State Water Heaters 21, 000 – 236, 000 BTU Tankless Water Heater Owner's Manual And Installation Manual

Owner’s Guide and Installation Manual

21,000 – 236,000 BTU Tankless Water Heater

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

-Do not store or use gasoline or other flammable vapors and liquids in the
vicinity of this or any other appliance.

-WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

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

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

gas supplier’s instructions.

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

-Installation and service must be performed by a qualified installer, service
agency or the gas supplier.

Thank you for purchasing this Gas Water Heater. Before using, please:
Read this manual completely for correct installation and operation instructions.

CERTIFIED

R

Low NOx

Approved by

SCAQMD

Completely fill out the warranty registration card (included separately) and
mail the detachable portion.
Keep this manual (and the remainder of the warranty registration card) where it
can be found whenever necessary.

Printed in the U.S.A. 1005 PART NO. 184959-107

SAR8437

*SAR8437 T*

Contents

Contents ........................................................................................................ 2

Owner's Guide

Important Safety Information....................................................................... 3

General Parts

Main Unit.................................................................................................... 8

Remote Controller .................................................................................... 9

Initial Operation ........................................................................................... 11

Setting and Using the Water Heater........................................................... 12

Flow Meter Alarm......................................................................................... 14

Muting the Remote Controller .................................................................... 16

Preventing Damage from Freezing ............................................................ 17

Regular Maintenance................................................................................... 19

Troubleshooting .......................................................................................... 21

Follow-up Service ........................................................................................ 25

Specifications .............................................................................................. 26

External Outfitting ....................................................................................... 27

Combustion Unit and Gas Route ............................................................... 29

Hot-Water Feed Route ................................................................................. 31

Electronic Control Unit................................................................................ 33

Electronic Control Unit, Remote Controller and Attached Set................ 34

Installation Manual ...................................................................................... 35

1. Included Accessories............................................................................ 36

2. Optional Accessories............................................................................ 36

3. Quick Connect Multi System Installation ............................................ 37

4. Before Installation ................................................................................. 38

5. Choosing Installation Site .................................................................... 38

6. Installation Clearances ......................................................................... 40

7. Installation.............................................................................................. 43

8. Vent Pipe Installation ............................................................................ 44

9. Gas Piping.............................................................................................. 47

10. Water Piping........................................................................................... 49

11. Plumbing Applications.......................................................................... 50

12. Electrical Wiring .................................................................................... 51

13. Maintenance........................................................................................... 55

14. Trial Operation ....................................................................................... 55

15. Dimensions and Wiring Diagram ......................................................... 56

16. Multi-System .......................................................................................... 58

Remote Controller Installation Guide ........................................................ 62

2

Important Safety Information-1

To prevent damage to property and injury to the user, the icons shown below will be used to warn of
varying levels of danger.
Every indication is critical to the safe operation of the water heater and must be understood and
observed.
Potential dangers from accidents during installation and use are divided into the following three
categories. Closely observe these warnings; they are critical to your safety.

Icons warning of risk level

Denotes content that may result in instantaneous fire, serious injury

Danger
Warning
Caution

Remarks

Other icons

and even death when ignored.
Denotes content that may result in fire, serious injury and even

death when ignored.
Denotes content that may result in bodily injury and physical

damage when ignored.
The content following this icon is necessary to understand for safe

and easy use of this water heater.

Electric
Shock.

Prohibited

High
Temperature.

No flame.

Danger

If you detect a gas leak:

1. Do not try to light any appliance

2. Do not touch any electrical
switch; do not use any phone in
your building.

3. Immediately call your gas
supplier from a neighbor’s phone.
Follow the gas supplier’s
instructions.

4. If you cannot reach your gas
supplier, call the fire department.

Be sure
to do.

Don’t
touch.

Ground.

Don’t
disassemble
the equipment.

Do not use the water heater if
the exhaust pipe is displaced, has
holes, or is corroded.

Don’t touch
with a wet
hand.

3

Important Safety Information-2

Warning

If you detect abnormal combustion
or abnormal odors, or during an
earthquake, tornado or fire:

1. Turn off the hot water supply

2. Turn off the power to the water
heater

3. Turn off gas and water at the
main

4. Consult the nearest sales agent

Check the temperature of the
running hot water before
entering the shower.

Check the temperature before
stepping into the bath tub.

Be sure the gas/power supplied
matches the gas on the rating
plate.

Do not allow small children to play
unsupervised in the bathroom.
Do not allow small children to
bathe unsupervised.

Do not turn off the water heater or
change the water temperature while
someone is using.

Consult the nearest sales agent if
the water heater location needs to
be changed.

Contact a qualified service
technician for any necessary
repairs, service or maintenance.

Contact sales agent before using
with a solar pre-heater.

4

Warning

Do not place combustibles such as
laundry, newspapers, oils etc. near
the heater or the exhaust vent
terminal.

Exhaust vent
terminal (indoor
installation)

Unit

Do not use combustible chemicals
such as oil, gasoline, benzene etc.
in the vicinity of the heater or the
exhaust vent terminal.

[When installing indoors]
Check the air supply
vent for dust or
obstructions.

Leave the proper clearance between
the water heater and nearby objects
(trees, timber, boxes with flammable
materials etc.).

Min. 3" from
vent pipe

Left side:
Min. 2"

Front:
Sug. 24"

*

*

Indicates suggested clearances for
maintenance.

Right side:
Min. 2"

Do not place or use a spray can
near the heater or the exhaust vent
terminal.

5

Important Safety Information-3

Caution

Be sure to electrically ground the
unit.

Do not touch the power cord with
wet hands.

Keep power cord free of dust.

Do not use a broken or modified
power cord. Do not bind, bend or

stretch power cords.
Do not scratch, modify, or subject

them to impact or force.

Do not use the water heater for
other than hot water supply,
shower and bath.

Do not touch the exhaust vent pipe
during or immediately after
operation of the water heater.

Do not use hair spray or spray
detergent in the vicinity of the

heater.

If this unit will be installed in a
salon or other location where hair

spray or aerosols will be used,
locate the unit in a seperate area
that is supplied with fresh air from

outdoors.

Do not install in locations where
excessive dust or debris will be

in the air.

6

Remark

Do not drink water that has been inside the
unit for an extended period of time. Do not
drink the first use of hot water from the

unit in the morning.

Clean the filter on the water inlet as
frequently as required by the quality of
your local water.

Keep the area around the unit clean.

If boxes, weeds, cobwebs, cockroaches etc. are in
the vicinity of the unit, damage or fire can result.

Do not install the equipment where the
exhaust will blow on walls or windows.

Treat hard, acidic or otherwise impure
supply water with approved methods to
ensure full warranty coverage.

Problems resulting from scale formation
are not covered by the warranty.

Do not disassemble the remote controller.

Do not use benzene, oil or fat detergents
to clean the remote controller.

This may cause deformation.

Do not get the remote controller wet.

Although it is water resistant, too much water can
cause damage.

Do not splash water on the remote
controller. Do not expose the remote
controller to steam.

Do not locate the remote controller near stoves or
ovens, this may cause damage or failure.

Preventing damage from freezing ( p.17)

Damage can occur from frozen water within the
device and pipes even in warm environments.
Be sure to read below for appropriate measures.
Repairs for damage caused by freezing are not
covered by the warranty.

Check ignition during use and extinction
after use.

This unit is only approved for installation
up to 4500 ft. above sea level.

For installations at higher elevations, contact sales
agent for Instructions.

Do not use parts other than those specified
for this equipment.

Take necessary measures to prevent
freezing of water and leakage of gas when
leaving the unit unused for long periods of
time. ( p.18)

If it is snowing, check the air inlet, exhaust
gas vent and exhaust vent terminal for
blockage.

7

General Parts-1

Main Unit

Indoor/Outdoor Wall Mounted, Power Vented Model

Flue Collar

Front Cover

Air Inlet

Water Drain Valve (with Water Filter)

(Inside Water Inlet) ( p.20)

Pressure Relief Valve

Water Supply Valve

Gas Supply Valve

* The above illustration shows an example of installation.

The exact installation configuration may be slightly different.

8

General Parts-2

Remote Controller (9004223)

Display

( next page)

Setting Buttons

For setting the hot
water temperature,
the flow meter alarm,
and other settings.

Power On/Off Button

For turning the
heater on and off.

Flow Meter Alarm Set Button

For setting the flow
meter alarm.

( p.14 and 15)

* Before use, remove the protective sheet from the remote controller surface.
* The unit has been shipped from the factory with the remote control set at 110°F.

9

General Parts-3

Display

The illustration below shows the remote controller display. What is actually displayed
depends on how the water heater is set.

Burner On Indicator

Priority Indicator

When this indicator
is lit, the hot water
temperature can be
set. ( p.13)

Temperature Setting

(Ex.: 110°F)

Flow Meter Setting

The display will flash
after hitting the flow
meter alarm set button.

( p.15)

Error Code

A number will flash if
a failure occurs.

( p.24)

10

Initial Operation

Before the first use of your water heater, make the following preparations.

Follow steps 1 through 4.

Open the water supply valve.

1

CLOSED

Open a hot water fixture to confirm that
water is available, and then close the

2

fixture again.

Hot water fixture

OPEN

Open the gas supply valve.

3

Turn on the power.

4

11

How to Use

Setting and Using the Water Heater

(Starting with the Power Off)

2

Press the Power
On/Off Button.

1

1

The temperature will be
displayed on the remote
control thermostat.

On

On

Caution

To prevent scalding:

High Temperature

Temperatures above 125 °F can scald.

•Check the water temperature by hand before bathing or
showering.

• When setting the unit to 125°F or higher, the
temperature display will flash for 10 seconds as a high
temperature warning.

• Take caution when using the unit again after setting to
125°F or higher. Always check the set temperature
before use.

Previous set
temperature
(Ex.: 110°F)

Remote Controller Display

Flashes for 10 sec

• Do not allow anyone to change the water temperature
while hot water is running.

12

Set temperature.

2

Always check the

temperature setting

(

before use.

Hot

Cold

)

3

Turn on hot
water.

4

Turn off the hot
water.

Check the indicator lights.

Water temperature

The temperature settings below are examples. The temperature setting

:

(°F

necessary depends on the usage, the length of piping and the time of year.

100 105 110 115 120 125 130 135 140 145 150 160 170 180

Washing
dishes, etc.

* For most residential applications, the recommended setting temperature is 120°F or less.

For applications that occasionally require a higher temperature setting, locate the remote controller
in a convenient location ( p.62).

* Consult local codes for minimum operating temperatures.

Shower, hot water
supply, etc.

High temperature

*Initial factory setting is 110°F

On

Off

)

If fixtures incorporate mixing
valves, set the temperature
higher than usual.

13

How to Use

Flow Meter Alarm

2,3
1

3

(Starting with the power off)

Preparation

1. Plug the bath drain.

Press the Power
On/Off Button

1

On

The temperature will be displayed
on the remote control thermostat.

On

Previous set temperature
(example:110°F)

Set temperature.

2

Always check
temperature setting

(

before use.

Hot

Cold

Check the indicator lights.

Water temperature

)

14

An alarm will sound for ten
seconds when the flow
reaches the set level.

Water Temperature

The temperatures settings below are only examples. The

:

temperature setting necessary will depend on the usage,

(°F

the length of piping and the time of year.

100 105 110 115 120

)

The water will continue to run unless it is
manually turned off.

To set the flow meter alarm:

Adjust flow meter

3

alarm setting.

Press the flow meter alarm set button
(the setting will flash on the display)
and adjust with the setting buttons.

Increase

Decrease

Choose the flow meter alarm setting
from the following options: 10 - 60
(In 5 gallon intervals), 70 - 100 (In
10 gallon intervals), or 990 gallons.

The alarm will not sound if

Note:

it is set for 990 gal.

4

Turn on hot
water.

On

Warmer HotWarm

* Initial factory setting: 110°F

Turn off the hot
water when the

5

alarm sounds.

The alarm will sound when
the set level has been
reached. Stop the water.

The alarm will not

Note:

sound if it is set for
990 gal.

Off

Flow meter setting will be flashing
(ex. 45 gal.)
* The level can only be adjusted

while the indicator is flashing.

* After ten seconds, the remote

will again display the temperature.

If the flow meter alarm is being used to indicate when a tub is full:

• If any hot water is being used besides what is going into the tub, the alarm will sound before
the tub is full.

• If there was water in the tub before the fill began, or if the water is not shut off manually when
the alarm sounds, the tub may overflow.

• If there was water in the tub before the fill began, the temperature in the tub after it is full may
be different from the temperature setting.

15

How to Use

Muting the Remote Controller

The remote controller will emit a sound
when any button is pushed. This sound
can be muted if it is desired.

* Initial factory setting is with sound.

1

1

With the remote controller
off, hold the Power On/Off
Button for five seconds.

Muted

No sound
after 5 sec.

Sound

Tone sounds
after 5 sec.

The flow meter alarm cannot be muted.

16

Preventing Damage from Freezing-1

Remarks

* Damage can occur from frozen water within the device and pipes even

in warm environments. Be sure to read below for appropriate measures.

* Repairs for damage caused by freezing are not covered by the warranty.

Freezing is prevented within the device automatically by the freeze-prevention heater

Freezing cannot be prevented when the power is disconnected.Do not remove the power plug
from the wall outlet.

(Freezing will be prevented regardless of whether the operation switch is ON or OFF.)

* The freeze prevention heaters will not prevent the plumbing external to the unit from freezing.

Protect this plumbing with insulation, heat tape or electric heaters, solenoids, or pipe covers.
If there remains a freezing danger, contact the nearest sales agent.

Take the measures below for extremely cold temperatures*.

(outside temperature including wind chill factor less than 5°F)
This method can protect not only to the heater, but also to the water supply,

water piping and mixing valves.

1. Turn the unit on with the Power Button on the Remote Controller.

2. Close the gas supply valve.

3. Open a hot water fixture and let it run for approx. 1 minute, and
then check that the number 11 is flashing on the remote controller
display.
* If multiple units are being used, drain one minute for each unit.
* It is possible that a different number may be displayed on the

remote controller, but as long as it is flashing, you may continue.

4. Partially close the hot water fixture, but keep a small amount of hot
water running (.1 gal./minute or about .2” thick).
* If there is a mixing valve, set it to the highest level.
* When linking multiple units, discharge water equivalent to
.1 gal./minute per unit.

5. The flow may become unstable from time to time. Check the flow
30 minutes later.

Hot Water Fixture

.2" thick

* Remember to set mixing valves and fixtures to their original levels before using the unit again
to prevent scalding.
* If there is still a chance that the unit will freeze, drain the unit as on the next page.

If water will not flow because it is frozen:

1. Close the gas and water valves.

2. Turn off the power button.

3. Open the water supply valve from time to time to check whether water is running.

4. When the water is flowing again, check for water leaks from the equipment and piping
before using.

If the heater or the piping is frozen, do not use the heater or it may get damaged.

17

Preventing Damage from Freezing-2

If the water heater will not be used for a long period of time,
Drain the water.

Drain the water as follows:

Caution

High Temperature

Drain water into a bucket to prevent water damage.

1. Close the gas valve.

2. (1) Turn the power on.
(2) Turn and leave open the hot water fixture for more than 1 minute and close.

*If multiple units are being used, drain one minute for each unit.
*An 11 Error Code may appear on the remote control.

This is not a malfunction of the unit. Do not turn Power ON/OFF Button OFF.

3. Close the water supply valve, disconnect
the electrical power supplied to the unit.

Do not touch with wet hands.

4. Fully open all hot water fixtures.

To avoid burns, wait until the equipment cools down
before draining the water. The appliance will remain hot
after it is turned off.

Fixture

Fixture

5. Open all drain plugs and drain the water out

of the unit.

6. When the water is completely drained, replace all drain

plugs and close the hot water fixtures.

1. Check that all drain plugs are inserted.

2. Check that all hot water fixtures are closed.

3. Follow the procedure on p.11 “Initial operation”, steps 1 through 4.

18

Drain Plugs

Turning the Unit Back On

Regular Maintenance-1

Periodic Inspection

Caution

Check

Check

Check

Check

Check

For laundry, newspaper, timber,
oil, spray cans and other
combustible materials. ( p.5)

For abnormal sounds
during operation.

For abnormalities in
external appearance,
discoloration or flaws.

For proper operation of
pressure relief valve.

For water leaks from the
equipment and piping.

High Temperature

To avoid burns, wait until the equipment cools down
before draining the water. The appliance will remain
hot after it is turned off.

Check

Check

For dust and soot in
the exhaust vent or
exhaust vent terminal.

For dust or debris in
the air inlet.

Periodic Maintenance

Equipment

Wipe the outside surface with a wet cloth, then dry the surface. Use a neutral detergent to
clean any stains.

Remote Controller

Wipe the surface with a wet cloth.

• Do not use benzene, oil or fatty detergents to clean the remote controller;
deformation may occur.

• The remote controller is water resistant but not water proof. Keep it is dry as possible.

19

Regular Maintenance-2

Periodic Maintenance

Water Drain Valve (with Water Filter)

If the water drain valve (with water filter) is covered with debris, the hot water may not run
smoothly, or the unit may put out cold water. Check and clean the filter as explained below.

* To avoid burns, wait until the equipment cools down before draining the water.

The appliance will remain hot after it is turned off.

* Water will be discharged from the trap plug. Place

a container, etc. to receive the discharged water.

1. Close the water supply valve.

2. Open all hot water fixtures.

3. Remove the inlet and outlet drain plugs (about

0.3 gal. will drain out)

4. Take the water drain valve (with water filter) out
of the inlet. (See illustration to right).

5. Clean the water drain valve (with water filter) with
a brush under running water.

6. Replace the water drain valve (with water filter).
(Take care not to lose the packing.)

7. Close all hot water fixtures.

8. Open the water supply valve and check that
water does not leak from the drain plugs or water
drain valve (with water filter).

Optional Maintenance

Water Heater Service Valves

Inlet

Packing

Drain Plug
(with filter)

Water Supply
Valve

Hot Water
Service Valve

Pressure Relief Valve

Drain

Water Outlet

20

Water Intlet

Cold Water
Service Valve

* Isolator valve kits may be purchased as an

accessory from sales agent (Call parts
department for ordering information).
They allow for one man full diagnostic testing
and easy flushing of the system.

* The kit includes two full port isolation valves

and a pressure relief valve for the hot side.
Contact sales agent for more information.

Troubleshooting-1

Initial Operation

Unit does not attempt to ignite
when water is running.

Unit attempts to ignite but fails

Hot water is not available
when a fixture is opened.

• Is water running?

• Check for reversed plumbing or crossed pipes.

•Check the water drain valve filter. ( p.20 )

• Reset unit and try again. There may be air in the gas line.

• Have a professional check the gas supply pressure.

Temperature

•Are the gas and water supply valves fully open?

• Is the water supply cut off?

•Is the hot water fixture sufficiently open?

•

Is the gas being cut off by the gas meter ?

(Can other gas devices such as stoves be used?)

•(For LP) Is there enough gas in the tank?
(Can other gas devices such as stoves be used?)

• Is the water drain valve filter clogged? ( p.20)

No water is available when
a fixture is opened.

The hot water is not the correct
temperature.

Water takes time to become hot
when turning the hot water fixture.

The water is too hot.

• Is the power button turned on?

• Is the water supply cut off?

• Is the heater frozen?

•Is the hot water fixture sufficiently open?

• Have you allowed enough time for the cold water in the
pipes to drain out?

•Are the gas and water supply valves fully open?

• (Using the remote controller) Is the water temperature
setting appropriate? ( p.12 and p.13)

• If the water supply temperature is high, it is possible

for the temperature to be higher than the temperature
set on the remote controller.

• If only a small amount of hot water is demanded, it is

possible for the temperature to be higher than the
temperature set on the remote controller.

• If the supply water goes through a solar pre-heating

system, it is possible for the temperature to be higher
than the temperature set on the remote controller.

21

Troubleshooting-2

Temperature

The water is not hot enough.

The water is cold when only a
single fixture is open.

Fluctuations in hot water
temperatures.

Amount of Hot Water

•Are the gas and water supply valves fully open?

• (Using the remote controller) Is the water temperature
setting appropriate? ( p.12 and p.13)

• If the amount of hot water required is very high, it is

possible for the temperature to be lower than the temp­ erature set on the remote controller.
Decrease the amount of water passing through the unit
and the temperature should stabilize.

• The unit will not heat the water if the flow rate is less than

0.7 gallons per minute.
Open the fixture more or open other fixtures so that a greater
flow passes through the unit, and the unit should begin
heating again.

• Set water temperature at 115°F to 120°F. This will allow you
to use a higher flow of hot water thus meeting the minimum
flow requirement of 0.7 gpm.

• Clean the water filter of any debris ( p. 20)

The amount of hot water at a
certain fixture is not constant.

The amount of hot water in the tub
is less/more than the set amount.

The flow meter alarm does not
sound even when filled to the set
amount.

Amount of hot water available
has decreased over time.

•When hot water is demanded at other fixtures, the
amount available may be reduced. The maximum flow
available from this unit is 8.4 GPM at a 45°F temp. rise.

• Pressure fluctuations and other plumbing conditions can
cause the temperature and pressure at a fixture to be
unstable, but it should stabilize after a short time.

• There are some types of hot water taps that discharge large

volumes of hot water initially, but stabilize after time.

•To keep the temperature stable, the heater limits the
amount of water that can flow through it to a small
amount initially, but the amount increases over time.

•When hot water is used for other fixtures while filling the
bath tub, the tub will not fill as much.

• If there is water in the tub already, or when filling is stopped
and resumed, the tub will fill more.

•

The flow meter alarm is set to sound when hot water
is continuously discharged for the set volume of water. If mixing
valves are used, or if cold water is mixed with hot water at the
fixture, the tub will fill more than the setting of the flow meter
alarm.

• Is the water drain valve filter clogged? ( p.20)

22

Troubleshooting-3

Remote Controller

The light on the power button
does not come on.

The water temperature changes
after a power failure or when the
power is disconnected.

The fan can be heard after
operation is stopped.

A motor can be heard when turning
the unit ON or OFF, when opening
or closing a fixture, or after the unit
has been running for a while.

• Has there been a power failure?

•Is the power connected properly?

• The temperature setting and the flow meter alarm setting
may both need to be reset after a power outage.

Sounds

• These noises indicate the proper operation of devices
which are designed to let the unit reignite more quickly,

and ensure the water temperature is stable.

Other

The heater stops burning during
operation.

exhaust vent on a cold day.
The hot water is turbid.

Water leaks from the drain plugs
on the outlet.

• Are the gas and water supply valves fully open?

• Is the water supply cut off?

• Is the hot water fixture sufficiently open?

• Is the gas being cut off by the gas meter?

(Can other gas devices such as stoves be used?)

• (For LP) Is there enough gas in the tank?

(Can other gas devices such as stoves be used?)

• This is normal. The white smoke is actually steam.White smoke comes out of the

• This is harmless. Small air bubbles appear as the
water is heated and depressurized rapidly to
atmospheric pressure.

•When the unit is under very high pressure, water will leak
from the drain plugs as a safety so that the unit is not
damaged by the high pressure.

23

Troubleshooting-4

Other

The water appears blue or
The bath tub/wash-basin has turned
blue

åÃè·ï\é¶Ç Ç®íÇÇÇæÇÇ¢ åÃè·ï\é¶Ç Ç®íÇÇÇæÇÇ¢

• This can be caused by a reaction of copper ions in the
water with fat particles (furring). This is not a health risk,
and the discloration of the tub or basin can be cleaned.

Check for an Error Code

If there is a problem with the unit, a numerical error code will flash on the remote controller.
If this occurs, take appropriate measures as listed below.

When an error code appears, the display and the operation light will flash
together.

Remote Controller

Error Code Cause Action

Flashing

Ignition error

Abnormal combustion,
low gas supply pressure

Contact our sales agent if:

• Any other error code appears.

• An error code is indicated again after the above actions were followed.

• There are any other questions.

Check whether the gas valve is open. Press the power
button to turn the unit off, open a hot water fixture,
and turn the unit back on. If the flashing number
doesn't return the problem is solved.

Have a professional check the gas supply pressure.
Contact the nearest sales agent.

Contact the nearest sales agent.Abnormal combustion

24

Follow-up Service

Requesting Service

First follow the instructions in the troubleshooting section (p.21 to p.24).
If the error is not corrected, contact our sales agent.

We will need to know:

The Model ................ (check the rating plate)

*See p.4 for the location of the label

Date of purchase ..... (see the warranty)

Details of problem... (flashing error codes,

etc., in as much detail as possible)

Your name, address, and telephone number
Desired date of visit

*A request for service may be rejected if the water heater is installed

in a location where working on the unit may be dangerous. Contact a
plumber.

Warranty

A warranty registration card is included separately.
Be sure that the plumber, date of purchase and other necessary items are filled in.
Read the content carefully, and keep the warranty card in a safe place.

For repairs after the warranty period, there will be a charge on any service, and service will only
be performed if the unit is deemed repairable.

Period of Time for Stocking Repair Parts

The manufacturer will stock repair and maintenance parts for this unit for a minimum of seven
years after production has ceased.

Reinstallation

If you want to reinstall the appliance at a different location, confirm that the gas and power
supply indicated on the rating plate are available at the new location. If you are not sure,
consult the local utility company.

If you move to a region that uses a different type of gas, conversion and adjustment of the
appliance will be necessary. This work must be performed by a certified service agent and will
be charged for even during the warranty period.

25

Specifications

Specifications

•Specifications may be changed without prior notice.

• The capacity may differ slightly, depending on the water
pressure, water supply, piping conditions, and water temperature.

Item
Type

Ignition
Operating Pressure
Minimum Flow Rate
Dimensions
Weight
Water Holding Capacity
Connection Sizes

Power Supply

Materials

Safety Devices

Accessories

Installation
Air Supply/Exhaust

Water Inlet
Hot Water Outlet
Gas Inlet
Supply
Consumption
Casing
Flue Collar
Heat Exchanger

Specification

Indoor/ Outdoor, Wall Hanging

Power Vented
Direct Ignition

15-150 PSI

0.7 GPM

24.2"(Height) x 18.3"(Width) x 9.4"(Depth)
63 lbs.

0.3 Gallon
3/4"
3/4"
3/4"

120 VAC (60Hz)

NG:80W, LP:93W, Freeze Prevention 135W

Zincified Steel Plate/Polyester Coating

Stainless Steel

Copper Sheeting, Copper Tubing

Flame Rod, Thermal Fuse, Pressure Relief Valve,

Lightning Protection Device (ZNR),

Electric Leakage Prevention Device (GFCI), Overheat

Prevention Device, Freezing Prevention Device,

Fan Rotation Detector

9004223 Remote Controller, Remote Controller Cord,
Anchoring Screws

Item
Gas

Consumption
Maximum Hot Water Capacity
Capacity Range

Temperature Settings

Default Temperature Options

26

Performance

Maximum Performance
NG
LP
45°F Rise 8.4 Gal./min.

236,000 btuh
236,000 btuh

0.7-8.4 Gal./min.

100-150°F (In 5°F intervals),

160, 170, 180°F (In 10°F intervals) (14 Options)

120,130,140,180°F(Original is 120°F)

Minimum Performance

21,000 btuh
21,000 btuh

External outfitting

074

016

071

070

003

002

010

001

012

072

009

026

074

025

015

017

018

007

006

004

005

002

008

003

070

035

034

013

014

070

073

27

External outfitting

Part Nos. Part Names Order Nos. Q'ty/unit

001 AOS Front SET-AS SKB7073 1<AOS>

STA Front SET-AS SKB7075 1<STA>
002 Front packing S AAP AAPL015 2
003 Front packing L AAP AAPL017 2
004 Lamp seal plate DEC DECK008 1
005 Connection diagram label-AOS EJM EJMK010 1
006 Caution label 1 EHU EHUK018 1
007 Caution label 2 EAU EAUK004 1
008 Raintight seal plate BUB BUBK004 1
009 Plug insulation sheet CRU CRUK002 1
010 Exhause box EDM EDMF001 1
012 Exhause joint packing DHN DHNL003 1
013 Wiring coupling BXK BXKA022 2
014 Grommet CXP CXPA026 2
015 Exhaust sylinder packing EDL EDLL002 1
016 Case top cover 2 for AOS EHV EHVA008 1
017 Case top cover for AOS EJM EJMA007 1
018 Case top packing EDM EDML001 1
025 Case for AOS EJM EJMA005 1
026 Air themistor-300 BWC BWCH003 1
034 Junction box set EHU EHUA008 1
035 Junction box packing EHU EHUL002 1

070 Cross recessed round-head collar N-tapping screw 4X8
071 Cross recessed truss type3 EVERTIGHT tapping screw with PW 4X12
072 Cross recessed round-head collar N-tapping screw 4X10
073 Cross recessed round-head collar type3 EVERTIGHT tupping screw 4X12
074 Cross&straight recessed truss type3 S TIGHT tapping screw 4X10

28

Combustion unit and gas route

100

109

171

172

111

114

117

110

114

116

102

101

105

126

070

117

118

112113

115

170

173

070

103

104

070

070

141

132

128

125

070

176

131

070

129

173

072

175

175

127

119

121

120

172

121

124

172

122

123

171

073

29

Combustion unit and gas route

Part Nos. Part Names Order Nos. Q'ty/unit

100 Combustion tube set EAC SET-V SBP7302 1
101 Flame rod DLK SET-V SBA7506 1
102 Plug packing (for N) DLK DLKL012 1
103 Ignition plug Q(N)SET-V SBA7504 1
104 Burner sensor DLK SET-V SBA7505 1
105 Plug fixing plate (for N) DLK DLKC009 1
109 Suction air joint packing DHN DHNL002 1
110 Manifold set 15 EDM SET-AS SBE7875 1<LPG>

Manifold set 24 EDM SET-AS SBE7874 1<NGA>
111 Solenoid S16L CRU SET-AS SAQ7346 1
112 Solenoid S24L CRU SET-AS SAQ7406 1
113 Solenoid S09LCRU S30 SET-AS SAQ7486 2
114 O-ring S30 type 1A SAD6433 3
115 O-ring S-38 SAD6372 1
116 Manifold seal packing top CRP CRPL002 1
117 Manifold seal packing side CRP CRPL004 2
118 Manifold seal packing bottom CRP CRPL003 1
119 Fan moter DKE DKEF030 1
120 Manifold pipe set EDM EDME006 1
121 O-ring P25.5 SAB1512 2
122 Gas mech. S24DQ CRP SET-V SAQ7708 1
123 O-ring JASO 2028A 8590109 1
124 Gas fitting 20A set EJH EJHE001 1
125 Mounting plate for burner case DLT DLTC001 1
126 Main damper 11 CRP CRPC052 1
127 Conduit R10 EDM EDMJ006 1
128 Igniter CRP CRPJ002 1
129 High-voltage cord 470 SAC1229 1
131 Mounting plate for igniter EAC EACC011 1
132 Mounting plate for igniter DTJ DTJA015 1
141 Bell-mouse φ44 CRU CRUC045

Bell-mouse φ48 CRU CRUC046

1<LPG>

1<NGA>

170 Cross recessed round-head type3 EVERTIGHT tapping screw 5X16
171 Cross recessed hexagon head machine screw M4X8
172 Cross recessed round-head machine screw M4X8
173 Cross recessed round-head N-tapping screw 4X8
175 Cross recessed round-head SPAKmachine screw with guide M4X12
176 Cross recessed round-head collar N-tapping screw 4X12

30

Hot-water feed route

413

507

173

408

508

425

468

410

A

471

434

412

427

406

407

B

412

456

470

411

456

434

402

424

417

472

413

428

511

433

402

471

434

456

456

422

434

412

413

458

A

402

400

D

401

421

412

423

413

510

402

C

409

406

435

173

414

452

172

073

442

441

511

508

509

413

418

435

412

507

444

420

176

453

172

172

434

445

456

455

443

C

(Thermal fuse rounding procedure)

(Left side view)

Thermal fuse fastener

402

B

D

418

(Front side view)

Thermal fuse fastener

402

Freeze preventive heater

431

509

Heater fastener

408

428

454

(Right side view)

Thermal fuse

463

509

440

172

401407

439

434

438

418

437

(Rear side view)

Thermal fuse fastener

456

434

446

447

073

402

31

Hot-water feed route

Part Nos. Part Names Order Nos. Q'ty/unit

400 Heat exchanger EJM SET-AS SKA7139 1
401 Thermal fuse DHN SET-V SBA7398 1
402 Thermal fuse fastener CXD CXDH003 5
406 Thermal fuse cover DHN DHNA014 2
407 Freeze preventive heater CRP SET-V SAQ7745 1
408 Heater fastener EHK EHKH001 1
409 Remaining flame safety device 96 EHU EHUH001 1
410 Water flow servo set 2 DZT DZTD011 1
411 Heat exchanger thermister-300 BWC BWCD098 1
412 O-ring P4C 1323709 5
413 Thermistor holding plate ALS ALSD088 5
414 O-ring P20C 3059502 1
417 Water flow servo set 1 DZT DZTD010 1
418 Freeze preventive heater 3 BGD BGDH002 3
420 O-ring P22C 7573308 1
421 Hot-water feed pipe DHN DHND010 1
422 Bypass pipe EAC EACD003 1
423 Hot-water thermistor-300 BWC BWCD096 1
424 Water flow sensor set 3 DUV DUVD019 1
425 Water inlet thermistor-300 BWC BWCD097 1
427 Water outlet magnetic sensor BWC BWCD090 1
428 O-ring P12.5C 3359808 2
431 Water inlet pipe EAC EACD001 1
433 Quick fastener 13-22 SAD6537 1
434 O-ring P16C 3223302 7
435 Shut-off cock AXG AXGD089 2
437 Water inlet fitting 20A set EJM EJMD002 1
438 Water filter (SUS) EGB EGBD032 1
439 O-ring 16DF BRQ BRQL008 1
440 Water filter cover DTJ DTJD006 1
441 Drain cock CRU CRUD003 1
442 Hot-water resistant O-ring P3 SAD6633 1
443 Mixing coupling EAC EACD007 1
444 Mixing body EAC EACD013 1
445 Mixing cylinder BWC BWCD035 1
446 QMF safety valve A(S) SAA2811 1
447 Hot-water resistant O-ring P9 SAD6635 1
452 Hot-water outlet fitting EJM EJMD001 1
453 O-ring P11C 1326503 1
454 Quick fastener 12.7 6340202 1
455 O-ring JASO 2026 type4 C SAA6483 1
456 Quick fastener 16A 6340300 6
458 Water flow sensor set 1 DUV DUVD017 1
463 Magnetic sensor BWC BWCD093 1
468 Thermostat BHV BHVH002 1
470 Conduit 86 DZT DZTJ008 1
471 Waterproof cover CZL CZLD041 2
472 servo motor cable conduit (86) DZT DZTJ009 1

507 Cross recessed truss P TIGHT screw 4X10
508 Cross recessed round-head P TIGHT screw 4X14
509 Cross&straight recessed round-head collar type3 S TIGHT tapping screw 4X8
510 Cross&straight recessed type3 S TIGHT tapping screw 4X8
511 Cross recessed round-head P TIGHT screw 4X14

32

Electronic control unit

707

070

731

706

716

732

176

070

714

070

708

704

070

705

703

700

176

701

731

Remote controller

kitchen remote controller
(9004223)

Attached set

801

751

802

752

753

176

754

755

<Special part>

Special part Special part no.

Installation manual

888

33

Electronic control unit, Remote controller and Attached set

Part Nos. Part Names Order Nos. Q'ty/unit

700 Relay case EJM-C SET-AS SHA7842 1
701 Harness EJM EJMJ002 1
703 Lamp cable conduit CRP CRPJ014 1
704 Current leakage safety device DTJ DTJJ015 1
705 Relay case cover DEK DEKA014 1
706 Transformer EDN EDNJ006 1
707 Transformer cover DJP DJPA054 1
708 Mounting plate for terminal block DZT DZTA006 1
714 Nylon clamp HP-4N (NK-4N) 7287909 1
716 Conduit 90-2 CCP CCPJ028 1

731 Cross recessed bind machine screw M3.5X6
732 Cross recessed round-head N-tapping screw 4X12

751 9004223 body AOS QME QMEJ006 1
752 Dressed frame body QHU QHUA013 1
753 Wall packing QHU QHUA115 1
754 Oar plug 6X25
755 Cross recessed round wood screw 4.1X25

800 AOS packing SET-V SKB7074 1<AOS>

STA packing SET-V SKB7076 1<STA>
801 Cross recessed round-head type 1 tapping screw 5X35
802 Remote controller cord S set EAU (See P.36)
888 Installation manual AOS 1

(See P.36)

1

34

Installation Manual

GAS WATER HEATER

WARNING: If the information in this manual is not followed exactly, a fire or explosion may result

causing property damage, personal injury or death.

Potential dangers from accidents during installation and use are divided into the following three
categories. Closely observe these warnings, they are critical to your safety.

Danger of serious injury or even death as well as danger of fire when the

Danger

Warning

Caution

product is misused by ignoring this symbol.
Possibility of serious injury or even death as well as possibility of fire when

the product is misused by ignoring this symbol.
Possibility of bodily injury or damage to property when the product is

misused by ignoring this symbol.

Prohibited

Disconnect
Power

Ground

Be sure to do

Requests to Installers

• In order to use the water heater safely, read this installation manual carefully,

Caution

• Failures and damage caused by erroneous work or work not as instructed in this manual are not
covered by the warranty.

• Check that the installation was done properly in accordance with this Installation Manual upon
completion.

• After completion of installation, be sure to hand the Operation Manual (with warranty) to the
customer upon filling in all of the required items.

Installation must conform with local codes, or in the absence of local codes, the National Fuel Gas
Code, ANSI Z223.1/NFPA 54.

and follow the installation instructions.

35

1.

Included Accessories

The following accessories are included with the unit.
Check for any missing items before starting installation.

Part Shape Q’ty

Tapping Screw

9004223

Remote Controller

(See p. 52)

2.

Optional Accessories

9004226

Outdoor Vent Cap

9005696

Quick Connect

Cord

9005694

Remote Controller

Cord (26')

IK-WV-2

Isolator Valves

(includes pressure

relief valve)

Q’tyShapePart

184959-107

5

1

1

1

1

1

Installation Manual

(this document)

9005712

Remote Controller

Cord (10')

The accessories listed below are not
included with the units, but may be necessary
for installation.

9005695

System Controller

9005697

Pipe Cover

1

1

Q’tyShapePartPart Shape Q’ty

1

1

9005699

Recess Box

and

9005700

Installation Kit

9005711

1

Outdoor Remote

Control

Junction Box

1

36

3.

Quick Connect Multi System Installation

• The Quick Connect Multi System allows the installation of two units together utilizing only the Quick
Connect Cord.

The Quick Connect Cord is 6 ft. long. Install the two units 18.5"-37.4" apart at the center to
ensure the cord will be able to reach between the units. (See Typical Plumbing diagram).
(If the distance between the two units is too great, not only will the cord not be able to reach,
but the water temperature may also become unstable because of the difference in pipe length
between the two units.)

System Diagram

Quick Connect
Cord

Cord
Connector

Typical Plumbing

Cord
Connector

Terminal Block

Remote Controller

Remote Controller Cord

G

Distance at center: 18.5-37.4 in.

Distance on sides

0.19-19 in.

* When connecting 2 devices, use only a

single remote controller.

Note: Connect the remote

controller to only one
of the devices.

Gas Supply Piping

Cold Water Supply

Hot Water

Quick Connect
Cord

Make this distance as short as possible.
* The hot water temperature will
become unstable as the pipe
length increases.

Pressure
Relief
Valve

• Insulate the hot water piping to prevent heat loss. Insulate and apply heating materials to the cold
water supply piping to prevent heat loss and freezing of pipes when exposed to excessively cold
temperatures.

Union

Shutoff
Valve

Leave enough clearance around the plumbing
to apply insulation. It will be necessary to add
bends to the piping to ensure that this
clearance is available.

Union

Shutoff Valve

Union
Gas Valve

Shutoff
Valve

Hot Water
Cold Water

Size the piping to allow for the maximum
flow rates of the units.

37

Before Installation

4.

Check the Gas

• Check that the rating plate indicates the correct type of gas.
Check that the gas supply line is sized
for 236,000 Btuh for this unit.

Check the Power

• The power supply required is 120V AC,
at 60Hz. Using the incorrect voltage
may result in fire or electric shock.

Do Not Use Equipment for Purposes Other Than Those Specified

• Do not use for purposes other than increasing the temperature of the water supply,
as unexpected accidents may occur as a result.

Check Water Supply Quality

• If the water supply is hard, acidic or otherwise impure, treat the water with approved methods in
order to ensure full warranty coverage.

Use Extreme Caution if Using With A Solar Pre-Heater

• Using this unit with a solar pre-heater can lead to unpredictable output temperatures and

possibly scalding. If absolutely necessary, use mixing valves to ensure output temperatures do

not get to scalding levels. Do not use a solar pre-heater with the quick-connect multi-system.

Caution

Checkup

• Check the fixing brackets and vent pipe yearly for damage or wear. Replace if necessary.

Choosing Installation Site

5.

* Locate the appliance in an area where leakage from the unit or connections will not result in damage

to the area adjacent to the appliance or to the lower floors of the structure. When such locations
cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed
under the appliance. The pan must not restrict combustion air flow.

Caution

• Install the water heater in a location where it is free from obstacles and

stagnant air.

• Consult with the customer concerning the location of installation.

• Do not install the water heater near staircases or emergency exits.

•Avoid places where fires are common, such as those where gasoline,

benzene and adhesives are handled, or places in which corrosive
gases (ammonia, chlorine, sulfur, ethylene compounds, acids) are
present.
This may cause incomplete combustion or failures.

38

Caution

• Install the exhaust vent so that there are no obstacles around the
termination and so that exhaust can't accumulate. Do not enclose
the termination with corrugated metal or other materials.

•Do not install the water heater where the exhaust will blow on
outer walls or material not resistant to heat. Also consider the
surrounding trees and animals.

The heat and moisture from the water heater may cause discol­oration of walls and resinous materials, or corrosion of aluminum
materials.

• Do not locate the vent termination directed towards a window

or anything other structure which has glass or wired glass
facing the termination.

• Avoid installation above gas ranges or stoves.

• Avoid installation between the kitchen fan and stove. If oily
fumes or a large amount of steam are present in the installation
location, take measures to prevent the fumes and steam from
entering in the equipment.

•Avoid installation in places where dust or debris will accumulate.

Dust may block the air-supply opening, causing the perfor­mance of the device fan to drop and incomplete combustion to
occur as a result.

• Install in a location where the exhaust gas flow will not be
affected by fans or range hoods.

• Take care that noise and exhaust gas will not affect neighbors.

• Make sure that the location allows installation of the exhaust
vent as specified.

• Avoid installation in places where special chemical agents
(e.g., hair spray or spray detergent) are used.

Ignition failures and malfunction may occur as a result.

• For outdoor installation, use the outdoor vent cap. If it is neces­sary to vent above the roof line in an outdoor installation, also
use the base of the vent cap for rain protection.

• Avoid installation where the unit will be exposed to excessive
winds.

• Before installing, make sure that the vent termination (or the vent
cap in an outdoor installation) will have the proper clearances
according to the National Fuel Gas Code (ANSI Z223.1).

39

6. Installation Clearances

Caution

Before installing, check for the following:

Install in accordance with relevant building and mechanical codes, as well as any local, state
or national regulations.

Item

•Maintain the following clearance from
both combustible and non-combustible
materials.

From Heater

Required Clearances

• If the unit will be installed in the vicinity of a
permanent kitchen range or stove that has
the possibility of generating steam that
contains fats or oils, use a dividing plate or
other measure to ensure that the unit is not
exposed to air containing such impurities.

Check Illustration

12" Indoor

36" Outdoor

24" Outdoor

4" Indoor

2" Indoor

24" Outdoor

Exhaust hood

* The dividing plate should be of noncombust-

ible material of a width greater than the
water heater.

Cooking Equipment

• If possible, leave 8" or more on either
side of the unit to facilitate inspection.

• If possible, leave 24" or more in front of
the unit to facilitate maintenance
and service if necessary.

repair/inspection

Securing of space for

Dividing plate

Range

8" or
more

Water
heater

Min: 3"
Min: 3"

8" or
more

24" or
more

(unit: inch)

40

Clearance Requirements from Vent Terminations to Building Openings

* All clearance requirements are in accordance with ANSI Z21.10.3a-2003 and the National Fuel Gas

Code, ANSI Z223.1.

A=

B=

C=

D=

E=
F=

G=
H=

I=

J=

K=
L=

M=

Clearance

Above grade, veranda, porch, deck,

or balcony
Window or door that may be opened

Permanently closed window
Vertical clearance to ventilated soffit

located above the terminal within a
horizontal distance of 2 feet from the
center of the terminal

Unventilated soffit
Outside corner
Inside corner
Each side of center line extended

above meter/regulator assembly
Service regulator vent outlet
Nonmechanical air supply inlet or

combustion air inlet to any other
appliance

Mechanical air supply inlet

Above paved sidewalk or paved

driveway located on public property

Under veranda, porch, deck, or

balcony

Vent Terminal

Air Supply Inlet

Indoor Installation

(See p.42)

12" (12")

4' below or to the side of

opening, or 1' above opening

(36")

*

*

*
*
*

3' within a height 15' above
meter/regulator assembly

3'

4' below or to the side of

opening, or 1' above opening

(36")

3' above if within 10' (6')

(7' ***)

* (12"- Canada Only****)

Area Where Terminal
is Not Permitted

Outdoor Installation

(See p.42)

12" (12")

12" (36")

*

*

*
*
*

3' within a height 15' above
meter/regulator assembly

3'

12" (36")

3' above if within 10' (6')

(7' ***)

* (12"- Canada Only****)

()= indicates clearances required in Canada
*Maintain clearances in accordance with local installation codes and the requirements of the gas supplier
***A vent shall not terminate directly above a sidewalk or paved driveway that is located between two
single family dwellings and serves both dwellings.
****Permitted only if veranda,porch,deck,or balcony is fully open on a minimum of two sides beneath the floor.

41

Clearance Requirements from Vent Terminations to Building Openings

* All clearance requirements are in accordance with ANSI Z21.10.3a-2003 and the National Fuel Gas

Code, ANSI Z223.1.

Maintain the following clearances to any

opening in any building:

• 4' below, 4' horizontally from, or 1' above
any door, operable window, or gravity air
inlet into any building.
3' above any forced air inlet within 10'.

Installed Indoors

Vent Clearances When Heater is

• 1' below, 1' horizontally from, or 1' above
any door, operable window, or gravity air
inlet into any building.
3' above any forced air inlet within 10'.

Illustration

4'

4'

1'

3'

9004226

Vent Clearances When Heater is

Installed Outdoors With a Vent Cap

• 1' below, 1' horizontally from, or 1' above
any door, operable window, or gravity air
inlet into any building.
3' above any forced air inlet within 10'.

Installed in a Recess Box

Outdoor Vent Cap

1'

1'

1'

3'

1'

1'

1'

3'

Vent Clearances When Heater is

(recess box installation with cover removed)

* For Installations in Canada, clearances are as follows: To windows, doors, & gravity air inlets: 36".

To forced air inlets: 6'. These clearance requirements hold true for all of the above situations: Indoor,
Outdoor w/vent cap, & Recess Box.

42

7. Installation

Securing to the wall

• The weight of the device will be applied to the wall. If the strength of the wall is not suffi­ cient, reinforcement must be done to prevent the transfer of vibration.

• Do not drop or apply unnecessary force to the device when installing. Internal parts may
be damaged and may become highly dangerous.

• Install the unit on a vertical wall and ensure that it is level.

Item

Caution

1. Drill a single screw hole, making sure to hit a stud.

2. Insert and tighten the screw and hang the unit by
the upper wall mounting bracket.

Locating Screw Holes

3. Determine the positions for the remaining four screws

(two for the top bracket and two for the bottom), and
remove the unit.

4. Drill holes for the remaining four screws.

5. Hang the unit again by the first screw, and then
insert and tighten the remaining four screws.

Check

• When installing with bare hands,
take caution to not inflict injury.

• Be careful not to hit electrical
wiring, gas, or water piping while
drilling holes.

Illustration

Location of Screw Hole

Mounting Bracket
(upper)

Locating Screw Holes

Tapping Screw

6. Take waterproofing measures so that water does
not enter the building from screws mounting the
device.

Mounting

• Make sure the unit is installed securely so that it will

not fall or move due to vibrations or earth-quakes.

Structure

43

Vent Pipe Installation

8.

(Indoor Installation Only)

Vent Piping

• Use only listed category III vent materials.

• Follow the vent pipe manufacturer's installation
instructions.

Pipe diameter 4"

No. of Elbows Max. Straight Vent Length

3 15'
2 27'
1 39'

• Make the vertical section of the exhaust vent
as short as possible.

• Maintain the same vent pipe diameter all the
way to the end.

Clearances

Manufacturer and Enclosed Unenclosed

Product Hor. Vert. Hor. Vert.
Noritz N-Vent 4" 3" 3"
Protech FasNSeal 4" 3" 3"
Protech FasNSeal W2 6" 4" 3" 3"
HeatFab SafTVent 6" 6" 2" 2"
Z-Flex Z-Vent 8" 4" 1" 1"
Flex-L StaR-34 8" 4" 1" 1"

These clearances are subject to change.
Refer to the UL listing for the proper clearances.

10" (sides)
15"(top)
6"(bottom)
8" (sides)
12"(top)
4"(bottom)

• The first vertical run from the top of the heater
should be no longer than 3'.

• Make sure vent pipe is gas tight and will not
leak. Use silicon sealant wherever necessary.

• Do not common vent or connect more than
one appliance to this venting system.

• The total vent length including horizontal &
vertical vent runs should be no less than 3'.

• Do not place any dangerous objects at the end
of the exhaust vent.

• Steam (smoke) or water drops may come out
from the end of the exhaust pipe. Select the
location for the end of the vent so that steam is
not visible, and the vent is not wet with drip­ping water.

• If snow is expected to accumulate, take care
the end of the pipe is not covered with snow or
hit by falling lumps of snow.

• Consult the vent pipe manufacturer's install­ation instructions for chimney connections.

Appliance Adapters

• Use the following adapters to connect the
unit to the venting system.

Manufacturer and

Product
Protech FasNSeal FSAA4
HeatFab SafTVent 9401RYPK

Z-Flex Z-Vent 2SVWA04
Flex-L Star-34 SRASPSA4

Part No.

Horizontal Vent Termination

Hanger

Straps

Elbow

Slope

Downwards

3'

Max.

Appliance

Adapter

44

Wall

Thimble

Termination

• Terminate at least 12" above
grade or above snow line.

• Terminate at least 7' above a
public walkway, 6' from the
combustion air intake of any
appliance, and 3' from any
other building opening, gas
utility meter, service regulator
etc.

• Terminate at least 3' above any
forced air inlet within 10', 4'
below, 4' horizontally from and
1' above any door, window, or
gravity air inlet into any building
per National Fuel Gas Code
ANSI Z223.1/NFPA 54.

•Slope the horizontal vent 1/4"
downwards for every 12".

• Use a condensation drain if
necessary.

Vertical Vent Termination

Elbow

Condensation

3'

Max.

Drain (Install
According to

Local Codes)

Hanger

Strap

Rain

Cap

Flashing

Firestop/

Support

Firestop

Roof

• Terminate at least 6' from the
combustion air intake of any
appliance, and 3' from any

other building opening, gas

utility meter, service regulator
etc.

• Enclose exterior vent systems
below the roof line to limit
condensation and protect
against mechanical failure.

• When the vent penetrates a
floor or ceiling and is not

running in a fire rated shaft, a

firestop and support is required.

• Terminate the vent system at
least 3' above, but not more
than 6' above the roof line, or
according to the vent pipe
manufacturer's instructions.

• Provide vertical support every
12' or as required by the vent
pipe manufacturer's instructions.

•Slope the horizontal vent 1/4"
downwards for every 12".

• Do not vent straight upwards.
Always have a horizontal section
of venting.

• Install a condensation drain in
the horizontal section of the
venting.

Appliance

Adapter

45

Combustion Air

Supply combustion air to the units as per the National Fuel Gas Code, ANSI Z223.1.

•Provide two permanent openings to allow
circulation of combustion air.

•Make each opening 236 square inches if
they provide indoor air, and 100 square
inches for outdoor air.

• If the unit is installed in a mechanical closet,
provide a 24" clearance in front of the unit to
the door.

• If combustion air will be provided through a
duct, size the duct to provide 86 cubic feet of
fresh air per minute.

12"

20"

20"

12"

Openings supplying indoor air

46

Gas Piping

Sample Gas Line

Sample Calculation

9.

Follow the instructions from the gas supplier.

The appliance and its individual shutoff valve must be disconnected from the gas supply piping system
during any pressure testing of that system at test pressures in excess of 1⁄2 psig (3.5 kPa).
The Appliance must be isolated from the gas supply piping system by closing its individual manual shutoff
valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1⁄2
psig (3.5 kPa).

The appliance and its gas connections must be leak tested before placing the appliance in operation.
The inlet gas pressure must be within the range specified. This is for the purposes of input adjustment.
In order to choose the proper size for the gas line, consult local codes or the National Fuel Gas Code ANSI

Z223.1.

Gas Pressure

Size the gas line according to total btuh demand
of the building and length from the meter or

Gas Meter

Select a gas meter capable of supplying the entire

btuh demand of all gas appliances in the building.
regulator so that the following supply pressures
are available even at maximum demand:

Natural Gas Supply Pressure

Min. 5" WC
Max. 10.5" WC

LP Gas Supply Pressure

Min. 10.5" WC

Gas Connection

• Do not use piping with a diameter smaller than
the inlet diameter of the water heater.

• Gas flex lines are not recommended unless they
are rated for 236,000 btuh.

• Install a gas shutoff valve on the supply line.

•Use only approved gas piping materials.

Max. 14" WC

Measuring Gas Pressure

In order to check the gas supply pressure to the unit, a
tap is provided on the gas inlet. Remove the hex head
philips screw from the tap, and connect a manometer
using a silicon tube.

In order to check the gas manifold pressure, a pair of
taps are provided on the gas valve inside the unit.
The pressure can be checked either by removing the hex
head philips screw and connecting a manometer with a
silicon tube, or by removing the 1/8" NPT screw with an
allen wrench and connecting the appropriate pressure
gauge.

Tankless Water Heater

(236,000 Btuh)

Outlet E

Section 4

5'

10'

Natural Gas

Meter

Sample Gas Line

Clothes Dryer

10'

Section 3 Section 2

5' 5'

Outlet D

Gas Fireplace
(25,000 Btuh)

**See next page for the pipe capacity charts.

(35,000 Btuh)

Outlet C

5'

Instructions

1. Size each outlet branch starting from the furthest

Barbecue

(50,000 Btuh)

Outlet A

10'

5'

Section 1

10'

Outlet B

5'

Gas Range Stove

(65,000 Btuh)

using the Btuh required and the length from the
meter.

2. Size each section of the main line using the
length to the furthest outlet and the Btuh
required by everything after that section.

Sample Calculation
Outlet A: 45' (Use 50'), 50,000 Btuh requires 1/2"
Outlet B: 40', 65,000 Btuh requires 1/2"
Section 1: 45' (Use 50'), 115,000 Btuh requires 3/4"
Outlet C: 30', 35,000 Btuh requires 1/2"
Section 2: 45' (Use 50'), 150,000 Btuh requires 3/4"
Outlet D: 25' (Use 30'), 25,000 Btuh requires 1/2"
Section 3: 45' (Use 50'), 175,000 Btuh requires 1"
Outlet E: 25' (Use 30'), 236,000 Btuh requires 1"
Section 4: 45' (Use 50'), 411,000 Btuh requires 1 1/4"

47

Natur

al Gas

Liquified P

etroleum

Maximum Natur

Pipe

Size

1/2"
3/4"

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

2"
2 1/2"

3"

3 1/2"

4"

Gas Line Sizing

Adapted from UPC 1997

al Gas

Delivery Capacity in Cubic Feet per Hour (0.60 Specific Gravity, 0.5" WC Pressure Drop)

10' 20' 30' 40' 50' 60' 70' 80' 90' 100' 125'

174
363

684
1404
2103

4050

6455
11,412
16,709
23,277

Contact the Gas Supplier for Btu/Cubic Ft. of the Supplied Gas. 1000 BTU/Cubic Ft. is a Typical Value

119
249
470

965
1445
2784
4437

7843
11,484
15,998

96
200
377

775
1161
2235
3563

6299
9222

12,847

82
171
323
663

993
1913
3049
5391
7893

10,995

Length in Feet

73
152
286
588
880

1696
2703
4778
6995
9745

66
138
259

532

798
1536
2449
4329
6338
8830

61
127
239
490
734

1413
2253

3983
5831
8123

56 53 50 44
118 111 104 93
222 208 197 174
456
683

1315
2096

3705
5425
7557

428

641
1234
1966

3476
5090
7091

404

605
1165
1857
3284
4808
6698

358

536
1033
1646
2910
4261
5936

Maximum Liquified P

Maximum Capacity of Flex TracPipe in Cubic Feet per Hour of Natural Gas

Maximum Capacity of Flex TracPipe in Thousands of Btuh Liquified Petroleum ( 0.5" WC Pressure Drop)

etroleum

Pipe

10' 20' 30' 40' 50' 60' 70' 80' 90' 100' 125' 150' 200'

Size

1/2"

275

3/4"

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

2"

** For reference only. Please consult gas pipe manufacturer for actual pipe capacities.

Pipe
Size

3/4"

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

2"

Pipe
Size

3/4"

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

2"

** For reference only. Please consult gas pipe manufacturer for actual pipe capacities.

TracPipe® is a registered trademark of Omega Flex.

189

567

393

1071

732

2205

1496

3307

2299

6221

4331

10' 20' 30' 40' 50' 60' 70' 80' 90' 100' 150' 200'
206
383

614

1261
2934

10' 20' 30' 40' 50' 60' 70' 80' 90' 100' 150' 200'
325
605

971

1993
4638

147
269
418
888

2078

232
425
661

1404
3285

(Undiluted) Delivery Capacity in Thousands of Btuh (0.5" WC Pressure Drop)

Length in Feet

152

129

114

315

590
1212
1858

3465

1698

1143
2684

121
218
334
723

191
344
528

267

504
1039
1559
2992

R

105
188
284
625

1472

166
297
449
988

2327

237
448

913
1417
2646

R

103
217
409

834
1275
2394

94
168
251
559

1317

149
265
397
884

2082

96
196
378
771

1181
2205

Length in Feet

86
153
227

509

1203

Length in Feet

136
241
359

805

1902

80
141
209
471

1114

126
222
330
745

1761

89
185
346
724

1086
2047

75
132
194
440

1042

118
208
307
696

1647

83
173
322
677

1023
1921

69

63
132
252
511
787

1496

55
94

137
320

762

87
143
217
506

1205

55
112
213
440
675

1260

48

82

116
277
661

76

129
183

438

1045

78

162

146
275

307

567

630

866

976

1606

1811

(0.60 Specific Gravity, 0.5" WC Pressure Drop)

71
125
181

415
983

112
197
286

656

1554

67
118
171
393

933

106

186
270

621

1475

Maximum Capacity for Gas Flex Connectors in Cubic Feet per Hour of Natural Gas

Pipe
Size

1/2"

3/4"

1"

1 1/4"

12" 24" 36" 48" 60" 72"

180 150

290
581

1470

Maximum Capacity for Gas Flex Connectors in Thousands of Btuh Liquified Petroleum

Pipe
Size

1/2"

3/4"

1"

1 1/4"

** For reference only. Please consult gas pipe manufacturer for actual pipe capacities.

12" 24" 36" 48" 60" 72"

288 240

465
930

2352

48

Length in Inches

125
255
512

1200

Length in Inches

200
409
825

1920

106
215

442

1130

169
344

708

1808

(0.60 Specific Gravity, 0.5" WC Pressure Drop)

93
197
397

960

( 0.5" WC Pressure Drop)

149
315
638

1536

86
173
347
930

137

278
556

1488

Ask a qualified plumber to perform the installation

10. Water Piping

This appliance is suitable for potable water and space heating applications. Do not use this appliance if any part has
been underwater. Immediately call a qualified service technician to inspect the appliance and replace any part of the
control system and gas control which has been under water.

If the water heater is installed in a closed water supply system, such as one having a backflow preventer in the cold
water supply line, means shall be provided to control thermal expansion. Contact the water supplier or a local plumb­ing inspector on how to control this situation.

A pressure relief valve must be installed near the hot water outlet that is rated in accordance with and complying with
either The Standard for Relief Valves and Automatic Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22, or
The ANSI/ASME Boiler and Pressure Vessel Code, Section IV ( Heating Boilers ). This pressure relief valve must
be capable of an hourly Btu rated temperature steam discharge of 236,000 Btuh. Multiple valves may be used. The
pressure relief capacity must not exceed 150 psig. No valve shall be placed between the relief valve and the water
heater. The relief valve must be installed such that the discharge will be conducted to a suitable place for disposal
when relief occurs. No reducing coupling or other restriction may be installed in the discharge line. The discharge line
must be installed to allow complete drainage of both the valve and the line. If this unit is installed with a separate
storage vessel, the separate vessel must have its own temperature and pressure relief valve. This valve must also
comply with The Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, ANSI
Z21.22. (in the U.S. only). A temperature relief valve is not required, but if one is used, do not install the valve with the
probe directly in the flow of water. This may cause unwarranted discharge of the valve.

Piping and components connected to the water heater shall be suitable for use with potable water.
Toxic chemicals, such as those used for boiler treatment, shall not be introduced into the potable water.
A water heater used to supply potable water may not be connected to any heating system or components previously
used with a nonpotable water heating appliance.
When water is required in one part of the system at a higher temperature than in the rest of the system, means such
as a mixing valve shall be installed to temper the water to reduce the scald hazard.

of the plumbing. Observe all applicable codes.

• Flush water through the pipe to clean out metal powder, sand and dirt before connecting it.

• Take appropriate heat insulation measures (e.g., wrapping with heat insulation materials, using electric heaters)
according to the climate of the region to prevent the pipe from freezing.

•

Use a union coupling or flexible pipe for connecting the pipes to reduce the force applied to the piping.

• Do not use piping with a diameter smaller than the coupling.

• When feed water pressure is too high, insert a depressurizing valve, or take

• Avoid using joints as much as possible to keep the piping simple.

• Avoid piping in which an air holdup can occur.

• Use approved piping materials.

• If installing the unit on a roof:
If the unit is installed on a roof to supply water to the levels below, make sure that the water pressure supplied to
the unit does not drop below 29 psi. It may be necessary to install a pump system to ensure that the water pressure
is maintained at this level.
Check the pressure before putting the unit into operation.
Failing to supply the proper pressure to the unit may result in noisy operation, shorter lifetime of the unit, and
may cause the unit to shut down frequently.

Supply water piping

• Do not use PVC piping.

• Mount a check valve and a shut off valve (near
the inlet).

• In order for the client to use the water heater
comfortably, 98.1 to 491 kPa (14 to 70 PSI) of
pressure is needed from the water supply.
Be sure to check the water pressure. If the water
pressure is low, the water heater cannot perform
to its full capability, and may become a source of
trouble for the client.

Drain piping

• Expansion water may drop from the pressure
prevention device and wet the floor. If neces­sary, provide drain piping or use a drain hose to

Hot water piping

•Do not use lead or PVC piping.

• The longer the piping, the greater the heat loss.
Try to make the piping as short as possible.

•Use mixing valve with a low water resistance.
Use shower heads with low pressure loss.

• If necessary, use a pump or other means to en­sure that the supply water pressure to the inlet
of the heater does not fall below 29 PSI when
the maximum amount of water is being de­manded. Also install a pressure meter on the in­let. If this is not done, local boiling will occur in­side the water heater causing abnormal sounds
and decreasing the durability of the heat ex­changer.

water hammer prevention measures.

remove the water.

49

11. Plumbing Applications

Recirculation System

Hot Water Return

Pump

(See notes for Sizing)

8-10 Gal.
Storage T ank
(To Alleviate Cold
Water Sandwich)

Fixtures

* Size the pump to provide at least 2 GPM through the system at 10 Ft of Head plus
piping losses. Check the maintenance monitors on the unit to make sure the pump
is providing that much flow.
** Make sure that the flow rate is not greater than 4 ft/sec. (3/4”: 5 GPM, 1 1/4”: 13 GPM)

Pressure

Relief
Valve

Drain

Cold Water Supply

(Relay for

Shutoff Valv e

Hot Water

Pump

> 85 W)

(See p. 54)

Check

Valve

Expansion T ank

(Install According

to Local Codes)

Pump Control Signal

(See p. 54)

Check V alve

Aquastat
(Use Aquastat if Unit

Isn't Controlling Pump)

Aquastat Wiring

Use Honeywell Aquastat

(Model L6006A or L6006C)

Pump

AC120

Neutral

Ground

Live

105

W

R

B

5

Pressure

Relief Valv e

Drain

Cold Water Supply

(Relay for

Shutoff Valv e

Shutoff

Valve

Hot Water

Pump

> 85 W)

(See p. 54)

Expansion

(Install According

to Local Codes)

Boiler Drain Valve

Heating System

Backflow

Preventer

(Optional)

Pressure

Reducing

Valve

(Optional)

Check

Valve

Pump Control signal

(See p. 54)

Check V alve

Aquastat
(Use Aquastat if

Unit Isn't Controlling
Pump)

Tank

Temp. &

Press. Gauge

(Optional)

Hot Water Return

Pump

(See notes for Sizing)

Air Scoop

(Optional)

Heating
Controls

* Size the pump to provide at least 2 GPM through the system at 10 Ft of Head plus
piping losses. Check the maintenance monitors on the unit to make sure the pump
is providing that much flow.
** Make sure that the flow rate is not greater than 4 ft/sec. (3/4”: 5 GPM, 1 1/4”: 13 GPM)

Hydronic Heat

Exchanger or
Radiant Heat

Piping

For Baseboard
Applications:
Please contact
sales agent for
compatibility.

Mixing V alve

50

Cold Water Supply

Tempered Potable Hot Water

Hot Water for Heating

For Space Heating Purposes:

If the system requires water
for space heating at a higher
temperature than for other
uses, means such as a mixing
valve shall be provided to
temper the water for the other
uses to help prevent scalding.

Consult qualified electrician

12.

This appliance must be electrically grounded in accordance with local codes, or in the absence of local codes,
with the National Electrical Code, ANSI/NFPA 70. In Canada, the latest CSA C22.1 Electrical Code.

Caution: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper
and dangerous operation.

Verify proper operation after servicing.
Field wiring to be performed at time of appliance installation.

Electrical Wiring

aз=езн=ЕзееЙЕн=ЙдЙЕнкбЕ~д=йзпЙк=нз=нЬЙ=мебн=менбд=~дд=ЙдЙЕнкбЕ~д=пбкбеЦ=Ь~л=ДЙЙе=ЕзгйдЙнЙЗK

for the electrical work.

Caution

• The electrical supply required by the water
heater is 120V AC at 60 Hz.
The power consumption may be up to 135W or
higher if using optional accessories.
Use an appropriate circuit.

• Do not disconnect the power supply when not
in use. When the power is off, the freeze
prevention in the water heater will not acti­vate, resulting in possible freezing damage.

Ground

• To prevent electrical shock, provide a ground
with resistance less than 100 . An electrician
should do this work.

•A grounding screw is provided on the back of
the junction box lid.

Do not connect the ground to the city water
or gas piping. Do not tie the ground to a tele­phone line.

Breaker Installation

• Mount a device which shuts off the electrical
path automatically (leakage breaker) when
electrical leakage is detected.

Do not turn on the power until the electrical wiring is finished.
This may cause electrical shock or damage to the equipment to occur.

• Do not let the power cord contact the gas piping.
Tie the redundant power cord outside the wa-

ter heater. Putting the redundant length of
cord inside the water heater may cause elec­trical interference and faulty operation.

Junction Box Lid

Junction Box

Power Cord

1.Unscrew the junction box lid and open.

2.Push the power cord through the bottom of the unit.

3.Connect the live and neutral wires to the black and
white wire in the junction box.

4.Screw the ground wire to the ground screw on the
back of the junction box lid and close junction box.

(back)

Ground

Terminal

Block

51

Remote Controller

• Applicable Model

Remote controller

Install the remote controller according to the instructions in the Installation Guide (p. 62).

• The unit can be programmed so that it will default to one of four temperatures if the remote controller
is removed (180, 140, 130, 120°F). To change the default temperature, the remote controller must be
initially installed, and removed after programming.

* Changing the default temperature setting:

1. Within the first ten minutes of connecting electrical power to the unit, but before pressing the

Power On/Off button, hit the up [ ] or down [ ] button on the remote controller. This will put
the unit into maintenance writer mode. If pressing either of these buttons does not put the unit
into maintenance writer mode, unplug the unit for sixty seconds and try again.

2. The maintenance monitor item number will flash on the display. (the initial item number will be “99”).

3. The up [ ] and down [ ] buttons can be used to change the maintenance writer item number.

4. Choose a temperature from the chart below and set the 14 and 15 maintenance writers according to

the chart. Pressing the Flow Meter Alarm Set button for 0.5 seconds will switch the indicated item
number from “OFF” to “ON” or “ON” to “OFF”. If the Priority lamp is flashing when an item number
is displayed, this indicates an “ON” setting for that item number, and if the Priority lamp is off, the
item number is off.
*Do not change the other item numbers. This may cause a fault in the water heater.

5. After setting the 14 and 15 item numbers for the desired temperature, press and hold the up [ ]

and down [ ] buttons together for five seconds to confirm the new settings. The remote control­ler will emit a tone when the settings are confirmed. If this is not done, the unit will not put the
setting changes into effect. After confirming the setting, remove the remote controller to initiate
the default temperature setting.

Note:The setting changes can be cancelled by pressing the Power On/Off button before confirming the

settings, or if the unit is left alone for ten minutes without confirming the settings. If the default
setting needs to be changed again, disconnect the electrical power to the unit, reconnect it and
follow this procedure again.

9004223

Temp.

Item No.

180°F
140°F
130°F
120°F*

52

14

ON

OFF

ON

OFF

15
ON
ON

OFF
OFF

*Factory Default Setting

Connecting Remote Controller Cord to Unit

• Keep the remote controller cord away from the freeze prevention heaters in the unit.

• Tie the redundant cord outside the water heater. Do not put the extra length inside the equipment.

• The remote controller cord can be extended up to 300' with 18AWG wire.

•Use a Y type terminal with a resin sleeve. (Without the sleeve, the copper wire may corrode and
cause problems).

• Be sure to hand tighten when screwing to the terminal block. Power tools may cause damage to the
terminal block.

Remote controller cord

• For extensions, a 26' cord can be purchased (Part # 9005694) or use 18AWG wire.

• Install according to the National Electrical Code and all applicable local codes.

1. Leave enough slack so that the remote controller
cord will not be damaged if the unit is removed
from the wall.

2. Remove the front cover of the heater (4 screws).

3. Pass the remote controller cord through the wiring
throughway and into the unit.

4. Connect the Y terminals at the end of the remote
controller cord to the terminal block.

5. Secure the remote controller cord with a clamp.

6. Replace the front cover.

Wiring
Throughway

Clamp

Terminal Block

18AWG Wire

53

Pump Wiring

Connecting the pump control wire

*This feature is not available when using

the Quick Connect Multi System feature.

1. Leave enough slack so that the pump control

wires will stay connected if the unit is removed
from the wall.

PUMP

Pump Control
Wire Tag

2. Remove the front cover of the heater (4 screws).

3. Cut off the connector at the end of the pump

Crimping Terminal

control wires.

4. Wire the pump control wires through the wiring

throughway and connect them to the wiring inside
the pump (this will be the power supply for the pump,
do not also connect 120 V to the pump).
If a large pump is being used (greater than 85W)
use the voltage from these wires as the signal to
close a normally open relay through which 120 V will
be supplied directly from a wall circuit to the pump.

Wiring
Throughway

Supplies Power for
Circulating Pump
(Use a Relay for
Larger Pumps)

5. Replace the front cover.

Relay connection with larger pumps (>85 W)

1.Locate and prepare the pump control wires as described above.

2.Choose a suitable installation location for the relay where it will be protected from moisture.

3.Connect the pump control wires from the heater to the signal input on the relay.

4.Cut one of the electrical supply leads and wire it across the open terminals of the relay.

5.Secure all connections and replace the front cover of the heater.

Connect to Pump Control
Wires in Unit

AC120V

4

012

Circulation Pump

Relay (ex. Omron G7L2ABUBJCBAC120)

54

Periodically check the following to ensure proper

13.

• The venting system must be examined periodically by a qualified service technician to check for
any leaks or corrosion.

• The burner flame must be checked periodically for a proper blue color and consistency.

• If the flame does not appear normal, the burner may need to be cleaned.

• If the burner needs to be cleaned, it must be performed by a qualified service technician.

• Do not obstruct the flow of combustion and ventilation air.

• The pressure relief valve must be operated once a year to ensure that it is functioning properly
and there is no obstruction. Turn the power off to the unit before opening the relief valve, and
make sure that water draining out of the valve will not cause any damage.

• If the relief valve discharges periodically, it may be due to thermal expansion in a closed water
system. Contact the water supplier or a local plumbing inspector on how to correct this situation.
Do not plug the relief valve.

• See Operation Manual for further maintenance.

Warning:

14.

Maintenance

There is a scald potential if the output temperature is set too high.
Should overheating occur, or the gas supply fail to shut off, turn off the manual gas control valve to the appliance.
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.
Periodically check and clean the filter inside the cold water inlet of the unit.

Trial Operation

operation of the water heater.

The installer should test operate the unit, explain to
the customer how to use the unit, and give the owner
this manual before leaving the installation

• Preparation

(1) Open a hot water fixture and confirm that the Burner On lamp comes on, and that hot water is

being produced. (If necessary, repeat until the air in the gas piping is bled out).
*White smoke may be noticed from the exhaust vent during cold weather. However, this is not a

malfunction of the unit.

* If an “11” error code appears on the remote controller, turn the unit off and then back on again,

and then open a hot water fixture again.

(2) Change the temperature setting on the remote controller and check that the water temperature changes.

• If the water heater does not operate normally, refer to “Troubleshooting” in the Operation Manual.
* After the trial operation, clean the filter in the cold water inlet.

<If installed with a quick connect multi-system>

• Turn the system power on with the remote controller.

•Slowly open a hot water fixture and check that the units ignite sequentially. Check to see that the
hot water temperature is the same as the temperature displayed on the remote controller. (*1)

* If both units do not ignite, switch which unit will ignite first by pressing the Max. or Min. Mani-

fold Pressure Set Button on the circuit board (see p. 57). (*2)

Unit A Ignites
Unit B Doesn't Ignite

...........

(1) Open a hot water fixture to confirm that water is available, and then close

the fixture.

(2) Open the gas supply valve, turn on the power supply, and press the Power

On/Off button on the remote controller (the Operation lamp will turn on).

Press Max. or Min. Manifold
Pressure Set Button on Unit B

Unit A Doesn't Ignite
Unit B Ignites

* If an 11 or F11 error code flashes on the remote controller, hit the Power Button on the remote

controller off and on 2-3 times.

* If (*1) and (*2) cannot be done, the Quick Connect Cord may not be properly connected.

Check that the cord is properly connected.

55

Caution

Handling after trial operation

• If the unit will not be used immediately, close off all gas and water shutoff valves, drain all of
the water out of the unit and the plumbing system to prevent the unit and system from
freezing, and bleed the gas out of the gas line.

Freezing is not covered by the warranty.

Lighting Instructions

This water heater does not have a pilot. It is equipped with an ignition device that automatically lights
the burner.
Do not try to light the burner by hand.

1. Read the safety information in the installation manual or on the front of the water heater.

2. Turn off all electrical power to the unit.

3. Do not attempt to light the burner by hand.

4. Turn the gas control manual valve (external to the unit) clockwise to the off position.

5. Wait five minutes to clear out any gas. If the smell of gas remains, stop, and follow the instructions
on page 3 of this manual.

6. Turn the gas control manual valve counterclockwise to the on position.

7. Turn on electric power to the unit.

8. The unit will now operate whenever hot water is called for. If the unit will not operate, follow the
shutdown instructions and call a service technician.

Shutdown Instructions

1. Stop any water demand.

2. Turn off electric power.

3. Turn the gas control manual valve clockwise to the off position.

Should overheating occur, or the gas supply fail to shut off, turn off the manual control valve to the appliance.

15.

Dimensions

(VIEW FROM TOP)

14.2"

11"

9.6"

HOT WATER OUTLET (3/4")

UPPER WALL MOUNT BRACKETS

6.8"

3.5"

7"

2.4"

2.8"

6.7"

5.5"

3.9"

2.8"

1.4"

GAS INLET (3/4")

WIRING THROUGHWAYS

"

26.2

3.4"

5.5"

6.9"

COLD WATER INLET (3/4")

9.4"0.4"

3.7"

1.6"

2.8"

24.2"

17.7"

18.3"

17.7"

4"

FLUE COLLAR

LED

AIR INLET

LOWER WALL MOUNT BRACKETS

56

1.4"

2.8"

3.9"

5.5"

6.7"

0.4"

BOTTOM
OF CASE

WIRING THROUGHWAYS

WATER DRAIN VALVE
(WATER FILTER)

HOT WATER OUTLET

WATER DRAIN VALVES

1.7"

BOTTOM OF CASE

2"

2.2"

COLD

HOT

COLD WATER INLET

GROUND

GAS

GAS INLET

WATER DRAIN VALVES

MAIN WATER
FLOW CONTROL
VALVE

BYPASS FLOW
CONTROL VALVE

<Optional>

SYSTEM CONTROLLER

MAIN FLOW
SENSOR

BYPASS FLOW SENSOR

AIR INLET
THERMISTOR

WATER INLET
THERMISTOR

HEAT EXCHANGER
THERMISTOR

WATER OUTLET
THERMISTOR

FREEZE PREVENTION
SWITCH

DISCONNECT FOR
SYSTEM CONTROLLER

REMOTE CONTROLLER

TRANSFORMER

<AC120V>

FLAME ROD

FAN MOTOR

ELECTRODE

HIGH-LIMIT SWITCH

COLOR CODING

W : White
R : Red

BK : Black
V : Violet
O : Orange

BL : Blue

GY : Gray

G : Green

BR : Brown

Y : Yellow

WIRING DIAGRAM

8

BK

BK

7

V

(VCC)

(VCC)
(Fully open)
(GND)

(VCC)

(VCC)
(Fully open)
(GND)

(Pulse)

(VCC)
(GND)

(Pulse)

(VCC)
(GND)

W
BL

R
Y
O

IG

1

W

2

WW

B5

W
W

6
5

4

BL

3
2
1

W

V

6

W

5

GG

4

O

3

R

2

Y

1

BL BL

8

BK

7

V

6

W

5

G

4

O

3

3

R

2

2

Y

1

1

BL

1
2

BK

3
2

R

1

BL

3

Y

2
1

BK
BK

W

W

11

BL
W

W

R
Y
O

BK

W

W
O

R

Y

BK

V
W
G
O

Y
BL
BL

R

YRY
BL

W
Y
BLRBL

BL

2
1

3
2
1

4
3
2
1

2
1

BK
BK

BL BL
BL

THERMAL FUSE

R1
BL

THERMAL FUSE

1

R

R

R

R

W
W
W

W
WWW

WW

WW
W
WWW

2

BL

1

CURRENT LEAKAGE
SAFETY DEVICE
(GFCI)

BK

G

W

<CN59>

Y

W

Y

8

W

7
6
5
4

W

3

W

2

W

1

W

<CN63>

<CN78>

BL

<CN89>

12
34
56
78

10

9
11 12

R

13 14
15 16

BK

17 18

BL

19 20

1

BL
BL

WBK

WW

GROUND

3
2
1

3214

<CN92>

<CN100>

G

<CN102>

3

6

O

BK

5

2

Y

4

1

W

R

<CN75>

MAIN CIRCUIT
BOARD

WGW

36142

<CN1>

5

W

WW

12

R

34
56

W

78

O

10

9

BK

11 12

V

13 14

GBL

15 16
17 18

Y

19 20

W

21 22

BK

<CN38>

1
2
3

R

4

W

BL
W
O
BK
V
G

Y
BL
BL

<CN27>

56

W

<CN184>

<CN10>

POWER CIRCUIT
BOARD

123

4

BL

ROY

1
2
3
4
5
6
7

2

1

4

3

BR

O

6

5

WBKBK

87

GYBL

<CN102>

O

Y

W

<CN103>

7
6
5
4
3
2
1

BK

GROUND

W

W

12

W

W

WWW

W

WWW

W

FREEZE PROTECTION
HEATERS

WWW

121222 1 1

WWWWW

P

CIRCULATION PUMP
<Optional>

BURNER THRMISTOR

1

R

R

2
3

W

W

Manifold Gas Pressure
Increase Button
Manifold Gas Pressure
Decrease Button

Minimum Manifold Pressure Set Button
Maximum Manifold Pressure Set Button

1

1

R

R
BK
W
G
BL
BL

1
2

R

2

2

BK

3

3

W

4

4

G

5

5

BL

6

6

BL

BL

R

O
BL
BR
GY
W
BK

HOT

DC140V

15V POWER CIRCUIT

R (W)
BK (G)
W (R)
G (BK)

BL
BL

8

BL

7

R

6

O

5

BL

4

BR

3

GY

2

W

1

BK

DC90V

DC15V(1)

WATER FLOW SENSOR 1

WATER FLOW SENSOR 2

WATER FLOW SERVO 1

WATER FLOW SERVO 2

WIND PRESSURE SWITCH

FREEZE PREVENTION SWITCH

THERMAL FUSE

DU

GAS PROPORTION VALVE
POWER CONTROL CIRCUIT

FLAME DETECTING CIRCUIT

FR FLAME ROD

BLBL

BLBL BL

Other Unit in Quick Connect Multi System

MAIN CIRCUIT
BOARD

184

<CN184>

(For Quick Connect Multi System Only)

Quick Connect Cord(Optional)

BURNING LED

2

BKBK

1

W

W

BK
BK

GY
GY

O
O

BR
BR

W
W

RELAY 7

RELAY 8

VARISTOR

RELAY 9

IG

RELAY 3

SV0

RELAY 1

SV1

RELAY 4

SV2

RELAY 5

SV3

RELAY 2

SV4

POWER
CONTROLLER

DC15V(2)

PRIMARY

SECONDARY

RELAY 1

RELAY 2

RELAY 5

RELAY 7

RELAY 8

RELAY 9

A B

GND

1

1

RR

2

BKWBK

3
4
5
6

BL BL

7

BL

R

11

12

13

14

10

AC120V

AC100V

CIRCULATION PUMP

IGNITER

SOLENOID VALVE 0

SOLENOID VALVE 1

SOLENOID VALVE 2

SOLENOID VALVE 3

SOLENOID VALVE 4

RELAY
DRIVING
CIRCUIT

(R) W
(BK) G
(W) R
(G) BK

BL
BL

DU

SV

Q1

SV

Q2

SV

Q3

SV

Q4

SV

0

FAN

C

CPU

CENTRAL
PROCESSING
UNIT

1
2
3
4

GWG

5

BLBL

6

1
2
3
4
5
6

GAS VALVES

PRIMARY

SECONDARY

FREEZE PROTECTION
HEATERS

COMBUTION FAN

INPUT AND
OUTPUT PULSE

10A(FUSE)

HIGH LIMIT
SWITCH

DC90V

FAN
PULSE
CONTROL
CIRCUIT

WATER OUTLET THERMISTOR

WATER INLET THERMISTOR
WATER THERMISTOR FOR

HEAT EXCHANGER

AIR INLET THERMISTOR

BURNER SENSOR

NEUTRAL

ARRESTER

DC140V

BA

5V POWER CIRCUIT

VARISTOR

GND

C

SM

LS

SM

LS

QS

QS

2

W

W

BK

BK

1

W (Vs)
BL(GND)

FM

R (Vcc)

Y (FG)

O (Vsp)

57

Connecting Quick Connect Cord

Caution

The wire coloring on the Quick Connect Cord will
not be the same as the wire coloring from the
connection plug inside the unit.
* The remote controller can be connected to either

unit A or B.

Instruction for connecting the Quick Connect
Cord to each unit:

1. Turn off the power.

2. Remove the front cover of the heater (4 screws).

3. Pass the Quick Connect Cord through the wiring
throughway and into the unit.

4. Plug the connector on the Quick Connect Cord to
the receptacle inside the unit.

5. Attach the ground wire of the Quick Connect Cord
to the terminal block fixing plate.
(If the ground wire is not attached, electrical noise
may cause problems)

6. Secure the coupling cord with a clamp.

7. Replace the front cover.

For Quick Connect Multi System Installation
use a Quick Connect Cord (Sold Separately).

1.Red

Quick Connect
Cord

1.Red

2.Black

2.Black

3.White

3.White

4.Green

4.Green

5.Blue

5.Blue

6.Blue

6.Blue

AB

1.Red

1.White

2.Black

2.Green

3.White

3.Red

4.Green

4.Black

5.Blue

5.Blue

6.Blue

6.Blue

"Quick Connect Cord" tag

Ground wire

Connector

Clamp

Junction Box

Wiring Throughway

Coupling Cord

16.

Multi-System

A. Installation without a recirculation system

Unit No.6

Hot Water Pipe

(1 1/4"-2")

Unit No.2

Install one system controller
(Part # 9005695) for every six units.

System Controller

Unit
No.1

Disconnect this Connector

* Disconnect this
connector
on units 2-6 also

System Select Connector

* Do not connect to

Disconnect for system controller

the connector.

Remote Controller

Gas pipe

G

Cold Water Supply

(1 1/4"-2")

Pipe

• Insulate or apply heating materials to both the cold water supply piping and the hot water piping to
prevent freezing during cold weather and to prevent heat loss through the piping.

58

B-1. Example of Recirculation with a Multi-System

G

(1 1/4"-2")

(3/4"-1 1/4")

Hot Water

Supply

Circulation Pump 2

(If Necessary)

Circulation Pump 1

System select connector

Connect to the "Recirculation System"

connector.

Remote Controller

Pump Connection Wire (for pumps

> 85 W, use an external relay)

When installing 2 pumps in parallel

* Set dipswitch 3 to "OFF".

(See Part # 9005695 Installation

Manual page 13)

Gas Pipe

Hot Water Return Line

*

Size the water supply piping to

allow for maximum flow rates

of the units.

Hot Water

(1 1/4"-2")

Water supply

* Also disconnect this connector on units 2-6

Disconnect this Connector

Expansion

Tank

Unit

6

Unit

2

Unit

1

System Controller

This system will make hot water more quickly available to remote fixtures.
The pump will circulate water through the loop until the entire loop is warm, and then the system
controller will turn off the pump until the loop cools down.

Check the maintenance monitors on the unit to make sure the pump is providing adequate flow.

Make sure that the flow rate is not greater than 4 ft./sec.

(3/4”: 5 GPM, 1 1/4”: 13 GPM)

If the flow is too low, the recirculation loop temperature will not be warm enough, if the flow is too

* Size the pump to provide at least 2 GPM @ 10 feet of head + piping losses through the system.

•

high, the lifetime of the unit will be reduced.

* If there are multiple circulation loops, try to make the flow rate .75-1.25 GPM in each loop.

* Use copper or stainless water piping for the entire system.

59

G

(1 1/4"-2")

Unit 6 Unit 2 Unit 1

System Controller

Storage tank supply line

(1 1/4"-2")

Storage tank return line

(Copper or Stainless Pipe)

(Copper or Stainless Pipe)

Storage Tank Circulation Pump 1

Storage Tank Circulation Pump 2

(if Necessary)

Gas Pipe

Hot Water

Storage Tank

Relief Valve

Hot water supply line

(Copper or Stainless Pipe)

Return line

circulation pump

Hot water return line

(Copper or Stainless Pipe)

Cold Water Supply

* Size the water supply piping to

allow for maximum flow rates

of the building.

* Set dipswitch 3 to OFF.

(See Part #9005695 Installation

Manual page 13)

* If the tank thermostat will control the pump

set dipswitch 2 to OFF.

(See Part #9005695 Installation Manual)

Do not connect more than one pump to the tank

thermostat.

Hot Water

Supply

Remote

Controller

Option 2-Unit

Control

Option 1-Tank

Thermostat Control

When installing 2 pumps in parallel

The system controller will stop the units from heating when the tank is up to temperature,

and the unit will cut the flow through it to 1.3 GPM.

Install the plumbing so that a change in flow will not damage the pump.

Thermostat

System select connector

Connect to the “Sto-

rage system”

connector"

Pump Control

Wires (use

external relay)

* Also

disconnect this

connector on units 2-6

Disconnect this Connector

B-2. Example of Installation with a Storage Tank and Recirculation System

The pump will push water through the Multi-System to heat up the tank.
When the return temperature is high, the flow within the device will be limited to 1.3 GPM*.

236,000btuh : 7.4 GPM (each) @ 40 ft. of head (160°F setting or less) + piping losses through the system).

* For the set temperature of the remote control, use the temperature (of the thermostat) + about 9°F.

Verify the supply pressure to the units is at least 30 PSI.

* To achieve the highest recovery, size the storage tank circulation pump for maximum capacity.

60

Multi-System Wiring (Part # 9005695)

System Controller

* Connect these to the

remote control terminal
block in each unit

No.6
No.5

No.4

No.3
No.2

Unit 1

Disconnect this
Connector

Disconnect for system controller

Remote control
terminal block

Remote Controller Cord

Disconnect this
Connector

Remote Control
terminal block

Remote
Controller

Unit 2

PCB

DPSW

12345678

90 90 89

B5 B5

PCB

102

Power
PCB

System select connectors

* The remote controller terminal

location may differ depending
on the unit.

Remote Controller Cord

Disconnect this
Connector

Remote control
terminal block

Remote Controller Cord

Units 3-6

Power
PCB

PCB

Disconnect for system controller Disconnect for system controller

Power
PCB

* The connector location may

be slightly different on the
actual circuit boards than in
these illustrations.

61

For Installers:

Remote Controller

Read this installation guide
carefully before carrying out
installation.

Installation Guide

Note

Do not connect power to the water heater before the remote controller has been properly
installed.

Included Parts List

Part Name
Remote Controller

Wall Packing
Phillips Roundhead Wood Screw
Wall Anchor

Do not disassemble the remote controller.

Quantity

1
1
2
2

Notes on the Installation Location

•The remote should be installed in an easily
accessible location.

• Avoid installing in a place where water may
splash on the controller.

• Avoid locations where special chemical
agents (e.g., benzene, fatty and oily deter­gents) are used.

• Avoid outdoor installation, or installation in an
indoor location where it will be exposed to
direct sunlight.

Wall Packing

9004223
Remote Controller

Connecting Wire

Phillips Roundhead
Wood Screw

Wall Anchor

Connection of Remote Controller Cord

White Connector
Y-shaped terminals To Water heater

(two-core)
* Confirm the connection with the labels at

both ends of the remote controller cord.

•A 26' cord can be purchased separately
(Part # 9005694).

• The remote controller cord can be ex­tended up to 300 ft. by splicing the cord
and using 18 gauge wire to extend the
cord to the appropriate length.

To Remote controller

62

Installation

1. Apply Wall Packing to the rear side of the
remote controller.

2. Connect the remote controller wires to the
separate remote controller cord.

Remote
Control
Wires

Wall Packing
(take off the paper)

Remote Controller Cord

Rear Side of
Remote Controller

3. Remove the cover of the remote control,
mark the location of the screw holes, and
drill holes for the wall anchors.

4. Insert the wall anchors, screw the remote
control to the wall and replace the cover.

Wall Anchor

Phillips Roundhead

Wood Screw

63

Installing the Remote Controller Outdoor Junction Box

1. Insert the remote controller wires through the
wall pipe and secure the wall pipe to the
remote controller. Locate the remote controller
wall packing, slide it over the pipe and wires,
and apply it to the rear side of the remote.

Rear side of remote controller

Wall Packing

Secure the wall pipe
firmly into the remote
controller.

Take off the
paper.

2. Drill a 1-1/4" hole in the wall where the
remote controller will be installed.

* Do not install the remote controller in a

location that is exposed to moisture, direct
sunlight, or chemical agents. These can
damage the remote controller.

5. Slide the box nut over the remote controller
wires and screw it onto the wall pipe.

Wall Pipe

Box Nut

Remote
Controller
Wires

6. Connect the remote controller wires to the
separate remote controller cord inside the box.
Wind the excess remote controller wire on the
provided hooks as illustrated below.

(Wind the
excess wire
here.)

3. Insert the wall pipe containing the remote
controller wires through the hole.

4. Slide the junction box packing and the junction
box over the remote controller wires and wall
pipe protruding from the outside wall.

Wall packing

Take off the paper.

Wall pipe

Take out the pipe about
3/4" from the wall.

Junction Box

Box Nut

Remote
Controller
Wires

Junction Box Packing

Remote Controller
Wires

Junction Box

Remote Controller
Cord

Tie the redundant length of the remote
controller cord outside the junction box.

7. Close the junction box.

64

65

66

67