State Industries U287-084, Tankless On-Demand 705 User Manual

Direct Vent Tankless Water Heater

Operation and Installation Manual

Models:

305 505 705

FOR INDOOR APPLICATIONS ONLY

Models 305 and 505 are Energy Star Qualified

Table of Contents .................... 2

Consumer Safety Information .. 4

Operating Instructions .............. 5

Maintenance ............................ 8

ANS Z21.10.3

●

CSA 4.3

Error Codes ............................. 9

Installation Instructions ............ 13

Warranty .................................. 38

INSTALLER: Leave this manual with the appliance. CONSUMER: Retain this manual for future reference.

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

— Do not store or use gasoline or other flammable vapors and

liquids in the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in

your building.

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

Follow the gas supplier’s instructions.

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

department.

— Installation and service must be performed by a qualified

installer, service agency or the gas supplier.

Table of Contents

Specifications ..................................................... 3

Consumer Safety Information

Safety Definitions ............................................. 4

Safety Behaviors and Practices ....................... 4

Safety Features ............................................... 4

Description of Operation ................................... 5

Operating Instructions

Features Available on Temperature

Controllers ....................................................... 5

Setting the Temperature .................................. 6

Temperature Options Without

a Temperature Controller ................................ 6

Temperature Ranges ....................................... 7

Setting Controller to Mute ................................ 7

Maintenance

Cleaning ...................................................... 8

Vent System ................................................ 8

Motors ......................................................... 8

Temperature Controller ............................... 8

Lime / Scale Build-up .................................. 8

Snow Accumulation..................................... 8

Visual Inspection of Flame .......................... 8

Error Codes

Error Code Table ....................................... 9, 10

Trouble Shooting for Common Issues ........... 11

Accessing Operating Information .................. 11

Water Quality ................................................. 11

Flushing the Heat Exchanger ........................ 12

(Error Code: LC or 00)

Installation Instructions ................................... 13

General Instructions ...................................... 13

Clearances from Appliance ........................... 14

Attachment of the Water Heater .................... 14

Electrical Connection ..................................... 15

Gas Piping

General Instructions ................................ 15

Pipe Sizing Procedure - Example ........... 16

Water Piping

General Instructions ................................ 17

Pressure Relief Valve .............................. 17

Freeze Protection .................................... 17

Freeze Protection Piping ............................... 18

Recommended Piping for Basic Installation .. 19 Recommended Piping for

Circulation Systems ....................................... 20

Optional Piping for Circulation Systems ........ 21

Venting Instructions

Intake / Exhaust Guidelines .................... 22

Condensate ............................................. 22

Maximum Vent Length ............................ 23

Venting Products ........................................... 24

Flue Terminal Clearances (ANS Z21.10.3 ● CSA 4.3

Additional Clearances - Vent Terminal .......... 26

Flue Installation for 305 and 505 Models ...... 27

Flue Installation for 705 Model ................ 28, 29

High Altitude Installation ................................ 30

Connecting Multiple Water Heaters ............... 30

Temperature Controller Installation

Location ................................................... 31

Configurations ......................................... 31

Cable Lengths and Size .......................... 31

Mounting the Controller ........................... 32

Operating Instructions ................................... 33

Technical Data

Pressure Drop Curve ..................................... 34

Outlet Flow Data ............................................ 34

Space Heating ............................................... 35

Dimensions .................................................... 36

Ladder Diagram ............................................. 37

Warranty ...................................................... 38, 39

) ............................ 25

2 305, 505, 705 Indoor Manual

Specifications

Model

Minimum Gas Consumption Btu/h 15,000 19,000

Maximum Gas Consumption Btu/h 180,000

Hot water capacity (Min - Max) *

Hot water capacity (45°F rise) 6.6 GPM (25.0 L/min)

Default Temperature Setting (no controller) 120º F (49º C)

Temperature Controller Default Setting 104º F (40º C)

Maximum Temp Setting (Commercial) ** 160º F (71º C) 185º F (85º C)

Maximum Temp Setting (Residential) Selectable at 120º F (49º C) or at 140º F (60º C) 140º F (60º C)

Minimum Temperature Setting 98º F (37º C)

Weight 50 lb (23 kg) 55 lb (25 kg)

Efficiency Rating 84%

Noise level 49 dB

Normal 65 W 79 W 99 W

Electrical Consumption

By-Pass Control Fixed Electronic

Minimum Gas Supply Pressure

Maximum Gas Supply Pressure

Type of Appliance Direct Vent, Temperature controlled continuous flow gas hot water system.

Operation With or without temperature controls, mounted in kitchen, bathroom, etc.

Approved Gas Type Natural Gas or Propane - Ensure unit matches gas type it's being installed on.

Connections Gas Supply: 3/4" MNPT, Cold Water Inlet: 3/4" MNPT, Hot Water Outlet: 3/4" MNPT

Ignition System Direct Electronic Ignition

Electric Connections Appliance: AC 120 Volts, 60Hz. Temperature Control: DC 12 Volts (Digital)

Water Temperature Control Simulation Feedforward and Feedback.

Water Supply Pressure Minimum Water Pressure: 20 PSI (Recommended 30-80 PSI for maximum performance)

Maximum Water Supply Pressure 150 PSI

Temperature Control Cable Non-Polarized Two Core Cable (Minimum 22 AWG)

Energy Star Qualified Yes Yes No

Standby

Anti-frost Protection 100 W 116 W

Natural Gas 5.0 inch W.C.

Propane 8.0 inch W.C.

Natural Gas 10.5 inch W.C.

Propane 13.5 inch W.C.

305

0.6 - 7.5 GPM

(2.3 - 28.4 L/min)

505 705

199,000 Natural Gas

190,000 Propane Gas

0.6 - 9.4 GPM

(2.3 - 35.5 L/min)

7.4 GPM (28.0 L/min) Natural Gas

7.1 GPM (26.9 L/min)

Propane Gas

2 W

237,000

0.6 - 9.8 GPM

(2.3 - 37 L/min)

8.8 GPM (33.5 L/min)

* Minimum flow may vary slightly depending on the temperature setting and the inlet water temperature.

** for commercial and hydronic applications requiring higher temperatures

Specifications are subject to change without prior notice.

The maximum inlet gas pressure must not exceed the value specified by the manufacturer. The minimum value listed is for the purpose of input adjustment.

305, 505, 705 Indoor Manual 3

Consumer Safety Information

Safety Definitions

This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and

others.

DANGER

WARNING

CAUTION

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices.

Safety Behavior and Practices

WARNING

• Keep the area around the appliance clear and free from combustible materials, gasoline, and other flammable vapors and liquids.

• Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

• This appliance is equipped with a three-prong plug for your protection against shock hazard and should be plugged directly into a properly grounded threeprong receptacle. Do not cut or remove the ground prong from this plug.

• Any alteration to the appliance or its controls can be dangerous and will void the warranty.

• Always check the water temperature before entering a shower or bath.

Safety Features

• Overheat: The appliance will automatically shut down when the appliance exceeds a predetermined temperature.

• Flame Failure: The appliance will automatically shut down if the burner flame is extinguished.

• Power Failure: The appliance will cut off the gas if it loses electrical power.

• Power Surge Fuse: A glass fuse protects against overcurrent. If the fuse blows then all indicator lamps will be off.

• Fusible Link: In case the overheat feature does not prevent the temperature from rising then the fusible link will break shutting off the appliance.

4 305, 505, 705 Indoor Manual

Description of Operation

This appliance is one of the most advanced water heaters available. It provides a continuous supply of hot water at a preset temperature. This appliance is direct vent where air is brought in from the outside and combustion gases are exhausted to the outside.

While electricity, water, and gas supplies are connected, this appliance produces hot water whenever a hot water tap is open.

Ignition is electronic. There is no pilot light consuming gas while the water heater is not being used. The gas burner lights automatically when the hot water tap is

opened and goes out when the tap is closed.

Installation of the temperature controller is highly recommended. The temperature controller can set the temperature within a specific range and can provide error codes to diagnose any problems.

The temperature of the outgoing hot water is constantly monitored. This appliance may adjust the water flow in order to maintain the temperature setting. The water flow may vary from summer to winter due to the difference in ground water temperature.

Operating Instructions

Features Available on Temperature Controllers

The temperature controller is supplied with the appliance. Dimensions (inches): 3.5 W x 4.75 H x 0.75 D

In Use

Indicator

Priority

Indicator

Temperature

Display

Priority

Button

Temperature

Selection

On/Off Button

Features

Error Codes When a fault is detected an error code flashes at the temperature

In Use Indicator Indicates that hot water is being supplied (i.e. a hot water tap is

open).

On/Off Button Used to turn the water heater On or Off.

Priority Button / Indicator

Temperature Display Shows the temperature setting.

Indicates that this controller is setting the temperature . Priority can be switched to another controller by pressing its Priority Button when no hot water is running.

Description

Thermostat Increases or decreases the temperature setting.

305, 505, 705 Indoor Manual 5

Setting the Temperature

DANGER

1. Press the “Priority button” on the temperature controller. The green Priority light will glow indicating that this controller is controlling the temperature and that the water heater is ready to supply hot water.

The priority can only be changed

while no hot water is running.

Hot water can be dangerous, especially for infants or children, the elderly, or infirm. There is hot water scald potential if the thermostat is set too high.

Water temperatures over 125º F (51º C) can cause severe burns or scalding resulting in death.

Hot water can cause first degree burns with exposure for as little as:

3 seconds at 140º F (60º C)

20 seconds at 130º F (54º C)

8 minutes at 120º F (48º C)

Test the temperature of the water before placing a child in the bath or shower.

Do not leave a child or an infirm person in the bath unsupervised.

NOTICE

While any hot water is being provided, the temperature setting can only be adjusted between 98º F and 110º F.

NOTICE

Check local codes for the maximum water temperature setting allowed when used in nursing homes, schools, day care centers, and all other public applications.

2. Press the ▲ or ▼ buttons to

obtain the desired temperature setting.

All hot water sources are able to

provide water at this temperature

NOTICE

If a newly installed unit with a temperature controller has not been powered for at least 6 hours then the temperature will return to the default setting of 104º F (40º C) if power is

interrupted. setting until it is changed again at this or another temperature controller.

NOTICE

There may be a variation between the temperature displayed on the temperature controller and the temperature at the tap due to weather conditions or the length of pipe to the water heater.

Temperature Options Without a Temperature Controller

The default temperature setting for this appliance installed without a temperature controller is 120º F (49º C). If desired the temperature setting can be changed to 140º F (60º C) by adjustment of a dip switch.

Set dip switch 5 to ON to obtain 140º F water temperature setting.

Set dip switch 5 to OFF (default) to obtain 120º F

WARNING

DO NOT adjust the other dip switches unless specifically instructed to do so.

120º F (49º C) 140º F (60º C)

Switch No.

O F F

Switch No.

O F F

6 305, 505, 705 Indoor Manual

Temperature Ranges

This water heater will attempt to provide hot water at the temperature setting even when the water flow is varied or when more than 1 tap is in use. The water heater can deliver water at only one temperature setting at a time. The available temperatures for a given model are provided below.

Model

305

505

705

Temp in Celsius ºC 37 38 39 40 41 42 43 46 49 52 54 57 60 66 71 85

* Re-setting the Maximum Temperature Models 305 and 505 have a default maximum temperature of 120º F (49º C) and an option to increase the

maximum temperature to 140 ºF (60 ºC). Temperature settings from 125-140 ºF (52-60 ºC) are available by setting dip switch 6 to ON in the SW1 bank of 8 dip switches.

Model 705 has a default maximum temperature of 140 ºF (60 ºC).

** Commercial Controller These settings require the commercial controller which is for commercial and hydronic applications requiring

higher temperatures. When the commercial controller is connected, these higher temperatures are available on all controller models in the system.

98 100 102 104 106 108 110 115 120

98 100 102 104 106 108 110 115 120 125 130 135 140

Temperature Settings Available (ºF)

125 * 130* 135* 140* 150

125* 130* 135* 140* 150

150

160

185

The commercial controller is intended for commercial and hydronic applications only. If commercial controller is used in a residential dwelling for a hydronics application, a mixing valve must also be installed to limit the potable hot water temperature to a safe temperature. Water temperatures over 125º F (51º C) can cause severe burns or scalding. Refer to the Danger Alert on water temperatures. The manufacturer shall not, in any event, be liable for damages resulting from such misuse or misapplication.

Suggested temperatures are

• Kitchen 120 ºF (49º C)

• Shower 98º - 110º F (37º - 43º C)

To change the temperature scale from Celsius to Fahrenheit or vice versa, press and hold the “On/Off” button for 5 seconds while the water heater is OFF.

These temperatures are suggestions only.

A temperature lower than 98º F (37º C) can be obtained at the tap by mixing with cold water.

Setting Controller to Mute

To eliminate the beeps when keys are pressed or to turn the beeps back on, press and hold both the ▲and ▼ buttons until a beep is heard (approximately 5 seconds).

305, 505, 705 Indoor Manual 7

Maintenance

WARNING

Turn off the electrical power supply, the manual gas valve and the manual water control valve whenever servicing the unit.

Repairs and maintenance should be performed by a qualified service technician. The appliance should be inspected annually by a qualified service technician. Verify proper operation after servicing.

Cleaning

It is imperative that control compartments, burners, and circulating air passageways of the appliance be kept clean.

Clean as follows:

1. Turn off and disconnect electrical power. Allow to cool.

2. Remove and clean the water inlet filter.

3. Remove the front panel by removing 4 screws.

4. Use pressurized air to remove dust from the main burner, heat exchanger, and fan blades. Do not use a wet cloth or spray cleaners on the burner. Do not use volatile substances such as benzene and thinners. They may ignite or fade the paint.

Snow Accumulation

Keep the area around flue terminal free of snow and ice. The appliance will not function properly if the intake air or exhaust is impeded (blocked or partially blocked) by obstructions.

Visual Inspection of Flame

The burner must flame evenly over the entire surface when operating correctly. The flame must burn with a clear, blue, stable flame. See the parts breakdown of the burner for the location of the view ports.

The flame pattern should be as shown in the figures below.

5. Use soft dry cloth to wipe cabinet.

Vent System

The vent system should be inspected at least annually for blockages or damage.

Motors

Motors are permanently lubricated and do not need periodic lubrication. Keep fan and motor free of dust and dirt by cleaning annually.

Temperature Controller

Use a soft damp cloth to clean the temperature controller. Do not use solvents.

Lime / Scale Build-up

If you receive Error Code “LC”, refer to the procedure,

Flushing the Heat Exchanger. Refer to the section on Water Quality to see if your water needs to be treated

or conditioned. (When checking maintenance code history, “00” is substituted for “LC”.)

8 305, 505, 705 Indoor Manual

Error Codes

This appliance has the ability to check its own operation continuously. If a fault occurs, an error code will flash on the Display of the temperature controller. This assists with diagnosing the fault and may enable you to overcome a problem without a service call. Please identify the code displayed when inquiring about service.

WARNING

Some of the checks below may need to be done by a qualified service technician. Call a service technician for any remedy that involves gas or electricity. Call a service technician if you have any doubt or reservation about performing the remedy yourself.

Error Code Table

Code Fault Remedy

No burner operation during freeze protection mode

Air Supply or Exhaust Blockage

No Ignition Check that the gas is turned on at the water heater, gas meter, or cylinder.

Flame Failure Check that the gas is turned on at the water heater and gas meter. Check for

Service Call

Ensure approved venting materials are being used. Check that nothing is blocking the flue inlet or exhaust. Check all vent components for proper connections. Ensure vent length is within limits. Ensure condensation collar was installed correctly. Verify dip switches are set properly. Check fan for blockage.

Ensure gas type and pressure is correct. Ensure gas line, meter, and/or regulator is sized properly. Bleed all air from gas lines. Verify dip switches are set properly. Ensure appliance is properly grounded. Disconnect all 2-Unit or Multi-Unit connections to isolate the problem. Ensure igniter is operational. Check igniter wiring harness for damage. Check gas solenoid valves for open or short circuits. Remove burner cover and ensure all burners are properly seated. Remove burner plate and inspect burner surface for condensation or debris.

obstructions in the flue outlet. Ensure gas line, meter, and/or regulator is sized properly. Ensure gas type and pressure is correct. Bleed all air from gas lines. Ensure proper venting material was installed. Ensure condensation collar was installed properly. Ensure vent length is within limits. Verify dip switches are set properly. Ensure appliance is properly grounded. Disconnect keypad. Disconnect all 2-Unit or Multi-Unit connections to isolate the problem. Check power supply for loose connections. Check power supply for proper voltage and voltage drops. Ensure flame rod wire is connected. Check flame rod for carbon build-up. Disconnect and reconnect all wiring harnesses on unit and PC board. Check all components for electrical short. Check gas solenoid valves for open or short circuits. Remove burner plate and inspect burner surface for condensation or debris.

305, 505, 705 Indoor Manual 9

Error Code Table

Code Fault Remedy

No code

Thermal Fuse Check gas type of unit and ensure it matches gas type being used.

Check for restrictions in air flow around unit and vent terminal. Check for low water flow in a circulating system causing short-cycling. Ensure dip switches are set to the proper position. Check for foreign materials in combustion chamber and/or exhaust piping. Check heat exchanger for cracks and/or separations. Check heat exchanger surface for hot spots which indicate blockage due to scale build-

up. Refer to instructions in manual for flushing heat exchanger. Measure resistance of safety circuit. Ensure high fire and low fire manifold pressure is correct. Check for improper conversion of product.

Over Temperature Warning

Outgoing Water Temperature Sensor Fault

Heat Exchanger Outgoing Temperature Sensor Fault

Combustion Air Temperature Sensor Fault

Modulating Solenoid Valve Signal Abnormal Combustion Fan Failure

SV0, SV1, SV2, and SV3 Solenoid Valve Circuit Fault Flame Sensing Device Fault

Scale Build-up in Heat Exchanger (when checking maintenance code history, “00” is substituted for “LC”) Nothing happens when water flow is activated.

Check for restrictions in air flow around unit and vent terminal. Check for low water flow in a circulating system causing short-cycling. Check for foreign materials in combustion chamber and/or exhaust piping. Check for clogged heat exchanger. Check sensor wiring for damage. Measure resistance of sensor. Clean sensor of scale build-up. Replace sensor. Check sensor wiring for damage. Measure resistance of sensor. Clean sensor of scale build-up. Replace sensor. Check for restrictions in air flow around unit and vent terminal. Check sensor wiring for damage. Measure resistance of sensor. Clean sensor of scale build-up. Ensure fan blade is tight on motor shaft and is in good condition. Replace sensor. Check modulating gas solenoid valve wiring harness for loose or damaged terminals. Measure resistance of valve coil. Ensure fan will turn freely. Check wiring harness to motor for damaged and/or loose connections. Measure resistance of motor winding. Check wiring harness to all solenoids for damage and/or loose connections. Measure resistance of each solenoid valve coil.

Ensure flame rod is touching flame when unit fires. Check all wiring to flame rod for damage. Remove flame rod and check for carbon build-up; clean with sand paper. Check inside burner chamber for any foreign material blocking flame at flame rod. Measure micro amp output of sensor circuit with flame present. Replace flame rod. Flush heat exchanger. Refer to instructions in manual. Replace heat exchanger.

Clean inlet water supply filter. On new installations ensure hot and cold water lines are not reversed. Check for bleed over. Isolate unit from building by turning off hot water line to building.

Isolate the circulating system if present. Open your pressure relief valve; if water is

flowing, there is bleed over in your plumbing. Ensure you have at least the minimum flow rate required to fire unit. Ensure turbine spins freely. Measure the resistance of the water flow control sensor. Check for DC shorts at components.

10 305, 505, 705 Indoor Manual

Trouble Shooting for Common Issues

I don’t have any hot water when I open the tap.

Make sure there is gas, water, and electricity to the water heater (power is turned on and the gas is turned on).

When I was using the hot water, the water got cold.

If you adjusted the flow from the tap to lessen it, you may have gone below the minimum flow required. This water heater requires a minimum flow rate to operate. (See the specification page for the flow rate of your model.) Decrease the temperature setting at the temperature controller or increase the water flow.

White smoke comes out of the exhaust.

During colder weather when the exhaust temperature is much hotter than the outside air, the exhaust fumes condense producing water vapor.

When I open a hot tap, I do not immediately get hot water.

Hot water must travel through your plumbing from the water heater to the faucet. The time period for hot water to reach your fixture is determined by the amount of water in the plumbing system between the water heater and the fixture, water pressure, and the flow rate of the fixture.

After I turn off the hot water tap, the fan on the water heater continues to run.

The fan is designed to continue running for a short time after the flow of water stops. This is to ensure constant water temperatures during rapid starting and stopping, as well as exhausting any residual gas flue products from the unit.

Accessing Operating Information

To display the most recent error codes press and hold the “On/Off” button for 2 seconds. While holding the “On/ Off” button press the ▲ button. The last 9 error codes will flash one after the other. To exit this mode press the “On/Off” and ▲ button as before.

To display the water flow through the water heater press and hold the ▲ button for 2 seconds and without releasing the ▲ button press the “On/Off” button.

To display the outlet water temperature press and hold the ▼ button for 2 seconds and without releasing the ▼ button press the “On/Off” button.

Water Quality

Consideration of care for your water heater should include evaluation of water quality. If the water quality exceeds the target levels provided in the table, you may want to treat or condition the water.

* Source: Part 143 National Secondary Drinking Water Regulations

Total Hardness Up to 200 mg / L

Aluminum * Up to 0.2 mg / L

Chlorides * Up to 250 mg / L

Copper * Up to 1.0 mg / L

Iron * Up to 0.3 mg / L

Manganese * Up to 0.05 mg / L

Maximum Level

pH * 6.5 to 8.5

TDS (Total Dissolved Solids) *

Zinc * Up to 5 mg / L

305, 505, 705 Indoor Manual 11

Up to 500 mg / L

Flushing the Heat Exchanger (Error Code: LC or 00)

An “LC” or “00” error code indicates the unit is beginning to lime up and must be flushed. Failure to flush the appliance will cause damage to the heat exchanger. Damage caused by lime build-up is not covered by the unit’s warranty. After flushing, reset the LC fault code by turning off the power to the unit and turning the power back on.

1. Disconnect electrical power to the water heater.

2. Close the shutoff valves on both the hot water and cold water lines (V3 and V4).

3. Connect pump outlet hose (H1) to the cold water line at service valve V2.

4. Connect drain hose (H3) to service valve V1.

5. Pour approximately 4 gallons of virgin, food grade, white vinegar or citric acid into pail.

Water Heater

6. Place the drain hose (H3) and the hose (H2) to the pump inlet into the cleaning solution.

7. Open both service valves (V1 and V2) on the hot water and cold water lines.

8. Operate the pump and allow the cleaning solution to circulate through the water heater for at least 45 minutes.

9. Turn off the pump.

10. Rinse the cleaning solution from the water heater as follows:

a. Remove the free end of the drain hose (H3) from the pail.

b. Close service valve, (V2), and open shutoff valve, (V4).

Do not open shutoff valve, (V3).

c. Allow water to flow through the water heater for 5 minutes d. Close service valve, (V1), and open shutoff valve, (V3).

11. Disconnect all hoses.

12. Remove the in-line filter at the cold water inlet and clean out any residue. Place filter back into unit.

13. Restore electrical power to the water heater.

5 gallon pail of virgin, food grade, white vinegar (or virgin,

food grade, citric acid).

Circulating Pump

KEY

3/4" Ball Valve

3/4" Union

Check Valve

Pressure Relief Valve

Pressure Regulator

Circulating Pump

Boiler Drain Valve

Solenoid Valve

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