State Industries GP6 50 YTPDT 120, GP6 50 HTPDT 120, GP6 50 HTPDT 121, GP6 50 YTPDT 121 User Manual
RESIDENTIAL GAS WATER HEATERS
Ashland City, TN 37015
www.statewaterheaters.com
Instruction Manual
POWER VENT/POWER DIRECT VENT GAS MODELS
WITH HOT SURFACE IGNITION
• For Your Safety •
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
PRINTED 0410 317447-000
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
1
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
TABLE OF CONTENTS
TABLE OF CONTENTS ........................................................................2
SAFE INSTALLATION, USE AND SERVICE........................................3
APPROVALS ........................................................................................3
GENERAL SAFETY INFORMATION ....................................................4
Precautions .....................................................................................4
Grounding Instructions ...................................................................4
Hydrogen Gas Flammable ..............................................................4
TROUBLESHOOTING .........................................................................6
INTRODUCTION ..................................................................................7
Abbreviations Used ........................................................................7
Qualications ..................................................................................7
Qualied Installer or Service Agency ........................................7
iCOMM™ & BACnet Compatible ....................................................7
Preparing For The Installation ........................................................7
FEATURES AND COMPONENTS .......................................................8
INSTALLATION CONSIDERATION ......................................................9
Rough in Dimensions .....................................................................9
Locating The Water Heater ...........................................................10
Insulation Blankets .......................................................................11
Combustion Air and Ventilation .....................................................11
Unconned Space ........................................................................11
Unusually Tight Construction ..................................................12
Conned Space ............................................................................12
Direct Vent Appliances ...........................................................12
Exhaust Fans .........................................................................12
Louvers and Grilles ................................................................12
Fresh Air Openings For Conned Spaces ....................................12
Outdoor Air Through Two Openings .............................................12
Outdoor Air Through One Opening ...............................................12
Outdoor Air Through Two Horizontal Ducts ..................................13
Air From Other Indoor Spaces ......................................................13
INSTALLING THE NEW WATER HEATER ........................................14
Chemical Vapor Corrosion ............................................................14
Water Piping .................................................................................14
Power Supply ...............................................................................14
Power Fluctuations and Electrical Noise ................................14
Dedicated Power Wiring and Breakers ..................................14
Polarity Sensitive ....................................................................14
Mixing Valves ................................................................................15
Dishwashing Machines .................................................................15
Space Heating and Potable Water System ..................................15
Closed Water Systems .................................................................15
Thermal Expansion .......................................................................16
Temperature-Pressure Relief Valve ..............................................17
T&P Valve Discharge Pipe Requirements: .............................17
Gas Piping ....................................................................................18
Condensate Piping .......................................................................18
High Altitude Installations .......................................................19
Sediment Traps ......................................................................19
Filling the Water Heater ................................................................19
Venting ..........................................................................................20
Vent Pipe Termination ............................................................20
Planning the Vent System ......................................................20
Installation of Vent System .....................................................21
Vent Terminal Installation, Sidewall ........................................21
Installation Requirements - Commonwealth of Massachusetts ....22
Termination Clearances Sidewall Power Vent ..............................23
Termination Clearances Sidewall Direct Vent ...............................24
Sequence of Installations, Figure 18A ....................................25
Direct Vent Terminal Installation .............................................25
Installation Sequence .............................................................25
Vent Terminals Supplied with Heater Must be Used. .............25
Vertical Vent Terminal Installation ...........................................26
Concentric Vent Installation ....................................................27
Kit Components ......................................................................27
Safety Considerations ............................................................27
Installation Procedure 1 Roof Termination, see Figure C ......27
DIRECT VENT DIAGRAM ..................................................................30
Vent Pipe Preparation...................................................................31
Primer .....................................................................................31
Primer and Cement ................................................................31
Applicators ..............................................................................31
Controls and Switches ..................................................................33
Blower Prover Switch .............................................................33
Blocked Exhaust Switch .........................................................33
Blocked Intake Switch ............................................................33
On/Off Switch .........................................................................33
Hot Surface Igniter .................................................................33
TEMPERATURE REGULATION ........................................................36
Hi Limit Switch (E.C.O.) ................................................................36
CONTROL SYSTEM OPERATION ....................................................37
Overview .......................................................................................37
Commercial And Residential Models ......................................37
Control System Navigation ...........................................................37
User Input Buttons ..................................................................37
The Desktop Screen ...............................................................37
Status Icons ............................................................................38
Operating States ....................................................................39
Control System Menus ...........................................................39
User Settings & Control System Menus .......................................40
Temperatures .........................................................................40
Operating Set Point And Differential Adjustment ....................40
Temperatures (cont) ...............................................................41
Heater Status .........................................................................41
Display Settings ......................................................................42
Heater Information ..................................................................42
Current Fault ..........................................................................43
Fault History ...........................................................................43
Fault Occurrence ....................................................................43
Restore Factory Defaults ........................................................43
Service Contact Information ...................................................44
FOR YOUR INFORMATION ...............................................................45
Start Up Conditions ......................................................................45
Smoke/Odor ...........................................................................45
Thermal Expansion ................................................................45
Operational Conditions .................................................................45
Smelly Water ..........................................................................45
“Air” in Hot Water Faucet ........................................................45
PERIODIC MAINTENANCE ...............................................................46
Venting System Inspection ...........................................................46
Anode Rod Inspection ..................................................................46
Temperature-Pressure Relief Valve Operation .............................46
Draining and Flushing ...................................................................46
To Drain the Water Heater Storage Tank ......................................47
To Flush the Water Heater Storage Tank ......................................47
Service ..........................................................................................47
MAINTENANCE .................................................................................48
Temperature-Pressure Relief Valve Test ......................................48
LEAKAGE CHECKPOINTS ................................................................49
TROUBLESHOOTING .......................................................................50
Installation Checklist .....................................................................50
Water Heater Location............................................................50
Venting ...................................................................................50
Gas Supply and Piping ...........................................................50
Condensate Drain ..................................................................50
Electrical Connections ............................................................50
Sequence Of Operation Flow Chart .............................................51
Operational Problems ...................................................................52
Rough Starting, Rough Operation ..........................................52
Momentary Ignition .................................................................52
Not Enough Or No Hot Water .................................................52
Water Is Too Hot .....................................................................52
Noisy Operation ......................................................................52
Replacement Parts .................................................................52
Fault and Alert Conditions ............................................................52
Fault Conditions .....................................................................52
Alert Conditions ......................................................................52
Resetting Control System Lock Outs .....................................53
Diagnostic Checks ..................................................................53
Fault and Alert Messages .......................................................54
NOTES ...............................................................................................56
LIMITED WARRANTY ........................................................................59
2
DANGER
WARNING
CAUTION
CAUTION
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
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.
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
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
SAFE INSTALLATION, USE AND SERVICE
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.
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.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances
known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of
potential exposure to such substances.
This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This
appliance can cause low level exposure to some of the substances listed in the Act.
APPROVALS
3
Explosion Hazard
Flammable hydrogen gases
may be present.
Keep all ignition sources away
from faucet when turning on
hot water.
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.
Te mperature 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 temperature and
pressure 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 flood damaged.
•
Inspect and anode rods regularly, replace if damaged.
•
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.
CAUTION
GENERAL SAFETY INFORMATION
PRECAUTIONS
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER
WATER. Immediately call a qualied service agency to inspect the
appliance 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 agency.
1. External re.
2. Damage.
3. Firing without water.
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 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.
HYDROGEN GAS FLAMMABLE
Hydrogen gas can be produced in a hot water system served by this
appliance that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely ammable. To
reduce the risk of injury under these conditions, it is recommended
that a hot water faucet served by this appliance be opened for
several minutes before using any electrical appliance connected
to the hot water system. If hydrogen is present there will probably
be an unusual sound such as air escaping through the pipe as the
water begins to ow. THERE SHOULD BE NO SMOKING OR OPEN
FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.
Verify the power to the water heater is turned off before performing any service procedures.
4
GENERAL SAFETY INFORMATION
5
Fire Hazard
Do not install water heater on
carpeted floor.
Do not operate water heater if
flood damaged.
For continued protection against
risk of fire:
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 water heater controls 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
Fire and Explosion Hazard
Leak test before placing the
water heater in operation.
Disconnect gas piping and main
gas shutoff valve before leak
testing.
Install sediment trap in
accordance with NFPA 54.
Use joint compound or Te flon tape
compatible with propane gas.
Fire and Explosion Hazard
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
Excessive gas pressure to gas valve can
cause serious injury or death.
Do not use water heater with any gas
other than the gas shown on the rating
plate.
Turn off power to the water heater
before performing any service.
Electrical Shock Hazard
•
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.
•
Jumping out control circuits or components can
result in property damage, personal injury or death.
Service should only be performed by a qualified service
agent using proper test equipment.
•
Altering the water heater controls and/or wiring in any way
could result in permanent damage to the controls or water
heater and is not covered under the limited warranty.
•
Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the appliance warranty.
Altering the water heater controls and/or wiring in any way
could result in altering the ignition sequence allowing gas to
flow to the main burner before the hot surface igniter is at
ignition temperature causing delayed ignition which can
cause a fire or explosion.
•
GENERAL SAFETY INFORMATION
6
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
• GAMA - Gas Appliance Manufacturer’s Association
• 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.”
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.
ICOMM™ & BACNET COMPATIBLE
This water heater is compatible with the iCOMM™ remote monitoring
system. The iCOMM™ system hardware and monitoring service is
purchased separately. It allows users to monitor critical operational,
diagnostic and energy usage data from a secure web site.
The iCOMM™ system can automatically notify selected personnel
via email and/or cellular phone text messages if operational
problems or user dened Alert Conditions occur.
Detailed installation diagrams are also found in this manual.
These diagrams will serve to provide the installer with a
reference. It 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 on page 8 in this manual. Use
this reference to locate and identify various components on the
water heater.
See the Installation Checklist and Troubleshooting on page 50.
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.
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.
All documents are available from 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.
iCOMM™ system hardware is compatible with BACnet compliant
supervisory controls and building management systems. For more
information call 888 928-3702.
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 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.
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 10 and the Rough In
Dimensions on page 9.
.
6. For installation in California this water heater must be braced or
anchored to avoid falling or moving during an earthquake. See
instructions for correct installation procedures. Instructions may
be obtained from California Ofce of the State Architect, 1102 Q
Street, Suite 5100, Sacramento, CA 95811.
7. Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5. See Commonwealth of Massachusetts
on page 22.
7
FEATURES AND COMPONENTS
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A Control Assembly
B Blocked Inlet Switch
C Blocked Outlet Switch
D Fan Prover Switch
E Blower Assembly
F Burner Assembly
G Flame Sensor
H Hot Surface Igniter
I Junction Box
J Gas Valve Assembly
K Display Board
L Top Plastic Enclosure
M Display Enclosure
** N Exhaust Elbow Assembly
** O Condensate Tubing
P Off/On Switch
Q Display Label
R Hot Water Outlet
T Gas Supply
U Main Manual Gas Shutoff Valve
V Union
W Inlet Water Shutoff Valve
X Cold Water Inlet
Y Inlet Dip Tube
REPLACEMENT PARTS AND DELIMING PRODUCTS
Replacement parts and recommended delimer may be ordered through
authorized servicers or distributors. When ordering parts, provide complete
model and serial numbers (see rating plate), quantity and name of part
desired. Standard hardware items may be purchased locally.
Z T/P Relief Valve
AA Rating Plate
BB Labels
CC Drain Valve
** DD Vent Terminal
EE Drain Pan
FF Anode
GG Insulation
HH Upper Temperature Probe
II Access Door
VACUUM RELIEF
VALVE
*INSTALL PER
LOCAL CODES
* CAUTION HARNESS HAS 120 VAC. IN OPERATION.
** See “Planning the Vent System,” “Installation of Vent System” and “Condensate Piping” for more information.
FIGURE 1.
8
ACCESS PANEL
Caution:
This access panel covers
a 2” NPT plug that was required
during the manufacturing of this
water heater. This 2” NPT ange is
not a cleanout tting, removing the
2” NPT plug and using this tting as a
cleanout could void your warranty.
ROUGH IN DIMENSIONS
INSTALLATION CONSIDERATION
FIGURE 1A.
Rough-In-Dimensions
Units A B C D E F
Inches 66.75 49.25 22.00 15.75 3.00 8.00
cm 169.5 125.09 55.88 40.00 7.62 20.32
Top/Side Inlet and Outlet: 3/4” NPT
Gas Inlet: 1/2” NPT
Capacity, Gas and Electrical Characteristics
Approximate Capacity Manifold Pressure Electrical Characteristics
U.S. Gals. Liters Gas Type “WC kPA Volts/Hz Amperes
50 189 Nat./LP 0” 0” 120/60 <5
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.
Recovery Capacities - U.S. Gallons/Hr. and Liters/Hr. at Temperature Rise Indicated
Input Recovery Capacities
Rating
(Btu/hr)
100,000 29.3
Recovery capacity based on 96% thermal efciency
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 387 291 233 194 166 145 129 116 106 97 90 83
LPH 1465 1102 882 734 628 549 488 439 401 367 341 314
9
LOCATING THE WATER HEATER
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
CAUTION
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 appliance.
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.
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, adequately drained, be installed under the
appliance.
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 14 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 11.
9. Locate the water heater where the vent and intake air piping,
when installed, will remain within the maximum equivalent
lengths allowed. See Venting on page 20.
10. Do not locate the water heater where noise (such as
the Combustion Blower) during normal operation will be
objectionable in adjacent areas.
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 starting on page 20.
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS
(VA P ORS ) A RE LIK ELY TO BE PR ESE NT OR ST ORE D
(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 hot surface igniter or
main burner. The resulting ashback and re can cause death or
serious burns to anyone in the area.
Also, the water heater must be located and/or protected so it is not
subject to physical damage by a moving vehicle.
This water heater must not be installed directly on carpeting.
Carpeting must be protected by metal or wood panel beneath the
appliance extending beyond the full width and depth of the appliance
by at least 3” (7.6 cm) in any direction, or if the appliance is installed
10
in an alcove or closet, the entire oor must be covered by the panel.
Failure to heed this warning may result in a re hazard.
Minimum clearances between the water heater and combustible
construction are 0 inch at the sides and rear, 5.5” (14.0 cm) from
the front and 18” (45.7 cm) from the top. (Standard clearance.) If
clearances stated on the heater differ from standard clearances, install
water heater according to clearances stated on the heater.
Adequate clearance 30” (76 cm) for servicing this appliance should be
considered before installation, such as changing the anodes, control
system components and gas valve.
A minimum clearance of 5.5” (14.0 cm) must be allowed for access to
replaceable and/or serviceable parts such as the thermostats, drain
valve, condensate drain, relief valve, clean out opening, and the vent
connection (exhaust elbow).
• Do not apply insulation to the top of the water heater, as this will
interfere with safe operation of the blower assembly.
• 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.
• Do obtain new warning and instruction labels from the manufacturer
for placement on the blanket directly over the existing labels.
COMBUSTION AIR AND VENTILATION
A gas water heater cannot operate properly without the correct
amount of air for combustion. Do not install in a conned area such
as a closet, unless you provide air as shown in the “Facts to Consider
About Location” section. 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.
When installing the heater, consideration must be given to proper
location. Location selected should be as close to the wall as practicable
and as centralized with the water piping system as possible.
FIGURE 2.
INSULATION BLANKETS
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 Figure 1). Failure to follow these instructions
can restrict the air ow required for proper combustion, potentially
resulting in re, asphyxiation, serious personal injury or death.
FIGURE 3.
If this water heater will be used in beauty shops, barber shops,
cleaning establishments, or self-service laundries with dry cleaning
equipment, 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
hydrochloric acid when exposed to the combustion products of
the water heater. The results can be hazardous, and also cause
product failure.
UNCONFINED SPACE
An Unconned Space is one whose volume IS NOT LESS THAN
50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the
total input rating of all appliances installed in the space. Rooms
communicating directly with the space, in which the appliances are
installed, through openings not furnished with doors, are considered
a part of the unconned space.
Makeup air requirements for the operation of exhaust fans, kitchen
11
ventilation systems, clothes dryers and replaces shall also be
considered in determining the adequacy of a space to provide
combustion, ventilation and dilution air.
UNUSUALLY TIGHT CONSTRUCTION
In unconned spaces in buildings, inltration may be adequate to
provide air for combustion, ventilation and dilution of ue gases.
However, in buildings of unusually tight construction (for example,
weather stripping, heavily insulated, caulked, vapor barrier, etc.)
additional air must be provided using the methods described in the
Conned Space section that follows.
CONFINED SPACE
A Conned Space is one whose volume IS LESS THAN 50 cubic
feet per 1,000 Btu/hr (4.8 cm per kW) of the total input rating of all
appliances installed in the space.
Openings must be installed to provide fresh air for combustion,
ventilation and dilution in conned spaces. The required size for
the openings is dependent on the method used to provide fresh
air to the conned space AND the total Btu/hr input rating of all
appliances installed in the space.
OUTDOOR AIR THROUGH TWO OPENINGS
FIGURE 4.
DIRECT VENT APPLIANCES
Appliances installed in a Direct Vent conguration that derive all
air for combustion from the outdoor atmosphere through sealed
intake air piping are not factored in the total appliance input Btu/hr
calculations used to determine the size of openings providing fresh
air into conned spaces.
EXHAUST FANS
Where exhaust fans are installed, additional air shall be provided
to replace the exhausted air. When an exhaust fan is installed in
the same space with a water heater, sufcient openings to provide
fresh air must be provided that accommodate the requirements
for all appliances in the room and the exhaust fan. Undersized
openings will cause air to be drawn into the room through the water
heater’s vent system causing poor combustion. Sooting, serious
damage to the water heater and the risk of re or explosion may
result. It can also create a risk of asphyxiation.
LOUVERS AND GRILLES
The free areas of the fresh air openings in the instructions that
follow do not take in to account the presence of louvers, grilles or
screens in the openings.
The required size of openings for combustion, ventilation and
dilution air shall be based on the “net free area” of each opening.
Where the free area through a design of louver or grille or screen is
known, it shall be used in calculating the size of opening required to
provide the free area specied. Where the louver and grille design
and free area are not known, it shall be assumed that wood louvers
will have 25% free area and metal louvers and grilles will have 75%
free area. Non motorized louvers and grilles shall be xed in the
open position.
The conned space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. The openings shall communicate directly with the
outdoors. See Figure 4.
Each opening shall have a minimum free area of 1 square inch per
4,000 Btu/hr (550 mm
appliances installed in the enclosure. Each opening shall not be
less than 100 square inches (645 cm2).
2
per kW) of the aggregate input rating of all
OUTDOOR AIR THROUGH ONE OPENING
FIGURE 5.
FRESH AIR OPENINGS FOR CONFINED SPACES
The following instructions shall be used to calculate the size, number
and placement of openings providing fresh air for combustion,
ventilation and dilution in conned spaces. The illustrations shown
in this section of the manual are a reference for the openings that
provide fresh air into conned spaces only. DO NOT refer to these
illustrations for the purpose of vent installation. See Venting Installation
on page 20 for complete venting installation instructions.
Alternatively a single permanent opening, commencing within 12
inches (300 mm) of the top of the enclosure, shall be provided.
See Figure 5. The water heater shall have clearances of at
least 1 inch (25 mm) from the sides and back and 6 inches (l50
mm) from the front of the appliance. The opening shall directly
communicate with the outdoors or shall communicate through a
vertical or horizontal duct to the outdoors or spaces that freely
communicate with the outdoors and shall have a minimum free
area of the following:
12
1. 1 square inch per 3000 Btu/hr (700 mm2 per kW) of the total
input rating of all appliances located in the enclosure, and
2. Not less than the sum of the areas of all vent connectors in the space.
OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS
AIR FROM OTHER INDOOR SPACES
FIGURE 6.
The conned space shall be provided with two permanent horizontal
ducts, one commencing within 12 inches (300 mm) of the top and
one commencing within 12 inches (300 mm) of the bottom of the
enclosure. The horizontal ducts shall communicate directly with the
outdoors. See Figure 6.
Each duct opening shall have a minimum free area of 1 square inch
per 2,000 Btu/hr (1100 mm2 per kW) of the aggregate input rating of
all appliances installed in the enclosure.
When ducts are used, they shall be of the same cross sectional area
as the free area of the openings to which they connect. The minimum
dimension of rectangular air ducts shall be not less than 3 inches.
FIGURE 7.
The conned space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. See Figure 7.
Each opening shall communicate directly with an additional room(s)
of sufcient volume so that the combined volume of all spaces
meets the criteria for an Unconned Space.
Each opening shall have a minimum free area of 1 square inch per
1,000 Btu/hr (1100 mm
appliances installed in the enclosure. Each opening shall not be
less than 100 square inches (645 cm
2
per kW) of the aggregate input rating of all
2
).
13
INSTALLING THE NEW WATER HEATER
CHEMICAL VAPOR CORROSION
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. (See
limited warranty for complete terms and conditions).
WATER PIPING
This water heater shall not be connected to any heating systems or
component(s) used with a non-potable water heating appliance.
All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
Toxic chemicals, such as those used for boiler treatment shall not
be introduced into this system.
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 Figure 8 for suggested
piping arrangement.
POWER SUPPLY
The water heaters covered in this manual require a 120 VAC,
1Ø (single phase), 60Hz, 15 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.
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
electrical line noise such as EMI (electro magnetic interference)
or RFI (radio frequency interference) may cause erratic control
system operation and malfunction.
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 6. Valves
for reducing point of use temperature by mixing cold and hot
water are also available:
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 in this manual.
A high quality power supply lter/suppressor such as the Kleen Line
model SELF/T-10 Series SC-L or equivalent must be installed if the
above conditions exist. Call the technical support phone number
listed on the back cover of this manual 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.
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.
POLARITY SENSITIVE
The control system on the water heaters covered in this manual is
polarity sensitive; electronic ame sensing requires correct polarity.
The control system is programmed to monitor the incoming power
supply. If the Hot and Neutral wires in the 120 VAC power supply
are reversed, the control system will declare a Fault condition and
lock out, heating operation will be disabled until the power supply is
correctly wired. The control system will display the “AC Reversed”
Fault message on the LCD.
14
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.
Te mperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
HOT WATER
OUTLET
TO TANK
INLET
CHECK
VAL VE
MIXING
VAL VE
COLD
WATER
INLET
TEMPERED WATER
OUTLET
12” TO 15”
(30-38 cm)
CHECK
VAL VE
in improperly sanitized dishes. Where pressures are high, a water
pressure reducing or ow regulating control valve should be used in
the line to the dishwashing machine and should be adjusted to deliver
water pressure between these limits.
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 1 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 (see Figure 8) or at the hot water taps
to further reduce system water temperature.
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.
Table 1
Water Temperature
Time to Produce 2nd & 3rd
Degree Burns on Adult Skin
160°F (71°C) About 1/2 second
150°F (66°C) About 1-1/2 seconds
140°F (60°C) Less than 5 seconds
130°F (54°C) About 30 seconds
120°F (49°C) More than 5 minutes
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
FIGURE 8.
SPACE HEATING AND POTABLE WATER SYSTEM
Your water heater is equipped with inlet/outlet connections for use in
space heating applications (see Figure 9). 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.
• 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 tempering valve (provided) must be installed per the
manufacturer’s instructions in the potable hot water supply to limit
the risk of scald injury.
• Pumps, valves, piping and ttings must be compatible with potable
water.
• A properly installed flow 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 and pressure relief valve (T
& P) 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
tempering 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 heating appliances when
used to supply potable water.
15
FIGURE 9.
CLOSED WATER SYSTEMS
Water supply systems may, because of code requirements or such
conditions as high line pressure, among others, have installed
devices such as pressure reducing valves, check valves, and back
ow preventers. Devices such as these cause the water system to
be a closed system.
FIGURE 10.
NOTE: To protect against untimely corrosion of hot and cold
water ttings, it is strongly recommended that di-electric unions
or couplings be installed on this water heater when connected
to copper pipe, see Figure 10 also.
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.
Figures 9 and 10 show the typical attachment of the water piping to
the water heater. The water heater is equipped with 3/4 inch NPT
water connections.
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 harm the dip tube and damage the tank.
T & P Valve and Pipe Insulation (if supplied)
Remove insulation for T & P valve and pipe connections from
carton.
FIGURE 11.
16
Fit pipe insulation over the incoming cold water line and the hot
Explosion Hazard
Te mperature-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.
Water Damage Hazard
Te mperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
•
CAUTION
Burn hazard.
Hot water discharge.
Keep clear of TemperaturePressure Relief Valve
discharge outlet.
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
This water heater is provided with a properly rated/sized and
certied combination Temperature-Pressure Relief Valve (T&P
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.
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 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.
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 relief
valve and the drain.
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 above 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
input rate as shown on the water heater’s model rating plate.
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. Call the toll free
technical support phone number listed on the back cover of
this manual for technical assistance in sizing a TemperaturePressure Relief Valve for remote storage tanks.
For safe operation of the water heater, the TemperaturePressure 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 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.
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
Temperature-Pressure 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 pages 15 and 16.
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.
17
GAS PIPING
Make sure gas supplied is same type listed on model rating plate.
The inlet gas pressure must not exceed 14 inch water column (3.5
kPa) for natural and propane gas (L.P.). The minimum inlet gas
pressure shown on rating plate is that which will permit ring at
rated input.
All gas piping must comply with local codes and ordinances or with the
National Fuel Gas Code (ANSI Z223.1/ NFPA-54). 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 appliances is used, also
turn “off” the gas at each appliance. Leave all gas appliances shut
“off” until the water heater installation is complete.
Consideration must be given to avoid freezing of the condensate
lines which could result in excessive build up of condensate inside
the water heater.
freezing of the condensate
condensate drain does not create a slippery condition which could
lead to personal injury.
CONDENSATION WARNING: THIS WATER HEATER IS A
CONDENSING UNIT AND REQUIRES A DRAIN TO BE LOCATED
IN CLOSE PROXIMITY TO ALLOW CONDENSATE TO DRAIN
SAFELY. THE CONDENSATE DRAINS FROM UNIT AT THE
EXHAUST ELBOW LOCATED AT BOTTOM OF UNIT. NOTE:
IT IS IMPORTANT THAT THE CONDENSATE HOSE NOT BE
ELEVATED ABOVE THE EXHAUST ELBOW, SEE FIGURE 12.
CONDENSATE BUILD-UP WILL BLOCK THE EXHAUST OUTLET,
WHICH WILL CAUSE IMPROPER OPERATION.
Waterproof heat tape may be required to prevent
lines. Please ensure that the outlet of the
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) 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 drip leg (sediment trap) ahead of the gas control valve to help
prevent dirt and foreign materials from entering the gas control
valve.
• A exible gas connector or a ground joint union between the shut
off valve and 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 dry.
CONDENSATE PIPING
This water heater is a condensing unit and requires a drain to be
located in close proximity to allow the condensate to drain safely.
The condensate drains from the unit at the exhaust tee located at
the bottom of the unit (see gure 12). Condensate from this water
heater is mildly acidic. Please note that some local codes require
that condensate is treated by using a pH neutralizing lter prior to
disposal.
Caution must be used to ensure that the drain is free and clear of
debris and will not allow backow through the condensate hose.
FIGURE 12
The condensate drain line must be routed to a suitable drain. If
no oor drain is available or the drain is above the level of the
condensate line, install a condensate pump that is resistant
to the acidic condensate. These pumps are available from
local distributors. If the pump is not resistant to acidic water,
a condensate neutralizer must be used ahead of the pump.
When installing the drain line, note the following:
• Plastic pipe or tubing must be used to connect the condensate
drain to a suitable drain or condensate pump. Do not use copper
tubing, iron, or steel pipe for the condensate drain line.
• Condensate drain lines should be installed in conditioned
areas only. Drain lines installed in areas that are subject to
freezing temperatures should be wrapped with a nationally
recognized/listed heat tape and/or approved insulation for
freeze protection. Install per manufacturer’s instructions.
• Do not common drain with the temperature and pressure relief
valve or the condensate line from an air conditioner evaporator
coil.
• Slope the condensate drain toward the inside oor drain or
condensate pump.
• The condensate drain line and connection to the drain piping
must comply with all local codes.
18
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