Manuals - Lochinvar
Contents
1. 2 Use the proper PVC cement to secure the 90 exhaust vent and air intake terminals provided with the water heater to the plastic pipes The distance between the back edge of the 90 exhaust vent terminal and the exterior wall see Figure 11 must be 6 inches 12 7 cm more for the exhaust vent terminal than the air intake terminal Use the proper cement or sealant and assembly procedures to secure the vent connector joints between the terminal and the blower outlet Provide support brackets for every 3 feet 97 m of horizontal vent Figure 11 Typical Horizontal Direct Vent System EVERY 3 MIN SUPPORT BRACKET 90 EXHAUST TERMINAL 90 INTAKE TERMINAL 3 OR 4 PVC PIPE SUPPORT BRACKET Vertical Installation Vertical venting system must be supported every 5 feet of vertical run and every 3 feet of horizontal run of vent pipe length Stress levels in the pipe and fittings can be significantly increased by improper installation If rigid pipe clamps are used to hold the pipe in place or if the pipe cannot move freely through a wall penetration the pipe may be directly stressed or high thermal stresses may be formed when the pipe heats up and expands Install accordingly to minimize such stresses Follow the following procedure to vent through the roof 1 Cut the necessary holes through the roof and ceiling 2 Install the exhaust vent and air intake plastic pipes as shown in Figure 12 Make sure that the i2. ap SSA water outlet are identified on the water heater Make the proper vacuum Breaker 1 ET TELA Te T plumbing connections between the water heater and the plumbing CoD WATER SUN Sea system to the house Install a shut off valve in the cold water i supply line 2 If this water heater is installed in a closed water supply system such as the one having a back flow preventer in the cold water supply provisions must be made to control thermal expansion DO NOT operate this water heater in a closed system without provisions for controlling thermal expansion Warranties do not cover damages TNR I amp S 02 from thermal expansion such as pressure bulges and or deformities Your ad Table 1 water supplier or local plumbing inspector should be contacted on how to control this situation Approximate Time Temperature Scald Chart APPROXIMATE TIME TEMPERATURE 3 After installation of the water lines open the main water supply valve RELATIONSHIPS IN SCALDS and fill the water heater While the water heater is filling open 120 F several hot water faucets to allow air to escape from the water system 125 F When a steady stream of water flows through the faucets close them 130 F About 30 seconds and check all water connections for possible leaks 135 F About 10 seconds 140 F Less than 5 d 4 Never operate the water heater without first being certain it is filled gt ad ai gt 145 F Less than 3 seconds with water
3. FLOW CONTROL J ALTERNATE SPACE HEATING OUTLET BRONZE CIRCULATOR b Typical Plumbing Schematic for Zoned Heating 18 MIN IF CONVENTIONAL AIR SEPARATOR AIR VENT TEMPERATURE AND PRESSURE GAUGE PRESSURE RELIEF VALVE BALL VALVE TO HYDRONIC 5 HEATING ZONE S HOT WATER OUTLET POTABLE WATER EXPANSION TANK ALTERNATE SPACE HEATING RETURN COLD WATER SUPPLY BALL VALVE PRESSURE REDUCING VALVE SPACE HEATING AIR SEPARATOR EXPANSION TANK FROM HYDRONIC AS REQ D COLD WATER SUPPLY BALL VALVE HEATING ZONE S DENOTES THAT THE SPECIFIC COMPONENT NEEDS TO BE PROPERLY SIZED FOR THE SYSTEM THAT IS BEING DESIGNED DRAIN PAN VENTING A WARNING The vent system must be properly installed Failure to properly install the vent system could result in property damage personal injury or death DO NOT install damaged venting system components If damage is evident then please contact the supplier where the water heater was purchased or the manufacturer listed on the rating plate for replacement parts Use only the vent terminals provided or factory authorized terminals for venting this water heater The water heater requires its own separate venting system Do not connect the exhaust vent into an existing vent pipe or chimney All of the exhaust venting connections must be leak checked with a soap solution upon initial start up of the water heater Any leaks mu
4. HIGHEST ANTICIPATED SNOW LEVEL Install rain cap and small diameter pipe assembly in concentric Y fitting and large pipe assembly Ensure small diameter pipe is cemented ROOF DET ERR and bottomed in concentric Y fitting FIELD SUPPLIED Secure assembly to structure as shown in Figure 21 Ensure clearances as shown in Figure 21 Cement heater combustion air and vent pipes to concentric Y fitting SUPPORT Q termination assembly See Figure 21 for proper pipe attachment FIELD SUPPLIED Operate heater through one cycle to ensure combustion air and vent pipes are properly connected to concentric vent termination connections COMBUSTION AIR Figure 21 STRAP FIELD SUPPLIED ELBOW FIELD SUPPLIED COMBUSTION AIR TNR I amp S 02 Concentric Vent Side Wall Attachment ROOF OVERHANG 12 MINIMUM Tr 1 MAX VENT NOTE STRAP MUST BE FIELD INSTALLED TO PREVENT MOVEMENT OF VENT TERMINAL IN WALL COMBUSTION AIR MAINTAIN 12 IN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER VENT PIPE PREPARATION A WARNING DO NOT attempt to start this water heater until vent pipe solvent fumes completely clear from the room and inside the vent piping INITIAL PREPARATION l Make sure the solvent cement you are planning to use is designed for the specific application you are attempting 2 Know
5. 150 F About 1 4 seconds SCALDING 155 F About 1 second This water heater can deliver scalding temperature water at any faucetin ALTERNATE SPACE HEATING WATER CONNECTIONS the system Be careful whenever using hot water to avoid scalding injury Certain appliances such as dishwashers and automatic clothes washers A DANGER may require increased temperature water By setting the thermostat on Toxic chemical such as those used for boiler treatment shall not be this water heater to obtain the increased temperature water required by introduced into potable water used for space heating these appliances you may create the potential for scald injury To protect This water heater shall not be connected to an existing heating against injury you should install ASSE approved mixing valve in the water system or component s previously used with a non potable water system This valve will reduce point of discharge temperature by mixing heating appliance cold and hot water in branch supply lines Such valves are available from All piping components connected to this water heater for space the local plumbing supplier heating applications must be suitable for use with potable water Figure 7 Scald Warning A WARNING N D A N G F R When the system requires water for space heating at temperatures higher than required for other means a tempering valve shall be installed to temper the water for those uses in order to reduce the scald haz
6. WHICH CAN ALSO CREATE A RISK OF ASPHYXIATION Refer to local codes and or National Fuel Gas Code for proper air opening sizing UNCONFINED SPACE 1 In buildings of conventional frame brick or stone construction unconfined spaces may provide adequate air for combustion and ventilation If the unconfined space is within a building of tight construction buildings using the following construction weather stripping heavy insulation caulking vapor barrier etc air for combustion and ventilation must be obtained from outdoors This may be accomplished by piping air directly to the water heater from outside or providing opening or ducts in the wall The installation instructions for confined spaces in tightly constructed buildings must be followed to ensure adequate air supply CONFINED SPACE 1 When drawing combustion air from inside a conventionally constructed building to a confined space such a space shall be provided with two permanent openings The top opening is to be located within twelve 12 inches of the enclosure top and the bottom opening within twelve 12 inches of the enclosure bottom e Each opening shall have a free area of at least one square inch per 1000 Btu hr of the total input of all appliances in the enclosure but not less than 100 square inches 2 If the confined space is within a building of tight construction air for combustion and ventilation must be obtained from outdoors This may be accompl
7. turn on the main power switch Adjust thermostat to the Max setting Watch the LED s light as the controller goes through the S OP as previously described 7 Upon ignition observe the main burner flame 8 Readjust thermostat to previous setting 9 Replace combustion surround top and latch it securely in place 19 TNR I amp S 02 TROUBLESHOOTING GUIDE Main power light is not lit Make sure that water heater is plugged in When the switch is on is there 120VAC between L1 and N on the terminal block If not then check for loose wire connections on the Power Switch Wire Harness If connections are ok then replace the switch If there is voltage between L1 and N then the light on the switch is burnt out Replace switch Thermostat does not call for heat Make sure that the temperature of the tank is cool IF the thermostat does not call for heat then check the PRIMARY voltage across the Transformer If there is voltage across the PRIMARY then check the voltage across the SECONDARY leads of the Transformer Install a jumper wire from N O terminal to the COM terminal on the Thermostat PC Board If the thermostat calls for heat after installing a jumper wire then check the Thermostat Sensor Probe leads for proper resistance with an OHM meter See appendix A If sensor reading are not correct replace Thermostat Sensor Probe If the sensor readings are correct then check Potentiometer for the proper resistance If the
8. And Less Then 50 Ohms at Maximum Be Careful When Making Voltage Measurements or Jumping Terminals Not to Damage or Deform Connectors or Connector Pins
9. SEDIMENT AND LIME SCALE REMOVAL Waterborne impurities consist of the particles of soil and sand which settle out and form a layer of sediment on the bottom of the tank The amount of calcium carbonate lime released from water is in direct proportion to water temperature and usage The higher the water temperature or water usage the more lime deposits are dropped out of 18 INTERVAL REQUIRED me Sey C i O O ona ime ly me O m me my S S Replace as Required Proper Operation Soft Brush Joints should be sealed Clean of dust and dirt Remove object that caused restriction Confirm S OP Remove restriction the water This is the lime scale which forms in pipes water heaters and on cooking utensils Lime accumulation not only reduces the life of the equipment but also reduces efficiency of the water heater and increases fuel consumption The usage of water softening equipment greatly reduces the hardness of the water However this equipment does not always remove all of the hardness lime For this reason it is recommended that a regular schedule of deliming be maintained The depth of the buildup should be measured periodically Water heaters will have about 3 inches of lime buildup when the level of lime has reached the bottom of the cleanout opening or about 1 inch of lime buildup if it has reached the drain valve opening A schedule for deliming should be set up based on the amount of time it would tak
10. act as a retarding agent to extend curing time Select the proper cement Schedule 40 cement should be used for Schedule 40 pipe Never use all purpose cements or commercial glues and adhesives to join PVC or CPVC pipe and fittings SAFETY PRECAUTION PRIMERS AND CEMENTS ARE EXTREMELY FLAMMABLE AND MUST NOT BE STORED OR USED NEAR HEAT OR OPEN FLAME ALSO USE ONLY IN A WELL VENTILATED AREA 13 TNR I amp S 02 GAS CONNECTIONS A WARNING Connect this water heater only to the type of gas as shown on the rating plate Use clean black iron pipe or equivalent material approved by local codes and ordinances Dirt and scale from the pipe can enter the gas valve and cause it to malfunction The inlet gas line must have at least a 3 inch 7 62 cm drip leg sediment trap installed as close to the water heater s gas valve as possible A ground joint union must be installed in the gas supply line as close to the water heater as possible to permit servicing of the water heater Compounds used on the threaded joints of the gas piping must be resistant to the action of liquefied petroleum gases propane gas DO NOT apply pipe dope to the gas valve inlet and make certain that no pipe dope has become lodged in the inlet screen of the gas valve Extreme care must be taken to ensure no pipe dope enters the gas valve and to avoid excessive torque when tightening the gas supply line to the gas valve Excessive torque may result in cracking of the gas valve
11. electrical disconnect switch 2 Open the drain valve and allow water to flow until it runs clean 3 Close the drain valve when finished flushing 4 Turn ON the water heater electrical disconnect switch DRAINING WATER HEATER The water heater must be drained if it is to be shut down and exposed to freezing temperatures Maintenance and service procedures may also require draining the water heater 1 Turnoff the water heater electrical disconnect switch 2 Connect a hose to the drain valve 3 Locate hose s discharge in an area where hot water will not cause any damage or injury 4 Close the cold water inlet valve to water heater 5 Open a nearby hot water faucet to vent the system 6 Open the heater drain valve 7 df the water heater is being drained for an extended shutdown it is suggested the drain valve be left open during this period FILLING WATER HEATER l Close the water heater drain valve by turning the knob or valve stem clockwise If alternative water connections are provided but not used make certain they are plugged i e rear connections 2 Open the cold water supply shut off valve 3 Open several hot water faucets to allow air to escape from the system 4 When a steady stream of water flows from the faucets the water heater is filled Close the faucets and check for water leaks at the water heater drain valve combination temperature and pressure relief valve and the hot and cold water connections
12. not sense flame and the water heater will not operate Verify polarity before connecting the water heater TNR I amp S 02 WARNING If the unit is exposed to the following do not operate water heater until all corrective steps have been made by a factory authorized independent service contractor or qualified service professional 1 Flooding to or above the level of the burner or controls 2 External firing 3 Damage 4 Firing without water 5 Sooting NEVER OPERATE THE WATER HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER AND A TEMPERATURE AND PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE OPENING OF THE WATER HEATER WIRING DIAGRAM AND SCHEMATIC 2 12 3 P2 Pi Pr Pi ELECTRONIC CONTROL MODULE N C TEMP ors P S N C pa NO ms VALVE ELECTRONIC THERMOSTAT Figure 23 OPERATING INSTRUCTIONS A WARNING Water heaters are heat producing appliances To avoid damage or injury there must be no materials stored against the water heater or direct vent system and proper care must be taken to avoid unnecessary contact especially by children with the water heater and direct vent system UNDER NO CIRCUMSTANCES SHOULD FLAMMABLE MATERIALS SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER Installation or service of this water heater requires ability equivalent to that of a licensed t
13. readings are correct then replace the Thermostat PC Board otherwise replace the Potentiometer Ignition module Power LED is not lit Check for 120 VAC at the ignition module on 120 VACIN If there is voltage then replace the ignition module If there is not any voltage check the voltage across the transformer as previously described Blower does not energize Is the Vacuum Switch air intake switch N C If no then check the hose and see if it is filled with condensate If the hose is not filled with condensate then replace vacuum switch If filled empty hose Is the Pressure Switch exhaust pressure switch N 0 If no then check the hose and see if it is filled with condensate If the hose is not filled with condensate then replace pressure switch If filled empty hose Is the Collector Limit Switch N C If no then reset switch If this switch trips more than 3 times call service If all items above are ok then replace the blower Ignitor does not glow Is there voltage to the Hot Surface Ignitor Check for 120VAC to the ignitor from the ignition module Is there continuity across the Hot Surface Ignitor If no then replace hot surface ignitor If yes then replace the ignition module Main valve does not turn on Put your hand on the gas valve When the Valve LED lights on the ignition module can you feel it energize If not then check the voltages at the ignition module across pi
14. shock can cause personal injury 12 30 5 cm or death MIN DO NOT operate this water heater with the rain cap removed or recirculation of combustion products may occur Water may also collect NE inside larger combustion air pipe and flow to the burner assembly sce E Failure to follow this warning could result in product damage or improper operation personal injury or death Figure 16 Vent Terminal Low Ground Clearance 1 2 54 cm FOR INTAKE TERMINAL 7 6 15 2 cm FOR EXHAUST TERMINAL A CAUTION i DO NOT use field supplied couplings to extend pipes Airflow restriction will occur and the water heater pressure switches may cause intermittent problems Vertical Installation Recommended 1 Become familiar with coaxial vent kit Storage Rated Max Vent Length ft Max Vent Length ft Capacity Input 3 PVCor CPVC 4 PVC or CPVC Figure 17 Gallon Bn He Dimensional Layout of Concentric Vent Kit PVC INTAKE COMBUSTION AIR EL 31 7 8 1 i d 3 NOMINAL 4 NOMINAL 4 46 3 4 PVC VENT EXHAUST Figure 18 Determining required vent length Concentric Vent Kit Part Identitication l Determine the total length of straight vent pipe in feet required uae iiid 2 Add 5 feet of venting for every 90 elb
15. situation NOTICE DO NOT include the 3 exhaust elbow or vent terminals in determining maximum vent length POWER VENT INSTALLATION Power venting is where the indoor air is used and the exhaust is vented to the outside Venting may be run horizontally through an outside wall or vertically through a roof through using either 3 inch 7 6 cm or 4 inch 10 2 cm diameter PVC or CPVC This water heater is supplied with a screened intake and exhaust 90 elbow referred to as the exhaust vent terminal and the air intake terminal Power Vent Terminal Location Refer to the Direct Vent Terminal Location see page 7 section previously mentioned to determine the proper exhaust vent location Plan the vent system layout so that proper clearances are maintained from plumbing and wiring Vent pipes serving power vented appliances are classified by building codes as vent connectors Required clearances from combustible materials must be provided in accordance with information in this manual under LOCATION OF WATER HEATER and CLEARANCES and with National Fuel Gas Code and local codes TNR I amp S 02 NOTICE This unit can be vented using only PVC Class 160 ASTM D 2241 Schedule 40 ASTM D 1785 or Cellular Core Schedule 40 DWV ASTM F 891 Schedule 40 CPVC ASTM F 411 pipe The fittings other than the TERMINATIONS should be equivalent to PVC DWV fittings meeting ASTM F 2665 Use CPVC fittings ASTM F 438 for CPVC pipe
16. these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance does not have a pilot elf you cannot reach your gas supplier It is equipped with an ignition device call the fire department which automatically lights the burner C Tum off main power to the water Do not try to light the burner by hand heater BEFORE OPERATING smell all around D Do not use this appliance if any part the appliance for gas Be sure to has been under water Immediately smell next to the floor because some call a qualified service technician to gas is heavier than air and will settle inspect the appliance and to replace on the floor any part of the control system and WHAT TO DO IF YOU SMELL GAS any gas control which has been Do not try to light any appliance under water Do not touch any electric switch do not use any phone in your building LIGHTING INSTRUCTIONS STOP read the safety information above 6 Wait 5 minutes to clear out any gas on this label If you then smell gas STOP Follow B Set the thermostat to lowest setting in the safety information above on this Turn off all electrical power to the lapal if you dont smell gas go to next appliance PTP f This appliance does not have a pilot 7 Set the thermostat to desired setting It is equipped with an ignition device 8 Tum on main power which automatically light the burner Do not try to light the burner
17. HAUST TERMINAL SUPPORT BRACKET 90 INTAKE TERMINAL 10 TNR I amp S 02 Through The Wall Venting With Low Ground Clearance COAXIAL VENTING INSTALLATION PROCEDURE When venting cannot exit through the wall at a height greater than or A WARNING equal to 12 30 5 cm and above expected snow level from the ground i 4 fe mproper installation adjustment service or maintenance can cause then the installation must be modified as shown below see Figure 16 vus na f api property damage personal injury or death Consult a qualified installer Refer to Tables 2 or 3 for maximum venting lengths using 3 7 6 cm or th lier for informati ist 4 16 2 en diametet plosik pipe service agency or the gas supplier for information or assistance i i This kit must be used only for terminating this water heater Do not use this termination kit for any other appliance Using this kit on other appliances and or water heaters can result in property damage personal injury or death 3 7 6 cm OR DO NOT operate this water heater until the installation and assembly 4 10 2 cm PVC of this kit is complete and the piping completed Failure to complete 90 INTAKE OR installation bef ti ti iyd EXHAUST TERMINAL installation before operation can result in property damage persona injury or death Before beginning any installation be sure the main electrical disconnect switch is in the OFF position Electrical
18. If CPVC pipe and fittings is used then the proper cement must be used for all joints including joining the pipe to the Termination PVC material PVC materials should use ASTM D2564 grade cement CPVC materials should use ASTM F 493 grade cement For water heaters in locations with high ambient temperatures above 100 F and or insufficient dilution air it is recommended that CPVC pipe and fittings MUST USE SUPPLIED VENT TERMINAL be used Horizontal Installation In a horizontal application it is important that condensate not be allowed to buildup in the exhaust vent pipe To prevent this from happening the pipe should be installed with an slight upward slope The vent system should be supported every 5 feet of vertical run and every 3 feet of horizontal run of vent pipe length Stress levels in the pipe and fittings can be significantly increased by improper installation If rigid pipe clamps are used to hold the pipe in place or if the pipe cannot move freely through a wall penetration the pipe may be directly stressed or high thermal stresses may be formed when the pipe heats up and expands Install accordingly to minimize such stresses Follow the following procedure to vent through the wall 1 Cut one 3 V in 9 0 cm diameter hole for 3 7 6 cm diameter pipe or 4 11 5 cm diameter hole for 4 10 2 cm diameter pipe 2 Use the proper PVC cement or sealant to secure the 90 exhaust vent terminal prov
19. LAMMABLE To prevent the possibility of injury under these conditions we recommend the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system If hydrogen is present there will be an unusual sound such as air escaping through the pipes as hot water begins to flow Do not smoke or have open flame near the faucet at the time it is open Figure 4 Typical Two Water Heater Connection HOT WATER OUTLET SUUS Lur T Keep clear of the combination temperature and pressure relief valve VACUUM BREAKER MTs par discharge line outlet The discharge may be hot enough to cause scald soos elem ia injury The water is under pressure and may splash A CAUTION If sweat fittings are to be used DO NOT apply heat to the nipples in front or side of the water heater Sweat the tubing to the adapter before fitting the adapter to the water connections It is imperative that heat is not applied to the nipples containing a plastic liner INSTRUCTIONS FOR CONNECTIONS ee ical Three Water Heater Connection 1 BEFORE PROCEEDING WITH THE INSTALLATION CLOSE THE MAIN YP WATER SUPPLY VALVE After shutting off the main water supply open a faucet to relieve the water line pressure to prevent any HOT WATER OUTLET UT water from leaking out of the pipes while making the water NM it connections to the water heater The COLD water inlet and HOT one
20. LATION INSTRUCTIONS This water heater must be located in an area where the general public does not have access to set temperatures A WARNING This water heater must be located in an area where leakage of the tank water line connections or the combination temperature and pressure relief valve will not result in damage to the area adjacent to the water heater or to lower floors of the structure When such locations cannot be avoided a suitable drain pan must be installed under the water heater The drain pan depth must be svitable for draining and collecting water and have a minimum length and width of at least four 4 inches 10 0 cm measured from the jacket of the water heater The drain pan as described above can be purchased from your plumbing professional The drain pan must be piped to an adequate drain The piping must be at least 34 inch 2 0 cm in diameter and pitched for proper drainage Locating The Water Heater Ad WARNING DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE FOLLOWING e Liquefied petroleum gases propane gas and natural gas have an odorant added by the gas supplier that aids in detection of the gas Most people recognize this odor as a sulfur or rotten egg smell Other conditions such as odorant fade can cause the odorant to diminish in intensity or fade and not be as readily detectable If you have a diminished sense of smell or are in any way
21. N VALVE AND TANK ACCESS PANEL The water heaters are equipped with a 34 inch drain valve An access panel covers the cleanout opening in the tank which is sealed by a gasket and cover RELIEF VALVE At least twice a year the temperature and pressure relief valve should be checked to ensure that it is in operating condition To check the relief valve lift the lever at the end of the valve several times The valve should seat properly and operate freely If water does not flow remove and inspect for obstructions or corrosion Replace with a new valve of the recommended size as necessary A thorough inspection of the valve should be performed at least every three years by removing the temperature and relief valve from the tank Do not attempt to repair the valve as this could result in improper operation and a tank explosion In areas with poor water conditions it may be necessary to inspect the T amp P valve more often than the recommended maintenance schedule A CAUTION Before manually operating the valve make sure that a drain line has been attached to the valve to direct the discharge to an open drain Failure to take this precaution could mean contact with extremely hot water passing out the valve during this checking operation If the temperature and pressure relief valve on the water heater discharges periodically or continuously it may be due to thermal expansion of water in a closed water supply system or it may be due
22. TNR I amp S 02 INSTALLATION amp SERVICE MANUAL HIGH EFFICIENCY COMMERCIAL GAS WATER HEATER A WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any telephone in your building Immediately call your gas supplier from a neighbor s telephone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier TABLE OF CONTENTS GENERAL INFORMATION scscsscococsssssssesessssscosersssncoces 1 INSTALLATION cssssssccovcssscsssssusesessccossaciccsscscsesessansenssescosossie 2 Locating The Water Heater ener 2 Minimum Clearances eene euer roooooue 2 VR ssssosasnnsceasssuenssenssecsnseoon nnsnssnen sashesenssaatesosobaniovses 6 Combustion Air Supply eene 19 Water Connections eere eee ee eere en eno nus 4 Gas Connections eerie eese esee eap seta on 14 GENERAL OPERATION cccccccscsssseccesscesessecscececsecececececcess 15 MAINTENANCE scscos
23. and softened water causes rapid consumption of the anode requiring frequent inspections The replacement anodes rods are available from your local distributor To inspect or replace an anode The anodes on this water heater are easily accessible from the top of the water heater making replacement simple and quick Use the following procedure to remove and inspect the anodes l Drain the heater Refer to DRAINING THE WATER HEATER instructions in this section 2 Flush the heater Refer to FLUSHING THE WATER HEATER instructions in this section 3 Remove the combustion surround top by unlatching 4 Remove the second pass access cover If equipped 5 Remove the second pass insulation 6 Remove the second pass collector cover 7 Remove the anode using a socket of the appropriate size Sometimes a breaker bar will need to be used DO NOT use an impact wrench 8 Inspect and replace the anode as required Use pipe tape or sealant when reinstalling the anode 9 Closethe drain valve Open a hot water fixture to allow air to escape Open the cold water supply to water heater and allow the tank to fill Follow the lighting instructions 10 Check your anode and drain valve for leaks 11 Replace second pass collector cover Make sure to clean off any sealant and reseal before fastening 12 Replace second pass insulation 13 Replace second pass access cover 14 Replace combustion surround top and latch it securely in place DRAI
24. ard potential Failure to properly pipe this water heater may result in improper operation and damage to the water heater or structure Oxygen contamination of this water heater will cause corrosion of iron and steel components and can lead to water heater failure Connect the system supply and return piping to the water heater BURN Refer to Figure 8 and Figure 9 for installation examples Maintain a minimum 14 clearance from hot water piping to combustible materials Water temperatures over 125 F j can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded Figure 8 Alternate Space Heating Connections W a N See oree Adjustment section ot this manual before setting thermostat at water heater o SUPPLY HEATING SYSTEM HEAT EXCHANGER HOT WATER OUTLET T amp P RELIEF VALVE L RETURN FROM SYSTEM I HEAT EXCHANGER HJ Feel water before bathing or showering Temperature limiting valves are available consult local plumbing supplier COLD WATER INLET The following chart details the relationship of water temperature and time with regard to scald injuy and may be used as a guide in determining the EXHAUST VENTING TO OUTDOORS safest water temperature for your applications ace TNR I amp S 02 Figure 9 HEAT EXCHANGER UNION BALL VALVE TuboCharger Water Heater
25. as a back flow preventer check valve or water meter with check valve provisions for thermal expansion of water in the hot water system must be provided Figure 2 Typical Front Inlet Connection INLET VENT W n T amp P RELIEF VALVE D SUPPORT BRACKET HOT WATER OUTLET EXHAUST VENT COLD WATER Pd SUPPLY CLEAN OUT DRAIN DRAIN PAN bh ELEVATED BASE FRONT VIEW TNR I amp S 02 Figure 3 Typical Front Inlet Connect with Storage Tank W zm S wes De Figure 6 Typical Four Water Heater Connection OUTLET HOT WATER OUTLET OUTLET T amp P RELIEF VALVE VACUUM BREAKER COLD WATER SUPPLY a HOT OUTLET m CHECK VALVE EXHAUST VENT AQUASTAT CONNECTED TO CIRCULATOR WATER CONNECTIONS A WARNING H C Failure to install and maintain a new listed temperature and pressure DRAN PAN relief valve will release the manufacturer from any claim which might BN result from excessive temperature and pressures ELEVATED BASE COLD WATER SUPPLY REFER Hydrogen gas can he produced in an operating water heater that has CIRCULATOR not had water drawn from the tank for a long period of time generally two weeks or more HYDROGEN GAS IS EXTREMELY F
26. by hand n A Turn off the main power switch LIGHTED MAIN POWER SWITCH Ultra High Efficiency TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to lowest setting 2 Tum off main the main power switch Figure 24 Lighting Instruction Label 16 TEMPERATURE ADJUSTMENT The temperature selector knob of the thermostat has been adjusted to 120 F when shipped from the factory NOTICE The lower the temperature setting the greater the energy efficiency both to heat the water and to maintain the storage temperature during standby periods Lower water temperatures also extend tank life Remember no water heating system will provide exact temperatures at all times Allow a few days of operation at this setting to determine the correct temperature setting consistent with the requirements for the installation A CAUTION This water heater when set at a lower temperature setting is not capable of producing hot water of sufficient temperature for sanitizing purposes During the winter season or any cold period you may desire a higher temperature setting to adjust for the colder incoming water This adjustment however may cause additional condensation to form on the colder tank surface This does not mean the tank is leaking During summer months the warmer incoming water temperatures will benefit the performance of your water heater and reduce the amount of condensation developed Condensation does not mean your tank is l
27. ce Do not touch any electric switch do not use any telephone in your building Immediately call your gas supplier from a telephone in another building Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department DO NOT OPERATE THE APPLIANCE UNTIL THE LEAKAGE IS CORRECTED Minimum Clearance To Combustible WALL WITH COMBUSTIBLE MATERIAL WALL WITH COMBUSTIBLE Lz MATERIAL TOP VIEW SOLID ELEVATED LLA BASE DRAIN PAN FRONT VIEW AIR REQUIREMENTS l 2 Do not obstruct the flow of combustion and ventilating air For safe operation adequate air is needed for combustion and ventilation Sooting may result in serious damage to the water heater and risk of fire or explosion It can also create a risk of asphyxiation Such a condition often will result in a yellow luminous burner flame causing carboning or sooting of the combustion chamber burner and flue tubes MECHANICAL EXHAUSTING OF ROOM AIR 1 Where an exhaust fan is installed in the same room with this water heater and combustion air is drawn from inside the room sufficient openings for air must be provided in the walls UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE WATER HEATER S VENTING SYSTEM CAUSING POOR COMBUSTION THAT MAY BE HAZARDOUS TO LIFE SOOTING MAY RESULT IN SERIOUS DAMAGE TO THE WATER HEATER AND RISK OF FIRE OR EXPLOSION
28. cscecessssccecesececcecscessssececesecsccecesecaccers y TROUBLESHOOTING GUIDE creen enne enn 20 GENERAL INFORMATION This gas fired water heater is design certified by CSA International under the American National Standard Z21 10 3 as indicated on the rating plate and CAN CGA 4 3 M as indicated on the rating plate available from CSA Standards Association 178 Rexdale Blvd Etobicoke Ontario Canada M9W 1R3 This water heater must be installed in accordance with local codes In the absence of local codes it must be installed in compliance with the National Fuel Gas Code ANSI 7223 1 Latest Edition or in Canada CAN CGA B 149 1 Natural Gas Installation Code Latest Edition or CAN CGA B149 2 Propane Installation Code Latest Edition Ay DANGER DO NOT store or use gasoline or other flammable combustible or corrosive vapors and or liquids in the vicinity of this or any other appliance DO NOT install any damaged venting system components If damage is evident then please contact the supplier where the water heater was purchased or the manufacturer listed on the rating plate for replacement parts TEMPERATURE amp PRESSURE RELIEF VALVE Ay DANGER Use only vent terminals provided or factory authorized terminals for venting this water heater This water heater is equipped with an adjustable thermostat fo control water temperature Hot water temperatures required for automatic dishwasher and lau
29. driveway located on public property 3 Within 6 feet 1 8 m of a mechanical air supply inlet to any building Vent Terminal Location ROOF AIR INTAKE ROOF EXHAUST TERMINAL INTAKE AIR TERMINAL 3 FT MIN 1m oda N MN 30 5cm GAS pal 30 5 cm N MIN EXHAUST VENT TERMINAL 4 Above a gas meter regulator assembly within 3 feet 0 9 m horizontally of the vertical centerline of the regulator 5 Within 6 feet 1 8m of any gas service regulator vent outlet 6 Less than 1 foot 30 5 cm above grade level 7 Within 12 inches 30 5 cm of a window or door which can be opened in any building any non mechanical air supply inlet to any building or the combustion air inlet of any other appliance 8 Underneath a veranda porch or deck unless e The veranda porch or deck is fully open on a minimum of two sides beneath the floor and e The distance between the top of the vent termination and the underside of the veranda porch or deck is greater than 1 foot 30 5 cm The vent system must terminate so that proper clearances are maintained as cited in local codes or the latest edition of the National Fuel Gas Code ANSI 2223 1 73 4e and 7 8a b as follows l Donotterminate the exhaust vent terminal over public area where condensate or vapor can cause nuisance or hazard 2 For direct vent the venting system shall terminate at least 1 foot below 1 foot horizontally from or 1 foot above any door window o
30. e for a Y inch buildup of lime Example Initial inspection shows an inch of lime accumulation Therefore the water heater can be delimed once a year To remove sediment and lime scale l Drain the heater Refer to DRAINING THE WATER instructions in this section 2 Remove outer cover plate from lower side of water heater jacket 3 Remove cover and gasket from cleanout opening 4 Remove lime scale or sediment using care not to damage the glass lining 5 Inspect cleanout plate gasket Replace gasket if necessary Contact local distributor for correct part number 6 Install gasket and cleanout plate Be sure to draw plate up tight by tightening screws securely Close the drain valve Open a hot water fixture to allow air to escape Open the cold water supply to water heater and allow the tank to fill Follow the lighting instructions Check for water leakage Install outer jacket cover plate TNR I amp S 02 ANODE INSPECTION AND REPLACEMENT This water heater is equipped with multiple sacrificial anodes Anodes protect the glass lined tank from corrosion by sacrificing themselves through electrolysis When the anode material is consumed there is no more protection and corrosion of the tank accelerates Inspection of the anode every 6 months allows you to identify the rate of anode degradation The anode should be replaced when its diameter is 3 8 of an inch or annually which ever is first Aggressive very hot
31. eaking Most of reported tank leaks on installation are proven to be condensation To avoid unnecessary inconvenience and expense make sure the tank is leaking before calling an independent servicing contractor or qualified service professional Ay DANGER Hotter water increases the risk of scald injury Scalding may occur within 5 seconds at a temperature setting of 135 F 57 C To protect against hot water injury install an anti scald tempering valve in the water system This valve will reduce point of discharge temperature by mixing cold and hot water in branch water lines A licensed plumbing professional or local plumbing authority should be consulted This water heater is equipped with an energy cut out device to prevent overheating Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance and call a qualified service agency If the water heater is to remain idle for 30 days or more or is subjected to freezing temperatures while shut off the water heater and piping should be fully drained and the drain valve should be left fully open Refer to the General Operation section of this Installation and Operating Instructions Manual for the procedure on draining the water heater BURNER FLAME CHECK At the time of installation and at monthly intervals a visual check of the burner flames should be made to determine if they are burning properly The main burner may be seen thr
32. h the sensor would be 8449 sce shaded area NOTE Sensor resistance increases as the temperature falls LN ae 2 PRU ANNE 28109 25400 ul T AT ef 18906 19383 Tu 18876 76 78383 47440 16990 16553 _ 83 17905 1 16990 16553 16128 90 ise 4 74925 14548 14180 13477 13140 12812 12494 70 11884 i692 11308 EUR 10763 10502 10248 E 9760 80 8250 6057 7669 7888 90 7333 7165 7000 ee 6683 Ss 1 6383 6238 6098 10 5827 5697 5570 5446 5326 5208 5094 4982 4873 4767 7410 4663 4562 4464 4368 4274 4183 4094 4006 3922 3839 120 3758 3670 T 3602 j 3527 ml 3382 J 3312 3244 3177 302 f PAS Tir O ara eit atr 130 3048 2986 2 2808 2752 2697 2643 i 2298 E RE 2209 2166 11820 i 1786 204 3085 4 1753 1720 1891 1856 150 2043 SECO a 160 1688 1656 4 1625 1i 1568 1537 1509 1481 1454 1427 1 oe pope EN je ode EN Pup i i t om 170 1402 1351 c 1280 1257 1235 1213 1191 180 1170 i L M 4071 1053 1025 1017 999 i90 982 965 949 933 917 90i Bee 87i 8b 842 E ql 828 814 80i e 762 737 725 713 APPENDIX B Temperature Dial Resistance Proper Readings Should Be Greater Then 4800 Ohms at Minimum Setting
33. housing The suggested maximum torque is 31 5 foot lbs 4 4 kg m The manufacturer of this water heater will not be liable for any damage or injury caused as a result of a cracked gas inlet as a result of excessive torque This water heater and its gas connection must be leak tested before placing the water heater in operation Check for gas leaks with a soap and water solution and a brush or a commercial leak detector fluid NEVER USE A MATCH OR OPEN FLAME FOR TESTING The water heater is not intended for operation at higher than 14 0 inch water column 1 psi supply gas pressure Higher gas supply pressures require supplemental reducing service regulation Exposure to higher gas supply pressure may cause damage to the gas controls which could result in fire or explosion If overpressure has occurred such as through improper testing of gas lines or emergency malfunction of the supply system the gas valve must be checked for safe operation Make sure that the outside vents on the supply regulators and the safety vent valves are protected against blockage These are parts of the gas supply system not the water heater A CAUTION The water heater and individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of the system at test pressures in excess of psi 3 5 kPa The water heater must be isolated from the gas supply piping system by closing its manual shutoff valve during any pressure testi
34. ided with the water heater to the plastic pipes The distance between the back edge of the 90 exhaust vent terminal and the exterior wall see Figure 14 must be 6 inches 13 0 cm Use the proper cement and assembly procedures to secure the vent connector joints between the terminal and the blower outlet Provide support brackets for every 3 feet 1 0 m of horizontal vent Figure 14 Typical Horizontal Power Vent System 90 INTAKE TERMINAL aT em SUPPORT BRACKET 90 EXHAUST TERMINAL 6 Vertical Installation Vertical venting must be supported every 5 feet of vertical run and every 3 feet of horizontal run of vent pipe length Stress levels in the pipe and fittings can be significantly increased by improper installation If rigid pipe damps are used to hold the pipe in place or if the pipe cannot move freely through a wall penetration the pipe may be directly stressed or high thermal stresses may be formed when the pipe heats up and expands Install accordingly to minimize such stresses Follow the following procedure to vent through the roof l Cut the necessary holes through the roof and ceiling 2 Install the exhaust vent and air intake plastic pipes as shown in Figure 15 Make sure that the installation meets the local codes and or The National Fuel Gas Code ANSI 2223 1 Latest Edition or CGA CAN B149 Installation Code Figure 15 ypical Vertical Power Vent System Installation 90 EX
35. ished by piping air directly to the water heater from outside or providing opening or ducts in the wall When directly communicating with the outdoors through vertical ducts two permanent openings located in the above manner shall be provided e Each opening shall have a free area of not less than one square inch per 4000 Btu hr of the total input of all appliances in the enclosure TNR I amp S 02 e f horizontal ducts are used each opening shall have a free area of not less than one square inch per 2000 Btu hr of the total input of all appliances in the enclosure 3 If the water heater is installed as a direct vent outside air piped directly to the water heater then additional opening other than the opening for the air intake are not required However adequate ventilation air must be provided in all cases to prevent increased room temperature CHEMICAL VAPOR CORROSION Corrosion of the flue ways and vent system will occur if air for combustion contains certain chemical vapors Such corrosion may result in poor combustion and create a risk of asphyxiation Spray can propellants cleaning solvents refrigerator and air conditioning refrigerants swimming pool chemicals calcium and sodium chloride waxes and process chemicals are corrosive Products of this sort should not be stored near the water heater or outside by the air intake if applicable TYPICAL INSTALLATION ILLUSTRATION A CAUTION If building cold water supply h
36. king pressure of the water heater The combination temperature and pressure relief valve rating must not be less than the hourly rating of the water heater Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose on the water heater Note Some models may already be equipped or supplied with an installed combination temperature and pressure relief valve Verify that the combination temperature and pressure relief valve complies with local codes If the combination temperature and pressure relief valve does not comply with local codes replace it with one that does Install a discharge line so that water discharged from the combination temperature and pressure relief valve will exit within six 6 inches 15 2 cm above or any distance below the structural floor and cannot contact any live electrical part The discharge line is to be installed to allow for complete drainage of both the combination temperature and pressure relief valve and the discharge line The discharge opening must not be subjected to blockage or freezing DO NOT thread plug or cap the discharge line Itis recommended that a minimum clearance of four 4 inches 10 2 cm be provided on the side of the water heater for servicing and maintenance of the combination temperature and pressure relief valve Do not place a valve between the combination temperature and pressure relief valve and the tank TNR I amp S 02 INSTAL
37. ld use ASTM D2564 grade cement CPVC materials should use ASTM F 493 grade cement For water heaters in locations with high ambient temperatures above 100 F and or insufficient dilution air it is recommended that CPVC pipe and fittings MUST USE SUPPLIED VENT TERMINAL be used Horizontal Installation In a horizontal application it is important that condensate not be allowed to buildup in the exhaust vent pipe To prevent this from happening the pipe should be installed with an slight upward slope so the condensate will run back toward the water heater The vent system should be supported every 5 feet of vertical run and every 3 feet of horizontal run of vent pipe length Stress levels in the pipe and fittings can be significantly increased by improper installation If rigid pipe clamps are used to hold the pipe in place or if the pipe cannot move freely through a wall penetration the pipe may be directly stressed or high thermal stresses may be formed when the pipe heats up and expands Install accordingly to minimize such stresses Follow the following procedure to vent through the wall 1 Cut two 3 1 2 in 8 9 cm diameter holes for 3 7 6 cm diameter pipe or 4 11 4 cm diameter holes for 4 10 2 cm diameter pipe in the wall with the centerline hole distances at least 18 45 72 cm apart in the location where the exhaust vent and air intake terminals will exit the outside wall if vented on the same wall
38. llation of any vent pipe read the vent pipe manufacturer s installation instructions Water heater must be protected from freezing downdrafts during shutdown periods Provide protection of the building materials from degradation by flue gases from the exhaust vent terminal The venting instructions must be followed to avoid restricted combustion or recirculation of flue gases Such conditions cause sooting or risks of fire and asphyxiation This water heater can be installed as either a direct vent system or power vent air from inside system If it is installed as a direct vent system then the air intake and the exhaust vent are piped to the outside If a power vented system is used then air is drawn from inside and only the exhaust is piped to the outside Determine which system is best for your application and install as described in the following sections DIRECT VENT INSTALLATION Venting may be run horizontally through an outside wall or vertically through a roof through using either 3 inch 7 6 cm or 4 inch 10 2 cm diameter PVC or CPVC pipe This water heater is supplied with a 3 inch PVC screened intake and exhaust 90 elbow referred to as the exhaust vent terminal and the air intake terminal NOTICE If 4 inch PVC or CPVC pipe is used then a 4 inch PVC or CPVC screened intake and exhaust 90 elbow is required Direct Vent Terminal Location Plan the vent system layout so that proper clearances are maintained fro
39. m plumbing and wiring Before the vent is installed determine the vent pipe termination location as shown below in Figure 10 Figure 10 m M bis EXHAUST VENT TERMINAL Vent terminals must terminate at least 3 feet 0 9 m above any forced air inlet located within 10 feet 3 1 m This provision does not apply to 1 The combustion air intake of a direct vent appliance or the circulating air inlet and flue gas discharge of listed outdoor appliances 2 The exhaust vent terminal must be installed with at least 12 inches 30 cm dearance from any air opening into a building 3 The bottom of the exhaust vent and combustion air intake terminals must be located at least 12 inches 30 am above grade and above the anticipated snow level 4 Must be installed at least 3 feet 0 9 m from any gas meter gas valve or other gas regulating equipment Must be installed in a location where it will not be blocked by snow 5 The exhaust vent and combustion air intake terminals must be installed so that the centerline distances are at least 18 inches 45 7cm apart and the exhaust vent terminal elbow extends 6 inches 15 2 cm past the combustion air intake terminal TNR I amp S 02 EXCEPTIONS FOR INSTALLATIONS The vent terminal must not terminate l Directly above a paved sidewalk or paved driveway which is located between two single family dwellings and serves both dwellings 2 Less than 7 feet 2 1 m above a paved sidewalk or a paved
40. ndry use can cause scald burns resulting in serious personal injury and or death The temperature at which injury occurs varies with the person s age and the time of exposure The slower response time of disabled persons increases the hazards to them NEVER allow small children to use a hot water tap or to draw their own bath water NEVER leave a child or disabled person unattended in a bathtub or shower Failure to properly install the vent and air intake if applicable system could result in property damage personal injury or death A WARNING Keep clear of the combination temperature and pressvre relief valve discharge line outlet The discharge may be hot enough to cause scald injury The water is under pressure and may splash For protection against excessive temperatures and pressure install temperature and pressure protective equipment required by local codes but not less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials as meeting the requirements of the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems ANSI 221 22 and the Standard CANT 4 4 Temperature Pressure Temperature and Pressure Relief Valves and Vacuum Relief Valves The combination temperature and pressure relief valve must be marked with a maximum set pressure not fo exceed the maximum wor
41. ng of the gas supply system at test pressures equal to or less than Y psi 3 5 kPa The supply line must be capped when not connected to the water heater If copper supply lines are used they must be internally tinned and certified for gas service Figure 22 Drip Leg GAS PIPE COMBUSTION SURROUND DRIP LEG WATER HEATER The gas supply lines must meet all requirements of the National Fuel Gas Code ANSI 7223 1 Latest Edition or in Canada CAN CGA B149 1 Natural Gas Installation Code Latest Edition or CAN CGA B149 2 Propane Installation Code Latest Edition GAS METER SIZE NATURAL GAS ONLY Be sure that the gas meter has sufficient capacity to supply the full rated gas input of the water heater as well as the requirements of all other gas fired equipment supplied by the meter If the gas meter is too small ask the gas company to install a larger meter having adequate capacity GAS PRESSURE REGULATION Main line gas pressure to the water heater should be between a maximum 14 0 inch W C and a minimum supply pressure as shown on the rating plate The inlet gas pressure must not exceed the maximum value BEFORE PLACING THE WATER HEATER IN OPERATION CHECK FOR GAS LEAKAGE USE SOAP AND WATER SOLUTION OR OTHER MATERIAL ACCEPTABLE FOR THE PURPOSE OF LOCATING GAS LEAKS A WARNING DO NOT USE MATCHES CANDLES FLAME OR OTHER SOURCES OF IGNITION FOR THIS PURPOSE ELECTRICAL CONNECTIONS A WARNING Turn off or disconnec
42. ns 2 and 7 on the plug CONTROL If there is 24 VAC across these pins then check to see if the Rectifier Harness is secure If it is secure then replace the Gas Valve If you can feel the gas valve energize check the main gas supply is not in the off position Burner Flame keeps going out Is there minimum gas supplied to water heater as stated on the rating plate If not then increase the supply pressure to the water heater Measure the microAmps through the flame sensor using a multimeter Is there at least 4 microAmps If not then replace the Flame Sensor or flame sensor wire Thermostat does not satisfy Is the tank temperature above the temperature set point Does the T amp P relief valve leak If yes then replace Thermostat PC Board Blower did not post purge Check Vacuum Switch air intake switch as previously mentioned Check Pressure Switch exhaust pressure switch as previously mentioned Check Collector Limit Switch as previously mentioned If above switches are all ok then replace Ignition Module 20 9 07 Printed in USA APPENDIX A ee Sensor Resistance at Various Temperatures Be Careful When Making Voltage Measurements or Jumping Terminals Not to Damage or Deform Connectors or Connector Pins Draw Water From The T amp P Valve Compare Temperature With Temperature Ohms Chart Below Example If temperature of sensor is 84 F then the resistance throug
43. nstallation meets the local codes and or The National Fuel Gas Code ANSI 2223 1 Latest Edition or CGA CAN B149 Installation Code Figure 12 Typical Vertical Direct Vent System Installation 90 EXHAUST anne TERMINAL 90 INTAKE TERMINAL r SUPPORT BRACKET EVERY 5 MIN Through The Wall Venting with Low Ground Clearance When venting cannot exit through the wall at a height greater than or equal to 12 30 5 cm and above expected snow level from the ground then the installation must be modified as shown below see Figure 13 Figure 13 Vent Terminal Low Ground Clearance 3 7 6 cm OR 4 10 2 cm PVC 90 INTAKE OR EXHAUST TERMINAL 12 30 5 cm MIN Jm LEVEL 1 2 54 cm FOR INTAKE TERMINAL 6 15 2 cm FOR EXHAUST TERMINAL TNR I amp S 02 Table 2 Direct Vent Maximum Vent Length Rated Max Vent Length ft Max Vent Length ft Input 3 PVC or CPVC 4 PVC or CPVC BTU HR Storage Capacity Gallons Determining required vent length l Determine the total length of straight vent pipe in feet required for both the intake and the exhaust 2 Add 5 feet of venting for every 90 elbow 3 Add 2 V feet of venting for every 45 elbow 4 Total vent length can not exceed Max Vent Length in Table 2 5 Air intake can not exceed exhaust by more than 30 feet in any venting
44. ough the sight glass window on the front of the combustion insert mounting bracket Figure 25 The burner flames should be a blue flame near the burner surface in a uniform flame pattern Occasional yellow or white streaks are normal TNR I amp S 02 Figure 25 Sight Glass Location SIGHT GLASS MAINTENANCE Ay DANGER DO NOT ATTEMPT TO REPAIR GAS VALVE DO NOT ATTEMPT TO REPAIR IGNITION MODULE DO NOT ATTEMPT TO REPAIR VENTURI DO NOT ATTEMPT TO REPAIR THERMOSTAT BOARD DO NOT ATTEMPT TO REPAIR TRANSFORMER DO NOT ATTEMPT TO REPAIR PRESSURE SWITCH GENERAL KEEP APPLIANCE AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS Water heater maintenance includes periodic tank flushing and cleaning and removal of lime scale The unit should be inspected and adjusted to maintain proper combustion Refer to Table 4 Suggested Maintenance Schedule A periodic inspection of the venting system should be made MAINTENANCE SCHEDULE Following are the instructions for performing some of the recommended maintenance Unit inspection and adjustment should be performed by a competent technician 17 TNR I amp S 02 Table 4 Suggested Maintenance Schedule COMPONENT Tank Anode Rods Relief Valve Blower Vent amp Air Intake System Ignition System OPERATION Vent Terminal Combustion System Condensate Line FLUSHING WATER HEATER 1 Turn OFF the water heater
45. ow 3 Add 2 feet of venting for every 45 elbow N 4 DIA PIPE CONCENTRIC Y FITTING 4 Total vent length can not exceed Max Vent NOTICE 2 Determine the best location for the termination kit ength in Table 3 Do not include the 3 exhaust elbow or vent terminals in determining T 3 Cut the recommended 5 diameter hole maximum vent length TNR I amp S 02 4 Partially assemble vent kit by performing the following 7 Install rain cap and small diameter pipe assembly in roof penetration a Cement concentric Y fitting to larger diameter pipe See Figure assembly Ensure small diameter pipe is cemented and bottomed in 18 Y concentric fitting b Cement rain cap to smaller diameter pipe See Figure 19 8 Cement heater combustion air and vent pipes to concentric y fitting assembly Figure 18 See Figure 20 for proper pipe attachment Figure 19 Rain Cap to Small Vent Pipe Ass y 9 Operate heater through one cycle to ensure combustion air and vent DRILL CLEARANCE HOLE IN pipes are properly connected to concentric vent termination RAIN CAP AND PILOT HOLE IN VENT CAP connections Horizontal Installation l Become familiar with coaxial vent kit As shown in Figures 17 through 19 2 Determine the best location for the termination kit STAINLESS STEEL SCREW FIELD SUPPLIED NOTICE Position termination where vent vapors will not damage plants shrubs or ai
46. r conditioning equipment Position termination where vent vapors will not be adversely effected 5 Install concentric Y fitting and pipe assembly through the structure s hole and field supplied roof boot flashing Do not allow insulation or other materials to accumulate inside pipe assembly when installing through the hole by wind condition Position termination where it will not be damaged or be subjected to foreign objects 6 Secure assembly to roof structure as shown in Figure 20 using field d mr p Position termination where vapors will not be objectionable supplied metal strapping or equivalent support material NOTICE Cut the recommended 5 diameter hole Ensure termination height is above the roof surface or anticipated snow level Figure 20 If assembly is too short to meet height Partially assemble vent kit requirements the 2 pipe supplied in the kit may be replaced by using a Cement Y concentric fitting to larger diameter kit pipe See Figure the same diameter pipe DO NOT extend the overall dimension by 18 more than 60 in See Figure 17 b Cement rain cap to smaller diameter kit pipe See Figure 19 Install concentric Y fitting and pipe assembly through the structure s Figure 20 r hole and field supplied roof boot flashing Do not allow insulation or Concentric Vent Roof Top Attachment A s E E other materials to accumulate inside pipe assembly when installing CLEARANCE ABOVE through the hole
47. r gravity air inlet into building TNR I amp S 02 3 For horizontal the venting system shall terminate 4 foot below 4 foot horizontally from or 1 foot above any door window or gravity air inlet into building 4 The manufacturer also recommends the vent system terminations not be installed closer than 3 feet from an inside corner of an L shaped structure 5 The vent termination shall not be mounted directly above or within 3 feet horizontally from an oil tank vent or gas meter to avoid potential freeze up from condensation 6 The vent shall terminate a minimum of 12 inches above expected snowfall level to prevent blockage of vent termination Vent pipes serving power vented appliances are classified by building codes as vent connectors Required clearances from combustible materials must be provided in accordance with information in this manual under LOCATION OF WATER HEATER and CLEARANCES and with National Fuel Gas Code and local codes NOTICE This unit can be vented using only PVC Class 160 ASTM D 2241 Schedule 40 ASTM D 1785 or Cellular Core Schedule 40 DWV ASTM F 891 Schedule 40 CPVC ASTM F 411 The fittings other than the TERMINATIONS should be equivalent to PVC DWV fittings meeting ASTM F 2665 Use CPVC fittings ASTM F 438 for CPVC pipe If CPVC pipe and fittings are used then the proper cement must be used for all joints including joining the pipe to the Termination PVC material PVC materials shou
48. radesman in the field involved Plumbing air supply venting gas supply and electrical work are required Light the unit in accordance with the operating instructions label attached to the water heater Under no circumstances should the input rate exceed the input rate shown on the water heater rating plate Over firing could result in damage or sooting of the water heater m IGNITOR LADDER DIAGRAM Wiring Diagram and Schematic 15 GENERAL INSTRUCTIONS TO FILL THE WATER HEATER l Closethe water heater drain valve by turning the knob or valve stem clockwise If alternative water connections are provided but not used make certain they are plugged i e rear connections 2 Open the cold water supply shut off valve 3 Open several hot water faucets to allow air to escape from the system 4 When a steady stream of water flows from the faucets the water heater is filled Close the faucets and check for water leaks at the water heater drain valve combination temperature and pressure relief valve and the hot and cold water connections SEQUENCE OF OPERATION 1 A call for heat from thermostat 6 Main burner ON 2 Blower ON 7 Flame signal confirmed 3 Pressure switch proves blower operation 8 Thermostat satisfied 4 Blower pre purge 9 Main burner OFF 5 Igniter warm up 10 Blower post purge TNR I amp S 02 LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow
49. st be repaired before continuing operation of the water heater Do not terminate the venting where noise from the exhaust or intake will be objectionable This includes locations close to or across from windows and doors Avoid anchoring the vent and intake pipes directly to framed walls floors or ceilings unless rubber isolation pipe hangers are used This prevents any vibrations from being transmitted into the living spaces Do not exceed the venting distances or the number of elbows listed in this manual Exceeding the maximum venting distances may cause the water heater fo malfunction or cause an unsafe condition DO NOT operate this water heater until the venting installation is complete and the piping completed Failure to complete installation before operation can result in property damage personal injury or death A CAUTION The vent shall terminate a minimum of 12 inches above expected snowfall level to prevent blockage of vent termination The horizontal centerline of the exhaust vent terminal if applicable must not be located lower than the horizontal centerline of the air intake terminal if vented through the same wall Aservice drain loop must be installed in the drain tubing to serve as a condensate trap to prevent flue gases from escaping in the room DO NOT position air intake terminal above exhaust terminal NEVER locate air intake terminal when exhaust gases can be introduced NOTICE Before beginning insta
50. t the electrical power supply to the water heater before servicing Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing All electrical wiring must be installed and grounded in accordance with local codes or in the absence of local codes the National Electrical Code ANSI NFPA 70 and or CSA 22 2 Electrical Code The water heater must be wired to a 120 VAC 60 Hz 15A power supply The water heater should be connected to a GFI outlet and wired on a separate circuit and breaker If a flexible line cord and plug is permitted by local code then provide a three wire GFI grounding type receptacle within reach of the line cord provided on the control box DO NOT plug the line cord into a receptacle that can have the power supply interrupted by a switch that is used to control lights or another appliance 14 If wiring in conduit is required remove the line cord and strain relief bushing in the control panel and install an electrical conduit connector Connect the hot neutral and ground leads to the terminal block using quick connect terminals Refer to the wiring diagram for the correct terminal locations for each wire lead A CAUTION Do not energize the electric circuit before the water heater tank is filled with water This controller is Polarity sensitive If the Hot and Neutral Supply voltage is reversed the controller will
51. the physical and chemical characteristics and limitations of the PVC PVC cellular core or CPVC piping materials that you are about to use 3 Know the reputation of your pipe and cement manufacturer and their products 4 Know your own qualifications or those of your contractor The solvent welding technique of joining PVC PVC cellular core or CPVC pipe is a specialized skill just as any other pipe fitting technique 5 Closely supervise the installation and inspect the finished job before start up 6 Contact the manufacturer supplier or competent consulting agency if you have any questions about the application or installation of PVC PVC cellular core or CPVC pipe 7 Take the time and effort to do a professional job Shortcuts will only cause you problems and delays in start up The majority of failures in these systems are the result of shortcuts and or improper joining techniques SELECTION OF MATERIALS PRIMER It is recommended that Tetrahydrofuran THF be used to prepare the surfaces of pipe and fittings for solvent welding DO NOT use water rags gasoline or any other substitutes for cleaning PVC cellular core or CPVC surfaces A chemical cleaner such as MEK may be used CEMENT The cement should be a bodied cement of approximately 500 to 1600 centipoises viscosity containing 10 20 by weight virgin PVC material solvated with tetrahydrofuran THF Small quantities of dimethylformamide DMF may be included to
52. to a faulty relief valve Thermal expansion is the normal response of water when it is heated In a closed system thermal expansion will cause the system pressure to build until the relief valve actuation pressure is equaled Then the relief valve will open allowing some water to escape slightly lowering the pressure Contact your water supplier or local plumbing inspector on how to control this situation A WARNING Above all do not plug the temperature and pressure relief valve This is not a solution and can create a hazardous situation VENT AND AIR INTAKE SYSTEM Examine the vent and air intake system every 3 months Points of inspection are as follows l Check for obstructions and or deterioration of vent piping and vent terminal Replace immediately where needed 2 Vent pipe and vent hood screen should be cleaned of any foreign material The screen is located inside the vent hood outlet and is accessible from the outside of the hood DO NOT reach inside the vent hood when the water heater is in operation 3 Check all vent system connections for leakage and reseal as required COMBUSTION SYSTEM INSPECTION Inspect the operation of the combustion system monthly Use the following procedure to inspect the combustion system l Turn off the main power switch of the water heater Adjust the thermostat to the Min setting Remove the top of the combustion surround by unlatching it While observing the ignition module
53. unsure of the presence of gas immediately contact your gas supplier from a telephone in another building e Gas detectors are available Contact your gas supplier or 1 LOCATE so that venting connections will be short and direct lumi fessional f cod 2 THIS WATER HEATER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE _P mbing professional tor more information FLOOR DO NOT install this water heater on carpeting Liquefied petroleum gases propane gas is heavier than air and will 3 FOR BASEMENT INSTALLATION provide a solid level elevated base atn at floor level if there is a leak Basements crawl spaces Sud ene closets and areas below ground level will serve as pockets for 4 Minimum clearance to combustible material is 0 for the Top Sides accumulation of leaking gas Before lighting smell all around the KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND and Rear of this water heater However it is recommended that at least 18 from the Top 24 from the Front and 4 for the Sides and Rear of the water heater be provided for servicing Clearance for servicing may be reduced down to minimum clearance to combustible material but service time and effort may be greatly increased LOCATION LIQUIDS Figure 1 appliance area for gas Be sure to smell next to the floor IF YOU SMELL GAS Do not try to light any applian
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