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7. 22 Power Vent Installation 22 Direct Vent Installation eee u uu 22 Vertical Termination Installation 23 Sidewall Termination Installation 25 Polypropylene Installations 26 AL29 4C Vent Installations 27 Concentric Termination Installation 28 6 Inch Concentric Termination Installation 29 Low Profile Vent Installation 32 Venting Arrangements issus 33 Termination Clearances Sidewall Power Vent 35 Termination Clearances Sidewall Direct Vent 36 WATER HEATER INSTALLATION 37 Condensate Drain Installation 37 Supply Gas Line Installation 38 Gas Line Leak Testing 39 eis uu avast dit 00000 39 Electrical elle EE 39 Enable Disable Circuit For Building Management Systems 40 Water Line Connections 40 T amp P Valve Discharge Pipe 41 TEMPERATURE REGULATION 22 42 High Temperature Limit Control ECO 42 Thermostat iseer 42 CONTROL SYSTEM OPERATION u u uu 43 OVOJ EW a atun rein cire sm
8. 11 Extended Vent Terminations u U uuu 11 Optional Direct Vent Terminations 12 Hard Meester nn Neutre Ee 12 le IER e ir E 12 Insulation Blankets 12 INSTALLATION REQUIREMENTS 222 13 Gas Supply Systems 13 Supply Gas Regulator 13 Power SUPPIY 0070000000 13 Mixing VANES da na 14 Dishwashing Machines 88 8 8 8 2 l 14 Closed Water Systems 14 Thermal EXpPamSlomia 14 Temperature Pressure Relief Valve 15 Gondensat Dial a a uuu areae ss 16 Combustible Material Storage 16 Contaminated u nine 16 Air Reouirements 3282283 33 83 l 17 Unconfined Zoe u u Aceh e us susu ashaku 17 el le Te 17 Fresh Air Openings For Confined Spaces 18 Outdoor Air Through Two Openings 18 Outdoor Air Through One Opening 18 Outdoor Air Through Two Horizontal Ducts 18 Outdoor Air Through Two Vertical Ducts 19 Air From Other Indoor Spaces 19 VENTING INSTALLATION ss 20 General Venting Information 20 General Venting Instructions 20 Venting Requirements 21 Venting Installation Sequence
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42. 74 SAFE INSTALLATION USE AND SERVICE The proper installation use and servicing of this water heater is extremely important to your safety and the safety of others Many safety related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard Read and obey all safety messages and instructions throughout this manual It is very important that the meaning of each safety message is understood by you and others who install use or service this water heater This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently hazardous situation which if not avoided A DANGER will result in injury or death WARNING indicates a potentially hazardous WARNING situation which if not avoided could result in injury or death CAUTION indicates a potentially hazardous situation which if not avoided could result in CAUTION minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous CAUTION situation which if not avoided could result in property damage All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury The California Safe Drinking Water and Tox
43. ajqedeo n peunod snayesiiin UOHEOUUaN lsi 91189 JUESIIIN UT GG abed ej g afpuugcda je uolel e Sul p lonuo aler JOA nea ayjneyo SJUESOdWO9 SISAIP s l 1919d91 INOd oe Joen NULU juaseid eg syuesodwos je senbijs19 92129 uonoas p SUeP s lmu pi 1405 ne yneyo xnedioulid sluesoduuo2 seq ne Jineuo np JUSWISUUO OUO l INOd S8112SS899U JUOS 19 Xn99 nb uuop uge s linpuo Sewayos s l ins s nbipul 51 xne s gwowiay s p uo mele su uo nu ne lu uu j nnoiued 19 914 n enbipui 158 tuutuuo5 ejqgo np 266 s linpuoo s p ne p s linpuoo s p UOHEIU A l quu su Jol IsuLD nu ss 159 n reileysur l anod 29U219 91 JUOIIAIAS SEU UOS S D suep lu uu eB JUdINBY sa jle ap UOIEIEISULD sewgyos saq lunoes E Nes ayneyo zuawauuoyouoy uoq nE s nu ss zuos SUOHONJISUI s s lno Je S U U SS H AB S 5 21HEUUOIEI 19 ul nej ilinb seabed s p ne sjuswassieAe sep jJuswalebe lu lluoo ne jjneuo np aOUEUSIUIELU ej 19 JUBWAUUO OUO ne uoHelieisul e saage SUONONIJSUI s p uanuoo jonuew 29 HOW Seinsse q s p 5 518 s nboAold enod 9111 095 ua sed au anbeu ne
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48. 11 Restore power to the water heater 12 From the water heaters UIM Heater Information Screen select Use External Enable and change to Yes See Figure 3 on page 8 to locate the UIM NOTE Whenever the external control opens the set of dry contacts used water heating operation will be disabled Whenever the external control closes the set of dry contacts used water heating operation will be enabled A diagonal line and circle appears over the thermometer icon on the UIM when water heating operation is disabled See the Status Icons descriptions in Table 16 on page 44 NOTE Ensure the water heater is protected from freezing temperatures when water heating operation is disabled Damage to the water heater caused by freezing temperatures is not covered under the limited warranty WATER LINE CONNECTIONS The water piping installation must conform to these instructions and to all local and national code authority having jurisdiction Good practice requires that all heavy piping be supported Read and observe all requirements in the following sections before installation of the water piping begins 1 Mixing Valves on page 14 Dishwashing Machines on page 14 Temperature Pressure Relief Valve on page 15 Closed Systems and Thermal Expansion on page 14 Hr ZS oN For multiple water heater installations see Water Piping Diagrams beginning on page 67 WATER PIPING DIAGRAMS This manual provides detailed water p
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50. CHECKING THE FIRING RATE If firing rate adjustment is required follow these instructions to determine the actual firing rate of the water heater NOTE The heaters covered by this manual are capable of modulating their firing rate The firing rate should be checked with the heater operating at it s full firing rate 1 Ensure there are no other gas fired appliances connected to the gas meter firing during this test 2 Contact the gas supplier to determine the heating value in Btu per cubic foot of the gas supply 3 Start the water heater and ensure it is firing 4 Locate the gas meter serving the water heater 5 Time how long in seconds it takes for one cubic foot of gas to be used while the water heater is firing with a stop watch 6 Use the formula below to clock the gas meter and determine the actual firing rate of the water heater based on the heating value Btu per cubic foot of the gas supply 3600 x H Btu hr Example de x 1050 300 000 Btu hr 87 9 kW 3600 seconds in one hour T time in seconds to burn one cubic foot of gas H heating value of gas in Btu per cubic foot Btu hr actual firing rate of the water heater NOTE 1050 Btu per cubic foot is a standard value for natural gas Standard propane gas Btu content is 2500 Btu per cubic foot Btu values may change in certain areas and at high elevations Check with the local gas utility company TO TURN OFF GAS 1 Change the O
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55. Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death ADANGER Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at fixtures AWARNING Overheated water can cause water tank explosion e Properly sized temperature and pressure relief valve must be installed in the opening provided CAUTION Improper installation use and service may result in property damage Do not operate water heater if flood damaged Inspect and anode rods regularly replace if damaged Install in location with drainage Fill tank with water before operation Properly sized thermal expansion tanks are required on all closed water systems Refer to this manual for installation and service GENERAL SAFETY INFORMATION PAYANTE AVVARNING Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and For continued protection against liquids in the vicinity of this or any other appliance risk of fire Avoid all ignition sources if you smell gas Do not install water heater on Do not expose water heater controls to excessive gas carpeted floor pressure Do not operate water heater if e Use only the gas shown on the water heater rating label expos
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69. w SONDE DE CONTR LE e SOUPAPE DE D CHARGE DE TEMPERATURE 1 CLAPET ANTI RETOUR AVERTISSEMENT CE SCHEMA ILLUSTRE LA A S CURIT THERMIQUE CONFIGURATION DE TUYAUTERIE SUGGEREE ET P SOUPAPE DE D CHARGE VIDANGE JAUGE DE TEMP RATURE D AUTRES DISPOSITIFS CONSULTER LES CODES ET ORDONNANCES LOCAUX POUR TOUTES EXIGENCES SUPPL MENTAIRES CLAPET BILLE PASSAGE INTEGRAL INTERRUPTEUR DE DEBIT D EAU POMPE DE CIRCULATION TOUS CHANGEMENTS DE MATERIAUX DE COMPOSANTS OU DU VENDEUR DOIVENT AVOIR UNE APPROBATION PREALABLE DU SERVICE D ING NIERIE DU PRODUIT APPLICABLE EAU CHAUDE VERS APPAREILS TUYAU DST POUR OUVRIR VIDANGE RETOUR D EAU CHAUDE ALIMENTATION EN EAU FROIDE RESERVOIR DE DILATATION SOL FINI REMARQUES 1 Sch ma de tuyauterie pr f r 2 Le r glage de la soupape de d charge et de s curit thermique ne doit pas d passer la pression nominale de tout composant dans le syst me 3 Les robinets de service sont illustr s pour l entretien de l unit Cependant les codes locaux r gissent leur utilisation 99 v9 ni AYLNAN 27 NOLLWINOwIO 20 3dWOd e o OZI 30 4 31 NOILVLNANITV 1 AGNVWWOO 30 AWALSAS Nd anol vyuda LNAWANNOILONOSA NN V YANAW 30 13 3001819313 3N T dd LINN NN uanooAodd 20 anosid 1939 AND ANNOG LNVLA 134vddv NN NOI 1VIN3NITV 1 14 SVd AN AdWOd 20 LINDY
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71. 3700 7500 oo a0 sov 1220 t950 3450 7200 SUPPLY GAS LINE SIZING METRIC UNITS TABLE 14 LENGTH NORMAL IRON PIPE SIZES INCHES IN INPUT IN kw 202 182 337 542 952 161 299 483 864 126 GAS LINE CONNECTION 1 The water heaters covered by this manual are shipped from the factory with a 1 1 2 supply gas connection see Table 1 on page 10 Connect the supply gas line to the water heater s 24 VAC Gas Valve in accordance with all applicable local and national code requirements see Figure 52 BTH 500 natural gas models require a 1 1 2 minimum supply gas line All other water heaters covered by this manual require a 1 1 4 minimum supply gas line See Table 5 on page 10 Apply thread sealing compounds pipe dope Teflon tape sparingly and only to the male threads of the pipe joints Do not apply sealing compound to the first two threads Use pipe dope or Teflon tape marked as being resistant to the action of liquid petroleum LP propane gases Use only a smooth jaw adjustable wrench such as a monkey wrench as a back up on the body of the 24 VAC Gas Valve when tightening the first pipe nipple into the body of the valve DO NOT use a standard pipe wrench Stillson wrench with metal tooth jaws as this may permanently damage the valve Use a standard pipe wrench Stillson wrench as a back up on the first pipe nipple installed above when connecting other fittings and pipe in the supply gas
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73. SIDEWALL TERMINATION INSTALLATION Determine the location for the termination s If installing only vent exhaust piping in a Power Vent configuration through a sidewall ensure that all exterior sidewall clearance requirements for the termination shown in Figure 48 on page 35 are being maintained These clearances and those cited by local and national codes must be maintained If installing both intake air and vent piping in a Direct Vent configuration through a sidewall ensure that all exterior sidewall clearance requirements for the terminations shown in Figure 49 on page 36 for the vent and intake air termination are being maintained These clearances and those cited by local and national codes must be maintained If installing both an intake air and vent termination in a Direct Vent configuration through a sidewall there must be a minimum of 24 inches 61 cm separation measured on vertical center line between the intake air and vent terminations see Figure 22 NOTE In colder climates this separation should be increased to at least 48 inches 122 cm between the intake air and vent termination or any other appliance vent that discharges moisture laden air such as clothes dryers This will reduce possibility of frost over from side winds blowing exhaust vapors to the intake air termination and is recommended for Canadian installations If installing both intake air and vent terminations in a Direct Vent configuration thr
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81. 6 inch pipe for intake air piping is also 120 equivalent feet 36 5 m IE On Direct Vent installations both pipes can be up to 120 equivalent feet 36 5 m INTAKE AIR AND VENT PIPE CLEARANCES The minimum clearance from combustible materials for the vent exhaust and intake air piping shall be 0 inches Vent or intake air piping passing through a combustible wall or ceiling must be a continuous run no joints MINIMUM EQUIVALENT LENGTHS Four Inch Pipe The water heaters covered in this manual are certified to a minimum length of 4 inch pipe for the vent exhaust of 15 21 equivalent feet 4 6 m There is no minimum equivalent feet requirement for the intake air pipe Six Inch Pipe The water heaters covered in this manual are certified to a minimum length of 6 inch pipe for the vent exhaust of 70 equivalent feet 21 3 m There is no minimum equivalent feet requirement for the intake air pipe MAXIMUM NUMBER OF ELBOWS The vent pipe may have a maximum of six 90 elbows installed The intake air pipe may have a maximum of six 90 elbows installed IE in a Direct Vent configuration each pipe can have up to six 6 90 elbows installed Two 2 45 elbows equal one 1 90 elbow Each 90 elbow is equivalent to 5 feet 1 5 m of linear pipe 45 elbows are equivalent to 2 5 feet 0 75 m of linear pipe Note Refer to Table 10 and Table 11 for equivalent linear pipe length of AL29 4C 45 and 90 elbows FAC
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83. C 3 49 kPa for natural and propane gas Install a positive lock up gas pressure regulator in the gas supply line if inlet gas pressure can exceed these pressures at any time 13 If a positive lock up regulator is required follow these instructions 1 Positive lock up gas pressure regulators must be rated at or above the input Btu hr rating of the water heater they supply Supply gas regulators shall have inlet and outlet connections not less than the minimum supply gas line size for the water heater they supply See Table 13 page 38 Positive lock up gas pressure regulator s should be installed no closer than 3 feet 1 meter and no farther than 8 feet 2 4 meters from the water heater s inlet gas connection After installing the positive lock up gas pressure regulator s an initial nominal supply pressure setting of 7 0 W C while the water heater is operating is recommended and will generally provide good water heater operation Some addition adjustment maybe required later to maintain a steady gas supply pressure When installing multiple water heaters in the same gas supply system it is recommended that individual positive lock up gas pressure regulators be installed at each unit POWER SUPPLY The water heaters covered in this manual require a 120 VAC 19 single phase 60Hz 15 amp power supply and must also be electrically grounded in accordance with local codes or in the absence of local codes with the Nati
84. Do not try to light any appliance D Do not use this appliance if any part hasbeen under Do not touch any electric switch water Immediately contact a qualified installer or do not use any 5 in your building service agency to replace a flooded water heater Do not attempt to repair the unit It must be replaced Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions OPERATING INSTRUCTIONS 5 This appliance is equipped with a device which automatically lights the burner Tank Temperature 103 F DO NOT TRY TO LIGHT THE BURNER BY HAND Operating Set Point 120 F Tar Status Heating 6 Wait five 5 minutes to clear out any gas orr If you then smell gas STOP Follow B in Di the safety information above on this label If you don t smell gas go to the next step 7 Turn on all electrical power to the appliance 8 Set the Enable Disable switch on the control panel to the Enable position 9 Set the thermostat to the desired setting CAUTION Hotter water increases the risk of scald injury Consult the instruction manual before changing temperature EO STOP Read the safety information above 10 If the appliance will not operate follow the ENABLE DISABLE SWITCH on this label instructions TO TURN OFF GAS TO APPLIANCE and call your technician or gas supplier 2 Enli postion switch on the control panel WARNING TURN OFF ALL
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88. Show Contact Information Change Contact Name Change Contact Phone Current Contact Info 000 000 0000 Access Code CHANGE Service Contact Information Show Contact Information Yes Change Contact Name Change Contact Phone Current Contact Info 000 000 0000 Access Code UPDATE CS CANCEL Service Contact Information Show Contact Information Yes Change Contact Name Change Contact Phone Current Contact Info 000 000 0000 Access Code SELECT BACK HELP Enter the service contact below Use the gt and lt keys to move between characters Use the UP and DOWN keys to change the character NAME _ lt gt UPDATE Service Contact Information Show Contact Information Yes Change Contact Name Change Contact Phone YOUR COMPANY NAME HERE 123 456 7890 Access Code START UP PRIOR TO START UP Installation and start up of this water heater requires abilities and skills equivalent to that of a licensed tradesman in the field involved see Qualifications on page 6 Do not place the water heater in operation if any part has been under water Immediately call a qualified service technician to inspect the water heater and to replace any part of the control system and any gas control which has been under water Light the water heater in accordance with the Lighting and Operation Instruction label on the water heater and in this manual on page 52 The water heaters covered by this manual a
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92. etc Replacement parts after expiration of this warranty LIMITATIONS NOTWITHSTANDING ANYTHING ELSE TO THE CONTRARY THIS IS YOUR SOLE AND EXCLUSIVE WARRANTY ALL OTHER WARRANTIES INCLUDING A WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED SELLER SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL INCIDENTAL SPECIAL PUNITIVE OR OTHER INDIRECT DAMAGES TOTAL LIABILITY ARISING AT ANY TIME SHALL NOT EXCEED THE PURCHASE PRICE PAID WHETHER BASED ON CONTRACT TORT STRICT LIABILITY OR ANY OTHER LEGAL THEORY For service inquiries call the telephone number listed below Be prepared to provide the following information name address and telephone number the model and serial number of the water heater proof of installation and a clear description of the problem For your records fill in the product Serial Model U S Customers A O Smith Corporation 500 Tennessee Waltz Parkway Ashland City Tennessee 37015 800 527 1953 www hotwater com Canadian Customers P O Box 310 768 Erie Street Stratford Ontario N5A 6T3 800 265 8520 75 Ge Smith 500 Tennessee Waltz Parkway Ashland City TN 37015 Technical Support 800 527 1953 Parts 800 433 2545 Fax 800 644 9306 www hotwater com UJ009 19 EWOU MMM 9066 9 008 In ldoo9 91 9792 667 008 Soe S61 229 008 enbiuyoe u nnos GLOZE NL AUD puelysy zyem 9ss uu l 009 lIUS y GZ
93. gt e Do not obstruct water heater air intake with insulating blanket e Gas and carbon monoxide detectors are available e Install water heater in accordance with the instruction manual ng carbon monoxide can cause brain damage or death Always read and understand instruction manual Insulation blankets are available to the general public for external use on gas water heaters but are not necessary with these products The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters The water heaters covered by this manual meet or exceed the Energy Policy Act standards with respect to insulation and standby heat loss requirements making an insulation blanket unnecessary Should you choose to apply an insulation blanket to this heater you should follow these instructions See the Features and Components section of this manual for identification of components mentioned below Failure to follow these instructions can restrict the air flow required for proper combustion potentially resulting in fire asphyxiation serious personal injury or death DO NOT apply insulation to the top of the water heater as this will interfere with safe operation of the blower assembly DO NOT cover the control system LCD on top of the water heater DO NOT cover the Temperature Pressure Relief Valve DO NOT cover the instruction manual Keep it on the side of the water heater or nearby for future ref
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100. their firing rate The CCB monitors the water temperature in the tank and regulates the firing rate to achieve the target temperature setpoint The firing rate is dictated by the hot water draw proximity to the tank temperature setpoint and various other temperature limitations Periodically when the heater is in modulation mode the CCB will increase the blower speed for a short period of time to clear out any condensation that has accumulated in the heat exchanger then decreases the blower speed back to the modulating firing rate required to maintain the desired tank temperature setpoint This ramping up and down of the blower speed is considered normal operation of the water heater BLOWER BURNER ASSEMBLY DETAIL INTAKE AIR combustion air CONNECTION 4 INCH PVC COMBUSTION BLOWER BLOWER FLANGE FLAME SENSOR MAIN BURNER y B radial design Figure 2 Spark Electrode The control system energizes the spark ignition control with 120 VAC during the ignition period The spark ignition control then sends a high voltage electrical current to the spark igniter which in turn ignites the main burner air gas mixture Flame Sensor The control system also monitors the flame sensor to confirm a flame is present at the Main Burner If a flame is not verified during the ignition trial period 3 5 seconds the control system will immediately de energize the 24 VAC Gas Valve See the Sequence of Operation Flow Chart on pag
101. two red wires see Figure 3 on page 8 for location The ECO switch contacts will open when the water temperature reaches approximately 202 F 94 C and close at approximately 140 F 49 C If the ECO activates contacts open due to abnormally high water temperatures in the storage tank the control system will immediately de energize the 24 VAC Gas Valve and end the current heating cycle The control system will lock out disabling further heating operation The control system will display the Energy Cut Out ECO Fault message on the LCD screen It is important that a Qualified Service Agent be contacted to determine the reason for the ECO activation before resetting the ECO Once the reason has been determined and corrected the ECO can be reset as follows Should the ECO activate the water temperature must drop below 140 F 49 C before the control system can be reset Once the water temperature has cooled below this point the power supply to the water heater must be turned off and on again to reset the control system THERMOSTAT CONTROL Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death ADANGER Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at
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104. 24 are being maintained These clearances and those cited by local and national codes must be maintained NOTE On flat roof installations the intake air and the vent terminations must be a minimum of 24 inches 60 cm above any parapet vertical wall or structure within 10 feet 3 m horizontally See Figure 20 on page 24 If installing only vent piping in a Power Vent configuration vertically through the roof the following instructions must be followed The vent termination must be oriented facing downward as shown in Figure 19 and Figure 20 on page 24 The bottom edge of the vent termination must be a minimum of 12 inches 30 cm 18 inches 45 cm in Canada above the average or expected snow level as shown in Figure 19 on page 24 If installing both intake air and vent piping in a Direct Vent configuration vertically through the roof the following instructions must be followed The intake air and vent pipes must penetrate the same side of the roof as shown in Figure 21 on page 24 The intake air and vent terminations must be oriented facing downward and in the same direction as shown in Figure 21 on page 24 The intake air and vent terminations must have a minimum 10 separation of 24 61 cm measured on center line as shown in Figure 21 on page 24 In colder climates this separation should be increased to at least 48 inches 122 cm The bottom edge of the intake air and vent terminations must be a minimum of 12 inche
105. 43 normal shower temp 116 47 pain threshold 7 116 47 U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 DISHWASHING MACHINES All dishwashing machines meeting the National Sanitation Foundation requirements are designed to operate with water flow pressures between 15 and 25 pounds per square inch 103 kPa and 173 kPa Flow pressures above 25 pounds per square inch 173 kPa or below 15 pounds per square inch 103 kPa will result in improperly sanitized dishes Where pressures are high a water pressure reducing or flow regulating control valve should be used in the 180 F 82 C line to the dishwashing machine and should be adjusted to deliver water pressure between these limits 14 HOT WATER 12 TO 15 30 38 cm TEMPERED WATER INLET Figure 8 The National Sanitation Foundation also recommends circulation of 180 F 82 C water Where this is done the circulation should be very gentle so that it does not cause any unnecessary turbulence inside the water heater The circulation should be just enough to provide 180 F 82 C water at the point of take off to the dishwashing machine Adjust flow by throttling a full port ball valve installed in the circulating line on the outlet side of the pump Never throttle flow on the suction side of a pump See the Water Piping Diagrams beginning on page 67 NOTE To comply with NSF Standard 5 installation requirements the bo
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108. DIEDUEIS SUOS EU LL s p anuajurew n 1n d eu sunjon4js eun no n loved aun jedesed un e esinbei souejsip IS ANOYVINAY 1 e anbipul 15 NO d n oed no jedesed no ep Id OL uu unnuuului un E S yop UOS EU UL EI uone e p uouonoq sseJu l0 UN e Walsall uosiguluu9 unp UOIEIIEISUI 5407 snu luleui JUBAIOP XTEUOHEU xneoo s po Se sed s l xne9 je 91 s senusjurew juos ez ebed el g 92 ein El g je gz abed el g pz ej g s nsnili enbljueouoo UOSICUILUJ9 El nod in Ll x Elan JueweBebop s ou Bix s s mo nb u msses ol 5 E anbujusou0d uosimeuiuu9 unp UOoUEIEISULU S107 s qISIA SUIOLU JUOS UOHE U A sunedeA Sai nb uolss ulpe p slugeuituugluo5 xne senbsi s upuilouu e ll nb sie6 p xne l qnd osns sulow jee uuop uge lqel y id 1s uosieuluu oun ANOHVNAH uosiguluuJ8 lu uu 5p duu Jouets s nbiu ouo suosieuluM s p nod januewW BINUSANOD EI ins nbipul s ld s p uoud 1 s soduloo no jesoj in nquisip l 2 G001788006 2981d oJeunn od 9 od
109. Do not locate the water heater where noise such as the Combustion Blower during normal operation will be objectionable in adjacent areas 11 Do not locate the water heater where the subsequent installation of the vent exhaust or intake air terminations would be objectionable due to noise at the termination s This includes locations close to or across from windows and doors See Venting Installation on page 20 AWARNING Fire or Explosion Hazard e Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance e Avoid all ignition sources if you smell gas Do not expose water heater controls to excessive gas pressure e Use only the gas shown on the water heater rating label e Maintain required clearances to combustibles e Keep ignition sources away from faucets after extended periods of non use H 4 Read instruction manual before installing using or servicing water heater Thereis a risk in using fuel burning appliances such as gas water heaters in rooms garages or other areas where gasoline other flammable liquids or engine driven equipment or vehicles are stored operated or repaired Flammable vapors are heavy and travel along the floor and may be ignited by the water heater s igniter or Main Burner flames causing fire or explosion Flammable items pressurized containers or any other potential fire hazardous articles must never be placed on or ad
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111. Exhaust error occurs when blower is running check for restrictions in exhaust pipe including exhaust elbow condensate drain and outside termination Also check exhaust pipe installation size length per manual If Blocked Exhaust error occurs before blower runs make sure pressure switch connections are clean and tight Check pressure switch continuity resistance Switch should be closed continuity 0 ohms Replace switch if open no continuity Other possible causes high wind conditions and excessive negative air pressure in building 59 Ignition Failure Fault occurred 2 mins ago Flame not detected Clean flame rod ES Check gas supply Call a service professional Your Company Name Here press DOWN for more hd BACK ADVANCED Low Gas Pressure Fault occurred 2 mins ago Gas pressure is below minimum required to operate this unit Check gas pressure and switch Call a service professional Your Company Name Here Blocked Exhaust Fault occurred 2 mins ago Restriction in exhaust pipe Check exhaust pipe and termination for blockage Call a service professional Your Company Name Here press DOWN for more hd BACK ADVANCED FAULT AND ALERT MESSAGES CONT Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualified service agent in your area POSSIBLE CAUSES CHECK REPAIR DISPLAYED FAULT ALERT MESSAGE Ensure excessive wind is not p
112. GROUND EXTERIOR WALL SIDEWALL TERMINATION INSTALLATION INTAKE AIR AND OR VENT EXHAUST Figure 23 Place a bead of silicone caulking field supplied around the gap between the installed pipe s and the wall Apply enough to fill the gap between the pipe s and wall Press the wall plate flush against the outside wall Working from the inside apply enough silicone caulking on the back of the interior wall plate s to hold it in place and slide the wall plate over the installed pipe s Install a coupling to the end of the pipe s inside the building Before the silicone caulking has time to completely set go outside the building and ensure the termination s is still pointing down towards the ground See Figure 23 Return to Power Vent Installation on page 22 or Direct Vent Installation on page 22 to complete the installation of the intake air and or vent piping between the termination s and the water heater POLYPROPYLENE INSTALLATIONS The water heaters covered by this manual have been approved to be installed with Polypropylene vent material as shown in Table 8 and Table 9 The approved application of single wall non flexible non concentric Polypropylene vent material is offered by two specific manufacturers Centrotherm ECO Systems and DuraVent Polypropylene These listed products must be installed by following the vent manufacturer s instructions Refer to Table 7 on Page 22 to determine the maximum pipe le
113. If the Cycle Count per day is high divide cycle count by days to determine cycles per day or the cycle duration is short determine burner on time total minutes divide burner on time total minutes by cycle count consider rasing the Differential setting to avoid short cycling and excessive component wear see Operating Set Point And Differential Adjustment on page 46 This historical data can also be used to assist facilities managers in forecasting planned replacement of equipment to help avoid lengthy and costly hot water supply interruptions 48 CURRENT FAULT DESCRIPTION ACTION DISPLAY Select Current Fault from the Main Menu and press the Operational Button under SELECT to enter this menu This menu contains non adjustable operational information Use the Up amp Down Buttons to navigate the menu Blocked Exhaust Fault occurred 2 mins ago Restriction in exhaust pipe Check exhaust pipe and termination for blockage This menu contains the current Fault or Alert error message The time the Fault or Alert message occurred appears directly below A brief description of what causes the particular Fault or Alert condition appears below that Pressing the Operational Button under ADVANCED will give more detailed service Call a service professional information and a list of possible causes for the Fault or Alert Your Company Name Here condition See Fault And Alert Messages on page 59 for more press DOWN for more det
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118. POTABLE HEATING AND SPACE HEATING 1 All water piping components connected to the water heater that are for space heating applications shall be suitable for use with potable water 2 Toxic chemicals such as those used for boiler treatment must NEVER be introduced into this system 3 The water heaters covered in this manual may never be connected to any existing heating system or component s previously used with non potable water heating appliance When the system requires water for space heating that exceed safe temperatures at domestic water fixtures a mixing valve must be installed see Mixing Valves on page 14 5 These water heaters cannot be used in space heating applications only T amp P VALVE DISCHARGE PIPE AWARNING Temperature Pressure Relief Valve must comply with ANSI Z21 22 CSA 4 4 and ASME code e Properly sized temperature pressure relief valve must be installed in opening provided e Can result in overheating and excessive tank pressure Can cause serious injury or death 41 This water heater is provided with a properly rated sized and certified combination temperature pressure T amp P relief valve by the manufacturer See Temperature Pressure Relief Valve on page 15 for information on replacement and other requirements CAUTION e Temperature Pressure Relief Valve discharge pipe must terminate at adequate drain Install a discharge pipe between the T amp P valve discharge o
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121. a la page 66 1 al la section M langeurs a la page 14 7 Si une pompe est install e dans un circuit boucl de recirculation entre le chauffe eau et un Voir la section Lave vaisselle la page 14 fil de lave vaisselle commercial conform ment a la Figure 64 a la page 66 2 3 Voir la section Soupape de d charge a s curit thermique a la page 15 4 Voir la section Syst mes d eau ferm s et Dilatation thermique a la page 14 Avant UN CHAUFFE EAU TEMPERATURE UNIQUE AVEC LEGENDE RECIRCULATION FORCEE DANS RESERVOIR DE STOCKAGE HORIZONTAL AVEC RECIRCULATION BATIMENT SONDE DE CONTROLE i SOUPAPE DE DECHARGE DE TEMPERATURE To CLAPET ANTI RETOUR A SECURITE THERMIQUE AVERTISSEMENT CE SCHEMA ILLUSTRE LA k CONFIGURATION DE TUYAUTERIE SUGG R E ET SOUPAPE DE D CHARGE VIDANGE JAUGE DE TEMPERATURE D AUTRES DISPOSITIFS CONSULTER LES CODES ET ORDONNANCES LOCAUX POUR TOUTES EXIGENCES SUPPL MENTAIRES CLAPET BILLE POMPE DE CIRCULATION PASSAGE INT GRAL INTERRUPTEUR DE D BIT D EAU TOUS CHANGEMENTS DE MAT RIAUX DE COMPOSANTS OU DU VENDEUR DOIVENT AVOIR UNE APPROBATION PREALABLE DU SERVICE D ING NIERIE DU PRODUIT APPLICABLE EAU CHAUDE VERS APPAREILS POMPE DE CIRCULATION TUYAU DST POUR OUVRIR VIDANGE RETOUR D EAU CHAUDE EMPLACEMENT ALTERNATIF ALIMENTATION EN EAU FROIDE RESERVOIR DE DILATATION SOL FINI REMARQUES Sch ma de tuy
122. allowed See Venting Requirements on page 21 Do not install the vent or intake air piping in a manner that will allow water to be trapped in the piping Vent pipes must be pitched a minimum of a 1 4 inch per foot back to the water heater to allow drainage of condensate Do not anchor the vent or intake air pipe directly to framed walls floors or ceilings unless rubber isolation pipe hangers are used to prevent vibration noise from being transmitted Use only approved vent intake air pipe sizes and materials See Venting Requirements on page 21 Use only factory supplied vent and intake air concentric or low profile terminations See the Venting Requirements on page 21 Do not locate the vent exhaust or intake air terminations where they would be objectionable due to noise at the termination s This includes locations close to or across from windows and doors Direct venting into dead air spaces such as alleys atriums and inside corners can cause recirculation of flue gases Recirculation of flue gases will cause sooting premature failure of the heat exchanger and icing of the combustion air intake during severe cold weather To prevent the recirculation of flue gases maintain as much distance as possible between the intake air and vent terminations Do not locate the vent termination over a public area where condensate or vapor can cause a nuisance or ice hazard Ensure the screens in the factory supplied terminations are securely i
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125. do not need replacing unless damaged Inspection and cleaning should be performed once a year NOTE Follow the instructions to drain the water heater storage tank on page 61 first Remove the powered anodes from the water heater by loosening the 3 4 NPT bushing that forms the top of the anodes Do not disassemble the retaining nut and wire terminal from the top while installed in the water heater the anode s electrode may fall inside the tank Remove the entire anode rod from the water heater prior to inspection Clean the anode rods with a soft cloth and reinstall Follow the instructions for filling the water heater on page 51 when finished DRAIN VALVE AND ACCESS PANELS The water heaters covered in this manual are equipped with a drain valve see Features And Components on page 7 for location The water heaters covered in this manual are also equipped with a cleanout opening for sediment and lime scale removal See Figure 59 on page 62 TEMPERATURE PRESSURE RELIEF VALVE TEST ADANGER e Burn hazard e Hot water discharge e Keep clear of Temperature Pressure Relief Valve discharge outlet It is recommended that the Temperature Pressure Relief Valve should be checked to ensure that it is in operating condition every 6 months When checking the Temperature Pressure Relief Valve operation make sure that 1 no one is in front of or around the outlet of the Temperature Pressure Relief Valve discharge line and 2 that the wa
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127. field involved Installation skills such as plumbing air supply venting gas supply and electrical supply are required in addition to electrical testing skills when performing service ANSI 2223 1 2006 Sec 3 3 83 Qualified Agency Any individual firm corporation or company that either in person or through a representative is engaged in and is responsible for a the installation testing or replacement of gas piping or b the connection installation testing repair or servicing of appliances and equipment that is experienced in such work that is familiar with all precautions required and that has complied with all the requirements of the authority having jurisdiction If you are not qualified as defined by ANSI above and licensed or certified as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the procedures described in this manual If you do not understand the instructions given in this manual do not attempt to perform any procedures outlined in this manual ICOMM amp BACNET COMPATIBLE This water heater is compatible with the iCOMM remote monitoring system The iCOMM system hardware and monitoring service is purchased separately It allows users to monitor critical operational diagnostic and energy usage data from a secure web site The iCOMM system can automatically notify selected personnel via email and or cellular phone text messages if ope
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134. on page 8 to locate the CCB enclosure and Figure 61 on page 64 for the CCB layout Install field wiring to the enable disable circuit 1 Turn off power at the water heater s enable disable switch and the breaker that supplies power to the water heater 2 Locate the CCB enclosure 3 Carefully remove the Temperature Probe connectors and CCB enclosure cover 4 Locate pins 1 and 2 on the CCB J17 plug See Figure 61 on page 64 5 Connect the two field supplied control wires to pins 1 and 2 on the CCB J17 plug 6 Thread the control wires out of the CCB enclosure with the other wiring and carefully replace the CCB enclosure cover Ensure all wiring is routed through the intended area provided for strain relief Ensure no wiring is being pinched 7 Reinstall the CCB enclosure cover 40 8 Route the control wires inside the junction box on the top of the water heater see Figure 3 on page 8 to locate the junction box Use an available knock out to route the wires inside the junction box Install field supplied control wiring and conduit as required by national and local codes between the water heater s junction box and the external supervisory control Connect the wiring from the external control to the control wires inside the junction box using wire nuts and electrical tape 10 Connect the control wiring to a set of dry contacts on the external control Follow the control manufacturer s instructions for making connections
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137. pressure blocked exhaust blocked intake and ECO energy cut out switch contacts are closed The Blower Prover Switch contacts are confirmed open If all diagnostic checks are successfully passed the control system energizes the Combustion Blower for pre purge The control system must confirm the Blower Prover Switch contacts close after the Combustion Blower is energized If the Blower Prover Switch contacts are confirmed closed the control system energizes the spark ignition control The control system energizes the 24 VAC Gas Valve allowing gas to flow to the Main Burner The control system monitors the flame sensor to confirm a flame is present at the Main Burner If a flame is not verified during the ignition trial period the control system will try for ignition up to two more times If flame can not be verified after three trials for ignition the control system will lock out and display the Ignition Failure Fault message If a flame is verified the control system will enter the heating mode where it will continue heating the water until the Operating Set Point is reached At this point the control system will de energize the 24 VAC Gas Valve and enter the post purge cycle approximately 30 seconds 10 The control system de energizes the Spark Ignition Control 11 The water heaters covered by this manual are capable of modulating their firing rate The firing rate is dictated by the hot water draw and various o
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140. scale accumulation also reduces the life span of water heaters For these reasons a regular schedule for deliming should be set up The depth of lime accumulation in the bottom of the water heater should be measured periodically Inspect by removing the cleanout cover once every 6 months at first Deliming maintenance should then be performed based on the time it takes for 1 inch 2 5 cm of lime to accumulate in the bottom of the water heater Sediment and lime scale removal may be accomplished manually through the cleanout opening furnished on the water heater see Figure 59 CLEANOUT ACCESS PANEL CLEANOUT LT GASKET TANK CLEANOUT OPENING CLEANOUT COVER Figure 59 MANUAL LIME SCALE REMOVAL NOTE Contact your local distributor or call the parts department phone number on the back cover of this manual to order a new cleanout gasket Have the new gasket available before removing the cleanout cover The cleanout opening is shown in Figure 59 To remove lime scale manually through the cleanout opening proceed as follows 1 Turn off the electrical supply to the water heater 2 The water heater must be drained see Draining And Flushing on page 61 follow the instructions on how to drain the water heater 3 Remove outer cleanout access plate from lower side of the water heater jacket Remove the cleanout cover from cleanout opening 5 Remove lime scale and or sediment using care not to damage the glass li
141. suitable means the water flow may cause property damage 15 CAUTION e Temperature Pressure Relief Valve discharge pipe must terminate at adequate drain T amp P Valve Discharge Pipe Requirements e Shall not be smaller in size than the outlet pipe size of the valve or have any reducing couplings or other restrictions Shall not be plugged or blocked Shall not be exposed to freezing temperatures Shall be of material listed for hot water distribution Shall be installed so as to allow complete drainage of both the Temperature Pressure Relief Valve and the discharge pipe Must terminate a maximum of six inches above a floor drain or external to the building In cold climates it is recommended that the discharge pipe be terminated at an adequate drain inside the building Shall not have any valve or other obstruction between the relief valve and the drain ADANGER e Burn hazard e Hot water discharge e Keep clear of Temperature Pressure Relief Valve discharge outlet The Temperature Pressure Relief Valve must be manually operated at least twice a year Caution should be taken to ensure that 1 no one is in front of or around the outlet of the Temperature Pressure Relief Valve discharge line and 2 the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot If after manually operating the valve it fails to completely reset and continues to rele
142. to gas valve can cause serious injury or death e Turn off gas lines during installation e Contact a qualified installer or service agency for installation and service Make sure gas supplied is same type listed on the water heater s rating label The water heaters covered in this manual are not intended for operation at higher than 14 0 W C 2 49 kPa for natural and propane gas supply pressure see Table 4 on page 10 The water heaters covered in this manual require supply gas regulators to maintain required supply gas pressure 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 malfunction of the supply system the water heater s gas valve must be checked for safe operation by a Qualified Service Agency Ensure supply regulator vent lines and the safety vent valves are protected against blockage These are components of the gas supply system not the water heater Vent blockage may occur during ice storms It is important to guard against gas valve fouling from contaminants in the gas ways Such fouling may cause improper operation fire or explosion If copper supply lines are used they must be internally tinned and certified for gas service REGULATED GAS SUPPLY LINE MAIN GAS 7 SHUTOFF VALVE TEE FITTING x SEDIMENT TRAP 7 PIPE CAP Figure 51 Ensur
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145. 0 Btu hr 3 kW 12 inches 30 14 feet 1 2 m below R Clearance to vvindovv 5 Clearance to service or door that may be cm for appliances between 10 000 or to side of opening regulator vent outlet 3 feet 91 cm 3 feet 91 cm opened Btu hr 3 kW and 100 000 Btu hr 30 1 foot 30 cm above H kW 36 inches 91 cm for appliances opening above 100 000 Btu hr 30 kW 6 inches 15 cm for appliances up Clearance to a non to 10 000 Btu hr 3 kW 12 inches i 4 feet 1 2 m below or to Clearance to mechanical air supply 30 cm for appliances between Clearance above grade veranda porch deck or 12 inches 30 cm 12 inches 30 cm balcony 3 feet 91 cm within a height 15 feet 4 5 m above the meter regulator assembly permanently closed 12 inches 30 cm 12 inches 30 cm inlet into building or 10 000 Btu hr 3 kW and 100 000 ld of opening 1 foot window combustion air inlet to Btu hr 30kW 36 inches 91cm 80 cm above opening any other appliance for appliances above 100 000 Btu hr 30 KW Vertical clearance to ventilated soffit located above the terminal Clearance to a 7 91 en above if within a horizontal 12 inches 30 cm 12 inches 30 cm mechanical air supply 6 feet 1 83 m 10 feet 3 m horizontally distance of 2 feet 61 inlet cm from the center line of the terminal Clearance above paved Clearance to R e sidewalk or paved 7 feet 2 13 m unventilated soffit 12 inches 30 cm 1
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152. 2 inches 30 cm driveway located on 7 feet 2 13 m t public property Clearance to outside Clearance under cartier 2 feet 60 cm 2 feet 60 cm veranda porch deck or 12 inches 30 cm 12 inches 30 cm balcony G 55 co inside 18 inches 45 cm 18 inches 45 cm corner 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code T Avent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings Where it may cause hazardous frost or ice accumulations on adjacent property surfaces Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer s installation instructions 35 TERMINATION CLEARANCES SIDEWALL DIRECT VENT DIRECT VENT using outdoor air for combustion EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION FIXED OPERABLE CLOSED NW VENT TERMINAL Q AIR SUPPLY INLET SSS AREA WHERE TERMINAL IS NOT PERMITTED Figure 49 Vent terminal clearances for Direct Vent installations Direct Vent configurations use outdoor air for combustion CANADIAN INSTALLATIONS 1 US INSTALLATIONS 2 CANADIAN INSTALLATIONS 1 US INSTALLATIONS 2 Clearance to each side o
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158. 4 and 6 diameter pipes M amp G Duravent PolyPro Vent system part numbers Flue Outlet Adapter Ring Nominal Pipe Diameter 4PPS AD PPS PAC 4PPS LB 4PPS E90B PPS 5 PPS PACL 6PPS LBC 6PPS E90 PPS TABLE 9 Vent Terminal s 4PPS E45B for Exhaust 4PPS E45B for Intake Direct Vent only 6PPS E45 for Exhaust 6PPS E45 for Intake Direct Vent only Centrotherm InnoFlue SW Vent system part numbers Nominal Pipe Diameter ISAGL 0404 IAFC04 IANS04 ISEL0487 Polypropylene ISAGL 0606 IAFC06 IANS06 ISEL0687 Polypropylene Flue Outlet Ring Adapter Adapter Connector 90 Degree Elbow Vent Material Vent Terminal s ISELLO445UV for Exhaust ISELLO445UV for Intake Direct Vent only ISELLO645UV for Exhaust ISELLO645UV for Intake Direct Vent only AL29 4C VENT INSTALLATIONS AL29 4C is a registered trademark of Allegheny Technologies Inc The water heaters covered by this manual are approved to be installed with AL29 4C stainless steel vent material using parts from the manufacturers listed in Table 10 and Table 11 below These listed systems must be installed using the vent manufacturer s instructions including their listed clearances to combustible and noncombustible materials Refer to Table 7 on page 22 for the maximum and minimum equivalent linear vent lengths and number of elbows that may be used However use Table 10 and Table 11 below to find the appropriate equivalent linear vent lengths for the
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164. AL29 4C elbows Note The equivalent lengths of the AL29 4C elbows are different than those from smooth walled plastic vents Consult Table 10 and Table 11 for the correct equivalent linear vent lengths Listed vent systems composed of AL29 4C must not mix parts from the different manufacturers The joints of these products are sealed by internal gaskets Do not use any other type of sealant When assembling these vent systems follow the vent manufacturer s instructions for cleaning and lubricating the joints if required Each section must be locked together using the method supplied by the vent manufacturer The water heaters covered by this manual are approved to be installed using the approved vent terminations shown in this manual This means that the installer must use the adapter listed in Table 10 and Table 11 and a short piece of PVC pipe to complete the end of the vent system with an approved termination In Canada the PVC pipe length must be listed to ULC636 TABLE 10 HeatFab Saf T Vent AL29 4C Vent System Parts z Equivalent Linear Diameter Flue Outlet Straight Pipe 3 45 Elbow Length 45 90 Elbow Equivalent Linear Adapter to PVC Adapter Section Elbow length 90 Elbow 9401 PVC 9307 9411 9414 10 feet 9454CPVC e 9601 PVC 9607 9611 9614 10 feet 9656CPVC Consult vent manufacturer s catalog for other available lengths TABLE 11 Duravent FasNSeal AL29 4C Vent System Parts d Equivale
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169. ELECTRIC 3 Set the thermostat to the lowest setting POWER BEFORE SERVICING 4 Set the Enable Disable switch on the control panel to the Disable position TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to the lowest setting 2 Set the Enable Disable switch on the control panel to the Disable position 3 Turn off all electrical power to the appliance if service is to be performed SUPPLY GAS PRESSURE ADJUSTMENT AWARNING Fire and Explosion Hazard e Do not use water heater with any gas other than the gas shown on the rating label e Excessive gas pressure to gas valve can cause serious injury or death e Turn off gas lines during installation e Contact a qualified installer or service agency for installation and service Supply gas pressure shall be measured while the water heater is not firing static pressure AND while the water heater is firing at full capacity dynamic pressure If the supply gas pressure to the water heater is not between the required minimum and maximum values given in Table 4 on page 10 adjust the supply gas regulator as necessary Adjust the supply gas regulator s per the regulator manufacturer s instructions to achieve the required static and dynamic supply gas pressure Multiple Appliance Installations In multiple water heater installations or in installations where the installed water heater s share a common gas supply main with other gas fired applian
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171. ER INFORMATION DESCRIPTION ACTION DISPLAY Select Heater Information from the Main Menu and press the Operational Button under SELECT to enter this menu This menu contains non adjustable operational information Elapsed Time Heater Information Elapsed Time Total accumulated time the control system 10 day 0 hrs 0 mins water heater has been energized Burner On Time Burner On Time Total accumulated time the control system 5 hrs 22 mins has been in the heating operating state burner run time Total Cycle Count 00000035 Total Cycle Count Total accumulated count of heating CCB Version X XX cycles Config CRC 0 x 605D CCB Version Software version for central control board UIM Version Software version for user interface module Config CRC Verifies the configuration key matches the CCB programming Use External Enable Enables Disables the external enable circuit UIM Version External Enable Status displays whether or not the Use External Enable external enable circuit has been activated External Enable Status Ignition Trials displays the number of ignition trials allowed Ignition Trials NOTE Historical data is stored in the configuration key If this key is replaced during servicing the historical data will be lost The data stored in the new configuration key will no longer reflect the entire history of the water heater The Elapsed Time Burner On Time and Cycle Count indicate age usage and wear
172. F 3 IPEX Part Pipe Outside Hole Spacing Center to Center x 5666060651 1 RE Beo x 6 1 1 x 5 RE 32 VENTING ARRANGEMENTS Power Vent Vertical Power Vent Horizontal Figure 39 Figure 40 Direct Vent Vertical Direct Vent Horizontal Figure 41 Figure 42 33 VENTING ARRANGEMENTS Direct Vent Vertical Vent Horizontal Intake Direct Vent Horizontal Vent Vertical Intake Direct Vent Vertical Concentric Figure 43 Figure 44 Figure 45 Direct Vent Horizontal Concentric Direct Vent Horizontal Low Profile Figure 46 Figure 47 34 TERMINATION CLEARANCES SIDEWALL POWER VENT POWER VENT using room air for combustion EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION INSIDE CORNER DE TAIL N VENT TERMINAL K i AIR SUPPLY INLET NS AREA WHERE TERMINAL IS NOT PERMITTED Figure 48 Vent terminal clearances for Power Vent installations Power Vent configurations use room air for combustion 1 CANADIAN INSTALLATIONS US INSTALLATIONS 2 CANADIAN INSTALLATIONS I US INSTALLATIONS 2 Clearance to each side of center line extended above meter regulator assembly 3 feet 91 cm within a height 15 feet 4 5 m above the meter regulator assembly 6 inches 15 cm for appliances up to R 10 00
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174. I Gauge Water heaters require gas regulators that are properly sized for the water heater input and deliver the rating plate specified pressures Gas supply systems where pressure exceeds 5 PSI often require multiple regulators to achieve desired pressures Systems in excess of 5 PSI building pressure should be designed by gas delivery professionals for best performance Water heaters connected to gas supply systems that exceed 14 W C 1 2 PSI Gauge at any time must be equipped with a gas supply regulator All models require a minimum gas supply pressure of 4 4 W C for natural gas and 8 5 W C for propane gas The minimum supply pressure is measured while gas is flowing dynamic pressure The supply pressure should never fall below 4 4 W C for natural gas and 8 5 W C for propane gas The supply pressure should be measured with all gas fired appliances connected to the common main firing at full capacity If the supply pressure drops more than 1 5 W C as gas begins to flow to the water heater then the supply gas system including the gas line and or the gas regulator may be restricted or undersized See Supply Gas Regulator section and Gas Piping section of this manual The gas valve on all models has a maximum gas supply pressure limit of 14 W C The maximum supply pressure is measured while gas is not flowing static pressure SUPPLY GAS REGULATOR The maximum allowable gas supply pressure for this water heater is 14 0 W
175. ING Temperature Pressure Relief Valve must comply with ANSI Z21 22 CSA 4 4 and ASME code Properly sized temperature pressure relief valve must be installed in opening provided Can result in overheating and excessive tank pressure Can cause serious injury or death This water heater is provided with a properly rated sized and certified combination Temperature Pressure Relief Valve T amp P valve by the manufacturer The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems ANSI 221 22 CSA 4 4 and the code requirements of ASME If replaced the new T amp P valve must meet the requirements of local codes but not less than a combination Temperature Pressure Relief Valve rated sized and certified as indicated in the above paragraph The new valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater 150 psi 1 035 kPa and a discharge capacity not less than the water heater Btu hr or kW input rate as shown on the water heater s model rating label NOTE In addition to the factory installed Temperature Pressure Relief Valve on the water heater each remote storage tank that may be installed and piped to a water heating appliance must also have its own properly sized rated and approved Temperat
176. INTAKE AIR PIPE Y FITTING ASSEMBLY VENT CAP VENT PIPE ASSEMBLY INTAKE AIR PIPE 6 INCH CONCENTRIC TERMINATION KIT FIELD ASSEMBLY REQUIRED 6 INCH CONCENTRIC TERMINATION VERTICAL INSTALLATION Figure 25 Assemble and install the 6 inch concentric termination Refer to Figure 26 Figure 25 Figure 26 and Figure 27 for these instructions 1 Cement the Y fitting to the larger diameter intake air pipe NOTE SECURING STRAP MUST BE 2 Slide the intake air pipe and Y fitting assembly from inside the FIELD INSTALLED TO PREVENT building through the hole cut for the termination in the roof MOVEMENT OF TERMINATION KIT or sidewall Ensure no foreign materials such as insulation IN SIDEWALL accumulate inside the assembly VENT STRAP 3 Secure the intake air Y fitting assembly using field supplied field supplied metal strapping or equivalent support materials 4 On installations installed through the roof slide a field supplied plumbing boot or roof flashing over the intake air Y fitting assembly and secure it to the roof 5 Seal around the plumbing boot or roof flashing 6 Cement the vent cap onto the vent pipe Alternately a field supplied stainless steel screw may be used to secure the 2 components together when field disassembly is desired for MAXIMUM cleaning A pilot hole must
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178. IVI Ge Smith 500 Tennessee Waltz Parkway Ashland City TN 37015 www hotwater com Pan O CERTIFIED www ahridirectory org o ur LOVV LEAD CONTENT GAS FIRED ar di LISTED D QUALITY ANSI NSF 5 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 e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e 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 buying this energy efficient water heater We appreciate your confidence in our products Instruction Manual A AS WATER HEATER MODELS BTH 300 A 400 A 500 A SERIES 200 amp 201 INSTALLATION OPERATION SERVICE MAINTENANCE LIMITED WARRANTY CANADIAN MANUAL This model is iCOMM COMPATIBLE For info call 1 888 WATERO2 CH AWARNING Read and understand this instruction manual and the safety messages herein before installing operating or serv
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183. NT Si SOUPAPE DE DECHARGE SONDE DE CONTROLE 1 CLAPETANTIRETOUR A SECURITE THERMIQUE CONFIGURATION DE TUYAUTERIE SUGGEREE ET SOUPAPE DE D CHARGE r VIDANGE JAUGE DE TEMPERATURE D AUTRES DISPOSITIFS CONSULTER LES CODES ET ORDONNANCES LOCAUX POUR TOUTES EXIGENCES SUPPL MENTAIRES CLAPET BILLE POMPE DE CIRCULATION PASSAGE INT GRAL INTERRUPTEUR DE D BIT D EAU AVERTISSEMENT CE SCHEMA ILLUSTRE LA k TOUS CHANGEMENTS DE MATERIAUX DE EAU CHAUDE COMPOSANTS OU DU VENDEUR DOIVENT AVOIR VERS APPAREILS UNE APPROBATION PR ALABLE DU SERVICE D ING NIERIE DU PRODUIT APPLICABLE TUYAU DST POUR OUVRIR VIDANGE RETOUR D EAU CHAUDE H VMOOLS 30 qdIOAd3S338 8 ki ALIMENTATION EN EAU FROIDE I CONNEXION SECONDAIRE b h EAU FROIDE RESERVOIR DE DILATATION i SOL FINI REMARQUES Sch ma de tuyauterie pr f r Le r glage de la soupape de d charge et de s curit thermique ne doit pas d passer la pression nominale de tout composant dans le syst me Les robinets de service sont illustr s pour l entretien de l unit Cependant les codes locaux r gissent leur utilisation La commande de temp rature du r servoir devrait tre c bl e et contr ler la pompe entre le chauffe eau et le r servoir de stockage Le thermostat du chauffe eau devrait tre r gl 5 degr s F plus haut que la commande de temp rature du r servoir SCHEMAS DE CONDUITES D EAU 5 Voir la
184. Nidid YSLVM NOTES 74 COMMERCIAL WATER HEATER LIMITED WARRANTY EFFECTIVE For 3 Years in the event of a tank leak we will repair or at our discretion replace the defective water heater For 1 Year in the event of part failure we will repair or at our discretion replace the defective part We warrant this product against defects in materials or workmanship as described in this document if installed within the United States or Canada and provided the product remains at its original place of installation Warranty coverage begins the date of installation OR the date of manufacture if installation cannot be verified WHAT S COVERED Subject to these terms in the event of defect in materials and or workmanship resulting in a tank leak during the first three years we will e Replace the water heater should the tank leak Subject to these terms in the event of a defect in materials and or workmanship appearing during the first year we will e Repair or at our discretion replace any part of the water heater covered under this limited warranty excluding parts subject to normal maintenance Example non electronic anode rod filter etc Service labor shipping delivery installation handling or any other costs are not covered at any time under this warranty Any replacement part or product will be warranted only for the unexpired portion of the original water heater s limited warranty period If an
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188. ON PR ALABLE DU SERVICE SORTIE D ING NIERIE DU PRODUIT APPLICABLE l SORTIE D EAU TEMP R E RETOUR D EAU TEMP R E ALIMENTATION EN 3 7 46M EAU FROIDE 12 PI A 15 Pl MELANGEUR RETOUR D EAU CHAUDE TUYAU DST POUR OUVRIR VIDANGE SOL FINI REMARQUES 1 Sch ma de tuyauterie pr f r 2 Le r glage de la soupape de d charge et de s curit thermique ne doit pas d passer la pression nominale de tout composant dans le syst me 3 Les robinets de service sont illustr s pour l entretien de l unit Cependant les codes locaux r gissent leur utilisation SCHEMAS DE CONDUITES D EAU 5 Voir la section Connexions de conduites d eau la page 40 Avant l installation des conduites d eau examiner ce qui suit 1 2 3 4 6 Siune pompe est install e entre un chauffe eau et un r servoir de stockage ou sur un circuit boucl de recirculation d un b timent conform ment la Figure 63 la page 66 1 1 7 Si une pompe est install e dans un circuit boucl de recirculation entre le chauffe eau et un Voir la section Lave vaisselle a la page 14 fil de lave vaisselle commercial conform ment a la Figure 64 a la page 66 Voir la section Soupape de d charge a s curit thermique a la page 15 Voir la section Syst mes d eau ferm s et Dilatation thermique a la page 14 Voir la section M langeurs a la page 14 UN CHAUFFE EAU TEMPERATURE LEGENDE UNIQUE AVEC RECIRCULATION BATIMENT
189. OUO 2118 S EU E N sajqiuodsip juos uoqueo apAxouow 266 ap sin lo p Seq nea ayneyo ajuixoud e sanbiwiyo sinadea sap 1u n uu inb synpoid s p 1 oel d sed N lue osi inu Anoo no aun Jed nea ayneyo nu l Janyjsqo sed N ins uonel nuuinooe p Sed US i uuonouoj sed N I nueuu u s id np s pninie s ineu s l ins uono s El 1 lInsuoo sp d 000 OL w g 0 ep snid e s nhs suonelle sui Sa inod s eio ds s ins ui s p pu id ne p Se69p sap no uonepuoul aun sed e LS Nea ayyneyo l sin sed N S2p09 XNE U UI ULO UO uonl nu A ui s s l 1 l le sul EERIE A4 NOILV ILIN4A 40 NOILVTIVLSNI 6L od wo 9 7 Sulow ne p 6 s ure nB6ue1591 S INDUOD WNWIUILW uoisu uiip E7 1u9 99uuoo as s l s jl nbxne s inu Ano sap ail uoz EI nb ajesseAsued uono s Euns w u EI JUOIAS s S Siliin JUOS SJINPUO9 s nbsio7 lui Su SUED S E1SU Sil redde soi sno leqol6 nbijuole5 np mg 000 00 1 2 099 00 001 wo gpg D uunuului asq uoz un ene jnpuoo mu Ano nbeuo ep sulow ne elas mu Ano nbguo l l u l suep s lle su CL N 110A IneU9Xe JUBWA OSJIP JaNbJUNWWOD s sedde s l sno jeqoj6
190. OVED MATERIALS Approved vent and intake air pipe materials that may be used in the United States e PVC Schedule 40 ASTM D 2241 CSA B181 2 ASTM 1785 CSA B137 3 e CPVC Schedule 40 ASTM F 411 CSA B137 6 e Polypropylene See Page 26 e AL29 4C Stainless Steel See Page 27 Approved vent and intake air pipe materials that must be used in Canada e ULC S636 PVC CPVC e ULC S636 Polypropylene See Page 26 e AL29 4C Stainless Steel See Page 27 CATEGORY IV APPLIANCE Category IV appliances operate with a positive vent exhaust static pressure and with vent gas temperatures low enough to produce condensate in the vent piping POWER VENT CONFIGURATION Power Vent configurations derive all combustion air from the room where they are installed and discharge all flue gases to the outdoor atmosphere through a sealed vent exhaust pipe Power vent configurations have one vent pipe connected to the water heater which can be terminated in a vertical or horizontal arrangement See Figure 39 and Figure 40 on page 33 DIRECT VENT CONFIGURATION Direct Vent configurations derive all combustion air directly from the outdoor atmosphere through a sealed intake air pipe and discharge all 20 flue gases to the outdoor atmosphere through a sealed vent exhaust pipe Direct Vent configurations have two pipes connected to the water heater one vent pipe and one intake air pipe Direct Vent configurations can be terminated in one of
191. Otd s duuod jueouqes suopepuewwooa xne JUDWAWIOJUOD jinu n Op dwod P SE 97 uol i u A neesai uon dsul sun 1 n 5 J mne AJUeAINS qe 15402 udoidde uonsnquloo aun Jjuajyulew mod snle o dsu n yop nes ayneyo 97 oureoyeo np uonmgeulunm anb sure 10 senbipoued abeAoyeu un je Be uu un jnjoul ned ayneyo np soueusjulew 871 oc el e Lg lnBij El HOA jediouud 286 jeuiqoi l 1 uu j sed ojoue s ou 266 IS NO ayjneyouns seo ug H 199 R SUEP lle sui hop a enbape nbiuu u uno s e Bieuo p dednos oun ne p 1IOA19S91 np uolsojdxa med sayneyoins nee aun e uoisojdx p sabueg INAWASSILUaAV 4 gi Bed eg enbiueu luno s g oafmgu2en dednos uon s p nE Hneu ins aBseyosp edednos ap suep l e sui 1S S1981109 uoisu uuip enbiueu 1uno s g Bieuo p dednos eun nb due is I nb einsse l s zuene Nes ayneyo l JOUUONOUO sewel N eyenb s s ueloiuy9e UN Jed S8A1H981109 s de s l ag UEL JIOAE P zuene nea yneyo l se
192. PLY GAS it 4 PVC AIR INTAKE 75 75in 63 13in 69 25in 19241em 160 35cm 175 9cm 33 12in OD WATER 84120m HEIGHT 3 4 NPT RECIRC RETURN 4 EXHAUST VENT CONNECTION 23 00in 58 43cm CLEANOUT 12 75in 32 39cm 1 1 475in 12 07cm i 3 4 NPT 1 1 2 NPT WATER INLET Figure 6 These designs comply with the current edition of the American National Standard for Gas Fired Water Heaters Volume III ANSI Z21 10 3 CSA 4 3 BTH 300 and 400 are Automatic Circulating Tank or Automatic Storage Water Heaters BTH 500 is Automatic Circulating Tank or Automatic Instantaneous Water Heater GAS LINE CONNECTION SIZE STORAGE CAPACITIES TABLE 1 TABLE 2 MODEL SERIES NATURAL GAS PROPANE GAS U S Gallons BTH 300 200 201 1 1 2 NPT 1 1 2 NPT ASME Standard ASME Standard BTH 400 200 201 1 1 2 NPT 1 1 2 NPT 119 119 450 96 450 96 BTH 500 200 201 1 1 2 NPT 1 1 2 NPT 450 06 48036 This table shows connections sizes only Depending on the installed equivalent length and or the number of appliances connected the supply gas line size may have to be increased beyond the minimum required sizes see Gas Line Sizing on page 39 RECOVERY CAPACITIES TABLE 3 26007 0 7 mi U S GALLONS HR amp LITERS HR AT TEMPERA
193. PS displays the current state Blocked Outlet PS Closed of the switch contacts open or closed Blower Prover PS Open Igniter On Gas Valve On displays whether or not the Igniter On control system is currently energizing these water heater components yes energized no de energized Flame Detected displays whether or not the control system has detected Main Burner flame during ignition from Bottom of Menu the flame sensor Heater Status Gas Valve On Flame Detected 47 DISPLAY SETTINGS DESCRIPTION ACTION DISPLAY Select Display Settings from the Main Menu and press the Display Settinas Operational Button under SELECT to enter this menu This E g menu contains adjustable display options for viewing information Tem perature Units on the UIM s LCD screen Use the Up amp Down Buttons to Backlight Delay navigate the menu Contrast e Temperature Units Adjustable user setting that changes temperature units display to Celsius C or Fahrenheit F Backlight Delay Adjustable user setting that determines how long the UIM s LCD backlight remains illuminated after a key has been pressed Available settings are Always Off 10 30 or 60 seconds and Always On CHANGE BACK Contrast Adjustable user setting to adjust the UIM s LCD screen contrast between text and background NOTE These settings are adjusted in the same way described for the Operating Set Point And Differential Adjustment on page 46 HEAT
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196. TORY SUPPLIED FITTINGS The water heater ships with two 2 factory supplied 4 inch terminations PVC 45 elbows with debris screen Factory supplied vent and intake air terminations or concentric and low profile terminations must be used Factory supplied terminations and installed fittings exhaust elbow and intake air connection add zero equivalent feet to the vent and intake air piping NOTE 3 inch vent and or intake pipe as well as 3 inch terminations previously used on older BTH 300 and 400 models must be replaced with 4 inch or 6 inch pipe and 4 inch or 6 inch terminations depending on installed length TABLE 7 4 Inch Pipe 6 Inch Pipe 90 Elbows Installed Maximum Feet Meters Maximum Feet Meters One 1 65 feet 19 8 meters Two 2 60 feet 18 2 meters Number of 115 feet 35 0 meters 110 feet 33 5 meters Three 3 55 feet 16 8 meters 105 feet 32 0 meters 50 feet 15 2 meters 45 feet 13 7 meters 40 feet 12 2 meters 6 INCH EXTENDED VENT TERMINATIONS When 6 inch intake air or vent pipe is installed using standard terminations factory supplied 6 inch terminations must be used Contact your local distributor or call the parts department phone number listed on the back cover of this manual to order 6 inch termination s See Optional Direct Vent Terminations on page 12 Four 4 100 feet 30 5 meters Five 5 95 feet 29 0 meters Six 6 90 feet 27 4 meters The water heaters covered b
197. TRIC TERMINATION CAPS END VIEW A 0 2 INCHES 0 5 cm CLOSE PROXIMITY FOUR CONCENTRIC TERMINATIONS THROUGH A ROOF OR SIDEWALL Figure 30 CONCENTRIC TERMINATION CAPS END VIEW A 0 2INCHES 0 5cm 24 INCHES 61 cm CLOSE PROXIMITY OR GREATER FOUR CONCENTRIC TERMINATIONS THROUGH A ROOF OR SIDEWALL Figure 31 Groups Of Terminations 1 When installing multiple groups of concentric terminations through a roof or through a sidewall in close proximity they can be installed into stacked groups of four as shown in Figure 32 Lateral groups of four as shown in Figure 31 may be a more convenient installation arrangement for multiple groups depending on available space CONCENTRIC TERMINATION CAPS END VIEW A 0 2 INCHES 0 5 cm CLOSE PROXIMITY B 24 INCHES 61 cm OR GREATER BETWEEN GROUPS OF FOUR EIGHT CONCENTRIC TERMINATIONS THROUGH A ROOF OR SIDEWALL Figure 32 MULTIPLE CONCENTRIC TERMINATION ARRANGEMENTS The illustrations on this page show some of the installation arrangements for multiple concentric terminations that are allowed See Multiple Concentric Termination Clearances on page 30 for detailed information on clearances and additional arrangement options NOTE When multiple concentric terminations are installed through a roof in the same location all termination ca
198. TURE RISE INDICATED mode ype a a a Thermal Gas Efficiency ge H 1 0 F LPH 4404 3303 2643 2202 1888 1652 1468 1321 1201 1101 1016 em 400 Natural 900 117 1535 1151 5810 4357 3486 2905 2490 2179 1937 1743 1585 1452 1341 1245 BTH 500 Natural co oo 146 oe 1919 1439 1151 i 7263 5447 4358 3631 3113 2724 2421 2179 1981 1816 1676 1556 GAS PRESSURE REQUIREMENTS TABLE 4 MODEL MANIFOLD PRESSURE MINIMUM SUPPLY PRESSURE MAXIMUM SUPPLY PRESSURE NATURAL GAS PROPANE GAS NATURAL GAS PROPANE GAS NATURAL GAS PROPANE GAS BTH 300 0 W C 0 kPa 0 W C 0 kPa 4 8 W C 1 19 kPa 8 5 W C 2 12 kPa 14 W C 3 49 kPa 14 W C 3 49 kPa BTH 400 0 W C 0 kPa 0 W C 0 kPa 4 8 W C 1 19 kPa 8 5 W C 2 12 kPa 14 W C 3 49 kPa 14 W C 3 49 kPa BTH 500 0 W C 0 kPa 0 W C 0 kPa 4 8 W C 1 19 kPa 8 5 W C 2 12 kPa 14 W C 3 49 kPa 14 W C 3 49 kPa Manifold gas pressure reading can only be taken while gas is flowing Reading taken should be 0 3 W C of the listed value These water heaters are certified for use without modification for altitudes up to 10 100 feet For elevations above 10 100 feet 3 079 meters see High Altitude Installations on page 54 Minimum supply gas pressure readings are taken wh
199. VENTING 1 Ensure the intake air and or vent exhaust piping is the correct size for the installed length See Venting Requirements on page 21 Ensure the maximum equivalent feet of pipe has not been exceeded for the intake air and or vent pipe See Table 7 on page 21 Ensure the maximum number of elbows has not been exceeded in the intake air and or vent pipe See Venting Requirements on page 21 Ensure the intake air screen is removed from the intake air connection on the water heater when installing the water heater in a Direct Vent configuration See Figure 17 on page 23 Ensure all exterior clearances for the intake air vent concentric and low profile terminations are maintained See Vertical Termination Installation on page 23 Sidewall Termination Installation on page 25 Concentric Termination Installation on page 28 Low Profile Termination Installation on page 32 These clearances and those cited by local and national codes must be maintained GAS SUPPLY AND PIPING 1 Ensure a supply gas regulator has been installed for each water heater See the requirements for a Supply Gas Regulator on page 13 Ensure the supply gas line to each water heater meets the minimum supply gas line size requirements See the requirements for the Supply Gas Line on page 13 and the installation instructions on page 38 and 39 CONDENSATE DRAIN Ensure the condensate drain is properly connected to the exhaust elbow on the water heate
200. Water Heater on page 51 11 Turn on the electrical supply to place the water heater back in operation 12 Allow the water heater to complete several heating cycles to ensure it is operating properly FILLING THE WATER HEATER See Filling The Water Heater on page 51 SEDIMENT 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 For convenience sediment removal and lime scale removal should be performed at the same time LIME SCALE REMOVAL When water is heated dissolved minerals in the water such as calcium and magnesium carbonate lime scale become less soluble As the water temperature rises these minerals will precipitate or fall out of solution The amount of lime scale 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 the water Water hardness also affects lime scale accumulation With the temperature and usage being the same hard water will release more lime scale than softer water Lime scale reduces heating efficiency as it accumulates inside a water heater Heating transfer surfaces become coated with lime scale deposits which increases fuel costs to operate the water heater Lime scale deposits can also cause rumbling and pounding noises as air molecules trapped in the lime scale escape when heated Lime
201. When ordering parts be sure to have the complete water heater Model Number Serial Number and Series Number available This information can be found on the rating label affixed to the water heater Refer to the parts list included with the water heater from the factory for more information or call the parts department or technical support phone number listed on the back cover of this manual for further assistance FAULT AND ALERT CONDITIONS FAULT CONDITIONS When the control system declares a Fault condition it will display a Fault message on the control system s LCD with an exclamation mark The control system will lock out and disable heating operation until the condition is corrected The water heater must be serviced by a qualified service agent before operation can be restored 58 ALERT CONDITIONS When the control system declares an Alert condition it will display an Alert message on the control system s LCD with a question mark The water heater will continue to operate during an Alert condition but the water heater must be serviced by a qualified service agent as soon as possible RESETTING CONTROL SYSTEM LOCK OUTS To reset the control system from a lock out condition turn the electrical power supply off for approximately 20 seconds and then back on Keep in mind if the condition that caused the Fault has not been corrected the control system will continue to lock out DIAGNOSTIC CHECKS AWARNING Turn off
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206. age 23 and Figure 22 on page 25 Debris clogging blocking the Main Burner see Figure 2 on page 7 NOT ENOUGH OR NO HOT WATER No power to the water heater check breaker or fuses Enable Disable switch in disabled position Set to enable to allow unit to operate Hot water supply valve s to fixtures closed Operating Set Point is set too low Differential setting is set too high See Control System Operation on page 43 Tank Probe Offset is causing the heating cycles to terminate prematurely see Temperatures Menu cont on page 47 The heating capacity of the water heater has been exceeded the water heater is unable to meet demand Colder incoming water temperature lengthening the time required to heat water to desired temperature Hot water piping leaks open faucets water heater drain valve leaking or open Sediment or lime scale accumulation may be affecting water heater operation See Maintenance on page 61 for sediment and lime scale removal procedures Water heater not firing at full input rating Check actual firing rate of the water heater see instructions on page 53 WATER IS TOO HOT Operating Set Point is set too high See Operating Set Point And Differential Adjustment on page 46 If installed check Thermostatic Mixing Valve settings Tank Probe Offset setting improperly set see Temperatures Menu cont on page 47 Lime build up on temperature probes Inspect and clean Improper water piping see dia
207. ailed information and diagnostic procedures BACK ADVANCED If there is no Fault or Alert condition active this menu will not contain any information none will be shown next to Current Fault in the Main menu FAULT HISTORY DESCRIPTION ACTION DISPLAY Select Fault History from the Main Menu and press the Operational Button under SELECT to enter this menu This menu contains non adjustable operational information Use the Blocked Air Intake Fault History ZN Up amp Down Buttons to navigate the menu 51 mins ago Wy This menu contains a list of the last nine 9 Fault and Alert Blocked Exhaust A8 Z messages with a time stamp The newest event will replace the 54 mins ago oldest Low Gas Pressure Press the Operational Button under VIEW to view details for 57 mins ago each Fault or Alert message stored Blower Prover Failure AC FAULT OCCURRENCE DESCRIPTION ACTION DISPLAY Select Fault Occurrence from the Main Menu and press the Operational Button under SELECT to enter this menu This menu contains non adjustable operational information Use the Ignition Failure Up amp Down Buttons to navigate the menu ECO Fault Occurrence This menu contains a running total of how many times each Low Gas Pressure Fault condition has occurred since the water heater was first Blocked Intake Air installed Blocked Exhaust NOTE Historical data is stored in the Configuration Key If this Blower Prover key is rep
208. air connection 4 inch PVC Supply gas line connection See Supply Gas Line on page 10 Low Gas Pressure switch see description under Figure 3 on page 8 See Table 4 and the Gas Pressure Requirements on page 10 Water heater 24 VAC Gas Valve Water outlet 1 1 2 NPT connection VFD variable frequency drive blower motor drive see Figure 3 on page 8 for description 10 UIM user interface module The UIM includes the display circuit 11 12 13 14 15 16 17 18 19 Figure 5 board the control system s LCD display and operational buttons Used to adjust various user settings and view operational information See Control System Operation on page 43 Temperature Pressure Relief Valve Pressure Relief Valve on page 15 See Temperature Temperature Pressure Relief Valve discharge pipe see T amp P Valve Discharge Pipe Requirements on page 15 Lower Temperature Probe 1 of 2 temperature probes The water heater s control system monitors this probe to detect water temperature in the lower portion of the storage tank Water inlet connection 1 1 2 NPT connection Water heater drain valve Combustion Blower Vent connection exhaust condensate elbow 4 inch aluminum Recirculation loop return connection 3 4 NPT Spark Ignition Control When energized sends the electrical current to the spark igniter INSTALLATION CONSIDERATIONS ROUGH IN DIMENSIONS 1 1 2 SUP
209. air connection on the water heater 15 If installing 6 intake air pipe transition to 4 pipe at the intake air connection on the water heater as shown in Figure 18 The field installed 4 pipe between the intake air connection and the 6 x 4 reducer coupling should be 18 inches 45 cm or less in length 6 PIPE FIELD SUPPLIED INTAKE AIR aft Il 6 x 4 REDUCER 4 x 3 REDUCER FIELD SUPPLIED FACTORY INSTALLED INTAKE AIR CONNECTION INTAKE AIR CONNECTION 4 PIPE FIELD SUPPLIED 3 PIPE FACTORY INSTALLED Figure 18 VERTICAL TERMINATION INSTALLATION Determine the location for the termination s If installing only the vent exhaust piping in a Power Vent configuration vertically through the roof ensure that all exterior vertical clearance requirements shown in Figure 19 and Figure 20 on page 24 are being maintained These clearances and those cited by local and national codes must be maintained NOTE On flat roof installations the vent termination must be a minimum of 24 inches 60 cm above any parapet vertical wall or structure within 10 feet 3 m horizontally See Figure 20 on page 24 If installing both intake air and vent piping in a Direct Vent configuration vertically through the roof ensure that all exterior vertical clearance requirements shown in Figure 20 and Figure 21 on page
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211. ances installed in the space Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors are considered a part of the unconfined space Makeup air requirements for the operation of exhaust fans kitchen ventilation systems clothes dryers and fireplaces shall also be considered in determining the adequacy of a space to provide combustion ventilation and dilution air 17 UNUSUALLY TIGHT CONSTRUCTION In unconfined spaces in buildings infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases However in buildings of unusually tight construction for example weather stripping heavily insulated caulked vapor barrier etc additional air must be provided using the methods described in the Confined Space section that follows CONFINED SPACE A Confined Space is one whose volume IS LESS THAN 50 cubic feet per 1 000 Btu hr 4 8 cm per kW of the total input rating of all appliances installed in the space Openings must be installed to provide fresh air for combustion ventilation and dilution in confined spaces The required size for the openings is dependent on the method used to provide fresh air to the confined space AND the total Btu hr input rating of all appliances installed in the space DIRECT VENT APPLIANCES Appliances installed in a Direct Vent configuration that derive all air for combustion from the outdoor atmo
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213. ase water immediately close the cold water inlet to the water heater follow the draining instructions in this manual and replace the Temperature Pressure Relief Valve with a properly rated sized new one NOTE The purpose of a Temperature Pressure Relief Valve is to prevent excessive temperatures and pressures in the storage tank The T amp P valve is not intended for the constant relief of thermal expansion A properly sized thermal expansion tank must be installed on all closed systems to control thermal expansion see Closed Water Systems and Thermal Expansion on page 14 Ifyou do not understand these instructions or have any questions regarding the Temperature Pressure Relief Valve call the toll free number listed on the back cover of this manual for technical assistance CONDENSATE DRAIN The water heaters covered in this manual are condensing appliances and require a building drain to be located in close proximity to allow the condensate to drain safely Condensate drains from the water heater at the exhaust condensate elbow located at the bottom The field installed condensate drain line must not be elevated above the condensate drain connection on the exhaust condensate elbow see Figure 9 If the condensate does not drain properly it will build up in the exhaust vent elbow This will restrict the flow of flue gases and cause the Blocked Exhaust pressure switch to open its contacts The control system monitors all pressure swit
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215. athing Hazard Carbon Monoxide Gas e Install water heater in accordance with the Instruction Manual and NFPA 54 or CAN CSA B149 1 To avoid injury combustion and ventilation air must be taken from outdoors Do not place chemical vapor emitting products near water heater Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual For safe operation an adequate supply of fresh uncontaminated air for combustion and ventilation must be provided An insufficient supply of air can cause recirculation of combustion products resulting in contamination that may be hazardous to life Such a condition often will result in a yellow luminous burner flame causing sooting of the combustion chamber burners and flue tubes and creates a risk of asphyxiation Do not install the water heater in a confined space unless an adequate supply of air for combustion and ventilation is brought in to that space using the methods described in the Confined Space section that follows Never obstruct the flow of ventilation air If you have any doubts or questions at all call your gas supplier Failure to provide the proper amount of combustion air can result in a fire or explosion and cause property damage serious bodily injury or death UNCONFINED SPACE An Unconfined Space is one whose volume IS NOT LESS THAN 50 cubic feet per 1 000 Btu hr 4 8 cubic meters per kW of the total input rating of all appli
216. ation Checklist and Troubleshooting page 55 By using this checklist the user may be able to make minor operational adjustments and avoid unnecessary service calls However service and diagnostic procedures should only be performed by a Qualified Service Agency NOTE Costs to correct installation errors are not covered under the limited warranty Be sure to turn off power when working on or near the electrical system of the water heater Never touch electrical components with wet hands or when standing in water The installation must conform to all instructions contained in this manual and the local code authority having jurisdiction These shall be carefully followed in all cases Authorities having jurisdiction should be consulted before installation begins if there are any questions regarding compliance with local state or national codes In the absence of local codes the installation must comply with the current editions of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and the National Electrical Code NFPA 70 or CAN CSA B149 1 the Natural Gas and Propane Installation Code and CSA C22 1 the Canadian Electrical Code All documents are available from the Canadian Standards Association 8501 East Pleasant Valley Road Cleveland OH 44131 NFPA documents are also available from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 If after reading this manual you have any questions or do not understand an
217. auterie pr f r Le r glage de la soupape de d charge et de s curit thermique ne doit pas d passer la pression nominale de tout composant dans le syst me Les robinets de service sont illustr s pour l entretien de l unit Cependant les codes locaux r gissent leur utilisation La commande de temp rature du r servoir devrait tre cabl e a et contrdler la pompe entre le chauffe eau et le r servoir de stockage Le thermostat du chauffe eau devrait tre r gl 5 degr s F plus haut que la commande de temp rature du r servoir SCHEMAS DE CONDUITES D EAU 5 Voir la section Connexions de conduites d eau la page 40 6 Siune pompe est install e entre un chauffe eau et un r servoir de stockage ou sur un circuit boucl de recirculation d un b timent conform ment la Figure 63 la page 66 1 1 7 Si une pompe est install e dans un circuit boucl de recirculation entre le chauffe eau et un Voir la section Lave vaisselle a la page 14 fil de lave vaisselle commercial conform ment a la Figure 64 a la page 66 2 3 Voir la section Soupape de d charge a s curit thermique a la page 15 4 Voir la section Syst mes d eau ferm s et Dilatation thermique la page 14 Avant l installation des conduites d eau examiner ce qui suit 1 Voir la section Melangeurs a la page 14 UN CHAUFFE EAU TEMPERATURE UNIQUE AVEC LEGENDE RECIRCULATION FORCEE DANS RESERVOIR DE STOCKAGE VERTICAL AVEC RECIRCULATION BATIME
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220. be drilled for the screw to prevent damage cracking of the vent cap and or vent pipe 6 INCH CONCENTRIC TERMINATION 7 Install the vent cap vent pipe assembly into the intake air Y SIDEWALL INSTALLATION fitting assembly Ensure small diameter vent pipe is cemented and bottomed in the Y fitting 8 Connect the intake air and vent piping from the water heater Figure 27 29 MULTIPLE CONCENTRIC TERMINATION CLEARANCES When installing multiple concentric terminations vertically through a roof or horizontally through a sidewall ensure the required clearances separation between terminations are maintained Ensure multiple terminations are arranged or grouped as required NOTE These clearances must be maintained to prevent the recirculation of vent exhaust gases to the intake air Clearances are measured between the edges of the concentric termination caps When installing multiple concentric terminations through a roof or through a sidewall the clearances shown in Figure 28 must be maintained See Multiple Concentric Termination Arrangements on page 31 Close Proximity amp Standard Clearance 1 The clearance between multiple termination caps must be 0 inches touching to a maximum of 2 inches 5 cm dimension A Figure 28 when installing concentric terminations in close proximity See Figure 28 through 32 The clearance between multiple termination caps must be increased to a minimum of 24 inches 61 cm dimension B Fi
221. cceptable hot water supply This will always provide the most energy efficient operation and longer life CHANGE With the adjustment mode for the Operating Set Point activated Temperatures the selection bar will change from a black fill to a black outline p Operating Set Point Use the Up and Down Buttons to change the current setting Differential Tank Temperature Upper Temperature Lower Temperature Tank Probe Offset Press the Operational Button under UPDATE to save the new setting Press the Operational Button under CANCEL to discard changes and return to the previously saved setting NOTE Use this same procedure to change the Differential setting and other adjustable user settings in the control system menus 46 TEMPERATURES MENU CONT DESCRIPTION ACTION DISPLAY e Tank Temperature non adjustable control system sensed temperature averaged from upper and lower temperature probes Upper Temperature non adjustable control system sensed temperature from the Upper Temperature Probe Lower Temperature non adjustable control system sensed temperature from the Lower Temperature Probe Tank Probe Offset adjustable user setting range 5 to 5 factory setting 0 NOTE These settings should only be used if the hot water Temperatures supply temperature varies greatly from the Operating Set Point setting Operating Set Point Differential Tank Temperature temperature control in the storage tank a
222. ce should only be performed by a qualified service technician using proper test equipment Turn off power at the branch circuit breaker serving the water heater before performing any service Label all wires prior to disconnecting when performing service Wiring errors can cause improper and dangerous operation e Altering the water heater controls and or wiring in any way could result in permanent damage to the controls or water heater and is not covered under the limited warranty Any bypass or alteration of the water Verify proper operation after servicing heater controls and or wiring will result Failure to follow these instructions can in voiding the appliance warranty result in personal injury or death INTRODUCTION Thank You for purchasing this water heater Properly installed and maintained it should give you years of trouble free service ABBREVIATIONS USED Abbreviations found in this Instruction Manual include ANSI American National Standards Institute e ASME American Society of Mechanical Engineers e GAMA Gas Appliance Manufacturer s Association NEC National Electrical Code e NFPA National Fire Protection Association e UL Underwriters Laboratory CSA Canadian Standards Association QUALIFICATIONS QUALIFIED INSTALLER OR SERVICE AGENCY nstallation and service of this vvater heater requires ability equivalent to that of a Qualified Agency as defined by ANSI below in the
223. ces the supply gas pressures shall be measured at each water heater with all gas fired appliances connected to a common main firing at full capacity On multiple water heater installations the supply gas line regulators shall be adjusted to provide gas pressure to each water heater within the minimum and maximum supply pressure requirements listed in Table 4 on page 10 with all gas fired appliances connected to a common gas main firing at full capacity NOTE A pressure drop of more than 1 5 W C 0 37 kPa when the Main Burner ignites is an indication of an inadequate supply of gas and can lead to ignition failure rough starts and or rough operation If a drop of more than 1 5 W C 0 37 kPa in supply gas pressure occurs when the Main Burner ignites ensure the supply gas lines and regulator s are properly sized and installed See the requirements for Supply Gas Regulator and Supply Gas Line on page 13 See Supply Gas Line Installation on page 38 and Supply Gas Regulator on page 13 Ensure all requirements and installation instructions are maintained 53 MANIFOLD GAS PRESSURE The manifold pressure is non adjustable The manifold gas pressure is factory set and cannot be field adjusted If the manifold gas pressure readings taken on these models is off by more than 0 3 W C from the listed values in Table 4 on page 10 call the technical support phone number listed on the back cover of this manual for further assistance
224. ches if the Blocked Exhaust Switch contacts are open the control system will lock out and disable heating operation The Blocked Exhaust Fault message will be displayed on the control system s LCD see Fault And Alert Conditions beginning on page 58 The Condensate Cleanout Cap must be on and tight when unit is in operation NOTE If the Blocked Exhaust Fault message is ever displayed on the control system LCD check the condensate drain first and ensure it is not blocked THIS SIDE VIEW OF EXHAUST ELBOVV AND ARROW INDICATE THE LOCATION OF THE PRESSURE PORT DRAIN LINE TO TERMINATE NO MORE THAN 6 INCHES 15 2cm L ABOVE DRAIN EXHAUST VENT ELBOW CONDENSATE DRAIN LINE CONNECTION CONDENSATE CLEANOUT CAP CONDENSATE DRAIN LINE FIELD INSTALLED BUILDING DRAIN Figure 9 CONDENSATE DRAIN WATER TRAP AWARNING e Ensure a functioning water trap is installed in the condensate drain 22 Gas and carbon monoxide detectors are available e Install water heater in accordance with b the instruction manual Breathing carbon monoxide can cause brain damage or death Alvvays read and understand instruction manual Do not remove the factory installed exhaust condensate elbow for any reason see Figure 9 The water heater s vent pipe is under a slight positive pressure while unit is in operation The water trap prevents flue gases f
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229. d rather than failed components IE A Low Gas Pressure Fault condition is most often caused by low supply gas pressure rather than a defective Low Gas Pressure switch Rough starting and rough operation are often caused by undersized supply gas lines and or the absence of a supply gas regulator at the water heater Prior to performing any operational checks inspect the water heater installation to ensure all installation requirements and instructions have been maintained and followed See the Installation Checklist on page 55 NOTE Costs to correct installation errors are not covered under the limited warranty ROUGH STARTING ROUGH OPERATION AWARNING Fire and Explosion Hazard e Do not use water heater with any gas other than the gas shown on the rating label e Excessive gas pressure to gas valve can cause serious injury or death e Turn off gas lines during installation e Contact a qualified installer or service agency for installation and service Undersized supply gas line low volume of supply gas see Supply Gas Line on page 13 Supply gas regulator is not installed per installation 57 requirements erratic gas supply volume pressures see Supply Gas Regulator on page 13 Excessive supply gas pressure see Table 4 on page 10 and Supply Gas Pressure Adjustment on page 53 Vent exhaust gas recirculation at the vent and intake air pipe terminations on Direct Vent installations see Direct Vent Instal
230. d9 WOAd90 Sdd9 ineyeydepe p Jn lo99uuoo 1 uolsnquuoo neAn np ne uuy alos feuluou n ulciq u t91s S oid lod JUBALING 9 9 IN ld soJOWINN od 9 je od p xneAn s p s ulof s l 1951oJu i u doid od ue uonejjusA jue911qe np ejqiuodsip jepu 1uio np sin jo uuoo xneeuue s Joen Z A P SNOA ne yneyo np IUEOUOEL np seouebixe se ezsyes 1100 19 9695 01 NO g 21 IN 8 uuojuoo lu uu ul l d n p UYY UORE U A ul s4S uos e uye UORE U A EI 1ueSuqe Jed 1s inayeydepe7 neaused np uom uuo2 ej Neaaiu ne 5 uongipuan inejejdepe S n yop Inayelje Sul UOHE U A zueouqe np sjulof sin o uuoo SOP S99XI H NAAIOG UOHE U A suoix uuo2 S s no 1 6 995 1 np Dene aUa AdoJdAjod l 18p1099e1 18jue sed N 1110 l quu su Jassnod Jnod un 1u siinn siew apnod ja neAn suol 8s s l 18p109921 inod lu uli5 sed juesinnu aua AdoidAjod ue uonejjuen s uu s s seq nbille1 uu uou UOHE U A ap SUOUEIEISUL s ueyeuued mb ne yneyo anon INOd QAd ua no SAd ud xneAn s p pos Jasin z anod snoa EOO p
231. ding drain see Figure 50 3 Terminate the condensate drain piping with an elbow above the drain Ensure that any discharge will exit the condensate drain line no more than 6 inches 15 2 cm above a suitable building drain or external to the building see Figure 50 NOTE In cold climates it is recommended the condensate drain be terminated at a suitable drain inside the building 4 Ensure the condensate drain line is not elevated above the condensate drain connection on the exhaust condensate elbow see Figure 50 5 Brace the condensate drain line with floor mounted standoffs every three feet 6 Ensure the condensate drains freely during start up see Start Up on page 51 CONDENSATE DRAIN LINE FIELD INSTALLED DRAIN LINE TO TERMINATE NO MORE THAN 6 INCHES 15 2 cm ABOVE DRAIN san Figure 50 37 SUPPLY GAS LINE INSTALLATION Contact your local gas utility company to ensure that adequate gas service is available and to review applicable installation codes for your area Be sure that the gas meter has sufficient capacity to supply the 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 undersized the gas company will have to install a properly sized gas meter AWARNING e Do not use water heater with any gas other than the gas shown on the rating label Excessive gas pressure
232. e lqluodsip se yenbape 266 oiAj s un nb 55 5 nod e5o 266 np luBeduuo2o e 48 0e U0D NOILVLNANI1VY Q ZV 30 ALINGNOO V1 30 NOILVTIVLSNI LE Oe 1 LNAWILYd 30 1YSN3ANO9 NG N31937109 ASVAOLLAN na snssaq nv Od 9 wo 291 Ad SNIOW V 20 3LINGNO9 YANIWYAL ALIS d s AATIVLSNI IYSN3ANO9 30 H NVQIA 30 SALINGNOO LG aBed eg 9IAJ S UD S VV 401995 EI ue sluu JUCINP Ju uui iqi BuEpiA S Jesu puo2o nb 1e1nsse s id w p Sa sno ne 9S10 94 U9 p aple R 1 5 ap neAn l JBDIOJUBY OG nBijJ EI 110A pno ans yesuapuod ap uoim uuo2o EI SNssap ne A sed 1s u 1esu puo lnpuo nb Jainsse S 3u uuneq np nangu e yenbape un E yesu puo El 4 U UL 1 pueuuuuo281 159 SPIOI SEU S sueq INOYYNIY 0S an4 EI ju uuneq ne no yenbape 1u uuineq in o llio5 un p snss p ne od 9 WO Z g SUIOW eSUBPUOD ap linpuo2o los nb Jeunsse s abuepiA snss p ne un p apie e u ln
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235. e 56 TOP VIEW Figure 3 COMPONENTS All Models IMPORTANT The Enable Disable switch listed in this manual is NOT an on off switch and does not disconnect 120 volt power to the CCB and other heater components 1 Water Heater s Enable Disable Switch When in the Disabled position the switch removes electrical power from the gas valve so that water heating is disabled The display CCB and other electrical components will still be energized and the display will read Water Heating Disabled Powered anode rods The water heater s covered in this manual are equipped with two powered non sacrificial anode rods Protective current is fed by the control system to the titanium electrodes at the end of each anode rod This current flows through the water to the conductive surfaces inside the storage tank which diminishes the corrosive effect rusting of water when it comes in contact with steel Central Control Board CCB enclosure This enclosure houses the control system s main circuit board power supply board power transformer and configuration key The CCB regulates water temperature and controls all water heater functions see Control System Operation on page 43 120 VAC junction box Incoming power supply ground connections and other field installed electrical connections are made here See Power Supply on page 13 and Power Supply Connections on page 39 Intake air connection 4 inch PVC Blocked Intake Air s
236. e 6 x 4 reducer coupling should be 18 inches 45 cm or less in length DIRECT VENT INSTALLATION 1 D 10 11 12 Read the General Venting Instructions on page 20 and Venting Requirements on page 21 before proceeding These instructions and requirements must be followed in addition to the instructions below that are specific for Direct Vent configurations Determine which Direct Vent arrangement will be used for the installation There are seven 7 Direct Vent arrangement options see pages 33 and 34 Determine vent and intake air pipe size to be used for the installation see Venting Requirements on page 21 Plan the layout of the vent and intake air piping backwards from the termination point outdoors to the water heater Layout the vent and intake air piping to use a minimum of pipe and elbows Install the terminations first If standard terminations are being used and the intake air or vent piping will terminate vertically through a roof see Vertical Termination Installation on page 23 If standard terminations are being used and the intake air or vent piping will terminate horizontally through a sidewall see Sidewall Termination Installation on page 25 If a concentric termination s will be used see Concentric Termination Installation on page 28 If alow profile termination will be used see Low Profile Termination Table 12 on page 32 When installation of the termination s is complete Install neces
237. e all gas pipe is clean on the inside before installation To trap any dirt or foreign material in the gas supply line a sediment trap must be installed as shown in Figure 51 The sediment trap must be readily accessible and not subject to freezing conditions Install in accordance with the recommendations of the local gas utility company GAS LINE SIZING Minimum required supply gas line sizes are shown in Table 5 on page 10 Depending on the developed equivalent length and or the number of appliances connected to a common main the size of supply gas lines may have to be increased Size the supply main gas line s in accordance with Table 13 or Table 14 The values given in Table 13 and Table 14 are for straight lengths of iron pipe at 0 5 W C 125 Pa pressure drop which is considered normal for low pressure systems Note that fittings such as elbows and tees will add to the pipe pressure drop Schedule 40 Steel or Wrought Iron Pipe is the preferred material for the gas line of this water heater It is imperative to follow the sizing recommendations in the latest version of the National Fuel Gas Code if Corrugated Stainless Steel Tubing CSST is used as the gas line for this water heater SUPPLY GAS LINE SIZING U S UNITS TABLE 13 LENGTH NORMAL IRON PIPE SIZES INCHES ao ev 990 1900 3000 5300 10900 a seo ov 1680 2650 a750 9700 eo 530 to 1520 2400 4300 8800 eo 260 sov 1300 2050
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241. e senson l Water is heated to 24 VAC Gas Valve set point de energized 24 VAC Gas Valve de energized Inter Purge cycle Retries up to Post Purge cycle iwo mor times Control System Locks Out Ignition Failure Fault Msg is displayed Water heater goes into standby mode Figure 58 56 OPERATIONAL PROBLEMS A WARNING Read and understand this instruction manual and the safety messages herein before installing operating or servicing this water heater Failure to follow these instructions and safety messages could result in death or serious injury This manual must remain with the water heater This section of the manual is intended to be an aid in correcting common operational problems it is not all inclusive The installer may be able to observe and correct certain problems which might arise when the water heater is first put into operation or when it is re fired after a prolonged shutdown However only qualified service agents as defined in Qualifications on page 6 using appropriate test equipment should perform any service procedures on the water heater NOTE Call the technical support phone number listed on the back cover of this manual for further technical assistance or to locate a qualified service agent in your area INSTALLATION ERRORS Operational problems on new installations are often the result of installation requirements that have been overlooke
242. e to achieve the target temperature setpoint The firing rate is dictated by the hot water draw proximity to the tank temperature setpoint and various other temperature limitations Periodically when the heater is in modulation mode the CCB will increase the blower speed for a short period of time to clear out any condensation that has accumulated in the heat exchanger then decreases the blower speed back to the modulating firing rate required to maintain the desired tank temperature setpoint This ramping up and down of the blower speed is considered normal operation of the water heater HIGH TEMPERATURE APPLICATIONS Higher operating temperatures cause more wear on all water heaters and will decrease the life span of the water heater Consider installing a small booster water heater for high temperature applications such as commercial dishwashers to raise the outlet temperature from the larger primary water heater to the desired point of use temperature Contact your local distributor or call the technical support phone number listed on the back cover of this manual for further technical assistance MANUFACTURER MODEL INFORMATION Tank Temperature 103 F Operating Set Point 120 F Status Heating j od Figure 54 CONTROL SYSTEM OPERATION OVERVIEW The water heaters covered in this manual are equipped with an electronic control system that regulates water temperature inside the storage tank Heating cycles and i
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244. ed to flooding or water Maintain required clearances to combustibles damage Keep ignition sources away from faucets after extended periods of non use AWARNING Read instruction manual before installing using or servicing water heater Use joint compound or Teflon tape compatible with propane gas Leak test gas connections before placing the water heater in operation Disconnect gas piping at main A WAR N N G P before leak Breathing Hazard Carbon Monoxi Install sediment trap in accordance aa o 577 onoxida Gas with NFPA 54 or CAN CSA 149 1 e Do not obstruct water heater air intake with insulating blanket Gas and carbon monoxide detectors WARNING e Install water heater in accordance with SN ne instruction manual Fire and Explosion Hazard Breathing carbon monoxide can cause brain damage or Do not use water heater with any gas death Always read and understand instruction manual other than the gas shown on the rating label Excessive gas pressure to gas valve can cause serious injury or death CAUTION e Turn off gas lines during installation e Contact a qualified installer or service Property Damage Hazard agency for installation and service e All water heaters eventually leak e Do not install without adequate drainage AWARN N G Jumping out control circuits or components can result in property damage personal injury or death Electrical Shock Hazard e Servi
245. egory n n Spark ignition wire 220 C 25kVDC 8mm EMI suppression Figure 62 65 CIRCULATION PUMP WIRING DIAGRAMS CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK OR BUILDING RECIRCULATION FIELD SUPPLIED TEMPERATURE CONTROL INSTALLED IN THE STORAGE TANK OR CIRCULATING LOOP RETURN LINE NOTE USE SEPARATE 120 VAC POWER SUPPLY FOR PUMP CIRCUIT DO NOT SHARE POWER WITH APPLIANCE AS THIS MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION L1 HOT 120 VAC POWER L2 NEUTRAL Figure 63 CIRCULATING PUMP WIRING DIAGRAM DISHWASHER LOOP WITH TOGGLE SWITCH DISHWASHER FIELD SUPPLIED TEMPERATURE TOGGLE CONTROL INSTALLED IN THE SWITCH CIRCULATING LOOP RETURN LINE NOTE USE SEPARATE 120 VAC POWER SUPPLY FOR PUMP CIRCUIT DO NOT SHARE POWER WITH APPLIANCE AS THIS MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION L1 HOT 120 VAC POWER L2 NEUTRAL Figure 64 66 abesn 1194 uj AoB IIEUS S PO 290 18A8MOH JUN HUIDIAJAS 10 UMOUS BJE 9IAJ9S wayshs eu u JUsUOdWOD Aug Jo Buel inss id p x jou ileus Buas AJLA J I 1 a1nssaid pue aul e Alddns MAYA G102 Nan134 MAYA LOH 93911 13 OL LOH HOLIMS MOT YILYM ANWA 1778 1304 1103 Q diNfd HE HANA 131134 4M1SS4Md ay 3SVS 4uni vdad i
246. en does not clear and the information can not be reset Restore Factory Defaults This control system feature allows the user to restore control system user settings to their factory default settings Display Settings preferences ARE NOT changed when factory defaults are restored Help Screens Text based operational and user information explaining how to change user settings navigate the control system menus and icon descriptions 45 USER SETTINGS amp CONTROL SYSTEM MENUS TEMPERATURES MENU Operating Set Point And Differential Adjustment The Operating Set Point is adjustable from 90 F 42 C to 180 F 82 C The factory setting is 120 F 49 C The Differential is adjustable from 2 to 20 The factory setting is 8 These user settings are accessed from the Temperatures menu The following instructions will explain how to adjust these settings and navigate the control system menus When the water temperature sensed by the control system from the two upper and lower Temperature Probes reaches the Operating Set Point the control system will end the heating cycle A heating cycle will be activated again when the sensed water temperature drops below the Operating Set Point minus the Differential setting NOTE Lower Differential settings may cause excessive heating cycles short cycling which can cause premature failure of components such as the Hot Surface Igniter Set the Differential at the highest setting which produces an accep
247. entilation air must be taken from outdoors e Do not place chemical vapor emitting products near water heater Corrosion of the flue ways and vent system may occur if air for combustion contains certain chemical vapors Such corrosion may result in failure and risk of asphyxiation Combustion air that is contaminated can greatly diminish the life span of the water heater and water heater components such as hot surface igniters and burners Propellants of aerosol sprays beauty shop supplies water softener chemicals and chemicals used in dry cleaning processes that are present in the combustion ventilation or ambient air can cause such damage Do not store products of this sort near the water heater Air which is brought in contact with the water heater should not contain any of these chemicals If necessary uncontaminated air should be obtained from remote or outdoor sources The limited warranty is voided when failure of water heater is due to a corrosive atmosphere See limited warranty for complete terms and conditions If the water heater will be used in beauty shops barber shops cleaning establishments or self service laundries with dry cleaning equipment it is imperative that the water heater s be installed in a Direct Vent configuration so that all air for combustion is derived directly from the outdoor atmosphere through a sealed intake air pipe See Venting Installation on page 20 AIR REQUIREMENTS AWARNING Bre
248. erence DO obtain new warning and instruction labels from the manufacturer for placement on the blanket directly over the existing labels DO inspect the insulation blanket frequently to make certain it does not sag thereby obstructing combustion air flow INSTALLATION REQUIREMENTS GAS SUPPLY SYSTEMS Low pressure building gas supply systems are defined as those systems that cannot under any circumstances exceed 14 W C 1 2 PSI Gauge These systems do not require pressure regulation Measurements should be taken to insure that gas pressures are stable and fall within the requirements stated on the water heater rating plate Readings should be taken with all gas burning equipment off static pressure and with all gas burning equipment running at maximum rate dynamic pressure The gas supply pressure must be stable within 1 5 W C from static to dynamic pressure to provide good performance Pressure drops that exceed 1 5 W C may cause rough starting noisy combustion or nuisance outages Increases or spikes in static pressure during off cycles may cause failure to ignite or in severe cases damage to appliance gas valves If your low pressure system does NOT meet these requirements the installer is responsible for the corrections High Pressure building supply systems use pressures that exceed 14 W C 1 2 PSI Gauge These systems must use field supplied regulators to lower the gas pressure to less than 14 W C 1 2 PS
249. ers and grilles shall be fixed in the open position FRESH AIR OPENINGS FOR CONFINED SPACES The following instructions shall be used to calculate the size number and placement of openings providing fresh air for combustion ventilation and dilution in confined spaces The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only DO NOT refer to these illustrations for the purpose of vent installation See Venting Installation on page 20 for complete venting installation instructions OUTDOOR AIR THROUGH TWO OPENINGS Figure 10 The confined space shall be provided with two permanent openings one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm of the bottom of the enclosure The openings shall communicate directly with the outdoors See Figure 10 Each opening shall have a minimum free area of 1 square inch per 4 000 Btu hr 550 mm2 per kW of the aggregate input rating of all appliances installed in the enclosure Each opening shall not be less than 100 square inches 645 cm2 OUTDOOR AIR THROUGH ONE OPENING Figure 11 18 Alternatively a single permanent opening commencing within 12 inches 300 mm of the top of the enclosure shall be provided See Figure 11 The water heater shall have clearances of at least 1 inch 25 mm from the sides and back and 6 inches 150 mm from the front of the water heate
250. es and to ensure safe temperatures at fixtures Water heated to a temperature which will satisfy clothes washing dish washing and other sanitizing needs can scald and cause permanent injury upon contact Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the water heater s temperature setting by up to 20 F 11 C Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm and the physically mentally disabled Table 6 shows the approximate time to burn relationship for normal adult skin If anyone using hot water provided by the water heater being installed fits into one of these groups or if there is a local code or state law requiring a certain water temperature at the point of use then special precautions must be taken In addition to using the lowest possible temperature setting that satisfies the demand of the application a Mixing Valve should be installed at the water heater see Figure 8 or at the hot water taps to further reduce system water temperature Mixing valves are available at plumbing supply stores Consult a Qualified Installer or Service Agency Follow mixing valve manufacturer s instructions for installation of the valves TABLE 6 Time for Permanent Burns 2nd amp 3rd Degree Most Severe Burns Water Temperature Time for 1st Degree Burn F C Less Severe Burns 110
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254. f center line extended above meter regulator assembly 6 inches 15 cm 6 inches 15 cm for appliances tu kI up to 10 000 Btu hr 3 kW 12 9 inches 23 cm for Clearance to window or inches 30 cm for appliances appliances between Clearance to service between 10 000 Btu hr 3 kW 3 feet 91 cm 3 feet 91 cm door that may be opened 10 000 Btu hr 3 kW regulator vent outlet and 100 000 Btu hr 30 kW 36 and 50 000 Btu hr 15 inches 91 cm for appliances kW 12 inches 30 cm above 100 000 Btu hr 30 kW Sg for appliances above 50 000 Btu hr 15 kW 5 6 inches 15 cm for 6 inches 15 cm for appliances up nn up 7 10 000 Clearance to a non to 10 000 Btu hr 3 KW 12 inches Clearance to mechanical air supply 1 30 cm for appliances between C permanently closed 6 inches 15 cm 6 inches 15 cm inlet into building or 10 000 Btu hr 3 kW and 100 000 pp Clearance above grade veranda porch deck or 112 inches 30 cm 12 inches 30 cm balcony 3 feet 91 cm within a height 15 3 feet 91 cm within a height feet 4 5 m above the meter 15 feet 4 5 m above the regulator assembly meter regulator assembly window combustion air inlet Btu hr 30 kW 36 inches 91 cm 10 000 Btu hr 3 kW and 8 50 000 Btu hr 15 kW 12 any other appliance above 100 000 Btu inches 30 cm for appliances above 50 000 Btu hr 15 kW Vertical clearance to ventilated soffit
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256. fixtures Hot water temperatures required for automatic dishwasher and laundry use can cause scald burns resulting in serious personal injury and or death Table 15 shows the approximate time to burn relationship for normal adult skin The temperature at which injury occurs varies with the person s age and duration of exposure The slower response time of children the elderly or disabled persons increases the hazards to them If anyone using hot water provided by the water heater being installed fits into one of these groups or if there is a local code or state law requiring a certain water temperature at the point of use then special precautions must be taken In addition to using the lowest possible temperature setting that satisfies the demand of the application a mixing valve can be installed at the water heater see Figure 8 on page 14 or at the hot water taps to further reduce system water temperature Never allow small children to use a hot water tap or draw their own bath water Never leave a child or disabled person unattended in a bathtub or shower The water heater should be located in an area where the general public does not have access to set temperatures Setting the Operating Set Point at 120 F 49 C will reduce the risk of scalds Some States require settings at specific lower temperatures 42 TABLE 15 Water Temperature F C 110 43 116 47 116 47 122 50 131 55 140 60 Time for Permanen
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258. gas line joints and connections upstream of the water heater with a rich soap and water solution to test for leaks Bubbles indicate a gas leak Do not use matches candles flame or other sources of ignition for this purpose 4 Repair any leaks before placing the water heater in operation PURGING Gas line purging is required with new piping or systems Purging should be performed per the current edition of NFPA 54 the National Fuel Gas Code ELECTRICAL WIRING All electrical work must be installed in accordance with the National Electrical Code ANSI NFPA 70 or the Canadian Electrical Code CSA C22 1 and local requirements When installed the water heater must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 or the Canadian Electrical Code CSA C22 1 If any of the original wire as supplied with the water heater must be replaced it must be replaced with 105 C rated wiring or its equivalent except in the burner housing In this case 200 C rated wire must be used DEDICATED POWER WIRING AND BREAKERS Dedicated power supply wires ground wiring and dedicated circuit breakers often prevent electrical line noise and are required when installing the water heater POWER SUPPLY CONNECTIONS Read the requirements for the Power Supply on page 13 before connecting power Power supply connections must be made as follows 1 Ensure the power s
259. gnition are managed by the control system The ECO energy cut out flame sensor pressure switches and temperature probes are monitored by the control system The Combustion Blower spark ignition control 24 VAC Gas Valve and anode rods are all powered by the control system The main components of the control system are a UIM user interface module and a CCB central control board The UIM is located on the top front side of the water heater The CCB is mounted on top of the water heater inside a protective enclosure See Features And Components on page 7 for location of these and all water heater components POWER SUPPLY BOARD T me CONFIGURATION KEY Le 9 ee f dt e s 1 CCB BOARD TRANSFORMER Figure 55 CONTROL SYSTEM NAVIGATION All operational information and user settings are displayed and accessed from the UIM The UIM houses the control system s LCD liquid crystal display and five snap acting momentary user input buttons an up down and three 3 multi functional operational buttons below the LCD see Figure 56 User Input Buttons e The up and down buttons are used to navigate menus and adjust user settings The operational buttons are used to enter exit menus select menu items activate adjustment modes and confirm or cancel new user settings The operational buttons are multifunctional their current function is defined by the te
260. grams beginning on page 67 NOISY OPERATION Sediment or lime scale accumulations can cause rumbling and pounding noises during heating cycles See the Maintenance section of this manual beginning on page 61 for sediment and lime scale removal procedures e Normal operating noise of electrical components Combustion Blower transformer hum relay contact closure WATER LEAKAGE IS SUSPECTED e Ensure the water heater drain valve is tightly closed e Check cleanout opening for leaks see Figure 4 on page 9 e Check inlet outlet water connections and system piping e Check the Temperature Pressure Relief Valve e Excessive water temperature Excessive water pressure e Defective Temperature Pressure Relief Valve NOTE Excessive water pressure is the most common cause of Temperature Pressure Relief Valve leakage Excessive water system pressure is most often caused by thermal expansion in a closed system See Thermal Expansion and Closed Water Systems on page 14 The Temperature Pressure Relief Valve is not intended for the constant relief of thermal expansion Temperature Pressure Relief Valve leakage due to pressure build up in a closed system that does not have a thermal expansion tank installed is not covered under the limited warranty Thermal expansion tanks must be installed on all closed water systems REPLACEMENT PARTS Replacement parts may be ordered from the manufacturer authorized service agencies or distributors
261. gure 28 when installation in close proximity above is not possible This is the standard clearance CONCENTRIC TERMINATION CAPS END VIEW A OR STANDARD CLEARANCE B 24 INCHES 61 cm OR GREATER TWO CONCENTRIC TERMINATIONS THROUGH A ROOF OR SIDEWALL CLOSE PROXIMITY A 0 2 INCHES 0 5 cm Figure 28 Three Concentric Terminations 1 When installing three concentric terminations through a roof or through a sidewall the third termination may be installed in close proximity as indicated by dimension A in Figure 29 If close proximity installation of the third termination is not possible the third termination may be installed as indicated by dimension B in Figure 29 A CONCENTRIC TERMINATION CAPS END VIEW THIRD TERMINATION B 24 INCHES 61 cm OR GREATER A 0 2 INCHES 0 5 cm CLOSE PROXIMITY THREE CONCENTRIC TERMINATIONS THROUGH A ROOF OR SIDEWALL Figure 29 30 Four Concentric Terminations 1 When installing four concentric terminations through a roof or through a sidewall in close proximity they may be arranged into stacked rows of two as shown in Figure 30 or lateral rows of two as shown in Figure 31 Four is the maximum number of concentric terminations that may be installed in a group where all terminations are in close proximity as shown in Figure 30 CONCEN
262. h e Service should only be performed by a qualified service technician using proper test equipment e Altering the water heater controls and or wiring in any way could result in permanent damage to the controls or water heater and is not covered under the limited warranty Any bypass or alteration of the water heater controls and or wiring will result in voiding the appliance warranty FAULT AND ALERT MESSAGES Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualified service agent in your area POSSIBLE CAUSES CHECK REPAIR DISPLAYED FAULT ALERT MESSAGE Using a manometer ensure that gas supply pressure is above minimum requirement listed on heater s data plate and does not drop more than 1 5 W C when unit fires Ensure wire connections to gas valve are clean and tight Ensure wire connections to flame sensor are clean and tight Ensure wire connections to spark igniter are clean and tight Inspect flame sensor clean replace as needed Inspect spark igniter realign igniter gap as needed Ensure adequate electrical ground to heater Confirm supply gas is turned on Using a manometer ensure the supply gas pressure is above minimum pressure requirement listed on heater s data plate before and during operation Ensure wire connections to gas pressure switch are clean and tight If all above conditions are met replace gas pressure switch If Blocked
263. he Tank Temperature is at or above the Operating Set Point Input Verification The control system is conducting a diagnostic check at the beginning of a heating cycle Water heating A Fault condition is detected by the control or when the Enable Disable switch on front panel or the Building Management disabled system Enable Disable is an open circuit The Combustion Blower is energized to flush residual flue gases from the combustion chamber prior to ignition Spark Igniter r The Spark Igniter is energized Ignition Activation The 24 VAC Gas Valve is energized and opens to allow fuel gas to flow to the Main Burner The control system is monitoring the flame sensor for the required minimum flame sensing current See the Sequence Of Operation on page 55 for minimum flame sensing current DC micro amps information The Combustion Blower is energized to flush residual fuel gas from the combustion chamber after a failed ignition attempt Ignition was successful flame sensing current has been established The water in the storage tank is being heated Post Purge The Combustion Blower is energized to flush residual flue gases from the combustion chamber at the end of a heating cycle The control system has detected a Fault condition Heating operation is disabled until the Fault condition is corrected Fault Power to the water heater must be cycled off and on at the breaker to reset the control system NOTE Cycling power will not reset the con
264. he back cover of this manual to order 6 Concentric Termination Part 9008841005 e 4 Low Profile Termination Part 9008934005 e 6 Low Profile Termination Part 9008935005 HARD WATER Where hard water conditions exist water softening or the threshold type of water treatment is recommended This will protect the dishwashers coffee urns water heaters water piping and other equipment See Maintenance on page 61 for sediment and lime scale removal procedures CIRCULATION PUMPS A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the water heater The tank is provided with a 3 4 NPT recirculation loop return connection Refer to Figure 6 for its location See the Water Piping Diagrams beginning on page 67 for installation location of circulating pumps See Circulation Pump Wiring Diagrams on page 66 for electrical hookup information Install in accordance with the current edition of the National Electrical Code NFPA 70 or the Canadian Electrical Code CSA C22 1 Stainless Steel circulators are recommended for used with commercial water heaters Some circulating pumps are manufactured with sealed bearings and do not require further lubrication Some circulating pumps must be periodically oiled Refer to the pump manufacturer s instructions for lubrication requirements 12 INSULATION BLANKETS WARNING Breathing Hazard Carbon Monoxide Gas
265. he circuit conductors and connected to the equipment grounding terminal or lead on the water heater HYDROGEN GAS FLAMMABLE AWARNING Explosion Hazard e Flammable hydrogen gases may be present Keep all ignition sources away from faucet when turning on hot water Hydrogen gas can be produced in a hot water system served by this water heater that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable To reduce the risk of injury under these conditions it is recommended that a hot water faucet served by this water heater be opened for several minutes before using any electrical appliance connected to the hot water system If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow THERE SHOULD BE NO SMOKING OR OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN Verify the power to the water heater is turned off before performing any service procedures The Enable Disable switch on front panel disables the 24 volt gas valve Electrical supply must be turned off at circuit breaker serving water heater Read and understand this instruction manual and the safety messages herein before installing operating or servicing this water heater Failure to follow these instructions and safety messages could result in death or serious injury This manual must remain with the water heater
266. he supply gas pressure this is a static supply gas pressure reading while the water heater is not firing Adjust supply gas pressure as necessary see Supply Gas Pressure Adjustment on page 53 AIR INTAKE PRESSURE REFERENCE CONNECTION SUPPLY GAS PRESSURE TEST PORT MANIFOLD PRESSURE TEST PORT Figure 57 LIGHTING amp OPERATION LABEL The instruction label below is affixed to the water heater s covered by this manual at the factory and must be followed when lighting and operating the water heater FOR YOUR SAFETY READ BEFORE LIGHTING Zl WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life BEFORE OPERATING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A This appliance does not have a pilot It is equipped with If you cannot reach your gas supplier call the an ignition device which automatically lights the fire department burner Do not try to light the burner by hand C Use only your hand to push in the control B BEFORE OPERATING smell all around the appliance buttons Never use tools if the control area for gas Be sure to smell next to the floor because buttons will not push in don t try to repair them call some gas is heavier than air and will settle on the floor a qualified service technician Force or attempted repair may result in a fire or explosion WHAT TO DO IF YOU SMELL GAS
267. hut down for an extended period 3 Ensure the cold water inlet valve is open 4 Open a nearby hot water faucet and let the water run until the water is no longer hot 5 Connect a hose to the water heater drain valve and terminate it to an adequate drain 6 Close the cold water inlet valve 7 Open the water heater drain valve and allow all the water to drain from the storage tank 8 Close the water heater drain valve when all water in the storage tank has drained 9 Close the hot water faucet opened in Step 4 10 If the water heater is going to be shut down for an extended period the drain valve should be left open To Flush the tank perform the following steps 1 Turn off the electrical supply to the water heater 2 Ensure the cold water inlet valve is open 3 Open a nearby hot water faucet and let the water run until the water is no longer hot Then close the hot water faucet 4 Connect a hose to the drain valve and terminate it to an adequate drain 5 Ensure the drain hose is secured before and during the entire flushing procedure Flushing is performed with system water pressure applied to the water heater Open the water heater drain valve to flush the storage tank 7 Flush the water heater storage tank to remove sediment and allow the water to flow until it runs clean 8 Close the water heater drain valve when flushing is completed 9 Remove the drain hose 10 Fill the water heater see Filling The
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269. ic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances listed in the Act APPROVALS GAS FIRED lic C UL An ai CERTIFIED UL www ahridirectory org WATER QUALITY LOW LEAD LISTED ANSI NSF 5 HLW CONTENT GENERAL SAFETY INFORMATION PRECAUTIONS DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN EXPOSED TO FLOODING OR WATER DAMAGE Immediately call a qualified service agency to inspect the appliance and to make a determination on what steps should be taken next If the unit is exposed to the following do not operate heater until all corrective steps have been made by a qualified service agency 1 External fire 2 Damage 3 Firing without water GROUNDING INSTRUCTIONS This water heater must be grounded in accordance with the National Electrical Code and or local codes These must be followed in all cases Failure to ground this water heater properly may also cause erratic control system operation This water heater must be connected to a grounded metal permanent wiring system or an equipment grounding conductor must be run with t
270. icing this water heater Failure to follow these instructions and safety messages could result in death or serious injury This manual must remain with the water heater PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE PRINTED 0614 327747 000 TABLE OF CONTENTS SAFE INSTALLATION USE AND SERVICE 3 APPROVALS visa u haine men dites 3 GENERAL SAFETY INFORMATION 4 Precautions sneri mau 4 Grounding Instructions 4 Hydrogen Gas Flammable 4 INTRODUCTION u alas ier ne 6 Abbreviations Used 6 RETTEN 6 iCOMM amp BACnet Compatible 6 Preparing for the 1 5 6 FEATURES AND COMPONENTS 7 Basic ee Le BEE 7 u u n u antec R 7 Blower Burner Assembly Detail 7 leie 8 SITE VIG WS aapi E hE 9 INSTALLATION CONSIDERATIONS L 10 Rough In DIMENSIONS arsina ran 10 Gas Line Connection Size 10 Storage Capacilties 10 Recovery 165 10 Gas Pressure Requirements 10 Minimum Supply Gas Line Size 10 Locating the Water Heater
271. identical model is no longer available due to a change in law regulation or standard we will replace the product with one having comparable capacity and input In these instances the owner will have the option of paying the difference between what was paid for the original model and the new model with the additional features or receiving a refund of the portion of the purchase price on a pro rata basis allocable to the unexpired portion of the warranty SERVICE INQUIRIES e Problems caused by improper gas supply line sizing gas type va 3 11eu cns combustion air voltage wiring or fusing e Failure to follow applicable codes e Failure to follow printed instructions e Abuse misuse accident fire flood Acts of God e Improper installation sizing delivery or maintenance e Claims related to rust noise smell or taste of water e Failure to conduct authorized factory start up if required Alterations to the water heater e Non outdoor heaters installed outdoors Damages due to a failure to allow for thermal expansion e Heat exchanger failure due to lack of adequate proper supply of water e Heaters moved from their original location Service trips to explain proper installation use or maintenance of the product unit or to describe compliance requirements under applicable codes and regulations e Charges related to accessing your heater including but not limited to door wall removal equipment rental
272. ield installed 4 pipe between the exhaust elbow and the 6 x 4 reducer coupling should be 18 inches 45 cm or less in length FACTORY INSTALL TEE FITTING AS CLOSE INSTALLED TO WATER HEATER INTAKE AIR INTAKE AIR CONNECTION CONNECTION AS POSSIBLE 4 x 3 REDUCER FIELD SUPPLIED 4 x4 x 1 2 TEE Q VV TH HOSE BARB FITTING INSTALLED CONNECT FIELD SUPPLIED FLEXIBLE DRAIN HOSE TO BARB FITTING AND FORM A LOOP WATER TRAP IN DRAIN HOSE RUN DRAIN HOSE TO SUITABLE FLOOR DRAIN SEPARATELY FROM OTHER CONDENSATE DRAINS INTAKE AIR CONDENSATE TEE INSTALLATION Figure 16 13 Ensure the Intake Air Screen on the Intake Air Connection is removed before connecting the intake air pipe to the water heater see Figure 17 Breathing Hazard Carbon Monoxide Gas e Do not obstruct water heater air intake e Gas and carbon monoxide detectors are available e Install water heater in accordance with the instruction manual NOTE Do not leave the screen inside the Intake Air connection in Direct Vent installations Once the intake air pipe is installed the screen will be hidden from view and may become clogged with debris over time This will cause improper combustion INTAKE AIR SCREEN remove for Direct Vent 4 x 3 REDUCER COUPLING FACTORY INSTALLED INTAKE AIR CONNECTION DETAIL Figure 17 14 If installing 4 inch intake air pipe connect the intake air pipe to the intake
273. igh altitude orifices For installations above 10 100 feet call the technical support phone number listed on the back cover of this manual for further technical assistance Call the local gas or utility company to verify Btu per cubic foot content before calling for technical assistance and have that information available NOTE The actual firing rate of the water heater must not exceed the input rating on the water heater s rating label under any circumstances NOTE Due to the input rating reduction at high altitudes the output rating of the water heater is also reduced and should be compensated for in the sizing of the equipment TROUBLESHOOTING INSTALLATION CHECKLIST The list below represents some of the most critical installation requirements that when overlooked often result in operational problems down time and needless parts replacement This is not a complete list Before performing any troubleshooting procedures use the list below to check for installation errors Costs to correct installation errors are not covered under the limited warranty Ensure all installation requirements and instructions in this manual have been maintained and followed WATER HEATER LOCATION 1 Ensure proper clearances to combustibles are maintained and there is sufficient room to service the water heater See Clearances on page 11 Ensure the area is free of corrosive elements and flammable materials See the instructions on page 16
274. ile gas is not flowing static pressure AND while gas is flowing dynamic pressure Supply pressure must never fall below the minimum values Supply gas pressures should be measured with all gas fired appliances connected to a common main firing at full capacity If supply pressure drops more than 1 5 W C as gas begins to flow the supply gas system gas line regulator may be restricted or undersized See Table 5 and the Supply Gas Regulator requirements below See Supply Gas Line Installation on page 38 and Supply Gas Regulator on page 13 for sizing and installation instructions also Maximum supply gas pressure readings are taken while gas is not flowing static pressure AND while gas is flowing dynamic pressure Supply pressure must never exceed this maximum value MINIMUM SUPPLY GAS LINE SIZE TABLE 5 MODEL NATURAL GAS PROPANE GAS BTH 300 11 4 NPT 1 174 NPT BTH 400 1 1 4 NPT 11 4 NPT TBTH 500 1 1 2 NPT 11 4 NPT T Note that BTH 500 natural gas models require a 1 1 2 minimum supply gas line size Depending on the installed equivalent length and or the number of appliances connected the supply gas line size may have to be increased beyond the minimum required sizes shown in this table see Gas Line Sizing on page 38 10 LOCATING THE WATER HEATER Carefully choose a location for the new water heater The placement is a very important consideration for the safety of the occupants in the building and for the most econo
275. ing connected to the water heater is not restricted The control system monitors this switch and will disable heating operation if its contacts are open during a heating cycle VFD variable frequency drive blower motor drive Temperature Pressure Relief Valve See Temperature Pressure Relief Valve on page 15 Upper Temperature Probe 1 of 2 temperature probes The water heater s control system monitors this probe to detect water temperature in the upper portion of the storage tank The Upper Temperature Probe also houses the ECO energy cut out switch This is a non adjustable high temperature limit switch The ECO switch contacts are normally closed and will open on a temperature rise See High Temperature Limit Control ECO on page 42 Water outlet connection 1 1 2 NPT 18 UIM user interface module The UIM includes the display circuit board the control system s LCD display and operational buttons Used to adjust various user settings and view operational information See Control System Operation on page 43 Spark Ignition Control When energized sends the electrical current to the spark igniter Figure 4 SIDE VIEWS 1 Cleanout access panel covers water heater cleanout opening CCB enclosure see Figure 3 on page 8 for description 120 VAC junction box Incoming power supply ground connections and other field installed electrical connections are made here See Power Supply on page 13 Intake
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277. ipe to the factory provided terminations PVC material PVC Materials should use ASTM D 2564 Grade Cement CPVC Materials should use ASTM F 493 Grade Cement PIPE SIZE REQUIREMENTS The water heaters covered in this manual are certified for the use of 4 and 6 inch pipe for the vent exhaust and intake air piping If the installed equivalent length for the intake air or vent piping will be 70 feet 21 3 m or less 4 inch pipe must be used If the installed equivalent length will be more than 70 feet 21 3 m 6 inch pipe must be used NOTE Install the pipe size required for the installed equivalent length of each pipe independently IE If the intake air pipe will be 70 equivalent feet or less and the vent pipe will be more than 70 equivalent feet the intake air pipe must be installed using 4 inch pipe and the vent must be installed using 6 inch pipe MAXIMUM EQUIVALENT LENGTHS Four Inch Pipe The water heaters covered in this manual are certified to a maximum length of 4 inch pipe for the exhaust venting arrangement of 70 equivalent feet 21 3 m The certified maximum length of 4 inch pipe for intake air piping is also 70 equivalent feet 21 3 m IE On Direct Vent installations both pipes can be up to 70 equivalent feet 21 3 m Six Inch Pipe The water heaters covered in this manual are certified to a maximum length of 6 inch pipe for the exhaust venting arrangement of 120 equivalent feet 36 5 m The certified maximum length of
278. iping diagrams for typical methods of application for the water heaters see Water Piping Diagrams beginning on page 67 The water heater may be installed by itself or with a separate storage tank When used with a separate storage tank the circulation may be either by gravity or by means of a circulating pump When a circulating pump is used it is important to note that the flow rate should be slow so that there will be a minimum of turbulence inside the water heater storage tank Adjust flow by throttling a full port ball valve installed in the circulating line on the outlet side of the pump Never throttle flow on the suction side of a pump See the Water Piping Diagrams beginning on page 67 NOTE In addition to the factory installed Temperature Pressure Relief Valve T amp P valve on the water heater each remote storage tank that may be installed and piped to a water heating appliance must also have its own properly sized rated and approved Temperature Pressure Relief Valve installed Call the toll free technical support phone number listed on the back cover of this manual for further assistance in sizing a T amp P valve for remote storage tanks THERMOMETERS NOT SUPPLIED Thermometers are installed in the water piping system as a means of detecting the temperature of the hot water supply at critical points in the system Field supplied thermometers should be obtained and installed See Water Piping Diagrams on page 67 WATER
279. is required distance to a parapet vertical wall or structure cannot be maintained standard terminations must be used See Vertical Termination Installation on page 24 When installing a concentric termination through a sidewall ensure that all exterior sidewall clearance requirements for the termination shown in Figure 49 on page 37 are being maintained These clearances and those cited by local and national codes must be maintained When installing multiple concentric terminations vertically through a roof or horizontally through a sidewall ensure the required clearances between terminations and groupings of multiple terminations are maintained See pages 31 and 32 for more information Cut a 7 inch 18 cm diameter hole for 6 inch concentric terminations where they will pass through the wall or roof NOTE Beware of concealed wiring and piping when cutting through the wall or roof installing multiple concentric terminations vertically through the roof in the same location the 28 termination caps for all concentric terminations must be at the same height measured from ground See Multiple Concentric Termination Arrangements on page 31 Determine if the concentric termination will need to be shortened to accommadate required clearances or to ensure all vent caps are tat the same height when installing multiple terminations vertically through the roof in the same location See Figure 25 for the minimum lengths allowed for
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281. jacent to the water heater CLEARANCE TO COMBUSTIBLE MATERIALS The water heaters covered in this manual are approved for installation on combustible flooring The clearance to combustible and non combustible construction materials is 0 inches on the back and sides of the water heater These water heaters are also approved for installation in an alcove When the water heater is installed directly on carpeting the water heater shall be installed on a metal or wood panel extending beyond the full width and depth of the water heater by at least 3 in 76 2 mm in any direction or if the water heater is installed in an alcove or closet the entire floor shall be covered by the panel The panel must be strong enough to carry the weight of the heater when full of water NOTE Adequate clearance for servicing should be maintained on all installations See Service Clearance below ALCOVE 22222 CLEARANCES TO COMBUSTIBLE AND NON COMBUSTIBLE CONSTRUCTION MATERIALS ZzZZ TOP COVER WATER HEATER FRONT FRONT VIEVV TOP VIEW Figure 7 SERVICE CLEARANCE A service clearance of 24 inches 61 cm should be maintained from serviceable parts such as the T amp P valve control system components gas valve clean out opening drain valve the vent connection exhaust condensate elbow and the condensate drain Leave as much room as possible above the water heater and near the exhaust elbow for thi
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283. junction box Figure 53 and wiring diagram Figure 62 on page 65 Replace the junction box cover when connections are complete NOTE Do not apply power to the water heater before installation is complete and the water heater is filled with water Heater Wiring Ground Terminal Factory Installed Jumper Wires MOV Ground XC Li Neutral Figure 53 ENABLE DISABLE CIRCUIT For Building Management Systems The water heaters covered in this manual are equipped with an enable disable circuit for use with field supplied external supervisory controls such as time clocks or Building Management Systems The enable disable circuit may be used to disable heating operation during periods when the building is unoccupied or there is no demand for hotwater To use the enable disable circuit it must first be activated by selecting the Use External Enable from the UIM Field supplied wiring is then installed between the water heater s CCB and a set of dry contacts no voltage or load on the field supplied external control NOTE The water heater s enable disable circuit is a switching circuit only Do not apply external voltage or connect any load IE relay coil to this circuit This will damage the CCB circuit board and is not covered under the limited warranty CONNECTING AN EXTERNAL SUPERVISORY CONTROL The enable disable circuit is accessed from the CCB s J17 plug inside the CCB enclosure see Figure 3
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287. l Their current function is defined by the text that appears directly above each button on the LCD screen MANUFACTURER MODEL INFORMATION Title Bar Up amp Down buttons navigate menus adjust user settings 4 3 Operational buttons enter exit menus select menu items activate adjustment modes confirm cancel changes Figure 56 43 STATUS ICONS The Status Icons are displayed on the Desktop screen and convey operational and diagnostic information The icons are described in the table below See Figure 58 on page 56 and the Sequence Of Operation on page 55 TABLE 16 Water temperature in the tank has fallen Shaded area of the animated thermometer icon will rise and fall in response to water temperature in the storage tank as sensed from the Upper and Lower Temperature Probes See Figure 3 on page 8 and Figure 4 on page 9 for location of Temperature Probes Water temperature in the tank has reached the Operating Set Point The control system enters the Standby mode The control is unable to initiate a heating cycle This will happen whenever a Fault condition is detected by the control system or when the Enable Disable switch on front panel or Building Management system Enable Disable circuit is an open circuit Display will read Status Water Heating Disabled For more information see Enable Disable Circuit on page 40 The Combustion Blower is being energized The Bl
288. laced during servicing the historical data will be lost Flame Detect Error The data stored in the new configuration key will no longer reflect the entire history of the water heater RESTORE FACTORY DEFAULTS DESCRIPTION ACTION DISPLAY Select Restore Factory Defaults from the Main Menu and press the Operational Button under SELECT to enter this menu Restore Factory Defaults To restore the adjustable user settings to their factory default settings press the Operational Button underneath YES The Are you sure you want to display will show text confirming the factory default settings restore the system to factory have been restored defaults Press the Operational Button underneath BACK to exit the Restore Factory Defaults menu 49 SERVICE CONTACT INFORMATION The control system has a discrete menu that Installing contractors and or service agents can access to enter contact information for their customers This contact information will be displayed with all Fault and Alert messages DESCRIPTION ACTION DISPLAY From the Desktop Screen see Figure 56 on page 43 press and hold down the middle unmarked Operational Button for 30 seconds and then release it This will launch a discrete menu where personalized contact information can be entered Using the UP and DOWN buttons select highlighted in black the Show Contact Information menu item Press the Operational Button under CHANGE to activate the adjus
289. lack Uio TV Module 4 Yellow Speed t back Neutral gt B 5 White Green Dad I gt gt Brown Neutral 6 White MV enable 3 Yellow 7 WhilelYellow Drive enable 2 White Green TBlue A White Green 3 Orange 4 120V Speed Faik ES CCB J6 120V Out BLOWER FEEDBACK TBlue Upper Temperature Probe ECO No factory connections Central Control Board CCB S ECO ermislor Thermistor ECO PIa Be lo MOT z r goo CCB JS Upper Probe 6 White Green 5 Orange 4 Blue ite Blue 2 White Blue 1 White Red White Red Pind Outlet Pressure INDE Lower k swith Temperature AVAC VAC Probe 1 Black 2 Inlet Pressure CL Switch ul 86ey0A MOT gir 909 Transformer Thermistor Thermistor Oe souuojsuesL Tuepuos s souuojsuedL CCB J10 Lower Probe Blower Prover Pressure 1 Black A 2Red Switch 3 White 4 Green Enable Disable Switch Inlet retu
290. lation on page 22 Excessive equivalent lengths of intake air and or vent exhaust piping installed see Venting Requirements on page 21 Debris clogging blocking the intake air screen s see Figure 17 on page 23 and Figure 22 on page 25 Debris clogging blocking the Main Burner see Figure 2 on page 7 MOMENTARY IGNITION CAUTION The combustion chamber and burner sleeve and housing become very hot during operation e Do not reach into the burner housing or combustion chamber if the water heater is still hot e Allow the water heater to cool and always use gloves when handling the main burner If the Main Burner ignites momentarily but does not sustain ignition allow the water heater to try to ignite up to two more times until control system locks out and the Ignition Failure Fault message is displayed on the control system s LCD If the water heater is experiencing rough starts see Rough Starting Rough Operation on this page For momentary ignition problems without rough starting check the following Undersized supply gas line low volume of supply gas see Supply Gas Line on page 38 Supply gas regulator is not installed per installation requirements erratic gas supply volume pressures see Supply Gas Regulator on page 13 See the list of possible causes and things to check and repair for the Ignition Failure Fault message on page 59 Debris clogging blocking the intake air screen s see Figure 17 on p
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293. lete venting installation instructions Figure 13 The confined space shall be provided with two permanent vertical ducts one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm of the bottom of the enclosure The vertical ducts shall communicate directly with the outdoors See Figure 13 Each duct opening shall have a minimum free area of 1 square inch per 4 000 Btu hr 550 mm2 per kW of the aggregate input rating of all appliances installed in the enclosure When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be not less than 3 inches 19 AIR FROM OTHER INDOOR SPACES Figure 14 The confined space shall be provided with two permanent openings one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm of the bottom of the enclosure See Figure 14 Each opening shall communicate directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an Unconfined Space Each opening shall have a minimum free area of 1 square inch per 1 000 Btu hr 1100 mm2 per kW of the aggregate input rating of all appliances installed in the enclosure Each opening shall not be less than 100 square inches 645 cm2 VENTING INSTALLATION AWARNING Breathing Hazard Carbon Mono
294. line to prevent the 24 VAC Gas Valve on the water heater from twisting during installation To prevent damage care must be taken not to apply too much torque when connecting the supply gas line to the water heater 7 Install a sediment trap as shown in Figure 51 on page 38 8 Install a Main Gas Shutoff valve in the supply gas line as shown in Figure 51 on page 38 NOTE Should overheating occur or the gas supply fail to shut off turn off the Main Gas Shutoff valve to the water heater Gas Line Connection Figure 52 GAS LINE LEAK TESTING AWARNING Use joint compound or Teflon tape compatible with propane gas Leak test gas connections before placing the water heater in operation Disconnect gas piping at main gas shutoff valve before leak testing heater Install sediment trap in accordance with NFPA 54 or CAN CSA 149 1 39 Any time work is done on the gas supply system perform a leak test to avoid the possibility of fire or explosion 1 For test pressures exceeding 1 2 psi 3 45 kPa disconnect the water heater and its Main Gas Shutoff Valve from the gas supply piping system during testing see Figure 51 on page 38 The gas supply line must be capped when disconnected from the water heater For test pressures of 1 2 psi 3 45 kpa or less the water heater need not be disconnected but must be isolated from the supply gas line by closing the Main Gas Shutoff Valve during testing Paint all supply
295. located Glesrancete a above the terminal within A P R 3 feet 91 cm above if within horizontal distance of 12 inches 30 cm 12 inches 30 cm mechanical air supply 6 feet 1 83 m 10 feet 3 m horizontally inlet 2 feet 61 cm from the center line of the terminal Clearance above paved sidewalk or paved driveway located 7 feet 2 13 m t 7 feet 2 13 m t on public property Clearance to outside Clearance under corner 2 feet 60 cm 2 feet 60 cm veranda porch deck 12 inches 30 cm 12 inches 30 cm or balcony Gr to inside 18 inches 45 cm 18 inches 45 cm corner 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code T Avent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings Where it may cause hazardous frost or ice accumulations on adjacent property surfaces Clearance to unventilated soffit 12 inches 30 cm 12 inches 30 cm Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer s installation instructions 36 WATER HEATER INSTALLATION CONDENSATE DRAIN INSTALLATION Installation must conform with these ins
296. mical use of the water heater CAUTION Property Damage Hazard e All water heaters eventually leak e Do not install without adequate drainage Whether replacing an existing water heater or installing the water heater in a new location observe the following critical points 1 The water heater must be located indoors 2 The water heater must not be located in an area where it will be subject to freezing temperatures 3 Locate the water heater so it is protected and not subject to physical damage by a moving vehicle 4 Locate the water heater on a level surface 5 Locate the water heater near a floor drain The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure When such locations cannot be avoided it is recommended that a metal drain pan adequately drained be installed under the water heater 6 Locate the water heater close to the point of major hot water usage 7 Locate the water heater close to a 120 VAC power supply See Power Supply on page 13 for requirements 8 Locate the water heater where an adequate supply of fresh air for combustion and ventilation can be obtained See Air Requirements on page 17 9 Locate the water heater where the vent and intake air piping when installed will remain within the maximum equivalent lengths allowed See Venting Requirements on page 20 10
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298. n 0 10 W C NOTE All test equipment must be acclimated to ambient temperature before calibration and use 51 PREPARATION 1 Using the control system menus change the Operating Set Point to the lowest temperature setting see Operating Set Point And Differential Adjustment on page 46 2 Turn the water heater s Enable Disable switch to the Disable position Close the Main Gas Shut Off Valve see Figure 51 on page 38 Wait five 5 minutes for any residual gas to clear 5 Connect one manometer higher range to an available test port for the supply gas pressure to the water heater On the water heaters covered by this manual there are test ports for supply and manifold gas pressure readings on the gas valve Using a small flat tip pocket screw driver open the needle valve inside the supply gas pressure test port one full turn only turn the needle valve screw counter clockwise to open the valve Slide the manometer sensing tube over the top of the test port see Figure 57 6 Connect one manometer lower range to an available test port for manifold gas pressure to the Main Burner Using a small flat tip pocket screw driver open the needle valve inside the manifold gas pressure test port one full turn only turn the needle valve screw counter clockwise to open the valve Slide the manometer sensing tube over the top of the test port see Figure 57 7 Open the Main Gas Shutoff Valve 8 Measure and record t
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301. nd at points of use Upper Temperature This feature can also be used to compensate for building Lower Temperature recirculation loops hot water returning to the storage tank Tank Probe Offset that may cause the heating cycles to terminate prematurely The Tank Probe Offset is used to calibrate control system temperature sensing This can improve the precision of Example If the current sensed temperature from a CHANGE BACK temperature probe is 120 F 49 C and the Offset setting for that probe is adjusted to a value other than 0 the control system would calibrate or offset the sensed temperature from the probe and the averaged tank temperature Heating cycles would be activated and deactivated based on the calibrated offset temperature A 5 setting results in 5 hotter water These settings are adjusted in the same way described for the Operating Set Point And Differential Adjustment on page 46 HEATER STATUS MENU DESCRIPTION ACTION DISPLAY Select Heater Status from the Main Menu and press the Top of Menu Operational Button under SELECT to enter this menu This Heater Status menu contains non adjustable operational information Use the Up amp Down Buttons to navigate the menu Status Standby EZ Status displays the current Operating State see Table 17 ECO Contact Closed on page 45 Low Gas PS Closed ECO Contact Low Gas PS Blocked Inlet PS Blocked Blocked Inlet PS Closed Outlet PS Blower Prover
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307. ngth and number of elbows that can be used Insulation should not be used on Polypropylene venting materials The use of insulation will cause increased vent wall temperatures which could result in vent pipe failure Use only the adapters and vent system listed in Tables below DO NOT mix vent systems of different types or manufacturers Failure to comply could result in severe personal injury death or substantial property damage TABLE 8 Installations must comply with applicable national state and local codes For Canadian installation Polypropylene vent must be listed as a ULC S636 approved system If Polypropylene vent is not required by your local code you may use either PVC or CPVC pipes for your water heater that allows non metallic venting material installations Polypropylene vent systems do not use cement to connect the pipe and elbow sections but use a push together gasket seal method Do not attempt to connect Polypropylene with sealant cement All vent connections MUST be secured by the vent manufacturer s joint connector The installer must use a specific vent starter adapter at the flue connection The adapter is supplied by the vent manufacturer to adapt to its vent system In order to be in full compliance with UL 1738 or ULC S636 and to meet the requirements of the water heater manufacturer you must use the metal joint connector rings available from the Polypropylene vent manufacturer to stiffen the joints of
308. ning Install a new cleanout gasket if required Reinstall the cleanout cover Be sure to draw plate up tight by tightening screws securely Close the water heater drain valve 9 Fill the water heater see Filling The Water Heater on page 51 10 Turn on the electrical supply to place the water heater back in operation See Initial Start Up on page 51 11 Allow the water heater to complete several heating cycles to ensure it is operating properly 12 Check for water leakage 13 Reinstall the cleanout access plate CHEMICAL LIME SCALE REMOVAL To dissolve and remove more stubborn lime scale deposits UN LIME Professional Delimer should be used UN LIME Professional Delimer is an easy to handle patented food grade acid formulated specifically for lime scale removal from all types of water using equipment Hydrochloric base acids must not be used to delime the water heaters covered in this manual Follow the instructions on the UN LIME to delime the water heater NOTE Call the parts department phone number on the back cover of this manual to order UN LIME Professional Delimer See Table 20 for part numbers TABLE 20 UN LIME PROFESSIONAL DELIMER 9005416105 4 1 gallon case 9005417105 1 5 gallon POWERED ANODE RODS To insure a long trouble free operating life the water heaters covered in this manual are factory equipped with a powered anode system The anode rods are of a permanent design and
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311. nstalled to prevent blockage in the vent system Stress levels in pipe 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 stressed or high thermal stresses may be formed when the pipe heats up and expands Install accordingly to minimize such stresses Carefully read the Venting Requirements on page 21 and then proceed to the Venting Installation Sequence on page 22 10 11 12 13 14 15 16 17 18 19 VENTING REQUIREMENTS FIELD SUPPLIED FITTINGS Field supplied fittings should be equivalent to the piping material being installed Field installed supplied fittings will add equivalent feet to the vent or intake air piping as indicated below All field supplied installed fittings and piping must be factored into the equivalent feet calculations 90 elbows short or long radius are equivalent to 5 linear feet 152 cm of pipe 45 elbows short or long radius are equivalent to 2 5 linear feet 76 cm of pipe Note Refer to Table 10 and Table 11 for equivalent linear pipe length of AL29 4C 45 and 90 elbows PRIMER AND CEMENT Tetrahydrofuran THF primer should be used to prepare the surfaces of pipe and fittings for solvent welding If CPVC pipe and fittings are used then the proper cement must be used for all joints including joining the p
312. nt Linear Equivalent Linear Diameter Flue CAUSE Straight Pipe 3 45 Elbow Length 45 90 elbow Length 90 Adapter to PVC Adapter Section Elbow Elbow 810005545 FSVL3604 FSELB4504 FSELB9004 10 feet 810009529 e 810005225 FSVL3606 FSELB4506 FSELB9006 10 feet 81005572 Consult vent manufacturer s catalog for other available lengths 27 CONCENTRIC TERMINATION INSTALLATION 1 Concentric terminations must be ordered separately When BTH 300 500 models must use the 6 inch concentric termination for both 4 amp 6 vent diameters Part Number 9008841005 Contact your local distributor or call the parts department phone number on the back cover of this manual to order concentric terminations Determine the location for the termination NOTE Roof termination is preferred since it is less susceptible to damage has reduced chances to intake contaminants and vent vapors are less visible When installing a concentric termination vertically through the roof ensure that all exterior vertical clearance requirements for the concentric termination shown in Figure 24 on page 29 and Figure 26 on page 30 are being maintained These clearances and those cited by local and national codes must be maintained When installing a concentric termination vertically through a flat roof the termination s vent cap must be a minimum of 10 feet 3 m away from any parapet vertical wall or structure as shown in Figure 24 NOTE If th
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317. ofessional Your Company Name Here press DOWN for more ADVANCED MAINTENANCE GENERAL Keep water heater area clear and free from combustible materials gasoline and other flammable vapors and liquids See Locating The Water Heater on page 11 Water heater maintenance includes periodic tank flushing and cleaning and removal of lime scale The water heater should be inspected and adjusted to maintain proper combustion See Initial Start Up on page 51 A periodic inspection of the venting system should be made Where used water circulating pump s should be oiled according to the pump manufacturers recommendations PRECAUTIONS A CAUTION Do not operate the water heater if it has been exposed to or exhibits the following Exposed to flooding or water damage External damage Firing without water Sooting Do not operate the water heater until all corrective steps have been made by a qualified service technician Never operate the water heater without first being certain it is filled with water and a properly sized and rated Temperature Pressure Relief Valve is installed in the relief valve opening on the water heater See Temperature Pressure Relief Valve on page 15 AWARNING Explosion Hazard Overheated water can cause water tank explosion Properly sized temperature and pressure relief valve must be installed in the opening provided Should overheating occur or the gas su
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320. onal Electrical Code ANSI NFPA 70 or the Canadian Electrical Code CSA C22 1 DEDICATED POWER WIRING AND BREAKERS Dedicated power supply wires ground wiring and dedicated circuit breakers often prevent electrical line noise and are required when installing the water heater POWER FLUCTUATIONS AND ELECTRICAL NOISE The water heater s control system requires a source of stable clean electricity for proper operation Connecting the water heater to a branch circuit that is subject to fluctuations in voltage level or electrical line noise such as EMI electro magnetic interference or RFI radio frequency interference may cause erratic control system operation and malfunction A high quality power supply filter suppressor such as the Kleen Line model SELF T 10 Series SC L or equivalent must be installed if the above conditions exist Call the technical support phone number listed on the back cover of this manual for more information NOTE Malfunctions caused by the power supply and the costs to install power supply filters are not covered under the limited warranty MIXING VALVES Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury ADANGER Feel water before bathing or showering Temperature limiting devices such as mixing valves must be installed when required by cod
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323. ough a sidewall the intake air and vent terminations must be installed at the same elevation measured on horizontal center line see Figure 22 INTAKE AIR TERMINATION VENT EXHAUST TERMINATION ELEVATION INSTALL ON CENTERLINE KEEP INTAKE AND VENT TERMINATION SCREENS CLEAR OF DEBRIS I 24 INCHES 61 cm MINIMUM I Xk VF 48 INCHES 122 cm IN COLDER CLIMATES SIDEWALL TERMINATION DIRECT VENT STANDARD TERMINATIONS Figure 22 6 When the intake air and or vent piping from multiple water heaters will terminate at the same location through a sidewall the vent terminations can be grouped together in close proximity 0 inches touching The intake air terminations can also be grouped together in close proximity 0 inches touching However the distance between the closest vent and intake air terminations must be a minimum of 24 inches 61 cm In colder climates this separation should be increased to at least 48 inches 122 cm See Figure 22 25 T 10 11 METAL PLATES INSTALL INSIDE AND OR OUTSIDE FROM Cut a 5 inch 13 cm diameter hole for 4 inch pipe or 7 inch 18 cm diameter hole for 6 inch pipe where the pipe s will pass through the wall NOTE Beware of concealed wiring and piping when cutting through the wall Cut a length s of pipe being installed 3 5 inches 8 9 cm to 9 5 inches 24 1 cm longer than the wall thickness at the opening See Figure 23 NOTE Vent Te
324. ower Prover pressure switch contacts have closed The check mark icon is visual confirmation of contact closure See Figure 3 on page 8 for Blower Prover Switch location The spark igniter is being energized See Figure 2 on page 7 for spark igniter location The 24 VAC Gas Valve is being energized The control system has sensed flame at the Main Burner from the flame sensor See the Sequence Of Operation Flow Chart on page 56 and Figure 2 on page 7 The control system has declared a Fault condition and must be inspected serviced by a Qualified Service Agent Fault message details can be viewed in the Current Fault menu Heating operation is disabled lock out until the condition that caused the Fault is corrected Power to the water heater must be cycled off and on at the breaker to reset the control system NOTE Cycling power will not reset the control system if the condition that caused the Fault has not been corrected The control system has declared an Alert condition and must be inspected serviced by a Qualified Service Agent The water heater will continue to operate during an Alert condition 44 OPERATING STATES The current operational state of the water heater is displayed on the Desktop screen as the Status The common operational states are described in the table below See Figure 58 on page 56 and the Sequence Of Operation on page 55 TABLE 17 State EE Standby The water heater is not in an active heating cycle IE t
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330. pe shall be no more than 2 inches 5 cm see Figure 19 2 5 cm MAXIMUM FIELD FACTORY SUPPLIED STANDARD TERMINATION POINTED DOWN TOWARDS SUPPLIED THE GROUND 90 ELBOW FIELD SUPPLIED PLUMBING ROOF BOOT OR FLASHING MAINTAIN 12 30 cm 18 45 cm FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL SUPPLIED STRAP SUPPORT VERTICAL TERMINATION S INSTALLATION INTAKE AIR AND OR VENT EXHAUST Figure 19 24 IF LESS THAN 10 FEET 3 m 24 INCHES 60 cm MINIMUM HEIGHT ABOVE INTAKE AIR AND OR VENT TERMINATION S MUST BE A MINIMUM OF 24 INCES 60 cm ABOVE ANY PARAPET VERTICAL WALL OR STRUCTURE WITHIN 10 FEET 3 m HORIZONTALLY VERTICAL TERMINATION S FLAT ROOF CLEARANCE INTAKE AIR AND OR VENT EXHAUST Figure 20 11 Return to Power Vent Installation on page 22 or Direct Vent Installation on page 22 to complete the installation of the intake air and or vent piping between the termination s and the water heater 24 INCHES 61 cm MINIMUM 48 INCHES 122 cm IN COLDER CLIMATES FIELD SUPPLIED 90 ELBOW INTAKE AIR TERMINATION VENT EXHAUST TERMINATION FACTORY SUPPLIED STANDARD TERMINATIONS POINTED DOWNWARD MAINTAIN 12 30 cm 18 45 cm FOR CANADA MINIMUM CLEARANCE K ABOVE HIGHEST ANTICIPATED SNOW LEVEL FIELD SUPPLIED PLUMBING ROOF BOOTS OR FLASHINGS VERTICAL TERMINATION DIRECT VENT STANDARD TERMINATIONS Figure 21
331. pening and a suitable floor drain Do not connect discharge piping directly to the drain unless a 6 15 2 cm air gap is provided To prevent bodily injury hazard to life or property damage the relief valve must be allowed to discharge water in adequate quantities should circumstances demand If the discharge pipe is not connected to a drain or other suitable means the water flow may cause property damage T amp P Valve Discharge Pipe Requirements Shall not be smaller in size than the outlet pipe size of the valve or have any reducing couplings or other restrictions Shall not be plugged or blocked Shall not be exposed to freezing temperatures Shall be of material listed for hot water distribution Shall be installed so as to allow complete drainage of both the Temperature Pressure Relief Valve and the discharge pipe Must terminate a maximum of six inches above a floor drain or external to the building In cold climates it is recommended that the discharge pipe be terminated at an adequate drain inside the building Shall not have any valve or other obstruction between the relief valve and the drain TEMPERATURE REGULATION HIGH TEMPERATURE LIMIT CONTROL ECO This water heater is equipped with an ECO energy cut off non adjustable high temperature limit switch The ECO is a normally closed switch that opens activates on a rise in temperature The ECO is located inside the Upper Temperature Probe
332. perating Set Point to the lowest temperature setting see Operating Set Point And Differential Adjustment on page 46 When the water heater has completed its shut down sequence and enters the standby mode tum the water heater s Enable Disable switch to the Disable position When in the Disable position the switch only removes electrical power from the gas valve so that water heating is disabled The display CCB and other electrical components will still be energized and the display will read Water Heating Disabled 3 Close the Main Gas Shutoff Valve see Figure 51 on page 38 HIGH ALTITUDE INSTALLATIONS AWARNING e Under no circumstances should the input exceed the rate shown on the water heater s rating label e Overfiring could result in fire or explosion e Gas and carbon monoxide detectors are available AWARNING Breathing Hazard Carbon Monoxide Gas e Under no circumstances should the input exceed the rate shown on the water heater s rating label e Overfiring could result in damage to the water heater and sooting e Gas and carbon monoxide detectors are available Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual 54 The water heaters covered by this manual are certified for use without modification for altitudes up to 10 100 feet Most gas utility companies de rate their gas for high altitudes making it unnecessary to install h
333. power at the branch circuit breaker serving the water heater before performing any service Label all wires prior to disconnecting when performing service Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Failure to follow these instructions can result in personal injury or death The following section Fault And Alert Messages on page 59 and 61 lists some of the messages the control system will display on the LCD when there are operational problems This is not a complete list Along with each of the Fault and Alert messages described there will be a list of possible causes and things to check and repair Only qualified service agents as defined in Qualifications on page 6 using appropriate test equipment should perform any service procedures on the water heater NOTE ff you are not qualified and licensed or certified as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the diagnostic or service procedures described in the following section If you do not understand the instructions in the following section do not attempt to perform any procedures Call the technical support phone number listed on the back cover of this manual for further technical assistance or to locate a qualified service agent in your area AVVARNING Jumping out control circuits or components can result in property damage personal injury or deat
334. pply fail to shut off turn off the Main Gas Shutoff valve See Figure 51 on page 38 Water heater maintenance includes periodic tank flushing and cleaning and removal of lime scale The water heater should be inspected and adjusted to maintain proper combustion Refer to the following table A periodic inspection of the venting system should be made Where used the water circulating pump should be oiled according to the pump manufacturer s recommendations 61 MAINTENANCE SCHEDULE TABLE 19 COMPONENT OPERATION INTERVAL Tank Sediment Semi Annually Removal REQUIRED Flushing Lime Scale UN LIME Semi Annually Removal Anode Rods Inspection Annually Cleaning T amp P Valve Test Operation Semi Annually Vent System Annually DRAINING AND FLUSHING It is recommended that the water heater storage tank be drained and flushed every 6 months to reduce sediment buildup The water heater should be drained if being shut down during freezing temperatures See Features And Components on page 7 for the location of the water heater components described below ADANGER Clean Scale Deposits Test Termination Screens Clean Reseal Repair e Burn hazard e Hot water discharge e Keep hands clear of drain valve discharge To drain the water heater storage tank 1 Turn off the electrical supply to the water heater Turn off the gas supply at the Main Gas Shutoff Valve if the water heater is going to be s
335. ps must be at the same height measured from the ground Two Concentric Terminations Two concentric terminations may be installed in close proximity as shown in Figure 33 or with standard clearances when this arrangement is not possible See Figure 28 on page 30 for detailed information on clearances See Figure 29 on page 30 when installing three concentric terminations Figure 34 Eight Concentric Terminations Eight concentric terminations may be installed in two stacked groups of four in close proximity as shown in Figure 35 See Figure 32 on page 30 for detailed information on clearances Lateral groups of four as shown in Figure 31 on page 30 may be a more convenient installation arrangement for multiple groups depending on available space Figure 33 Four Concentric Terminations Four concentric terminations may be installed in close proximity as shown in Figure 34 See Figure 30 and Figure 31 on page 30 for detailed information on clearances and additional arrangement options Figure 35 31 LOW PROFILE VENT INSTALLATION To Boiler Intake Air Connection This water heater is certified for sidewall direct venting with IPEX System 636 Low Profile Vent Kit Follow instructions below for roper installations From Boiler Vent Pipe Connection 12 Min to Overhang All termination kits must be located and installed in accordance with local building code and CSA B149 1 Natural Gas and Propane In
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337. r The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of the following 1 1 square inch per 3000 Btu hr 700 mm2 per kW of the total input rating of all appliances located in the enclosure and 2 Not less than the sum of the areas of all vent connectors in the space OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS Figure 12 The confined space shall be provided with two permanent horizontal ducts one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm of the bottom of the enclosure The horizontal ducts shall communicate directly with the outdoors See Figure 12 Each duct opening shall have a minimum free area of 1 square inch per 2 000 Btu hr 1100 mm2 per kW of the aggregate input rating of all appliances installed in the enclosure When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be not less than 3 inches OUTDOOR AIR THROUGH TWO VERTICAL DUCTS The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only DO NOT refer to these illustrations for the purpose of vent installation See Venting Installation on page 21 for comp
338. r with a water trap to prevent vent gases from escaping into the installed space and draining freely to a suitable floor drain See Figure 9 on page 16 and Condensate Drain Installation on page 37 ELECTRICAL CONNECTIONS 1 Ensure the power supply connections to the water heater are polarity correct See the requirements for the Power Supply on page 13 and Electrical Wiring on page 39 Ensure the water heater is properly grounded Flame sensing requires an adequate earth ground If the water heater is not properly grounded it will cause Ignition Failure 55 SEQUENCE OF OPERATION Read the Sequence of Operation below before attempting to correct any operational problems Refer to the Features And Components section beginning on page 7 for the location of various water heater components described below See the Sequence Of Operation Flow Chart on page 56 also 1 When the control system is first powered during boot up it will display water heater model information during initialization After a few moments the control system LCD which is part of the UIM user interface module will display the default screen known as the Desktop screen If the control system determines that the actual water temperature inside the tank is below the programmed Operating Set Point minus the Differential setting a heating cycle is activated The control system then performs selected diagnostic system checks This includes confirming the low gas
339. rational problems or user defined Alert Conditions occur iCOMM system hardware is compatible with BACnet compliant supervisory controls and building management systems For more information call 888 928 3702 PREPARING FOR THE INSTALLATION 1 Read the entire manual before attempting to install or operate the water heater Pay close attention to the General Safety Information on pages 4 and 5 If you dont follow the safety rules the water heater may not operate safely It could cause property damage injury and or death This manual contains instructions for the installation operation and maintenance of the water heater It also contains warnings throughout the manual that you must read and be aware of All warnings and all instructions are essential to the proper operation of the water heater and your safety Detailed installation diagrams are also found in this manual These diagrams will serve to provide the installer with a reference It is essential that all venting water piping gas piping and wiring be installed as shown Particular attention should be given to the installation of thermometers at the locations indicated in the piping diagrams as these are necessary for checking the operation of the water heater The principal components of the water heater are identified in Features And Components on page 7 in this manual Use this reference to locate and identify various components on the water heater See the Install
340. re equipped with an electronic control system see page 43 which automatically sequences the Combustion Blower pre and post purging of the combustion chamber the spark generator the 24 VAC Gas Valve Main Burner ignition and flame sensing The control system will lock out after three unsuccessful ignition attempts Before attempting start up thoroughly study and familiarize yourself with the exact Sequence Of Operation see the written Sequence Of Operation on page 55 and the Sequence Of Operation Flow Chart on page 56 Be certain that the water heater is full of water that air is purged from the gas and water lines and that there are no leaks in the gas and water lines Ensure all inlet water valves are open FILLING THE WATER HEATER Follow these steps to fill the water heater prior to start up 1 Close the heater drain valve 2 Open a nearby hot water faucet to permit the air in the system to escape 3 Fully open the cold water inlet valve allowing the piping and water heater to fill with water 4 Close the hot water faucet opened in Step 2 as water starts to flow INITIAL START UP REQUIRED TEST EQUIPMENT Two U tube manometers recommended ranges 0 14 W C 0 3 5 kPa and 0 35 W C 0 8 7 kPa or pressure gauges Two digital manometers can be used in place of U tube manometers or pressure gauges Recommended ranges 14 00 to 14 00 W C 0 3 5 kPa resolution 0 01 W C and 0 35 W C 0 8 7 kPa resolutio
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342. ressurizing the intake air or exhaust pipe Confirm wire connections of the blower prover switch are clean tight and not jumped shorted Use multi meter to check continuity resistance of blower prover pressure switch Switch should be open no continuity when blower is not operating Replace switch if contacts are closed when blower is off Confirm that blower runs during a call for heat If blower runs confirm sensing tube is connected and clear of obstructions blower port for sensing tube is clear of obstructions and wire connections for blower prover switch are clean and tight If all above conditions are met replace pressure switch If Blocked Intake error occurs before blower runs make sure pressure switch connections are clean and tight Check pressure switch continuity resistance Switch should be closed continuity 0 ohms Replace switch if open no continuity If Blocked Intake error occurs when blower is running check for restrictions in intake pipe including intake air connection outside termination and inlet condensate drains if installed Other possible causes High wind conditions excessive negative air pressure in building Ensure wire connections to upper temperature probe are clean and tight Using a thermometer check the water temperature of the heater Use a multi meter and check for continuity between the two red wires of the upper temperature probe If the two red wires are open no continui
343. rmination exhaust gases of this water heater are less than 140 F In cold climates water vapor in the exhaust gases will condense into a cloud of vapor where the vent exits the building This vapor can gradually discolor exterior building surfaces The vent termination should be located where this vapor cloud and potential discoloration are nota concern Extending the exposed vent piping up to a maximum of 6 inches 15 2 cm from the wall helps vapor from being trapped along a building s face To avoid this problem the vent can also be terminated vertically through the roof see Vertical Termination Installation on page 23 Cement the intake air and or vent termination to the section s of pipe cut to length in the above Step Slide the included metal wall plate s over the pipe s to stop against the intake air and or vent termination Place some silicone caulking field supplied on the back of the wall plate s to secure it to the wall Working from outside slide the pipe and termination s assembled in the above steps through the wall Ensure the termination s is pointed down towards the ground See Figure 23 INCREASE EXPOSED VENT PIPING UP TO A MAXIMUM OF 6 INCHES 15 2 cm FROM WALL TO HELP PREVENT VAPOR FROM DISCOLORING THE WALL SURFACE IN COLDER CLIMATES WATER HEATER COUPLING Bag INTERIOR WALL gt 12 13 14 15 16 FACTORY SUPPLIED STANDARD TERMINATION POINTED DOWN TOWARDS THE
344. rn Prover power ie return Inlet power Prover retum Outlet power CCB J15 Pressure Switches Junction Box Neutral 8 White IT aci mm uu uu u em um mm em Pump Common Auxiliary 5 Green Pump NO Connects Flame Rod AUX Common 4 While AUX Common Anode TBlue to burner Yellow 5 AH T AUKNO J Dand 2 Green Green bolt Protective UXNC 2Red ME Flame Rod 3 Yellow Green PE ondensate Black Earth PE 1 Neutral LI Field Box HIGH Voltage J1 ul BeoA Lr goo Green Condensate Gas PS Gas PS Gas V Switch Ground Bar Gas V Switch Gas VZ4V l Gas Pressure AV Rin TZ Back 1 zem fs Switch CCB J14 Limit String Gas Valve V Dgnd Write protect fala SDA data W5 White Orange Wa Wnite Blue W3 White Brown Configuration W2 Green Key WI Red Display Display AIN CGB J12 Configuration Key NIV Aeidsiq ELr 809 18AWG AWM wire 105 C 600V UL style 1015 Flame rod wire 200 C 300V UL 1180 m m multi conductor power limited cable 18AWG 80 C 300V UL cat
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346. rom escaping into the installed space See Condensate Drain Installation on page 37 CONDENSATE PH LEVEL The condensate drains from the water heaters covered in this manual have PH levels between 4 3 and 5 0 Install a commercially available neutralizing kit if required by local codes NOTE Lower PH levels are acidic Do not connect a metal drain line such as copper to the water heater for this reason See Condensate Drain Installation on page 37 16 COMBUSTIBLE MATERIAL STORAGE PANNE Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance e Avoid all ignition sources if you smell gas e Do not expose water heater controls to excessive gas pressure e Use only the gas shown on the water heater rating label Maintain required clearances to combustibles Keep ignition sources away from faucets after extended periods of non use d Read instruction manual before installing using or servicing water heater Keep appliance area clear and free of combustible materials gasoline and other flammable vapors and liquids CONTAMINATED AIR AWARNING Breathing Hazard Carbon Monoxide Gas Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual e Install water heater in accordance with the Instruction Manual and NFPA 54 or CAN CSA B149 1 To avoid injury combustion and v
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348. s 30 cm 18 inches 45 cm in Canada above the average or expected snow level as shown in Figure 19 and Figure 21 on page 24 When the intake air and or vent piping from multiple water heaters will terminate in the same location the vent terminations can be grouped together in close proximity 0 inches touching Intake air terminations can also be grouped together in close proximity 0 inches touching The distance between the closest vent and intake air terminations must be a minimum of 24 inches 61 cm as shown in Figure 21 In colder climates this separation should be increased to at least 48 inches 122 cm Cut a 5 inch 13 cm diameter hole for 4 inch pipe or 7 inch 18 cm diameter hole for 6 inch pipe where the pipe s will pass through the roof NOTE Beware of concealed wiring and piping when cutting through the roof Suspend the pipe s through center of hole using field supplied metal strapping or equivalent support materials as shown in Figure 19 Slide a roof boot or equivalent flashing over the pipe and secure roof boot or equivalent flashing to roof see Figure 19 and seal around the flashing Install the factory supplied intake air and or vent termination s using field supplied pipe and one field supplied 90 elbow as shown in Figure 19 The short section of pipe that connects between the field supplied 90 elbow and the factory supplied termination must not be excessive in length The exposed portion of this pi
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351. s d eau ferm s et Dilatation thermique a la page 14 DEUX CHAUFFE EAU TEMPERATURE LEGENDE UNIQUE AVEC RECIRCULATION BATIMENT SONDE DE CONTR LE E SOUPAPE DE D CHARGE DE TEMPERATURE CLAPET ANTI RETOUR AVERTISSEMENT CE SCHEMA ILLUSTRE LA CONFIGURATION De TUVALTERE puren Viano se eens ORDONNANCES LOCAUX POUR TOUTES EXIGENCES CLAPET BILLE SUPPL MENTAIRES q POMPE DE CIRCULATION PASSAGE INTEGRAL INTERRUPTEUR DE DEBIT D EAU S CURIT THERMIQUE TOUS CHANGEMENTS DE MAT RIAUX DE COMPOSANTS O DU VENDEUR DOIVENT AVOIR UNE APPROBATION PR ALABLE DU SERVICE D ING NIERIE DU PRODUIT APPLICABLE EAU CHAUDE VERS APPAREILS RETOUR D EAU CHAUDE ALIMENTATION EN EAU FROIDE R SERVOIR DE DILATATION SOL FINI REMARQUES 1 Sch ma de tuyauterie pr f r 2 Le r glage de la soupape de d charge et de s curit thermique ne doit pas d passer la pression nominale de tout composant dans le syst me 3 Les robinets de service sont illustr s pour l entretien de l unit Cependant les codes locaux r gissent leur utilisation SCHEMAS DE CONDUITES D EAU 5 Voir la section Connexions de conduites d eau a la page 40 installation des conduites d eau exenineree au sulk 6 Siune pompe est install e entre un chauffe eau et un r servoir de stockage ou sur un circuit q boucle de recirculation d un batiment conformement a la Figure 63
352. s reason INTAKE AIR AND VENT PIPE CLEARANCES The minimum clearance from combustible materials for the vent exhaust and intake air piping shall be 0 inches Vent or intake air piping passing through a combustible wall or ceiling must be a continuous run no joints EXTENDED VENT TERMINATIONS The water heaters covered by this manual can be installed using 4 inch pipe for the intake air and or vent piping up to a maximum of 70 equivalent feet 21 3 m The intake air and or vent piping can be extended up to 120 equivalent feet 36 5 m by installing 6 inch pipe See the Venting Requirements on page 21 The water heater ships from the factory with two 2 4 inch terminations that are 45 PVC elbows with a debris screen installed When 6 inch intake air or vent pipe is installed factory supplied 6 inch terminations must be used Contact your local distributor or call the parts department phone number listed on the back cover of this manual to order 6 inch termination s OPTIONAL DIRECT VENT TERMINATIONS The water heaters covered by this manual can be installed in a Direct Vent configuration using optional concentric and low profile terminations See the Venting Requirements on page 21 Concentric Termination Installation on page 28 and Low Profile Vent Installation on page 32 Concentric and low profile terminations must be ordered separately Contact your local distributor or call the parts department phone number listed on t
353. sary piping and fittings to route the intake air and vent piping back to the water heater The intake air and vent piping must be supported properly to avoid bending or failure The water heater manufacturer recommends that the vent and intake air piping be supported every 5 feet 152 cm of vertical run and every 3 feet 91 cm of horizontal run Do not install the vent or intake air piping in a manner that will allow water to be trapped in the piping A field supplied condensate Tee fitting and drain hose should be installed in the intake air piping near the water heater in colder climates with heavy snow accumulations and in areas that regularly experience high humidity The drain hose should be routed to an adequate floor drain separate from any other condensate drains See Figure 16 on page 23 NOTE Snow being pulled into the intake air piping and then melting can lead to excessive amounts of water accumulation and damage water heater components Warm humid outdoor air can lead to excessive condensation inside the intake air piping and may also damage water heater components All vent exhaust pipes must be pitched a minimum of a 1 4 inch per foot back to the water heater to allow drainage of condensate If installing 4 inch vent pipe connect the vent pipe to the exhaust elbow on the water heater If installing 6 inch vent pipe transition to 4 inch pipe at the exhaust elbow on the water heater as shown in Figure 15 The f
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355. section Connexions de conduites d eau a la page 40 installation des conduites d eau exenineree au sulk 6 Siune pompe est install e entre un chauffe eau et un r servoir de stockage ou sur un circuit q boucle de recirculation d un batiment conformement a la Figure 63 a la page 66 7 Si une pompe est installee dans un circuit boucle de recirculation entre le chauffe eau et un fil de lave vaisselle commercial conformement a la Figure 64 a la page 66 Avant 1 Voir la section Melangeurs a la page 14 2 Voir la section Lave vaisselle a la page 14 3 Voir la section Soupape de d charge a s curit thermique a la page 15 4 Voir la section Systemes d eau ferm s et Dilatation thermique a la page 14 UN CHAUFFE EAU DEUX TEMPERATURES LEGENDE AVEC RECIRCULATION EN BOUCLE DE TEMPERATURE 1 ELEVEE AVEC RECIRCULATION BATIMENT SONDE DE CONTROLE DE TEMPERATURE SOUPAPE DE DECHARGE 1 CLAPET ANTI RETOUR AVERTISSEMENT CE SCHEMA ILLUSTRE LA A SECURITE THERMIQUE VIDANGE CONFIGURATION DE TUYAUTERIE SUGG R E ET e k SOUPAPE DE D CHARGE JAUGE DE TEMP RATURE D AUTRES DISPOSITIFS CONSULTER LES CODES CLAPET BILLE ORDONNANCES LOCAUX POUR TOUTES EXIGENCES N PASSAGE INTEGRAL SUPPL MENTAIRES POMPE DE CIRCULATION INTERRUPTEUR DE D BIT D EAU k MELANGEUR TOUS CHANGEMENTS DE MAT RIAUX DE COMPOSANTS OU DU VENDEUR DOIVENT AVOIR UNE APPROBATI
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357. seven different arrangements See Figure 41 on page 33 through Figure 47 on page 34 GENERAL VENTING INSTRUCTIONS These instructions must be followed on all installations 1 DO NOT install the water heater in a Power Vent configuration unless there is adequate supply of fresh air see Air Requirements on page 17 If the installation space does not provide an adequate supply of fresh air the water heater must be installed in a Direct Vent configuration If the water heater is to be installed in a beauty shop barber shop cleaning establishment a laundry with dry cleaning equipment or any space with contaminated air it is imperative that the water heater s be installed in a Direct Vent configuration so that all air for combustion is derived from the outdoor atmosphere The vent and intake air piping must terminate outdoors The minimum clearance from combustible materials for the vent exhaust and intake air piping shall be 0 inches Vent piping passing through a combustible wall or ceiling must be a continuous run no joints The water heater must be protected from freezing downdrafts during shutdown periods The vent exhaust pipe must not be combined or connected to any other appliance s vent system or chimney The intake air pipe must not be combined or connected to any other appliance s intake air piping Locate the water heater where the vent exhaust and intake air piping will remain within the maximum equivalent lengths
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360. soupape de d charge et de s curit thermique ne doit pas d passer la pression nominale de tout composant dans le syst me 3 Les robinets de service sont illustr s pour l entretien de l unit Cependant les codes locaux r gissent leur utilisation SCHEMAS DE CONDUITES D EAU Avant 1 3 4 installation des conduites d eau examiner ce qui suit Voir la section M langeurs a la page 14 Voir la section Lave vaisselle a la page 14 Voir la section Soupape de d charge a s curit thermique a la page 15 Voir la section Syst mes d eau ferm s et Dilatation thermique a la page 14 TROIS CHAUFFE EAU TEMPERATURE UNIQUE AVEC RECIRCULATION BATIMENT AVERTISSEMENT CE SCHEMA ILLUSTRE LA CONFIGURATION DE TUYAUTERIE SUGGEREE ET D AUTRES DISPOSITIFS CONSULTER LES CODES ET ORDONNANCES LOCAUX POUR TOUTES EXIGENCES SUPPLEMENTAIRES TOUS CHANGEMENTS DE MATERIAUX DE COMPOSANTS OU DU VENDEUR DOIVENT AVOIR UNE APPROBATION PREALABLE DU SERVICE D ING NIERIE DU PRODUIT APPLICABLE 27 EAU CHAUDE VERS APPAREILS SOL FINI REMARQUES 1 Sch ma de tuyauterie pr f r 5 Voir la section Connexions de conduites d eau la page 40 6 Si une pompe est install e entre un chauffe eau et un r servoir de stockage ou sur un circuit boucl de recirculation d un b timent conform ment la Figure 63 la page 66 7 Si une pompe est install e dans un circuit boucl de recirculation entre le chauffe ea
361. sphere through sealed intake air piping are not factored in the total appliance input Btu hr calculations used to determine the size of openings providing fresh air into confined spaces EXHAUST FANS Where exhaust fans are installed additional air shall be provided to replace the exhausted air When an exhaust fan is installed in the same space with a water heater sufficient openings to provide fresh air must be provided that accommodate the requirements for all appliances in the room and the exhaust fan Undersized openings will cause air to be drawn into the room through the water heater s vent system causing poor combustion Sooting serious damage to the water heater and the risk of fire or explosion may result It can also create a risk of asphyxiation LOUVERS AND GRILLES The free areas of the fresh air openings in the instructions that follow do not take in to account the presence of louvers grilles or screens in the openings The required size of openings for combustion ventilation and dilution air shall be based on the net free area of each opening Where the free area through a design of louver or grille or screen is known it shall be used in calculating the size of the opening required to provide the free area specified Where the louver and grille design and free area are not known it shall be assumed that wood louvers will have 25 free area and metal louvers and grilles will have 75 free area Non motorized louv
362. st be installed on all closed water systems DO NOT PLUG THE TEMPERATURE PRESSURE RELIEF VALVE OPENING THIS CAN CAUSE PROPERTY DAMAGE SERIOUS INJURY OR DEATH AWARNING Temperature Pressure Relief Valve must comply with ANSI Z21 22 CSA 4 4 and ASME code Properly sized temperature pressure relief valve must be installed in opening provided Can result in overheating and excessive tank pressure Can cause serious injury or death VENT SYSTEM Examine the vent system once a year Points of inspection are as follows 1 Check for obstructions and or deterioration of the intake air and or vent piping and the intake air and vent terminations Replace immediately where needed The debris screens in the intake air and vent terminations should be should be cleaned of foreign material and soot See Figure 22 on page 25 NOTE Do not reach inside the vent termination when the heater is in operation Check all vent system connections for leakage and repair or reseal as necessary DIAGRAMS CCB CENTRAL CONTROL BOARD LAYOUT CCB CENTRAL CONTROL BOARD J13 m O gt 4 J16 8 5 o b 1 TE EE J5 4 32 1 Figure 61 64 WIRING DIAGRAM VFD ZAV enable 4 White Drive enable 3 White Yellow Oto 107 2 White Black Dad T White Green 120V to VFD 1 White Green TBlue 24Vureg Spark 3 White B
363. stallation Code 1 Once the proper location has been determined cut 2 holes in the wall large enough to accommodate the pipe Pipe diameters and distance between hole centers can be found in Table 12 2 Slide both the intake and exhaust pipes through the holes Solvent cement both pipes to the base of the vent termination kit follow the solvent cementing procedures outlined in the IPEX System 636 Installation Guide which is available on the web www ipexinc com 3 To fasten the Base to the wall use the supplied screws and anchors A 3 16 5mm hole 1 3 16 30mm deep will need to be drilled for the anchors Locate the anchor hole using the base as a template 4 Screw the Cap to the Base using the supplied screws 5 Once the vent termination and pipes are secured the wall penetrations will need to be sealed from the interior using a 12 Min between Edge PVC compatible sealant material of Air Inlet and Adjacent 6 All vent pipes and air inlets must terminate at the same Vent Outlet height to avoid possibility of severe personal injury death or substantial property damage 7 Operate heater through 1 heat cycle to ensure combustion air and vent pipes are properly connected to concentric vent termination VentiAir Termination 42 Min Grade or Snow Line Figure 37 Air Vent Base Vent Piping Vent Air Termination Figure 38 Figure 36 TABLE 12 Lovv Profile Termination Kits Dimensions P
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365. t Burns Time for 1st Degree Burn 2nd amp 3rd Degree Less Severe Burns Most Severe Burns normal shower temp 8000 pain threshold 149 65 154 68 e water heaters covered in this manual are equipped wi an electronic control system to regulate the water temperature inside the storage tank The control system senses temperature from two factory installed temperature probes one installed in the top of the storage tank and one installed near the bottom See Figure 3 on page 8 and Figure 4 on page 9 for location The Operating Set Point is adjusted to regulate water temperature inside the storage tank This is an adjustable user setting in the control system s Temperatures Menu This and all control system menus are accessed through the UIM user interface module located on the front of the water heater see Figure 56 The Operating Set Point is adjustable from 90 F 42 C to 180 F 82 C The factory setting is 120 F 49 C See Operating Set Point And Differential Adjustment on page 47 for instructions on how to adjust the Operating Set Point and other user settings Set the Operating Set Point at the lowest setting which produces an acceptable hot water supply This will always provide the most energy efficient operation MODULATION The water heaters covered by this manual are capable of modulating their firing rate The CCB monitors the water temperature in the tank and regulates the firing rat
366. table hot water supply Set the Operating Set Point to the lowest setting which produces an acceptable hot water supply for most efficient use DESCRIPTION ACTION DISPLAY From the Desktop screen press the Operational Button under MENU The Main Menu screen will be displayed EE Tank Temperature Operating Set Point Status Standby The Main Menu is where all control system menus are listed see Table 18 on page 45 for a complete list and description of control system menus Use the Up and Down Buttons to view Tem peratu res all control system menus from the Main Menu Heater Status With Temperatures menu selected highlighted in black in Disol ttin the Main Menu screen press the Operational Button under P ay Se gs SELECT to enter the Temperatures menu Heater Information Current Fault Main Menu If the Temperatures menu is not selected use the Up and Down Buttons to select this menu item SELECT VVith the Operating Set Point selected in the Temperatures menu press the Operational Button underneath CHANGE to activate the adiustment mode for this menu item Operating Set Point Differential f Operating Set Point is not selected use the Up and Dovvn Tank Temperature Buttons to select this menu item Upper Temperature Lovver Temperature NOTE Higher Temperature settings increase vvear and z 9 Tank Probe Offset operating costs Set the Operating Set Point to the lowest setting which produces an a
367. ter discharge will not cause any property damage as the water may be extremely hot Use care when operating valve as the valve may be hot To check the relief valve lift the lever at the end of the valve several times see Figure 60 The valve should seat properly and operate freely If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater and drain the water heater see Draining And Flushing on page 61 Replace the Temperature Pressure Relief Valve with a properly rated sized new one see Temperature Pressure Relief Valve on page 15 for instructions on replacement 63 TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE Figure 60 If the Temperature Pressure Relief Valve on the water heater weeps or discharges periodically this may be due to thermal expansion NOTE Excessive water pressure is the most common cause of Temperature Pressure Relief Valve leakage Excessive water system pressure is most often caused by thermal expansion in a closed system See Thermal Expansion and Closed Water Systems on page 14 The Temperature Pressure Relief Valve is not intended for the constant relief of thermal expansion Temperature Pressure Relief Valve leakage due to pressure build up in a closed system that does not have a thermal expansion tank installed is not covered under the limited warranty Thermal expansion tanks mu
368. the 4 inch concentric termination Note When shortening the length of the termination carefully measure and cut the larger intake air pipe first Cut the same amount of pipe off of the smaller vent pipe Note Lengthening of the Concentric Vent Termination is not permitted CONCENTRIC MUST AMINIMUM 10 7 3 m AWAY FROM ANY PARAPET VERTICAL VVALL OR STRUCTURE 6 INCH CONCENTRIC TERMINATION FLAT ROOF CLEARANCE Figure 24 6 INCH CONCENTRIC TERMINATION INSTALLATION to the 6 inch concentric termination using field supplied 6 x 4 reducer couplings as needed 9 Return to Direct Vent Installation on page 22 to complete AS NS po x the installation of the intake air and vent piping between the FACTORY 6 x 6 x 6 concentric termination and the vvater heater MAINTAIN 12 30 cm 18 45 cm FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 60 cm ABOVE ROOF INSTALLED p FITTING COMBUSTION VENT CONNECTION 4 INCH PVC VENT CAP AIR VENT PIPE IS 4 INCH SDR 26 PIPE SUPPLIED LENGTH 46 50 118 cm MINIMUM ALLOWABLE LENGTH 16 38 41 6 cm ROOF FLASHING field supplied INTAKE AIR PIPE IS 6 INCH SDR 26 PIPE SUPPLIED LENGTH 25 38 64 5 cm MINIMUM ALLOWABLE LENGTH 12 30 cm STRAP field supplied NOTE SECURING STRAP MUST BE FIELD INSTALLED TO PREVENT MOVEMENT OF TERMINATION KIT
369. ther temperature limitations 12 The Combustion Blower will run for the duration of the post purge cycle to purge the water heater of all combustion gases When the post purge cycle is complete the blower is de energized and will coast to a stop 13 The control system now enters the standby mode while continuing to monitor the internal storage tank water temperature and the state of other system devices If the tank temperature drops below the Operating Set Point minus the Differential setting the control will automatically return to Step 2 and repeat the operating cycle SEQUENCE OF OPERATION FLOW CHART Sequence is shown with Enable Disable Switch in the Enable position If tank temperature drops below Operating Set Point minus Differential setting a heating cycle is activated Control System performs diagnostic checks Normal State of all pressure switches and ECO are checked Control System Locks Out L NOS Blovver Prover pressure svvitch verified open Displays Fault Msg All other pressure switches and ECO are verified closed Combustion Blower is energized Pre Purge cycle D Blower Prover switch contacts confirmed closed by control system Control System Locks Out Blower Prover Open Fault Msg is displayed Spark Ignition Control is energized 24 VAC Gas Valve is energized gas flows to Main Burner Is flame sensed at the Main Burner control system monitors the flam
370. tment mode for this parameter With the adjustment mode for Show Contact Information activated the selection bar will change from a black fill to a black outline Use the Up and Down Buttons to change the setting from No to Yes and press the Operational Button underneath UPDATE to save the new setting NOTE The Access Code at the bottom of the Service Contact Information screen is for manufacturing engineering purposes only There are no user settings or information accessed through this menu item Using the UP and DOWN buttons select highlighted in black the Change Contact Name menu item Press the Operational Button under SELECT to open the Change Contact Name menu Follow the on screen instructions to enter your name or the name of your company There is a maximum of 20 character spaces for this purpose When finished press the Operational Button UPDATE to save the new Contact Name The control system will return to the discrete menu Using the UP and DOWN buttons select highlighted in black the Change Contact Phone menu item and press the Operational Button under SELECT Follow the on screen instructions to enter a new Contact Phone number and press the Operational Button under UPDATE to save the new phone number When the new Contact Name and Contact Phone number have both been updated press the Operational Button under BACK to return to the Desktop screen 50 Service Contact Information
371. trol system if the condition that caused the Fault has not been corrected CONTROL SYSTEM MENUS From the Desktop screen pressing the Operational directly below Menu on the LCD will display the Main Menu this is where all control system menus are located The table below describes the control system menus TABLE 18 mens festge OOOO 5 1 Most commonly accessed menu Contains the Operating Set Point and Differential user settings Heater Status This menus displays the current state of all pressure switches and the ECO open closed The on off status of the Combustion Blower gas valve spark igniter flame sensor and other monitored water heater components are displayed in this menu Display Settings Temperature units F or C the LCD appearance brightness contrast and backlight delay user adjustable settings are located in this menu Heater Information Elapsed time of operation total heating cycle time heating cycle count heating on time along with UIM and CCB software revisions can be viewed in this menu Current Fault Displays any current Alert or Fault messages Fault History This control system menu retains a list of the last nine 9 Fault and Alert messages with a time stamp The newest event will replace the oldest Faults will clear after 30 days Fault Occurrence This control system menu retains a running total of how many times each Fault condition has occurred since the water heater was first installed This scre
372. tructions and local building codes Condensate neutralizer kits are available Contact your distributor or Service Agency Field supplied materials required for installation include Approved PVC cement and PVC primer 1 2 inch PVC pipe minimum length to equal the distance between the water heater and a suitable building drain 1 2 inch PVC fittings elbows couplings and adapters necessary to install a condensate drain line between the exhaust condensate elbow assembly and a suitable building drain Floor mounted standoffs to brace the drain line INSTALLATION NOTES 1 The condensate drains from the water heater s covered by this instruction have PH levels between 4 3 and 5 0 Install a commercially available neutralizing kit if required by local codes Lower PH levels are acidic Do not connect a metal condensate drain line such as copper pipe to the water heater for this reason EXHAUST CONDENSATE VENT ELBOW PRESSURE PORT 1 2 NPT CONDENSATE DRAIN CONNECTION CONDENSATE BUILDING m CLEANOUT DRAIN 2 The field installed condensate drain line must not be less than 1 2 inch PVC in size 3 DO NOT remove modify or alter the factory condensate trap INSTALLATION INSTRUCTIONS 1 Ensure the water heater s Enable Disable switch is in the Disable position 2 Install a 1 2 inch PVC condensate drain line between the condensate drain connection on the Exhaust Condensate Elbow and a suitable buil
373. ttom of the water heater must be sealed to the floor with a silicone based sealant or elevated 6 inches above the floor CLOSED WATER SYSTEMS Water supply systems may because of code requirements or such conditions as high line pressure among others have installed devices such as pressure reducing valves check valves and back flow preventers Devices such as these cause the water system to be a closed system THERMAL EXPANSION As water is heated it expands thermal expansion In a closed system the volume of water will grow when it is heated As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent Temperature Pressure Relief Valve operation water discharged from the valve due to excessive pressure build up This condition is not covered under the limited warranty The Temperature Pressure Relief Valve is not intended for the constant relief of thermal expansion A properly sized thermal expansion tank must be installed on all closed systems to control the harmful effects of thermal expansion Contact a local plumbing service agency to have a thermal expansion tank installed See Water Line Connections on page 40 and the Water Piping Diagrams beginning on page 67 TEMPERATURE PRESSURE RELIEF VALVE AWARN
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375. ty and water temperature is below 160 F replace upper temperature probe If the water temperature exceeds 195 F turn off electric power and gas supply and call Tech Support for further instructions Confirm the water heater is full of water Confirm the powered anode wire connections are tight and free of debris or moisture i e rust solder metal pipe shavings Confirm proper electrical ground to the water heater 60 Blower Operation Error Fault occurred 2 mins ago Blower Prover Pressure Switch may have failed closed Check replace pressure switch Call a service professional Your Company Name Here press DOWN for more hd BACK ADVANCED Blower Prover Open Fault occurred 2 mins ago The blower prover switch remains open after the blower has been energized Call a service professional Your Company Name Here press DOWN for more ADVANCED Blocked Air Intake Fault occurred 2 mins ago Restriction in air intake Check intake pipe and termination for blockage Call a service professional Your Company Name Here press DOWN for more ka BACK ADVANCED Energy Cut Out ECO Fault occurred 2 mins ago Tank temperature is excessive The water heater has been disabled Call a service professional Your Company Name Here press DOWN for more BACK ADVANCED Alert No Water Alert occurred 2 mins ago No water detected by Powered Anode Call a service pr
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380. u et un fil de lave vaisselle commercial conform ment la Figure 64 la page 66 L GENDE 2 SONDE DE CONTR LE e e SOUPAPE DE DECHARGE DE TEMPERATURE PSX CLAPET ANTIRETOUR A S CURIT THERMIQUE k SOUPAPE DE D CHARGE VIDANGE JAUGE DE TEMP RATURE CLAPET BILLE POMPE DE CIRCULATION PASSAGE INTEGRAL INTERRUPTEUR DE DEBIT D EAU RETOUR D EAU CHAUDE ALIMENTATION EN EAU FROIDE RESERVOIR DE DILATATION 2 Le r glage de la soupape de d charge et de s curit thermique ne doit pas d passer la pression nominale de tout composant dans le syst me 3 Les robinets de service sont illustr s pour l entretien de l unit Cependant les codes locaux r gissent leur utilisation SCHEMAS DE CONDUITES D EAU 5 Voir la section Connexions de conduites d eau la page 40 Avanttinstaliation des conduites d eau Scam eres dul 6 Siune pompe est install e entre un chauffe eau et un r servoir de stockage ou sur un circuit q boucle de recirculation d un batiment conformement a la Figure 63 a la page 66 7 Si une pompe est installee dans un circuit boucle de recirculation entre le chauffe eau et un fil de lave vaisselle commercial conformement a la Figure 64 a la page 66 1 Voir la section Melangeurs a la page 14 2 Voir la section Lave vaisselle a la page 14 3 Voir la section Soupape de d charge a s curit thermique a la page 15 4 Voir la section Systeme
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383. ua m as s 43 Control System Navigation 43 User Settings amp Control System Menus 46 STARTUP EE 51 Prior TOS LAUD EEN 51 Lighting amp Operation Label 52 Checking the Firing Rate 53 High Altitude Installations ll 54 TROUBLESHOOTING 55 Installation Checklist 2 88 8228 3 55 Sequence of 55 Sequence of Operation Flow Chart 56 Operational Probleme u u 57 Fault and Alert Conditions 58 5 5 61 61 Maintenance Gchedule iii s ii 61 Draining and Flushing 2338882282 338888 61 Filling the Water Heater is 62 Sediment Rernovall uu vedic an en eati 62 Lime Scale Removal 62 Powered Anode 05 63 Drain Valve and Access Panels 63 Temperature Pressure Relief Valve Test 63 Vent Syste saon isr es pa aa pp seca 63 DIAGRAMS iseenese E ne 64 CCB Central Control Board Layout 64 Wining Diagram terassit aee a E 65 Circulation Pump Wiring Diagrams 66 Water Piping Diagramm S 25 22 67 LIMITED WARRANTY
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389. ulation d un b timent conform ment la Figure 63 la page 66 Voir la Serion M langeurs a page 14 7 Si une pompe est install e dans un circuit boucl de recirculation entre le chauffe eau et un Voir la section Lave vaisselle a la page 14 fil de lave vaisselle commercial conform ment a la Figure 64 a la page 66 Voir la section Soupape de d charge a s curit thermique a la page 15 Voir la section Syst mes d eau ferm s et Dilatation thermique a la page 14 QUATRE CHAUFFE EAU TEMPERATURE LEGENDE UNIQUE AVEC RECIRCULATION BATIMENT R SONDE DE CONTR LE SOUPAPE DE DECHARGE DE TEMPERATURE 1 CLAPET ANTI RETOUR AVERTISSEMENT CE SCHEMA ILLUSTRE LA A SECURITE THERMIQUE CONFIGURATION DE TUYAUTERIE SUGGEREE 2 SOUPAPE DE DECHARGE VIDANGE T JAUGE DE TEMPERATURE D AUTRES DISPOSITIFS CONSULTER LES CODES ET ORDONNANCES LOCAUX POUR TOUTES EXIGENCES epee ees SUPPLEMENTAIRES POMPE DE CIRCULATION PASSAGE INTEGRAL INTERRUPTEUR DE DEBIT D EAU TOUS CHANGEMENTS DE MATERIAUX DE COMPOSANTS OU DU VENDEUR DOIVENT AVOIR UNE APPROBATION PREALABLE DU SERVICE D ING NIERIE DU PRODUIT APPLICABLE EAU CHAUDE VERS APPAREILS COMMANDE DE TEMPERATURE DU RESERVOIR TUYAU DST POUR OUVRIR VIDANGE 2 m RETOUR D EAU CHAUDE ne H yT SOL FINI REMARQUES R SERVOIR DE DILATATION 1 Sch ma de tuyauterie pr f r 2 Le r glage de la
390. upply is turned off at the breaker or disconnect switch Remove the junction box cover See Figure 3 on page 8 for junction box location Connect the 120VAC hot wire from the power supply to the black jumper wire or the terminal block location marked L1 inside of the junction box located on top of the water heater If the black jumper wire is used make the connection inside of the junction box with a properly sized wire nut and wrap electrical tape around the wire nut and wire end See junction box Figure 53 and wiring diagram Figure 62 on page 65 Connect the 120VAC neutral wire from the power supply to the white jumper wire or the terminal block location marked Neutral inside of the junction box located on top of the water heater If the white jumper wire is used make the connection inside of the junction box with a properly sized wire nut and wrap electrical tape around the wire nut and wire end See junction box Figure 53 on page 40 and wiring diagram Figure 62 on page 65 NOTE If electrical connections are made directly to the terminal block remove the jumper wires before making connection Connect the ground wire from the power supply to the green jumper wire or the ground terminal location inside of the junction box located on top of the water heater If the green jumper wire is used make the connection inside of the junction box with a properly sized wire nut and wrap electrical tape around the wire nut and wire end See
391. ure Pressure Relief Valve installed Call the toll free technical support phone number listed on the back cover of this manual for technical assistance in sizing a Temperature Pressure Relief Valve for remote storage tanks For safe operation of the water heater the Temperature Pressure Relief Valve must not be removed from its designated opening nor plugged The Temperature Pressure Relief Valve must be installed directly into the fitting of the water heater designed for the relief valve Install discharge piping so that any discharge will exit the pipe within 6 inches 15 2 cm above an adequate floor drain or external to the building In cold climates it is recommended that it be terminated at an adequate drain inside the building Be certain that no contact is made with any live electrical part The discharge opening must not be blocked or reduced in size under any circumstances Excessive length over 30 feet 9 14 m or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve No valve or other obstruction is to be placed between the Temperature Pressure Relief Valve and the tank Do not connect discharge piping directly to the drain unless a 6 15 2 cm air gap is provided To prevent bodily injury hazard to life or property damage the relief valve must be allowed to discharge water in adequate quantities should circumstances demand If the discharge pipe is not connected to a drain or other
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397. wards from the termination point outdoors to the water heater Layout the vent piping to use a minimum of pipe and elbows Install the termination first If the vent piping will terminate vertically through a roof see Vertical Termination Installation on page 23 If the vent piping will terminate horizontally through a sidewall see Sidewall Termination Installation on page 25 6 PIPE FIELD SUPPLIED 6 x 4 REDUCER FIELD SUPPLIED 4 PIPE FIELD SUPPLIED ALUMINUM EXHAUST CONDENSATE ELBOW VENT CONNECTION FACTORY INSTALLED SSS VENT EXHAUST CONNECTION Figure 15 When installation of the termination is complete install necessary piping and fittings to route the vent piping back to the water heater The vent pipe must be supported properly to avoid bending or failure The water heater manufacturer recommends that the vent pipe be supported every 5 feet 152 cm of vertical run and every 3 feet 91 cm of horizontal run Do not install the vent piping in a manner that will allow water to be trapped in the piping All vent exhaust pipes must be pitched a minimum of a 1 4 inch per foot back to the water heater to allow drainage of condensate 10 If installing 4 inch vent pipe connect the vent pipe to the 11 exhaust elbow on the water heater If installing 6 inch pipe transition to 4 inch pipe as shown in Figure 15 The field installed 4 pipe between the exhaust elbow and th
398. witch Normally closed contacts that open on fall in pressure This switch is used to insure intake combustion air to the water heater is not restricted The control system monitors this switch and will disable heating operation if its contacts are open during a heating cycle Water heater s 24 VAC Gas Valve Supply gas line connection See the requirements for the Supply Gas Line on page 10 Low Gas Pressure switch Normally open contacts that close on a rise in pressure This switch is used to insure supply 10 11 12 13 14 15 16 17 19 gas pressure is above minimum requirements The control system monitors this switch and will disable heating operation if its contacts are open during a heating cycle See Table 4 and the Gas Pressure Requirements on page 10 Blower Prover switch Normally open contacts that close on a rise in pressure This switch is used to insure the Combustion Blower is operating properly The control system monitors this switch and will disable heating operation if its contacts are closed before the Combustion Blower is energized or open any time during a heating cycle See Sequence Of Operation on page 56 Vent connection exhaust condensate elbow 4 inch aluminum Combustion Blower Assembly Includes Gas Valve and Venturi gas feed system Blocked Exhaust vent switch Normally closed contacts that open on a rise in pressure This switch is used to insure the Exhaust vent pip
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400. xide Gas Install vent system in accordance with codes Do not operate water heater if exposed to flooding or water damage Special consideration must be taken with installations above 10 000 feet 3 048 m refer to high altitude section of this manual Do not operate if soot buildup Do not obstruct water heater air intake with insulating jacket or blanket Do not place chemical vapor emitting products near water heater Gas and carbon monoxide detectors are available Never operate the heater unless it is vented to the outdoors and has adequate air supply to avoid risks of improper operation fire explosion or asphyxiation Analyze the entire vent system to make sure that condensate will not become trapped in a section of vent pipe and therefore reduce the open cross sectional area of the vent Breathing carbon monoxide can cause brain damage or death Always read and understand the instruction manual Never operate the water heater unless it is vented to the outdoors The instructions in this section of the manual must be followed to avoid choked combustion or recirculation of flue gases Such conditions cause sooting of the combustion chamber burners and flue tubes and creates a risk of asphyxiation GENERAL VENTING INFORMATION The water heaters covered in this manual are operationally equivalent to Category IV appliances and may be installed in either a Power Vent or Direct Vent configuration APPR
401. xt that appears directly above each button on the LCD screen THE DESKTOP SCREEN During normal operation the control system will display the Desktop screen on the LCD which is the default screen The control system will return to the Desktop screen when there are no active Fault or Alert conditions or when there has been no user input for several minutes Manufacturer and water heater model information is displayed in Title Bar at the top of the Desktop screen Menu titles are displayed in the Title Bar when navigating the control system menus The first temperature shown on the Desktop screen Tank Temperature is the temperature of the water inside the water heater s storage tank The second temperature shown on the Desktop screen is the Operating Set Point The Operating Set Point is the temperature at which the control system will maintain the water inside the storage tank Beneath the Operating Set Point is the Status line The Status line shows the current operational state of the control system in real time see Table 17 on page 45 for a description of the various operational states The Desktop screen also displays animated Status Icons to convey operational information see Table 16 on page 44 for descriptions of the Status Icons UIM user interface module Desktop Screen Shown LCD Screen Information Display Tank Temperature Operating Set Point Status Heating Status Icons Operational buttons are multi functiona
402. y portion of the instructions call the toll free number on the back cover of this manual for technical assistance In order to expedite your request please have the full Model Serial and Series number of the water heater you are working with available for the technician This information is located on the water heater s rating label Carefully plan the placement of the water heater Examine the location to ensure that it complies with the requirements in Rough In Dimensions on page 10 and Locating the Water Heater on page 11 FEATURES AND COMPONENTS BASIC OPERATION The water heaters covered in this manual have a helical coil shaped heat exchanger that is submerged in the storage tank The water heater s Main Burner is a radial design burner it is mounted on the top and fires downward through the heat exchanger This is a forced draft burner hot burning gases are forced through the heat exchanger under pressure and exit through the exhaust vent connection located at the bottom of the water heater See Figure 1 and Figure 2 BURNER ASSEMBLY INTAKE AIR combustion air CONNECTION 4 INCH PVC MAIN BURNER radial design EXCHANGER D be v lt HELICAL A gt T ms nas haa 1510 DEE A EES LGS V VENT exhaust OUTLET ik k qan m m un un m m m 1 Figure 1 MODULATION The water heaters covered by this manual are capable of modulating
403. y this manual may be installed in a Direct Vent configuration using a 6 inch concentric or 6 inch low profile termination Contact your local distributor or call the parts department phone number listed on the back cover of this manual to order 6 Concentric Termination Part 9008841005 e 6 Low Profile Termination Part 9008935005 VENTING INSTALLATION SEQUENCE 1 Read the General Venting Instructions on page 20 and Venting Requirements on page 21 before proceeding These instructions and requirements must be followed on all installations Determine whether the water heater will be installed in a Power Vent or Direct Vent configuration and which vent system arrangement will be used for the installation See the various venting arrangements on pages 33 and 34 Proceed to the applicable installation instructions that follow Power Vent Installation or Direct Vent Installation POWER VENT INSTALLATION 1 Read the General Venting Instructions on page 20 and Venting Requirements on page 21 before proceeding These instructions and requirements must be followed in addition to the instructions below that are specific for Power Vent configurations Determine which Power Vent arrangement will be used for the installation vertical or horizontal termination See Figure 39 and Figure 40 on page 33 Determine the vent pipe size for the installation see Venting Requirements on page 21 Plan the layout of the vent piping back
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