CATALOGNO.:RM-001
Effective: 01-15-02
Replaces: 03-15-01
OPERATING AND
INSTALLATION
INSTRUCTIONS
Models 136-1826
MODEL
SERIAL NUMBER
INSTALLATION DATE
START UP DATE
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors or liquids or other combustible
materialsinthevicinityofthisoranyotherappliance. Todosomayresultinanexplosion
or fire.
WARNING
Improperinstallation,adjustment,alteration,serviceormaintenancecancauseproperty
damage, personal injury or loss of life. Refer to the user's information manual provided
with this heater. Installation and service must be performed by a qualified installer,
service agency or the gas supplier.
FOR YOUR SAFETY
WHAT TO DO IF YOU SMELL GAS
* Do not try to light any appliance.
* Do not touch any electrical switch; do not use any phone in your building.
* Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier'sinstructions.
* If you cannot reach your gas supplier, call the fire department.
IMPORTANT WARNING
THE HEATER MUST BE INSTALLED IN ACCORDANCE WITH THE INSTRUCTIONS IN THIS MANUAL. WAR-
RANTYWILLNOTAPPLYTOUNITSNOTINSTALLED,OPERATEDORMAINTAINEDACCORDINGTOTHESE
INSTRUCTIONS. THEINSTALLATIONMUSTCONFORMTOTHEAUTHORITIESHAVINGJURISDICTIONAND/
OR WITH THE LATEST EDITIONS OF THE NATIONAL FUEL GAS CODE ANSI Z223.1, THE NATIONAL
ELECTRICCODEANSI/NFPA70.
Rheem Commercial Water Heater Products
Ruud Commercial Water Heater Products
One Bell Road • Montgomery, AL 36117
(205) 260-1500
PartNo. 240454
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COPPER SANIMASTER AND TYPHOON
HOT WATER HEATERS
Series GB
forcirculatingtanksystems
136through1826MBTUH
ModelApplications
Hot water Supply Heaters are designed to provide hot water service to a variety of applications when used in
conjunctionwithanappropriatelysizedstoragetank. Modelsareavailableforindoororoutdoorinstallations, and
controls and pump are factory tested and mounted.*
ConstructionFeatures
1. All copper high efficiency heat exchanger.
2. Factory mounted pump suited for a wide variety of water conditions.*
3. Flow Switch included on all models.
4. All models feature an energy saving pump control.
5. Glass-lined cast iron headers to handle the most aggressive water conditions.+
6. All units are tested and certified to ANSI Z21.10.3 and carry National Board Stamps HLW.
7. Factoryinstalledpressurereliefvalve.
8. Temperaturepressuregaugeandtankstatareincluded.
9. All inputs over a 400,000 BTU feature intermittent pilot ignition.
10. Models available for Natural or LP Gas.
* Pump shipped separate in carton on Models 136 through 399.
+ Model 136 features Bronze Headers.
3
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SPECIFICATION DATA
MBH Natural Gas
Sanimaster
(Indoor)
Input
Typhoon
(Outdoor)
STYLE
MODEL
In-
Out-
Output
112.0
148.0
216.0
274.0
327.0
419.4
514.0
595.0
676.5
Input Output
Door
Door
ELECTRICALRATINGS
With Pump
136
181
264
331
399
136.0
181.0
264.0
334.0
399.0
511.5
627.0
726.0
825.0
136.0
181.0
264.0
334.0
399.0
511.5
627.0
726.0
825.0
926.0
112.0
148.0
216.0
274.0
327.0
419.4
514.0
595.0
676.5
759.0
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Model
Size
136-264 3.4 amps @ 120V(1/8 hp pump)
331-399 3.6 amps @ 120V(1/6 hp pump)
512-1826 7.9 amps @ 120V (1/2 hp
pump)
512
627
726
825
MBTUHPROPANEGAS†
Model
926
962
961.7
788.6
•
•
•
•
•
•
•
Size
Multiplier
1083
1125
1178
1223
1287
1337
1413
1467
1570
1630
1758
1826
1083.0 888.0
1178.0 966.0
1287.0 1055.0
1413.0 1158.5
1570.0 1287.0
1758.0 1441.5
•
•
•
•
•
•
136-399
512-825
926-1826
Same as natural gas
.94
1124.7 922.0
1222.5 1002.4
1336.6 1096.0
1467.0 1203.0
1630.0 1336.6
1825.6 1497.0
.92 Indoor
.955 Outdoor (Input)
.92 Outdoor (Output)
† Multiplier x Nat. MBTUH =
Pro. MBTUH
Rated inputs are suitable for up to 2000 feet elevation. For elevations above 2000 feet, reduce input 4% for each
1000 feet above sea level. These heaters are tested and certified to ANSI Standard Z 21.10.3
4
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5
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SHIPPING
WEIGHT
Jacket Gas
Height Conn.
Flue
Dia.
K
Height
Overall
B
Water
Connection
H
Reference
to
LBS(APPROX)
MODEL
SIZE
136
Width
A
J
Drawing
C
30-1/8
38
G
1/2
3/4
3/4
3/4
3/4
1
L
Indoor Outdoor
Less Pump
160
W/Pump
210
1
6
45
9-1/4
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
2
24-1/8
18-1/4
22-3/8
25-3/4
29-1/4
32-3/4
37-1/2
41-5/8
45-3/4
52-3/8
52-3/8
59-1/4
59-1/4
63-5/8
63-5/8
68-5/8
68-5/8
74-7/8
74-7/8
81-1/8
81-1/8
89-3/8
12-1/16
11-1/8
10-3/4
12-1/2
6
181
62-5/8
62-7/8
63-3/4
65-3/8
57
232
182
38
7
264
255
205
2
3
8
38
331
275
225
38
9
399
294
244
33
10
12
12
14
512
25-3/8
29-1/2
34-1/4
38-1/2
530
475
33
1
627
57
2
540
485
33
1
726
57
2
690
635
33
1
825
57
2
700
645
1
926
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
840
785
23-5/8
23-5/8
23-5/8
23-5/8
23-5/8
23-5/8
33-1/2
33-1/2
33-1/2
1
14
16
16
18
18
18
20
962
76-1/8
78-1/8
78-1/8
80-1/8
80-1/8
83-1/8
85-1/8
28
32
32
36
36
36
40
•
•
•
•
•
•
•
760
705
1
1083
1125
1178
1223
1287
1337
1413
1467
1570
1630
1758
1826
•
•
•
•
•
•
920
865
1
800
745
1
4
980
925
1
860
805
1-1/4
1035
930
980
33-1/2 1-1/4
1-1/4
875
1130
1000
1190
1040
1220
1090
1080
945
33-1/2 1-1/4
1-1/4
1130
985
36-1/2 1-1/4
1-1/4
1160
1035
36-1/2
1-1/4
23-5/8
6
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A. INTRODUCTION
WE RECOMMENDTHATTHISMANUALBEREVIEWEDTHOROUGHLYBEFOREINSTALLINGTHE
WATERHEATER. SHOULDANYQUESTIONSARISE,NOTCOVEREDBYTHISDATA,CONTACTYOUR
LOCAL DISTRIBUTORORTHESERVICE DEPARTMENTATTHEFACTORY.
MODELIDENTIFICATION
Themodelnumberofthe waterheater isfoundontheratingplate. Eachmodelnumberidentifiestheapplication,
theconstructionandthefunctionofthewaterheater, andprovidesapositivemeansofidentificationforapplication,
installation, operation, service and parts of the unit in a minimum amount of time.
RECEIVINGEQUIPMENT
On receiving equipment it is suggested that you
• Review packing slip for the number of packages.
• Inspect for concealed damage immediately.
• Advise carrier, in writing, of shortages or damage.
• Claims are filed by the receiver against the carrier. The carrier, not the shipper, is responsible for any
shortage or damage whether visible or concealed.
B. INSTALLATION GUIDELINES
INSTALLATIONREGULATIONS
THEINSTALLATIONMUSTCONFORMWITHTHESEINSTRUCTIONS, REQUIREMENTSORCODESOF
AUTHORITIES HAVING JURISDICTION, THE LATEST EDITION OF THE NATIONAL FUEL GAS CODE, ANSI
Z223.1ANDTHENATIONALELECTRICALCODE.
ANYALTERATIONORMODIFICATIONTOTHEWATERHEATER,ITSCOMPONENTSORITSINTENDED
APPLICATIONMAYVOIDTHEWARRANTYEXTENDEDWITHTHEPRODUCTBYTHEMANUFACTURER.
WARNING:
Improper installation, adjustment, alteration, service or maintenance can damage the
water heater, or create a hazard resulting in asphyxiation, explosion or fire.
WATERFLOW
Lowwatercontentheatexchangersrequirecontinuousflowforproperoperation.
WATERCONDITIONS:
DomesticHotwaterheaters aredesignedforoperationwithvariouswaterconditions. Corrosivewaterthathas
high chlorine content or other chemicals require that the tubes in the heat exchanger be cupro-nickel. Provide us
with an analysis of water where this potential exists.
7
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BASEREQUIREMENTS
Indoor water heaters must be installed on a level noncombustible surface, except as noted below. Do not install
on carpeting. Heater sizes 926 to 1758 Typhoon (Outdoor) are supplied with a combustible flooring base as
standard. The following chart lists the part number required for a combustible base, for water heaters supplied
without a combustible base.
COMBUSTIBLEFLOORBASE
BOILER PART BOILER PART BOILER PART
BOILER
1337
1467
1630
1826
PART
059236
059237
059238
059239
136
181
264
331
001749
058313
058314
058315
399
512
627
726
058316
056199
056200
056201
825
962
1125
1223
056202
059233
059234
059235
Fig.#8148.1
Fig.#8276
Hollow concrete cinder block; align holes and leave ends open.
Alternative method for providing a non-combustible base.
HEATERWITHCOMBUSTIBLE
FLOORSHIELD
HEATERINSTALLATION
ONCONCRETEBLOCKSORTILE
8
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COMBUSTIBLECONSTRUCTIONCLEARANCES
The water heater should be positioned to provide the minimum clearances from combustible surfaces and to
provide sufficient space for servicing the unit as follows.
MINIMUMCLEARANCES:
PROTECTED SURFACES
Clearances to surfaces installed
in rooms which are large (2) in
comparison with size of heater.
Rear
Left Side
Right Side
Indoor Top
12"
12"
6"
9
9
5
6
6
3
4
4
3
6
6
6
4
4
2
4
4
3
4
4
3
4
4
3
136
42"
42
42
42
42
42
42
42
42
Rear
Left Side
Right Side
Indoor Top
Outdoor Top(1)
12"
12"
12"
39"
9
9
9
6
6
6
4
4
4
6
6
6
4
4
4
4
4
4
4
4
4
4
4
4
181-399
512-825
39
39
39
39
39
39
39
39
Rear
12
18
6
36
(1)
9
12
5
6
9
3
4
6
3
6
6
6
4
6
2
4
6
3
4
6
3
4
6
3
Left Side
Right Side
Indoor Top
Outdoor Top
36
36
36
36
36
36
36
36
Rear
24
24
24
24
(1)
16
16
16
24
12
12
12
24
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
Left Side
Right Side
Indoor Top
Outdoor Top
926-1826
24
24
24
24
24
24
(1) Unobstructed.
(2) Large rooms are defined as having a volume at least 16 times the total volume of the heater.
(3) Installation clearances for heaters in rooms not large in comparison with the heater size shall be as listed
under combustible surfaces and shall not be reduced by the protection methods.
SERVICINGCLEARANCES:
24" in front of heater for removal of burner tray.
18" on side opposite water connection for deliming of Heat Exchanger on
Models181-1826only.
9
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COMBUSTIONANDVENTILATIONAIRSUPPLY
CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater
andvoidthewarranty.
IMPORTANT: Adequate air must be provided for proper combustion and ventilation of the surrounding area. An
inadequate supply of combustion air will result in incomplete combustion and eventual sooting of the heater.
Insufficient ventilation will cause excessive heat and rapid deterioration of electronic and electrical components.
EquipmentroomsshouldbeprovidedwithTWOpermanentairsupplyopeningsdirectlyconnected tooutsideair.
Each opening must have a minimum FREE area of one square inch per 4000 BTU per hour input of the total input
ratingofallequipmentintheroom. Localcodesorauthoritieshavingjurisdictionshouldbeconsultedforthefollowing
table.
RECOMMENDEDMINIMUMAIROPENINGS
NET
FREE
AREA
34
47
66
NET
FREE
AREA
128
157
182
NET
FREE
AREA
282
306
335
367
408
457
BOILER
SIZE
136
181
264
BOILER
SIZE
512
627
726
BOILER
SIZE
1125
1223
1337
1467
1630
1826
331
399
84
100
825
962
207
241
All area shown in square inches
For other conditions refer to the latest edition of the National Fuel Gas Code ANSI Z 223.1. Net free area, sq. in.
requiresdatafromlouvermanufacturerbasedonresistanceofscreening, ifprovided.
OUTDOORINSTALLATIONS
MODEL181-399
MODEL136
Step 1: Removethefront(4)screws
Step 2: Lineupoutdoortopventopeningoverheater
ventopening.
Step 3: Loweroutdoortopontounitliningupslotsinthe
outdoor top with screws holes in jacket top.
Step 4: Reinstall (5) screw to secure jacket top and
outdoor top to unit.
VENTTERMINAL(Outdoor)StacklessTopInstallation
1. Insert tabs into keyhole (4 places).
Pagoda Top
(Shipped
Loose with
Heater)
Fig.#8114
10
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2. Snap tabs into keyholes so as not to pull out.
MODELS926-1758
Heatershippedwithoutdoorventterminalfactory
installed.
INDOORHEATERS
IndoorInstallations
MODEL136
Step 1: Shut off main electrical per switch to heater.
Step 2: Turn heater manual switch located in upper
control panel to the "OFF" position.
Step 3: Shut off gas supply and water supply to the
heater.
MODELS 512 - 825
Step 4: Mount drafthood on boiler and attach with the 4
sheet metal screws provided. Drafthood should
be positioned with the vent sensor located on
the front left side as shown.
Step 1: Lower outdoor "Stackless" top on to unit.
Position top so it is centered on unit from
side to side and front to rear.
Step 5: Remove plastic plug from left side of boiler
jacket and install the plastic grommet provided.
Step 6: Route flue sensor wire harness through the
grommet installed in Step 5.
TEMPERATURE
SENSOR
SENSOR
SHIELD
MOUNTING
SCREWS
JACKET
TOP
HARNESS
ASSY.
CONTROL
PANEL
HEATER
ON/OFF
SWITCH
Fig.#8166.1
LOWER
DOOR
Step 2: Tighten the (4) screws (Shown below) until
they come in contact with the unit jacket top,
then evenly tighten all (4) screws to secure to
unit.
GROMMET
Fig.#8946
JACKE
FASTENING
SCREW
Fig.#8233
11
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Step 7: Remove door and locate wire from roll out sensor to Hi Limit with the male/female connector.
Fig.#8947
Step 8: Disconnect male/female connector and attach to the 2 wires from drafthood vent sensor harness.
MODELS 181-399
VENTTERMINAL/INDOORSTACKINSTALLATION
1. Removethelouveredjackettopbyremoving
four (4) #10 flat head screws.
2. Iforiginallyinstalled, remove"Pagoda"top
from the louvered jacket top.
3. Place the inner stack adapter panel over the
flue collector inside the heater. Make sure
the flanged side of the flue opening is up.
4. Turn the stack (draft hood) up side
down and set it down bottom side up.
5. Turn the jacket top panel (removed in step 1) up
side down and place it through the stack.
6. Attach the three (3) mounting brackets to the
stack using the screws provided and the holes
that are pre-drilled in the stack. Make sure the
bracketsarepositionedwiththeflangenearthe
top side of the stack (see illustration).
Caution must be taken not to over tighten and
strip the screw threads.
7. Turn the assembled stack and jacket top, right side
up. The jacket top will be trapped between the
brackets and the top of the stack. Place the stack
overtheinneradapterpanelflangedholeandlower
the louvered jacket top panel back into its original
position. Reinstall the four (4) green #10 flat head
screws removed in step 1 above.
DRAFTHOOD
JACKET TOP PANEL
(part of the heater)
SCREW HOLE
LOCATION
#10 SHEET METAL SCREW (3)
MOUNTING BRACKET (3)
3-1/4"
INNER STACK ADAPTER PANEL
FLUE COLLECTOR
(part of heater)
Fig.#8246.5
12
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MODELS181-399
Step 1. Shut off main electrical power switch to heater.
Step 2. Turn heater manual switch located in upper control panel to the "OFF" position.
Step 3. Shut off gas supply and water supply to the heater.
Step 4. Mount drafthood on top of boiler as shown on page 8. Drafthood should be positioned with the vent
sensor located on the front right side as shown.
Step 5. Remove plastic plug from left side of boiler jacket and install plastic grommet provided.
Step 6. Route flue sensor wire harness through the grommet installed in Step 5.
Step 7. Remove door and locate wire from roll out sensor to hi limit with the male/female connector.
Step 8. Disconnect male/female connector and attach to the 2 wires from draft hood vent sensor harness.
Fig#9350
Fig#9349
HEATERBEFORE
DRAFTHOOD
HEATERAFTER
DRAFTHOOD
INSTALLATION
INSTALLATION
MODELS 512 - 825
Locate and assemble as shown below. Secure with
screws supplied in envelope in carton
Fig.#8167.0
13
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MODELS962-1826
Locate and assemble as shown below. Secure with screws supplied in envelope in carton.
Fig.#8265.0
WARNING:
Indoor heaters require a drafthood that must be connected to a vent pipe and properly vented to the outside.
Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning.
Ventpipingthesamesizeorlargerthanthedrafthoodoutletisrecommended,however,whenthetotalventheight
is at least ten (10) feet (draft hood relief opening to vent terminal), the vent pipe size may be reduced as specified
inChapter10oftheNationalFuelGasCode, ANSIZ223.1. Asmuchaspossibleavoidlonghorizontalrunsofvent
pipe and too many elbows. If installation requires horizontal non-vertical runs, the vent pipe must have a minimum
of 1/4 inch per foot rise and should be supported at not less than five foot intervals. Plumbers tape, criss-crossed,
willservetospacebothhorizontalandverticalpiping. Gasventssupportedonlybytheflashingandextendingabove
the roof more than five feet should be securely guyed or braced to withstand snow and wind load. We recommend
use of insulated vent pipe must terminate with a vent cap which complies with the local codes or, in the absence of
such codes, to the latest edition of the National Fuel Gas Code, ANSI Z223.1.
The discharge opening must be a minimum of three feet
verticallyfromtheroofsurfaceandatleasttwofeethigherthanany
10' OR LESS
part of the building within ten feet. Vent stack shall be at least five
VENT CAP
feet in vertical height above the drafthood outlet. The vent cap
locationshallhave aminimumclearanceof4feethorizontallyfrom,
and in no case above or below, unless a 4-foot horizontal distance
2' MIN
2' MIN
ismaintained,fromelectricmeters,gasmetersregulatorsandrelief
equipment.
The weight of the vent stack or chimney must not rest on the
heater draft hood. Support must be provided in compliance with
5' MIN
VENT PIPE
applicable codes. The heater top and draft hood must be readily
removable for maintenance and inspection. Vent pipe should be
adequatelysupportedtomaintainproperclearancesfromcombus-
tible construction.
Type "B" double wall or equivalent vent pipe is recommended.
Howeversinglewallmetalventpipemaybeusedasspecifiedinthe
DRAFT HOOD
latest edition of the National Flue Gas Code ANSI Z223.1.
HEATER
Fig # 8119
14
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Atthetimeofremovalofanexistingheater,thefollowing (d) Place in operation the appliance being inspected.
steps shall be followed with each appliance remaining
connected to the common venting system placed in
operation, while the other appliances remaining con-
Follow the lighting instructions. Adjust thermostat
so appliance will operate continuously.
nected to the common venting system are not in opera- (e) Test for spillage at the draft hood relief opening
tion.
after 5 minutes of main burner operation. Use the
flame of a match or candle, or smoke from a
cigarette, cigar or pipe.
(a) Seal any unused openings in the common venting
system.
(f) After it has been determined that each appliance
remaining connected to the common venting sys-
tem properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace
dampers and any other gas burning appliance to
their previous conditions of use.
(b) Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockageorrestriction,leakage,corrosionandother
deficiencies which could cause an unsafe condi-
tion.
(c) Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the com-
mon venting system are located and other spaces
of the building. Turn on clothes dryers and any
appliance not connected to the common venting
system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will operate
at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
(g) Anyimproperoperationofthecommonventing
system should be corrected so the installation
conforms with the latest edition of the National
Fuel Gas Code, ANSI Z223.1. When resizing
any portion of the common venting system,
the common venting system should be resized
to approach the minimum size as determined
using the appropriate tables in Part 11 of
the National Fuel Gas Code, ANSI Z223.1.
Manifolds that connect more than one heater to a
commonchimneymustbesizedtohandlethecombined
load.
Consultavailableguidesforpropersizingofthemanifold
andthechimney. Atnotimeshouldtheareabelessthan
the area of the largest outlet.
Fig.#7043.1
15
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POWERVENTING
Heaters may be connected to systems requiring mechanical draft exhaust fans. The installation must be
engineeredbycompetentpersonnelinaccordancewiththelatesteditionofANSIZ223.1, localcodesandwiththe
supplier of the fan.
Particular attention must be given to the type of vent pipe used, its size and location. Suitable interlocks must
be provided to prevent heater operation until the fan is operating as designed.
OUTDOORWATERHEATERS
The point from where the flue products exit the heater must be a minimum of four (4) feet below, four (4) feet
horizontally from or one (1) foot above any door, window or gravity inlet to a building. The top surface of the heater
shall be at least three (3) feet above any forced air inlet, or intake ducts located within ten (10) feet horizontally.
Fig.#8245.1
HIGHWINDCONDITIONS(OutdoorUnitsOnly)
Inareaswherehighwindsarefrequent,itmaybenecessarytolocatetheheateraminimumof3'fromhighvertical
walls, or install a wind break so the heater is not in direct wind current.
VENTDAMPERINSTALLATION
(MODELS 136 THROUGH 264) WHERE REQUIRED
LOCATION
Theventdampermustbelocatedintheventsothat
it serves only the appliance for which it is intended.
If improperly installed, a hazardous condition, such
as an explosion or carbon monoxide poisoning, could
result. Make certain that it is mounted in an accessible
location at least 6 in. (152.4 mm) from any combustible
material or the heat exchanger and that the position
indicator is in a visible location.
Theventdampermustbeinstalledaftertheappliance
drafthood,asclosetothedrafthoodaspracticable,and
without modification of the draft hood.
Fig.#8182.0
16
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MOUNTING
On vertical vents, the vent damper may be mounted with the actuator in any position. On horizontal vents, do
not mount the actuator either directly above or directly below the vent pipe; mount the vent damper actuator to the
side of the vent.
The vent damper is set up for a continuous pilot system. If the vent damper is installed on an intermittent Pilot
or Direct Spark Ignition equipped system, the energy savings of the vent damper can be improved by plugging the
hole in the vent damper blade using the knockout plug, Part No 105612R, provided in the parts envelope.
DO NOT plug the hole if installing the vent damper on a continuous pilot system as this will create a hazardous
condition.
INSTALLINGTHEVENTDAMPERINHORIZONTAL&
VERTICALVENTS.
D80BGENERALWIRINGDIAGRAM
INSTALLTHEVENTDAMPERTOSERVICEONLYTHESINGLEAPPLIANCEFORWHICHITISINTENDED. IF
IMPROPERLYINSTALLED, AHAZARDOUSCONDITION,SUCHASANEXPLOSIONORCARBONMONOXIDE
POISONING,COULDRESULT.
VENTDAMPER
THEVENTDAMPERMUSTBEINSPECTEDATLEAST
ONCE A YEAR BY A TRAINED, EXPERIENCED SER-
VICE TECHNICIAN.. THE NAME OF THE PERSON
WHOORIGINALLYINSTALLEDYOURVENTDAMPER
NORMALOPERATIONSUMMARY
Forsafe,efficientoperation,theventdamperandall ISSHOWNONTHEINSTALLATIONLABEL. DAMPER
flue product carrying areas of the appliance must be MUST BE IN OPEN POSITION WHEN HEATER MAIN
checkedannually,withparticularattentiongiventodete- BURNERSAREOPERATING.
rioration from corrosion or other sources. Check vent
damperoperationasfollows:
indicator
Damperposition
1. Whenthefurnaceorheaterisoff,checkthatthevent
damper position indicator points to the closed posi-
tion, Fig. 4.
2. Turn the thermostat or controller up to call for heat
and check that the vent damper indicator points to
the open position, Fig. 4.
3. Turn the thermostat or controller down again and
check that the vent damper position indicator re-
DAMPER OPEN
DAMPER CLOSED
turns to the closed position.
FIG.4-VENTDAMPERPOSITIONINDICATOR
SHOWINGOPEN&CLOSEDPOSITIONS.
17
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PIPING: General. Consult particular heater section for specific information.
a. GAS
Gas piping must be installed in accordance with the latest edition of the National Fuel Gas Code ANSI
Z 223.1 and other local or regulatory agency codes that have jurisdiction.
1. Check heater rating plate for
•
•
Correct Fuel Gas
Rated input to meet local conditions such as altitude, gas specification, etc.
2. Piping from meter must be of sufficient size to provide the required amount of gas at flowing
pressures as follows:
Gas
BTU/CF
Natural
1000
Propane
2500
SP. GR
0.60
1.53
MinimumFlowingPressure
MaximumShut-offPressure
7" W.C.
14" W.C.
12" W.C.
14" W.C.
PIPESIZES
Fuel
Length(feet)
Model
136
Nat.
100-200
Propane
100-200
0-100
200-300
0-100
200-300
1
3/4
1
1
1-1/4
1-1/4
1-1/2
1-1/2
2
2
2
2
2-1/2
2-1//2
2-1/2
2-1/2
2-1/2
2-1/2
3
3
3
3
3
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
2
3/4
1
1
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
2
2
2
2
2
2
2
2
2
1
1
181
264
331
399
512
627
726
825
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
2
2
2
2
2
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
2
2
2
2
2
1-1/4
1/1/2
1-1/2
1-1/2
2
2
2
2
2
2
2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
3
3
3
3
3
926
962
1083
1125
1178
1223
1287
1337
1413
1467
1570
1630
1758
1826
2
2
2
2
2
2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
3
3
3
3
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
Chart is based on:
0.5" W.C. Pressure Drop Natural Gas
0.6" W.C. Pressure Drop Propane Gas
Fitting provided in gas line have equivalent length of pipe, in feet, as follows:
Size
Elbow
Tee
3/4
2.5
5
1
3
6
1-1/4
1-1/2
4.5
9
2
5.5
12
2-1/2
6.5
3
8
4
4
8
12
22
14
17
3. All gas piping must be tested after installation with air or an inert gas and all connections should be
checked using a soapy solution.
18
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CAUTION: The heateranditsmanualshutoffvalvemustbedisconnectedfromthegassupplyduringanypressure
testing of that system at test pressures in excess of 1/2 psig (3.45 KPA). Dissipate test pressure in the gas supply
line before reconnecting the heater and its manual shut off valve to gas supply line. FAILURE TO FOLLOW THIS
PROCEDURE MAY DAMAGE THE GAS VALVE. OVER PRESSURED GAS VALVES ARE NOT COVERED BY
WARRANTY. The heater and its gas connections shall be leak tested before placing the appliance in operation.
Use soapy water for leak test. Do NOT use open flame.
Test piping as follows:
Pressure 1/2 PSIG (14" W.C.) or less - isolate heater by closing the manual shut-off valve prior to applying
pressure.
Pressure in excess of 1/2 PSIG (14" W.C.) - The heater must be disconnected from the gas system.
Waterheatershavinggastraincomponentsthathavediaphragmsintheirconstructionaresuppliedwithableed
lineconnectionthatmustbeconnectedtotheoutsideatmosphereasrequiredbytheNationalFuelGasCode. Under
NO circumstances shall bleed lines terminate in the gas utilization equipment flue or exhaust system.
Fig.#8185.1
BurnerManifoldPressures. Thegaspressureregulatorsuppliedwiththeheaterisfactorysettoprovideamanifold
pressure,asmeasuredwithamanometer,of3.7in.W.C.forNaturalGasand10.5in.W.C.forPropane. Ifadjustment
isrequiredtoobtainthesepressuresremovecapandturnscrewclockwisetoincreasepressure,counter-clockwise
todecreasepressure.
19
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b. WATER
Water piping should be installed according to the local code requirements, ASHRAE, ASPE and BOCA
or other regulatory agencies.
COLDWATERSUPPLY
Thecoldwatersupplypiping,totheheatermustbeadequatetohandlethedesignloadrequirementsofthehot
water system. The following table illustrates the flow and minimum pipe sizes.
Min
Pipe
NPT
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
2
Min
Min
Flow
GPM
90
90
90
90
90
90
Pipe
NPT
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
Model
Size
136
181
264
331
399
512
627
726
Flow
GPM
22
30
42
53
63
82
85
Model
Size
825
926
962
1083
1125
1178
1287
1337
Flow
GPM
85
90
90
90
90
90
90
Pipe
NPT
2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
Model
Size
1413
1467
1570
1630
1758
1826
2
2
90
85
It isrecommended that agatevalvebeinstalledinthecoldwatersupplylineadjacenttotheheater. IfLocalCodes
require a check valve - provisions must be made for thermal expansion.
Aminimumpressureof30PSIGmustbemaintainedinthesystemtopreventdamagetotheheaterduetolack
of water circulation caused by vapor formation at suction side of the system pumps.
NOTE: Should the cold water supply be interrupted, for any reason, the gas supply must be manually shut off to
prevent heater damage. When the service is restored the lines must be vented to eliminate accumulated air.
20
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HOTWATERSUPPLYHEATER
Model136-1826
The heater is direct fired and used with a storage tank. The model number indicates the BTU/holds input. (i.e. an
1826 holds input of 1,826,000 BTU/ HR)
See specification and dimension information on pages 4, 5 and 6.
TANKTEMPERATURECONTROL
1. The tank temperature controller is shipped loose for installation in the field. It is found in the burner tray.
2. Install in the tapping provided in the storage tank as shown.
3. Wire the "TH" leads, provided in the boiler control box, to the tank temperature controller. DO NOT WIRE IN
SERIES WITH 115 VOLT SUPPLY TO THE HEATER.
NOTE: The "TH" wires are in the 24 volt control circuit. DO NOT connect to the 115 volt circuit.
4. Set temperature to 140°F or to desired tank temperature.
21
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SEQUENCEOFOPERATION
1. Power to heater and recirculation pump.
2. Control switch, located on heater control box, placed in "ON" position.
a. High limit controller circuit closed.
b. Tank temperature controller calls for heat.
c. Pump relay energized starting heater pump.
d. Flow switch activated, if sufficient flow is determined, sending power to
e. The ignition relay, S8600.
f. The pilot is energized and when proven lit.
g. Spark to pilot stops and
h. The main gas opens allowing the burners to light.
3. Tanktemperaturereachesdesiredtemperature.
a. Controlleropenscircuit.
b. Ignition relay de-energizes shutting off main and pilot gas.
c. Heater pump continues to operate until residual heat in the heater is dissipated.
d. Stack temperature drops below 140°F. A stack sensor, a part of the energy saving control, opens
the pump relay circuit shutting down pump.
4. Heater waits for next call for heat.
INSTALLATIONWATERHEATERPLUMBING:
The Recirculation pump , supplied by the installer should be sized according to heater input Model # ie. 825
would require 8.25 GPM. This pump is in addition to the pump supplied with the heater. The pump should
be set for constant recirculation. DO NOT WIRE to heater or tank operating controls.
PIPINGDIAGRAM-1HEATER1TANKTHERMOSTATSUPPLIED
Fig. # 8054-RHEEM
22
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PIPINGDIAGRAM-1HEATER2TANK
* PIPING MUST BE EQUAL BETWEEN TEES AND TANKS.
NOTES:
1.
2.
3.
4.
5.
Plumb all swing check valves in gravity closed position.
Minimum pipe size equal to heater inlet/outlet connection size (between heater and tanks).
Pipe sizes between tanks are to be based on estimated GPM flow rates (Max. 10 FPS Vel.)
Pipe all relief valves to drain or as local codes require.
Duplex manifold kit & 115 gallon jacketed and insulated storage tanks available from factory.
23
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PIPINGDIAGRAM-1HEATER3TANK
Fig. # 8067-RHEEM
* PIPING MUST BE EQUAL BETWEEN TEES AND TANKS.
NOTES:
1.
2.
3.
4.
5.
Plumb all swing check valves in gravity closed position.
Minimum pipe size equal to heater inlet/outlet connection size (between heater and tanks).
Pipe sizes between tanks are to be based on estimated GPM flow rates (Max. 10 FPS Vel.)
Pipe all relief valves to drain or as local codes require.
Duplex manifold kit & 115 gallon jacketed and insulated storage tanks available from factory.
24
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PIPINGDIAGRAM-1HEATER4TANK
* PIPING MUST BE EQUAL BETWEEN TEES AND TANKS.
NOTES:
1.
2.
3.
4.
5.
Plumb all swing check valves in gravity closed position.
Minimum pipe size equal to heater inlet/outlet connection size (between heater and tanks).
Pipe sizes between tanks are to be based on estimated GPM flow rates (Max. 10 FPS Vel.)
Pipe all relief valves to drain or as local codes require.
Duplex manifold kit & 115 gallon jacketed and insulated storage tanks available from factory.
25
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PIPINGDIAGRAM-2HEATER1TANKSPECIALTHERMOSTATANDWELL
NOTES:
1.
2.
3.
4.
5.
Plumb all swing check valves in gravity closed position.
Minimum pipe size to be (1) size larger than heater inlet/outlet connection size.
Pipe all relief valves to drain or as local codes require.
115 gallon jacketed and insulated storage tanks available from factory.
When two heaters are paralleled, do not use factory supplied thermostats. Order thermostat part
number 600887 and Well PN 650590 from factory. See electrical wiring on page 29.
Heaters with 2" or 2-1/2" manifold size may require more than one storage tank. Consult factory for
proper storage sizes.
6.
26
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DESCRIPTIONOFCONTROLSINGENERAL
ENERGYSAVINGPUMPCONTROL
ELECTRONICIGNITION
The energy saving pump control is an electronic
devicethatallowstheoperatortosetthedesiredtimefor
the pump to run after the heater shuts off. The time is
factory-set at 7 minutes and it can be re-adjusted in the
field anywhere from 3 to 10 minutes.
In a conventional system, when the tankstat is
satisfied, the main gas valve closes, but the pump
continues operating. With the energy saving pump
control, the heater pump is programmed to continue
running for an optimum period of time in order to absorb
theresidualheatfromthecombustion chamberanduse
it in the system.
Theintermittentignitiondeviceconservesenergyby
automatically extinguishing the pilot when desired tem-
peratureisreached. Whenadditionalheatisneeded,the
pilotre-igniteselectrically,eliminatingcostsofmaintain-
ing a constant pilot. To assure safe operation, the gas
valve cannot open until the pilot lights and is proven.
The pump then shuts off until the next call for heat is
received from the tankstat.
Fig.#8929.1
Fig#9331
EconomasterControl
Ignition Module Electronic Safety
27
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TANKSTATTEMPERATURECONTROL
FLOWSWITCH
Dual purpose control shuts off heater in case of
pump failure or low water flow condition.
Factorymountedonallboilersexcept136andwired
in series with main gas valve.
This is a bulb immersion type device that will
regulate the water temperature in the storage tank.
When the water temperature rises to the set point, the
switch opens and shuts off the main burners. As the
water cools down, the switch closes and turns on the
main burners again to maintain the desired water tem-
perature.
NOTE: Flow switch will not operate if flow is less than
12 GPM.
Fig.#8643
Fig.#9317
TemperatureControl
HIGHLIMIT
Flow Switch
The high limit is also a bulb immersion type device
that limits the water temperature in the heater outlet. It
willshutoffthemainburnerswhentheheateroutletwater
temperature exceeds the high limit setting, and cycles
on again when the water temperature drops to the set
point, less the differential.
Modelsareequippedwithmanualresethighlimiton
all models except 136. Model 136 is equipped with an
automatic reset high limit.
HIGHLIMIT(ManualReset)
The manual reset high limit is similar to the auto-
maticresethighlimit,excepttheresetbuttononthefront
ofthecasemustbepushedintoallowthemainburners
to operate again after a high limit shutdown.
Models are equipped with manual reset high limit.
Thetemperaturesettingisusuallyset30°to40°Fabove
theoperatingtemperature.
Fig.#9314
Manual Reset High Limit
28
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100% PILOT SAFETY (IID Units)
All heaters employ electronic devices, which close
themaingasvalvewithin8/10ofasecondwheneverthe
pilot flame is interrupted. Pilot flame is automatically lit
whenthedeviceispowered. Unitperformsitsownsafety
check and opens the main valve only after the pilot is
proven to be lit.
ELECTRICAL
Heater electrical characteristics are
Primary: 115 volt 60 Hz 1 phase.
Secondary: Control Circuit: 24 volts.
CAUTION: Allwirespriortodisconnectionwhenservic-
ing controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.
Single Stage Tankstat
NOTES:
1. Field Installed ground to inside of junction box.
2. If anyoftheoriginalwireassuppliedwiththeheater
must be replaced, it must be replaced with 105°C
wire or its equivalent.
DANGER-SHOCKHAZARD
makesureelectricalpowertotheheaterisdisconnected
to avoid potential serious injury or damage to compo-
nents.
The heater is normally wired for 120 Volts. The WARNING:
voltageisindicatedonthetie-inleads. Consultthewiring Beforestartingchecktoinsurepropervoltageissupplied
diagramshippedwiththeboilerintheinstructionpacket. to heater and pump.
The "TH" leads are for the remote tank control connec-
tions24Voltsaresuppliedtothisconnectionthroughthe Heatermustbeelectricallygroundedinaccordancewith
heater transformer. DO NOT attach line voltage to the the National Electrical Code ANSI/NFPA No 70 latest
"TH" leads on sized 133-1826. Before starting heater edition.
check to insure proper voltage to boiler and pump.
Use wiring diagram supplied with the heater.
START-UP
1. Fill system with water, flush, to remove particles
and other foreign objects that can cause pump
damage.
2. Check electric supply characteristics
a. Voltage to heater: 115 volts 60 Hz. 1 phase
15 amp circuit breaker.
b. Voltage to pump:
3. Set operating and limit controls.
ON-OFFOPERATION
Set storage tank tankstat to desired temperature.
This is the operating control. See Operation sequence,
page22.
Single Stage Tankstat
HEATERDPSTTANKSTATCONTROLWIRING
Heatermustbeelectricallygroundedinaccordance
with National Electrical Code ANSI/NFPA No. 70.
29
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General Safety Precautions
Tomeetcommercialwateruseneeds,thethermostaton The following chart details the relationship of water
this water heater is adjustable up to 210°F. However, temperatureandtimewithregardtoscaldinjuryandmay
watertemperaturesover125°F.cancausesevereburns be used as a guide in determining the safest water
instantly or death from scalds. This is the preferred temperatureforyourapplications.
startingpointforsettingthecontrolforsupplyinggeneral
purpose hot water.
Temperature
Time to Produce Serious Burn
More than 5 minutes
1-1/2 to 2 minutes
120°F.
Safetyandenergyconservationarefactorstobeconsid-
eredwhensettingthewatertemperatureonthethermo-
stat. Themostenergyefficientoperationwillresultwhen
the temperature setting is the lowest that satisfies the
needs consistent with the application.
125°F.
130°F.
About 30 seconds
135°F.
About 10 Seconds
140°F.
Less than 5 seconds
Less than 3 seconds
About 1-1/2 seconds
About 1 second
145°F.
150°F.
155°F.
TablecourtesyofShinersBurnInstitute
TIME/TEMPERATURERELATIONSHIPSINSCALDS
Thetemperatureofthewaterinthewaterheatercanbe
regulated by setting the temperature dial on front of the
thermostat. To comply with safety regulations the
thermostatwassetatitslowestsettingbeforethewater
heater was shipped from the factory. The illustration
below illustrates the thermostat and how to adjust the
watertemperature.
To adjust the water tem-
perature, insert a small
straight screwdriver into
slottedscrewinholeinfront
of thermostat and turn
wheel to desired setting.
Thermostatisadjustableup
to 210°F.
Water temperature over 125°F can
cause severe burns instantly or
death from scalds.
CAUTION!!-Hotterwater
increases the risk of
SCALDING!
Children, disabled and elderly are at
highest risk of being scalded.
See instruction manual before set-
ting temperature at water heater.
Feelwaterbeforebathingorshower-
ing.
!
DANGER
There is a Hot Water SCALD Potential if the thermostat
is set too high.
Temperature limiting valves are
available, see manual.
NOTE: When this water heater is supplying general
purposehotwaterrequirementsforusebyindividuals,a
thermostatically controlled mixing valve for reducing
Maximumwatertemperaturesoccurjustafterburnerhas point of use water temperature is recommended to
shut off. To find hot water temperature being delivered, reduce the risk of scald injury. Contact a licensed
turnonahotwaterfaucetandplaceathermometerinthe plumberorthelocalplumbingauthorityforfurtherinfor-
hot water stream and read the thermometer.
mation.
30
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LIGHTINGINSTRUCTIONSFORHEATERSWITHELECTRONICIGNITION(IID)
For Models with Manual Gas Valves 512, 627, 726
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING:If you do not follow these instructions exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
A. This appliance is equipped with an ignition device which
automatically lights the pilot. Do not try to light the pilot
by hand.
*
If you cannot reach your gas supplier, call the fire de-
partment.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or turn
by hand, do not try to repair it, call a qualified service
technician. Force or attempted repair may result in a fire
or explosion.
B. BEFORE OPERATING Smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
*
*
Do not try to light any appliance.
Do not touch any electric switch:
do not use any phone in your building.
Immediately call your gas supplier from your neighbor’s
phone. Follow the gas supplier’s instructions.
D. Do not use this appliance if any part has been under
water. Immediately call a qualified service technician to
inspect the appliance and to replace any part of the
control system and any gas control which has been
under water.
*
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above on this label.
2. Set the thermostat on the lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device which
automatically lights the pilot. Do not try to light the pilot
by hand.
For Honeywell Gas Valve: Turn gas control knob
counter clockwise from “OFF” until it
stops. Push in gas control knob and continue
rotating counter clockwise to “ON”
position. Make sure knob rest against stop.
5. Remove boiler door panel.
6. For Robertshaw gas valve: Turn gas control knob
GASCONTROL
KNOBSHOWN
IN"ON"POSITION
clockwise
to “OFF”.
For Honeywell Gas Valve: Turn gas control knob clock-
wise
stop.
to “OFF". Make sure knob rest against
GAS INLET
For Honeywell Gas Valve:
Push in gas control knob slightly and turn clockwise
Fig.#8082
to “OFF”. Knob cannot be turned to
“OFF”
unless knob is pushed in slightly. Do not force.
7. Wait five (5) minutes to clear out any gas. Then smell
for gas, including near the floor. If you smell gas, STOP!
Follow “B” in the safety information previously stated. If
you do not smell gas, go to the next step.
9. Replace boiler door panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the instructions
“To Turn Off Gas To Appliance” and call your service
technician or gas supplier.
8. For Robertshaw Gas Valve: Turn gas control knob
counter clockwise
to “ON”.
GASCONTROL
KNOBSHOWN
IN"ON"POSITION
GAS INLET
Fig.#8080
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to the lowest setting.
2. Turn off all the electric power to the appliance if service
is to be performed.
ForHoneywellGasValve: Turngascontrolknobclock-
wise
stop.
to “OFF”. Make sure knob rest against
3. Remove door panel.
4. For Robertshaw Gas Valve: Turn gas control knob
For HoneywellGasValve:
Push in gas control knob slightly and turn clockwise
to“OFF”.
clockwise
to “OFF”.
5. Replace heater door panel.
31
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LIGHTINGINSTRUCTIONSFORHEATERSWITH
ELECTRONICIGNITION(IID)
FOR MODELS WITH AUTOMATIC GAS VALVES
726-1826
1. Close all gas valves. Turn off electric power
supply. Wait five (5) minutes.
2. Openmanualpilotvalve. Turnonelectricpower.
Pilot is automatically lighted.
3. Openmaingasvalve.
4. Set temperature controls to desired temperature.
TOSHUTDOWN
Close all manual gas valves. Turn off electric
power.
TOPILOT(S)
PILOTSHUT-OFF
VALVECON
SHOWN IN
"ON"POSIT
MAINGASSHUT-OFF
VALVE SHOWN IN THE
"ON"POSITION
32
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INSPECTIONANDMAINTENANCEPROCEDURES
Six Months:
1. HeatExchangerSurfaces.
a. Shut off electric and gas supply to heater.
b. Examine external surfaces
2. Preliminary examination maybe done by using a
mirror and a light in the burner area.
3. Removeventing,heaterjackettop,fluecollectorand
heatexchangerbaffles.Removeinspectionbaffles.
c. If surfaces are sooted or foreign material is lodged
in fins, cleaning is required.
It is a good practice to make a periodic inspection of the
heater. Itisrecommendedthatthehomeowneroruser
checks the heater after the first and third month of
operation, and then on an annual basis, or more often if
desired. It is also recommended to have a qualified
service agency check the heater before each heating
season, or at anytime there may be an indication of a
problem.
1. Keep heater area free from combustibles and
flammableliquids.
To clean:
A. Removeburnertray.
2. Be certain that All combustion and ventilation air
openings are free and clear of all obstructions.
Screens, covering same, must be clean.
- Disconnect gas control valves and pilot valves by
breaking at unions.
- Disconnect wiring from gas valves.
- Remove burner tray retention screws.
-Slidetrayfromheatercarefullytoavoiddisturbing
ordamagingIID.
Monthly:
1. Make visual inspection of burner flames.
B. Removetubebundle.
-Disconnectinlet-outletheaderby removingflange
nuts and retaining bolts.
- Slide tube bundle away from inlet-outlet header,
taking care to avoid damage to refractory and
sheetmetal.
- Washdown external surfaces of tube bundle.
- Inspect interior surfaces of tubes. Clean deposits
over 1/16" thickness.
Fig.#8144
- Clean tubes using tube cleaning kit.
C. Ream tubes by using auger bit.
D. Complete cleaning by wire brushing to remove all
debris.
E. Immerse tube bundle in non-inhibited descale sol-
vent.
a. Flame should be blue with light yellow tips.
b. Yellow flame indicates clogged air openings.
c. Lifting of flame indicated high gas pressure.
Check using manometer at 1/8 in. NPT tapping
located between the gas valve and the burners.
Pressure should be 3.7 in. W.C.
NOTE: DO NOT wire brush external surfaces. Steam
cleaningisarecommendedprocedure.
2. Inspect and operate all controls and gas valves.
3. Visually inspect system for water leaks
F. Replace tube bundle using the reverse of the
aboveprocedures.
G. Beforereplacingburnertraycleanburners.
4. Flow switch should be removed and checked.
5. Lowwatercutout, ifprovided, shouldberemoved
and checked.
33
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DANGER: Keep heater area clear and free from com- 2. Venting System Inspection
bustibles and flammable materials. Do not obstruct the
Visuallyinspecttheventingsystem. Makesurethe
flow of combustion and ventilating air into the heater vent connections are secure and have not become
enclosure. Failure to observe these safety precautions disengaged. Look for any indication of corrosion, or
can cause fire, explosion, or asphyxiation.
carbon (soot) streaks which could cause leakage of
productsofcombustionintothelivingspace. Inspectthe
vent terminal outside the building. Make sure it is not
1. Burner Inspection
Clean the main burners and air louvers of dust, lint damagedtocauseblockageorrestrictionofthefluegas.
anddebris. Withburnerinoperation,makeavisualcheck Observeforanyindicationofsoot. Thepresenceofsoot
oftheburnerflameandthepilotflame(whenequipped). accummulation in the vent terminal would indicate an
Yellowflamesindicatesomerestrictionofcombustionair abnormal operating condition. This should be investi-
openings. Abrightorange,luminousflameisnotnormal gated and corrected by a qualified service agency.
and can cause sooting under prolonged operation. 3. Circulator (Water Pump) Inspection
Shouldthisconditionbeobserved, contactimmediately
a qualified service agency to correct the problem.
The circulator is permanently lubricated and thus,
will not require any lubrication. Inspect for evidence of
waterleakage. Thisshouldbecorrectedtopreventany
possibledamagetoelectricalcomponentsoftheboiler.
CAUTION: In case of a prolonged power failure during
freezing weather conditions, heater and piping system
mustbedrainedcompletelytoavoidpossibledamageto
the system.
To prevent the potential freezing damage to the
system, it is recommended that the following system
shutdownprocedurebeperformed.
SYSTEMSHUTDOWNPROCEDURE
1. Set the thermostat to "OFF" or the lowest setting.
2. Turn off all electric switches to the heater.
3. Turn off all gas valves supplying gas to the heater.
Refer to operating instruction label on the heater.
4. Shutoffthewatersupplytotheheaterpipingsystem
loop.
5. Opendrainvalveontheheatertoremovewater
from the heater and the piping circuits.
NOTE: It may be necessary to open the purge valves
and/ormanualairventstofacilitatecompletedrainageof
water from the heating system.
4. Service Assistance
If service is required on the heater, contact your
local service agency. It is important and very often will
save timeifyoustate themodelnumber, serialnumber
and type of gas used. This information will be found on
the nameplate of the heater.
Fig.#8204.1
34
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TROUBLE SHOOTING
PROBLEM
CAUSE
SOLUTION
Check pilot gas line.
When thermostat is turned on nothing IID Pilot is not lit….…………………….
happens.
No power to the heater…………………. Check the circuit breaker, outdoor con-
troller, etc., upstream of heater.
Bad
Trans- If power to Leads L1 and L2 of trans-
former, but no power on 24V side, re-
place.
former…………………………
Jumper thermostat , replace with new if
Inoperative thermostat………………… heater fires.
If power totoggleswitch,butnotthrough
Inoperative toggle switch……………… switch, replace.
If power to relay, but not operating, re-
Inoperativerelay………………………… place.
Thermostat in on position causes relay
Open"A"valve.
and pump to operate, but heater does "A" valve closed………………………… Loosen bleed line and clean.
not fire.
Plugged bleed line……………………… Low flow. Bleed air from the system.
Flow switch open………………………. Adjust bypass valve to allow proper flow
to activate the flow switch. If flow prob-
lem persists due to system design,
primary-secondary pumping should be
considered.
Replace coupler. Inspect bearing as-
Broken
pler……………………
pump
cou- sembly, and if frozen lubricate or re-
place.
Bleed air reset button.
Shut down on low water cutoff, caused Check for power to gas valve. If valve
byair……………………………………… has power but will not open, replace the
Gas valve defective…………………….
valve.
Continuous shut down of low water cut
off.
Inspect for leakage and repair.
Inspect for leakage and repair. Install
Low water due to leaking……………… an automatic air vent in top of low water
Air in system……………………………. cutoff.
35
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TROUBLE SHOOTING
Possible Cause
Action
Problem
1. Heater will not operate:
Electrical:
Check circuit breaker, fuses, etc.
Power at boiler control switch should
be 115 volts.
•
Main power
Check all controls. If reset is tripped
determine reason and correct.
Check power to all controls with
voltmeter. Adjust to desired operat-
ing temperatures.
•
•
Manual reset switch.
Operating controller.
Remove sensor. Check for immer-
sion or sensing.
Replace if faulty.
•
•
Controller in-operative.
Flow Switch
Check pump for operation.
Mechanical:
Open shutoff cock(s)
Loosen bleed line and clean.
•
•
Gas Line
Plugged bleedline on pressure
regulator, gas valves, etc.
Broken pump coupler.
Check reason for failure.
Inspect bearing assembly, shaft and
impeller.
•
Replace coupling.
Check bleed line. Clean. Check
solenoid. Replace if defective.
•
Gas valve will not open:
1. Diaphram type.
Check auxiliary switches.
a. Auxiliary switch;
2. Motorizedtype
b. Valve closed switch.
Power should be 115 volts.
Note: Actuator is not field repairable. If problem is other than switch(es)
replace.
2. Pilot burner will not light
3. Combination type
Check controller.
Intermittent Ignition Module
(IID)
Check power to 25 VAC input
terminal
1. If25 VAC:
- Check for 1/8" spark @ pilot.
a. Spark ok:
• Check gas supply.
• Burner orifice.
• Dampness @ electrode
or high tension wire.
• Check for 25 VAC @
PV; MV/PV terminals.
1. Voltage @ 25 VAC
- Replace pilot valve.
2. Voltage not @ 25 VAC
- Replace module.
2. No 25 VAC @ input terminal.
- Check transformer output.
a. 25 VAC
• Check limit circuit.
b. No 25 VAC
• Replace transformer.
36
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Electrical continued
3. Pilot lights -
Main burner cyles.
Intermittent Ignition Module
•
Poor ground connection
Check ground connection.
Install or replace.
Main burners do not light.
Check for spark
4. Pilot lights -
1. Spark stays on while pilot is on.
• Check for loose ignition wire.
• Check for poor ground.
• Check flame coverage of both
spark and grounded electrodes.
• If okay replace ignition module
2. Spark goes out and pilot stays on:
• Check voltage at MV; MV/PV
terminals.
- Voltage @ 24 VAC - replace
main gas valve.
- Voltage not at 24 VAC - replace
module.
Voltage should read 24 VAC.
If valve does not open:
1st operator - replace valve
2nd operator- replace operator
assembly.
3. Mechanical Modulating Valve.
4. Failure to pump.
Check dial setting on valve and set to
meet requirements.
Unit keeps cycling on electrical limits -
adjust temperature setting on valve.
Pump not primed.
Pump rotation wrong direction.
• Check motor leads- reverse
to obtain proper rotation.
Speed too low-
• Check for proper voltage at
motor.
Total head too high.
5. Pump capacity insufficient.
Check for
• Air leaks in suction line.
• Clogged impeller.
• Strainer clogged.
• Excessive suction lift.
• Insufficient positive suction
head.
Total head greater than design.
Worn impeller.
6. Rapid coupling wear.
7. Pump loses prime.
Misaligned or bent shaft,
Sagging motor mounts.
Check for air leaks.
Check water seal in stuffing box.
Check suction lift and pump design
curves.
8. Overload.
Check head on pump if too low
throttle discharge.
9. Mechanical noise.
Check alignment. Correct if found.
Check for vapor binding and reduce
temperature to meet design.
Check shaft and bearings.
Check piping for correct alignment
and support.
37
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ELECTRICAL (ELECTRONICIGNITIONIID)
MODELS512-1826
WARNINGHIGHVOLTAGE
ForqualifiedTechniciansONLY
C. TroubleshootingforS8600control.
Refer to the following chart for future
servicing or the ignition control.
NOTE: Some heaters may be equipped with an ignition module that
shutsoffpilotgasifpilotfailstolight. Toreset,interruptpowertoheater.
IntermittentPilotSystem
TROUBLESHOOTING HONEYWELL S8600
START
TURN GAS SUPPLY OFF.
TURNTHERMOSTAT
(CONTROLLER) TO CALL
FORHEAT
NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout
procedure.
Check line voltage power, low voltage transformer, limit controller,
thermostat (controller) and wiring.
NO
POWER TO MODULE
(24 V NOMINAL)
YES
Pull ignition lead and check spark at module.
SPARKACROSS
IGNITER/SENSORGAP
YES
NO
Spark Okay?
YES
• Check ignition cable, ground wiring, ceramic insulator and gap, and correct.
• Check boot of the ignition cable for signs of melting or buckling. Take protective
action to shield cable and boot from excessive temperatures.
TURN GAS SUPPLY ON
PILOT BURNER LIGHTS?
YES
• Check that all manual gas valves are open, supply tubing and pressures are
good, and pilot burner orifice is not blocked.
• Check electrical connections between module and pilot operator on gas control.
• Check for 24 Vac across PV-MV/PV terminals on module. If voltage is okay,
replace gas control; if not, replace module.
NO
NO
NOTE: If S8600H goes into lockout, reset system. Lockout is used on L.P.G. models.
SPARK STOPS WHEN
PILOT IS LIT?
YES
• Check continuity of ignition cable and ground wire.
• Clean flame rod.
• Check electrical connections between flame rod and module.
• Check for cracked ceramic flame rod insulator.
• Check that pilot flame covers flame rod and is steady and blue.
• Adjust pilot flame.
• If problem persists, replace module.
• Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module.
• Check electrical connections between module and gas control. If okay, replace
gas valve or gas control operator, i.e. pilot gas valve, flow switch etc.
NO
NO
MAIN BURNER LIGHTS?
YES
NOTE: IF S8600H goes into lockout, reset system.
• Check continuity of ignition cable and ground wire.
SYSTEM RUNS UNTIL
CALL FOR HEAT ENDS?
YES
NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though
operation is normal at the time of checkout.
• Check that pilot flame covers flame rod and is steady and blue.
• If checks are okay, replace module.
CALL FOR HEAT ENDS
SYSTEMSHUTSOFF?
YES
• Check for proper thermostat (controller) operation.
• Remove MV lead at module; if valve closes, recheck temperature controller and
wiring; if not, replace gas valve.
NO
TROUBLESHOOTING
ENDS
Repeat procedure until troublefree operation is obtained.
38
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WIRING DIAGRAM KEY
39
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WIRING DIAGRAMS
WIRING DIAGRAM - MODELS 136 -264 WITH ENERGY PUMP SAVING CONTROL
Fig.#2288e
40
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WIRING DIAGRAM - MODELS 331 - 399
Fig.#1930e
WIRING DIAGRAM MODELS 512 - 627
Fig.#1924e
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WIRINGDIAGRAMMODELS512-726
Fig.#2194e
WIRING DIAGRAM MODELS 726 - 825
Fig.#2297e
42
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WIRING DIAGRAM MODEL 825 - 1826
WIRING DIAGRAM MODELS 962 - 1826
Fig.#1967e
43
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REPLACEMENT PARTS LISTS
M
44
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MODEL136GBONLY
45
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MODELS 181, 264, 331, 399 GB
46
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47
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MODELS 181, 264, 331, 399 GB
48
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MODELS181, 264, 331,339GB
49
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MODELS 512, 627, 726, 825 GB
50
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MODELS 512, 627, 726, 825 GB
51
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MODELS 512, 627, 726, 825 GB
52
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MODELS926-1826GB
53
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MODELS926-1826GB
54
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MODELS926-1826GB
NOTE:
To supply the correct part it is important that you state the model number, serial number and type of gas.
Any part returned for replacement under standard company warranties must be properly tagged with the
return parts tag, completely filled in with the heater serial number, model number etc., and shipped to the
Companyfreightprepaid.
If determined defective by the Company and within warranty, the part will be returned in kind or equal
substitution, freight collect. Credit will not be issued.
55
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