Instruction Manual
resIdentIal Gas water heaters
power vent/power dIrect vent Gas Models
wIth hot surface IGnItIon
Ashland City, TN 37015
www.statewaterheaters.com
• for Your safety •
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
Thank you for buying this energy efficient water heater.
We appreciate your confidence in our products.
all technIcal and warrantY questIons: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, CALL THE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING.
Keep thIs Manual In the pocKet on heater for future reference
whenever MaIntenance adjustMent or servIce Is requIred.
PRINTED 0410
317447-000
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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,
will result in injury or death.
DANGER
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
WARNING
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION
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 Toxic 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
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General safetY InforMatIon
precautIons
hYdroGen Gas flaMMable
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER
WATER. Immediately call a qualified service agency to inspect the
appliance and to make a determination on what steps should be
taken next.
Explosion Hazard
If the unit is exposed to the following, do not operate heater until all
corrective steps have been made by a qualified service agency.
Flammable hydrogen gases
may be present.
1. External fire.
2. Damage.
Keep all ignition sources away
from faucet when turning on
hot water.
3. Firing without water.
GroundInG InstructIons
Hydrogen gas can be produced in a hot water system served by this
appliance 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 appliance 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.
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 the circuit conductors and connected to the
equipment grounding terminal or lead on the water heater.
verify the power to the water heater is turned off before performing any service procedures.
Read and understand this instruction
Explosion Hazard
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Overheated water can cause
water tank explosion.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
This manual must remain with the
water heater.
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
CAUTION
Improper installation, use and service may result
in property damage.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
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.
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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.
Refer to this manual for installation and service.
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General safetY InforMatIon
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General safetY InforMatIon
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.
Fire Hazard
For continued protection against
risk of fire:
Do not install water heater on
carpeted floor.
Do not operate water heater if
flood damaged.
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas
pressure.
Use only the gas shown on the water heater rating plate.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended
periods of non-use.
Fire and Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Use joint compound or Teflon tape
compatible with propane gas.
Leak test before placing the
water heater in operation.
Disconnect gas piping and main
gas shutoff valve before leak
testing.
Install sediment trap in
accordance with NFPA 54.
Breathing Hazard - Carbon Monoxide Gas
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Fire and Explosion Hazard
Do not use water heater with any gas
other than the gas shown on the rating
plate.
Excessive gas pressure to gas valve can
cause serious injury or death.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
CAUTION
Property Damage Hazard
All water heaters eventually leak.
•
•
Do not install without adequate drainage.
Jumping out control circuits or components can
result in property damage, personal injury or death.
Service should only be performed by a qualified service
agent using proper test equipment.
•
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.
Electrical Shock Hazard
Turn off power to the water heater
before performing any service.
•
Altering the water heater controls and/or wiring in any way
•
could result in altering the ignition sequence allowing gas to
flow to the main burner before the hot surface igniter is at
ignition temperature causing delayed ignition which can
cause a fire or explosion.
Label all wires prior to disconnecting
•
when performing service. Wiring errors
can cause improper and dangerous
operation.
Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the appliance warranty.
Verify proper operation after servicing.
•
•
Failure to follow these instructions can
result in personal injury or death.
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IntroductIon
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
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.
abbrevIatIons used
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.
Abbreviations found in this Instruction Manual include :
•
•
•
•
•
•
•
ANSI - American National Standards Institute
ASME - American Society of Mechanical Engineers
GAMA - Gas Appliance Manufacturer’s Association
NEC - National Electrical Code
NFPA - National Fire Protection Association
UL - Underwriters Laboratory
The principal components of the water heater are identified
in Features And Components on page 8 in this manual. Use
this reference to locate and identify various components on the
water heater.
CSA - Canadian Standards Association
qualIfIcatIons
See the Installation Checklist and Troubleshooting on page 50.
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.
qualIfIed Installer or servIce aGencY
Installation and service of this water heater requires ability
equivalent to that of a Qualified Agency (as defined by ANSI below)
in the 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.
note: Costs to correct installation errors are not covered under
the limited warranty.
2. 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.
ansI Z223.1 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.”
3. 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.
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.
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.
All documents are available from National Fire Protection
Association, 1 Batterymarch Park, Quincy, MA 02269.
IcoMM™ & bacnet coMpatIble
ThiswaterheateriscompatiblewiththeiCOMM™remotemonitoring
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.
4. If after reading this manual you have any questions or do
not understand any 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 plate.
The iCOMM™ system can automatically notify selected personnel
via email and/or cellular phone text messages if operational
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.
5. Carefully plan the placement of the water heater. Examine
the location to ensure that it complies with the requirements
in Locating The Water Heater on page 10 and the Rough In
Dimensions on page 9.
preparInG for the InstallatIon
.
6. For installation in California this water heater must be braced or
anchored to avoid falling or moving during an earthquake. See
instructions for correct installation procedures. Instructions may
be obtained from California Office of the State Architect, 1102 Q
Street, Suite 5100, Sacramento, CA 95811.
1. Read the entire manual before attempting to install or operate
the water heater. Pay close attention to the General Safety
Information on page 4 through 6. If you don’t 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.
7. Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5. See Commonwealth of Massachusetts
on page 22.
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features and coMponents
Get to Know Your water heater - Gas Models
a
b
c
d
e
f
G
h
I
control assembly
blocked Inlet switch
blocked outlet switch
fan prover switch
blower assembly
burner assembly
flame sensor
Z
t/p relief valve
M
display enclosure
**n exhaust elbow assembly
aa rating plate
bb labels
cc drain valve
**dd vent terminal
ee drain pan
ff anode
GG Insulation
hh upper temperature probe
II
**o condensate tubing
p
q
r
t
u
v
w
X
Y
off/on switch
display label
hot water outlet
Gas supply
Main Manual Gas shutoff valve
union
Inlet water shutoff valve
cold water Inlet
Inlet dip tube
hot surface Igniter
junction box
Gas valve assembly
display board
j
access door
K
l
top plastic enclosure
replaceMent parts and delIMInG products
Replacement parts and recommended delimer may be ordered through
authorized servicers or distributors. When ordering parts, provide complete
model and serial numbers (see rating plate), quantity and name of part
desired. Standard hardware items may be purchased locally.
access panel
caution: This access panel covers
a 2” NPT plug that was required
during the manufacturing of this
water heater. This 2” NPT flange is
not a cleanout fitting, removing the
2” NPTplug and using this fitting as a
cleanout could void your warranty.
vacuuM relIef
valve
*Install per
local codes
* cautIon harness has 120 vac. In operatIon.
** see “planning the vent system,” “Installation of vent system” and “condensate piping” for more information.
fIGure 1.
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InstallatIon consIderatIon
rouGh In dIMensIons
fIGure 1a.
rough-In-dimensions
Units
Inches 66.75 49.25 22.00 15.75
cm 169.5 125.09 55.88 40.00
A
B
C
D
E
F
3.00
7.62
8.00
20.32
top/side Inlet and outlet: 3/4” npt
Gas Inlet: 1/2” npt
capacity, Gas and electrical characteristics
Approximate Capacity
Manifold Pressure
Electrical Characteristics
U.S. Gals.
Liters Gas Type “WC
189 Nat./LP 0”
kPA
0”
Volts/Hz
Amperes
<5
50
120/60
Maximum supply pressure: 14 inches w.c. (3.48kpa)
Minimum supply pressure for natural Gas: 3.50” (.87kpa)
Minimum supply pressure for propane Gas: 8.00” (1.99kpa)
Minimum pressure must be maintained under both load and no load (dynamic and static) conditions.
recovery capacities - u.s. Gallons/hr. and liters/hr. at temperature rise Indicated
Input
Recovery Capacities
F
30
17
40
22
50
28
60
33
70
39
80
44
90
50
100
56
110
61
120
67
130
72
140
78
Rating
(Btu/hr)
Rating
(kW)
Temp.
Rise
C
GPH
LPH
387
291
233
882
194
734
166
628
145
549
129
488
116
439
106
401
97
90
83
100,000
29.3
1465 1102
367
341
314
Recovery capacity based on 96% thermal efficiency
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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 economical use of the appliance.
CAUTION
Property Damage Hazard
All water heaters eventually leak.
•
•
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
appliance.
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 14 for requirements.
8. Locate the water heater where an adequate supply of fresh air
for combustion and ventilation can be obtained. See Combustion
Air and Ventilation on page 11.
9. Locate the water heater where the vent and intake air piping,
when installed, will remain within the maximum equivalent
lengths allowed. See Venting on page 20.
10.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 starting on page 20.
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS
(VAPORS) ARE LIKELY TO BE PRESENT OR STORED
(GARAGES, STORAGE AND UTILITY AREAS, ETC.): Flammable
liquids (such as gasoline, solvents, propane (LP or butane, etc.) and
other substances (such as adhesives, etc.) emit flammable vapors
which can be ignited by a gas water heater’s hot surface igniter or
main burner. The resulting flashback and fire can cause death or
serious burns to anyone in the area.
This water heater must not be installed directly on carpeting.
Carpeting must be protected by metal or wood panel beneath the
appliance extending beyond the full width and depth of the appliance
by at least 3” (7.6 cm) in any direction, or if the appliance is installed
Also, the water heater must be located and/or protected so it is not
subject to physical damage by a moving vehicle.
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in an alcove or closet, the entire floor must be covered by the panel.
Failure to heed this warning may result in a fire hazard.
• 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 outer door, thermostat or temperature & pressure
relief valve.
• Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
• Do obtain new warning and instruction labels from the manufacturer
for placement on the blanket directly over the existing labels.
coMbustIon aIr and ventIlatIon
A gas water heater cannot operate properly without the correct
amount of air for combustion. Do not install in a confined area such
as a closet, unless you provide air as shown in the “Facts to Consider
About Location” section. 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 death, serious bodily injury, or
property damage.
Minimum clearances between the water heater and combustible
construction are 0 inch at the sides and rear, 5.5” (14.0 cm) from
the front and 18” (45.7 cm) from the top. (Standard clearance.) If
clearances stated on the heater differ from standard clearances, install
water heater according to clearances stated on the heater.
Adequate clearance 30” (76 cm) for servicing this appliance should be
considered before installation, such as changing the anodes, control
system components and gas valve.
A minimum clearance of 5.5” (14.0 cm) must be allowed for access to
replaceable and/or serviceable parts such as the thermostats, drain
valve, condensate drain, relief valve, clean out opening, and the vent
connection (exhaust elbow).
When installing the heater, consideration must be given to proper
location. Locationselectedshouldbeasclosetothewallaspracticable
and as centralized with the water piping system as possible.
fIGure 2.
InsulatIon blanKets
Insulation blankets are available to the general public for external use on
gaswaterheatersbutarenotnecessarywiththeseproducts.Thepurpose
of an insulation blanket is to reduce the standby heat loss encountered
with storage tank heaters. Your water heater meets or exceeds the
Energy PolicyAct standards with respect to insulation and standby loss
requirements, making an insulation blanket unnecessary.
fIGure 3.
If this 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
direct vent so that all air for combustion and ventilation is taken
from outdoors.
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions (For identification of components
mentioned below, see Figure 1). Failure to follow these instructions
can restrict the air flow required for proper combustion, potentially
resulting in fire, asphyxiation, serious personal injury or death.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorine based chemicals, refrigerants, etc.) in addition to being
highly flammable in many cases, will also react to form corrosive
hydrochloric acid when exposed to the combustion products of
the water heater. The results can be hazardous, and also cause
product failure.
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 appliances 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
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ventilation systems, clothes dryers and fireplaces shall also be
considered in determining the adequacy of a space to provide
combustion, ventilation and dilution air.
outdoor aIr throuGh two openInGs
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.
fIGure 4.
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 4.
dIrect vent applIances
Appliances installed in a Direct Vent configuration that derive all
air for combustion from the outdoor atmosphere 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.
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).
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.
outdoor aIr throuGh one openInG
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 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 louvers and grilles shall be fixed in the
open position.
fIGure 5.
Alternatively a single permanent opening, commencing within 12
inches (300 mm) of the top of the enclosure, shall be provided.
See Figure 5. The water heater shall have clearances of at
least 1 inch (25 mm) from the sides and back and 6 inches (l50
mm) from the front of the appliance. 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:
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
illustrationsforthepurposeofventinstallation.SeeventingInstallation
on page 20 for complete venting installation instructions.
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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
aIr froM other Indoor spaces
2. Not less than the sum of the areas of all vent connectors in the space.
outdoor aIr throuGh two horIZontal ducts
fIGure 7.
fIGure 6.
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 7.
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 6.
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 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.
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).
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.
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InstallInG the new water heater
cheMIcal vapor corrosIon
CORROSION OF THE FLUEWAYS AND vENT SYSTEM MAY
OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN
CHEMICAL vAPORS. SUCH CORROSION MAY RESULT IN
FAILURE AND RISk OF ASPHYXIATION.
Spray can propellants, cleaning solvents, refrigerator and air
conditioning refrigerants, swimming pool chemicals, calcium
and sodium chloride (water softener salt), waxes, and process
chemicals are typical compounds which are potentially
corrosive.
This water heater shall not be connected to any heating systems or
component(s) used with a non-potable water heating appliance.
All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
Do not store products of this sort near the heater. Also, air which is
brought in contact with the heater should not contain any of these
chemicals. If necessary, uncontaminated air should be obtained
from remote or outside 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).
Toxic chemicals, such as those used for boiler treatment shall not
be introduced into this system.
When the system requires water for space heating at temperatures
higher than required for domestic water purposes, a tempering
valve must be installed. Please refer to Figure 8 for suggested
piping arrangement.
water pIpInG
power supplY
The water heaters covered in this manual require a 120 VAC,
1Ø (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 National Electrical Code, ANSI/
NFPA 70.
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.
Ahigh 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.
HOTTER WATER CAN SCALD:
Water heaters are intended to produce hot water. Water heated
to a temperature which will satisfy space heating, clothes
washing, dish washing, cleaning and other sanitizing needs can
scald and permanently injure you upon contact. Some people
are more likely to be permanently injured by hot water than
others. These include the elderly, children, the physically or
developmentally disabled. If anyone using hot water fits into one
of these groups or if there is a local code or state law requiring
a certain temperature water at the hot water tap, then you must
take special precautions. In addition to using the lowest possible
temperature setting that satisfies your hot water needs, a means
such as a *mixing valve, should be used at the hot water taps
used by these people or at the water heater, see Figure 6. Valves
for reducing point of use temperature by mixing cold and hot
water are also available:
note: Malfunctions caused by the power supply and the costs
to install power supply filters are not covered under the limited
warranty.
dedIcated power wIrInG and breaKers
Dedicated power supply wires, ground wiring and dedicated
circuit breakers often prevent electrical line noise and should be
considered when installing the water heater.
polarItY sensItIve
The control system on the water heaters covered in this manual is
polarity sensitive; electronic flame sensing requires correct polarity.
The control system is programmed to monitor the incoming power
supply. If the Hot and Neutral wires in the 120 VAC power supply
are reversed, the control system will declare a Fault condition and
lock out, heating operation will be disabled until the power supply is
correctly wired. The control system will display the “AC Reversed”
Fault message on the LCD.
Consult
a
Qualified Installer or Service Agency. Follow
manufacturer’s instructions for installation of the valves.
Before changing the factory setting on the thermostat, read the
“Temperature Regulation” section in this manual.
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in improperly sanitized dishes. Where pressures are high, a water
pressure reducing or flow regulating control valve should be used in
the line to the dishwashing machine and should be adjusted to deliver
water pressure between these limits.
MIXInG valves
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
HOT WATER
OUTLET
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
12” TO 15”
(30-38 cm)
TEMPERED WATER
OUTLET
Feel water before bathing or
showering.
CHECK
VALVE
COLD
WATER
INLET
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
MIXING
VALVE
CHECK
VALVE
TO TANK
INLET
fIGure 8.
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).
space heatInG and potable water sYsteM
Your water heater is equipped with inlet/outlet connections for use in
space heating applications (see Figure 9). If this water heater is to be
used to supply both space heating and potable (drinking) water, the
instructions listed below must be followed:
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 1 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.
•
•
•
Be sure to follow the manual(s) shipped with the air handler or other
type heating system.
This water heater is not to be used as a replacement for an existing
boiler installation.
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.
Do not use with piping that has been treated with chromates, boiler
seal or other chemicals and do not add any chemicals to the water
heater piping
•
If the space heating system requires water temperatures in excess
of 120°F, a tempering valve (provided) must be installed per the
manufacturer’s instructions in the potable hot water supply to limit
the risk of scald injury.
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 1
•
•
Pumps, valves, piping and fi ttings must be compatible with potable
water.
Time to Produce 2nd & 3rd
Water Temperature
Degree Burns on Adult Skin
A properly installed flow control valve is required to prevent
thermosiphoning. Thermosiphoning is the result of a continuous
flow of water through the air handler circuit during the off cycle.
Weeping (blow off) of the temperature and pressure relief valve (T
& P) or higher than normal water temperatures are the fi rst signs
of thermosiphoning.
160°F (71°C)
150°F (66°C)
140°F (60°C)
130°F (54°C)
120°F (49°C)
About 1/2 second
About 1-1/2 seconds
Less than 5 seconds
About 30 seconds
More than 5 minutes
•
•
The hot water line from the water heater should be vertical past any
tempering valve or supply line to the heating system to remove air
bubbles from the system.
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
Do not connect the water heater to any system or components
previously used with non-potable water heating appliances when
used to supply potable water.
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fIGure 9.
closed water sYsteMs
fIGure 10.
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.
note: to protect against untimely corrosion of hot and cold
water fittings, it is strongly recommended that di-electric unions
or couplings be installed on this water heater when connected
to copper pipe, see figure 10 also.
Figures 9 and 10 show the typical attachment of the water piping to
the water heater. The water heater is equipped with 3/4 inch NPT
water connections.
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.
note: If using copper tubing, solder tubing to an adapter before
attaching the adapter to the water heater connections. do not
solder the water lines directly to the water heater connections.
It will harm the dip tube and damage the tank.
t & p valve and pipe Insulation (if supplied)
Remove insulation for T & P valve and pipe connections from
carton.
A properly sized thermal expansion tank should be installed
on all closed systems to control the harmful effects of thermal
expansion.
fIGure 11.
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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 suitable means, the water flow
may cause property damage.
Fit pipe insulation over the incoming cold water line and the hot
water line. Make sure that the insulation is against the top cover of
the heater.Fit T & P valve insulation over valve. Make sure that the
insulation does not interfere with the lever of the T & P valve.
Secure all insulation using tape.
teMperature-pressure relIef valve
CAUTION
Water Damage Hazard
Explosion Hazard
Temperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
•
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22-
CSA 4.4 and ASME code.
t&p valve dIscharGe pIpe requIreMents:
Properly sized temperature-
pressure relief valve must be
installed in opening provided.
•
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.
•
•
•
•
Can result in overheating and
excessive tank pressure.
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.
Can cause serious injury or death.
•
This water heater is provided with a properly rated/sized and
certified combination Temperature-Pressure Relief Valve (T&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 Z21.22 • CSA 4.4, and the code requirements of ASME.
•
Shall not have any valve or other obstruction between the relief
valve and the drain.
Burn hazard.
If replaced, the new T&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 plate.
Hot water discharge.
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 release 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: 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
Temperature-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.
note: The purpose of a Temperature-Pressure Relief Valve is to
prevent excessive temperatures and pressures in the storage tank.
The T&P valve is not intended for the constant relief of thermal
expansion.Aproperly sized thermal expansion tank must be installed
on all closed systems to control thermal expansion, see Closed
Water Systems and Thermal Expansion on pages 15 and 16.
If you 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.
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Consideration must be given to avoid freezing of the condensate
lines which could result in excessive build up of condensate inside
the water heater. Waterproof heat tape may be required to prevent
freezing of the condensate lines. Please ensure that the outlet of the
condensate drain does not create a slippery condition which could
lead to personal injury.
Gas pIpInG
Make sure gas supplied is same type listed on model rating plate.
The inlet gas pressure must not exceed 14 inch water column (3.5
kPa) for natural and propane gas (L.P.). The minimum inlet gas
pressure shown on rating plate is that which will permit firing at
rated input.
Allgaspipingmustcomplywithlocalcodesandordinancesorwiththe
National Fuel Gas Code (ANSI Z223.1/ NFPA-54). Copper or brass
tubing and fittings (except tin lined copper tubing) shall not be
used.
CONDENSATION WARNING: THIS WATER HEATER IS A
CONDENSING UNIT AND REQUIRES A DRAIN TO BE LOCATED
IN CLOSE PROXIMITY TO ALLOW CONDENSATE TO DRAIN
SAFELY. THE CONDENSATE DRAINS FROM UNIT AT THE
EXHAUST ELBOW LOCATED AT BOTTOM OF UNIT. NOTE:
IT IS IMPORTANT THAT THE CONDENSATE HOSE NOT BE
ELEvATED ABOvE THE EXHAUST ELBOW, SEE FIGURE 12.
CONDENSATE BUILD-UP WILL BLOCk THE EXHAUST OUTLET,
WHICH WILL CAUSE IMPROPER OPERATION.
If the gas control valve is subjected to pressures exceeding 1/2 psi
(3.5 kPa), the damage to the gas control valve could result in a fire
or explosion from leaking gas.
If the main gas line Shut-off serving all gas appliances is used, also
turn “off” the gas at each appliance. Leave all gas appliances shut
“off” until the water heater installation is complete.
A gas line of sufficient size must be run to the water heater.
Consult the current edition of National Fuel Gas Code
(ANSI Z223.1/NFPA 54) and your gas supplier concerning pipe
size.
There must be:
• A readily accessible manual shut off valve in the gas supply line
serving the water heater, and
fIGure 12
• A drip leg (sediment trap) ahead of the gas control valve to help
prevent dirt and foreign materials from entering the gas control
valve.
the condensate drain line must be routed to a suitable drain. If
no floor drain is available or the drain is above the level of the
condensate line, install a condensate pump that is resistant
to the acidic condensate. these pumps are available from
local distributors. If the pump is not resistant to acidic water,
a condensate neutralizer must be used ahead of the pump.
when installing the drain line, note the following:
• A flexible gas connector or a ground joint union between the shut
off valve and control valve to permit servicing of the unit.
Be sure to check all the gas piping for leaks before lighting the
water heater. Use a soapy water solution, not a match or open
flame. Rinse off soapy solution and wipe dry.
• Plastic pipe or tubing must be used to connect the condensate
drain to a suitable drain or condensate pump. Do not use copper
tubing, iron, or steel pipe for the condensate drain line.
• Condensate drain lines should be installed in conditioned
areas only. Drain lines installed in areas that are subject to
freezing temperatures should be wrapped with a nationally
recognized/listed heat tape and/or approved insulation for
freeze protection. Install per manufacturer’s instructions.
• Do not common drain with the temperature and pressure relief
valve or the condensate line from an air conditioner evaporator
coil.
condensate pIpInG
This water heater is a condensing unit and requires a drain to be
located in close proximity to allow the condensate to drain safely.
The condensate drains from the unit at the exhaust tee located at
the bottom of the unit (see figure 12). Condensate from this water
heater is mildly acidic. Please note that some local codes require
that condensate is treated by using a pH neutralizing filter prior to
disposal.
• Slope the condensate drain toward the inside floor drain or
condensate pump.
Caution must be used to ensure that the drain is free and clear of
debris and will not allow backflow through the condensate hose.
• The condensate drain line and connection to the drain piping
must comply with all local codes.
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hIGh altItude InstallatIons
sedIMent traps
A sediment trap shall be installed as close to the gas inlet of the
water heater as practical at the time of water heater installation.
The sediment trap shall be either a tee fitting with a capped nipple
in the bottom outlet or other device recognized as an effective
sediment trap.
This high efficiency water heater is certified for use without
modification for an altitude of 10,000 feet (3,079 meters). Consult
the factory for installation at altitudes over 10,100 feet (3,079m).
Contaminants in the gas lines may cause improper operation of
the gas control valve that may result in fire or explosion. Before
attaching the gas line be sure that all gas pipe is clean on the
inside. To trap any dirt or foreign material in the gas supply line, a
drip leg (sometimes called a sediment trap) must be incorporated
in the piping. The drip leg must be readily accessible. Install in
accordance with the “Gas Piping” section. Refer to the current
edition of the National Fuel Gas Code (ANSI Z223.1/NFPA 54).
Some gas utility companies derate their gas for altitude, making
it unnecessary to install high altitude orifices. Call the local gas or
utility company to verify BTU content.
Due to the input ration reduction at high altitudes, the output rating
of the appliance is also reduced and should be compensated for in
the sizing of the equipment for applications.
fIllInG the water heater
Never use this water heater unless it is completely full of water.
To prevent damage to the tank, the tank must be filled with water.
Water must flow from the hot water faucet before turning “ON” gas
to the water heater.
Use pipe joint compound or teflon tape marked as being resistant
to the action of petroleum [Propane (L.P.)] gases.
To fill the water heater with water:
1. Close the water heater drain valve by turning the handle to the
right (clockwise). The drain valve is on the lower front of the
water heater.
The appliance and its gas connection must be leak tested before
placing the appliance in operation.
The appliance and its individual Shut-off valve shall be disconnected
from the gas supply piping system during any pressure testing of
that system at test pressures in excess of 1/2 pound per square
inch (3.5 kPa). It shall be isolated from the gas supply piping system
by closing its individual manual Shut-off valve during any pressure
testing of the gas supply piping system at test pressures equal to
or less than 1/2 pound per square inch (3.5 kPa).
2. Open the cold water supply valve to the water heater.
note: the cold water supply valve must be left open when
the water heater is in use.
3. To insure complete filling of the tank, allow air to exit by opening
the nearest hot water faucet. Allow water to run until a constant
flow is obtained. This will let air out of the water heater and the
piping.
IMPORTANT: MAKE SURE THE GAS LINE IS PIPED IN WITH
HARD PIPE. AvOID FLEX LINE CONSTRUCTION FOR GAS DUE
TO POSSIBLE GAS FLOW PROBLEMS.
4. Check all water piping and connections for leaks. Repair as
needed.
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planned location of the vent terminal.
ventInG
1. Layout total vent system to use a minimum of vent pipe and elbows.
2. This water heater is capable of venting flue gases equivalent to
45’ (13.7 m) of 2” pipe, 128’ (39 m) of 3” pipe as listed in Table 2.
table 2
number of
90° elbows
2” Maximum
pipe - ft. (m)
40 (12.19)
35 (10.66)
30 (9.14)
25 (7.62)
20 (6.09)
15 (4.57)
3” Maximum
pipe - ft. (m)
120 (36.57)
115 (35.05)
110 (33.52)
105 (32)
1
2
3
4
5
6
100 (30.48)
95 (28.95)
The minimum vent length for each of the pipe size is one 90° plus
2’ (61 cm) of straight pipe and the appropriate termination.
note: The equivalent feet (m) of pipe listed above are exclusive
of the termination. That is, the termination, with an installed
screen, is assumed to be in the system and the remainder of
the system must not exceed the lengths discussed above.
3. The exhaust elbow assembly is designed to accept only straight
sections of 2” pipe. To start, a minimum 2” (5.1cm) maximum
6” long of 2” pipe must be inserted and glued to the exhaust
elbow assembly if utilizing 3” vent pipe. Use the same method
with the blower inlet if a direct vent configuration is utilized.
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.
If using 2” inch vent pipe:
A minimum of 2” (5.1cm) diameter vent pipe must be attached
to the exhaust elbow assembly. The total system cannot exceed
the lengths discussed above, where each elbow is equal to 5
equivalent feet (1.5m) of straight pipe.
vent pIpe terMInatIon
If using 3” inch vent pipe:
The first step is to determine where the vent pipe will terminate. See
Figures 15, 16, and 17. The vent may terminate through a sidewall
as shown in Figures 15 and 16 or through the roof as shown in
Figures 17 and 18.
Two inches (5.1cm) of 2” pipe must be attached to the exhaust
elbow assembly before adding a reducer to acquire the desired
pipe diameter. An appropriately sized 45 degree elbow (supplied
locally-a schedule 40 DWV) vent terminal must be obtained with
an equivalent screen (supplied in vent kit). The total system cannot
exceed the equivalent pipe lengths discussed above where each
elbow is equal to 5 feet (1.5m) of straight pipe (3” vent pipe).
The vent system must terminate so that proper clearances are
maintained as cited in local codes or the current edition of the
National Fuel Gas Code, (ANSI Z223.1). See Figures 13 and 14.
note: This unit can be vented with PVC pipe materials
(DWV ASTM-D2665 or CSA B181.2; Schedule 40, 80, 120
ASTM-D1785 or CSA B137.3; or SDR Series ASTM-D2241 or
CSA B137.3), CPVC pipe materials (CPVC41 ASTM-D2846
or CSA B137.6; Schedule 40, 80 ASTM-F441 or CSA B137.6;
or SDR Series ASTM-F442), ABS pipe materials (Schedule
40 DWV ASTM-D2661 or CSA B181.1. The fittings, other than
the TERMINATION should be equivalent to PVC-DWV fittings
meeting ASTM D-2665 (Use CPVC fittings, ASTM F-438 for
CPVC pipe and ABS fittings, ASTM D-2661/3311 for ABS pipe).
If CPVC or ABS pipe and fittings are used, then proper cement
must be used for all joints, including joining the pipe to Termination
(PVC Material). If local codes do not allow the use of the PVC
termination when a material other than PVC is used for venting,
then an equivalent fitting of that material may be substituted if
the screen in the PVC terminal is removed and inserted into the
new fitting.
Instructions on proper installation through a sidewall are provided
in Figures 15A, 15B, 15C, and 16.
Plan the vent system layout so that proper clearances are maintained
from plumbing and wiring.
Vent pipes serving power vented appliances are classified by
building codes as “vent connectors”. Required clearances from
combustible materials must be provided in accordance with
information in this manual under FACTS TO CONSIDER ABOUT
LOCATION and INSTALLING THE WATER HEATER, and with the
National Fuel Gas Code and local codes.
plannInG the vent sYsteM
Plan the route of the vent system from the exhaust elbow to the
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PVC Materials should use ASTM D-2564 Grade Cement; CPVC
Materials should use ASTM F-493 Grade Cement and ABS
Materials should use ASTM D-2235 Grade Cement.
If you are installing your system so that it vents through roof,
please refer to section titled INSTALLATION OF VERTICAL VENT
SYSTEM.
If the water heater is being installed as a replacement for an
existing power vented heater in pre-existing venting, a thorough
inspection of existing venting system must be performed prior
to any installation work. Verify that correct material as detailed
above has been used, and that the minimum or maximum vent
lengths and terminal location as detailed in this manual have been
met. Carefully inspect the entire venting system for any signs of
cracks or fractures, particularly at joints between elbows and
other fittings and straight runs of vent pipe. Check system for signs
of sagging or other stresses in joints as a result of misalignment
of any components in the system. If any of these conditions are
found, they must be corrected in accordance with the venting
instructions in this manual before completing installation and
putting the water heater into service.
vent terMInal InstallatIon, sIdewall
1. Install the vent terminal by using the cover plate as a template
to mark the hole for the vent pipe to pass through the wall.
BEWARE OF CONCEALED WIRING AND PIPING INSIDE THE
WALL.
2. If the Vent Terminal is being installed on the outside of a finished
wall, it may be easier to mark both the inside and outside wall.
Align the holes by drilling a hole through the center of the
template from the inside through to the outside. The template
can now be positioned on the outside wall using the drilled hole
as a centering point for the template.
3. A) MASONRY SIDE WALLS
note: For water heaters in locations with high ambient
temperatures (above 100°F) it is recommended that CPVC or
ABS pipe and fittings be used.
Chisel an opening approximately one half inch (1.3 cm) larger
than the marked circle.
B) WOODEN SIDE WALLS
4. All vent (exhaust) pipes must be pitched a minimum of a
1/4” per foot back to the water heater to allow drainage of
condensation.
Drill a pilot hole approximately one quarter inch (0.64 cm) outside
of the marked circle. This pilot hole is used as a starting point
for a saws-all or sabre saw blade. Cut around the marked circle
staying approximately one quarter inch (0.64 cm) outside of the
line. (This will allow the vent to easily slide through the opening.
The resulting gap will be covered up by the Vent Terminal cover
plate.) Repeat this step on inside wall if necessary.
InstallatIon of vent sYsteM
Before beginning installation of piping system thoroughly read the
section of this manual VENT PIPE PREPARATION.
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InstallatIon requIreMents - coMMonwealth of Massachusetts
observes carbon monoxide detectors and signage installed in
accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
coMMonwealth of Massachusetts
For all side wall terminated, horizontally vented power vent, direct
vent, and power direct vent gas fueled water heaters installed in
every dwelling, building or structure used in whole or in part for
residential purposes, including those owned or operated by the
Commonwealth and where the side wall exhaust vent termination
is less than seven (7) feet above finished grade in the area of the
venting, including but not limited to decks and porches, the following
requirements shall be satisfied:
eXeMptIons
The following equipment is exempt from 248 CMR 5.08(2)(a)1
through 4:
1. The equipment listed in Chapter 10 entitled “Equipment Not
Required To Be Vented” in the most current edition of NFPA 54
as adopted by the Board; and
InstallatIon of carbon MonoXIde detectors
2. Product Approved side wall horizontally vented gas fueled
equipment installed in a room or structure separate from the
dwelling, building, or structure used in whole or in part for
residential purposes.
At the time of installation of the side wall horizontal vented gas
fueled equipment, the installing plumber or gasfitter shall observe
that a hard wired carbon monoxide detector with an alarm and
battery back-up is installed on the floor level where the gas
equipment is to be installed. In addition, the installing plumber or
gasfitter shall observe that a battery operated or hard wired carbon
monoxide detector with an alarm is installed on each additional
level of the dwelling, building or structure served by the sidewall
horizontal vented gas fueled equipment. It shall be the responsibility
of the property owner to secure the services of qualified licensed
professionals for the installation of hard wired carbon monoxide
detectors.
Manufacturer requIreMents - Gas
equIpMent ventInG sYsteM provIded
When the manufacturer of Product Approved side wall horizontally
vented gas equipment provides a venting system design or venting
system components with the equipment, the instructions provided
by the manufacturer for installation of the equipment and the
venting system shall include:
In the event that the side wall horizontally vented gas fueled
equipment is installed in a crawl space or an attic, the hard wired
carbon monoxide detector with alarm and battery back-up may be
installed on the next adjacent floor level.
1. Detailed instructions for the installation of the venting system
design or the venting system components; and
2. A complete parts list for the venting system design or venting
system.
In the event that the requirements of this subdivision can not be
met at the time of completion of installation, the owner shall have
a period of thirty (30) days to comply with the above requirements
provided that during said thirty (30) day period, a battery operated
carbon monoxide detector with an alarm shall be installed.
Manufacturer requIreMents - Gas
equIpMent ventInG sYsteM not provIded
WhenthemanufacturerofaProductApprovedsidewallhorizontally
vented gas fueled equipment does not provide the parts for
venting the flue gases, but identifies “special venting systems,” the
following requirements shall be satisfied by the manufacturer:
approved carbon MonoXIde detectors
Each carbon monoxide detector as required in accordance with
the above provisions shall comply with NFPA 720 and be ANSI/UL
2034 listed and CSA certified.
1. The referenced “special venting system” instructions shall
be included with the appliance or equipment installation
instructions; and
sIGnaGe
2. The “special venting systems” shall be Product Approved by the
Board, and the instructions for that system shall include a parts
list and detailed installation instructions.
A metal or plastic identification plate shall be permanently mounted
to the exterior of the building at a minimum height of eight (8) feet
above grade directly in line with the exhaust vent terminal for the
horizontally vented gas fueled heating appliance or equipment.
The sign shall read, in print size no less than one-half (1/2) inch
in size, “Gas vent dIrectlY below. Keep clear of all
obstructIons.”Inspection The state or local gas inspector of
the side wall horizontally vented gas fueled equipment shall not
approve the installation unless, upon inspection, the inspector
A copy of all installation instructions for all Product Approved
side wall horizontally vented gas fueled equipment, all venting
instructions, all parts lists for venting instructions, and/or all
venting design instructions shall remain with the appliance or
equipment at the completion of the installation.
22
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terMInatIon clearances sIdewall power vent
POWER VENT
(using room air for combustion)
EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION
G
V
H
D
A
E
v
L
B
v
B
B
B
V
C
B
D
E
X
I
F
E
D
CLOSED
E
X
I
OPERABL
F
V
M
V
V
X
CLOSED
V
E
X
OPERABL
V
F
B
K
J
A
VENT TERMINAL
AIR SUPPLY INLET
AREA WHERE TERMINAL IS NOT PERMITTED
V
X
fIGure 13
Vent terminal clearances for “Power Vent” installations. Power Vent configurations use room air for combustion.
1
1
us InstallatIons
us InstallatIons
Clearance to each side 3 feet (91 cm) within a
of center line extended height 15 feet (4.5 m)
Clearance above grade,
veranda, porch, deck or 12 inches (30 cm)
balcony
a
h
I
above meter/regulator
assembly
above the meter/regulator
assembly*
4 feet (1.2 m) below
Clearance to window
or to side of opening;
or door that may be
1 foot (30 cm) above
opened
Clearance to service
regulator vent outlet
3 feet (91 cm)*
b
opening
Clearance to a non
mechanical air supply
inlet into building or
combustion air inlet to
any other appliance
4 feet (1.2 m) below or to
side of opening; 1 foot
(30 cm) above opening.
Clearance to
permanently closed
window
12 inches (30 cm)*
c
j
Vertical clearance to
ventilated soffit located
above the terminal
within a horizontal
distance of 2 feet (61
cm) from the center line
of the terminal
3 feet (91 cm) above if
within
10 feet (3 m) horizontally
Clearance to a
mechanical air supply
inlet
12 inches (30 cm)*
12 inches (30 cm)*
d
e
K
Clearance above paved
sidewalk or paved
driveway located on
public property
Clearance to
unventilated soffit
7 feet (2.13 m)
l
Clearance under
veranda, porch, deck, or 12 inches (30 cm) ‡
balcony
Clearance to outside
corner
2 feet (60 cm)*
f
M
Clearance to inside
corner
18 inches (45 cm)*
G
1 In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.
23
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terMInatIon clearances sIdewall dIrect vent
DIRECT VENT
(using outdoor air for combustion)
EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION
G
V
H
D
A
E
v
L
B
v
B
B
B
V
C
B
D
E
X
I
F
E
D
CLOSED
E
X
I
OPERABL
F
V
M
V
V
X
CLOSED
V
E
X
OPERABL
V
F
B
K
J
A
VENT TERMINAL
AIR SUPPLY INLET
AREA WHERE TERMINAL IS NOT PERMITTED
V
X
fIGure 14
Vent terminal clearances for “Direct Vent” installations. Direct Vent configurations use outdoor air for combustion.
1
1
us InstallatIons
us InstallatIons
Clearance to each side
of center line extended
above meter/regulator
assembly
Clearance above grade,
veranda, porch, deck or 12 inches (30 cm)
balcony
3 feet (91 cm) within a height
15 feet (4.5 m) above the
meter/regulator assembly*
a
h
I
6 inches (15 cm)
for appliances up to
10,000 Btu/hr (3 kW),
9 inches (23 cm) for
Clearance to window or
door that may be opened 10,000 Btu/hr (3 kW)
and 50,000 Btu/hr (15
appliances between
Clearance to service
regulator vent outlet
3 feet (91 cm)*
b
kW), 12 inches (30 cm)
for appliances above
50,000 Btu/hr (15 kW)
6 inches (15 cm) for
appliances up to 10,000
Btu/hr (3 kW), 9 inches (23
cm) for appliances between
10,000 Btu/hr (3 kW) and
50,000 Btu/hr (15 kW), 12
inches (30 cm) for appliances
above 50,000 Btu/hr (15 kW)
Clearance to a non
mechanical air supply
inlet into building or
combustion air inlet to
any other appliance
Clearance to
permanently closed
window
6 inches (15 cm)*
c
j
Vertical clearance to
ventilated soffit located
above the terminal within
a horizontal distance of
2 feet (61 cm) from the
center line of the terminal
Clearance to a
mechanical air supply
inlet
3 feet (91 cm) above if within
10 feet (3 m) horizontally
12 inches (30 cm)*
12 inches (30 cm)*
d
e
K
Clearance above
Clearance to unventilated
soffit
paved sidewalk or
paved driveway located
on public property
7 feet (2.13 m)†*
l
Clearance under
veranda, porch, deck,
or balcony
Clearance to outside
corner
2 feet (60 cm)*
12 inches (30 cm) ‡*
f
M
Clearance to inside
corner
18 inches (45 cm)*
G
1 In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.
24
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sequence of InstallatIons, fIGure 15a
InstallatIon sequence
Cut a length of PVC pipe about 3.5 inches (8.9 cm) longer than the
wall thickness at the opening. Glue the vent terminal to this section of
pipe. Slidethewallplateoverthepipetostopagainsttheventterminal.
Place a bead of caulking (not supplied) around the gap between the
pipe and cover plate. Apply enough to fill some of the gap between
the pipe and wall. Place some of the caulking on the back of the plate
to hold it against the wall after installation. If the vent pipe is installed
up to the wall, with a coupling on the end against the wall opening, the
pipe with the vent terminal can be prepared for gluing before inserting
through the wall. Slide the pipe through the wall and insert into the
couplingontheothersideofthewall, makingsurethattheventterminal
ends up pointed in the correct position, see Figure 15A.
vent terMInals supplIed wIth heater Must be used.
NOTE: BEFORE BEGINNING INSTALLATION OF ANY
VENT PIPE READ THE VENT PIPE MANUFACTURER’S
INSTALLATION INSTRUCTIONS.
1. After the points of termination have been determined,
use the cover plates as templates to mark the holes for
the vent pipes to be inserted through the wall. BEWARE OF
CONCEALED WIRING AND PIPING INSIDE OF WALL. If the
vent terminals are being installed on the outside of a finished
wall, it may be easier to mark both the inside and outside
wall. Align the holesby drilling a hole through the center of the
template from the inside through to the outside. The template
can now be positioned on the outside wall using the drilled holes
as a centering point for the template.
A.) MASONRY SIDE WALLS Chisel an opening approximately
1/2” (1.3 cm) larger than the marked circle.
B.) WOODEN SIDE WALLS Drill a pilot hole approximately
one quarter inch outside of the marked circle. This
pilot hole is used as a starting point for a saws-all or
sabre saw blade. Cut around the marked circle staying
approximately one quarter inch outside of the line.
(This will allow the vent pipe to easily slide through
the opening. The resulting gap will be covered by the
vent terminal cover plates.) Repeat this step on the
inside wall if necessary.
vent terMInatIon - fIGure 15a
dIrect vent terMInal InstallatIon
The air intake provided on the unit contains a mesh screen to prevent
large particles from entering the unit.
2. Cut a length of 3” PVC pipe about 3.5” (8.9 cm) longer than the
wall thickness at the opening.
3. Glue the intake vent terminal to the section of the pipe.
4. Slide the wall plate over pipe to stop against intake vent terminal.
5. Place a bead of caulking (not supplied) around the gap between
the pipe and the wall. Place some of the caulking on the
back of the plate to hold it against the wall after installation.
6. If the vent pipe is installed up to the wall, with a coupling on the
end against the wall opening, the pipe with the vent terminal can
be prepared for gluing before inserting through the wall. Slide the
pipe through the wall and insert into coupling on the other side of
the wall, making sure that the vent terminal ends up pointed in the
correct position (Figure 15C and 16).
fIGure 15b
WHEN THE UNIT IS TO BE SETUP AS A DIRECT vENT, THE
MESH SCREEN MUST BE REMOvED. THE INLET vENT PIPE
MAY THEN BE GLUED TO THE AIR INTAKE (See Figure 15B)
PROvIDED ON THE UNIT.
THIS UNIT CONSISTS OF TWO vENT TERMINALS - AN INTAkE
vENTTERMINALANDAN EXHAUST vENTTERMINAL. THE INTAkE
VENT TERMINAL IS A 2” 90° PVC ELBOW(-) WITH A MESH WIRE
SCREEN AND THE EXHAUST VENT TERMINAL IS A 2” 22.5° PVC
COUPLING WITH A MESH WIRE SCREEN.
NOTE: TO PREVENT EXHAUSTING PRODUCTS FROM
CIRCULATING TO THE AIR INTAkE IN WINDY/COLD AREAS,
THE MAXIMUM PRACTICAL DISTANCE BETWEEN THESE TWO
TERMINALS IS RECOMMENDED.
fIGure 15c
fIGure 16
25
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vertIcal vent terMInal InstallatIon
when terMInatInG throuGh a roof, the followInG
specIfIcatIons pertaInInG to terMInal locatIon
Must be followed.
1. Proper support must be provided for all pipe protruding through
the roof.
2. The vertical roof terminations should be sealed with a plumbing
roof boot or equivalent flashing.
3. The intake vent termination and the exhaust vent termination
must penetrate the same side of roof.
fIGure 18.
4. The center line of the intake vent termination and the center
line of the exhaust vent termination must be no closer than 24”
(61cm).
IF LESS THAN
10 FEET (3 m)
The specifications are displayed in Figures 17 and 18.
NOTE: Exhaust vent terminal is installed using the same procedure.
flat roof InstallatIon
NOTE:
INTAKE VENT
TERMINATION
SHOWN HERE
24 INCHES (60 cm)
MINIMUM HEIGHT ABOVE
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 19.
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 19.
fIGure 17.
26
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concentrIc vent InstallatIon
1. Determine best location for termination kit.
This appliance is certified for concentric venting with concentric vent note: roof termination is preferred since it is less
kit #9003910105 and #9006328005. Follow instructions below for susceptible to damage, has reduced chances to intake
proper installations.
contaminants, and less visible vent vapors.
2. Cut 1 hole (5 in. diameter)
KIt coMponents
Each kit is comprised of the following:
3. Partially assemble concentric vent termination kit.
Item
Rain Cap
SDR-26 pipe
SDR-26 pipe
Y Concentric Fitting
Installation Instructions
Description
3 in.
4 in. dia.
2½ in. dia.
3 in.
Qty.
1
1
1
1
a) Cement Y concentric fitting to larger diameter kit
pipe, see Figure 20.
b) Cement rain cap to smaller diameter kit pipe, see Figure 22.
194504
1
Field supplied pipe and fittings are required to complete the
installation.
This concentric vent termination kit may be used with 3 inch diameter
pipe systems.
safetY consIderatIons
fIGure 22.
Installing and servicing water heating equipment can be hazardous
due to gas and electrical components. Installation and service of
the concentric vent termination requires ability equivalent to that
of a qualified installer or service agent, see page 7. All precautions
in the literature, on tags, and labels attached to the unit must be
observed.
note: Instead of cementing the smaller pipe to the rain cap,
a field-supplied stainless steel screw may be used to secure
the 2 components together when field disassembly is desired
for cleaning, see figure 22.
when using alternate screw method, drill clearance hole in
rain cap and pilot hole in vent pipe for screw size being used.
failure to drill adequate holes may cause cracking of pvc
components, allowing combustion products to be recirculated.
failure to follow this warning could result in personal injury
or death.
Follow all safety codes. Wear safety glasses and work gloves.
do not operate the heater with rain cap removed or
recirculation of combustion products may occur. water may
also collect inside larger combustion-air pipe and flow to
the burner enclosure. failure to follow this warning could
result in product damage or improper operation, personal
injury or death.
fIGure 20.
4. Install Y concentric fitting and pipe assembly through
structure’s hole and field supplied roof boot/flashing.
fIGure 21.
*
dimension 21 1/8 in. may be lengthened to 60 in. maximum.
dimension 21 1/8 in. may also be shortened by cutting the
pipes, provided in the kit, to 12 in. minimum.
** dimension 39 will change accordingly as dimension
21 1/8 in. is lengthened or shortened.
Do not use field-supplied couplings to extend pipes. Airflow
restriction will occur and the heater pressure switch may cause
intermittent operation.
fIGure 23.
InstallatIon procedure 1 roof terMInatIon, see
note: do not allow insulation or other materials to accumulate
figure 23.
inside pipe assembly when installing through hole.
27
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5. Secure assembly to roof structure as shown in Figure 23
using field supplied metal strapping or equivalent support
material.
note: ensure termination height is above the roof surface
or anticipated snow level as shown in figure 23.
6. Install rain cap and small diameter pipe assembly in
roof penetration assembly, Ensure small diameter
pipe is cemented and bottomed in Y concentric fitting.
7. Cement water heater combustion air intake and vent pipes to
concentric vent termination assembly. See Figure 23 for
proper pipe attachment.
fIGure 24.
8. Operate heater through 1 heat cycle to ensure combustion
air and vent pipes are properly connected to concentric vent
termination connections.
1. Determine best location for termination kit.
NOTE: Consideration for the following should be used when
determining an appropriate location for the termination kit:
flat roof InstallatIon
•
•
Termination kit positioned where the vent vapors will not damage
plants/shrubs or air conditioning equipment.
Termination kit positioned so it will not be affected by wind eddy
that may allow recirculation of combustion products, or airborne
leaves, or light snow.
Termination kit positioned where it will not get damaged or be
subjected to foreign objects, such as stones, balls, etc.
Termination kit positioned where the vent vapors will not be
objectionable.
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 23A.
•
•
If this required 10 foot (3 m) distance to a parapet, vertical wall
or structure cannot be maintained, standard terminations must
be used. See Vertical Termination Installation.
note: see the venting information (starting on page 20) in
this manual for additional vent location requirements.
2. Cut 1 hole (5 in. diameter)
3. Partially assemble concentric vent termination kit.
a) Cement the Y concentric fitting to larger diameter
kit pipe, see Figure 19.
b) Cement the rain cap to the smaller diameter kit
pipe, see Figure 22.
CONCENTRIC TERMINATION(S)
MUST BE A MINIMUM OF 10 FEET
(3 m) AWAY FROM ANY PARAPET,
VERTICAL WALL OR
note: Instead of cementing the smaller pipe to the rain cap, a
field-supplied stainless steel screw may be used to secure the
2 components together when field disassembly is desired for
cleaning, see figure 22.
STRUCTURE.
when using alternate screw assembly method, drill clearance
hole in rain cap and pilot hole in vent pipe for screw being
used. failure to drill adequate holes may cause cracking of pvc
components, allowing combustion products to be recirculated.
failure to follow this warning could result in personal injury
or death.
do not operate the heater with rain cap removed or
recirculation of combustion products may occur. water may
also collect inside larger combustion-air pipe and flow to the
burner enclosure. failure to follow this warning could result
in product damage or improper operation, personal injury
or death.
CONCENTRIC TERMINATION
FLAT ROOF CLEARANCE
4. Install Y concentric fitting and pipe assembly through
structure’s hole.
fIGure 23a.
note: do not allow insulation or other materials to accumulate
inside pipe assembly when installing through hole.
procedure 2 sIde wall terMInatIon, see fIGure 24.
28
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5. Install rain cap and small diameter pipe assembly in Y concentric
fitting and large pipe assembly. Ensure small diameter pipe is
bottomed and cemented in Y concentric fitting.
MultI-concentrIc vent terMInatIons
When two or more appliances are direct vented with concentric
vent terminations near each other, each appliance must be
individually vented. NEVER common vent this appliance. When
two or more appliances are direct vented using concentric vent
terminations, the appliances may be vented as shown in Figure
26 and 27.
6. Secure assembly to structure as shown in Figure 24 using field-
supplied metal strapping or equivalent support material.
note: ensure termination location clearance dimensions are
as shown in the diagrams found in figure 24 and 25. when
extending the length of the 4” pipe, the added length beyond
21-1/8” must be deducted from the maximum equivalent feet
of vent pipe.
note: If assembly needs to be extended to allow side wall
thickness requirement, the 2 pipes supplied in the kit may be
replaced by using same diameter, field-supplied SDR-26 PVC
(d2241) pipe. do not extend 21 1/8” dimension more than 60 in.
(see figure 20.)
Do not use field-supplied couplings to extend pipes. Airflow
restriction will occur and the heater pressure switch may cause
intermittent operation.
7. Cement heater combustion-air and vent pipes to concentric vent
termination assembly. See Figure 25 for proper pipe attachment.
8. Operate heater through 1 heat cycle to ensure combustion-air and
vent pipes are properly connected to concentric vent termination
connections.
fIGure 26.
Concentric Vent Terminations
for Horizontal Direct Venting.
fIGure 27.
Concentric Vent Terminations for Vertical
Direct Venting through a roof.
fIGure 25.
29
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dIrect vent dIaGraM
12” MINIMUM CLEARANCE
ABOVE HIGHEST ANTICIPATED
SNOW LEVEL
12” MINIMUM CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL
fIGure 28.
fIGure 29.
24” MINIMUM SEPARATION. EXHAUST
MUST BE AT SAME LEVEL OR ABOVE
INTAKE TERMINAL.
fIGure 30.
fIGure 31.
When direct venting through the wall, as shown in Figure 32, the
exhaust should terminate a minimum of 24” from the air intake. The
exhaust may be rotated up to 45 degrees left or right as long as the
24” distance is maintained.
The air intake screen can be removed for space heating at cold climate
installation to prevent potential air intake freeze up. If air intake screen
is removed during winter to prevent freezing it is recommended to re-
install the screen during non-space heating seasons.
If necessary to achieve the 12” minimum clearance above the highest
anticipated snow level or grade for the air intake install a snorkel,
similar to the exhaust, in the up position. Maintain the 24” distance
between the intake and exhaust terminations.
Optional cold climate sidewall direct vent kits are available: 318221-
000 for 2” vent systems and 318222-000 for 3” vent systems.
fIGure 32.
30
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prIMer
vent pIpe preparatIon
It is recommended that Tetrahydrofuran (THF) be used to prepare the
surfaces of pipe and fittings for solvent welding. Do not use water,
rags, gasoline or any other substitutes for cleaning PVC or CPVC
surfaces. A chemical cleaner such as MEK may be used.
1. InItIal preparatIon.
A.) Make sure the solvent cement you are planning to use is
designed for the specific application you are attempting.
B.) Know the physical and chemical characteristics and
limitations of the PVC and CPVC piping materials that you
are about to use.
prIMer and ceMent
Tetrahydrofuran (THF) primer should be used to prepare the surfaces
of pipe and fittings for solvent welding. If CPVC or ABS pipe and
fittings are used, then the proper cement must be used for all joints,
including joining the pipe 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 and ABS
Materials should use ASTM D-2235 Grade Cement.
C.) Know the reputation of your manufacturer and their products.
D.) Know your own qualifications or those of your contractor.
The solvent welding technique of joining PVC and CPVC pipe
is a specialized skill just as any other pipe fitting technique.
E.) Closely supervise the installation and inspect the finished
job before start-up.
F.) Contact the manufacturer, supplier, or competent consulting
agency if you have any questions about the application or
installation of PVC and CPVC pipe.
G.) Take the time and effort to do a professional job. Shortcuts will only
cause you problems and delays in start-up. By far, the majority of
failures in PVC and CPVC systems are the result of shortcuts and/or
improper joining techniques.
applIcators
2. selectIon of MaterIals.
Select a suitable pure bristle type paint brush. Use a proper width brush
or roller to apply the primer and cement (see chart below). Speedy
application of cement is important due to its fast drying characteristics.
IMPORTANT NOTE: A dauber type applicator should only be used
on pipe sizes 2” and below. For larger diameter pipe, a brush or roller
must be used.
Cutting Device - Saw or Pipe Cutter.
•
Deburring Tool, Knife, File, or Beveling Machine (2” and above).
•
Brush - Pure Bristle.
•
Rag - Cotton (Not Synthetic).
•
recoMMended brush* sIZe for prIMer
Primer and Cleaner.
and ceMent applIcatIons
•
Nominal Pipe (IPS)
Size Brush Width
1.5” (3.8cm)
Solvent Cement - PVC for PVC Components and CPVC for
CPVC Components.
•
2
3
1.5”-2.5” (3.8cm - 6.4cm)
Containers - Metal or Glass to hold Primer and Cement. Select the
•
type of PVC or CPVC materials to be used on the basis of their
application with respect to chemical resistance, pressure rating,
temperature characteristics, etc.
*use onlY natural brIstle
3. MaKInG the joInt.
Insertion Tool - Helpful for larger diameter pipe and fittings 6 inches
(15.2cm) and above.
•
A.) Cutting Pipe must be squarely cut to allow for the proper
interfacing of the pipe end and the fitting socket bottom. This
can be accomplished with a miter box saw or wheel type cutter
Wheel type cutters are not generally recommended for larger
diameters since they tend to flare the corner of the pipe end. If
this type of cutter is used, the flare on the end must be
completely removed.
NOTE: Power saws should be specifically designed to cut plastic pipe.
step a
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b. deburring
Use a knife, plastic pipe deburring tool, or file to remove burrs from
the end of small diameter pipe. Be sure to remove all burrs from
around the inside as well as the outside of the pipe. A slight chamfer
(bevel) of about 10°-15° should be added to the end to permit easier
insertion of the pipe into the end of the fitting. Failure to chamfer the
edge of the pipe may remove cement from the fitting socket, causing
the joint to leak.
step b
C. Test dry fit of the joint
step e
Tapered fitting sockets are designed so that an interfaced fit should
occur when the pipe is inserted about 1/3 to 2/3 of the way into the
socket.Occasionally,whenpipefittingdimensionsareatthetolerance
extremes, it will be possible to fully insert dry pipe to the bottom of
the fitting socket. When this happens, a sufficient quantity of cement
must be applied to the joint to fill the gap between the pipe and fitting.
The gap must be filled to obtain a strong, leak-free joint.
f. joint assembly
Working quickly, insert the pipe into the fitting socket bottom and
give the pipe or fitting a 1/4 turn to evenly distribute the cement.
Do not continue to rotate the pipe after it has hit the bottom of the
fitting socket. A good joint will have sufficient cement to make a
bead all the way around the outside of the fitting hub. The fitting
will have a tendency to slide back while the cement is still wet
so hold the joint together for about 15 seconds.
d. Inspection, cleaning, priming
Visually inspect the inside of the pipe and fitting sockets and
remove all dirt, grease or moisture with a clean dry rag. If wiping
fails to clean the surfaces, a chemical cleaner must be used.
Check for possible damage such as splits or cracks and replace
if necessary.
depth-of-entry
Marking the depth of entry is a way to check if the pipe has
reached the bottom of the fitting socket in Step F. Measure
the fitting depth and mark this distance on the pipe O.D. You
may want to add several inches to the distance and make a
second mark as the primer and cement will most likely destroy
your first one.
step f
G. cleanup and joint movement
Remove all excess cement from around the pipe and fitting with a
dry cotton rag. This must be done while the cement is still soft.
The joint should not be disturbed immediately after the cementing
procedure, and sufficient time should be allowed for proper curing
of the joint. Exact drying time is difficult to predict because it
depends on variables such as temperature, humidity and cement
integrity. For more specific information, you should contact your
solvent cement manufacturer.
Apply primer to the surface of the pipe and fitting socket with
a natural bristle brush. This process softens and prepares the
PVC or CPVC for the solvent cementing step. Move quickly and
without hesitation to the cementing procedure while the surfaces
are still wet with primer.
e. application of solvent cement
• Apply the solvent cement evenly and quickly around the
outside of the pipe at a width a little greater than the depth
of the fitting socket.
• Apply a light coat of cement evenly around the inside of the
fitting socket. Avoid puddling.
• Apply a second coat of cement to the pipe end.
step G
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pressure to change the electrical contacts from normally closed to
open. When this switch prevents the unit from igniting, most likely the
exhaust is blocked by some means. Check to see if the condensate
is allowed to flow freely from the exhaust elbow and for obstructions
in the exhaust venting and exhaust vent terminal. Also verify that
the vent length does not exceed the maximum allowed as shown in
the Vent Section of this manual.
controls and swItches
This model is provided with three pressure switches. These switches
are essential to the safe and proper operation of the unit.All switches
are wired in series. The controller is set up to shut the unit down
whenever there is a failure of any of the switches. It is important to
understand the purpose of each switch.
blocKed IntaKe swItch
(SEE FIGURE 33)
The Blocked Intake Switch is set up to shut the unit off when
a build-up of negative pressure in the intake air pipe occurs.
This switch is a negative pressure switch that requires an
increase in negative pressure to change the electrical contacts
from normally closed to open. The switch is connected to the
pressure tap on the PVC pipe connected to the inlet of the
blower. When this switch prevents the unit from igniting, most
likely the intake is blocked. Verify that the screen on the intake
air connection (conventional vent), the intake air pipe and
termination (direct vent installations) are free of obstructions
that may prevent air from entering the unit. Insure the screen
on intake air connection has been removed on direct vent
installations, see Figure 15. Also verify the intake air pipe length
does not exceed the maximum allowed as shown in the Vent
Section of this manual.
fIGure 33.
blower prover swItch
(SEE FIGURE 33)
on/off swItch
The ON/OFF Switch is a single-pole, single-throw rocker switch. This
switch provides 120V from the line source to the heater.
The Blower Prover Switch is provided on the heater to verify that
the fan is operating. It is a positive pressure switch whose electrical
contacts are normally open. When the fan increases the pressure
in the burner, the pressure switch will allow the electrical contacts
to close. The pressure switch is connected to the burner tap by a
piece of tygon tubing. This tubing must be connected in order for
the switch to change the electrical contacts. The controller requires
that the electrical contacts on this air flow switch be open before it
will allow the blower to come on.
cautIon
the water heater Is polarItY sensItIve. before
applYInG electrIcItY to thIs heater be certaIn that
supplY neutral wIre to Ground checK IndIcates
Zero voltaGe.
blocKed eXhaust swItch
(SEE FIGURE 33)
hot surface IGnIter
The Hot Surface Igniter is a device that ignites the main burner by
high temperature (>1800°F or >982°C). When 120VAC is applied to
the igniter, sufficient heat is generated to ignite the main burner.
The Blocked Exhaust Switch is set up to shut the unit off when a
build-up of positive pressure in the exhaust vent pipe occurs. This
switch is a positive pressure switch that requires an increase in
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cautIon
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERvICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND
DANGEROUS OPERATION. vERIFY PROPER OPERATION AFTER SERvICING.
THIS WATER HEATER
IS POLARITY SENSITvE.
BEFORE APPLYING
ELECTRICITY TO THIS
HEATER BE CERTAIN
THAT SUPPLY NEUTRAL
WIRE TO GROUND
CHECk INDICATES ZERO
vOLTAGE.
power vent wIrInG scheMatIc - fIGure 34.
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for Your safetY read before lIGhtInG
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
an ignition device which automatically lights the burner.
do not try to light the burner by hand.
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:
•
If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in the gas control buttons.
Never use tools. If the control buttons will not push in, don’t
trytorepairthem,callaqualifiedservicetechnician.Force
or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under
water. Immediately contact a qualified installer or service
agencytoreplaceafloodedwaterheater. Donotattempt
to repair the unit! It must be replaced!
•
•
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 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.
do not trY to lIGht the burner bY hand.
UP
Operating Set Point
Status: Heating
120 F
Help
6. Wait five (5) minutes to
gas. If you smell gas,
clear out any
STOP! Follow “B”
OFF
GAS
in the safety information above on this label.
If you don’t smell gas.
O
N
DN
Menu
7. Turn on all electrical power to the appliance.
8. Set the ON/OFF switch on the control box to the
“ON” 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.
on/off swItch
1.
STOP! Read the safety information above,
on this label.
10.If the appliance will not operate, follow the
instructions “TO TURN OFF GAS TO APPLIANCE”
and call your technician or gas supplier.
2. Set the ON/OFF switch on the control panel to
the “ON” position.
3. Set the thermostat to the lowest setting.
warnInG: turn off all electrIc
4. Set the ON/OFF switch on the control box to the
power before servIcInG
“OFF” position.
to turn off Gas to applIance
1. Set the thermostat to the lowest setting.
2. Set the ON/OFF switch on the control panel to the
“OFF” position.
3. Turn off all electrical power to the appliance if service
is to be performed.
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teMperature reGulatIon
It is recommended that lower water temperatures be used to avoid
for the lowest temperature which satisfies your hot water needs.
This will also provide the most energy efficient operation of the
water heater and minimize scale formation.
the risk of scalding. It is further recommended, in all cases, that the
water temperatures be set for the lowest temperature which satisfies
your hot water needs. This will also provide the most energy efficient
operation of the water heater.
Valves for reducing the point-of-use temperature by mixing cold
and hot water are available, see Figure 8. Also available are
inexpensive devices that attach to faucets to limit hot water
temperatures. Contact a licensed plumber or the local plumbing
authority.
The table below shows the approximate time-to-burn relationship for
normal adult skin. Short repeated heating cycles caused by small
hot water uses can cause temperatures at the point of use to exceed
the thermostat setting by up to 20°F/11°C. If you experience this
type of use, you should consider using lower temperature settings
to reduce scald hazards.
Time to Produce
Water Temperature
2nd & 3rd Degree
Burns on Adult Skin
About 1/2 Second
160° (71°C)
150° (65°C)
140° (60°C)
130° (54°C)
120° (49°C)
HOT WATER CAN SCALD: Water heaters are intended to produce
hot water. Water heated to a temperature which will satisfy space
heating, clothes washing, dish washing, and other sanitizing needs
can scald and permanently injure you upon contact. Some people
are more likely to be permanently injured by hot water than others.
These include the elderly, children, the infirm, or physically/mentally
handicapped. If anyone using hot water from this heater fits into
one of these groups or if there is a local code or state law requiring
a certain temperature water at the hot water tap, then you must
take special precautions. In addition to using the lowest possible
temperature setting that satisfies your hot water needs, a means
such as a mixing valve, should be used at the hot water taps used
by these people or at the water heater. Mixing valves are available
at plumbing supply or hardware stores, see Figure 8. Follow
manufacturer’s instructions for installation of the valves. Before
changing the factory setting on the thermostat, read the “Temperature
Regulation” section in this manual.
About 1 1/2 Seconds
Less than 5 Seconds
More than 30 Seconds
More than 5 Minutes
hI lIMIt swItch (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 Temperature Probe (two red wires).
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:
Never allow small children to use a hot water tap, or to draw their own
bath water. Never leave a child or handicapped person unattended
in a bathtub or shower.
SETTING THE WATER HEATER TEMPERATURE AT 120°F/49°C
WILL REDUCE THE RISK OF SCALDS. Some states require
settings at specific lower temperatures.
The water temperature is controlled using the Temperature
Control on the Display at the front of the unit (See Figure 1).
This control utilizes a temperature probe to determine the tank
temperature. The temperature probe is located behind the
heater’s front display.
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.
The temperature may be adjusted from 90°F/32°C to 160°F/71.1°C.
The temperature was preset to 120°F/49°C before the heater was
shipped from the factory. It is recommended that lower water
temperature be used to avoid the risk of scalding. It is further
recommended, in all cases, that the water temperature be set
Contact your dealer or servicer if continued high limit switch
operation occurs.
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control sYsteM operatIon
user Input buttons
overvIew
•
•
The up and down buttons are used to navigate menus and
adjust user settings.
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 ignition are managed by the
control system. The ECO (energy cut out), Flame Sensor, pressure
switches and Temperature Probe is monitored by the control
system. The Combustion Blower, Igniter and the 24 Volt Gas Valve
are all energized by the control system.
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 text that appears directly
above each button on the LCD screen.
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.
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.
coMMercIal and resIdentIal Models
The water heaters covered by this manual are produced for
commercial and residential use. The control system is programmed
differently for commercial and residential models. There are two
differences in control system operation between the residential and
commercial products:
•
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.
•
•
Commercial models will display Tank Temperature on the
Desktop screen, residential models will not.
Commercial models can regulate tank temperature up to a
maximum of 180°F (82°C), residential maximum is 160°F
(71°C).
•
•
•
The first temperature shown on the Desktop screen, Tank
Temperature, is the temperature of the water inside the water
heater's storage tank - commercial models only.
The Operating Set Point is also shown on the Desktop screen.
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 4 for a description of the various operating
states.
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 multifunction operational buttons
below the LCD, see Figure 35.
•
The Desktop screen also displays animated "Status Icons" to
convey operational information, see Table 3 for a complete list
and description of the Status Icons.
UIM (user interface module)
Desktop Screen Shown
LCD Screen
Information
Display
Title Bar
MANUFACTURER / MODEL INFORMATION
Operating Set Point
120°F
UP
DN
Status: Heating
Status Icons
OFF
GAS
O
N
Up & Down buttons:
navigate menus,
adjust user settings
MENU
HELP
3 Operational buttons:
enter/exit menus,
select menu items,
activate adjustment modes,
confirm/cancel changes.
Operational buttons are multifunctional. Their current function is defined by
the text that appears directly above each button on the LCD screen.
fIGure 35.
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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.
table 3.
Icon
description
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 Temperature Probe.
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.
The Combustion Blower is being energized.
The Blower Prover pressure switch contacts have closed. The check mark icon is visual confirmation of contact closure.
The Igniter is being energized.
The Igniter has been energized and the control system has sensed the required minimum igniter current. The check mark
icon is visual confirmation of minimum igniter current.
The 24 Volt Gas Valve is being energized.
OFF
GAS
O
N
The control system has sensed flame at the Main Burner from the Flame Sensor.
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 (control system lock out) until
the condition that caused the Fault is corrected. Power to the water heater must be cycled off and on 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.
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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.
table 4.
state
description
Standby
The water heater is not in an active heating cycle. IE: the Tank Temperature is at or above the Operating Set Point.
The control system is conducting a diagnostic check at the beginning of a heating cycle.
Input Verification
Short Cycle Delay The control system is waiting for a pre-defined time period to expire before initiating a heating cycle. This prevents "short-
cycling" which can greatly accelerate wear on components such as the Igniter and Combustion Blower.
note: If the control system is in this operational state increase the Differential setting in the Temperatures menu to lengthen
heating cycles.
Pre-Purge
The Combustion Blower is energized to flush residual flue gases from the combustion chamber prior to ignition.
The Igniter is energized and is currently warming up to ensure proper ignition.
Igniter Warm Up
Ignition Activation
The 24 Volt Gas Valve is energized and opens to allow fuel gas to flow to the Main Burner.
Ignition Verification The control system is monitoring the Flame Sensor for the required minimum flame sensing current.
Inter-Purge
Heating
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.
Fault
The control system has detected a Fault condition. Heating operation is disabled (control system lock out) until the Fault
condition is corrected. Power to the water heater must be cycled off and on 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.
control sYsteM Menus
From the Desktop screen pressing the Operational button 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 5.
Menu
description
Temperatures
Heater Status
Most commonly accessed menu. Contains the Operating Set Point and Differential user settings.
This menus displays the current state of all pressure switches and the ECO (open/closed). The on/off status of the
Combustion Blower, 24 Volt Gas Valve, 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
Fault History
Displays any current Alert or Fault messages.
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. Fault history memory is cleared 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. Fault occurrences numbers are saved in the CCB memory indefinitely.
note: if the CCB is replaced during service the fault occurrence historical information for the water heater is lost.
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.
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user settInGs & control sYsteM Menus
teMperatures
operatInG set poInt and dIfferentIal adjustMent
The Operating Set Point is adjustable from 90°F (42°C) to 180°F (82°C) for commercial and 160°F (71°C) on residential models. 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. These instructions explain how to adjust these settings and navigate the control system.
When the water temperature sensed by the control system from the Temperature Probe 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: Set the Operating Set Point to the lowest setting which produces an acceptable hot water supply for most efficient use. Lower
Differential settings may cause excessive heating cycles (short-cycling) which can cause premature failure of components such as the
Igniter. Set the Differential at the highest setting which produces an acceptable hot water supply to prevent short cycling.
descrIptIon/actIon
dIsplaY
From the Desktop screen, press the Operational Button under
MENU. The "Main Menu" screen will be displayed.
MANUFACTURER / MODEL INFORMATION
Tank Temperature
120°F
120°F
Operating Set Point
Status: Standby
MENU
HELP
The Main Menu is where all control system menus are listed,
see Table 5 for a complete list and description of control
system menus. Use the Up and Down Buttons to view all
control system menus from the Main Menu.
Main Menu
Temperatures
Heater Status
Display Settings
Heater Information
Current Fault
With Temperatures menu selected (highlighted in black) in
the Main Menu screen, press the Operational Button under
“SELECT” to enter the Temperatures menu.
If the Temperatures menu is not selected use the Up and Down
Buttons to select this menu item.
SELECT
BACK
HELP
With the Operating Set Point selected in the Temperatures
menu, press the Operational Button underneath “CHANGE” to
activate the adjustment mode for this menu item.
Temperatures
Operating Set Point
Differential
Tank Temperature
Tank Probe Offset
120°F
8°F
120°F
0°F
If Operating Set Point is not selected use the Up and Down
Buttons to select this menu item.
note: Higher Temperature settings increase wear and
operating costs. Set the Operating Set Point to the lowest
setting which produces an acceptable hot water supply. This
will always provide the most energy efficient operation and
longer life.
CHANGE
BACK
HELP
With the adjustment mode for the Operating Set Point activated
the selection bar will change from a black fill to a black outline.
Temperatures
Operating Set Point
140°F
8°F
120°F
0°F
Use the Up and Down Buttons to change the current setting.
Differential
Tank 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.
UPDATE
CANCEL
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teMperatures (cont)
descrIptIon/actIon
dIsplaY
• tank temperature - non adjustable - control system sensed
temperature from the Temperature Probe.
Temperatures
• tank probe offset - adjustable user setting, range -5° to +5°
(factory setting 0°).
Operating Set Point
140°F
8°F
120°F
0°F
Differential
The Tank Probe Offset is used to calibrate control system
temperature sensing. This can improve the precision of
temperature control in the storage tank and at points of use.
This feature can also be used to compensate for building
recirculation loops (hot water returning to the storage tank) that
may cause the heating cycles to terminate prematurely.
Tank Temperature
Tank Probe Offset
Example:Ifthecurrentsensedtemperaturefromthetemperature
probe is 120°F (49°C) and the Offset setting for the probe is
adjusted to a value other than 0°, the control system would
calibrate or “offset” the sensed temperature from the probe.
Heating cycles would be activated and deactivated based on
the calibrated (offset) temperature.
CHANGE
BACK
HELP
note:TheTankProbeOffsetshouldonlybeusedifthehotwater
supply temperature varies greatly from the Operating Set Point
setting. These settings are adjusted in the same way described
for the Operating Set Point and Differential Adjustment.
heater status
descrIptIon/actIon
dIsplaY
Select Heater Status 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 & Down Buttons to
navigate the menu.
Top of Menu
Heater Status
Status
Standby
Closed
Closed
Closed
Open
No
ECO Contact
• status - displays the current Operating State, see Table 4 for a
description of the various operational states.
Blocked Inlet PS
Blocked Outlet PS
Blower Prover PS
Blower Low On
Blower High On
• eco contact, blocked Inlet ps, blocked outlet ps, blower
prover ps - displays the current state of the switch contacts;
open or closed.
• blower low on, blower high on - displays whether the
blower is running at high speed during Pre/Post purge and
the Heating operational states or the blower is running at low
speed during the Igniter Warm Up operational state; yes =
blower is running at the designated speed, no = blower is not
running at the designated speed.
No
BACK
HELP
Bottom of Menu
• Igniter on, Gas valve on - displays whether or not the control
system is currently energizing these water heater components;
yes = energized, no = de-energized.
Heater Status
Blower High On
Igniter On
Igniter Current
Gas Valve On
Flame Detected
External Input Enable
Ignition Trials
No
No
No
No
No
No
3
• Igniter current - displays whether or not the control system
has detected the required minimum current.
• flame detected - displays whether or not the control system
has detected Main Burner flame during ignition from the Flame
Sensor.
• External Input enable - displays whether or not the S1
dipswitches have been configured to activate the Enable/
Disable circuit; yes = the Enable/Disable circuit has been
activated, no = the Enable/Disable circuit has not been
activated. The factory setting is "no" or deactivated.
BACK
HELP
• Ignition trials - displays whether or not the S1 dipswitches
have been configured to allow 1 or 3 trials for ignition before
declaring an "Ignition Failure" Fault condition. The factory
setting is for 3 trials.
41
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dIsplaY settInGs
descrIptIon/actIon
dIsplaY
Select Display Settings from the Main Menu and press the
Operational Button under "SELECT" to enter this menu. This menu
contains adjustable display options for viewing information on the
LCD screen. Use the Up & Down Buttons to navigate the menu.
Display Settings
Temperature Units
Backlight Delay
Contrast
°F
30s
60%
• 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 LCD backlight remains illuminated after a key has
been pressed. Available settings are; Always Off, 10, 30 or 60
seconds and Always On.
• contrast - Adjustable user setting to adjust the LCD screen
contrast between text and background.
CHANGE
BACK
HELP
note: These settings are adjusted in the same way described
for the Operating Set Point and Differential Adjustment.
heater 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.
Heater Information
Elapsed Time
• elapsed time - Total accumulated time the control system
(water heater) has been energized.
10 day 0 hrs 0 mins
Burner On Time
• burner on time - Total accumulated time the control system
has been in the heating operating state; burner run time.
5 hrs 22 mins
00000035
X.XX
Cycle Count
CCB Version
UIM Version
• cycle count - Total accumulated count of heating cycles.
• ccb version - Software version for central control board.
• uIM version - Software version for user interface module.
X.XX
CHANGE
BACK
HELP
note: Historical data is stored in the CCB's memory. If this CCB
is replaced during servicing the historical data on the CCB being
replaced will be lost. The data stored in the new circuit board 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.
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.
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.
42
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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 & Down Buttons to
navigate the menu.
Blocked Exhaust
Fault occurred 2 mins ago
The exhaust is blocked or
restricted. Ensure
condensate hose is draining.
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 information and
a list of possible causes for the Fault or Alert condition.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
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.
CHANGE
BACK
ADVANCED
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 Up & Down Buttons to
navigate the menu.
Fault History
1:
2:
3:
4:
Blocked Air Intake (A7)
51 mins ago
This menu contains a list of the last nine (9) Fault andAlert messages
with a time stamp. The newest event will replace the oldest.
Blocked Exhaust (A8)
54 mins ago
Press the Operational Button under "VIEW" to view details for each
Fault or Alert message stored.
Low Gas Pressure (A6)
57 mins ago
note: fault history memory is cleared after 30 days.
Blower Prover Failure (AC)
VIEW
BACK
HELP
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 Up & Down
Buttons to navigate the menu.
Fault Occurrence
Ignition Failure
ECO
Blocked Intake Air
Blocked Exhaust
Thermostat Input 4
Blower Prover
Flame Detect Error
10
0
This menu contains a running total of how many times each Fault
condition has occurred since the water heater was first installed.
0
0
note: Historical data is stored in the CCB's memory. If this CCB
is replaced during servicing the historical data on the CCB being
replaced will be lost. The data stored in the new circuit board will no
longer reflect the entire history of the water heater.
0
3
0
BACK
HELP
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
display will show text confirming the factory default settings have
been restored.
Are you sure you want to
restore the system to factory
defaults?
Press the Operational Button underneath “BACK” to exit the Restore
Factory Defaults menu.
YES
NO
43
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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 press and hold down the middle
(unmarked) Operational Button for 30 seconds and then release it.
Service Contact Information
Show Contact Information
No
This will launch a discrete menu where personalized contact
information can be entered.
Change Contact Name
Change Contact Phone
Current Contact Info:
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
adjustment mode for this parameter.
(000) 000-0000
Access Code
CHANGE
BACK
HELP
With the adjustment mode for "Show Contact Information"
activated the selection bar will change from a black fill to a black
outline.
Service Contact Information
Show Contact Information
Change Contact Name
Change Contact Phone
Current Contact Info:
Yes
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.
(000) 000-0000
Access Code
note: The Access Code at the bottom of the Service Contact
Information screen is for manufacturing purposes only. There are
no user settings or information accessed through this menu item.
UPDATE
CANCEL
Using the UP and DOWN buttons select (highlighted in black) the
"Change Contact Name" menu item.
Service Contact Information
Show Contact Information
Change Contact Name
Change Contact Phone
Current Contact Info:
Yes
Press the Operational Button under "SELECT" to open the Change
Contact Name menu.
(000) 000-0000
Access Code
SELECT
BACK
HELP
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.
Enter the service contact below:
-
-
Use the > and < keys to move between
characters. Use the UP and DOWN keys to
change the character.
When finished press the Operational Button "UPDATE" to save the
new Contact Name. The control system will return to the discrete
menu.
NAME: _
-
-
<
>
UPDATE
Using the UP and DOWN buttons select (highlighted in black) the
"Change Contact Phone" menu item and press the Operational
Button under "SELECT".
Service Contact Information
Show Contact Information
Change Contact Name
Change Contact Phone
Current Contact Info:
YOUR COMPANY NAME HERE
(123) 456-7890
Yes
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.
Access Code
BACK
HELP
44
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for Your InforMatIon
common complaint associated with the anode rod is one of a “rotten
egg smell” in the hot water. The smell is a result of four factors which
must all be present for the odor to develop:
start up condItIons
sMoKe/odor
It is not uncommon to experience a small amount of smoke and odor
during the initial start-up. This is due to burning off of oil from metal
parts, and will disappear in a short while.
a. A concentration of sulfate in the supply water.
b. Little or no dissolved oxygen in the water.
therMal eXpansIon
c. A sulfate reducing bacteria which has accumulated within the
water heater (this harmless bacteria is nontoxic to humans).
d. An excess of active hydrogen in the tank. This is caused by the
corrosion protective action of the anode.
Smelly water may be eliminated or reduced in some water heater
models by replacing the anode(s) with one of less active material, and
then chlorinating the water heater tank and all water lines. Contact
the local water heater supplier or a qualified service agency for
further information concerning an Anode Replacement Kit and this
chlorination treatment.
Water supply systems may, because of such events as high
line pressure, frequent cut-offs, the effects of water hammer
among others, have installed devices such as pressure
reducing valves, check valves, back flow preventers, etc.
to control these types of problems. When these devices
are not equipped with an internal by pass, and no other
measures are taken, the devices cause the water system
to be closed. As water is heated, it expands (thermal expansion)
and closed systems do not allow for the expansion of
heated water.
Ifthesmellywaterpersistsaftertheanodereplacementandchlorination
treatment, we can only suggest that chlorination or aeration of the
water supply be considered to eliminate the water problem.
do not remove the anode leaving the tank unprotected. by doing
so, all warranty on the water heater tank is voided.
“aIr” In hot water faucets
The water within the water tank expands as it is heated
and increases the pressure of the water system. If the
relieving point of the water heater’s temperature-pressure
relief valve is reached, the valve will release excess pressure. The
temperature-pressure relief valve is not intended for the constant
relief of thermal expansion. This is an unacceptable condition and
must be corrected. It is recommended that any devices
installed which could create a closed system have a
by-pass and/or the system have an expansion tank
or device to relieve the pressure built by thermal
expansion in the water system. Expansion tanks are
available for ordering through
a
local plumbing
HYDROGEN GAS: Hydrogen gas can be produced in a hot water
system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable and
explosive. To prevent the possibility of injury under these conditions,
we recommend the hot water faucet, located farthest away, be
opened for several minutes before any electrical appliances
which are connected to the hot water system are used (such as a
dishwasher or washing machine). If hydrogen gas is present, there
will probably be an unusual sound similar to air escaping through the
pipe as the hot water faucet is opened. There must be no smoking
or open flame near the faucet at the time it is open.
contractor. Contact the local water heater supplier
or qualified service agency for assistance in controlling these
situations.
operatIonal condItIons
sMellY water
In each water heater there is installed at least one anode rod (see
Figure 1) for corrosion protection of the tank. Certain water conditions
will cause a reaction between this rod and the water. The most
45
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perIodIc MaIntenance
rate of anode rod depletion. Once the anode rod is depleted, the
tank will start to corrode, eventually developing a leak.
ventInG sYsteM InspectIon
Certain water conditions will cause a reaction between the anode
rod and the water. The most common complaint associated with
the anode rod is a “rotten egg smell” produced from the presence of
hydrogen sulfide gas dissolved in the water. IMPORTANT: Do not
remove this rod permanently as it will void any warranties. A special
anode rod may be available if water odor or discoloration occurs.
NOTE: This rod may reduce but not eliminate water odor problems.
The water supply system may require special filtration equipment
from a water conditioning company to successfully eliminate all
water odor problems.
Artificially softened water is exceedingly corrosive because the
process substitutes sodium ions for magnesium and calcium ions.
The use of a water softener may decrease the life of the water
heater tank.
The anode rod should be removed from the water heater tank every
3 years for inspection. NOTE: artificially softened water requires
the anode rod to be inspected annually.
At least once a year a visual inspection should be made of the venting
system. You should look for:
The following are typical (but not all) signs of a depleted anode rod:
1. Obstructions which could cause improper venting.The combustion
and ventilation air flow must not be obstructed.
•
•
The majority of the rods diameter is less than 3/8”.
Significant sections of the support wire (approx. 1/3 or more of
the anode rod’s length) are visible.
2. Damage or deterioration which could cause improper venting or
leakage of combustion products.
If the anode rod show signs of either or both it should be replaced.
NOTE: Whether re-installing or replacing the anode rod, check for
any leaks and immediately correct if found.
Be sure the vent piping is properly connected to prevent escape of
dangerous flue gasses which could cause deadly asphyxiation.
Obstructions and deteriorated vent systems may present serious
health risk or asphyxiation.
In replacing the anode:
1. Turn off gas and electric supply to the water heater.
2. Shut off the water supply and open a nearby
hot water faucet to depressurize the water tank.
3. Drainapproximately5gallonsofwaterfromtank.(Referto“Draining
and Flushing” for proper procedures). Close drain valve.
4. Remove old anode rod.
Chemical vapor corrosion of the flue and vent system may occur
if air for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium chloride,
waxes, bleach and process chemicals are typical compounds which
are potentially corrosive.
5. Use Teflon® tape or approved pipe sealant on threads and
install new anode rod.
If after inspection of the vent system you found sooting or
deterioration, something is wrong. Call the local gas utility to correct
the problem and clean or replace the flue and venting before
resuming operation of the water heater.
6. Turn on water supply and open a nearby hot water faucet to
purge air from water system.
Check for any leaks and immediately correct any if found.
7. Restart the water heater as directed in this manual. See the
Repair Parts Illustration for anode rod location.
anode rod InspectIon
teMperature-pressure
relIef valve operatIon
Each water heater contains at least one anode rod, which will slowly
deplete (due to electrolysis) prolonging the life of the water heater
by protecting the glass-lined tank from corrosion. Adverse water
quality, hotter water temperatures, high hot water usage, hydronic
heating devices, and water softening methods can increase the
46
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5. Close the cold water inlet valve to the water heater.
6. Connect a hose to the water heater drain valve and terminate it
to an adequate drain.
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.
fIGure 36.
9. Close the hot water faucet opened in Step 4.
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
water discharge will not cause any property damage, as the water
may be extremely hot, see Figure 36.
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 water heater storaGe tanK:
11. Turn off the electrical supply to the water heater.
12.Ensure the cold water inlet valve is open.
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, follow the draining instructions, and replace the
temperature-pressure relief valve with a new one.
13.Open a nearby hot water faucet and let the water run until the
water is no longer hot. Then close the hot water faucet.
If the temperature-pressure relief valve on the appliance weeps or
discharges periodically, this may be due to thermal expansion. You
may have a check valve installed in the water line or a water meter
with a check valve. Consult your local water supplier or a qualified
service agency for further information. Do not plug the temperature-
pressure relief valve.
14.Connect a hose to the drain valve and terminate it to an
adequate drain.
15.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.
16.Open the water heater drain valve to flush the storage tank.
draInInG and flushInG
17.Flush the water heater storage tank to remove sediment and
allow the water to flow until it runs clean.
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 Figure 1, Features And Components in this manual for the
location of the water heater components described below.
18.Close the water heater drain valve when flushing is completed.
19.Remove the drain hose.
20.Fill the water heater - see Filling The Water Heater in this
manual.
Burn harzard.
21.Turn on the electrical supply to place the water heater back in
operation.
Hot water discharge.
22.Allow the water heater to complete several heating cycles to
ensure it is operating properly.
Keep hands clear of drain
valve discharge.
servIce
If a condition persists or you are uncertain about the operation of
the water heater contact a qualified service agency.
to draIn the water heater storaGe tanK:
Use this guide to check a “Leaking” water heater. Many suspected
“Leakers” are not leaking tanks. Often the source of the water can
be found and corrected.
1. Turn off the electrical supply to the water heater.
2. Turn off the gas supply at the Main Gas Shutoff valve if
the water heater is going to be shut down for an extended
period.
If you are not thoroughly familiar with gas codes, your water heater,
and safety practices, contact your gas supplier or qualified installer
to check the water heater.
3. Ensure the cold water inlet valve is open.
Read this manual first. Then before checking the water heater
make sure the gas supply has been turned “OFF”, and never turn
the gas “ON” before the tank is completely full of water.
4. Open a nearby hot water faucet and let the water run until the
water is no longer hot.
47
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MaIntenance
If the Temperature-Pressure Relief Valve on the water heater
weeps or discharges periodically, this may be due to thermal
teMperature-pressure relIef valve test
expansion.
Burn hazard.
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 Closed Water
Systems and Thermal Expansion on pages 15 and 16. The
Temperature-Pressure Relief Valve is not intended for the
constant relief of thermal expansion.
Hot water discharge.
Keep clear of Temperature-
Pressure Relief Valve
discharge outlet.
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.
It is recommended that the Temperature-Pressure Relief Valve
should be checked to ensure that it is in operating condition every
6 months.
WhencheckingtheTemperature-PressureReliefValveoperation, 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 water 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.
do not pluG the teMperature-pressure relIef
valve openInG. thIs can cause propertY daMaGe,
serIous InjurY or death.
Tocheckthereliefvalve,lifttheleverattheendofthevalveseveraltimes,
see Figure 37. 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 47. Replace the Temperature-Pressure
Relief Valve with a properly rated/sized new one, see Temperature-
Pressure Relief Valve on page 17 for instructions on replacement.
Explosion Hazard
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.
TEMPERATURE-PRESSURE
RELIEF VALVE
Can result in overheating and
excessive tank pressure.
DISCHARGE PIPE
Can cause serious injury or death.
fIGure 37.
48
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leaKaGe checKpoInts
Never use this water heater unless it is completely filled with water.
To prevent damage to the tank, the tank must be filled with water.
Water must flow from the hot water faucet before turning “ON” gas
to the water heater.
A *Condensation may be seen on pipes in humid weather or pipe
connections may be leaking.
B. *The anode rod fitting may be leaking.
C. Small amounts of water from temperature-pressure relief valve
may be due to thermal expansion or high water pressure in your
area.
D. *The temperature-pressure relief valve may be leaking at the
tank fitting.
E. Water from a drain valve may be due to the valve being slightly
opened.
F. *The drain valve may be leaking at the tank fitting.
G. Leakage from recirculation plug or pipe connection.
H. Leakage from the plug under the cleanout cover.
I. Leakage from the temperature probe connection.
J. Condensate from the exhaust connection.
fIGure 38.
Leakage from other appliances, water lines, or ground seepage
should also be checked.
*
To check where threaded portion enters tank, insert cotton
swab between jacket opening and fitting. If cotton is wet, follow
“Draining” instructions in the “Periodic Maintenance” section and
then remove fitting. Put pipe dope or teflon tape on the threads
and replace. Then follow “Filling the Water Heater” instructions
in the “Installing the New Water Heater” section.
49
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troubleshootInG
Flow Chart.
InstallatIon checKlIst
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.
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.
2. Ifthecontrolsystemdeterminesthattheactualwatertemperature
inside the tank is below the programmed Operating Set Point
minus the Differential setting, a heating cycle is activated.
water heater locatIon
3. The control system then performs selected diagnostic system
checks. This includes confirming the blocked exhaust, blocked
intake and ECO (energy cut out) switch contacts are closed.
The Blower Prover Switch contacts are confirmed open.
1. Ensure proper clearances to combustibles are maintained and
there is sufficient room to service the water heater.
2. Ensure the area is free of corrosive elements and flammable
materials.
4. If all diagnostic checks are successfully passed, the control
system energizes the Combustion Blower for pre-purge.
ventInG
5. The control system must confirm the Blower Prover Switch
contacts close after the Combustion Blower is energized.
3. Ensure the intake air and/or vent (exhaust) piping is the correct
size for the installed length.
6. If the Blower Prover Switch contacts are confirmed closed the
control system energizes the Hot Surface Igniter for the igniter
warm-up period.
4. Ensure the maximum equivalent feet of pipe has not been
exceeded for the intake air and/or vent pipe.
5. Ensure the maximum number of elbows has not been exceeded
in the intake air and/or vent pipe.
7. The control system monitors the igniter current and must sense
a minimum of 0.6 AC amps during the igniter warm up period
(10 seconds).
6. Ensure all exterior clearances for the intake air, vent and
concentric terminations are maintained. These clearances and
those cited by local and national codes must be maintained.
8. If igniter amperage is confirmed at or above the required
minimum the control system energizes the 24 V Gas Valve
allowing gas to flow to the Main Burner.
7. If venting “direct vent”, ensure the screen located in air intake at
the water heater was removed.
9. The control system de-energizes the Hot Surface Igniter.
Gas supplY and pIpInG
10.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.
8. Ensure the supply gas line to each water heater meets the
minimum supply gas line size requirements.
condensate draIn
9. Ensure the condensate drain is properly connected to the
exhaust elbow on the water heater with a water trap to prevent
vent gases from escaping into the installed space and draining
freely to a suitable floor drain.
11.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 V Gas Valve and enter the post-purge cycle
(approximately 30 seconds).
electrIcal connectIons
10.Ensure the power supply connections to the water heater are
polarity correct.
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.
11. 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.Sequence Of
Operation.
13.Thecontrolsystemnowentersthestandbymodewhilecontinuing
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.
InstallatIon checKlIst
Read the Sequence of Operation below before attempting to
correct any operational problems. See the Sequence Of Operation
50
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sequence of operatIon flow chart
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
Blower Prover pressure switch verified open
Control System Locks Out
Displays Fault Msg
NO
All other pressure switches and ECO are verified closed
Combustion Blower is energized
Pre-Purge cycle
Control System Locks Out
“Blower Prover Open”
Fault Msg is displayed
Blower Prover switch contacts confirmed
NO
closed by control system
Igniter is energized for warm up period
Control System Locks Out
“Low Igniter Current”
Fault Msg is displayed
Does Control System sense minimum
Igniter amps?
NO
24 V Gas Valve is energized
gas flows to Main Burner
0.6 minimum AC amps
Is flame sensed at the Main Burner?
(control system monitors the flame sensor)
YES
NO
Water is heated to
set point
24 V Gas Valve
de-energized
Approximately
30 second
Inter-Purge cycle
24 V Gas Valve
de-energized
Approximately
30 second
Post-Purge cycle
Retries up to
two more times
Control System
Locks Out
“Ignition Failure”
Fault Msg is
displayed
Water heater goes
into standby mode
fIGure 39.
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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:
operatIonal probleMs
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
•
•
•
•
Incorrect manifold (offset) gas pressure.
Undersized supply gas line (low volume of supply gas).
Low Gas Pressure
See the list of possible causes and things to check and repair
for the Ignition Failure Fault message.
Clogged/blocked intake air screen(s).
Clogged/blocked Main Burner.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
•
•
This manual must remain with the
water heater.
not enouGh or no hot water
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 should perform any service procedures on the water heater.
•
No power to the water heater, check breaker, fuses and the
water heater on/off switch.
•
•
Hot water supply valve(s) to fixtures closed.
Operating Set Point is set too low, Differential setting is set too
high.
•
•
•
•
•
Temperature Probe Offset setting are causing the heating cycles
to terminate prematurely.
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.
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.
rouGh startInG, rouGh operatIon
Sediment or lime scale accumulation may be affecting water
heater operation.
Fire and Explosion Hazard
Do not use water heater with any gas
other than the gas shown on the rating
plate.
Excessive gas pressure to gas valve can
cause serious injury or death.
water Is too hot
•
•
Operating Set Point is set too high.
Temperature Probe Offset settings improperly set.
noIsY operatIon
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
•
Normal operating noise of electrical components; Combustion
Blower, transformer hum, relay contact closure.
replaceMent parts
•
•
•
•
•
•
Undersized supply gas line (low volume of supply gas).
Low Gas Pressure.
Excessive supply gas pressure.
Excessive manifold (offset) gas pressure.
Incorrect Fuel Type
Vent (exhaust) gas recirculation at the vent and intake air pipe
terminations on Direct Vent installations.
Excessive equivalent lengths of intake air and/or vent (exhaust)
piping installed.
Replacement parts may be ordered from the manufacturer,
authorized service agencies or distributors. 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 plate affixed to the water heater.
•
Refer to the parts list for more information or call the parts
department or technical support phone number listed on the back
cover of this manual for further assistance.
•
•
Clogged/blocked intake air screen(s).
Clogged/blocked the Main Burner.
fault and alert condItIons
MoMentarY IGnItIon
fault condItIons
CAUTION
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.
Burn Hazard
The combustion chamber and burner sleeve
and housing become very hot during operation.
•
•
Do not reach into the burner housing or
combustion chamber if the water heater
is still hot.
alert condItIons
Allow the water heater to cool and always use
gloves when handling the main burner.
•
When the control system declares an Alert condition it will display
an Alert message on the control system's LCD with a question "?"
52
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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.
note: If 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.
resettInG control sYsteM locK outs
If you do not understand the instructions in the following section do
not attempt to perform any procedures.
To reset the control system from a lock out condition; turn the 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.
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.
dIaGnostIc checKs
Electrical Shock Hazard
Turn off power to the water heater
before performing any service.
•
Jumping out control circuits or components can
result in property damage, personal injury or death.
Label all wires prior to disconnecting
•
when performing service. Wiring errors
can cause improper and dangerous
operation.
Service should only be performed by a qualified service
•
agent using proper test equipment.
Altering the water heater controls and/or wiring in any way
•
Verify proper operation after servicing.
•
•
could result in permanent damage to the controls or water
heater and is not covered under the limited warranty.
Failure to follow these instructions can
result in personal injury or death.
Altering the water heater controls and/or wiring in any way
•
could result in altering the ignition sequence allowing gas to
flow to the main burner before the hot surface igniter is at
ignition temperature causing delayed ignition which can
cause a fire or explosion.
The following section, Fault And Alert Messages 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.
Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the appliance warranty.
Only qualified service agents, as defined in Qualifications using
appropriate test equipment, should perform any service procedures
on the water heater.
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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
• The water heater’s control system is polarity sensitive and will lock
out and disable heating operation if the polarity of the power supply
is reversed. The control system will display the “AC Reversed”
Fault message on the LCD in this condition.
AC Reversed
Fault occurred 2 mins ago
Power supply to water heater
has reversed polarity.
note: Electronic flame sensing requires correct power supply
polarity AND a proper earth ground to the water heater and the
Main Burner. The control system does not verify earth ground
but this should be checked first if ignition failure occurs. See the
Ignition Failure Fault message information below.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
• The control system has failed to ignite the Main Burner.
Ignition Failure
• Water heater is not properly grounded, loose or open ground wire
to the Main Burner.
Fault occurred 2 mins ago
The water heater has failed to
ignite the burner.
• Dirty/corroded flame sensor, clean flame sensor with fine steel
wool (replace if damaged).
• Loose or open wiring to the flame sensor.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
• Loose or open wiring to the 24 V Gas Valve.
• Supply gas turned off, low gas volume.
• Intake air and/or vent piping is restricted or improperly installed.
• Low or no manifold gas pressure to the Main Burner.
CHANGE
BACK
ADVANCED
• The control system has detected low current (AC amps) from the
Hot Surface Igniter. The control system monitors igniter current
and will declare this Fault condition if the current is not at or above
the programmed minimum requirement.
Low Igniter Current
Fault occurred 2 mins ago
Igniter current is low.
• Loose or open wiring to the Hot Surface Igniter.
• Damaged, worn or open circuit Hot Surface Igniter.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
note: Hot surface igniters are wearing parts. Wear is directly
related to heating cycle count. Heating cycle count can be viewed
in the Heater Information menu. Increasing the Differential setting
reduces heating cycle count.
CHANGE
BACK
ADVANCED
• The control system has detected the Blocked Exhaust Switch
contacts are open.
Blocked Exhaust
Fault occurred 2 mins ago
• The condensate drain is blocked filling the exhaust elbow with
water - clear the condensate drain.
The exhaust is blocked or
restricted. Ensure
condensate hose is draining.
• Loose or open wiring to the Blocked Exhaust Switch.
• Restricted/blocked vent piping - condensate trapped in low point.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
• Excessive equivalent pipe length, exceeded the maximum number
of 90° elbows or wrong pipe size used in the vent piping system.
• Excessive wind outdoors pressurizing the vent system piping.
• Excessive negative air pressure in the installed space.
CHANGE
BACK
ADVANCED
54
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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
• The control system has detected the Blower Prover Switch
contacts are closed when they should be open at the beginning of
a heating cycle.
Blower Prover Failure
Fault occurred 2 mins ago
The blower prover switch is
closed out of sequence.
• Pinched/shorted Blower Prover Switch wiring.
• Jumper wire connected to the Blower Prover Switch - remove
jumper wire. Jumper wires must never be used, read all Warnings.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
• Excessive wind outdoors pressurizing the vent system piping.
• Excessive negative air pressure in the installed space.
CHANGE
BACK
ADVANCED
• The control system has detected the Blower Prover Switch
contacts are remaining open after the control system has
energized the Combustion Blower.
Blower Prover Open
Fault occurred 2 mins ago
The blower prover switch remains
open after the blower has been
energized.
• Loose or open wiring to the Blower Prover Switch.
• Blower Prover Switch air sensing tube disconnected, kinked, filed
with condensate, damaged or leaking - repair or replace tube.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
• Combustion Blower is not running when energized.
• Loose or open wiring to Combustion Blower.
CHANGE
BACK
ADVANCED
• The control system has detected the Blocked Intake Air Switch
contacts are open.
Blocked Air Intake
Fault occurred 2 mins ago
• Loose or open wiring to the Blocked Intake Air Switch.
The combustion air intake is
restricted.
• Excessive equivalent pipe length, exceeded the maximum number
of 90° elbows or wrong pipe size used in the intake air piping
system.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
• Excessive negative air pressure in the installed space.
CHANGE
BACK
ADVANCED
• The control system has detected the ECO (energy cut out) Switch
contacts are open.
Energy Cut Out (ECO)
Fault occurred 2 mins ago
• The ECO switch is a normally closed switch that opens on a
temperature rise to prevent excessive water temperature in the
storage tank. The ECO switch is inside the Temperature Probe
(two red wires).
Tank temperature is excessive.
The water heater has been
disabled.
• Loose or open wiring to the ECO switch in the Temperature Probe
- two red wires.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
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notes
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notes
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notes
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limited warranty
State Water Heaters, the warrantor, extends the following LIMITED WARRANTY to the owner of this water heater.
1. THE TANk
If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable water
therein, during the first THREE years after initial installation, the warrantor will supply a replacement tank less burner and controls or a complete new
State water heater of equivalent size and current model at the warrantor’s option. Some government agencies are requiring energy efficient standards
for water heaters. In the event regulations prohibit sale of a model of equivalent size and construction, State will provide a model which complies with
the regulations of your area, in which case the consumer will be charged the difference in price between the like replacement and the energy efficient
model required. The warranty on the replacement water heater will be limited to the unexpired term of the original warranty.
2. ALL OTHER PARTS
If within ONE year after initial installation of this water heater, any part or portion shall prove upon examination by the warrantor to be defective in
material or workmanship, the warrantor will repair or replace such part or portion at its option.
3. CONDITIONS AND EXCEPTIONS
This warranty shall apply only when the water heater is installed in accordance with local plumbing and building codes, ordinances and regulations,
the printed instructions provided with it and good industry practices. In addition, a temperature and pressure relief valve, certified by CSA and
approved by the American Society of Mechanical Engineers, must have been installed.
a. This warranty shall apply only when the water heater is:
(1) owned by the original purchaser;
(2) used at temperatures not exceeding the maximum setting of its thermostat;
(3) used at water pressure not exceeding the working pressure shown on the heater;
(4) used when operated free of the damaging effects of uncontrolled water hammer;
(5) used when filled with potable water, free to circulate at all times;
(6) used in a non-corrosive and non-contaminated atmosphere;
(7) used with factory approved anode(s) installed;
(8) in its original installation location;
(9) in the United States, its territories or possessions, and Canada;
(10) sized in accordance with proper sizing techniques for commercial water heaters;
(11) bearing a rating plate which has not been altered, defaced or removed except as required by the warrantor;
(12) fired at the factory rated input using the fuel stated on the rating plate;
(13) maintained in accordance with the instructions printed in the manual included with the water heater.
b. Any accident to the water heater, any misuse, abuse (including freezing) or alteration of it, any operation of it in a modified form, or any attempt
to repair tank leaks will void this warranty.
c. This warranty is void if a device acting as a backflow prevention device (check valves etc.) is installed in the cold water supply the heater is
connected to, unless an effective method of controlling thermal expansion is also installed at the heater(s) and operational at all times.
The temperature and pressure relief valve installed on the heater is not an acceptable method.
4. SERvICE AND REPAIR EXPENSES
Under the limited warranty the warrantor will provide only a replacement water heater or part thereof. The owner is responsible for all other costs.
Such costs may include but are not limited to:
a. Labor charges for service removal, repair or reinstallation of the water heater or any component part;
b. Shipping, delivery, handling, and administrative charges for forwarding the new heater or replacement part from the nearest distributor and returning
the claimed defective heater or part to such distributor.
c. All cost necessary or incidental for any material and/or permits required for installation of the replacement.
5. LIMITATIONS ON IMPLIED WARRANTIES
Implied warranties, including the warranty of merchantability imposed on the sale of this heater under state law are limited to one (1) year duration
for the heater or any of its parts. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply
to you.
6. CLAIM PROCEDURE
Any claim under the warranty should be initiated with the dealer who sold the water heater, or with any other dealer handling the warrantor’s
products. If this is not practicable, the owner should contact:
U.S. Customers
State Water Heaters
500 Tennessee Waltz Parkway
Ashland City, TN 37015
Telephone: 1-(800)-365-0024
a. The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by the
warrantor.
b. Dealer replacements are made subject to in-warranty validation by warrantor.
7. DISCLAIMERS
NOOTHEREXPRESSWARRANTYHASBEENORWILLBEMADEINBEHALFOFTHEWARRANTORWITHRESPECTTOTHEMERCHANTABILITY
OF THE HEATER OR THE INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF THE WATER HEATER. THE WARRANTOR SHALL
NOTBE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OFTHE UNIT, INCONvENIENCE, LOSS OR DAMAGETO PERSONALPROPERTY
OR OTHER CONSEQUENTIAL DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY vIRTUE OF THIS WARRANTY OR OTHERWISE FOR
DAMAGE TO ANY PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR TORT.
a. Some states do not allow the exclusion or limitation of the incidental or consequential damage, so the above limitations or exclusions may not apply to you.
b. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Fill in the following for your own reference. keep it. Registration is not a condition of warranty. The model and serial number are found on the heater’s rating
plate.
Date Installed____________________ Model No. ______________________________________Serial No. ______________________________
Dealer’s Name___________________________________________________________ Phone No. ____________________________________
Dealer’s Address _____________________________________________ City and State _______________________ Zip Code _______________
fIll In warrantY and Keep for future reference.
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500 Tennessee Waltz Parkway, Ashland City, TN 37015
Phone: 800-527-1953 Fax: 800-433-2515
www.statewaterheaters.com
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