputs of 150,000 BTU/hr and
below, use 2" or 3" pipe. For units with inputs
of 175,000 BTU/hr and above, use only 3" pipe.
6. See Figure 11 from "Vent Pipe Termination" on
page 23 to properly locate the inlet and
exhaust terminals.
See
Note 6
12" Min. Above
Grade or
Anticipated
Snow Level.
See Note 2.
Tee with
Drain Tap
To Drain*
See Note 3
See Note 5
3" x 2"
Reducer
See Note 4
See
Note 5
3" x 2"
Reducer
See Note 4
Exhaust
Elbow
Assembly
*Direct vent combustion air intake drains are required in certain situations.
See the section on Direct Vent Air Intake Moisture Protection on page 25
Figure 24. SIDEWALL VENT INSTALLATION (ALL MODELS)
12" Min. Above
Roof or Anticipated
Snow Level.
See Note 2.
Notes:
1. Support Horizontal Pipe Every Four Feet.
Support Ve rtical Pipe Every Six Feet.
2. Increase The 12 Inches Minimum Above
See
Note 3
See
Note 1
Grade To Keep Te rminal Openings Above
Anticipated Snow Levels.
3. For units with inputs of 150,000 BTU/hr and
below, use 2" or 3" pipe. For units with inputs
of 175,000 BTU/hr and above, use only 3" pipe.
4. When venting with 2" pipe, a sufficient length of
3" pipe (6" minimum) must be inserted into the exhaust and
inlet elbow assembly before transitioning down to
2" pipe with a 3" x 2" reducer.
5. See Figure 11 from "Vent Pipe Termination" on page 23
to properly locate the inlet and exhaust terminals.
Drain Pan
(Piped To Adequate Drain)
*Direct vent combustion air intake drains are required in certain situations.
See the section on Direct Vent Air Intake Moisture Protection on page 25
3" x 2"
Reducer
See Note 4
See Note 5
12" Min.
See Note 1
See
Note 1
See
Note 3
3" x 2"
Reducer
See Note 4
Exhaust
Elbow
Assembly
Figure 25. ROOF VENT INSTALLATION (ALL MODELS)
28
CONCENTRIC VENT INSTALLATION
2" pipe with a 3" x 2" reducer.
5
For new installations of 130,000 & 150,000 btu/hr units, install
2” Concentric vent kit model KGAVT0501CVT, part number
100093946. For new installations of 175,000 & 199,000 btu/
hr units, install 3” Concentric vent kit model KGAVT0601CVT,
part number 100093947. See Manufacturer’s instructions for
complete installation or call the technical support number listed
on the back cover of this manual. For planning purposes, see
Figures 26 through 30 below for vent terminal specifications.
Note: When terminating concentric vents for additional units (all
models), see “Venting Multiple Units” on Page 30.
Field supplied pipe and ttings are required to complete the
installation.
SAFETY CONSIDERATIONS
Installing and servicing water heating equipment can be hazardous
due to gas and electrical components. Installation and service of
the concentric vent termination requires ability equivalent to that of
a qualied installer or qualied service technician, see Page 8. All
precautions in the literature, on tags, and labels attached to the unit
must be observed.
Follow all safety codes. Wear safety glasses and work gloves.
Figure 29. Through the Roof Termination
Tee with
Drain Trap
Trap
Figure 26. 2 Inch Concentric Vent
Figure 27. 3 Inch Concentric Vent
Figure 28. Through the Wall Termination
See Note 4
NOTES:
1. Support Horizontal Pipe Every Four Feet.
Support Vertical Pipe Every Six Feet.
2. Increase The 12” Minimum Above
Grade To Keep Inlet Opening
Above Anticipated
Snow Levels.
3. Slope All Piping 1/8” Per
Down Toward The
Foot
Water Heater.
4. For units with inputs of
150,000 BTU/hr
use 2" or 3" pipe. For units
inputs of
use only 3" pipe.
5. When venting with 2" pipe, a sufficient
length of 3" pipe (6" minimum) must be
inserted into the exhaust and inlet elbow
assembly before transitioning down to
and below,
175,000 BTU/hr
and above,
See Note 5
with
3" x 2"
Reducer
Drain Pan
(Piped to
Adequate
Drain)
Figure 30. Concentric Vent Piping Installation
3" x 2"
Reducer
See Note
Exhaust
Elbow
Assembly
29
VENTING MULTIPLE UNITS
VENTING ADDITIONAL POLARIS® UNITS
(130,000 & 150,000 BTU/HR MODELS)
When using two water heaters with inputs of 150,000 BTH/HR or
below, install vent terminations using either Method A or Method
B below:
Figure 31
When using three or more water heaters with inputs of 150,000
BTH/HR or below, install vent terminations per Method C or
Method D:
When using three or more water heaters with inputs of 175,000 BTH/
HR or above, install vent terminations per Method C or Method D:
Figure 34
CONCENTRIC VENTING MULTIPLE WATER HEATERS
(ALL MODELS)
When concentric venting two water heaters, install vent
terminations using either Method E or Method F below:
Figure 32
VENTING ADDITIONAL POLARIS® UNITS (175,000 &
199,000 BTU/HR MODELS)
When using two water heaters with inputs of 175,000 BTH/HR or
above, install vent terminations using either Method A or Method
B below:
When concentric venting three or more water heaters, install vent
terminations using Method G below:
Figure 35
Figure 33
30
WATER HEATER INSTALLATION
CONDENSATE DRAIN INSTALLATION
1. Ensure the water heater’s enable/disable switch is in the “disable”
position.
2. Install a 1/2 inch PVC condensate drain line between condensate
drain connection on the Exhaust/Condensate Elbow and a
suitable building drain with a slight downward slope to drain. The
exhaust elbow has a “built in” condensate trap. Do not install an
additional trap in the condensate drain piping. See Figure 36.
3. Terminate the condensate drain piping with an elbow above the
drain. Ensure that any discharge will exit the condensate drain
line no more than 6 inches (15.2 cm) above a suitable building
drain, or external to the building, see Figure 36.
EXHAUST/CONDENSATE
(VENT) ELBOW
PRESSURE PORT
1/2” NPT
CONDENSATE
DRAIN
CONNECTION
CONDENSATE
CLEANOUT
NOTE: In cold climates it is recommended the condensate drain be
terminated at a suitable drain inside the building.
4. Ensure the condensate drain line is not elevated above the
condensate drain connection on the Exhaust/Condensate Elbow,
see Figure 36.
5. Brace the condensate drain line with oor mounted standoffs
every three feet.
6. Ensure the condensate drains freely during start up and the
condensate clean out cap is on and tight when unit is in operation.
7. Condensate clean out cap must be on and tight when unit is in
operation.
CONDENSATE DRAIN
LINE - FIELD
INSTALLED
DRAIN LINE TO
TERMINATE NO
MORE THAN 6
INCHES (15.2 cm)
ABOVE DRAIN
BUILDING
DRAIN
Figure 36
SUPPLY GAS LINE INSTALLATION
Contact your local gas utility company to ensure that adequate gas
service is available and to review applicable installation codes for
your area.
Be sure that the gas meter has sufcient capacity to supply the
rated gas input of the water heater as well as the requirements of
all other gas red equipment supplied by the meter. If the gas meter
is undersized, the gas company will have to install a properly sized
gas meter.
Make sure the gas supplied is the same type listed on the water
heaters rating label.
The gas piping must be installed according to all local and state
codes or in absence of local and state codes with the “National
Fuel Gas Code”, ANSI Z223.1 (NFPA 54)-current edition. Canadian
installations must be performed in accordance with CAN/CSAB149.1-current edition.
Schedule 40 Steel or Wrought Iron Pipe is the preferred material
for the gas line of this water heater. It is imperative to follow the
sizing recommendations in the latest version of the National Fuel
Gas Code if Corrugated Stainless Steel Tubing (CSST) is used as
the gas line for this water heater.
Tables 8, 9, and 10 on Page 32 are provided as a sizing reference for
commonly used gas pipe materials. Consult the “National Fuel Gas
Code” for the recommended gas pipe size of other materials.
Follow the instructions below and reference Figure 37 for gas
piping installation.
1. Apply thread sealing compounds (pipe dope/ Teon tape)
sparingly and only to the male threads of the pipe joints. Do
not apply sealing compound to the rst two threads. Use pipe
dope or Teon tape marked as being resistant to the action of
liquid petroleum (LP/propane) gases.
2. Install a readily accessible manual shut-of f valve in the gas
supply line as recommended by the local utility. Know the
location of this valve and how to turn off the gas to this unit.
3. Install a sediment trap as shown. The sediment trap must be
no les s than 3 inch es long for the accumulation of dir t, foreign
material and water droplets.
4. Install a ground union between the water heater and the
manual shut-off valve. This is to allow easy servicing. See
Figure 37 below.
5. Turn the gas supply on and check for leaks. See Gas Line
Leak Testing on Page 32. Use a chloride-free soap and
water solution (bubbles forming indicate a leak) or other
approved method.
NOTE: Units wi th inputs of 175,000 BTU/H R or above must have a
minimum of 3/4” NPT gas pipe supplied to the water heater.
Sediment Trap
Figure 37
31
Table 8. Natural Gas Capacity (Cu. ft/hr)
Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity of 0.60 (natural gas).
Table 9. L.P. Gas Capacity
Table 10. L.P. Gas Capacity
CAN/CSA B149.1.
Nominal Iron
Pipe Size, in.
1/2
3/4
1
1-1/4
1-1/2
After the length of pipe has been determined, select the pipe size which will provide the minimum cubic feet per hour required for the
gas input rating of the water heater. By formula:
The gas input of the water heater is marked on the water heater data plate. The heating value of the gas (BTU/FT
by consulting the local natural gas utility.
Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches water column pressure).
Based on a Pressure Drop of 0.5 Inch Water Column.
Nominal Iron
Pipe Size, in.
1/2
3/4
1
1-1/4
10
132
278
520
1050
1600
10
275
576
1071
2205
20
n/a
190
350
730
1100
1496
30
n/a
152
285
590
890
Cu. Ft. Per Hr. Required =
20
189
393
732
40
n/a
130
245
500
760
30
152
315
590
1212
50
n/a
115
215
440
670
40
n/a
267
504
1039
Length of Pipe, Feet
60
n/a
105
195
400
610
50
n/a
237
448
913
70
n/a
96
180
370
560
Gas Input of Water Heater (BTU/HR)
Heating Value of Gas (BTU/FT
Length of Pipe, Feet
60
n/a
217
409
834
80
n/a
n/a
170
350
530
70
n/a
196
378
771
90
n/a
n/a
160
320
490
80
n/a
185
346
724
100
n/a
n/a
150
305
460
3
)
90
n/a
173
322
677
125
n/a
n/a
130
275
410
3
) may be determined
100
n/a
162
307
630
Example: Input BTU requirement of the water heater, 199,000 BTUH
To tal pipe length, 80 feet = 1" IPS required.
150
n/a
n/a
120
250
380
125
n/a
146
275
567
175
n/a
n/a
110
220
350
200
n/a
n/a
100
210
320
150
n/a
132
252
511
Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches water column pressure).
Based on a Pressure Drop of 0.5 Inch Water Column.
Copper Tubing
O.D. Size, in.
5/8
3/4
7/8
10
206
348
536
20
141
239
368
30
n/a
192
296
40
n/a
164
253
Example: Input BTU requirement of the water heater, 199,000 BT UH
To tal pipe length, 50 feet = 7/8" IPS required.
Additional tables are available in the current edition of the “National Fuel Gas Code”, ANSI Z223.1
GAS LINE LEAK TESTING
Fire and Explosion Hazard
Use joint compound or Teflon tape
compatible with propane gas.
Leak test gas connections before
placing water heater in operation.
Disconnect gas piping at main
gas shutoff valve before leak
testing heater.
Install sediment trap in
accordance with NFPA 54 or
Any time work is done on the gas supply system perform a leak test
to avoid the possibility of re or explosion.
Length of Pipe, Feet
50
n/a
146
224
60
n/a
132
203
80
n/a
n/a
174
100
n/a
n/a
154
125
n/a
n/a
137
1. For test pressures exceeding 1/2 psi (3.45 kPa) disconnect
the water heater and its Main Gas Shutoff Valve from the gas
supply piping system during testing, see Figure 37 on page
31. The gas supply line must be capped when disconnected
from the water heater.
2. For test pressures of 1/2 psi (3.45 kpa) or less, the water
heater need not be disconnected, but must be isolated from
the supply gas line by closing the Main Gas Shutoff Valve
during testing.
3. Paint all supply gas line joints and connections upstream of
the water heater with a rich soap and water solution to test
for leaks. Bubbles indicate a gas leak. Do not use matches,
candles, ame or other sources of ignition for this purpose.
4. Repair any leaks before placing the water heater in operation.
PURGING
Gas line purging is required with new piping or systems.
Purging should be performed per the current edition of NFPA 54
the National Fuel Gas Code or CAN/CSA B149.1 Natural Gas and
Propane Installation Code.
32
ELECTRICAL WIRING
If you lack the necessary skills required to properly install the
electrical wiring to this water heater, do not proceed but have a
qualied electrician perform the installation. Refer to the Power
Supply section on Page 18 for additional requirements.
When making the electrical connections, always make sure:
• The voltage and frequency must correspond to that specied
on the water heater data plate on the front of the water heater.
• The electrical supply has the proper overload fuse or breaker
protection. The heater draws less than 7 amps.
• Wire sizes, connections and conduits comply with all applicable
codes.
• The water heater and electrical supply are properly grounded.
• This water heater must be “hard-wired” do not use an extension
cord to supply electrical power to this water heater.
NOTE: The wiring diagram can be found in Figure 49 on page 57.
Always reference the wiring diagram(s) for the correct electrical
connections.
When installing the electrical wiring to the water heater:
1. Shut off the power at the electrical service box.
2. Loosen the screws securing the access panel to the electrical
compartment. (The electrical wiring diagram for all models can
be found on the inside of the access panel at the base of the
water heater. Set the access panel aside.
3. Connect the electrical supply to the water heater in accordance
with local utility requirements and codes. Use only a dedicated
electrical circuit containing a properly sized fuse or circuit
breaker. Maximum overload protection should not exceed 15
amperes.
4. Connect this circuit (directly from the electrical service box) to
an electrical disconnect switch.
5. Ground the water heater by connecting the electrical service
ground wire to the green ground wire (provided).
NOTE: The power supply to this water heater must be properly
polarized, [120 volts from the hot lead (black) to ground and 0 volts
from the neutral lead (white) to ground] otherwise, the unit will not
operate.
6. After making all electrical connections, completely ll the
tank with water and check all connections for leaks. Open the
nearest hot water faucet and let it run for 3 minutes to purge the
water lines of air and sediment and to ensure complete lling
of the tank. The electrical power may then be turned on. See
Page 44 for the complete Start Up instructions.
ENABLE/DISABLE CIRCUIT
(For Building Management Systems)
The water heaters covered in this manual are equipped with
an enable/disable circuit for use with eld supplied external
supervisory controls such as time clocks or Building Management
Systems. The enable/disable circuit may be used to disable
heating operation during periods when the building is unoccupied
or there is no demand for hotwater.
To use the enable/disable circuit it must rst be activated by
selecting the “Use External Enable” from the UIM. Field supplied
wiring is then installed between the water heater’s CCB and a
set of “dry contacts” (no voltage or load) on the eld supplied
external control.
NOTE: The water heater’s enable/disable circuit is a switching
circuit only: Do not apply external voltage or connect any load
(IE: relay coil) to this circuit. This will damage the CCB circuit
board and is not covered under the limited warranty.
CONNECTING AN EXTERNAL SUPERVISORY CONTROL
The enable/disable circuit is accessed from the CCB’s J17 plug
inside the CCB enclosure; see Figure 3 on page 12 to locate the
CCB enclosure and Figure 48 on page 56 for the CCB layout.
Install eld wiring to the enable/disable circuit:
1. Turn off power at the water heater’s enable/disable switch
and the breaker that supplies power to the water heater.
2. Locate the CCB enclosure.
3. Carefully remove the Temperature Probe connectors and
CCB enclosure cover.
4. Locate pins 1 and 2 on the CCB J17 plug. See Figure 48 on
page 56.
5. Connect the two eld supplied control wires to pins 1 and 2
on the CCB J17 plug.
6. Thread the control wires out of the CCB enclosure with the
other wiring and carefully replace the CCB enclosure cover.
Ensure all wiring is routed through the intended area provided
for strain relief. Ensure no wiring is being pinched.
7. Reinstall the CCB enclosure cover.
8. Route the control wires inside the junction box on the top
of the water heater; see Figure 3 on page 12 to locate the
junction box. Use an available knock-out to route the wires
inside the junction box.
9. Install eld supplied control wiring and conduit as required
by national and local codes between the water heater’s
junction box and the external supervisory control. Connect
the wiring from the external control to the control wires inside
the junction box using wire nuts and electrical tape.
10. Connect the control wiring to a set of dry contacts on the
external control. Follow the control manufacturer’s instructions
for making connections.
11. Restore power to the water heater.
12. From the water heaters UIM “Heater Information Screen”
select “Use External Enable” and change to “Yes”. See
Figure 3 on page 12 to locate the UIM.
NOTE: Whenever the external control opens the set of dry
contacts used, water heating operation will be disabled.
Whenever the external control closes the set of dry contacts
used, water heating operation will be enabled. A diagonal line and
circle appears over the thermometer icon on the UIM when water
heating operation is disabled. See the Status Icons descriptions
in Table 12 on page 37.
NOTE: Ensure the water heater is protected from freezing
temperatures when water heating operation is disabled. Damage
to the water heater caused by freezing temperatures is not
covered under the limited warranty.
WATER LINE CONNECTIONS
The water piping installation must conform to these instructions and
to all local and national code authority having jurisdiction. Good
practice requires that all heavy piping be supported.
Read and observe all requirements in the following sections before
installation of the water piping begins:
1. Mixing Valves on page 18.
2. Dishwashing Machines on page 19.
3. Temperature-Pressure Relief Valve on page 20.
4. Closed Systems and Thermal Expansion on page 19.
WATER PIPING DIAGRAMS
This manual provides detailed water piping diagrams for typical
methods of application for the water heaters, see Piping Diagrams
beginning on Page 59.
The water heater may be installed by itself, or with a separate storage
tank. When used with a separate storage tank, the circulation may
be either by gravity or by means of a circulating pump. When a
33
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 water heater storage tank.
Adjust ow by throttling a full port ball valve installed in the
circulating line on the outlet side of the pump. Never throttle ow
on the suction side of a pump. See Figure 55 in Piping Diagrams.
NOTE: In addition to the factory installed Temperature-Pressure
Relief Valve (T&P valve) on the water heater, each remote storage
tank that may be installed and piped to a water heating appliance must
also have its own properly sized, rated and approved TemperaturePressure Relief Valve installed. See Temperature-Pressure Relief
Valve on Page 20.
Call the toll free technical support phone number listed on the back
cover of this manual for further assistance in sizing a T&P valve for
remote storage tanks.
THERMOMETERS (NOT SUPPLIED)
Thermometers are installed in the water piping system as a means
of detecting the temperature of the hot water supply at critical points
in the system. Field supplied thermometers should be obtained and
installed. See Piping Diagrams beginning on Page 59.
WATER (POTABLE) HEATING AND SPACE HEATING
1. All water piping components connected to the water heater that
are for space heating applications shall be suitable for use with
potable water.
2. Toxic chemicals, such as those used for boiler treatment, must
NEVER be introduced into this system.
3. The water heaters covered in this manual may never be
connected to any existing heating system or component(s)
previously used with non-potable water heating appliance.
4. When the system requires water for space heating that exceed
safe temperatures at domestic water xtures a mixing valve must
be installed, see Mixing Valves on Page 18.
5. These water heaters cannot be used in space heating
applications only.
HOTTER WATER CAN SCALD:
Water heaters are intended to produce hot water. Water heated to
a temperature which will satisfy space heating, clothes washing,
dish washing, cleaning and other sanitizing needs can scald and
permanently injure you upon contact. Some people are more likely
to be permanently injured by hot water than others. These include
the elderly, children, the physically or developmentally disabled. If
anyone using hot water ts into one of these groups or if there is a
local code or state law requiring a certain temperature water at the
hot water tap, then you must take special precautions. In addition
to using the lowest possible temperature setting that satises your
hot water needs, a means such as a mixing valve should be used
at the hot water taps used by these people or at the water heater.
See Figure 8 in Mixing Valves. Valves for reducing point of use
temperature by mixing cold and hot water are also available:
T&P VALVE DISCHARGE PIPE
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
Properly sized temperaturepressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
This water heater is provided with a properly rated/sized and
certified combination temperature - pressure (T&P) relief
valve by the manufacturer. See Temperature-Pressure Relief
Valve on page 20 for information on replacement and other
requirements.
CAUTION
Water Damage Hazard
Temperature-Pressure Relief Valve discharge
•
pipe must terminate at adequate drain.
Install a discharge pipe between the T&P valve discharge opening
and a suitable oor drain. Do not connect discharge piping directly
to the drain unless a 6” (15.2 cm) air gap is provided. To prevent
bodily injury, hazard to life, or property damage, the TemperaturePressure Relief Valve must be allowed to discharge water in
adequate quantities should circumstances demand. If the discharge
pipe is not connected to a drain or other suitable means, the water
ow may cause property damage.
Consult a Qualied Installer or Service Agency. Follow
manufacturer’s instructions for installation of the valves. Before
changing the factory setting on the thermostat, read the Temperature
Regulation section beginning on Page 35.
T&P VALVE DISCHARGE PIPE REQUIREMENTS:
• Shall not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both the
Temperature-Pressure Relief Valve and the discharge pipe.
• Must terminate a maximum of six inches above a oor
drain or external to the building. In cold climates, it is
recommended that the discharge pipe be terminated at an
adequate drain inside the building.
• Shall not have any valve or other obstruction between the
Temperature-Pressure Relief Valve and the drain.
34
TEMPERATURE REGULATION
HIGH TEMPERATURE LIMIT CONTROL (ECO)
This water heater is equipped with an ECO (energy cut out) non
adjustable high temperature limit switch. The ECO is a normally
closed switch that opens (activates) on a rise in temperature. The
ECO is located inside the Temperature Probe (two red wires).
The ECO switch contacts will open when the water temperature
reaches approximately 202°F (94°C) and close at approximately
140°F (49°C).
If the ECO activates (contacts open) due to abnormally high
water temperatures in the storage tank, the control system will
immediately de-energize the 24 VAC Gas Control Valve and end
current heating cycle. The control system will lock out disabling
further heating operation. The control system will display the
Energy Cut Out (ECO) Fault message on the LCD screen. It is
important that a Qualied Service Technician be contacted to
determine the reason for ECO activation before resetting the ECO.
Once the reason has been determined and corrected the ECO can
be reset as follows:
Should the ECO activate, water temperature must drop below
140°F (49°C) before the control system can be reset. Once water
temperature has cooled below this point the power supply to water
heater must be turned off and on again to reset the control system.
THERMOSTAT CONTROL
DA NGER
Hot water temperatures required for automatic dishwasher and laundry
use can cause scald burns resulting in serious personal injury and/or
death. Table 11 shows the approximate time-to-burn relationship for
normal adult skin.
The temperature at which injury occurs varies with the person’s age
and duration of exposure. The slower response time of children, the
elderly or disabled persons increases the hazards to them. If anyone
using hot water provided by the water heater being installed ts into
one of these groups or if there is a local code or state law requiring a
certain water temperature at the point of use, then special precautions
must be taken.
Water Temperature
°F (°C)
110 (43.3) (normal shower temp.)
116 (46.7) (pain threshold)
116 (46.7) 35 minutes 45 minutes
122 (50) 1 minute 5 minutes
131 (55) 5 seconds 25 seconds
140 (60) 2 seconds 5 seconds
149 (65) 1 second 2 seconds
154 (67.8) instantaneous 1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)
Time for 1st Degree Burn
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, elderly and the physically
or mentally disabled are at highest risk
for scald injury.
Feel water before bathing or showering.
Temperature limiting devices such as
mixing valves must be installed when
required by codes and to ensure safe
temperatures at fixtures.
Read instruction manual for safe
temperature setting.
Table 11
Time for Permanent Burns
(Less Severe Burns)
2nd & 3rd Degree
(Most Severe Burns)
In addition to using the lowest possible temperature setting that
satises the demand of the application, a mixing valve can be installed
at the water heater (see Figure 8 on Page 18) or at the hot water taps
to further reduce system water temperature.
Never allow small children to use a hot water tap or 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.
Setting the Operating Set Point at 120°F (49°C) will reduce the risk of
scalds. Some States require settings at specic lower temperatures.
Check with the code authority having jurisdiction..
The water heaters covered in this manual are equipped with an
electronic control system to regulate water temperature inside
the storage tank. The control system senses temperature from
two factory installed temperature probes, one installed in the
top of the storage tank and one installed near the bottom. See
Figures 2 & 3 in Features and Components.
The “Operating Set Point” is adjusted to regulate water
temperature inside the tank. This is an adjustable user setting in
the control system’s “Temperature Menu.” This and all control
system menus are accessed through the UIM (user interface
module) located on the front of the water heater, see Figure 38.
The “Operating Set Point” is adjustable from 90°F (32°C)
to 181°F (83°C). The factory setting is 120°F (49°C). See
Operating Set Point and Differential Adjustment on Page 39 for
instructions on how to adjust the Operating Set Point and other
settings.
Set the Operating Set Point at the lowest setting which produces
acceptable hot water supply. This will always provide the most
efcient operation.
MODULATION
The water heaters covered by this manual are capable
of modulating their ring rate. The CCB monitors water
temperature in the tank and regulates the ring rate to achieve
the target temperature setpoint. The ring rate is dictated by the
hot water draw, proximity to the tank temperature setpoint, and
various other temperature limitations.
HIGH TEMPERATURE APPLICATIONS
Higher operating temperatures cause more wear on all water
heaters and will decrease the life span of the water heater.
Consider installing a small booster water heater for high
temperature applications, such as commercial dishwashers,
to raise the outlet temperature from the larger primary water
heater to the desired point of use temperature. Contact your
local distributor or call technical support phone number listed
on back cover of this manual for further technical assistance.
Tank Te mperature 103°F
Operating Set Point 120°F
Status: Heating
OFF
O
GAS
N
MENU HELP
Figure 38
35
CONTROL SYSTEM OPERATION
r
OVERVIEW
The water heaters covered in this manual are equipped with an
electronic control system that regulates water temperature inside
the storage tank. Heating cycles and ignition are managed by the
control system. The ECO (energy cut out), ame sensor, pressure
switches and temperature probes are monitored by the control
system. The Combustion Blower, Spark Ignition Transformer, 24
Volt Gas Control Valve are all powered by the control system.
The main components of the control system are a UIM (user
interface module) and a CCB (central control board). The UIM is
located on the top front side of the water heater. The CCB is mounted
on the base of the water heater inside a protective enclosure, see
Figure 39. This unit is equipped with an Enable/Disable switch. To
operate unit, make sure the switch is set to Enable. See Features
and Components beginning on Page 11 for location of these and
other water heater components.
CCB
BOARD
POWER
SUPPLY
BOARD
TRANSFORMER
Figure 39
CONTROL SYSTEM NAVIGATION
All operational information and user settings are displayed and
accessed from the UIM. The UIM houses the control system’s LCD
Touch Display (liquid crystal display). See Figure 40 below.
THE DESKTOP SCREEN
During normal operation the control system will display the
“Desktop” screen on the LCD Touch Display which is the default
screen. The control system will return to the Desktop screen when
there are no active Fault or Alert conditions or when there has
been no user input for several minutes.
• Manufacturer and water heater model information is
displayed in Title Bar at the top of the Desktop screen. Menu
titles are displayed in the Title Bar when navigating the
control system menus.
• The rst temperature shown on the Desktop screen, Tank
Temperature, is the temperature of the water inside the water
heater’s storage tank.
• The second temperature shown on the Desktop screen is
the Operating Set Point. The Operating Set Point is the
temperature at which the control system will maintain the
water inside the storage tank.
• Beneath the Operating Set Point is the “Status” line. The
Status line shows the current operational state of the control
system in real time, see Table 13 on Page 38 for a description
of the various operational states.
• The Desktop screen also displays animated “Status Icons” to
convey operational information, see Table 12 on Page 37 for
descriptions of the Status Icons.
LCD Touch Display
Information
Display
Tank Te mperature 103°F
Operating Set Point 120°F
Status: Heating
Status Icons
Operational menus are multi functional.
UIM (user interface module)
Desktop Screen Shown
OFF
O
GAS
N
Figure 40
36
Title Ba
HELPMENU
STATUS ICONS
OFF
O
N
Status Icons are displayed on the Desktop screen and convey operational and diagnostic information. Icons are described in the table
below. See Figure 40 on Page 36. Ensure the water heater is properly grounded. Flame sensing requires an adequate earth ground. If the
water heater is not properly grounded it will cause Ignition Failure. See Electrical Wiring on Page 33.
Table 12 – Status Icons
Icon Description
Water temperature in the tank has fallen. Shaded area of the animated thermometer icon will rise and fall in response
to water temperature in the storage tank as sensed from the Upper and Lower Temperature Probes. See Features and
Components section starting on page 11 for location of Temperature Probes.
Water temperature in the tank has reached the Operating Set Point. The control system enters the Standby mode.
The control is unable to initiate a heating cycle. This will happen whenever a Fault condition is detected by the control system
or when the Enable/Disable switch (located at the base of the water heater) is in disable position.
The Combustion Blower is being energized.
The Spark Igniter is being energized. See “Spark Igniter” on Page 14 in the Features and Components section.
GAS
The 24 Volt Gas Control Valve is being energized.
The control system has sensed ame at the Main Burner from the ame sensor. See the “Sequence Of Operation Flow
Chart” on page 49 and Figures 2 &3 in Features and Components.
The control system has declared a Fault condition and must be inspected/serviced by a Qualied Service Agent. Fault
message details can be viewed in the Current Fault menu. Heating operation is disabled (lock out) until the condition that
caused the Fault is corrected. Power to the water heater must be cycled off and on at the breaker to reset the control system.
NOTE: Cycling power will not reset the control system if the condition that caused the Fault has not been corrected.
The control system has declared an Alert condition and must be inspected/serviced by a Qualied Service Agent. The water
heater will continue to operate during an Alert condition.
37
OPERATING STATES
The current operational state of the water heater is displayed on the Desktop screen as the Status. The common operational states are
described in the table below.
Table 13 – OPERATING STATES
State Description
Standby
Input Verication The control system is conducting a diagnostic check at the beginning of a heating cycle.
Water Heating
Disabled
Pre-Purge The Combustion Blower is energized to ush residual ue gases from the combustion chamber prior to ignition.
Spark Igniter
Energized
Igniter Activiation The 24 Volt Gas Control Valve is energized and opens to allow fuel gas to ow to the Main Burner.
Ignition
Verication
Inter-Purge The Combustion Blower is energized to ush residual fuel gas from the combustion chamber after a failed ignition attempt.
Heating Ignition was successful, ame sensing current has been established. The water in the storage tank is being heated.
Post-Purge
Fault
Heating Disabled The heating is disabled by the Enable/Disable switch located at the base of the water heater.
The water heater is not in an active heating cycle. IE: the Tank Temperature is at or above the Operating Set Point minus
temperature differential.
A Fault condition is detected by the control or when the Enable/Disable switch at the base of the water heater is an
open circuit.
The Igniter is energized and is ready to ensure proper ignition.
The control System is monitoring the ame sensor for the required minimum ame sensing current. Ensure the water
heater is properly grounded. Flame sensing Requires an adequate earth ground. If the water heater is not properly
grounded it will cause ignition failure.
The Combustion Blower is energized to ush residual ue gases from the combustion chamber at the end of a heating
cycle.
The control system has detected a Fault condition. Heating operation is disabled (control system lock out) until the Fault
condition is corrected. Water Heating Enable/Disable Switch must be cycled off and on to reset the control system.
NOTE: Cycling Water Heating Enable/Disable Switch will not reset the control system if the condition that caused the Fault
has not been corrected.
CONTROL SYSTEM MENUS
From the Desktop screen pressing the Operational button directly below Menu on the LCD will display the Main Menu. This is where all
control system menus are located. The table below describes the control system menus.
Table 14 – CONTROL SYSTEM MENUS
Menu Description
Temperatures Most commonly accessed menu. Contains the Operating Set Point and Differential user settings.
Heater Status
Display Settings
Heater Information
Current Fault Displays any current Alert or Fault messages.
Fault History
Fault Occurrence
Restore Factory Defaults
Help Screens
This menu displays the current state of all pressure switches and the ECO (open/closed). The on/off status of the
Combustion Blower, 24 Volt Gas Control Valve, Igniter, Flame Sensor and other monitored water heater components
are displayed in this menu.
Temperature units (°F or °C), the LCD appearance (brightness/contrast) and backlight delay user adjustable settings
are located in this menu.
Elapsed time of operation, total heating cycle time, heating cycle count, heating on time along with UIM and CCB
software revisions can be viewed in this menu.
This control system menu retains a list of the last nine (9) Fault and Alert messages with a time stamp. The newest
event will replace the oldest. Fault history memory is cleared after 30 days.
This control system menu retains a running total of how many times each Fault condition has occurred since the water
heater was rst installed. This data does not clear and cannot be reset.
NOTE: if the CCB is replaced during service the fault occurrence historical information for the water heater is lost.
This control system feature allows the user to restore control system user settings to their factory default settings.
Display Settings preferences ARE NOT changed when factory defaults are restored.
Text based operational and user information explaining how to change user settings, navigate the control system menus
and icon descriptions.
38
USER SETTINGS & CONTROL SYSTEM MENUS
Main Menu
TEMPERATURES
OPERATING SET POINT AND DIFFERENTIAL ADJUSTMENT
The Operating Set Point is adjustable from 90°F (42°C) to 181°F (83°C). The factory setting is 120°F (49°C). The Differential is adjustable
from 2° to 20°F. The factory setting is 8°F. These user settings are accessed from the Temperatures menu. These instructions explain how
to adjust these settings and navigate the control system.
When the water temperature sensed by the control system from the Temperature Probe reaches the Operating Set Point the control system
will end the heating cycle. A heating cycle will be activated again when the sensed water temperature drops below the Operating Set Point
minus the Differential setting.
NOTE: Set the Operating Set Point to the lowest setting which produces an acceptable hot water supply for most efcient use. Lower
Differential settings may cause excessive heating cycles (short-cycling) which can cause premature failure of components such as the
Igniter. Set the Differential at the highest setting which produces an acceptable hot water supply to prevent short cycling.
DESCRIPTION/ACTION DISPLAY
From the Desktop screen, press MENU. The "Main Menu"
screen will be displayed.
MANUFACTURER /MODEL INFORMATION
Tank Temperature 71°F
Operating Setpoint 120°F
Status: Standby
The Main Menu is where all control system menus are listed,
see Table 14 on page 38 for a complete list and description of
control system menus. Use the Up and Down slidebar to view
all control system menus from the Main Menu.
Press “Temperatures” to access the Temperature menu.
With the Operating Set Point selected in the Temperatures
menu, press “CHANGE” to activate the adjustment mode for
this menu item.
Press the "Operating Set Point" menu if it is not selected
(highlighted in black).
NOTE: Higher Temperature settings increase wear and
operating costs. Set the Operating Set Point to the lowest
setting which produces an acceptable hot water supply. This
will always provide the most energy efcient operation and
longer life.
MENU
Temperatures >
Heater Status >
Display Settings >
Heater Information >
Current Fault >
Temperatures
Operating Setpoint 120°F >
Differential 8°F >
Tank Te mperature 120°F
Tank Probe Offset 0°F >
HELP
HELPBACK
HELPBACK
Use the "+" and "-" Buttons to change the current setting.
Press "ACCEPT" to save the new setting. Press "BACK" to
discard changes and return to the previously saved setting.
NOTE: Use this same procedure to change the Differential
setting and other adjustable user settings in the control system
menus.
39
Operating Setpoint
120°F
MIN
90°F
ACCEPT BACK
MAX
18 0°F
TEMPERATURES (CONT)
Heater Status
DESCRIPTION/ACTION DISPLAY
• Differential - Adjustable user setting that changes the tank
temperature differential with a range of 2° to 20°F. The factory
setting is 8°F.
• Tank Temperature - non adjustable - control system sensed
temperature (averaged from upper and lower temperature probes).
• Tank Probe Offset - adjustable user setting, range -5° to +5°F
(factory setting 0°F).
NOTE: These settings should only be used if the hot water supply
temperature varies greatly from the Operating Set Point setting.
The Tank Probe Offset is used to calibrate control system
temperature sensing. This can improve the precision of
temperature control in the storage tank and at points of use.
This feature can also be used to compensate for building
recirculation loops (hot water returning to the storage tank) that
may cause the heating cycles to terminate prematurely.
Example: If the current sensed temperature from a
temperature probe is 120°F (49°C) and the Offset setting is
adjusted to a value other than 0°F, the control system would
calibrate or “offset” the sensed temperature from the probe
and the averaged tank temperature. Heating cycles would
be activated and deactivated based on the calibrated (offset)
temperature. A -5°F setting results in +5°F hotter water.
These settings are adjusted in the same way described for
Operating Set Point And Differential Adjustment on page 39
HEATER STATUS MENU
DESCRIPTION/ACTION DISPLAY
Temperatures
Operating Setpoint 120°F >
Differential 8°F >
Tank Te mperature 120°F
Tank Probe Offset 0°F >
HELPBACK
Press Heater Status from the Main Menu to enter this menu. This
menu contains non adjustable operational information. Use the
slidebar to navigate the menu.
• Status - displays the current Operating State, see Table 13
on page 38.
• ECO Contact, Blocked Inlet PS, Blocked Outlet PS -
displays the current state of the switch contacts; open or
closed.
• Igniter On, Gas Valve On - displays whether or not the
control system is currently energizing these water heater
components; yes = energized, no = de-energized.
• Flame Detected - displays whether or not the control system
has detected Main Burner ame during ignition from the
ame sensor.
• Blower RPM CMD - displays the controls commanded
blower RPM.
• Blower RPM - displays the actual blower RPM.
NOTE: The menu display is shown with the Enable/Disable
switch in Enabled position and the water heater is in Standby
mode. When the Enable/Disable switch is in the Disabled
position, the water heater will be in “Water Heating Disabled”
mode.
NOTE:
The menu displays shown are for informational
purposes only. The actual heater display will vary dependent
upon the operational state of the water heater.
Top of Menu
Heater Status
Status: Standby
ECO Contact Closed
Blocked Inlet PS Closed
Blocked Outlet PS Closed
Igniter On No
HELPBACK
Bottom of Menu
Gas Valve On No
Flame Detected No
Blower RPM CMD 0
Blower RPM 0
HELPBACK
40
DISPLAY SETTINGS
Heater Information
DESCRIPTION/ACTION DISPLAY
Press Display Settings from the Main Menu to enter this menu.
This menu contains adjustable display options for viewing
information on the UIM’s LCD screen. Use the Slidebar to
navigate the menu.
• Temperature Units - Adjustable user setting that changes
temperature units display to Celsius °C or Fahrenheit °F.
• Backlight Delay - Adjustable user setting that determines
how long the UIM’s LCD backlight remains illuminated after
a key has been pressed. Available settings are; Always Off,
10, 30 or 60 seconds and Always On.
• Contrast - Adjustable user setting to adjust the UIM’s LCD
screen contrast between text and background.
NOTE: These settings are adjusted in the same way described
for the Operating Set Point And Differential Adjustment on
page 39.
HEATER INFORMATION
DESCRIPTION/ACTION DISPLAY
Press Heater Information from the Main Menu to enter this menu.
This menu contains non adjustable operational information.
• Elapsed Time - Total accumulated time the control system
(water heater) has been energized.
• Burner On Time - Total accumulated time the control system
has been in the heating operating state; burner run time.
• Total Cycle Count - Total accumulated count of heating
cycles.
• CCB Version - Software version for central control board.
• Cong CRC - Veries the conguration key matches the CCB
programming.
• UIM Version - Software version for user interface module.
• Use External Enable - Enables/Disables the external enable
circuit.
• External Enable Status - Displays whether or not the external
enable circuit has been activated.
• Ignition Trials - Displays the number of ignition trials allowed.
NOTE: Historical data is stored in the conguration key. If this
"key" is replaced during servicing the historical data will be lost.
The data stored in the new conguration key will no longer
reect the entire history of the water heater.
The Elapsed Time, Burner On Time and Cycle Count indicate
age, usage and wear.
If the Cycle Count per day is high (divide cycle count by days
to determine cycles per day) or the cycle duration is short
(determine burner on time total minutes, divide burner on time
total minutes by cycle count) consider rasing the Differential
setting to avoid short cycling and excessive component wear,
see Operating Set Point And Differential Adjustment on page 39.
This historical data can also be used to assist facilities managers
in forecasting planned replacement of equipment to help avoid
lengthy and costly hot water supply interruptions
.
Display Settings
Temperature Units °F >
Brightness 5 >
Backlight Delay 30s >
Language English >
HELPBACK
Elapsed Time 0days 0hrs 43mins >
Burner On Time 0days 0hrs 1mins
Use External Enable No >
External Enable Status No >
Ignition Trials 3 tries >
Modulation Enabled >
HELPBACK
Bottom of Menu
Heater Information
Ignition Trials 3 tries >
Modulation Enabled >
Total Cycles Counter 2 >
Ignition Failure Count 1 >
Flame Loss Count 0 >
CCB Version 3.17 >
HELPBACK
Heater Information
Ignition Failure Count 1 >
Flame Loss Count 0 >
CCB Version 3.17 >
Config CRC 0xD7A7 >
UIM Version 2.58 >
Configuration Raw 0x510C >
HELPBACK
41
CURRENT FAULT
Blocked Exhaust
Fault Occurrence
Restore Defaults
DESCRIPTION/ACTION DISPLAY
Press Current Fault from the Main Menu and press the Operational
Button under "SELECT" to enter this menu. This menu contains non
adjustable operational information. Use the Slidebar to navigate the
menu.
This menu contains the current Fault or Alert error message. The
time the Fault or Alert message occurred appears directly below. A
brief description of what causes the particular Fault or Alert condition
appears below that. Pressing "ADVANCED" will give more detailed
service information and a list of possible causes for the Fault or Alert
condition. See “Fault And Alert Messages” beginning on Page 51 for
more detailed information and diagnostic procedures.
If there is no Fault or Alert condition active this menu will not contain
any information, "(none)" will be shown next to Current Fault in the
Main menu.
FAULT HISTORY
DESCRIPTION/ACTION DISPLAY
Press "Fault History" from the Main Menu to enter this menu. This
menu contains non adjustable operational information. Use the
Slidebar to navigate the menu.
This menu contains a list of the last nine (9) Fault and Alert messages
with a time stamp. The newest event will replace the oldest.
Press the Fault to view details for each Fault or Alert message
stored.
0 days 0 hrs 0 mins ago
Error Code: A8-1201
Restriction in exhaust pipe.
Check exhaust pipe and
termination for blockage.
Press the Advanced button for
ADVANCEDBACK
Fault History
1: Upper Temp Probe (Open) (47) >
0 days 2 hrs 37 mins ago >
2: Hardware Failure (1A) >
0 days 2 hrs 37 mins ago >
3: Upper Temp Probe (Open) (47) >
0 days 2 hrs 40 mins ago >
FAULT OCCURRENCE
DESCRIPTION/ACTION DISPLAY
Press Fault Occurrence from the Main Menu to enter this menu.
This menu contains non adjustable operational information. Use the
Slidebar to navigate the menu.
This menu contains a running total of how many times each Fault
condition has occurred since the water heater was rst installed.
NOTE: Historical data is stored in the conguration key. If this "key"
is replaced during servicing the historical data will be lost. The data
stored in the new conguration key will no longer reect the entire
history of the water heater.
RESTORE FACTORY DEFAULTS
DESCRIPTION/ACTION DISPLAY
Press Restore Factory Defaults from the Main Menu to enter this
menu.
To restore the adjustable user settings to their factory default
settings press “YES.” The display will show text conrming the
factory default settings have been restored.
Press NO to exit the Restore Factory Defaults menu.
HELPBACK
Ignition Failure 0 >
ECO 0 >
Blocked Intake Air 1 >
Blocked Exhaust 1 >
External Input 0 >
HELPBACK
Are you sure you want to restore
the system to the factory
defaults?
NoYes
42
SERVICE CONTACT INFORMATION
>
Change Contact Name
The control system has a discrete menu that Installing contractors and/or service agents can access to enter contact information for their
customers. This contact information will be displayed with all Fault and Alert messages.
DESCRIPTION/ACTION DISPLAY
Contact Information
From the Desktop Screen (see Figure 40 on page 36) press
and hold down the middle (unmarked) Operational Button for 30
seconds and then release it. It is located between the "MENU" and
"HELP" buttons.
This will launch a discrete menu where personalized contact
information can be entered.
Using the Slidebar select (highlighted in black) the "Show Contact"
menu item.
Press "ACCEPT" to activate the adjustment mode for this parameter.
Show Contact No >
Change Contact Name >
Change Contact Phone >
Current Contact Info:
(000) 000-0000
HELPBACK
Contact Information
Show Contact Yes >
Press the "+" and "-" Buttons to change the setting from "No" to
"Yes" and press "ACCEPT" to save the new setting.
NOTE: The Access Code at the bottom of the Service Contact
Information screen is for manufacturing engineering purposes only.
There are no user settings or information accessed through this
menu item.
Change Contact Name >
Change Contact Phone >
Current Contact Info:
(000) 000-0000
Press the "Change Contact Name" to enter this menu.
Press the "+", "-", "<", and ">" icons to enter your name or the name
of your company.
When nished press "ACCEPT" to save the new Contact Name.
The control system will return to the discrete menu.
Follow these same instructions to change the Contact Phone
Number.
HELPBACK
Contact Information
Show Contact Yes >
Change Contact Name >
Change Contact Phone >
Current Contact Info:
(000) 000-0000
HELPBACK
ACCEPT
<
BACK
>
Show Contact Yes >
Change Contact Name >
When the new Contact Name and Contact Phone number have
both been updated, press "BACK" to return to the Desktop screen.
Change Contact Phone >
Current Contact Info:
YOURCOMPANYNAMEHERE
(123) 456-7890
43
Contact Information
HELPBACK
START UP
START UP CONDITIONS
SMOKE/ODOR
It is not uncommon to experience a small amount of smoke and odor
during the initial start-up. This is due to burning off of oil from metal
parts, and will disappear in a short while.
PRIOR TO START UP
Installation and start up of this water heater requires abilities and
skills equivalent to that of a licensed tradesman in the eld involved,
see Qualications on page 8.
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN
EXPOSED TO FLOODING OR WATER DAMAGE. Immediately
call a qualied service technician to inspect the water heater and
to make a determination on what steps should be taken next.
Light the water heater in accordance with the Lighting and
Operation Instruction label on the water heater and in this manual
on page 46.
The water heaters covered by this manual are equipped with
an electronic control system (see page 36) which automatically
sequences the Combustion Blower, pre and post purging of the
combustion chamber, the spark transformer, the 24 Volt Gas Control
Valve, Main Burner Ignition, and ame sensing. The control system
will lock out after three unsuccessful ignition attempts.
Before attempting start up, thoroughly study and familiarize
yourself with the exact Sequence of Operation. See the Sequence
of Operation Flow Chart on page 49. Ensure the water heater is
properly grounded. Flame sensing requires an adequate earth
ground. If the water heater is not properly grounded it will cause
Ignition Failure. See Electrical Wiring on page 33.
Be certain that the water heater is full of water, that air is purged
from the gas and water lines and that there are no leaks in the gas
and water lines. Ensure all inlet water valves are open.
FILLING THE WATER HEATER
Never use this water heater unless it is completely full of water.
To prevent damage to the tank, the tank must be lled with water.
Water must ow from the hot water faucet before turning ON gas
to the water heater.
To ll the water heater with water:
1. Locate the drain valve at the base of the water heater behind
the access panel. See Features and Components beginning
on Page 11.
2. Close the water heater drain valve by turning the handle to
the right (clockwise).
3. Open the cold water supply valve to the water heater.
NOTE: The cold water supply valve must be left open when
the water heater is in use.
4. To insure complete filling of the tank, allow air to exit by
opening the nearest hot water faucet. Allow water to run until
a constant flow is obtained. This will let air out of the water
heater and piping.
5. Check all water piping and connections for leaks. Repair as
needed. See Gas Line Leak Testing on Page 32.
44
INITIAL START UP
REQUIRED TEST EQUIPMENT
• One U-tube manometer, recommended ranges; 0-14” W.C. (0-
3.5 kPa) and 0-35” W.C. (0-8.7 kPa) or pressure gauges.
• One digital manometer can be used in place of U-tube
manometers or pressure gauges. Recommended ranges;
-14.00 to +14.00” W.C. (0-3.5 kPa) resolution 0.01” W.C. and
0-35” W.C. (0-8.7 kPa) resolution 0.10” W.C.
NOTE: All test equipment must be acclimated to ambient
temperature before calibration and use.
MANIFOLD GAS
PRESSURE
TEST PORT
(Non-Adjustable)
SUPPLY GAS
PRESSURE TEST PORT
GAS CONTROL VALVE TOP DETAIL VIEW
PREPARATION
1. Using the control system menus, change the Operating Set
Point to the lowest temperature setting, see Operating Set
Point And Differential Adjustment on page 39.
2. Turn the water heater’s Enable/Disable switch to the “Disabled”
position.
3. Close the manual gas shut off valve, see Figure 37 on page 31.
4. Wait ve (5) minutes for any residual gas to clear.
5. Connect the manometer to the supply gas pressure port on the
gas control valve, see Figure 41 and Figure 42.
On the water heaters covered by this manual there are test
ports for supply and manifold gas pressure readings on the gas
control valve. Using a small at tip pocket screw driver - open
the needle valve inside the supply gas pressure test port one
full turn only; turn the needle valve screw counter-clockwise to
open the valve. Slide the manometer sensing tube over the top
of the test port, see Figure 41 and Figure 42.
6. Open the Main Gas Shutoff Valve.
7. Measure and record the supply gas pressure, this is a “static”
supply gas pressure reading; while the water heater is not
ring. Adjust supply gas pressure as necessary, see Gas
Supply Systems on Page 17.
MANIFOLD GAS
PRESSURE
TEST PORT
(Non-Adjustable)
SUPPLY GAS
PRESSURE
TEST PORT
GAS CONTROL
VALV E
Figure 42
GAS
VALV E
COMBUSTION
AIR INLET
VENTURI
GAS CONTROL VALVE / VENTURI ASSEMBLY SIDE VIEW
SUPPLY GAS
CONNECTION
Figure 43
COMBUSTION
BLOWER
CONNECTION
COMBUSTION
AIR INLET
VENTURI
GAS CONTROL VALV E / VENTURI ASSEMBLY TOP VIEW
Figure 41
45
LIGHTING THE WATER HEATER
LIGHTING & OPERATION LABELS
The instruction label below is afxed to the water heater's covered by this manual at the factory and must be followed when lighting
and operating the water heater.
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING:
If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal injury
or loss of life.
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Operating Set Point 120°F
Status: Standby
MENU HELP
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2. Set the Enable / Disable switch at the base of
the water heater to the Enable position.
3. Set the thermostat to the lowest setting.
4. Set the Enable / Disable switch at the base of
the water heater to the Disable position.
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46
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CHECKING THE FIRING RATE
3600
12.6
Follow these instructions to determine the actual ring rate of the
water heater:
NOTE: The heaters covered by this manual are capable of
modulating their ring rate. The ring rate should be checked with
the heater operating at it's full ring rate.
1. Ensure there are no other gas red appliances connected to
the gas meter ring during this test.
2. Contact the gas supplier to determine the heating value, in Btu
per cubic foot, of the gas supply.
3. Connect a manometer to the supply gas pressure tap. Follow
the instructions for Start Up beginning on Page 44.
4. Start the water heater and ensure it is ring.
5. Check the supply gas pressure, refer to Supply Gas Systems
on page 17 for correct pressure.
6. Locate the gas meter serving the water heater.
7. Time how long (in seconds) it takes for one cubic foot of gas
to be used while the water heater is ring with a stop watch.
8. Use the formula below to “clock” the gas meter and determine
the actual ring rate of the water heater based on the heating
value (Btu per cubic foot) of the gas supply:
x H = Btu/hr
T
Example:
3600
x 1050 = 300,000 Btu/hr (87.9 kW)
When measuring the input rate these factors should be incorporated
into the calculations. Also measure the gas consumption over a
sufciently long time to obtain an accurate gas consumption rate
(e.g. 3-5 minutes, not one revolution of the meter needle).
Long vents and each additional elbow, inherently reduce the gas
input rate due to increased resistance to moving combustion air and
ue gases. The approximate maximum/minimum input for all PGC,
SPC, BSS, and BTS models is show in Figure 44.
Figure 44
HIGH ALTITUDE INSTALLATIONS
• 3600 = seconds in one hour.
• T = time, in seconds, to burn one cubic foot of gas.
• H = heating value of gas in Btu per cubic foot.
• Btu/hr = actual ring rate of the water heater.
NOTE: 1050 Btu per cubic foot is a standard value for natural gas.
Standard propane gas Btu content is 2500 Btu per cubic foot. Btu
values may change in certain areas and at high elevations. Check
with the local gas utility company.
TO TURN OFF GAS SUPPLY
1. Change the Operating Set Point to the lowest temperature
setting, see Operating Set Point And Differential Adjustment
on page 39.
2. When the water heater has completed its shut down sequence
and enters the standby mode, turn the water heater’s Enable/
Disable switch to the “Disable” position. When in the "Disable"
position the switch only removes electrical power from the gas
control valve so that water heating is disabled. The display,
CCB, and other electrical components will still be energized
and the display will read "Water Heating Disabled".
3. Close Main Gas Shutoff Valve, see Figure 37 on page 31
GAS INPUT RATE
The gas input rate of this water heater is affected by several
environmental factors such as:
• The heating value of the gas
• The air and gas densities (which vary widely due to barometric
pressure and temperature changes)
• Venting installations (pipe diameter, length and ttings)
• Altitude
Breathing Hazard - Carbon Monoxide Gas
Special consideration must be taken with
•
installations above 7,700 feet (2,347 m).
Please contact an A. O. Smith qualified
•
service agent to obtain the proper
setup and instructions before lighting.
Failure to implement the proper setup
•
will result in improper and inefficient
operation of the appliance resulting in
production of increased levels of
carbon monoxide gas in excess of the
safe limits which could result in serious
personal injury or death.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
This high efciency water heater is cer tied for use without
modication for an altitude of 7,700 feet (2,347 m). Consult the
factory for installation at altitudes over 7,700 feet (2,347 m).
Some gas utility companies derate their gas for altitude, making it
unnecessary to install high altitude orices. Call the local gas or
utility company to verify BTU content.
Due to the input rate reduction at high altitudes, the output rating of
the water heater is also reduced and should be compensated for in
the sizing of the equipment for applications. See Planning the Vent
System on Page 23.
47
TROUBLESHOOTING
INSTALLATION CHECKLIST
The list below represents some of the most critical installation
requirements that, when overlooked, often result in operational
problems, down time and needless parts replacement. This is not
a complete list. Before performing any troubleshooting procedures
use the list below to check for installation errors. Costs to correct
installation errors are not covered under the limited warranty.
Ensure all installation requirements and instructions in this manual
have been maintained and followed.
WATER HEATER LOCATION
1. Ensure proper clearances to combustibles are maintained
and there is sufcient room to service the water heater. See
Locating the Water Heater section on pages 15-16.
2. Ensure the area is free of corrosive elements and ammable
materials. See Combustion and Ventilation Air on page 16.
VENTING
1. Ensure the intake air and/or vent (exhaust) piping is the correct
size for the installed length. See the Vent Pipe Installation
section beginning on Page 22.
2. Ensure the maximum equivalent feet of pipe has not been
exceeded for the intake air and/or vent pipe. See the Vent
Pipe Installation section beginning on Page 22.
3. Ensure the maximum number of elbows has not been
exceeded in the intake air and/or vent pipe. See the Vent Pipe
Installation section beginning on Page 22.
4. Ensure all exterior clearances for the intake air, vent and
concentric terminations are maintained. These clearances and
those cited by local and national codes must be maintained.
See Horizontal Vent Terminal Installation on page 25, Vertical
Vent Termination on page 26, and Concentric Vent Installation
on page 29.
5. Ensure the integrated lter in air intake at the water heater is
clean and free of debris. See Integrated Filter Preventative
Maintenance on page 54.
GAS SUPPLY AND PIPING
1. Ensure a supply gas regulator has been installed for each
water heater. See Supply Gas Regulator on page 17.
2. Ensure the supply gas line to each water heater meets the
minimum supply gas line size rrequirements. See Supply
Gas Systems on page 17 and Supply Gas Line Installation
beginning on Page 31.
CONDENSATE DRAIN
1. Ensure the condensate drain is properly connected to the
exhaust elbow on the water heater and draining freely to a
suitable oor drain. See Condensate Drain Installation on
page 31.
ELECTRICAL CONNECTIONS
1. Ensure the power supply connections to the water heater are
polarity correct. See the requirements for the Power Supply on
page 18 and Electrical Wiring on page 33.
2. Ensure the water heater is properly grounded. Flame sensing
requires an adequate earth ground. If the water heater is not
properly grounded it will cause Ignition Failure. See Electrical
Wiring on Page 33.
Components beginning on page 11 for the location of various
water heater components described below. See the Sequence of
Operation Flow Chart on page 49 also.
1. When the control system is rst powered, during boot up, the
blower will run momentarily and stop, and the control system
will display water heater model information during initialization.
After a few moments the control system LCD which is part of
the UIM (user interface module) will display the default screen
known as the Desktop screen.
2. If the control system determines that the actual water
temperature inside the tank is below the programmed
Operating Set Point minus the Differential setting, a heating
cycle is activated.
3. The control system then performs selected diagnostic system
checks. This includes conrming the blocked exhaust, blocked
intake and ECO (energy cut out) switch contacts are closed.
4. If all diagnostic checks are successfully passed, the control
system energizes the Combustion Blower for pre-purge.
5. The control system energizes the Spark Ignition Transformer.
6. After a few seconds, the control system energizes the 24V
Gas Control Valve allowing gas to ow to the Main Burner.
7. The control system monitors the ame sensor to conrm a
ame is present at the Main Burner. If a ame is not veried
during the ignition trial period the control system will try for
ignition up to two more times. If ame can not be veried after
three trials for ignition, the control system will lock out and
display the Ignition Failure Fault message.
8. If a flame is verified, the control system will enter the
heating mode where it will continue heating the water until
the Operating Set Point is reached. At this point, the control
system will de-energize the 24 V Gas Control Valve and
enter the post-purge cycle (approximately 30 seconds).
9. The water heaters covered by this manual are capable of
modulating their ring rate. The ring rate is dictated by the
hot water draw and various other temperature limitations.
10. The Combustion Blower will run for the duration of the postpurge cycle to purge the water heater of all combustion gases.
When the post-purge cycle is complete, the blower is deenergized and will coast to a stop.
11. The control system now enters the standby mode while
continuing to monitor the internal storage tank water
temperature and the state of other system devices. If the tank
temperature drops below the Operating Set Point minus the
Differential setting, the control will automatically return to Step
2 and repeat the operating cycle.
SEQUENCE OF OPERATION
Read the Sequence of Operation below before attempting to
correct any operational problems. Refer to the Features and
48
SEQUENCE OF OPERATION FLOW CHART
If tank temperature drops below Operating Set Point minus
Differential setting a heating cycle is ac tivated
Control System performs diagnostic checks
Normal State of all pressure switches and ECO are checked
Pressure Switches and ECO are verified closed
Combustion Blow er is energized
30 Second Pre-Purge cycle
Igniter is energized
24 V Gas Control Valve is energized
gas flows to Main Burner
Is flame sensed at the Main Burner ?
(control system monitors the flame sensor)
YES NO
Water is heat ed to
set point
24 V Gas Control Valve
de-energized
Control System Locks Out
NO
Displays Fault Msg
24 V Gas Control Valve
de-energized
60 second Post Purge cycle
Water heater goes
into standby mode
60 second Inter-Purge cycle
Retries up to
two more times
Control System
Locks Out
“Ignition Failure”
Fault Msg is
displayed
Figure 45
49
OPERATIONAL PROBLEMS
CAUTION
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
If the Main Burner ignites momentarily but does not sustain ignition
allow the water heater to try to ignite up to two more times until
control system locks out and the Ignition Failure Fault message
is displayed on the control system's LCD. If the water heater is
experiencing rough starts - see Rough Starting, Rough Operation
on this page. For momentary ignition problems without rough
starting check the following:
• Undersized supply gas line (low volume of supply gas).
• Low Gas Pressure
• See the list of possible causes and things to check and repair
for the Ignition Failure Fault message.
• Clogged/blocked air intake integrated lter.
• Clogged/blocked Main Burner.
NOT ENOUGH OR NO HOT WATER
This section of the manual is intended to be an aid in correcting
common operational problems, it is not all inclusive. The installer
may be able to observe and correct certain problems which might
arise when the water heater is rst put into operation or when it
is re-red after a prolonged shutdown. However, only qualied
service technician should perform any service procedures on the
water heater.
NOTE: Call the technical support phone number listed on the back
cover of this manual for further technical assistance or to locate a
qualied service technician in your area.
ROUGH STARTING, ROUGH OPERATION
Fire and Explosion Hazard
Do not use water heater with any gas
other than the gas shown on the rating
plate.
Excessive gas pressure to gas control
valve can cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
technician for installation and service.
• Undersized supply gas line (low volume of supply gas).
• Low Gas Pressure.
• Excessive supply gas pressure.
• Excessive manifold (offset) gas pressure.
• Incorrect Fuel Type
• Vent (exhaust) gas recirculation at the vent and intake air pipe
terminations on Direct Vent installations.
• Excessive equivalent lengths of intake air and/or vent (exhaust)
piping installed.
• Clogged/blocked air intake integrated lter.
• Clogged/blocked the Main Burner.
MOMENTARY IGNITION
• No power to the water heater, check breaker, fuses.
• Enable/Disable switch in “disabled” position. Set to enable to
allow unit to operate.
• Hot water supply valve(s) to xtures closed.
• Operating Set Point is set too low, Differential setting is set too
high.
• Temperature Probe Offset setting are causing the heating cycles
to terminate prematurely.
• The heating capacity of the water heater has been exceeded,
the water heater is unable to meet demand.
• Colder incoming water temperature lengthening the time
required to heat water to desired temperature.
• Hot water piping leaks, open faucets, water heater drain valve
leaking or open. See Leakage Checkpoints on Page 53.
• Sediment or lime scale accumulation may be affecting water
heater operation.
WATER IS TOO HOT
• Operating Set Point is set too high. See Operating Set Point
and Differential Adjustment on Page 39.
• Temperature Probe Offset settings improperly set. See
Operating Set Point and Differential Adjustment on Page 39.
• If installed check Thermostatic Mixing Valve settings. See
Mixing Valves on Page 18.
• Lime build-up on temperature probes.
NOISY OPERATION
• Normal operating noise of electrical components; Combustion
Blower, transformer hum, relay contact closure.
REPLACEMENT PARTS
Replacement parts may be ordered from the manufacturer,
authorized service agencies or distributors. When ordering parts
be sure to have the complete water heater Model Number, Serial
Number and Series Number available. This information can be
found on the rating plate afxed to the water heater.
For more information or technical support call the technical support
phone number listed on the back cover of this manual.
Burn Hazard
The combustion chamber and burner sleeve
•
and housing become very hot during operation.
Do not reach into the burner housing or
•
combustion chamber if the water heater
is still hot.
Allow the water heater to cool and always use
•
gloves when handling the main burner.
50
FAULT AND ALERT CONDITIONS
Ignition Failure
Blocked Exhaust
FAULT CONDITIONS
When the control system declares a Fault condition it will display a
Fault message on the control system's LCD with an exclamation "!"
mark. The control system will lock out and disable heating operation
until the condition is corrected. The water heater must be serviced
by a qualied service technician before operation can be restored.
ALERT CONDITIONS
When the control system declares an Alert condition it will display
an Alert message on the control system's LCD with a question "?"
mark. The water heater will continue to operate during an Alert
condition but the water heater must be serviced by a qualied
service technician as soon as possible.
RESETTING CONTROL SYSTEM LOCK OUTS
To reset the control system from a lock out condition; turn the Enable/
Disable switch at the base of the unit to the “Disable” position for
approximately 20 seconds and then back to the “Enable” position.
Keep in mind: if the condition that caused the Fault has not been
corrected, the control system will continue to lock out.
DIAGNOSTIC CHECKS
Electrical Shock Hazard
Turn off power to the water heater
•
before performing any service.
Label all wires prior to disconnecting
•
when performing service. Wiring errors
can cause improper and dangerous
operation.
Verify proper operation after servicing.
•
Failure to follow these instructions can
•
result in personal injury or death.
are operational problems. This is not a complete list. Along with
each of the Fault and Alert messages described there will be a list
of possible causes and things to check and repair.
Only qualied service technician, as dened in Qualications using
appropriate test equipment, should perform any service procedures
on the water heater.
NOTE: If you are not qualied and licensed or certied as required
by the authority having jurisdiction to perform a given task do not
attempt to perform any of the diagnostic or service procedures
described in the following section.
If you do not understand the instructions in the following section do
not attempt to perform any procedures.
Call the technical support phone number listed on the back cover of
this manual for further technical assistance or to locate a qualied
service technician in your area.
The following section, Fault And Alert Messages lists some of the
messages the control system will display on the LCD when there
FAULT AND ALERT MESSAGES
Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualied service technician
in your area.
POSSIBLE CAUSES - CHECK/REPAIR DISPLAYED FAULT/ALERT MESSAGE
• Using a manometer, ensure that gas supply pressure is above
minimum requirement listed on heater’s data plate and does not
drop more than 1.5” W.C. when unit res.
• Ensure wire connections to gas control valve are clean and tight.
• Ensure wire connections to ame sensor are clean and tight.
• Ensure wire connections to spark igniter are clean and tight.
• Inspect ame sensor, clean/replace as needed.
• Inspect spark igniter, realign igniter gap as needed
• Ensure adequate electrical ground to heater.
• If Blocked Exhaust error occurs when blower is running, check for
restrictions in exhaust pipe, including exhaust elbow, condensate
drain, and outside termination. Also check exhaust pipe installation
(size/length) per manual.
• If Blocked Exhaust error occurs before blower runs, make sure
pressure switch connections are clean and tight. Check pressure
switch continuity/resistance. Switch should be closed (continuity/0
ohms). Replace switch if open (no continuity).
• High wind conditions may be another possible cause.
0 days 0 hrs 0 mins ago
Error Code: B2-70
Flame not detcted. Clean flame
rod. Check gas supply.
Press the Advanced button for
more information
ADVANCEDBACK
0 days 0 hr 0 min ago
Error Code: A8-1201
Restriction in exhaust pipe.
Check exhaust pipe and
termination for blockage.
Press the Advanced button for
ADVANCEDBACK
51
FAULT AND ALERT MESSAGES (CONT)
Blocked Air Intake
High Temp Limit Exceeded
Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualied service technician
in your area.
POSSIBLE CAUSES - CHECK/REPAIR DISPLAYED FAULT/ALERT MESSAGE
• If Blocked Intake error occurs before blower runs, make sure
pressure switch connections are clean and tight.
• If Blocked Intake error occurs when blower is running, check for
restrictions in intake pipe, including intake air connection, intake air
lter, outside termination, and inlet moisture drains.
• Other possible causes: High wind conditions, excessive negative
air pressure in building.
• Use a multi-meter to check the continuity / resistance of inlet air
pressure switch. Switch should be open (no continuity) when the
blower is off and closed (shorted) when the blower is on. Replace
the switch if necessary.
0 days 0 hrs 0 mins ago
Error Code: A7-1201
Restriction in air intake.
Check intake pipe and
termination for blockage.
Press the Advanced button for
ADVANCEDBACK
• Ensure wire connections to upper temperature probe are clean and
tight.
• Using a thermometer, check the water temperature of the heater.
• Use a multi-meter and check for continuity between the two red
wires of the upper temperature probe.
• If the two red wires are open (no continuity) and water temperature
is below 160°F, replace upper temperature probe.
• If the water temperature exceeds 195°F, turn off electric power and
gas supply and call Tech Support for further instructions.
0 days 0 hrs 0 mins ago
Error Code: A5-401
Energy Cut Off has shut off
water heater due to high tank
temperature.
Press the Advanced button for
ADVANCEDBACK
52
LEAKAGE CHECKPOINTS
A: Hot Water Outlet
C: T & P
Connection
D: T & P Outlet
H: Temperature
Probe Connections
B: Cold Water Inlet
Never use this water heater unless it is completely lled with water.
To prevent damage to the tank, the tank must be lled with water.
Water must ow from the hot water faucet before turning “ON” gas
to the water heater.
A *Condensation may be seen on the hot water outlet pipe in humid
weather or the hot water outlet connection may be leaking.
B. *Condensation may be seen on the cold water inlet pipe in humid
weather or the cold water inlet connection may be leaking.
C. Small amounts of water from temperature-pressure relief valve
may be due to thermal expansion or high water pressure in your
area.
D. *The temperature-pressure relief valve may be leaking at the tank
tting.
E. Water from a drain valve may be due to the valve being slightly
opened. (Not shown in Figure 46).
F. *The drain valve may be leaking at the tank tting. (Not shown in
Figure 46).
Figure 46
I: Flue Outlet
J: Condensate Clean
Out Cap
G. Leakage from recirculation plug or pipe connection. (Not shown in
Figure 46).
H. Leakage from the temperature probe connections.
I. Condensate from the exhaust connection.
J. Condensate Clean Out Cap
Leakage from other water heaters, water lines, or ground seepage
should also be checked.
* To check where threaded portion enters tank, insert cotton swab
between jacket opening and tting. If cotton is wet, follow the
“Draining” instructions in Draining and Flushing on Page 55 and
then remove the tting. Put pipe dope or teon tape on the threads
and replace. Then follow the instructions in Filling the Water Heater
on Page 44..
53
PERIODIC MAINTENANCE
Should overheating occur or the gas supply fails to shut off, turn off
the manual gas control valve to the appliance.
VENTING SYSTEM INSPECTION
Breathing Hazard - Carbon Monoxide Gas
•
Flue gases may escape if vent pipe is not connected.
•
Be alert for
system to avoid serious injury or death.
•
Do not store corrosive chemicals in vicinity of water
heater.
•
Chemical corrosion of flue and vent system can
cause serious injury or death.
•
Analyze the entire vent system to make sure that
condensate will not become trapped in a section of
vent pipe and therefore reduce the open cross
sectional area of the vent.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
At least once a year examine the vent system. Points of inspection
are as follows:
1. Check for obstructions and/or deterioration of the intake air and/
or vent piping and the intake air and vent terminations. Replace
immediately where needed.
NOTE: Do not reach inside the vent termination when the heater
is in operation.
2. Check all vent system connections for leakage and repair or
reseal as necessary.
Be sure the vent piping is properly connected to prevent escape
of dangerous ue gasses which could cause deadly asphyxiation.
Obstructions and deteriorated vent systems may present serious
health risk or asphyxiation.
Chemical vapor corrosion of the ue and vent system may occur
if air for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium chloride,
waxes, bleach and process chemicals are typical compounds which
are potentially corrosive.
If after inspection of the vent system you found sooting or
deterioration, something is wrong. Call the local gas utility to correct
the problem and clean or replace the ue and venting before
resuming operation of the water heater.
INTEGRATED FILTER PREVENTATIVE MAINTENANCE
The heater is designed to shut down if the pressure switch senses
that the air inlet vent or the exhaust vent is restricted. In this case, the
pressure switch will open and the heater will generate the “Blocked
Air Intake” fault (see Fault and Alert Messages beginning on Page
51). If the troubleshooting section of this manual indicates that there
is a blockage at the air inlet integrated lter, note the following:
• Turn off the gas supply to the water heater at the manual gas
shut-off valve (see Figure 37 on Page 31), and disconnect
power to the water heater. See Electrical Wiring on Page 33.
• To inspect the lter, loosen the hose clamp at the adaptor rubber
boot and slide the plastic pipe out and away from the adaptor
rubber boot (See Figure 14 in Integrated Filter Installation).
• Remove the adaptor rubber boot containing the outer clamshell
housing by turning clockwise approximately 1/2” (30.5 cm) and
pulling off of the internal clamshell housing (See Figure 14 in
Integrated Filter Installation).
• Using your ngers or a small at blade screwdriver, remove the
lter media from the outer clamshell housing, handle carefully
obstructed, sooted or deteriorated vent
(See Figure 16 in Integrated Filter Installation).
• To clean lter, lightly tap the back of the lter support to dislodge
any large debris. Smaller debris may be
• Removed by using a vacuum cleaner. the lter media may be
cleaned by dipping the lter media into a
• Solution of warm soapy water and rinsing in clean water. Do
not scrub, allow to air dry before reinstalling.
• Filter media may be cleaned on an average 2 to 3 times before
replacing with a new lter media is required.
• Reinstall lter media by doing the above steps in reverse order.
• Turn on the gas supply and reconnect power. Refer to Electrical
Wiring on Page 33, Control System Operation on Page 36,
and Start Up on Page 44. Verify proper operation of the water
heater before leaving.
The water heater must never be operated without the filter
media installed. Damages or service calls associated with
operating the heater without the filter media installed are not
covered under the limited warranty.
TEMPERATURE-PRESSURE RELIEF VALVE TEST
Burn hazard.
Hot water discharge.
Keep clear of TemperaturePressure Relief Valve
discharge outlet.
It is recommended that the Temperature-Pressure Relief Valve
should be checked to ensure that it is in operating condition
every 6 months.
When checking the Temperature-Pressure Relief Valve
operation, make sure that (1) no one is in front of or around the
outlet of the Temperature-Pressure Relief Valve discharge line,
and (2) that the water discharge will not cause any property
damage, as the water may be extremely hot. Use care when
operating valve as the valve may be hot.
To check the temperature-pressure relief valve, lift the lever at
the end of the valve several times. Refer to Figure 47 below.
The valve should seat properly and operate freely.
If after manually operating the valve, it fails to completely reset
and continues to release water, immediately close the cold
water inlet to the water heater and drain the water heater, see
Draining and Flushing on Page 55. Replace the TemperaturePressure Relief Valve with a properly rated/sized new one, see
Temperature-Pressure Relief Valve on Page 20 for instructions
on replacement.
TEMPERATURE-PRESSURE
RELIEF VALV E
DISCHARGE PIPE
Figure 47
If the Temperature-Pressure Relief Valve on the water heater weeps
or discharges periodically, this may be due to thermal expansion.
54
NOTE: Excessive water pressure is the most common cause of
Temperature-Pressure Relief Valve leakage. Excessive water system
pressure is most often caused by “thermal expansion” in a “closed
system.” See Closed Water Systems and Thermal Expansion on
Page 19. The Temperature-Pressure Relief Valve is not intended for
the constant relief of thermal expansion.
Temperature-Pressure Relief Valve leakage due to pressure build
up in a closed system that does not have a thermal expansion
tank installed is not covered under the limited warranty. Thermal
expansion tanks must be installed on all closed water systems.
DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF VALVE
OPENING. THIS CAN CAUSE PROPERTY DAMAGE, SERIOUS
INJURY OR DEATH.
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
Properly sized temperaturepressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
DRAINING AND FLUSHING
It is recommended that the water heater storage tank be drained and
ushed every 6 months to reduce sediment buildup. The water heater
should be drained if being shut down during freezing temperatures.
See Figures 2 & 3 in Features and Components for the location of the
water heater components described below.
Burn hazard.
Hot water discharge.
Keep hands clear of drain
valve discharge.
TO DRAIN THE WATER HEATER STORAGE TANK:
1. Switch the Enable/Disable switch, located at the base of the water
heater, to the “Disable” position and then turn off the electrical
supply to the water heater.
2. Turn off the gas supply at the Main Gas Shutoff Valve (see
Figure 37 on Page 31) if the water heater is going to be shut
down for an extended period.
3. Ensure the cold water inlet valve is open.
4. Open a nearby hot water faucet and let the water run until the
water is no longer hot.
5. Close the cold water inlet valve to the water heater.
6. Connect a hose to the water heater drain valve and terminate it to
an adequate drain.
7. Open the water heater drain valve and allow all the water to drain
from the storage tank.
8. Close the water heater drain valve when all water in the storage
tank has drained.
9. Close the hot water faucet opened in Step 4.
10. If the water heater is going to be shut down for an extended
period, the drain valve should be left open.
TO FLUSH THE WATER HEATER STORAGE TANK:
1. Switch the Enable/Disable switch, located at the base of the water
heater, to the “Disable” position and then turn off the electrical
supply to the water heater.
2. Ensure the cold water inlet valve is open.
3. Open a nearby hot water faucet and let the water run until the
water is no longer hot. Then close the hot water faucet.
4. Connect a hose to the drain valve and terminate it to an adequate
drain.
5. Ensure the drain hose is secured before and during the entire
ushing procedure. Flushing is performed with system water
pressure applied to the water heater.
6. Open the water heater drain valve to ush the storage tank.
7. Flush the water heater storage tank to remove sediment and
allow the water to ow until it runs clean.
8. Close the water heater drain valve when ushing is completed.
9. Remove the drain hose.
10. Fill the water heater - see Filling The Water Heater on page 44.
11. Turn on the electrical supply to place the water heater back in
operation and switch the Enable/Disable switch to the “Enable”
position.
12. Allow the water heater to complete several heating cycles to
ensure it is operating properly.
SERVICE
If a condition persists or you are uncertain about the operation of the
water heater contact a qualied service technician.
Use this guide to check a leaking water heater. Many suspected
Leakers are not leaking tanks. Often the source of the water can be
found and corrected.
If you are not thoroughly familiar with gas codes, your water heater,
and safety practices, contact your gas supplier or qualied installer
to check the water heater.
Read this manual rst. Then before checking the water heater make
sure the gas supply has been turned “OFF”, and never turn the gas
“ON” before the tank is completely full of water.
55
CCB - CENTRAL CONTROL BOARD LAYOUT
DIAGRAMS
10
11
12
5
6
4
J16
3
2
1
J5
4
5
6
78
5
3
3
2
1
4
J13
J3
8
2
1
1
J4
4
3
J9
4
J10
3
7
8
9
1
2
3
J14
4
2
1
5
6
3
4
1
2
J15
2
1
2
1
J17
6
5
4
3
2
1
8
7
4
1
9
6
J1
3
J12
6
3
2
1
5
4
2
J6
4
3
1
2
Figure 48
56
WIRING DIAGRAM
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND
DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.
Switch
Switch
Outlet Pressure
Inlet Pressure
Flame
Rod
Gas Valve
Key
Yellow
Spark
Module
Switched L1
Neutral
Ground
2 Blue
3 Green
1 Brown
Spark
Rod
1 Blue
2 Brown
Neutral
Line to Spark
PWM Signal
Speed f-back
CCB J5
Blower Logic
2 White/Blue
4 White/Orange
Power Out
CCB J6
Dgnd
5 White/Green
3 Orange
4 White/Green
Power
Power
Supply J1
2 White
Probe / ECO
Upper Temperature
CCB J17
Low Voltage Field
No factory
1 Blue
Supply J2
Power
Supply
3 Black
Red
Red
Black
Black
1 Red
3 Black
2 Black
ECO
Thermistor
Thermistor
(CCB)
Central Control Board
Low Voltage In
connections
Lower
Temperature
4
4 Red
Upper Probe
CCB J9
ECO
Dgnd
5VDC
12VDC
CCB J16
4 Blue
5 Orange
6 White/Green
Transformer
Transformer
Probe
24VAC
24VAC
1 Brown
2 White/Blue
White / Blue
Secondary
Primary
Black
Black
Black
2
1 Black
2 Black
CCB J10
Thermistor
Thermistor
White / Red
Transformer
White
1 White
Lower Probe
Inlet return
2 Red
4 Green
Switches
Pressure
CCB J15
Outlet power
Outlet return / Inlet power
Enable/Disable
1 Blue
Anode
L1
Neutral
CCB J1
HIGH Voltage In
8 Black
9 White
2 Green
3 Yellow
Dgnd
Flame Rod
4 Black
Condensate
6 Black
Condensate
9 Red
8 Black
10 Brown
Limit String
CCB J14
Gas PS
Gas V Switch
Gas V Switch
12 Gray
11 Violet
24V Rtn
Gas V 24V
+5V
CCB J3
1 Blue
1 Blue
+5V
Data +
3 Yellow
3 Yellow
4 Orange
Data +
+5V
Data -
D gnd
5 Violet
4 Orange
5 Violet
Display J1
Data -
D gnd
5
2 Red
3 Green
5 White/Blue
4 White/Brown
6 White/Orange
CCB J12
Dgnd
SCL (data)
SDA (data)
Write protect
4 White / Blue
5 White / Green
Dgnd
1 Black
L1
Blower
2 White / Orange
Speed
Blower
PWM Signal
Speed f-back
Black
White
Green
2 White
3 Green
Blower Power
PE
Neutral
L1
Neutral
MAIN INPUT
Figure 49: WIRING SCHEMATIC (All Models)
57
GROUND SCREW
Metal Oxide Varistors
TERMINAL BLOCK
3 CIRCUIT BARRIER
Earth
Protective
CIRCULATION PUMP WIRING DIAGRAMS
CIRCULATING PUMP WIRING DIAGRAM
CIRCULATING PUMP WIRING DIAGRAM
STORAGE TANK OR BUILDING RECIRCULATION
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH APPLIANCE AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
L1 HOT
FIELD SUPPLIED TEMPERATURE CONTROL
INSTALLED IN THE STORAGE TANK
OR CIRCULATING LOOP RETURN LINE
120 VAC
POWER
L2 NEUTRAL
DISHWASHER LOOP WITH TOGGLE SWITCH
DISHWASHER
TOGGLE
SWITCH
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH APPLIANCE AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
L1 HOT
CIRC
PUMP
MOTOR
Figure 50
FIELD SUPPLIED TEMPERATURE
CONTROL INSTALLED IN THE
CIRCULATING LOOP RETURN LINE
POWER
L2 NEUTRAL
120 VAC
CIRC
PUMP
MOTOR
Figure 51
58
PIPING DIAGRAMS
Metal
Drain
Pan
Mixing Valve
Check local codes.
6" (15.2cm)
Air Gap Max.
Adequate Drain
Figure 52: TYPICAL ONE-TEMPERATURE SYSTEM PIPING INSTALLATION (All Models)
Mixing Valve
(set to 120° F
[48.8° C] or lower)
Figure 53: SAMPLE MIXING VALVE INSTALLATION (All Models)
59
Mixing Valve
6" Max.
Drain
Above Drain
Figure 54: AIR HANDLER PIPING INSTALLATION (All Models)
Manual Shut Off Valve (Typ)
Mixing
Valve
(180°F Max.)
Figure 55: POLARIS WITH AUXILLARY STORAGE TANK,
One or Two Temperature System (With or Without Building Recirculation)
60
NOTES
61
NOTES
62
Copyright © 2016 A. O. Smith Corporation. All rights reserved.
For Tech Support please call
PGC models:
1-800-456-9805
SPC models:
1-800-365-0024
BSS/BTS models:
1-800-527-1953
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