State GS6 75 URRBS User Manual

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Page 1

RESIDENTIAL ULTRA LOW NOx GAS WATER HEATER

• INSTALLATION • OPERATION • SERVICE • MAINTENANCE •

LOW LEAD

CONTENT

CAUTION

TEXT PRINTED OR OUTLINED IN RED CONT AINS INFORMA TION RELATIVE TO YOUR SAFETY. PLEASE READ THOROUGHLY BEFORE INSTALLING AND USING THIS APPLIANCE.

PLACE THESE INSTRUCTIONS ADJACENT TO HEATER

PRINTED IN U.S.A. 1112 PART NO. 325321-000

AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.

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ROUGH-IN DIMENSIONS

TOP VIEW

*INSTALL IN ACCORDANCE WITH LOCAL CODES

FIGURE 1.

TABLE 1, DIMENSIONS

Units A B C D E F G H J K L M P Q

InchesCM66 5/8

169.22

TABLE 2, RECOVERY RATINGS ARE BASED ON 80% THERMAL EFFICIENCY

58 3/4

149.23

30 15/16

76.99

27 3/4

70.5

15 1/4

38.6410.2

15 3/4

40.01640.6

1 1/4

3.2

1 1/4

NPT

1/2

NPT

12 1/4

31.1

24 7/8

63.2

INPUT RATE Recovery in US Gallons/hr or Liters/hr at Indicated Temperature Rise in Fahrenheit or Celsius

75,100 BTU/H

22 KW

°F 30 36 40 50 54 60 70 72 80 90 100 108 110 120 126 130 140

GPH 243 203 182 145 134 122 104 101 91 81 73 67 66 60 57 56 52

°C 17 20 23 28 30 33 39 40 44 50 56 60 61 67 70 72 78

LPH 920 767 688 549 509 460 392 381 344 306 277 254 251 228 217 213 199

TABLE 3, GAS AND ELECTRICAL CHARACTERISTICS

Manifold Pressure Electrical Characteristics

Type of gas Inches W.C. kPa Voltz/Hz Amperes

Natural Gas 4.0 1.12 120/60 <5

All Models: Maximum supply pressure = 14.0 in. W.C. (3.48 kPa) Minimum supply pressure, Natural gas = 6 in. W.C. (1.49 kPa). Minimum pressures must be maintained under both load and no load (static and dynamic) conditions.

FOREWORD

The design of these models comply with the current edition of ANSI Z21.10.3/CSA 4.3 an automatic storage water heater.

Installation diagrams are found in this manual. These diagrams will serve to provide the installer with a reference for the materials and method of piping necessary. It is highly essential that all water and gas piping be installed as shown on the diagrams.

In addition to these instructions, the equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.

The installation must conform with these instructions and the local code authority having jurisdiction. In the absence of local codes, installations should comply with the National Fuel Gas Code (ANSI Z223.1/NFPA

54) and the National Electric Code (NFPA 70). These publications are available from The National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269

Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service.

Abbreviations Found In This Manual:

• CSA-Canadian Standards Association

• ANSI-American National Standards Institute

• NFPA-National Fire Protection Association

• AHRI-Air Conditioning, Heating and Refrigeration Institute

• UL-Underwriters Laboratories This gas-fired water heater is design certified by Underwriters

Laboratories Inc. under American National Standard/CSA Standard for Gas Wtare Heaters ANSI Z21.10.3•CSA 4.3 (current edition).

53 7/8

136.8

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GENERAL SAFETY

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TABLE OF CONTENTS

Page

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

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

GENERAL SAFETY INFORMATION

Precautions ................................................................................ 4

Preparing for the Installation ...................................................... 4

Grounding Instructions............................................................... 4

Chemical Vapor Corrosion ......................................................... 5

Extended Non-use Periods ........................................................ 5

Insulation Blankets..................................................................... 5

High Altitude Installations........................................................... 5

Circulating Pump ....................................................................... 6

INSTALLATION INSTRUCTIONS

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

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

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

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

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

Unconﬁ ned Space ..................................................................... 7

Conﬁ ned Space ......................................................................... 7

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

Vent Connection ........................................................................ 8

Thermometers ........................................................................... 8

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

Mixing Valves ............................................................................. 8

System Connections .................................................................. 9

Relief Valve ............................................................................... 9

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

Page

Purging ..................................................................................... 10

Gas Meter Size ......................................................................... 10

Gas Pressure Regulator ........................................................... 10

OPERATION ................................................................................. 10

To Operate The Heater ............................................................. 10

Heater Wiring ............................................................................ 11

Lighting Instructions .................................................................. 12

Temperature Regulation ........................................................... 13

Checking Venting ...................................................................... 13

HIgh Temperature Limit Switch ................................................. 13

SERVICE INFORMATION ............................................................ 14-15

Main Burner and Igniter ............................................................ 14

Checking Gas Input .................................................................. 14

Vent System.............................................................................. 14

Blower Maintenance ................................................................. 15

Relief Valve ............................................................................... 15

Hot Water Odor ......................................................................... 15

Winter Protection ...................................................................... 15

Replacement Parts ................................................................... 15

Draining and Flushing ............................................................... 15

CHECKLIST ................................................................................. 15-16

Condensation............................................................................ 16

Anode Rod Inspection .............................................................. 16

Service and Repair ................................................................... 16

TROUBLESHOOTING ................................................................. 17-19

GENERAL SAFETY

INFORMATION

PRECAUTIONS

DO NOT USE THIS WA TER HEA TER IF ANY P AR T HAS BEEN UNDER WATER. Immediately call a qualiﬁ ed service technician to inspect the water heater and to replace any part of the control system and any gas control which has been under water.

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

1. EXTERNAL FIRE.

2. DAMAGE.

3. FIRING WITHOUT WATER.

4. SOOTING. Heater must be protected from freezing downdrafts during shutdown periods.

PREPARING FOR THE INSTALLATION

1. Read the “General Safety” section, page 3 of this manual ﬁ rst and then the entire manual carefully. If you don’t follow the safety rules, the water heater will not operate properly. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.

This manual contains instructions for the installation, operation, and

maintenance of the gas-ﬁ red 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. Since we cannot put everything on the ﬁ rst few pages, READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO

INSTALL OR OPERATE THE WATER HEATER.

2. The installation must conform with these instructions and the local code authority having jurisdiction. In the absence of local codes, installations shall comply with the National Fuel Gas Code ANSI Z223.1/NFPA 54 current addition. This publication is available from the CSA International, 8501 East Pleasant Valley Rd., Cleveland Ohio 44131, or The National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

3. If after reading this manual you have any questions or do not understand any portion of the instructions, call the local gas utility or the manufacturer whose name appears on the rating plate.

4. Carefully plan the place where you are going to put the water heater. Correct combustion, vent action, and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and ﬁ res, see Figures 3 through 8A.

Examine the location to ensure the water heater complies with the

“Locating the New Water Heater” section in this manual.

5. For California installation this water heater must be braced, anchored, or strapped to avoid falling or moving during an earthquake. See instructions for correct installation procedures. Instructions may be obtained from California Ofﬁ ce of the State Architect, 400 P Street, Sacramento, CA 95814.

6. Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248-CMR 2.00: State Plumbing Code and 248-CMR 5.00.

7. Complies with SCAQMD rule #1146.2 and districts having equivalent NOx requirements.

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.

This water heater must be connected to a grounded metal, permanent wiring system; or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the water heater, see Figure 5.

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CHEMICAL VAPOR CORROSION

HIGH AL TITUDE INST ALLATIONS

CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS. SUCH CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION.

Spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride (water softener salt), waxes, and process chemicals are typical compounds which are potentially corrosive. Do not store products of this sort near the heater. Also, air which is brought in contact with the heater should not contain any of these chemicals. If necessary, uncontaminated air should be obtained from remote or outside sources. The limited warranty is voided when failure of water heater is due to a corrosive atmosphere. (Refer to the limited warranty for complete terms and conditions.)

EXTENDED NON-USE PERIODS

WARNING

HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER SYSTEM SERVED BY THIS HEATER THAT HAS NOT BEEN USED FOR A LONG PERIOD OF TIME (GENERALLY TWO WEEKS OR MORE). HYDROGEN GAS IS EXTREMELY FLAMMABLE.

these conditions, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical water heater connected to the hot water system. If hydrogen is present, there will probably be an unusual sound such as air escaping through the pipe as the water begins to ﬂ ow.

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

WARNING

To reduce the risk of injury under

THERE SHOULD BE NO SMOKING OR

INSULATION BLANKETS

Insulation blankets available to the general public for external use on gas water heaters are not required for use on this water heater. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank water heaters. This water heater meets or exceeds the current edition of ASHRAE/IES 90.1 standards with respect to insulation and standby loss requirement making an insulation blanket unnecessary.

Water heaters covered in this manual have been tested and approved for installation at elevations up to 7,700 feet (2,347 m) above sea level. For installation above 7,700 feet (2,347 m), the water heater’s Btu input should be reduced at the rate of 4 percent for each 1,000 feet (305 m) above sea level which requires replacement of the burner oriﬁ ce in accordance with the National Fuel Gas Code ANSI Z223.1/NFPA 54. Contact your local gas supplier for further information.

Failure to replace the standard oriﬁ ce with the proper high altitude oriﬁ ce when installed at elevations above 7,700 feet (2,347 m) could result in improper and inefﬁ cient operation of the water heater, producing carbon monoxide gas in excess of the safe limits. This could result in serious injury or death. Contact your local gas supplier for any speciﬁ c changes that may be required in your area.

WARNING

Should you choose to apply an insulation blanket to this heater, you should follow these instructions. Failure to follow these instructions can result in ﬁ re, asphyxiation , serious personal injury or death.

• Do not apply insulation to the top of the water heater, as this will interfere with safe operation.

• Do not cover the outer door, thermostat or temperature & pressure relief valve.

• Do not allow insulation to come within 2" (5cm) of the ﬂ oor to prevent blockage of combustion air ﬂ ow to the burner.

• Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.

• Do obtain new warning and instruction labels from 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 ﬂ ow.

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

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

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

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CIRCULATING PUMP

A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the heater. Refer to the piping diagrams at rear of manual for electrical hookup information and install in accordance with the current edition of the National Electrical Code ANSI/NFPA No. 70.

Only all bronze circulating pumps are used with commercial water heaters. Although circulators are oiled and operated by the manufacturer some circulators must be oiled again before operating. Please refer to manufacturer’s instructions.

INSTALLATION INSTRUCTIONS

REQUIRED ABILITY

INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES ABILITY EQUIV ALENT TO THAT OF A LICENSED TRADESMAN IN THE FIELD INVOLVED. PLUMBING, AIR SUPPL Y, VENTING, ELECTRICAL AND GAS SUPPLY WORK ARE REQUIRED.

LOCATING THE HEATER

WARNING

THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH AS GAS WATER HEATERS IN ROOMS, GARAGES OR OTHER AREAS WHERE GASOLINE, OTHER FLAMMABLE LIQUIDS OR ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED, OPERATED OR REPAIRED. FLAMMABLE VAPORS ARE HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE IGNITED BY THE HEATER’S PILOT OR MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION.

SOME LOCAL CODES PERMIT OPERATION OF GAS APPLIANCES IF INSTALLED 18 INCHES (45.7 CM) OR MORE ABOVE THE FLOOR. THIS MAY REDUCE THE RISK IF LOCATION IN SUCH AN AREA CANNOT BE AVOIDED.

DO NOT INST ALL THIS W A TER HEA TER DIRECTL Y ON A CARPETED FLOOR. A FIRE HAZARD MA Y RESUL T. Instead the water heater must

be placed on a metal or wood panel extending beyond the full width and depth by at least 3 inches (7.6 cm) in any direction. If the heater is installed in a carpeted alcove or closet, the entire ﬂ oor shall be covered by the panel. Also, see the drain requirements.

THE WATER SUPPLY PRESSURE SHOULD NOT EXCEED 80 PSI (551.58 kPa). IF THIS OCCURS, A PRESSURE REDUCING VALVE WITH A BYPASS SHOULD BE PLACED ON THE SUPPLY TO THE ENTIRE HOUSE IN ORDER TO MAINTAIN EQUAL HOT AND COLD WATER PRESSURES.

THE HEATER SHOULD BE LOCA TED IN AN AREA WHERE LEAKAGE FROM THE HEATER OR CONNECTIONS WILL NOT RESULT IN DAMAGE TO THE ADJACENT AREA OR TO LOWER FLOORS OF THE STRUCTURE.

WHEN SUCH LOCATIONS CANNOT BE AVOIDED, A SUITABLE DRAIN PAN SHOULD BE INSTALLED UNDER THE HEATER. Such pans should be fabricated with sides at least 2" (5cm) deep, with length and width at least 2" (5cm) greater than the diameter of the heater and must be piped to an adequate drain. The pan must not restrict combustion air ﬂ ow.

Drain pans suitable for these heaters are available from your distributor or Water Heater Parts Fulﬁ llment, 125 Southeast Parkway, Franklin, TN 37068.

For appliance installation locations with elevations above 7700 feet (610 meters), refer to HIGH ALTITUDE INSTALLATIONS section of this manual for input reduction procedure.

CLEARANCES

These heaters are approved for installation on combustible ﬂ ooring in a closet having a ceiling 12" (30.5cm) above top cover and with clearances to combustible construction of 6" (15.2cm) from ﬂ ue or vent connector, 0" (0cm) at the sides and rear and 5" (10.2cm) to front to prevent a possible ﬁ re hazard condition. A minimum of 4" (10.2cm) shall be allowed for installation of serviceable parts.

HARD WATER

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

See MAINTENANCE section for details of tank cleanout procedure.

AIR REQUIREMENTS

REFER TO THE CURRENT EDITION OF THE "NATIONAL FUEL GAS CODE ANSI Z223.1/NFPA 54.

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

DO NOT OBSTRUCT THE FLOW OF COMBUSTION OR VENTILATING AIR.

WARNING

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

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

WARNING

FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY OTHER

POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON OR ADJACENT TO THE HEATER. OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM WITH THE HEATER.

When installing the heater, consideration must be given to proper location. Location selected should be as close to the stack or chimney as practicable, with adequate air supply and as centralized with the piping system as possible.

THE HEATER MUST NOT BE LOCA TED IN AN AREA WHERE IT WILL BE SUBJECT TO FREEZING.

OPERATION OF THESE FANS CAN PRODUCE A NEGA TIVE DRAFT IN THE AREA OF THE W A TER HEA TER PREVENTING THE PRODUCTS OF COMBUSTION FROM EXHAUSTING THROUGH THE CHIMNEY OR VENT PIPE.

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

WARNING

FOR SAFE OPERATION PROVIDE ADEQUA TE AIR FOR COMBUSTION AND VENTILATION. AN INSUFFICIENT SUPPL Y OF AIR WILL CAUSE RECIRCULATION OF COMBUSTION PRODUCTS RESULTING IN AIR CONTAMINATION THAT MAY BE HAZARDOUS TO LIFE. SUCH A CONDITION OFTEN WILL RESULT IN A YELLOW, LUMINOUS BURNER FLAME, CAUSING CARBONING OR SOOTING OF THE COMBUSTION CHAMBER, BURNERS AND FLUE TUBES AND CREATES A RISK OF ASPHYXIATION.

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

UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE CHIMNEY, CAUSING POOR COMBUSTION. SOOTING MAY RESULT IN SERIOUS DAMAGE TO THE HEATER AND RISK OF FIRE OR EXPLOSION.

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

UNCONFINED SPACE

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

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

CONFINED SPACE

When drawing combustion and dilution air from inside a conventionally constructed building to a conﬁ ned space, such a space shall be provided with two permanent openings, ONE IN OR WITHIN 12 INCHES (30.5cm) OF THE ENCLOSURE TOP AND ONE IN OR WITHIN 12 INCHES (30.5cm) OF THE ENCLOSURE BOTTOM. Each opening shall have a free area of at least one square inch per 1000 Btuh (2,225mm

/Kw) of the total input of all appliances in the enclosure, but not less than 100 square inches (645 square cm).

If the conﬁ ned space is within a building of tight construction, air for combustion, ventilation, and draft hood dilution must be obtained from outdoors. When directly communicating with the outdoors or communicating with the outdoors through vertical ducts, two permanent openings, located in the above manner, shall be provided. Each opening shall have a free area of not less than one square inch per 4000 Btuh (8,900mm horizontal ducts are used, each opening shall have a free area of not less than one square inch per 2000 Btuh (4,450mm

/Kw) of the total input of all appliances in the enclosure. If

/Kw) of the total

input of all appliances in the enclosure.

VENTING

WARNING

THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST BE FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULA TION OF FLUE GASES. SUCH CONDITIONS CAUSE SOOTING OR RISKS OF FIRE AND ASPHYXIATION.

This water heater must be protected from freezing downdrafts. Remove all soot or other obstructions from the chimney that will retard

a free draft. Type B venting is recommended with these water heaters. This water heater must be vented in compliance with all local codes, the

current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and with the Category I Venting Table.

If any part of the vent system are exposed to ambient temperatures below 35 degrees F (2 degrees C) it must be insulated to prevent condensation.

• Do not connect the heater to a common vent or chimney with solid

SINGLE TEMPERATURE

MIXING VALVE APPLICATION FOR TWO TEMPERATURE WATER

WARNING TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES. SEE TEMPERA TURE REGULATION ON PAGE 11. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.

CIRCULATING RETURN LINE CONNECTIONS TEMPERED WATER LOOP, IF USED, CONNECT TO POINT "A". STORED TEMPERATURE WATER LOOP, IF USED, CONNECT TO COLD WATER INLET

VACUUM RELIEF VALVE *INSTALL PER LOCAL CODES.

CAUTION: IF BUILDING COLD WA TER SUPPL Y HAS A BACK-FLOW PREVENTER, CHECK VALVE OR WATER METER WITH CHECK VALVE, AN EXPANSION TANK MUST BE PROVIDED.

FIGURE 2.

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fuel burning equipment. This practice is prohibited by many local building codes as is the practice of venting gas ﬁ red equipment to

the duct work of ventilation systems.

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

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

As water is heated, it expands (thermal expansion). In a closed system, the volume of water will increase. As the volume of water increases, 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. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This condition is not covered under the limited warranty.

A properly-sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion. Contact a plumbing service agency or your retail supplier reguarding the installation of a thermal expansion tank.

FIGURE 3.

VENT CONNECTION

Vent connections must be made to an adequate stack or chimney . Size and install proper size vent pipe. Do not reduce pipe size to less than that of the blower outlet.

Horizontal runs of vent pipe must have a minimum upward slope toward the chimney of 1/4 inch per foot (2cm per meter). Dampers or other obstructions must not be installed in between the heater and the blower. Be sure that the vent pipe does not extend beyond the inside wall of the chimney.

Where a continuous or intermittent back draft is found to exist, the cause must be determined and corrected. A special vent cap may be required. If the back draft cannot be corrected by the normal methods or if a suitable draft cannot be obtained, a blower type ﬂ ue gas exhauster must be employed to assure proper venting and correct combustion.

THERMOMETERS (Not Supplied)

Thermometers should be obtained and ﬁ eld installed as shown in Figure 3. Thermometers are installed in the system as a means of detecting the

temperature of the outlet water supply.

COMBINATION WATER (POTABLE) HEATING

AND SPACE HEATING

1. All piping components connected to this unit for space heating applications shall be suitable for use with potable water.

2. These water heaters connot be used in space heating applications only.

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

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

appliance.

5. When the system requires water for space heating at temperatures higher than required for domestic water purposes, a tempering valve must be installed. Please refer to installation diagram on page 6 of

this manual for suggested piping arrangements.

CAUTION

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

MIXING VALVES

DANGER

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 inﬁ rm and the physically/ mentally disabled. Table 1 shows the approximate time-to-burn relationship for normal adult skin. If anyone using hot water provided by the water heater being installed ﬁ 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 application a Mixing Valve should be installed at water heater (see Figure 3) or at hot water taps to further reduce system water temperature.

Mixing valves are available at plumbing supply stores. Consult a Qualiﬁ ed Installer or Service Agency . Follow mixing valve manufacturer’s instructions for installation of the valves.

using lowest possible temperature setting that

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.

satisﬁ es demand of

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TABLE 4. GAS SUPPLY LINE SIZES (IN INCHES)*

Water Temperature °F

110 (normal shower temp.) 116 (pain threshold) 116 35 minutes 45 minutes 122 1 minute 5 minutes 131 5 seconds 25 seconds 140 2 seconds 5 seconds 149 1 second 2 seconds 154 instantaneous 1 seconds

(U.S. Government Memorandum, C.P .S.C., Peter L. Armstrong, Sept. 15, 1978)

WATER

Time for 1

TEMPERED WATER

COLD

INLET

OUTLET

Degree Burns

(Less Severe Burns)

HOT WATER

OUTLET

CHECK

VALV E

TO TANK

INLET

Time for Permanent Burns

2nd & 3rd Degree

(Most Severe Burns)

12” TO 15” (30-38 cm)

CHECK

VALV E

MIXING

VALV E

FIGURE 4.

SYSTEM CONNECTIONS

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

heavy piping be supported.

RELIEF VALVE

This water heater is equipped with a combination temperature-pressure relief valve that complies with the standard for relief valves for hot water supply systems Z21.22-CSA 4.4.

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

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

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

systems Z21.22-CSA 4.4.

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

VALVE AND TANK.

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

A DRAIN LINE MUST BE CONNECTED TO THE RELIEF VALVE TO DIRECT DISCHARGE TO A SAFE LOCATION TO AVOID SCALDING OR WATER DAMAGE. THIS LINE MUST NOT BE REDUCED FROM THE SIZE OF THE VALVE OUTLET AND MUST NOT CONTAIN VALVES,

FOR SAFE OPERATION OF THE

WARNING

RELIEF

RESTRICTIONS NOR SHOULD IT BE LOCATED IN FREEZING AREAS. DO NOT THREAD OR CAP THE END OF THIS LINE. RESTRICTED OR BLOCKED DISCHARGE WILL DEFEAT THE PURPOSE OF THE VALVE AND IS UNSAFE. DISCHARGE LINE SHALL BE INSTALLED TO ALLOW COMPLETE DRAINAGE OF BOTH THE VALVE AND LINE.

See SERVICE INFORMATION section for procedure and precautions. The type, size and location of the relief valves must be in accordance

with local codes. The location of the relief valve is shown in Figure 1. The heater has a factory installed high temperature limit switch.

GAS PIPING

Contact your local gas service company to ensure that adequate gas service is available and to review applicable installation codes for your area.

Size the main gas line in accordance with Table 4. The ﬁ gures shown are for straight lengths of pipe at 0.5" W.C. (.125 kPa) pressure drop, which is considered normal for low pressure systems. Note: Fittings such as elbows, tees and line regulators will add to the pipe pressure drop. Also refer to the current edition of the National Fuel Gas Code.

WARNING

The minimum gas supply pressure for input adjustment is 6.0" W.C.(1.49 kPa) for natural gas.

THE HEATER IS NOT INTENDED FOR OPERATION AT HIGHER THAN 14" W.C. (3.49 kPa) SUPPLY PRESSURE. EXPOSURE TO HIGHER GAS SUPPLY PRESSURE MAY CAUSE DAMAGE TO THE CONTROL WHICH COULD RESULT IN FIRE OF EXPLOSION.

such as through improper testing of gas lines or emergency malfunction of the supply system, the control must be checked for safe operation. Make sure that the outside vents on the supply regulators and the safety vent valves are protected against blockage. These are parts of the gas supply system not the heater. V ent blockage may occur during ice storms.

IT IS IMPORT ANT T O GUARD AGAINST GAS V AL VE FOULING FROM CONTAMINANTS IN THE GAS W AYS. SUCH FOULING MAY CAUSE IMPROPER OPERATION, FIRE OR EXPLOSION.

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

TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS SUPPLY LINE, A SEDIMENT TRAP MUST BE INCORPORA TED IN THE PIPING (SEE FIG. 5). THE SEDIMENT TRAP MUST BE READIL Y ACCESSIBLE AND NOT SUBJECT TO FREEZING CONDITIONS. INSTALL IN ACCORDANCE WITH RECOMMENDATIONS OF SERVING GAS SUPPLIERS. REFER TO THE CURRENT EDITION OF THE NA TIONAL FUEL GAS CODE.

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

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

If overpressure has occurred

Page 10

TABLE 5 MAXIMUM CAPACITY OF PIPE IN

CUBIC FEET PER HOUR

LENGTH

FEET

LENGTH

METERS

1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4"

10 175 360 680 1400 2100 3960 6300 11000 230000 20 120 250 485 950 1460 2750 4360 7700 15800 30 97 200 375 770 1180 2200 3520 6250 12800 40 82 170 320 660 990 1900 3000 5300 10900 50 73 151 285 580 900 1680 2650 4750 9700 60 66 138 260 530 810 1520 2400 4300 8800 70 61 125 240 490 750 1400 2250 3900 8100 80 57 118 220 460 690 1300 2050 3700 7500 90 53 110 205 430 650 1220 1950 3450 7200

100 50 103 195 400 620 1150 1850 3250 6700 125 44 93 175 360 550 1020 1650 2950 6000 150 40 84 160 325 500 950 1500 2650 5500 175 37 77 145 300 460 850 1370 2450 5000 200 35 72 135 280 430 800 1280 2280 4600

1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4"

3.0 51 105 199 410 615 1160 1845 3221 6735

6.1 35 73 142 278 428 805 1277 2255 4626

9.1 28 59 110 225 346 644 1031 1830 3748

12.2 24 50 94 193 290 556 878 1552 3192

15.2 21 44 83 170 264 492 776 1391 2840

18.3 19 40 76 155 237 445 703 1259 2577

21.3 18 37 70 143 220 410 659 1142 2372

24.4 17 35 64 165 202 381 600 1083 2196

27.4 16 32 60 126 190 357 571 1010 2108

30.5 15 30 57 117 182 337 542 952 1962

38.1 13 27 51 105 161 299 483 864 1757

45.7 12 25 47 95 146 278 439 776 1610

53.3 11 23 42 88 135 249 401 717 1464

61.0 10 21 40 82 126 234 375 688 1347

NORMAL IRON PIPE SIZES (INCHES)

INPUT IN THOUSANDS BTU/HR

NORMAL IRON PIPE SIZES (INCHES)

INPUT IN KW

BEFORE PLACING THE HEATER IN OPERATION, CHECK FOR GAS LEAKAGE.

the purpose in locating the leaks.

Use soap and water solution or other material acceptable for

DO NOT USE MA TCHES, CANDLES,

FLAME OR OTHER SOURCES OF IGNITION FOR THIS PURPOSE.

FIGURE 5. GAS PIPING AND SEDIMENT TRAP INSTALLATION

PURGING

Gas line purging is required with new piping or systems in which air has entered.

CAUTION

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

GAS METER SIZE — NATURAL GASES ONLY

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

GAS PRESSURE REGULATOR

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

The minimum gas supply pressure for input adjustment must not be less than 6" w.c. (1.49 kPa) for natural gas.

Do not subject the combination gas valve to inlet gas pressures of more than 14.0" w.c. (3.48 kPa) - natural gas. A service regulator is necessary if higher gas pressures are encountered.

Gas pressure speciﬁ ed in T able 5, refer to ﬂ ow pressure taken at pressure tap of automatic gas valve while heater is operating.

TABLE 6. GAS PRESSURE

Type of

Gas

Natural

Input Manifold Pressure

75,100 Btu/hr

22 KW/hr

4.0 in. W.C.

1.12 kPa

OPERATION

It is recommended that a qualiﬁ ed person perform the initial ﬁ ring of the heater. At this time the user should not hesitate to ask the individual any questions which he may have in regard to the operation and maintenance of the unit.

DISCONNECT THE HEATER AND ITS MANUAL GAS SHUTOFF VALVE FROM THE GAS SUPPLY PIPING SYSTEM DURING ANY SUPPLY PRESSURE TESTING EXCEEDING 1/2 PSIG (3.45 kPa). GAS SUPPLY LINE MUST BE CAPPED WHEN DISCONNECTED FROM THE HEATER FOR TEST PRESSURES OF 1/2 PSIG (3.45 kPa) OR LESS. THE WATER HEATER NEED NOT BE DISCONNECTED, BUT MUST BE ISOLATED FROM THE SUPPLY PRESSURE TEST BY CLOSING THE MANUAL GAS SHUTOFF VALVE.

TO OPERATE THE HEATER

1. Close the heater drain valve (Figure 1) by turning handle clockwise .

2. Open a nearby hot water faucet to permit the air in the system to

escape.

3. Fully open the cold water inlet pipe valve (Figure 1) allowing the heater

and piping to be ﬁ lled.

4. Close the hot water faucet as water starts to ﬂ ow.

5. The heater is ready to be operated.

WARNING

DO NOT ATTEMPT TO OPERATE WATER HEATER WITH COLD WATER INLET VALVE CLOSED.

NEVER OPERATE THE HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER AND A TEMPERATURE AND PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE OPENING OF THE HEATER.

Page 11

HEATER WIRING

All electrical work must be installed in the United States in accordance with the current edition of the National Electrical Code ANSI/NFPA No. 70, in Canada, must conform to all local code authority having jurisdiction. AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF ELECTRICAL SHOCK OR POSSIBLE ELECTROCUTION.

If any of the original wire as supplied with the appliance must be replaced, use only type 105°C thermoplastic or equivalent, 250°C type F must be used for the ﬂ ame sensor leads and the spark ignition cable must be high voltage 250°C.

CAUTION

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.

FIGURE 6. WIRING DIAGRAM AND SCHEMATIC

Page 12

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, a ﬁ re or explosion

may result causing property damage, personal injury or loss of life.

BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.

A. This appliance does not have a pilot. It is equipped with

an ignition device which automatically lights the burner.

Do not try to light the burner by hand. B. BEFORE OPERATING smell all around the appliance

area for gas. Be sure to smell next to the ﬂ oor because some gas is heavier than air and will settle on the ﬂ oor.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electric 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 ﬁ re department.

C. Use only your hand to push in the control buttons.

Never use tools. If the control buttons will not push in, don’t try to repair them, call a qualiﬁ ed service technician. Force or attempted repair may result in a

ﬁ re or explosion.

D. Do not use this appliance if any part has been under

water. Immediately call a qualiﬁ ed service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

OPERATING INSTRUCTIONS

VACATIONVACATION

WARM

COOLER

WARNING

ABC

HOTTER

VERY

HOT

1. STOP! Read the safety information above on this label.

2. Set the thermostat to the lowest setting by ﬁ rst pressing the COOLER

and HOTTER buttons together

and holding for 1 second. Then press the COOLER

button until the WARM indicator light appears.

3. Turn the "ON/OFF" swich on the blower control to the "OFF" position.

4. This appliance is equipped with a device which automatically lights the burner.

DO NOT TRY TO LIGHT THE BURNER BY HAND.

5. Wait ﬁ ve (5) minutes to clear out any gas. If you then smell gas, STOP! Follow "B" in the safety information above on this label.

If you don't smell gas, go to next step.

6. Turn on all electrical power to the appliance.

7. Set thermostat to desired setting by ﬁ rst pressing the COOLER

and HOTTER buttons together and holding for 1 second. Then press the HOTTER button.

8. If the appliance will not operate, follow the instructions "TO TURN OFF GAS TO APPLIANCE" and call your technician or gas supplier.

9. WATER TEMPERATURE ADJUSTMENT

is approximately 120°F (49°C).

CAUTION: Hotter water increases the risk of scald injury. Consult the instruction manual before changing temperatures.

WARNING: TURN OFF ALL ELECTRIC POWER BEFORE SERVICING

TO TURN OFF GAS TO APPLIANCE

A. Set thermostat to the lowest setting. B. Turn off all the electric power to the appliance if service is to be performed.

Page 13

TEMPERATURE REGULATION

DANGER

THIS WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT WATER TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHING AND LAUNDRY USE CAN CAUSE PAINFUL SCALDING WITH POSSIBLE SERIOUS AND PERMANENT INJURY. THE TEMPERATURE AT WHICH INJURY OCCURS VARIES WITH THE PERSON’S AGE AND THE TIME OF THE EXPOSURE. THE SLOWER RESPONSE TIME OF CHILDREN, AGED OR DISABLED PERSONS INCREASES THE HAZARDS TO THEM. NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER TAP, OR TO DRAW THEIR OWN BATH WATER. NEVER LEAVE A CHILD OR DISABLED PERSON UNATTENDED IN A BATHTUB OR SHOWER.

THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS. IF A SUIT ABLE AREA IS NOT A V AILABLE, A COVER SHOULD BE INST ALLED OVER THE THERMOSTAT TO PREVENT TAMPERING. Suitable covers are available through Water Heater Parts Fulﬁ llment, 125 Southeast Parkway, Franklin, TN 37068.

Water

Temperature

°F (°C)

110 (43.3) (normal shower temp.)

116 ( 46.6) (pain threshold) 116 ( 46.6) 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 (67.7) instantaneous 1 second

(U.S. Government Memorandum, C.P .S.C., Peter L. Armstrong, Sept. 15,1978)

Time for 1st

Degree Burn

(Less Severe Burns)

Time for Permanent Burns

2nd & 3rd Degree

(Most Severe Burns)

Display

Temperature Setting

C-Flashing = approx. 160°F (71°C) C = approx. 150°F (66°C) B = approx. 140°F (60°C) A = approx. 130°F (54°C) = approx. 120°F (49°C) WARM = approx. 80°F (27°C)

A B C

FIGURE 7.

SETTING THE WATER HEATER TEMPERATURE AT 120°F (49°C) (APPROX. " DIAL) WILL REDUCE THE RISK OF SCALDS.

" MARK ON FACE OF THE TEMPERA TURE ADJUSTING

Some States or Provinces

require settings at speciﬁ c lower temperatures. Figure 6 shows the approximate water temperatures produced at various

thermostat settings. Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the thermostat setting by up to 20°F (11°C). If you experience this type of use you should consider using lower temperature settings to reduce scald hazards.

Valves for reducing point of use temperature by mixing cold and hot water are available. Also available are inexpensive devices that attach to faucets to limit hot water temperatures. Contact a licensed plumber or the local plumbing authority.

To avoid any unintentional changes in water temperature settings, the control has a tamper resistant feature for changing the temperature setting. To change the temperature setting follow these instructions:

It is recommended that lower water temperatures be used to avoid the risk of scalding. It is further recommended, in all cases, that the water temperature setting be set for the lowest temperature that satisﬁ es your hot water needs. This will also provide the most energy efﬁ cient operation of the water heater. The water temperature adjustment was factory set at the lowest temperature. Pressing the "COOLER" button decreases temperature and pressing the "HOTTER"

button increases

the temperature

1. "Wake Up" the temperature indicators by holding down both the "COOLER" and "HOTTER" temperature adjustment buttons at the same time for one second (see Figure 6). One or two of the temperature indicators will light up. These indicators will only remain on for 30 seconds if no further buttons are pressed. After 30 seconds the control will go back to "Sleep" mode.

2. Release both of the temperature adjustment buttons.

A. To decrease the temperature press and release the "COOLER"

button until desired setting is reached.

B. To increase the temperature press and release the "HOTTER"

button until the desired setting is reached.

NOTE: Holding down the button will not continue to lower or raise the temperature setting. The button must be pressed and released for each temperature change desired.

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MAIN MANUAL GAS SHUTOFF VALVE TO THE APPLIANCE. SEE FIGURE 1 (G).

Page 14

CHECKING VENTING

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

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 Installation codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deﬁ ciencies which could cause an unsafe condition.

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

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

5. Test for vent system leakage after 5 minutes of main burner operation.

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

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

WARNING

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

HIGH TEMPERATURE LIMIT SWITCH (ECO)

The water heater is equipped with a manual reset type high limit (Energy Cutoff) sensor. The high limit switch interrupts the main burner gas ﬂ ow should the water temperature reach 195°F (90°C). The high limit switch must be manually reset by turning the power to the water heater off for 5 seconds then back on and cannot be reset until the water temperature drops below 120°F (49°C). It is important that a serviceman be called to determine the reason for limit operation and thus avoid repeated thermostat resetting.

FOR YOUR SAFETY AND SATISFACTORY OPERATION, IT IS RECOMMENDED THA T THIS HEA TER BE CHECKED ONCE A YEAR BY A COMPETENT SERVICE PERSON.

USERS OF THIS APPLIANCE SHOULD BE AWARE THAT GAS COMPONENTS WEAR OUT OVER A PERIOD OF TIME. THE GAS CARRYING COMPONENTS OF THIS APPLIANCE SHOULD BE INSPECTED FOR PROPER OPERATION PERIODICALLY BY A QUALIFIED SERVICE TECHNICIAN.

MAIN BURNER AND IGNITER

Check main burner (figure 7) at least every 6 months for proper ﬂ ame characteristics. The main burner should display the following characteristics:

BURNER HEAD

ASSEMBLY

BURNER TUBE

ASSEMBLY

H.S.I.

ASSEMBLY

FIGURE 8. MAIN BURNER AND IGNITER ASSEMBLY

1. Provide complete combustion of gas.

2. Cause rapid ignition and carryover of ﬂ ame across entire burner.

3. Give reasonably quiet operation during ignition, burning and extinction.

4. Cause no excessive lifting of ﬂ ames from burner ports. If preceding burner characteristics are not evident, check for accumulation

of lint or other foreign material that restricts or blocks the air openings to the heater or burner.

WARNING

SOOT BUILD-UP INDICATES A PROBLEM THAT REQUIRES CORRECTION BEFORE FURTHER USE. CONSULT WITH A QUALIFIED SERVICE TECHNICIAN.

Should the main burner or burner air openings require cleaning, remove the burner and clean with a soft brush. Clean main burner oriﬁ ce with a suitable soft material.

CHECK FOR GOOD FLOW OF COMBUSTION AND VENTILATING AIR TO THE UNIT. MAINTAIN A CLEAR OPEN AREA AROUND THE HEATER AT ALL TIMES. DO NOT STORE COMBUSTIBLES OR FLAMMABLE LIQUIDS NEAR OR AROUND AN APPLIANCE.

THE ON/OFF SWITCH MUST HA VE BEEN IN THE OFF POSITION FOR

WARNING

AT LEAST 5 MINUTES. This waiting period is an important safety step. Its purpose is to permit gas that may have accumulated in the combustion chamber to clear. IF YOU DETECT GAS ODOR A T THE END OF THIS PERIOD DO NOT PROCEED WITH LIGHTING. RECOGNIZE THAT GAS ODOR, EVEN IF IT SEEMS WEAK, MA Y INDICATE PRESENCE OF ACCUMULATED GAS SOMEPLACE IN THE AREA WITH RISK OF FIRE OR EXPLOSION. SEE THE FRONT PAGE FOR STEPS TO BE TAKEN.

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE.

SERVICE INFORMATION

The installer may be able to observe and correct certain problems which may arise when the unit is put into operation. HOWEVER, it is recommended that only qualiﬁ ed servicemen, using appropriate test equipment, be allowed to service the heater.

CHECKING GAS INPUT

For appliance installation locations with elevation above 2000 ft.(610m) refer to HIGH ALTITUDE INSTALLATIONS section of this manual for input reduction procedure.

With this heater in operation, determine whether it is receiving the full rated input of gas. This may be done by timing the gas meter and measuring gas pressure with a gauge or manometer. When the heater is operating at full capacity (full gas input) it should consume approximately 1 cubic foot of gas in the time shown in table 6.

TABLE 7 INPUT CHECK TIME REQUIRED TO CONSUME 1 CU. FT. OF GAS

Type of Gas BTU Per Cu. Ft.

Natural 1050 50.3 Seconds

Time Required To Consume 1 Cu.

Ft. of Gas

Page 15

Use this formula to “clock” the meter. Be sure that other gas consuming appliances are not operating during this interval.

3,600 X H = Btu/h T T = Time in seconds needed to burn one cubic foot of gas. H = Heating value of gas in Btu’s per cubic foot of gas. Btuh = Actual heater input rate. Example: T = 47.2 seconds/ft H = 1,050 Btu/ft3 (natural gas) Btuh = ? 3,600 X 1,050 = 75,100 Btu/h (22Kw)

50.3

• T o check UN•LIME for continued use or reuse, place some lime scale or white chalk into a glass with a small amount of solution. If the material is vigorously dissolved by the solution, the UN•LIME can be reused. If not, the UN•LIME has been weakened and should be replaced.

8. When deliming has been completed, the heater should be ﬂ ushed

for 3 to 5 minutes with fresh water.

• Remove the deliming equipment, install the drain valve, open the cold water inlet line and allow water to ﬂ ow through heater and out drain valve. Don’t forget to plug vent and cap opening in Flo-Jug.

9. When ﬂ ushing is completed:

Compare the actual input rate to that given on the heater’s rating plate. In the example, the full input rate should be 75,100 Btu/h (22 Kw) for natural gas.

VENT SYSTEM

Examine the venting system every 6 months for obstructions and/or deterioration of vent piping.

BLOWER MAINTENANCE

For safety and satisfactory operation it is recommended that the blower be checked once a year by a competent service person.

1. MOTOR - The motor is factory oiled and sealed and requires no further maintenance.

2. WHEEL - Wheel must be clean of soot, ash or any other coating which inhibits either rotation or air ﬂ ow. Remove all foreign material from vent system.

3. The pressure switch is inside the blower control box and is connected to the blower housing with a tube. This tubing should be soft and pliable and show no sign of deterioration.

RELIEF VALVE

At least once a year the temperature and pressure relief valve should be checked to ensure that it is in operating condition. (During manual operation of this valve, avoid any contact with hot water and take preventive steps for water damage). Lift the lever at the top of the valve several times until the valve seats properly and operates freely.

WARNING

THE WA TER P ASSING OUT OF THE V AL VE DURING THIS CHECKING OPERATION MAY BE EXTREMELY HOT. AVOID CONTACT AND DISCHARGE SAFELY TO PREVENT WATER DAMAGE.

If the temperature and pressure relief valve on the heater discharges periodically or continuously, a problem exists. This may be due to unusually high water temperatures or pressures in the system, or to a faulty relief valve. Contact your dealer or a qualiﬁ ed service technician to ﬁ nd the cause of the problem and to correct it. This may also be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation. DO

NOT PLUG THE TEMPERATURE AND PRESSURE RELIEF VALVE.

WARNING

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE.

HOT WATER ODOR

• Fill heater being certain to expel air from tank through a nearby hot water faucet or, if removed, the relief valve opening.

• The heater relief valve can be washed in UN•LIME if it is limed.

• Replace relief valve if removed for deliming.

• Restore gas, oil or electrical supply to heater.

• Check for water leakage.

10. Flo-Jug cleanup:

• Allow scale to separate from UN•LIME and settle on bottom of Flo-Jug.

• Pour off UN•LIME into plastic container and check for reuse.

• Rinse sediment from Flo-Jug.

DRAINING AND FLUSHING

It is recommended that the tank be drained and ﬂ ushed every 6 months to remove sediment which may build up during operation. The water heater should be drained if being shut down during freezing temperatures. To drain the tank, perform the following steps:

1. Turn off the gas to the water heater at the manual gas

shut off valve.

2. Open a nearby hot water faucet until the water is no

longer hot.

3. Close the cold water inlet valve.

4. Connect a hose to the drain valve and terminate it to an

adequate drain or external to the building.

5. Open the water heater drain valve and allow all of the

water to drain from the tank. Flush the tank with water as needed to remove sediment.

6. Close the drain valve, reﬁ ll the tank, and restart the

heater as directed in this manual.

If the water heater heater is going to be shut down for an extended period, the drain valve should be left open.

iMPORTANT: ccondensation may occur when reﬁ lling the

On occasion, hot water may develop a strong odor. If this occurs drain the heater completely, ﬂ ush thoroughly, and reﬁ ll. If the problem persists, chlorination of the heater and replacement of the factory installed magnesium anode with aluminum anode may correct the condition.

Occasionally water softener companies recommend removal of heater anodes for odor reasons.

tank and should not be confused with a tank leak.

Page 16

CHECKLIST

Before contacting your dealer, check the water heater to see if the apparent malfunction is caused by some external fault. Consulting this checklist may eliminate the need for a repair call and restore hot water service.

NOT ENOUGH OR NO HOT WATER

1. Look for leaking or open hot water faucets. Check for excessive usage.

2. Your gas company can check the gas input to the heater to see that it is correct. An underﬁ red heater will not produce hot water at its normal recovery rate.

3. If the heater was installed when incoming water temperatures were warm, colder incoming temperatures will create the effect of less hot water.

4. The thermostat water temperature adjusting dial may be set too low.

5. If you cannot determine the cause of the problems, contact your dealer.

WATER TEMPERATURE IS TOO HOT

1. The thermostat water temperature adjusting dial may be set too high.

2. If lowering control setting does not reduce the water temperature contact your dealer.

GAS SMELL AT THE HEATER

1. Close the main shutoff valve in the gas supply pipe near the heater, see Figure 5 on page 9.

2. Call your gas company.

WATER LEAKAGE IS SUSPECTED

1. Check to see if the heater drain valve is tightly closed.

2. The apparent leakage might be condensation. In warm or humid locations, condensation can accumulate and run from within the heater or its piping.

• When a water heater is ﬁ rst installed and ﬁ lled, the bottom of the

tank might condense water. The water accumulation, if excessive, can drip into the ﬂ oor shield. Also, during normal operation there may be occasions when large quantities of water are drawn, chilling the tank bottom. This too can result in condensation.

• Condensation, appearing in the vent pipe (water dripping from

draft diverter) during heater operation is evidence of poor vent action. Possible causes are too long a vent pipe or improper chimney operation.

3. If the leakage is from the temperature and pressure relief valve or its discharge pipe, it may represent a normal condition. However, see RELIEF VALVE section on page 7. DO NOT PLUG THE TEMPERATURE AND PRESSURE RELIEF VALVE. Also, the leakage could be due to unusually high water pressures or temperatures in the system, or to a faulty relief valve. Your dealer or a qualiﬁ ed service technician should be called to determine the cause of the problem and to correct it.

4. If you cannot identify or correct the source of water leakage:

• Close the main shutof f valve in the gas supply pipe at the heater.

See Figure 5, page 9.

• Close the valve which feeds water to the cold water inlet at the

top of the heater.

• Contact your dealer.

WATER HEATER MAKES SOUNDS

1. Occasional excessive condensation, as explained under LEAKAGE, can cause a sizzling sound as the moisture is vaporized by the gas ﬂ ame. This is a normal sound and may be disregarded.

2. Sediment and water scale accumulations may cause rumbling noises. See MAINTENANCE or contact your dealer for details of ﬂ ushing the heater.

3. If you cannot identify or remedy the condition, contact your dealer.

CONDENSATION

Water vapor can condense on the cooler surfaces of the tank forming droplets, these drip into the ﬁ re or run out on the ﬂ oor. This is common at the time of startup after installation, during periods of time when incoming water is very cold, or the heater may be undersized for the requirements.

Droplets from the bottom of the ﬂ ue may be due to corrosive combustion products or improper vent. Check with your dealer for more information.

ANODE ROD INSPECTION

Each water heater contains at least one anode rod, which will slowly deplete (due to electrolysis) prolonging the life of the water heater by protecting the glass-lined tank from corrosion. Adverse water quality, hotter water temperatures, high hot water useage, and water

softening methods can increase the rate of anode rod depletion the anode rod is depleted, the tank will start to corrode, eventually developing a leak.

Certain water conditions will cause a reaction between the anode rod and the water. The most common complaint associated with the anode rod is a "rotten egg smell" produced from the presence of hydrogen sulﬁ de gas dissolved in the water. IMPORTANT: Do not remove this rod permanently as it will void any warranties. The parts list includes a special anode rodthat can be ordered if water odor or discoloration occurs. NOTE: This rod may reduce but not eliminate water odor problems.

Artiﬁ cially softened water is exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions. The use of a water softener may decrease the life of the water heater tank.

The anode rod should be inspected after a maximum of three years and annually thereafter until the condition of the anode rod dictates its replacement. NOTE: Artiﬁ cially softened water requires the anode rod to be inspected annually.

The following are typical (but not all) signs of a depleted anode rod: * The majority of the rods diameter is less than 3/8" * Signiﬁ cant sections of the support wire (approx. 1/3 or more of

the anode rods length) are visible. If the anode rod shows signs of either or both it should be replaced. NOTE: Whether re-installing or replacing the anode rod, check for any leaks immediately, correct if found.

In replacing the anode:

1. Turn off gas supply to the water heater.

2. Shut off the water supply and open a nearby hot water faucet to

depressurize the water tank.

3. Drain approximately 5 gallons of water from the tank (Refer to

"Draining and Flushing" for proper procedures). Close drain

valve.

4. Reomve old anode rod.

5. Use Teﬂ on® tape or approved pipe sealant on threads and install

new anode rod.

6. Turn on water supply and open nearby hot water faucet to purge

air from water system. Check for any leaks and immediately

correct any if found.

. Once

Page 17

Restart the water heater as directed under "Operating Your Water Heater." See the repair parts illustration for anode rod location.

Figure 9

SERVICE AND REPAIR

The water heater requires no special care other than the normal maintenance as noted above. If you are having a problem with your water heater, before calling for service please refer to the following TROUBLESHOOTING sections. If service becomes necessary, contact your dealer, installer or an authorized service agent. Do not attempt to repair the water heater yourself. Any work performed by unauthorized personnel may void the warranty.

TROUBLESHOOTING

Water heaters may exhibit problems that are unrelated to a malfunction of the water heater itself. The following information and tables may serve to answer your question about a problem that you are having without having to call a service agent.

For your safety, water heater service should be performed only by a qualiﬁ ed service technician. Read the GENERAL SAFETY INFORMATION section ﬁ rst.

WATER HEATING CYCLE

(GAS AND ELECTRIC POWER ARE ON,“OFF/ON” SWITCH IS

ON)

1) CALLS FOR HEAT A) THERMOSTAT SENSES NEED FOR HEATING WATER

B) CONTACTS CLOSE IN THERMOSTAT, POWER (115 VAC)

FLOWS TO BLOWER MOTOR

2) BLOWER MOTOR ROTATES BLOWER WHEEL A) BLOWER WHEEL SPEED INCREASES

B) WHEEL SPEED INCREASES, AIR PRESSURE SWITCH

CONTACTS CLOSE

3) 120 VAC FLOWS TO HOT SURFACE IGNITER NOTE: THE CONTROL MODULE ON THIS UNIT WILL TRY A

MAXIMUM OF THREE TIMES TO LIGHT THE UNIT. CYCLE CAN BE RESTARTED AT ANY TIME BY TURNING OFF SWITCH AND THEN TURNING BACK ON. IF UNIT HAS GONE THROUGH THREE CYCLES AND DID NOT LIGHT, THEN REPAIRMAN SHOULD BE CALLED TO CHECK OPERATION OF HEATER.

4) MAIN BURNER IGNITES A) GAS FLOWS TO MAIN BURNER PORTS AND IS IGNITED

5) GAS VALVE SENSES BURNER FLAME

6) BURNER HEATS WATER A) BURNER HEATS WATER TO THERMOSTAT SETTING

B) CONTACTS IN THERMOSTAT OPEN, C) CYCLE IS COMPLETED

Page 18

TROUBLESHOOTING

For your safety, water heater service should be performed only by a qualiﬁ ed service technician.

Read the GENERAL SAFETY INFORMATION section ﬁ rst

PROBLEM

NOT ENOUGH OR NO HOT WATER

CONDENSATION A) Water on the ﬂ oor under heater. See "Condensation"

WATER LEAKS

LEAKING T&P VALVE

HOT WATER ODORS OR COLOR

(Refer to ANODE ROD)

POSSILBE MALFUNCTION

1) Blower will not run.

A) "ON/OFF" control switch turned off. Turn switch to the on position. B) Blower unplugged. Plug blower back into 115 vac. outlet. C) No power at outlet. Repair service to outlet. D) "ON/OFF" switch defective. Replace switch. E) Control harness defective. Replace control harness. F) Blower motor defective. Replace blower and motor.

2) Blower running, burner not on Replace switch. A) Fan not running fast enough to close

air switch contacts. B) Air pressure switch defective. Replace switch. C) Gas valve defective. Replace gas control valve/thermostat. D) Control harness defective. Replace harness. E) Igniter defective. Replace ignitor. F) Unit has completed three trials to light

and fail.

3) Thermostat problems

A) Thermostat set too low. Set temperature control higher. B) Thermostat or ECO defective. Replace thermostat. C) High limit control circuit open. Replace high limit control.

4) Others

A) Heater undersized. Reduce hot water usage. B) Low gas pressure. Contact a qualiﬁ ed person for service. C) Incoming water is unusually cold. Allow more time for heater to re-heat. D) Leaking hot water pipes or ﬁ xtures. Have plumber check and repair leaks.

Improperly sealed, hot or cold supply connections, relief valve, drain valve or thermostat threads.

Leakage from other appliances or water lines.

Condensation of ﬂ ue products. Refer to "CONDENSATION" Thermal expansion in closed water sys-

tem Improperly seated valves Check relief valve for proper operation

High sulfate or mineral content in water supply or iron or sulfate reducing bacteria in water supply

SERVICE TO BE PERFORMED

Check for low voltage, less than 102 vac., have service checked and repaired.

Reset cycle by turning switch off and then back on. If unit does not light in three trials, contact a qualiﬁ ed person for service.

Turn off heater & water, repair unit.

Inspect other appliances near water heater.

Install thermal expansion tank (DO NOT PLUG T&P V ALVE)

(DO NOT PLUG T&P VALVE) Drain and ﬂ ush heater thoroughly, chlori-

nate, reﬁ l and ﬂ ush again then chlorinate water supply.

Page 19

WARNING: DO NOT BY-PASS ANY CONTROLS TO MAKE HEATER OPERATE.

OPERATE ONLY AS WIRED FROM FACTORY.

TROUBLE SHOOTING

Please check guidelines below. For your safety, water heater service should be performed only by a qualiﬁ ed service technician.

Read the GENERAL SAFETY INFORMATION section ﬁ rst.

# LED STATUS PROBLEM SOLUTION

1 Ensure the wall outlet (power supply) is properly

The gas control valve/thermostat

has sensed inadequate or no earth ground.

The gas control valve/thermostat has sensed reversed polarity in the 120 VAC power supply.

Pressure switch circuit remaining closed for more than 5 seconds after heating cycle begins.

Blower may not start in this condition.

grounded.

2 Ensure all ground connections/wires on the water

heater are securely connected.

1 Ensure the wall outlet/power supply is properly wired. 2 Ensure all internal 120 VAC wiring connections and

wiring harness have no reversed wires. 120 VAC "hot" wire must connect to the on/off switch.

1 Ensure air pressure switch circuit wiring is correct and

the air pressure switch is not jumpered.

2 Replace the air pressure switch.

1 Ensure the air pressure switch sensing tube is properly

connected at both ends and is not kinked or damaged.

Pressure switch circuit remains open longer than 5 seconds after

the blower is energized.

Blower may run continuously in this condition.

The gas control valve/thermostat has detected an open igniter circuit.

Ignition/ﬂ ame failure. The gas control valve/thermostat

has reached the maximum number of retries (3) for ignition and is currently locked out for one hour.

Cycle the power to the water heater off and on to reset.

2 Ensure the correct size of vent and intake air pipe (direct

vent products) was used per the installation instructions in the manual that came with the water heater.

3 Ensure maximum number of elbows or maximum

equivalent feet of vent or intake air pipe has not been exceeded per the installation instructions in the manual that came with the water heater.

4 Ensure there are no obstructions in the vent or intake air pipe. 1 Check wiring to the hot surface igniter assembly -

replace igniter assembly if wiring is damaged or worn.

2 Check resistance of the igniter at igniter assembly

plug - should be between 11 and 18 ohms at room temperature (77° F at plug end) - replace igniter if open or shorted.

3 Check igniter assembly plug and the socket on the gas

control valve/thermostat for good connection. 4 Replace igniter assembly if the plug is worn or damaged. 5 Replace the gas control valve/thermostat if the igniter

assembly socket on the bottom of the control is worn or

damaged. 1 Ensure ﬂ ame sensor is making good contact with the

burner ﬂ ame and ensure ﬂ ame is steady. Also ensure

supply and manifold gas pressures are within the

requirements in the installation manual. 2 Gas supply is turned off - pressure is too low. 3 Ensure the ﬂ ame sensor is clean - use ﬁ ne steel wool

to clean the ﬂ ame sensor. 4 Check igniter assembly plug and the socket on the

bottom of the gas control valve/thermostat for good

connection. Replace igniter assembly if the plug is worn

or damaged. Replace the gas control valve/thermostat if

socket is worn or damaged. 5 Replace igniter assembly.

Page 20

# LED STATUS PROBLEM SOLUTION

Self diagnostic check has detected a problem with the gas valve driver circuit, internal microprocessor, or other internal circuits.

The gas control valve/thermostat has sensed main burner ﬂ ame out of proper sequence.

Water temperature in the tank has exceeded 195° F and has activated the ECO (energy cut off) high temperature limit.

Self diagnostic check has detected that one or both of the temperature adjust buttons are stuck.

Self diagnostic check has detected the water temperature sensor (located in the control valve's immersion probe) is either open or shorted.

Self diagnostic check has detected the FV (ﬂ ammable vapor) sensor is either open or shorted.

1 Turn the power off for 10-20 seconds then on again to

clear these error codes.

2 If any of these error codes persist or cannot be cleared

- replace the gas control valve/thermostat.

1 Turn the power off for 10-20 seconds then on again to

clear these error codes.

2 Replace the gas control valve/thermostat if this error

code persists.

1 Turn the power off for 10-20 seconds then on again to

clear these error codes.

2 Replace the gas control valve/thermostat if the error

code persists.

1 Press and release both temperature adjust buttons

several times - cycle water heater power off and on.

2 Replace the gas control valve/thermostat if the error

code persists.

1 Turn the power off for 10-20 seconds then on again to

clear these error codes.

2 Replace the gas control valve/thermostat if the error

code persists.

1 Turn off power to the water heater. Ensure all FV

sensor wiring, the ignitor assembly plug, and the ignitor assembly socket on the bottom of the Intellivent control are making good contact. Repair or replace any worn/damaged components that are not making good connection.

Self diagnostic check has detected the presence of ﬂ ammable vapors from the FV (ﬂ ammable vapor) sensor.

The gas control valve/thermostat has detected the air pressure switch circuit is opening repeatedly during one heating cycle.

LDO (Lint, Dust, and Oil) lockout condition.

2 Replace the FV sensor. 1 Do not touch any electrical switch, do not use any

phone in your building, and do not try to light any appliance.

2 Smell around the water heater to ensure there are

no gas leaks at the gas control valve/thermostat, in the supply gas line(s), or any other type of ﬂ ammable vapor(s) in the area.

3 Carefully inspect the area surrounding the water heater

for any substances such as gasoline, paint, paint thinners, varnish, or cleaners that could emit ﬂ ammable vapors. Remove anything that can potentially emit ﬂ ammable vapors from the area and store it properly in a different location.

4 Call the technical information support phone number

shown on the water heater labeling for further assistance.

1 On models equipped with a dilution air intake screen on

the blower assembly - check/clean this screen.

2 On models equipped with a combustion air intake

screen on the base ring (bottom) of the water heater check/clean the screen.

3 Ensure intake air screen(s) on models so equipped are

not obstructed.

Page 21

NOTES

Page 22

NOTES

Page 23

NOTES

Page 24

ALL TECHNICAL AND W ARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, CONTACT RESIDENTIAL TECHNICAL ASSIST ANCE A T 1-800-527-1953 COPYRIGHT © 2012, INC. ALL RIGHTS RESER VED.