1
Instruction Manual
PRINTED 0219 100313411_ 2000554312_Rev D
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
POWER VENT/POWER DIRECT VENT GAS MODELS
WITH DIRECT SPARK IGNITION
300/301 SERIES MODELS
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.
COMMERCIAL GAS WATER HEATERS
• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
Thank you for buying this energy efcient water heater.
We appreciate your condence in our products.
LOW LEAD
CONTENT
2
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE.................................3
APPROVALS .................................................................................3
GENERAL SAFETY INFORMATION .............................................4
Precautions ..............................................................................4
Grounding Instructions .............................................................4
Hydrogen Gas Flammable .......................................................4
INTRODUCTION ...........................................................................7
Abbreviations Used ..................................................................7
Qualications ............................................................................7
BACnet Compatibility ...............................................................7
Preparing For The Installation ..................................................7
DIMENSIONS AND CAPACITY DATA ...........................................8
Rough In Dimensions: 50 Gallon Unit ......................................8
Rough In Dimensions: 75 Gallon Unit ......................................8
FEATURES AND COMPONENTS ..............................................10
Controls And Switches ...........................................................13
INSTALLATION CONSIDERATIONS ..........................................14
Locating The Water Heater ....................................................14
Insulation Blankets .................................................................15
Combustion Air And Ventilation ..............................................15
Unconned Space ..................................................................16
Conned Space ......................................................................16
Fresh Air Openings For Conned Spaces ..............................16
Outdoor Air Through Two Openings .......................................16
Outdoor Air Through One Opening.........................................16
Outdoor Air Through Two Horizontal Ducts ............................17
Air From Other Indoor Spaces ...............................................17
INSTALLATION REQUIREMENTS .............................................18
Chemical Vapor Corrosion......................................................18
Water Piping ...........................................................................18
Power Supply .........................................................................18
Mixing Valves..........................................................................19
Gas Supply Systems ..............................................................20
Gas Pressure Requirements ..................................................20
Supply Gas Regulator ............................................................20
Dishwashing Machines ...........................................................20
Space Heating And Potable Water System ............................21
Closed Water Systems ...........................................................21
Thermal Expansion ................................................................21
Temperature-Pressure Relief Valve ........................................22
Condensate Piping .................................................................22
High Altitude Installations .......................................................23
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH
OF MASSACHUSETTS ...............................................................24
VENTING INSTALLATION ..........................................................25
Vent Installation Considerations .............................................25
Approved Vent/Intake Material ...............................................25
Polypropylene Installations .....................................................26
Vent Pipe Termination.............................................................27
Planning The Vent System .....................................................27
Installation Of Horizontal Through The Wall Vent System ......27
Direct Vent Terminal Installation .............................................28
Direct Vent Air Intake Moisture Protection ..............................28
Installation Sequence .............................................................28
Termination Clearances Sidewall Power Vent ........................29
Termination Clearances Sidewall Direct Vent .........................30
Vertical Vent Terminal Installation ...........................................31
Direct Vent Diagram ...............................................................32
Concentric Vent Installation ....................................................33
Low Prole Termination Installation ........................................36
WATER HEATER INSTALLATION ...............................................37
Condensate Drain Installation ................................................37
Gas Piping ..............................................................................38
Electrical Wiring ......................................................................38
TEMPERATURE REGULATION .................................................40
High Temperature Limit Control (ECO)...................................40
Thermostat Control .................................................................40
High Temperature Applications ...............................................40
CONTROL SYSTEM OPERATION .............................................41
Control System Navigation .....................................................41
User Settings & Control System Menus .................................44
FOR YOUR INFORMATION ........................................................50
Start Up Conditions .....................................................................50
Operational Conditions ................................................................50
START UP ...................................................................................51
Prior to Start Up ......................................................................51
Lighting and Operation Labels ...............................................52
PERIODIC MAINTENANCE ........................................................53
Venting System Inspection .....................................................53
Anode Rod INSPECTION ......................................................53
Temperature-Pressure Relief Valve Test ................................54
Draining and Flushing ............................................................54
Service ...................................................................................55
LEAKAGE CHECKPOINTS .........................................................56
TROUBLESHOOTING ................................................................57
Installation Checklist ...............................................................57
Sequence Of Operation ..........................................................57
Sequence Of Operation Flow Chart .......................................58
Operational Problems .............................................................59
Fault And Alert Conditions ......................................................60
DIAGRAMS ................................................................................62
CCB - Central Control Board Layout ......................................62
Wiring Diagram .......................................................................63
NOTES ........................................................................................65
3
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.
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.
DANGER
WARNING
CAUTION
CAUTION
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
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.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
APPROVALS
SAFE INSTALLATION, USE AND SERVICE
LOW LEAD
CONTENT
4
PRECAUTIONS
DO NOT USE THIS APPLIANCE IF ANY PART HAS
BEEN EXPOSED TO FLOODING OR WATER DAMAGE.
Immediately call a qualified service technician to inspect
the water heater and to make a determination on what steps
should be taken next.
If the unit is exposed to the following, do not operate heater
until all corrective steps have been made by a qualied service
technician.
1. External re.
2. Damage.
3. Firing without water.
GROUNDING INSTRUCTIONS
This water heater must be grounded in accordance with the National
Electrical Code and/or local codes. These must be followed in all
cases. Failure to ground this water heater properly may also cause
erratic control system operation.
This water heater must be connected to a grounded 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.
HYDROGEN GAS FLAMMABLE
Explosion Hazard
Flammable hydrogen gases
may be present.
Keep all ignition sources away
from faucet when turning on
hot water.
Hydrogen gas can be produced in a hot water system served by
this water heater that has not been used for a long period of
time (generally two weeks or more). Hydrogen gas is extremely
ammable. To reduce the risk of injury under these conditions, it is
recommended that a hot water faucet served by this water heater
be opened for several minutes before using any electrical appliance
connected to the hot water system. If hydrogen is present there will
probably be an unusual sound such as air escaping through the pipe
as the water begins to ow. THERE SHOULD BE NO SMOKING
OR OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
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.
Explosion Hazard
Overheated water can cause
water tank explosion.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
Verify the power to the water heater is turned off before performing any service procedures. The
Enable/Disable switch on front panel disables the 24 volt gas valve. Electrical supply must be
turned off at circuit breaker serving water heater.
Improper installation, use and service may result
in property damage.
Do not operate water heater if exposed to flooding or water
damage.
•
Inspect anode rods regularly, replace if damaged.
•
Install in location with drainage.
•
Fill tank with water before operation.
•
Properly sized thermal expansion tanks are required on all
closed water systems.
•
Refer to this manual for installation and service.
CAUTION
GENERAL SAFETY INFORMATION
5
GENERAL SAFETY INFORMATION
6
Fire Hazard
Do not install water heater on
carpeted floor.
Do not operate water heater if
exposed to flooding or water
damage.
For continued protection against
risk of fire:
Fire or Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Avoid all ignition sources if you smell gas.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating plate.
Keep ignition sources away from faucets after extended
periods of non-use.
Maintain required clearances to combustibles.
Do not expose water heater controls to excessive gas
pressure.
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.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Breathing Hazard - Carbon Monoxide Gas
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
CAUTION
Fire and Explosion Hazard
Leak test gas connections
before placing the water heater in
operation.
Disconnect gas piping at main
gas shutoff valve before leak
testing.
Install sediment trap in accordance
with NFPA 54 or CSA B149.1.
Use joint compound or Teflon tape
compatible with propane gas.
Fire and Explosion Hazard
Excessive gas pressure to gas valve can
cause serious injury or death.
Do not use water heater with any gas
other than the gas shown on the rating
plate.
Turn off gas lines during installation.
Contact a qualified installer or service
technician for installation and service.
Turn off power to the water heater
before performing any service.
Electrical Shock Hazard
•
Label all wires prior to disconnecting
when performing service. Wiring errors
can cause improper and dangerous
operation.
•
Verify proper operation after servicing.
•
Failure to follow these instructions can
result in personal injury or death.
•
GENERAL SAFETY INFORMATION
7
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
ABBREVIATIONS USED
Abbreviations found in this Instruction Manual include :
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• AHRI - Air-Conditioning, Heating and Refrigeration Institute
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• UL - Underwriters Laboratory
• CSA - Canadian Standards Association
QUALIFICATIONS
QUALIFIED INSTALLER OR SERVICE AGENCY
Installation and service of this water heater requires ability
equivalent to that of a Qualied Agency (as dened by ANSI below)
in the eld involved. Installation skills such as plumbing, air supply,
venting, gas supply and electrical supply are required in addition to
electrical testing skills when performing service.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualied Agency” - “Any
individual, rm, corporation or company that either in person or
through a representative is engaged in and is responsible for (a)
the installation, testing or replacement of gas piping or (b) the
connection, installation, testing, repair or servicing of appliances
and equipment; that is experienced in such work; that is familiar
with all precautions required; and that has complied with all the
requirements of the authority having jurisdiction.”
If you are not qualied (as dened by ANSI above) and licensed or
certied 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.
BMS/EMS COMPATIBILITY
This water heater is connectable to BACnet or Modbus compliant
Supervisory controls via the ICC BMS Gateway. This allows
connection of the water heater to local Building Management
Systems using Serial RS-485 (MS/TP) or IP connections. To nd
out more about ICC devices, logon to the manufacturer’s website
at http://www.hotwater.com/ or call 888-928-3702 (888-WATER02)
for more information.
PREPARING FOR THE INSTALLATION
1. Read the entire manual before attempting to install or operate
the water heater. Pay close attention to the General Safety
Information on Page 4 through Page 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.
Detailed installation diagrams are also found in this manual.
These diagrams will serve to provide the installer with a
reference. It is essential that all venting, water piping, gas piping
and wiring be installed as shown.
Particular attention should be given to the installation of
thermometers at the locations indicated in the piping diagrams
as these are necessary for checking the operation of the water
heater.
The principal components of the water heater are identied in
Features And Components on Page10 & Page 11 in this manual.
Use this reference to locate and identify various components on
the water heater.
See the Installation Checklist and Troubleshooting on page
57. 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 Qualied Service Agency.
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.
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.
In the absence of local codes, the installation must comply with
the current editions of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54 and the National Electrical Code, NFPA 70 or CAN/
CSA-B149.1, the Natural Gas and Propane Installation Code
and CSA C22.1, the Canadian Electrical Code. All documents
are available from the Canadian Standards Association, 8501
East Pleasant Valley Road, Cleveland, OH 44131. NFPA
documents are also available from the National Fire Protection
Association, 1 Batterymarch Park, Quincy, MA 02269.
4. If after reading this manual you have any questions or do not
understand any portion of the instructions, call the toll free
number found on the warranty sheet provided with the water
heater. 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.
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 14 and the Rough In
Dimensions on Page 8.
.
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 Ofce of the State Architect, 1102 Q
Street, Suite 5100, Sacramento, CA 95811.
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 24.
INTRODUCTION
8
DIMENSIONS AND CAPACITY DATA
ROUGH IN DIMENSIONS: 50 GALLON UNIT
Figure 1A: DIMENSIONS FOR 75 GALLON UNIT
ROUGH IN DIMENSIONS: 75 GALLON UNIT
Figure 1: DIMENSIONS FOR 50 GALLON UNIT
Table 1 – ROUGH-IN-DIMENSIONS
Units A B C D E F G H I
50G
Inches 66-3/4 49-1/4 22 15-3/4 3 8 8 62 65
cm 169.5 125.09 55.88 40.00 7.62 20.32 20.32 157.48 165.1
75G
Inches 65-1/4 45-5/8 27-3/4 16 3-3/4 8 8 57-3/8 59
cm 165.7 115.9 70.5 40.6 9.4 20.3 20.1 145.7 149.8
Top Inlet and Outlet: 50G - 3/4” NPT; 75G - 1” NPT
Side Inlet and Outlet: 3/4” NPT
Gas Inlet: 1/2” NPT
Condensate drain outlet: 1/2” NPT
FRONT VIEW BACK VIEW
9
DIMENSIONS AND CAPACITY DATA
Table 2 – CAPACITY, GAS AND ELECTRICAL CHARACTERISTICS
Approximate Capacity *Manifold Pressure Electrical Characteristics
U.S. Gals. Liters Gas Type “WC kPA Volts/Hz Amperes
50 189 Nat./LP 0 0 120/60 <5
75 284 Nat/LP 0 0 120/60 <5
* The manifold pressure is the factory setting and is not adjustable. A negative pressure will be seen with just the blower running without
the Gas Control Valve open.
All models - 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.
Table 3 – RECOVERY CAPACITIES
Recovery capacity based on 96% thermal efciency.
Input Recovery Capacities
Rating
(Btu/hr)
Rating
(kW)
Temp.
Rise
F 30 40 50 60 70 80 90 100 110 120 130 140
C 17 22 28 33 39 44 50 56 61 67 72 78
100,000 29.3
GPH 387 291 233 194 166 145 129 116 106 97 90 83
LPH 1465 1102 882 734 628 549 488 439 401 367 341 314
10
4
6
7
5
9
* CAUTION HARNESS HAS 120 VAC. IN OPERATION.
** See Venting Installation and Condensate Piping for more information.
Figure 1B : 50 GALLON UNIT
VACUUM RELIEF
VALVE
*INSTALL PER
LOCAL CODES
50 GALLON UNIT
FEATURES AND COMPONENTS
**13
**14
Caution:
This access panel covers
a 2” NPT plug that was required
during the manufacturing of this
water heater. This 2” NPT ange is
not a cleanout tting, removing the
2” NPT plug and using this tting as
a cleanout could void your warranty.
ACCESS PANEL
11
4
6
7
5
9
* CAUTION HARNESS HAS 120 VAC. IN OPERATION.
** See Venting Installation and Condensate Piping for more information.
VACUUM RELIEF
VALVE
*INSTALL PER
LOCAL CODES
75 GALLON UNIT
FEATURES AND COMPONENTS (CONT.)
Figure 1C: 75 GALLON UNIT
**13
**14
Caution:
This access panel covers
a 2” NPT plug that was required
during the manufacturing of this
water heater. This 2” NPT ange is
not a cleanout tting, removing the
2” NPT plug and using this tting as
a cleanout could void your warranty.
ACCESS PANEL
12
FEATURES AND COMPONENTS (CONT.)
1: Central Control Board (CCB) Enclosure
2: Blocked Intake Switch
3: Blocked Outlet Switch
4: Blower Assembly
5: Burner Assembly
6: Flame Sensor
7: Igniter Assembly
8: Junction Box
9: Gas Control Valve Assembly
10: UIM (user interface module)
11: Top Plastic Enclosure
12: Display Enclosure
** 13: Exhaust Elbow Assembly
** 14: Condensate Drain Outlet
15: Enable / Disable Switch
16: Hot Water Outlet
17: Gas Supply
18: Main Manual Gas Shutoff Valve
19: Union
20: Inlet Water Shutoff Valve
21: Cold Water Inlet
22: Inlet Dip Tube
23: T/P Relief Valve
24: Rating Plate
25: Labels
26: Drain Valve
** 27: Vent Terminal
28: Drain Pan
29: Anode Rod
30: Insulation
31: Temperature Probe
32: Access Door
33: Spark Module
13
CONTROLS AND SWITCHES
This model is provided with two pressure switches. These switches
are essential to the safe and proper operation of the unit. The switches
are wired in series. The controller is set up to shut the unit down
whenever there is a failure of either of the switches. It is important
to understand the purpose of both switches.
50 GALLON UNIT
75 GALLON UNIT
Figure 2
BLOCKED OUTLET SWITCH
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 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 ow 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.
BLOCKED INTAKE SWITCH
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.
Ensure the screen on intake air connection has been removed on
direct vent installations, see Figure 14. Also verify the intake air pipe
length does not exceed the maximum allowed as shown in the Vent
Section of this manual.
WATER HEATING ENABLE/DISABLE SWITCH
IMPORTANT: The Enable/Disable switch listed in this manual is NOT
an “on/off” switch and does not disconnect 120 volt power to the CCB
and other heater components.
Water Heater’s Enable/Disable Switch. When in the “Disabled”
position the switch removes electrical power from the gas valve so
that water heating is disabled. The display, CCB, and other electrical
components will still be energized and the display will read “Water
Heating Disabled”.
SPARK IGNITER
The Spark Igniter is a device that ignites the main burner by spark.
When high voltage is applied to the igniter, spark is generated to
ignite the main burner.
CONFIGURATION KEY
The configuration key is located inside the control box.
It provides for the ability of the heater to retain information
collected over its lifetime, even if the control board is replaced
because of failure.
The conguration key should stay with the heater.
POWERED ANODE ROD
Some of the models covered in this manual are equipped with a
powered (non-sacricial) anode rod. Protective current is fed by the
control system to the titanium electrode at the end of the anode rod.
This current ows through the water to the conductive surfaces inside
the storage tank which diminishes the corrosive effect of water when
it comes in contact with steel.
NOTE: To see if a powered anode rod is installed, check the Heater
Status menu of the UIM (user interface module). Refer to Features
and Components (page 10) to locate the UIM. If the water heater is
equipped with a powered anode rod, this menu will display the Anode
Current, Anode Tank Voltage, and Anode Drive Voltage statuses.
See Heater Status Menu (page 45) for more information.
14
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
water heater.
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
CAUTION
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 oor 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 oors of the structure. When
such locations cannot be avoided, it is recommended that
a metal drain pan, piped to adequate drain, be installed
under the water heater. Drain pan should be fabricated with
sides at least 2” deep with diameter at least 2” greater than
diameter of heater.
6. Locate the water heater close to the point of major hot
water usage.
7. Locate the water heater close to a 120 VAC power supply.
See Power Supply on Page 18 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 15.
9. Locate the water heater where the vent and intake air piping,
when installed, will remain within the maximum equivalent
lengths allowed. See Venting Installation on page 25.
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 Installation on page 25.
Do not locate water heater 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 ignition device or main burner.
The resulting flashback and fire can cause death or serious
burns to anyone in the area.
When the water heater is installed directly on carpeting, the water
heater shall be installed on a metal or wood panel extending
beyond the full width and depth of the water heater by at least 3
in (76.2 mm) in any direction or, if the water heater is installed in
an alcove or closet, the entire oor shall be covered by the panel.
The panel must be strong enough to carry the weight of the heater
when full of water.
INSTALLATION CONSIDERATIONS
15
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 water heater should
be considered before installation, such as changing the anode rods,
control system components and gas control 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, temperature-pressure relief valve, clean out opening,
and the vent connection (exhaust elbow).
When installing the heater, consideration must be given to proper
location. Location selected should be as close to the wall as practicable
and as centralized with the water piping system as possible.
Figure 3: CLEARANCES
INSULATION BLANKETS
Insulation blankets are available to the general public for external use
on gas water heaters but are not necessary with these products. The
purpose of an insulation blanket is to reduce the standby heat loss
encountered with storage tank heaters. Your water heater meets or
exceeds the Energy Policy Act standards with respect to insulation and
standby loss requirements, making an insulation blanket unnecessary.
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions (For identication of components
mentioned below, see Figure 1B & Figure 1C). Failure to follow these
instructions can restrict the air ow required for proper combustion,
potentially resulting in re, asphyxiation, serious personal injury or death.
• Do not apply insulation to the top of the water heater, as this will
interfere with safe operation of the blower assembly.
• Do not cover the control system LCD on top of the water heater.
• Do not cover the 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.
• Do inspect the insulation blanket frequently to make certain it does
not sag, thereby obstructing combustion air ow.
COMBUSTION AIR AND VENTILATION
A gas water heater cannot operate properly without the correct
amount of air for combustion. Do not install in a conned area such
as a closet, unless you provide air as shown in the Locating The
Water Heater section. Never obstruct the ow 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 re or explosion and cause death, serious bodily injury, or
property damage.
Figure 4: COMBUSTION AIR AND VENTILATION
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.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorine based chemicals, refrigerants, etc.) in addition to being
highly ammable in many cases, will also react to form corrosive
acids when exposed to the combustion products of the water heater.
The results can be hazardous, and also cause product failure.
16
UNCONFINED SPACE
An Unconned 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 unconned space.
Makeup air requirements for the operation of exhaust fans, kitchen
ventilation systems, clothes dryers and replaces shall also be
considered in determining the adequacy of a space to provide
combustion, ventilation and dilution air.
UNUSUALLY TIGHT CONSTRUCTION
In unconned spaces in buildings, inltration may be adequate to
provide air for combustion, ventilation and dilution of ue 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
Conned Space section that follows.
CONFINED SPACE
A Conned Space is one whose volume IS 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.
Openings must be installed to provide fresh air for combustion,
ventilation and dilution in conned spaces. The required size for
the openings is dependent on the method used to provide fresh
air to the conned space AND the total Btu/hr input rating of all
appliances installed in the space.
DIRECT VENT APPLIANCES
Appliances installed in a Direct Vent conguration 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 conned spaces.
EXHAUST FANS
Where exhaust fans are installed, additional air shall be provided
to replace the exhausted air. When an exhaust fan is installed in
the same space with a water heater, sufcient 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 re or explosion may
result. It can also create a risk of asphyxiation.
LOUVERS AND GRILLES
The free areas of the fresh air openings in the instructions that
follow do not take in to account the presence of louvers, grilles or
screens in the openings.
The required size of openings for combustion, ventilation and
dilution air shall be based on the net free area of each opening.
Where the free area through a design of louver or grille or screen is
known, it shall be used in calculating the size of opening required to
provide the free area specied. 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 xed in the
open position.
FRESH AIR OPENINGS FOR CONFINED SPACES
The following instructions shall be used to calculate the size, number
and placement of openings providing fresh air for combustion,
ventilation and dilution in conned spaces. The illustrations shown
in this section of the manual are a reference for the openings
that provide fresh air into conned spaces only. DO NOT refer to
these illustrations for the purpose of vent installation. See Venting
Installation on Page 25 for complete venting installation instructions.
OUTDOOR AIR THROUGH TWO OPENINGS
Figure 5
The conned 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 5.
Each opening shall have a minimum free area of 1 square inch per
4,000 Btu/hr (550 mm
2
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 cm
2
).
OUTDOOR AIR THROUGH ONE OPENING
Figure 6
17
Alternatively a single permanent opening, commencing within 12
inches (300 mm) of the top of the enclosure, shall be provided.
See Figure 6. The water heater shall have clearances of at
least 1 inch (25 mm) from the sides and back and 6 inches (150
mm) from the front of the 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:
1. 1 square inch per 3000 Btu/hr (733 mm
2
per kW) of the total
input rating of all appliances located in the enclosure, and
2. Not less than the sum of the areas of all vent connectors in the space.
OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS
Figure 7
The conned 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 7.
Each duct opening shall have a minimum free area of 1 square inch
per 2,000 Btu/hr (1100 mm
2
per kW) of the aggregate input rating of
all appliances installed in the enclosure.
When ducts are used, they shall be of the same cross sectional
area as the free area of the openings to which they connect. The
minimum dimension of rectangular air ducts shall be not less than
3 inches.
AIR FROM OTHER INDOOR SPACES
Figure 8
The conned 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 8.
Each opening shall communicate directly with an additional room(s)
of sufcient volume so that the combined volume of all spaces
meets the criteria for an Unconned Space.
Each opening shall have a minimum free area of 1 square inch per
1,000 Btu/hr (2200 mm
2
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 cm
2
).
18
INSTALLATION REQUIREMENTS
CHEMICAL VAPOR CORROSION
Corrosion of the ueways 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.
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).
WATER PIPING
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 ts 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 satises 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 9. Valves for reducing point of use temperature by
mixing cold and hot water are also available:
Consult a Qualied 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.
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.
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 mixing valve must be installed. Please refer to Figure 9 for
suggested piping arrangement.
These water heaters cannot be used in space heating
applications only.
POWER SUPPLY
The water heaters covered in this manual require a 120
VAC, 1Ø (single phase), 60Hz, 5 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 or the Canadian Electrical
Code, CSA C22.1.
If any of the original wire as supplied with the water heater must
be replaced, it must be replaced with 105°C rated wiring or its
equivalent, except in the burner housing. In this case 200°C rated
wire must be used.
19
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.
NOTE: This water heater should not be connected to an electrical
supply with a Ground Fault Circuit Interrupter (GFCI) or Arc Fault
Circuit Interrupter (AFCI) with Integral GFCI protection as dened
in NFPA 70, CSA C22.1 and UL 943.
POWER FLUCTUATIONS AND ELECTRICAL NOISE
The water heater’s control system requires a source of
stable clean electricity for proper operation. Connecting
the water heater to a branch circuit that is subject to
fluctuations in voltage level or electrical line noise such as
EMI (electro magnetic interference) or RFI (radio frequency
interference) may cause erratic control system operation
and malfunction.
A high quality power supply filter/suppressor must be
installed if the above conditions exist. Call the technical
support phone number listed on the back cover of this
manual for more information.
NOTE: Malfunctions caused by the power supply and the
costs to install power supply filters are not covered under
the limited warranty.
MIXING VALVES
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
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.
Water heated to a temperature which will satisfy clothes washing,
dish washing, and other sanitizing needs can scald and cause
permanent injury upon contact. Short repeated heating cycles
caused by small hot water uses can cause temperatures at the
point of use to exceed the water heater’s temperature setting by
up to 20°F (11°C).
Some people are more likely to be permanently injured by hot water
than others. These include the elderly, children, the inrm and the
physically/mentally disabled. Table 4 shows the approximate time-to-
burn relationship for normal adult skin. If anyone using hot water provided
by the water heater being installed ts into one of these groups or if there
is a local code or state law requiring a certain water temperature at the
point of use, then special precautions must be taken.
In addition to using the lowest possible temperature setting that
satises the demand of the application a Mixing Valve should be
installed at the water heater (see Figure 9) or at the hot water taps to
further reduce system water temperature.
Mixing valves are available at plumbing supply stores. Consult
a Qualied Installer or Service Agency. Follow mixing valve
manufacturer’s instructions for installation of the valves.
In all cases, the following burn table must be used.
Table 4
Water Temperature
°F (°C)
Time for 1st Degree Burn
(Less Severe Burns)
Time for Permanent
Burns
2nd & 3rd Degree
(Most Severe Burns)
110 (43.3) (normal shower temp.)
116 (46.7) (pain threshold)
116 (46.7) 35 minutes 45 minutes
122 (50) 1 minute 5 minutes
131 (55) 5 seconds 25 seconds
140 (60) 2 seconds 5 seconds
149 (65) 1 second 2 seconds
154 (67.8) instantaneous 1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)
20
GAS SUPPLY SYSTEMS
Low pressure building gas supply systems are dened as those
systems that cannot under any circumstances exceed 14” W.C. (1/2
PSI Gauge). These systems do not require pressure regulation.
Measurements should be taken to insure that gas pressures are
stable and fall within the requirements stated on the water heater
rating plate. Readings should be taken with all gas burning equipment
off (static pressure) and with all gas burning equipment running at
maximum rate (dynamic pressure). The gas supply pressure must
be stable within 1.5” W.C. from static to dynamic pressure to provide
good performance. Pressure drops that exceed 1.5” W.C. may cause
rough starting, noisy combustion or nuisance outages. Increases or
spikes in static pressure during off cycles may cause failure to ignite
or in severe cases damage to water heater gas control valves. If
your low pressure system does NOT meet these requirements, the
installer is responsible for the corrections.
High pressure building supply systems use pressures that exceed
14” W.C. (1/2 PSI Gauge). These systems must use eld supplied
regulators to lower the gas pressure to less than 14” W.C. (1/2 PSI
Gauge). Appliances require gas regulators that are properly sized
for the water heater input and deliver the rating plate specied
pressures. Gas supply systems where pressure exceeds 5 PSI often
require multiple regulators to achieve desired pressures. Systems in
excess of 5 PSI building pressure should be designed by gas delivery
professionals for best performance. Water heaters connected to gas
supply systems that exceed 14” W.C. (1/2 PSI Gauge) at any time
must be equipped with a gas supply regulator.
GAS PRESSURE REQUIREMENTS
All models require a minimum gas supply pressure of 3.5” W.C.(0.87
kPa) for natural gas and 8.0” W.C. (1.99 kPa) for propane. The
minimum supply pressure is measured while gas is not owing
(static pressure) AND while gas is owing (dynamic pressure). The
supply pressure (static and dynamic) should never fall below 3.5”
W.C.(0.87 kPa) for natural gas or 8.0” W.C. (1.99 kPa) for propane.
The supply pressure should be measured with all gas red water
heaters connected to the common main ring at full capacity. If the
supply pressure drops more than 1.5” W.C. (0.37 kPa) as gas begins
to ow to the water heater then the supply gas system including the
gas line and/or the gas regulator may be restricted or undersized.
See Supply Gas Regulator section and Gas Piping section of this
manual. The gas control valve on all models has a maximum gas
supply pressure limit of 14” W.C.(3.48 kPa) The maximum supply
pressure is measured while gas is not owing (static pressure) AND
while gas is owing (dynamic pressure).
SUPPLY GAS REGULATOR
The maximum allowable gas supply pressure for this water heater
is 14 inches W.C. (3.5 kPa). Install a positive lock-up gas pressure
regulator in the gas supply line if inlet gas pressure can exceed 14
inches W.C. (3.5 kPa) at any time. Regulators must be sized/used
according to manufacturer’s specications.
If a positive lock-up regulator is required follow these instructions:
1. Positive lock-up gas pressure regulators must be rated at or above
the input Btu/hr rating of the water heater they supply.
2. Supply gas regulators shall have inlet and outlet connections not
less than the minimum supply gas line size for the water heater
they supply
3. Positive lock-up gas pressure regulator(s) should be installed no
closer than 3 feet (1 meter) and no farther than 8 feet (2.4 meters)
from the water heater’s inlet gas connection.
4. After installing the positive lock-up gas pressure regulator(s) an
initial nominal supply pressure setting of 7.0” W.C.(1.74 kPa) for
Natural Gas and 11.0” W.C. (2.74 kPa) for Propane (LP) while
the water heater is operating is recommended and will generally
provide good water heater operation. Some additional adjustment
may be required later to maintain a steady gas supply pressure.
5. When installing multiple water heaters in the same gas supply
system it is recommended that individual positive lock-up gas
pressure regulators be installed at each unit.
All gas piping must comply with local codes and ordinances or with
the current editions National Fuel Gas Code (ANSI Z223.1/ NFPA-
54) or the Natural Gas and Propane Installation Code (CAN/CSA
B149.1) whichever applies. Copper or brass tubing and ttings
(except tin lined copper tubing) shall not be used.
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 re
or explosion from leaking gas.
If the main gas line Shut-off serving all gas water heaters is used,
also turn off the gas at each water heater. Leave all gas appliances
shut off until the water heater installation is complete.
A gas line of sufcient size must be run to the water heater. Consult
the current edition of National Fuel Gas Code (ANSI Z223.1/NFPA
54) or the Natural Gas and Propane Installation Code (CAN/CSA
B149.1) 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
• A sediment trap ahead of the gas control valve to help prevent dirt
and foreign materials from entering the gas control valve.
• A ground joint union of proper size between the manual 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 ame.
Rinse off soapy solution and wipe dry.
DISHWASHING MACHINES
All dishwashing machines meeting the National Sanitation
Foundation requirements are designed to operate with water ow
pressures between 15 and 25 pounds per square inch (103 kPa
and 173 kPa). Flow pressures above 25 pounds per square inch
(173 kPa), or below 15 pounds per square inch (103 kPa), will result
in improperly sanitized dishes. Where pressures are high, a water
pressure reducing or ow regulating control valve should be used
in the 180°F (82°C) line to the dishwashing machine and should be
adjusted to deliver water pressure between these limits.
HOT WATER
OUTLET
TO TANK
INLET
CHECK
VALVE
MIXING
VALVE
COLD
WATER
INLET
TEMPERED WATER
OUTLET
12” TO 15”
(30-38 cm)
CHECK
VALVE
Figure 9
The National Sanitation Foundation also recommends circulation of
180°F (82°C) water. The circulation should be just enough to provide
180°F (82°C) water at the point of take-off to the dishwashing
machine.
Adjust ow by throttling a full port ball valve installed in the circulating
line on the outlet side of the pump. Never throttle ow on the suction
side of a pump.
Note: To comply with NSF Standard 5 installation requirements the
bottom of the water heater must be sealed to the oor with a silicone
based sealant or elevated 6 inches above the oor.
21
SPACE HEATING AND POTABLE WATER SYSTEM
Your water heater is equipped with inlet/outlet connections for use
in space heating applications (see Figure 10). If this water heater
is to be used to supply both space heating and potable (drinking)
water, the instructions listed below must be followed:
• Be sure to follow the manual(s) shipped with the air handler or
other type heating system.
• This water heater cannot be used in space heating applications
only.
• This water heater is not to be used as a replacement for an
existing boiler installation.
• 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 mixing valve must be installed per the manufacturer’s
instructions in the potable hot water supply to limit the risk of scald
injury.
• Pumps, valves, piping and ttings must be compatible with
potable water.
• A properly installed ow control valve is required to prevent
thermosiphoning. Thermosiphoning is the result of a continuous
ow of water through the air handler circuit during the off cycle.
Weeping (blow off) of the temperature and pressure relief valve
(T & P relief valve) or higher than normal water temperatures are
the rst signs of thermosiphoning.
• The hot water line from the water heater should be vertical past
any mixing valve or supply line to the heating system to remove
air bubbles from the system 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.
Figure 10
CLOSED WATER SYSTEMS
Water supply systems may, because of code requirements or such
conditions as high line pressure, among others, have installed
devices such as pressure reducing valves, check valves, and back
ow preventers. Devices such as these cause the water system to
be a closed system.
THERMAL EXPANSION
As water is heated, it expands (thermal expansion). In a closed
system the volume of water will grow when it is heated. As the
volume of water grows there will be a corresponding increase in
water pressure due to thermal expansion. Thermal expansion can
cause premature tank failure (leakage). This type of failure is not
covered under the limited warranty. Thermal expansion can also
cause intermittent temperature-pressure relief valve operation:
water discharged from the valve due to excessive pressure build
up. This condition is not covered under the limited warranty. The
temperature-pressure relief valve is not intended for the constant
relief of thermal expansion.
A properly sized thermal expansion tank should be installed on all
closed systems to control the harmful effects of thermal expansion.
Contact a local plumbing service agency to have a thermal
expansion tank installed.
NOTE: To protect against untimely corrosion of hot and cold
water ttings, it is strongly recommended that di-electric unions
or couplings be installed on this water heater when connected
to copper pipe, see Figure 11 also.
Figure 11
Figure 11 show the typical attachment of the water piping to
the water heater. The water heater is equipped with 3/4 inch
NPT water connections for 50 gallon unit and 1 inch NPT water
connections for 75 gallon unit..
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)
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.
22
T&P VALVE DISCHARGE PIPE REQUIREMENTS:
• Shall not be smaller in size than the outlet pipe size of the valve,
or have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both the
Temperature-Pressure Relief Valve and the discharge pipe.
• Must terminate a maximum of six inches (15.2 cm) above a
oor drain or external to the building. In cold climates, it is
recommended that the discharge pipe be terminated at an
adequate drain inside the building.
• Shall not have any valve or other obstruction between the
temperature-pressure relief valve and the drain.
Burn hazard.
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: 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. A properly sized thermal expansion tank must be
installed on all closed systems to control thermal expansion, see
Closed Water Systems and Thermal Expansion on Page 21.
If you do not understand these instructions or have any questions
regarding the Temperature-Pressure Relief Valve call the toll free
number found on the warranty sheet provided with the water heater
for technical assistance.
CONDENSATE PIPING
The water heaters covered in this manual are condensing
appliances and require a building drain to be located in close
proximity to allow the condensate to drain safely.
Condensate drains from the water heater at the exhaust elbow
located at the bottom. The eld installed condensate drain line
must not be elevated above the condensate drain connection on
the condensate trap, see Figure 12. If the condensate does not
drain properly it will build up in the exhaust (vent) elbow. This will
restrict the ow of ue gases and cause the Blocked Exhaust
pressure switch to open its contacts. The control system monitors
all pressure switches, if the Blocked Exhaust Switch contacts are
open the control system will lock out and disable heating operation.
The “Blocked Exhaust” Fault message will be displayed on the
control system’s LCD.
The Condensate Cleanout Cap must be on and tight when unit is
in operation.
NOTE: If the “Blocked Exhaust “ Fault message is ever displayed
on the control system LCD, check the condensate drain rst and
ensure it is not blocked.
TEMPERATURE-PRESSURE RELIEF VALVE
This water heater is provided with a properly rated/sized and certied
combination Temperature-Pressure Relief Valve (T&P relief valve) by
the manufacturer. The valve is certied 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.
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 certied 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.
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.
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.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
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 tting 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 oor drain, or external to the
building. In cold climates it is recommended that it be terminated at
an adequate drain inside the building. Be certain that no contact is
made with any live electrical part. The discharge opening must not
be blocked or reduced in size under any circumstances. Excessive
length, over 30 feet (9.14 m), or use of more than four elbows can
cause restriction and reduce the discharge capacity of the valve.
No valve or other obstruction is to be placed between the
Temperature-Pressure Relief Valve and the tank. Do not connect
discharge piping directly to the drain unless a 6” (15.2 cm) air gap
is provided. To prevent bodily injury, hazard to life, or property
damage, the temperature-pressure 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 ow may cause property damage.
Water Damage Hazard
Temperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
•
CAUTION
23
EXHAUST (VENT)
ELBOW
THIS SIDE VIEW
OF EXHAUST
ELBOW AND
ARROW INDICATE
THE LOCATION OF
THE PRESSURE
PORT
BUILDING
DRAIN
CONDENSATE
CLEANOUT CAP
CONDENSATE DRAIN
LINE - FIELD INSTALLED
CONDENSATE
DRAIN LINE
CONNECTION
DRAIN LINE TO TERMINAT
E NO
MORE THAN 6 INCHES (15.2
cm)
ABOVE DRAIN
Figure 12
DO NOT remove the factory installed exhaust/condensate elbow
for any reason, see Figure 12. The water heater’s vent pipe is
under a slight positive pressure while unit is in operation. The
water trap inside of the exhaust/condensate elbow prevents ue
gases from escaping into the installed space.
Do not install any external condensate trap. The exhaust elbow
assembly has an internal condensate trap.
CONDENSATE PH LEVEL
The condensate drains from the water heater’s covered in this
manual have PH levels between 4.3 and 5.0. Install a commercially
available neutralizing kit if required by local codes.
NOTE: Lower PH levels are acidic. Do not connect a metal drain
line, such as copper, to the water heater for this reason. See
Condensate Drain Installation (page 39).
HIGH ALTITUDE INSTALLATIONS
This high efciency water heater is certied for use without
modication for an altitude of 10,100 feet (3,078 m). Consult the
factory for installation at altitudes over 10,100 feet (3,078 m).
Some gas utility companies derate their gas for altitude, making it
unnecessary to install high altitude orices. Call the local gas or
utility company to verify BTU content.
Due to the input rate reduction at high altitudes, the output rating
of the water heater is also reduced and should be compensated
for in the sizing of the equipment for applications.
24
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 nished grade in the
area of the venting, including but not limited to decks and porches, the following requirements should be satised:
INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled
equipment, the installing plumber or gastter should observe that a hard wired carbon monoxide detector with an alarm and battery
back-up is installed on the oor level where the gas equipment is to be installed. In addition, the installing plumber or gastter should
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 should be the responsibility of the property owner
to secure the services of qualied licensed professionals for the installation of hard wired carbon monoxide detectors.
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 oor level.
In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner should
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 should be installed.
APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above
provisions should comply with NFPA 720 and be ANSI/UL 2034 listed and CSA certied.
SIGNAGE A metal or plastic identication plate should 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 should 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 should not approve the
installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance
with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
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
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.
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 should include:
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.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer
of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the ue
gases, but identies special venting systems, the following requirements should be satised by the manufacturer:
1. The referenced special venting system instructions should be included with the appliance or equipment installation instructions; and
2. The special venting systems should be Product Approved by the Board, and the instructions for that system should include
a parts list and detailed installation instructions.
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 should remain with the appliance or
equipment at the completion of the installation.
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS
25
VENT INSTALLATION CONSIDERATIONS
This water heater can be vented using room air for intake
combustion air, or direct vented so that all intake air for
combustion comes from the outside through a sealed pipe.
The water heater venting may be installed in 4 separate
orientations depending on the requirements of the building and
the water heater. The installer must decide which method is
most appropriate for each installation. These orientations are:
1. Vertical Termination - vertical vent termination through
unenclosed or enclosed areas with roof penetration, refer
to Vertical Vent Terminal Installation on Page 31.
2. Through-the-Wall Termination - horizontal vent termination
directly through an outside wall, see Figure 13 on Page 27.
3. Horizontal Direct Vent - using Through-the-Wall Termination
to exhaust flue products and piping to bring combustion air
to the water heater from the outside. See Figure 15 on
Page 28 and Figure 23 and Figure 24 on page 32.
4. Vertical Direct Vent - using a vertical vent termination to
exhaust flue products and piping to bring combustion air
to the water heater from outside, see Figure 21 & Figure
22 on Page 32.
In cold climates any water vapor remaining in the flue gases
will condense into a cloud of vapor at the point where the
vent system exits the building. Special consideration is
recommended, before locating the vent termination near
walkways, windows and building entrances.
Direct venting into dead spaces such as alleys, atriums,
and inside corners can cause recirculation of flue gases.
Recirculation of flue gases will cause sooting, and icing of the
combustion air intake during severe cold weather. To prevent
the recirculation of flue gases, maintain as much distance as
possible between the combustion air intake and the exhaust
vent terminal refer to Figure 16 and Figure 17 on Page 29 &
Page 30 respectively.
APPROVED VENT/INTAKE MATERIAL
Approved vent and intake air pipe materials that may be used in
the United States:
PVC pipe materials:
• DWV ASTM-D2665 or CSA B181.2
• Schedule 40, 80, 120 ASTM-D1785 or CSA B137.3
• SDR Series ASTM-2241 or CSA B137.3
CPVC pipe materials:
• CPVC 41 ASTM-D2846 or CSA B137.6
• Schedule 40, 80 ASTM-F441 or CSA B137.6
• SDR Series ASTM-F442
Polypropylene - See page 26
• M & G Duravent PolyPro vent system
• Centrotherm InnoFlue vent system
Approved vent pipe materials that must be used in Canada:
• ULC S636 PVC / CPVC
• ULC S636 Polypropylene - See page 26
Approved intake air pipe materials that must be used in Canada:
PVC pipe materials:
• DWV ASTM-D2665 or CSA B181.2
• Schedule 40, 80, 120 ASTM-D1785 or CSA B137.3
• SDR Series ASTM-D2241 or CSA B137.3
CPVC pipe materials:
• CPVC 41 ASTM-D2846 or CSA B137.6
• Schedule 40, 80 ASTM-F441 or CSA B137.6
• SDR Series ASTM-F442
Polypropylene - See page 26
• M & G Duravent PolyPro vent system
• Centrotherm InnoFlue vent system
NOTE:
The use of cellular core PVC (ASTM F891), cellular core CPVC,
or Radel® (polyphenolsulfone) in non-metallic venting systems is
prohibited. Covering non-metallic vent pipe and ttings with thermal
insulation is prohibited.
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
ttings 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.
NOTE: For water heaters in locations with high ambient
temperatures above 100°F (38°C) it is recommended that CPVC or
Polypropylene pipe and ttings be used.
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.
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 ue gases. Such
conditions cause sooting of the combustion chamber, burners and
ue tubes and creates a risk of asphyxiation.
For direct vent application where combustion air might be supplied
from cold outdoor ambient temperatures through the fresh air
intake piping system, it is recommended that a backow preventer
and / or a drain tee be installed in the air intake before proceeding
with installation of the rest of the fresh air intake piping. See the
section on Direct Vent Air Intake Moisture Prevention or call the toll
free number found on the warranty sheet provided with the water
heater for technical assistance.
VENTING INSTALLATION
26
POLYPROPYLENE INSTALLATIONS
The water heater has been approved to be installed with
Polypropylene vent material as shown in Table 5 and Table 6. The
approved application of single wall, non-exible, non-concentric
Polypropylene vent material is offered by two specic manufacturers
(Centrotherm ECO Systems and DuraVent Polypropylene). These
listed products must be installed by following the vent manufacturer’s
instructions. Refer to Table 7 on Page 27 to determine the maximum
pipe length and number of elbows that can be used.
Insulation should not be used on Polypropylene venting materials.
The use of insulation will cause increased vent wall temperatures,
which could result in vent pipe failure.
Use only the adapters and vent system listed in Tables below. DO
NOT mix vent systems of different types or manufacturers. Failure
to comply could result in severe personal injury, death, or substantial
property damage.
Table 5
M & G Duravent PolyPro
Nominal Pipe
Diameter
Flue Outlet Adapter
Adapter
Connector
Ring
Connector
90 Degree
Elbow
Vent Material Terminal(s)
2” 2PPS-AD PPS-PAC 2PPS-LB 2PPS-E90 2PPS
2PPS & 2PPS-BG for Exhaust;
2PPS-E90 & 2PPS-BG for Intake (Direct Vent
only)
3” 3PPS-AD PPS-PAC 3PPS-LB 3PPS-E90 3PPS
3PPS & 3PPS-BG for Exhaust;
3PPS-E90 & 3PPS-BG for Intake (Direct Vent
only)
Installations must comply with applicable national, state, and local
codes. For Canadian installation, Polypropylene vent must be
listed as a ULC-S636 approved system. If Polypropylene vent is
not required by your local code, you may use either PVC or CPVC
pipes for your water heater that allows non-metallic venting material
installations.
Polypropylene vent systems do not use cement to connect the pipe
and elbow sections but use a push together gasket seal method.
Do not attempt to connect Polypropylene with sealant cement. All
vent connections MUST be secured by the vent manufacturer’s joint
connector. The installer must use a specic vent starter adapter at
the ue connection. The adapter is supplied by the vent manufacturer
to adapt to its vent system.
In order to be in full compliance with UL 1738 or ULC-S636 and to
meet the requirements of the water heater manufacturer, you must
use the metal joint connector rings, available from the Polypropylene
vent manufacturer, to stiffen the joints of 2”, and 3” diameter pipes.
Table 6
Centrotherm InnoFlue SW
Nominal Pipe
Diameter
Flue Outlet Adapter
Adapter
Connector
Ring
Connector
90 Degree
Elbow
Vent Material Terminal(s)
2”
ISAGL
0202
IAFC02 IANS02 ISELL0287 ISVL02
ISVL02 & IASPP02 for Exhaust;
ISELL0287 & IASPP02 for Intake (Direct Vent
only)
3”
ISAGL
0303
IAFC03 IANS03 ISELL0387 ISVL03
ISVL03 & IASPP03 for Exhaust;
ISELL0387 & IASPP03 for Intake (Direct Vent
only)
27
INSTALLATION OF HORIZONTAL THROUGH THE
WALL VENT SYSTEM
If you are installing your system so that it vents through roof, please
refer to section titled VERTICAL VENT TERMINAL INSTALLATION.
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 nished
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
Chisel an opening approximately one half inch (1.3 cm) larger
than the marked circle.
B) WOODEN SIDE WALLS
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 wall
plate.) Repeat this step on inside wall if necessary.
Cut a length of 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.
Slide the wall plate over the pipe to stop against the vent terminal.
Place a bead of caulking (not supplied) around the gap between the
pipe and cover plate. Apply enough to ll 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 coupling on the other side of the wall, making sure that the
vent terminal ends up pointed in the correct position, see Figure 13.
Figure 13: VENT TERMINATION
VENT PIPE TERMINATION
The rst step is to determine where the vent pipe will terminate.
See Figure 13, Figure 14A, and Figure 15. The vent may terminate
through a sidewall as shown in Figure 13, Figure 14A and Figure 15
or through the roof as shown in Figure 18, Figure 19 and Figure 20.
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, 12.9.1 through 12.9.4) or
the Natural Gas and Propane Installation Code (CAN/CSA-B149.1).
See Figure 16 and Figure 17.
Instructions on proper installation through a sidewall are provided
in Figure 13, Figure 14A, and Figure 15.
Plan the vent system layout so that proper clearances are
maintained from plumbing and wiring.
Vent pipes serving power vented water heaters are classied by
building codes as vent connectors. Required clearances from
combustible materials must be provided in accordance with information
in this manual under Locating The Water Heater and Installation
Requirements, 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
planned location of the vent terminal. Water heaters covered by
these instructions are Category IV appliances.
1. Layout total vent system to use a minimum of vent pipe and
elbows.
2. This water heater is capable of venting ue gases in equivalent
feet of pipe as listed in Table 7.
Table 7
Number of
90° Elbows
2” Maximum
Pipe - ft. (m)
3” Maximum
Pipe - ft. (m)
1 40 (12.19) 120 (36.57)
2 35 (10.66) 115 (35.05)
3 30 (9.14) 110 (33.52)
4 25 (7.62) 105 (32)
5 20 (6.09) 100 (30.48)
6 15 (4.57) 95 (28.95)
The minimum vent length for each of the pipe size is one 90° elbow
plus 2’ and 7’ (0.61 m and 2.1 m) of straight pipe for air intake and
exhaust vent respectively 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 and number of elbows
shown in Table 7.
If using 2” inch vent pipe: A 2” diameter vent pipe must be
inserted and fastened to the exhaust elbow assembly.
If using 3” inch vent pipe: Two inches (5.1cm) of 2” diameter pipe
must be inserted and fastened to the exhaust elbow assembly
before adding a 2’ x 3” reducer to acquire the desired pipe
diameter. A 3” coupling (supplied locally-a schedule 40 DWV)
vent terminal must be obtained. A 3” diameter screen is supplied
in the vent kit.
28
DIRECT VENT TERMINAL INSTALLATION
The air intake provided on the unit contains an air intake screen to
prevent large particles from entering the unit.
Figure 14: Air Intake Screen
When the unit is to be set up as a direct vent, the air intake screen
must be removed. The air intake pipe may then be glued to the air
intake (see Figure 14) provided on the unit.
This unit consists of two terminals - an air intake terminal and an
exhaust vent terminal. The air intake terminal is a 2” 90° pvc elbow
with an air intake screen and the exhaust vent terminal is a 2” straight
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 14A
DIRECT VENT AIR INTAKE MOISTURE PROTECTION
The air intake piping in a direct vent system will normally not
have any moisture accumulation in it. However, in cer tain cases,
moisture may build up and needs to be drained. Typical situations
include, but are not limited to:
* Cold outdoor temperature, particularly if the air inlet is short,
* Heater being used mostly for space heating and
* Air inlet pipe has vertical rise near the heater.
Installations with any of these conditions are required to provide
a moisture drain with a trap that ows to a waste drain. See
Figures 21 to 24. A horizontal section of the air inlet pipe, near
the heater should include a 2” by 2” by 1/2” tee and a hose barb
tting to drain the water. The tee should be as close to the heater
as is practical. The drain tubing in any installation should have a
loop trap and ow to an appropriate waste drain. The air intake
drain line must be entirely separate from the exhaust vent outlet
condensate line.
INSTALLATION SEQUENCE
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 nished
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.
2. Cut a length of pipe about 3.5” (8.9 cm) longer than the
wall thickness at the opening.
3. Glue the air intake terminal to the section of the pipe.
4. Slide the wall plate over pipe to stop against air intake 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 air intake pipe is installed up to the wall, with a coupling on the
end against the wall opening, the pipe with the air intake 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 air intake terminal ends up pointed in the
correct position (Figure 14A and Figure 15).
Figure 15
29
TERMINATION CLEARANCES SIDEWALL POWER VENT
Figure 16
Vent terminal clearances for “Power Vent” installations. Power Vent congurations use room air for combustion.
30
TERMINATION CLEARANCES SIDEWALL DIRECT VENT
Figure 17
Vent terminal clearances for “Direct Vent” installations. Direct Vent congurations use outdoor air for combustion.
31
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 ashing.
3. The air intake termination and the exhaust vent termination
must penetrate the same side of roof.
4. The center line of the air intake termination and the center line
of the exhaust vent termination must be no closer than 24”
(61cm). See Figure 18 and Figure 19.
FLAT ROOF INSTALLATION
On at roof installations the air intake and the exhaust vent
terminations must be a minimum of 24 inches (60 cm) above any
parapet, vertical wall or structure within 10 feet (3 m) horizontally.
See Figure 20.
Figure 18
Figure 19
Figure 20
32
Figure 21
Figure 23 Figure 24
Figure 22
DIRECT VENT DIAGRAM
DIRECT VENT INSTALLATIONS
Direct Vent combustion air intake drains are required in certain situations. See the section on Direct Vent Air Intake Moisture Protection on
page 28 and the Figures 21 and 22 below.
12” MINIMUM CLEARANCE
ABOVE HIGHEST ANTICIPATED
SNOW LEVEL
EXHAUST
*
Direct Vent combustion air intake drains are required in certain situations.
See the section on Direct Vent Air Intake Moisture Protection on page 28.
*
*
*
*
12” MINIMUM CLEARANCE
ABOVE HIGHEST ANTICIPATED
SNOW LEVEL
24” MINIMUM SEPARATION.
EXHAUST MUST BE AT SAME
LEVEL OR ABOVE INTAKE
TERMINAL.
SNORKELING IS ALLOWED TO
ACHIEVE PROPER CLEARANCE.
THE SNORKEL MUST BE
SECURELY SUPPORTED.
*
*
*
*
33
CONCENTRIC VENT INSTALLATION
This water heater is certied for concentric venting with concentric
vent kit #100111100. Follow the instructions below for proper
installations.
Table 8 – KIT COMPONENTS
Field supplied pipe and ttings are required to complete the
installation.
This concentric vent termination kit may be used with 3 inch diameter
pipe systems.
SAFETY CONSIDERATIONS
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 qualied installer or qualied service technician, see Page 7. All
precautions in the literature, on tags, and labels attached to the unit
must be observed.
Follow all safety codes. Wear safety glasses and work gloves.
Figure 25
Figure 26
* Dimension 19.50 in. may also be shortened by cutting the
pipes, provided in the kit, to 12 in. minimum.
** Dimension 36.10 will change accordingly as dimension
19.50 in. is shortened.
Do not use eld-supplied couplings to extend pipes. Airow restriction
will occur and the heater pressure switch may cause intermittent
operation.
INSTALLATION VERTICAL ROOF TERMINATION
1. Determine best location for termination kit.
NOTE: Roof termination is preferred since it is less
susceptible to damage, has reduced chances to intake contaminants,
and less visible vent vapors.
2. Cut 1 hole (5 in. diameter)
3. Partially assemble concentric vent termination kit.
a) Cement Y concentric fitting to larger diameter kit
pipe, see Figure 25.
b) Cement rain cap to smaller diameter kit pipe, see Figure 25.
STAINLESS STEE
L
SCREW AND NUT
Figure 27
NOTE: Instead of cementing the smaller pipe to the rain cap, a
stainless steel screw may be used to secure the 2 components
together when field disassembly is desired for cleaning, see Figure
27. Locate the drill location dimple on the outside of the rain cap;
at this location, drill a 3/16” hole through the cap and the inner
pipe wall with the path of the hole perpendicular to the inner pipe
NOT the outside of the cap; insert the screw and tighten the bolt;
do not over tighten.
When using alternate screw method, 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.
4. Install Y concentric fitting and pipe assembly through
structure’s hole and eld supplied roof boot/ashing.
Figure 28
34
NOTE: Do not allow insulation or other materials to accumulate
inside pipe assembly when installing through hole.
5. Secure assembly to roof structure as shown in Figure 28
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 28.
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 28 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.
FLAT ROOF INSTALLATION
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 29.
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 Vent Termination Installation.
CONCENTRIC TERMINATION(S)
MUST BE A MINIMUM OF 10 FEET
(3 m) AWAY FROM ANY PARAPET,
VERTICAL WALL OR
STRUCTURE.
VENT PIPE
INTAKE AIR PIPE
CONCENTRIC TERMINATION
FLAT ROOF CLEARANCE
Figure 29
INSTALLATION SIDE WALL TERMINATION
Figure 30
1. Determine best location for termination kit.
NOTE: Consideration for the following should be used when
determining an appropriate location for the termination kit:
• 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.
NOTE: See Venting Installation section (starting on Page 25) 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 tting to larger diameter kit pipe, see
Figure 25.
b) Cement the rain cap to the smaller diameter kit pipe, see Figure
25.
NOTE: Instead of cementing the smaller pipe to the rain cap, a
eld-supplied stainless steel screw may be used to secure the 2
components together when eld disassembly is desired for cleaning,
see Figure 27.
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.
4. Install Y concentric tting and pipe assembly through structure’s
hole.
NOTE: Do not allow insulation or other materials to accumulate
inside pipe assembly when installing through hole.
5. Install rain cap and small diameter pipe assembly in Y concentric
tting and large pipe assembly. Ensure small diameter pipe is
bottomed and cemented in Y concentric tting.
35
6. Ensure the Y connection is oriented so the air intake side of Y is
on top, see Figure 31.
7. Secure assembly to structure as shown in Figure 31 using eld-
supplied metal strapping or equivalent support material.
NOTE: Ensure termination location clearance dimensions
are as shown in Figure 30, 32 and 33. 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” (53.6 cm) dimension
more than 60” (1.5 m). See Figure 25.
Do not use field-supplied couplings to extend pipes. Airflow
restriction will occur and the heater pressure switch may
cause intermittent operation.
8. Cement heater combustion-air and vent pipes to concentric vent
termination assembly. See Figure 31 for proper pipe orientation
and attachment.
9. Operate heater through 1 heat cycle to ensure combustion-air and
vent pipes are properly connected to concentric vent termination
connections.
Figure 31
MULTI-CONCENTRIC VENT TERMINATIONS
When two or more water heaters are direct vented with concentric
vent terminations near each other, each water heater must be
individually vented. NEVER common vent this water heater. When
two or more water heaters are direct vented using concentric vent
terminations, the water heaters may be vented as shown in Figure
32 and Figure 33.
Figure 32 CONCENTRIC VENT TERMINATIONS FOR
HORIZONTAL DIRECT VENTING
Figure 33 CONCENTRIC VENT TERMINATIONS FOR
VERTICAL DIRECT VENTING THROUGH A ROOF
36
LOW PROFILE TERMINATION INSTALLATION
This water heater is certied for sidewall direct venting with IPEX
System 636 Low Prole Vent Kit. Follow instructions below for proper
installations.
All termination kits must be located and installed in accordance with
local codes or the current editions of the National Fuel Gas Code
(ANSI Z223.1/NFPA 54) or the Natural Gas and Propane Installation
Code (CAN/CSA B149.1).
1. Once the proper location has been determined, cut 2 holes in the
wall large enough to accomodate the pipe. Pipe diameters and
distance between hole centers can be found in Table 9.
2. Slide both the intake and exhaust pipes through the holes. Solvent
cement both pipes to the base of the vent termination kit, follow the
solvent cementing procedures outlined in the IPEX System 636
Installation Guide, which is available on the web www.ipexinc.com.
3. To fasten the Base to the wall, use the supplied screws and anchors.
A 3/16” (5mm) hole, 1-3/16” (3 0mm) deep, will need to be dr illed for
the anchors. Locate the anchor hole using the base as a template.
4. Screw the Cap to the Base using the supplied screws.
5. Once the vent termination and pipes are secured, the wall
penetrations will need to be sealed from the interior using a PVC-
compatible sealant material.
6. All vent pipes and air inlets must terminate at the same height to
avoid possibility of severe personal injury, death, or substantial
property damage.
8. Operate heater through 1 heat cycle to ensure combustion-air and
vent pipes are properly connected to concentric vent termination
connections.
Figure 34
Vent Base
Vent Cap
Air Piping
Vent Piping
Table 9
Low Prole Termination Kits - Dimensions
AOS Kit
Number
IPEX Part
Number
Description
Pipe Outside
Diameter
Hole Spacing
(ctr to ctr)
100187903 196984 2” Flush Mount Vent Kit 2.375” 5.6”
100187887 196985 3” Flush Mount Vent Kit 3.5” 5.6”
Table 10
Each Kit Contains
Qty Item Description
1 Base (two holes)
1 Cap (one hole)
8 Stainless Steek Screws
4 Plastic Anchors
To Boiler Intake
Air Connection
From Boiler Vent
Pipe Connection
Vent/Air
Termination
12”
Min to
Over-
Hang
12”
Min
Grade or
Snow Line
Possible Orientations
12” Min between Edge of Air
Inlet and Adjacent Vent Outlet
Air
Vent/Air
Termination
Vent
Figure 35
Figure 36
37
INSTALLATION INSTRUCTIONS
1. Ensure the water heater’s Enable/Disable switch is in the
“Disable” position.
2. Install a 1/2 inch PVC condensate drain line between condensate
drain connection on the Exhaust/Condensate Elbow and a suitable
building drain. The condensate line must slope to an open drain,
see Figure 37.
3. Terminate the condensate drain piping with an elbow above the
drain. Ensure that any discharge will exit the condensate drain
line no more than 6 inches (15.2 cm) above a suitable building
drain, or external to the building, see Figure 37.
• NOTE: In cold climates it is recommended the conden-
sate drain be terminated at a suitable drain inside the
building.
4. Ensure the condensate drain line is not elevated above the
condensate drain connection on the Exhaust/Condensate Elbow,
see Figure 37.
5. Brace the condensate drain line with floor-mounted standoffs
every three feet.
6. Ensure that the condensate drains freely during start up, see
Start Up on page 51.
7. Condensate clean out cap must be on and tight when unit is in
operation.
CONDENSATE DRAIN INSTALLATION
Installation must conform with these instructions and local building
codes.
Field supplied materials required for installation include:
• Approved PVC cement and PVC primer.
• 1/2 inch PVC pipe - minimum length to equal the distance
between the water heater and a suitable building drain.
• 1/2 inch PVC ttings (elbows, couplings, and adapters)
necessary to install a condensate drain line between the Exhaust/
Condensate Elbow Assembly and a suitable building drain.
• Floor mounted standoffs to brace the drain line.
INSTALLATION NOTES
1. The condensate drains from the water heater’s covered by
this instruction have PH levels between 4.3 and 5.0. Install a
commercially available neutralizing kit if required by local codes.
Lower PH levels are acidic. Do not connect a metal condensate
drain line, such as copper pipe, to the water heater for this reason.
2. The field installed condensate drain line must not be less than
1/2 inch PVC in size.
3. The exhaust elbow has a built in condensate trap. Do not install an
additional trap in the condensate drain piping. DO NOT remove,
modify or alter the factory condensate trap.
DRAIN LINE TO
TERMINATE NO
MORE THAN 6
INCHES (15.2 cm)
ABOVE DRAIN
BUILDING
DRAIN
1/2” NPT
CONDENSATE
DRAIN
CONNECTION
CONDENSATE
CLEANOUT
EXHAUST/CONDENSATE
(VENT) ELBOW
PRESSURE PORT
CONDENSATE DRAIN
LINE - FIELD
INSTALLED
Figure 37. Condensate Drain Installation
WATER HEATER INSTALLATION
38
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 ring at rated input.
Schedule 40 Steel or Wrought Iron Pipe is the preferred material
for the gas line of this water heater. It is imperative to follow the
sizing recommendations in the latest version of the National Fuel
Gas Code if Corrugated Stainless Steel Tubing (CSST) is used as
the gas line for this water heater.
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 tting with a capped nipple
in the bottom outlet or other device recognized as an effective
sediment trap.
Contaminants in the gas lines may cause improper operation of
the gas control valve that may result in re 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 sediment trap must be incorporated in the piping. The sediment
trap 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) or the Natural Gas and
Propane Installation Code (CAN/CSA B149.1)
Use pipe joint compound or teflon tape marked as being resistant
to the action of petroleum [Propane (L.P.)] gases.
The water heater and its gas connection must be leak tested
before placing the water heater in operation.
The water heater 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).
ELECTRICAL WIRING
All electrical work must be installed in accordance with the National
Electrical Code, ANSI/NFPA 70 or the Canadian Electrical Code,
CSA C22.1 and local requirements.
When installed, the water heater must be electrically grounded
in accordance with local codes or, in the absence of local codes,
with the National Electrical Code, ANSI/NFPA 70 or the Canadian
Electrical Code, CSA C22.1.
If any of the original wire as supplied with the water heater must
be replaced, it must be replaced with 105°C rated wiring or its
equivalent, except in the burner housing. In this case 200°C rated
wire must be used.
DEDICATED POWER WIRING AND BREAKERS
Dedicated power supply wires, neutral wires, ground wiring, and
dedicated circuit breakers often prevent electrical line noise and are
required when installing the water heater.
Note: This water heater should not be connected to an electrical
supply with a Ground Fault Circuit Interrupter (GFCI) or Arc Fault
Circuit Interrupter (AFCI) with Integral GFCI protection as dened in
NFPA 70, CSA C22.1 and UL 943.
POWER SUPPLY CONNECTIONS
Read the requirements for the Power Supply on page 18 before
connecting power.
The 120-VAC hot wire from the power supply must connect to the
black jumper wire or the “L1” terminal block location in the junction box
and the 120-VAC neutral wire must connect to the white jumper wire
or the “Neutral” terminal block location in the junction box for correct
polarity. See Figure 38 on page 39.
Power supply connections must be made as follows:
1. Turn off power at the water heater’s enable/disable switch and
the breaker that supplies power to the water heater.
2. Remove the junction box cover. See Figure 1B (page 10) and
Figure 1C (page 11) for junction box location.
3. Connect the 120-VAC hot wire from the power supply to the
black jumper wire or the terminal block location marked “L1”
inside of the junction box located on top of the water heater. If
the black jumper wire is used, make the connection inside of the
junction box with a properly-sized wire nut. Wrap electrical tape
around the wire nut and wire end. See junction box Figure 38 on
page 39 and the wiring diagram Figure 47 on page 63.
4. NOTE: If electrical connection is made directly to terminal block
remove black jumper wire before making connection.
5. Connect the 120-VAC neutral wire from the power supply to the
white jumper wire or the terminal block location marked “Neutral”
inside of the junction box located on top of the water heater. If
the white jumper wire is used, make the connection inside of the
junction box with a properly sized wire nut and wrap electrical
tape around the wire nut and wire end. See junction box Figure
38 on page 39 and the wiring diagram Figure 47 on page 63.
39
6. NOTE: If electrical connection is made directly to terminal block,
remove the white jumper wire before making the connection.
7. Connect the ground wire from the power supply to the grounding
lug inside the junction box. See junction box Figure 38 on page
39 and the wiring diagram Figure 47 on page 63.
8. Replace junction box cover when connections are complete.
9. Note: Do not apply power to the water heater before installation
is complete and the water heater is lled with water.
Heater Wiring
(Factory Installed)
MOV
Ground
Ground
Terminal
Jumper Wire
L1
Neutral
Figure 38. Electrical Wiring - Junction Box
ENABLE / DISABLE CIRCUIT
The water heaters covered in this manual are equipped with
an enable/disable circuit for use with eld-supplied external
supervisory controls, such as time clocks or Building Management
Systems. The enable/disable circuit may be used to disable
heating operation during periods when the building is unoccupied
or there is no demand for hot water.
To use the enable/disable circuit, it must rst be activated by
selecting the “Use External Enable” from the UIM. Field-supplied
wiring is then installed between the water heater’s central control
board (CCB) and a set of “dry contacts” (no voltage or load) on
the eld supplied external control.
NOTE: The water heater’s enable/disable circuit is a switching
circuit only: Do not apply external voltage or connect any load (IE:
relay coil) to this circuit. This will damage the CCB circuit board
and is not covered under the limited warranty. See the Commercial
Water Heater Limited Warranty supplied with this water heater.
CONNECTING AN EXTERNAL SUPERVISORY CONTROL
The enable/disable circuit is accessed from the CCB’s J17 plug
inside the CCB enclosure; see Figure 1B (page 10) and Figure 1C
(page 11) to locate the CCB enclosure. Install eld wiring to the
enable/disable circuit:
1. Turn off power at the water heater’s enable/disable switch and
the breaker that supplies power to the water heater.
2. Locate the CCB enclosure.
3. Carefully remove the Temperature Probe connectors and CCB
enclosure cover.
4. Locate pins 1 and 2 on the CCB J17 plug. See Figure 46 on
page 62.
5. Connect the two eld-supplied control wires to pins 1 and 2 on
the CCB J17 plug.
6. Thread the control wires out of the CCB enclosure with the other
wiring and carefully replace the CCB enclosure cover. Ensure
all wiring is routed through the intended area provided for strain
relief. Ensure no wiring is being pinched.
7. Reinstall the CCB enclosure cover and Temperature Probe
connectors.
8. Route the control wires inside the junction box on the top of the
water heater; see Figure 1B (page 10) and Figure 1C (page 11)
to locate the junction box. Use an available knock-out to route
the wires inside the junction box.
9. Install eld-supplied control wiring and conduit as required by
national and local codes between the water heater’s junction
box and the external supervisory control. Connect the wiring
from the external control to the control wires inside the junction
box using wire nuts and electrical tape.
10. Connect the control wiring to a set of dry contacts on the
external control. Follow the control manufacturer’s instructions
for making connections.
11. Restore power to the water heater.
12. From the water heaters UIM “Heater Information Screen” select
“Use External Enable” and change to “Yes”. See Figure 1B
(page 10) and Figure 1C (page 11) to locate the UIM.
NOTE: Whenever the external control opens the set of dry contacts
used, water heating operation is disabled. Whenever the external
control closes the set of dry contacts used, water heating operation
is enabled. A diagonal line and circle appears over the thermometer
icon on the UIM when water heating operation is disabled. See
Table 18 on page 42.
NOTE: Ensure the water heater is protected from freezing
temperatures when water heating operation is disabled. Damage to
the water heater caused by freezing temperatures is not covered
under the limited warranty. See the Commercial Water Heater
Limited Warranty supplied with this water heater.
40
HIGH TEMPERATURE LIMIT CONTROL (ECO)
This water heater is equipped with an ECO (energy cut out) 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).
See Figure 1B (page 10) and Figure 1C (page 11). The ECO switch
contacts will open when the water temperature reaches approximately
202°F (94°C) and close at approximately 140°F (60°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-volt 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 Qualied 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:
If the ECO activates, the water temperature must drop below 140°F
(60°C) before the control system can be reset. Once the water
temperature has cooled below this point the power supply to the water
heater must be turned off and on again to reset the control system.
THERMOSTAT CONTROL
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Hot water temperatures required for automatic dishwasher and laundry
use can cause scald burns resulting in serious personal injury and/
or death. Table 17 on page 40 shows the approximate time-to-burn
relationship for normal adult skin.
The temperature at which injury occurs varies with the person’s age
and duration of exposure. The slower response time of children, the
elderly or disabled persons increases the hazards to them. If anyone
using hot water provided by the water heater being installed ts into
one of these groups or if there is a local code or state law requiring a
certain water temperature at the point of use, then special precautions
must be taken.
In addition to using the lowest possible temperature setting that
satises the demand of the application a mixing valve can be installed
at the water heater or at the hot water taps to further reduce system
water temperature. See Figure 9 on page 20.
Never allow small children to use a hot water tap or draw their own
bath water. Never leave a child or disabled person unattended in a
bathtub or shower.
The water heater should be located in an area where the general
public does not have access to set temperatures.
Setting the Operating Set Point at 120°F (49°C) will reduce the risk of
scalds. Some States require settings at specic lower temperatures.
Table17. Time/Temperature to Burn
Water Temperature
°F (°C)
Time for 1st Degree Burn
(Less Severe Burns)
Time for Permanent
Burns
2nd & 3rd Degree
(Most Severe Burns)
110 (43) (normal shower temp.)
116 (47) (pain threshold)
116 (47) 35 minutes 45 minutes
122 (50) 1 minute 5 minutes
131 (55) 5 seconds 25 seconds
140 (60) 2 seconds 5 seconds
149 (65) 1 second 2 seconds
154 (68) instantaneous 1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)
The water heaters covered in this manual are equipped with an
electronic control system to regulate water temperature inside
the storage tank. The control system senses temperature from a
factory installed temperature probe in the top of the storage tank.
See Figure 1B (page 10) and Figure 1C (page 11) for location.
The “Operating Set Point” is adjusted to regulate water
temperature inside the storage tank. This is an adjustable user
setting in the control system’s “Temperatures Menu.” This and
all control system menus are accessed through the UIM (user
interface module) located on the front of the water heater, see
Figure 41 on page 41.
The Operating Set Point is adjustable from 90°F (32°C) to 181°F
(83°C). The factory setting is 120°F (49°C). See Operating Set
Point and Differential Adjustment on page 44 for instructions on
how to adjust the Operating Set Point and other user settings.
Set the Operating Set Point at the lowest setting that produces
an acceptable hot water supply. This will always provide the most
energy efficient operation.
HIGH TEMPERATURE APPLICATIONS
Higher operating temperatures cause more wear on all water
heaters and will decrease the life span of the water heater.
Consider installing a small booster water heater for high
temperature applications, such as commercial dishwashers, to
raise the outlet temperature from the larger primary water heater
to the desired point of use temperature.
Contact your local distributor or call the technical support phone
number listed on the back cover of this manual for further
technical assistance.
Operating Set Point 120°F
Status: Heating
MENU HELP
GAS
OFF
O
N
Figure 39. Tank Temperature Set point
TEMPERATURE REGULATION
41
LOCK OUT FUNCTION
The water heaters covered in this manual feature a lockout
functionality that is disabled at the factory. If the lockout
functionality is required by the end user, the initial installer/
contractor can access this functionality and enable it through the
UIM module.
THE DESKTOP SCREEN
During normal operation the control system will display the
"Desktop" screen on the LCD Touch Display which is the default
screen. The control system will return to the Desktop screen
when there are no active Fault or Alert conditions or when there
has been no user input for several minutes.
• Manufacturer and water heater model information is displayed
in Title Bar at the top of the Desktop screen. Menu titles are
displayed in the Title Bar when navigating the control system
menus.
• The first temperature shown on the Desktop screen, Tank
Temperature, is the temperature of the water inside the water
heater's storage tank.
• The second temperature shown on the Desktop screen
is the Operating Set Point. The Operating Set Point is the
temperature at which the control system will maintain the
water inside the storage tank.
• Beneath the Operating Set Point is the "Status" line. The
Status line shows the current operational state of the control
system in real time. See Table 19 (page 43) for a description
of the various operational states.
• The Desktop screen also displays animated "Status Icons" to
convey operational information, see Table 18 on page 42 for
descriptions of the Status Icons.
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 are monitored by the control
system. The Combustion Blower, Spark Ignition Transformer,
powered anode rod (if applicable) and 24-volt gas valve are all
powered by the control system.
The main components of the control system are the user
interface module (UIM) and the central control board (CCB). 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. This unit is equipped with an Enable/Disable switch.
To operate the unit, make sure the switch is set to Enable. See
Features and Components on page10 for location of these and
all water heater components.
POWER
SUPPL
Y
BOARD
TRANSFORMER
CCB
BOARD
Figure 40. Control System Components
CONTROL SYSTEM NAVIGATION
All operational information and user settings are displayed and
accessed from the UIM. The UIM houses the control system's
LCD Touch Display (liquid crystal display).
Operating Set Point 120°F
Status: Heating
GAS
OFF
O
N
HELPMENU
LCD Touch Display
Information
Display
Status Icons
Title Bar
Enable/Disable Switch*
Operational menus are multi functional.
* See the Features and
Components section of this
manual for the precise location.
Figure 41. User Interface Module (UIM) Desktop Screen
CONTROL SYSTEM OPERATION
42
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 18. Status Icons
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. See Figure 1B (page 10) and Figure 1C
(page 11) for location of 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 or when the Enable/Disable switch on front panel is in disable position or Building Management system Enable/
Disable circuit is an open circuit. Display will read "Status: Water Heating Disabled." For more information see Enable /
Disable Circuit on page 39.
NOTE: When water heater is in disabled mode, a text message will appear next to the icon identifying cause of
disable mode.
The Combustion Blower is being energized.
The Spark Igniter is being energized. See Figure 1B (page 10) and Figure 1C (page 11) for Spark Igniter location.
GAS
OFF
O
N
The 24-volt gas valve is being energized.
The control system has sensed ame at the Main Burner from the ame sensor.
The control system has declared a Fault condition and must be inspected/serviced by a Qualied Service Agent. Fault
message details can be viewed in the Current Fault menu. Heating operation is disabled (lock out) until the condition that
caused the Fault is corrected. Power to the water heater must be cycled off and on at the breaker to reset the control
system.
NOTE: Cycling power will not reset the control system if the condition that caused the Fault has not been corrected.
The control system has declared an Alert condition and must be inspected/serviced by a Qualied Service Agent. The
water heater will continue to operate during an Alert condition.
43
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 19. Operating States
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.
Input Verication The control system is conducting a diagnostic check at the beginning of a heating cycle.
Water Heating
Disabled
A Fault condition is detected by the control, the Enable/Disable switch on front panel is in disable position, or the Building
Management system Enable/Disable is an open circuit.
Pre-Purge The Combustion Blower is energized to ush residual ue gases from the combustion chamber prior to ignition.
Spark Igniter
Energized
The Spark Igniter is energized.
Ignition Activation The 24-volt gas valve is energized and opens to allow fuel gas to ow to the Main Burner.
Ignition Verication The control system is monitoring the ame sensor for the required minimum ame sensing current.
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.
Inter-Purge The Combustion Blower is energized to ush residual fuel gas from the combustion chamber after a failed ignition attempt.
Heating Ignition was successful, ame sensing current has been established. The water in the storage tank is being heated.
Post-Purge The Combustion Blower is energized to ush residual ue 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 until the Fault condition is corrected.
Power to the water heater must be cycled off and on at the breaker to reset the control system.
NOTE: Cycling power will not reset the control system if the condition that caused the Fault has not been corrected.
CONTROL SYSTEM MENUS
From the Desktop screen pressing "Menu" on the LCD Touch Display will display the "Main Menu" this is where all control system menus are
located. The table below describes the control system menus.
Table 20. Control System Menus
Menu Description
Temperatures Most commonly accessed menu. Contains the Operating Set Point and Differential user settings.
Heater Status This menu displays the current state of all pressure switches and the ECO (open/closed). The on/off status of the
Combustion Blower, gas valve, Spark Igniter, ame sensor and other monitored water heater components are dis-
played in this menu.
Display Settings Temperature units (°F or °C), the LCD appearance (brightness/contrast) and backlight delay user adjustable settings
are located in this menu.
Heater Information Elapsed time of operation, total heating cycle time, heating cycle count, heating on time along with UIM and CCB
software revisions can be viewed in this menu.
Current Fault Displays any current Alert or Fault messages.
Fault History This control system menu retains a list of the last nine (9) Fault and Alert messages with a time stamp. The newest
event will replace the oldest. Faults will clear after 30 days.
Fault Occurrence This control system menu retains a running total of how many times each Fault condition has occurred since the
water heater was rst installed. The data does not clear and cannot be reset.
Restore Factory Defaults This control system feature allows the user to restore control system user settings to their factory default settings.
Display Settings preferences ARE NOT changed when factory defaults are restored.
Help Screens Text based operational and user information explaining how to change user settings, navigate the control system
menus and icon descriptions.
44
USER SETTINGS & CONTROL SYSTEM MENUS
TEMPERATURES MENU
Operating Set Point and Differential Adjustment
The Operating Set Point is adjustable from 90°F (42°C) to 181°F
(83°C). The factory setting is 120°F (49°C). The Differential is
adjustable from 2° to 20°. The factory setting is 8°. These user
settings are accessed from the Temperatures menu. The following
instructions explain how to adjust these settings and navigate the
control system menus.
When the water temperature, sensed by the control system
from the Temperature Probe, reaches the Operating Set Point,
Temperatures Menu
Description/Action Display
From the Desktop screen, press MENU. The "Main Menu" screen will be
displayed.
Operating Setpoint 120°F
Status: Standby
HELP
MANUFACTURER/MODEL INFORMATION
MENU
The Main Menu is where all control system menus are listed, see Table 20
on page 43 for a complete list and description of control system menus.
Use the Up and Down slidebar to view all control system menus from the
Main Menu.
Press "Temperatures" to access the Temperature menu.
Main Menu
HELPBACK
Temperatures >
Heater Status >
Display Settings >
Heater Information >
Current Fault >
Press "Operating Setpoint" to access the temperature setpoint menu.
Press "CHANGE" to activate the adjustment mode for 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.
Temperatures
HELPBACK
Operating Setpoint 120°F >
Differential Mode Auto >
Differential 8°F >
Tank Probe Offset 0°F >
Use the "+" and "-" Buttons to change the current setting.
Press "ACCEPT" to save the new setting. Press "BACK" to discard changes
and return to the previously saved setting.
Note: Use this procedure to change the Differential setting and other
adjustable user settings in the control system menus.
ACCEPT BACK
Operating Setpoint
MIN
90
°
F
MAX
16 0
°
F
120
°
F
the control system ends the heating cycle. A heating cycle is
activated again when the sensed water temperature drops below
the Operating Set Point minus the Differential setting.
NOTE: Lower Differential settings may cause excessive heating
cycles (short-cycling) which can cause premature failure of heater
components. Set the Differential at the highest setting which
produces an acceptable hot water supply. Set the Operating Set
Point to the lowest setting which produces an acceptable hot
water supply for most efcient use.
45
Temperatures Menu
Description/Action Display
• Differential Mode - This mode is enabled at the factory and automatically
sets the differential to 8 F. If a lower differential is required, select the
Differential option below to manually reset the differential to desired
setting.
• Differential - Adjustable user setting that changes the tank temperature
differential with a range of 2° to 20°F. The factory setting is 8°F.
• Tank Temperature - Non adjustable. Control system sensed
temperature.
• Tank Probe Offset - adjustable user setting, range -5° to +5° (factory
setting 0°).
• NOTE: These settings should only be used if hot water supply
temperature varies greatly from the Operating Set Point setting.
• 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.
• Example: If the current temperature from the temperature probe is
120°F (49°C) and the Offset setting 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. A -5° setting results in
+5° hotter water.
• These settings are adjusted as described in Operating Set Point and
Differential Adjustment on page 44.
Temperatures
HELPBACK
Operating Setpoint 120°F >
Differential Mode Auto >
Differential 8°F >
Tank Probe Offset 0°F >
Heater Status Menu
Description/Action Display
Press Heater Status from the Main Menu to enter this menu. This menu contains
non adjustable operational information. Use the slidebar to navigate the menu.
• Status - displays the current Operating State, see Table 19 on page 43.
• ECO Contact, Blocked Inlet PS, Blocked Outlet PS - displays the
current state of the switch contacts; open or closed.
• Igniter On, Gas Valve On - displays whether or not the control system is
currently energizing these water heater components; yes = energized,
no = de-energized.
• Flame Detected - displays whether or not the control system has
detected Main Burner flame during ignition from the flame sensor.
• Anode Current, Anode Tank Voltage, Anode Drive Voltage - displays
the powered anodes current and voltage levels.
NOTE: Anode Current, Anode Tank Voltage, & Anode Drive Voltage will
only be displayed if the water heater is equipped with powered (non-
sacrificial) anodes.
NOTE: Menu displays shown are for informational purposes only. The
actual heater display will vary dependent upon the operational state of the
water heater.
Top of Menu
Heater Status
HELPBACK
Status: Standby
ECO Contact Closed
Blocked Inlet PS Closed
Blocked Outlet PS Closed
Igniter On No
Gas Valve On No
Bottom of Menu
Heater Status
HELPBACK
Flame Detected No
Anode Current 51.500mA
Anode Tank Voltage 2.641V
Anode Drive Voltage 3.539V
46
DISPLAY SETTINGS
Description/Action Display
Press Display Settings from the Main Menu to enter this menu. This
menu contains adjustable display options for viewing information on
the UIM’s LCD screen. Use the Slidebar to navigate the menu.
• Temperature Units - Adjustable user setting that changes
temperature units display to Celsius °C or Fahrenheit °F.
• Backlight Delay - Adjustable user setting that determines
how long the UIM’s LCD backlight remains illuminated after a
key has been pressed. Available settings are; Always Off, 10,
30 or 60 seconds and Always On.
• Contrast - Adjustable user setting to adjust the UIM’s LCD
screen contrast between text and background.
• NOTE: These settings are adjusted in the same way described for
the Operating Set Point and Differential Adjustment (page 44).
Display Settings
HELPBACK
Temperature Units °F >
Brightness 5 >
Backlight Delay 30s >
Language English >
HEATER INFORMATION
Description/Action Display
Press Heater Information from the Main Menu to enter this menu. This
menu contains non adjustable operational information.
• Elapsed Time - Total accumulated time the control system
(water heater) has been energized.
• Burner On Time - Total accumulated time the control system
has been in the heating operating state; burner run time.
• Total Cycle Count - Total accumulated count of heating
cycles.
• CCB Version - Software version for central control board.
• Config CRC - Verifies the configuration key matches the
CCB programming.
• UIM Version - Software version for user interface module.
• Use External Enable - Enables/Disables the external enable
circuit.
• External Enable Status - Displays whether or not the
external enable circuit has been activated.
• Ignition Trials - Displays the number of ignition trials allowed.
• NOTE: Historical data is stored in the configuration key. If
this "key" is replaced during servicing the historical data will
be lost. The data stored in the new configuration key will
no longer reflect the entire history of the water heater. The
configuration key should never be replaced unless directed
by Technical Support.
• 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 (page 44).
• 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.
Heater Information
HELPBACK
Elapsed Time 0days 0hrs 43mins >
Burner On Time 0days 0hrs 1mins
Use External Enable No >
External Enable Status No >
Ignition Trials 3 tries >
Total Cycles Counter 2 >
Bottom of Menu
Heater Information
HELPBACK
Ignition Failure Count 1 >
Flame Loss Count 0 >
CCB Version 3.17 >
Config CRC 0xD7A7 >
UIM Version 2.58 >
Configuration Raw 0x510C >
47
CURRENT FAULT
Description/Action Display
Press Current Fault from the Main Menu to enter this menu. This menu
contains non adjustable operational information. Use the Slidebar to
navigate the menu.
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 "ADVANCED" will give more detailed
service information and a list of possible causes for the Fault or Alert
condition. See Fault and Alert Messages on page 60 for more detailed
information and diagnostic procedures.
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.
ADVANCEDBACK
0 days 0 hr 0 min ago
Error Code: A8-1201
Blocked Exhaust
Restriction in exhaust pipe.
Check exhaust pipe and
termination for blockage.
Press the Advanced button for
FAULT HISTORY
Description/Action Display
Press "Fault History" from the Main Menu to enter this menu. This
menu contains non adjustable operational information. Use the
Slidebar to navigate the menu.
This menu contains a list of the last nine (9) Fault and Alert messages
with a time stamp. The newest event will replace the oldest. Faults will
clear after 30 days.
Press the Fault to view details for each Fault or Alert message stored.
Fault History
HELPBACK
1: Blocked Exhaust (A8) >
0 days 2 hrs 37 mins ago >
2: Hardware Failure (1A) >
0 days 2 hrs 37 mins ago >
3: Blocked Exhaust (A8) >
0 days 2 hrs 40 mins ago >
FAULT OCCURRENCE
Description/Action Display
Press Fault Occurrence from the Main Menu to enter this menu.
This menu contains non adjustable operational information. Use the
Slidebar to navigate the menu.
This menu contains a running total of how many times each Fault
condition has occurred since the water heater was rst installed.
NOTE: Historical data is stored in the conguration key. If this "key"
is replaced during servicing the historical data will be lost. The data
stored in the new conguration key will no longer reect the entire
history of the water heater.
Fault Occurrence
HELPBACK
Ignition Failure 0 >
ECO 0 >
Blocked Intake Air 1 >
Blocked Exhaust 1 >
External Input 1 >
Flame Detect Error 0 >
RESTORE FACTORY DEFAULTS
Description/Action Display
Press Restore Factory Defaults from the Main Menu to enter this
menu.
To restore the adjustable user settings to their factory default
settings press “YES.” The display will show text conrming the
factory default settings have been restored.
Press NO to exit the Restore Factory Defaults menu.
NoYes
Restore Defaults
Are you sure you want to restore
the system to the factory
defaults?
48
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.
Table 21. Contact Information
Description/Action Display
From the Desktop Screen press and hold down the middle
(unmarked) area located between the "MENU" and "HELP"
buttons for 15 seconds to activate the "Contact Information"
screen. See Figure 41 (page 41).
This will launch a discrete menu where personalized contact
information can be entered.
Using the Slidebar select (highlighted in black) the "Show
Contact" menu item.
Press "ACCEPT" to activate the adjustment mode for this
parameter.
Top of Screen
Contact Information
HELPBACK
Show Contact No >
Change Contact Name >
Change Contact Phone >
Current Contact Info:
(000) 000-0000
Press the "+" and "-" Buttons to change the setting from "No" to
"Yes" and press "ACCEPT" to save the new setting.
Note: The Access Code at the bottom of the Service Contact
Information screen is for manufacturing engineering purposes
only. There are no user settings or information accessed through
this menu item.
Contact Information
HELPBACK
Show Contact Yes >
Change Contact Name >
Change Contact Phone >
Current Contact Info:
(000) 000-0000
Press the "Change Contact Name" to enter this menu.
Contact Information
HELPBACK
Show Contact Yes >
Change Contact Name >
Change Contact Phone >
Current Contact Info:
(000) 000-0000
Press the "+", "-", "<", and ">" icons to enter your name or the
name of your company.
When nished press "ACCEPT" to save the new Contact Name.
The control system will return to the discrete menu.
Follow these instructions to change the Contact Phone Number.
ACCEPT
<
>
>
BACK
Change Contact Name
When the new Contact Name and Contact Phone number have
both been updated, press "BACK" to return to the Desktop screen.
Contact Information
HELPBACK
Show Contact Yes >
Change Contact Name >
Change Contact Phone >
Current Contact Info:
YOURCOMPANYNAMEHERE
(123) 456-7890
49
Table 21. Contact Information (Continued from page 48)
Description/Action Display
Access Code - Displays access code utilized to enable/disable
screen lock.
Enable Screen Lock - Factory default set to No. When enabled,
prevents access to any screen but the home screen and the
Contact Information screen. This feature restricts access code to
secure the water heater.
Calibration Mode - Used by service agent to adjust the gas
valve for minimum and maximum fire rate.
Calibration Speed - Used by service agents to adjust blower
speed to minimum fire rate if required.
Note: Calibration mode will reset back to No when the contact
information screen is exited either by pressing the Back
button or when the display times out. To be practical, the
installer/field service agent should first go to the Display
Setting screen from the Main Menu and set the Backlight
Delay to 240 (On) before setting Calibration mode.
Bottom of Screen
Contact Information
HELPBACK
(000) 000-0000
Access Code >
Enable Screen Lock No >
Calibration Mode No >
Calibration Speed Min >
50
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.
THERMAL EXPANSION
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 ow 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.
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
contractor. Contact the local water heater supplier or qualied 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 1B and Figure 1C) for corrosion protection of the
tank. Certain water conditions will cause a reaction between this
rod and the water. The most 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:
a. A concentration of sulfate in the supply water.
b. Little or no dissolved oxygen in the water.
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 rod.
Smelly water may be eliminated or reduced in some water heater
models by replacing the anode rod(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 qualied service agency for further
information concerning an Anode Rod Replacement Kit and this
chlorination treatment.
If the smelly water persists after the anode rod replacement and
chlorination 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 rod leaving the tank unprotected. By
doing so, all warranty on the water heater tank is voided.
AIR IN HOT WATER FAUCETS
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 ammable 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 ame near the faucet at the time it is open.
FOR YOUR INFORMATION
51
PRIOR TO START UP
Installation and start up of this water heater requires abilities and skills
equivalent to that of a licensed tradesman in the eld involved, see
Qualications on page 7.
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN EXPOSED
TO FLOODING OR WATER DAMAGE. Immediately call a qualied
service agency to inspect the appliance and to make a determination
on what steps should be taken next. If the unit is exposed to the
following, do not operate heater until all corrective steps have been
External fire
1. Damage
2. Firing without water
Light the water heater in accordance with the Lighting and Operation
Instruction label on the water heater and in this manual Lighting the
Water Heater on page 52.
The water heaters covered by this manual are equipped with an
electronic control system, which automatically sequences the
Combustion Blower, pre and post purging of the combustion chamber,
the spark transformer, the 24-volt gas valve, Main Burner ignition, and
ame sensing. The control system will lock out after three unsuccessful
ignition attempts. See Control System Operation on page 41.
START-UP PREPARATION
Before attempting start up, thoroughly study and familiarize yourself
with the exact Sequence Of Operation (page 58). 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.
Be certain that the water heater is full of water, that air is purged from
the gas and water lines and that there are no leaks in the gas and
water lines. Ensure all inlet water valves are open.
FILLING THE WATER HEATER
Never use this water heater unless it is completely full of water.
To prevent damage to the tank, the tank must be lled with water.
Water must ow from the hot water faucet before turning ON gas to
the water heater.
To ll 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.
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 lling of the tank, allow air to exit by opening the
nearest hot water faucet. Allow water to run until a constant ow
is obtained. This will let air out of the water heater and the piping.
4. Check all water piping and connections for leaks. Repair as needed.
START UP
52
LIGHTING THE WATER HEATER
LIGHTING AND OPERATION LABELS
The instruction label below is afxed to the water heaters that are covered by this manual at the factory and must be followed when
lighting and operating the water heater.
SNOITCURTSNI GNITAREPO
ECNAILPPA OT SAG FFO NRUT OT
ELBAMMALF
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.
.1
3. Set the Enable / Disable switch on the
control panel to the Enable position.
2. Turn on all electrical power to the appliance.
5. Set the Enable / Disable switch on the
control panel to the Disable position.
2.
Set the Enable / Disable switch on the control
panel to the Disable position.
8.
Set the Enable / Disable switch on the control
panel to the Enable position.
4. Set the thermostat to the lowest setting.
1. STOP! Read the safety information above
on this label.
10. If the appliance will not operate, follow instructions
“TO TURN OFF GAS TO APPLIANCE” and call
your technician or gas supplier.
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Operating Set Point 120°F
Status: Standby
MENU HELP
ENABLE/DISABLE
SWITCH
6. This appliance is equipped with an ignition
device which automatically lights the burner.
LIGHTING THE WATER HEATER
53
VENTING SYSTEM INSPECTION
At least once a year examine the vent system. Points of inspection
are as follows:
1. Check for obstructions and/or deterioration of the intake air and/
or vent piping and the intake air and vent terminations. Replace
immediately where needed.
2. The debris screens in the intake air and vent terminations should
be cleaned of foreign material and soot.
NOTE: Do not reach inside the vent termination when the heater
is in operation.
3. Check all vent system connections for leakage and repair or
reseal as necessary.
Be sure the vent piping is properly connected to prevent escape
of dangerous ue gasses which could cause deadly asphyxiation.
Obstructions and deteriorated vent systems may present serious
health risk or asphyxiation.
Chemical vapor corrosion of the ue 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.
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 ue and venting before
resuming operation of the water heater.
ANODE ROD INSPECTION
To insure a long, trouble-free operating life, the water heaters
covered in this manual are factory equipped with one of two types
of anodes: powered and sacricial. The following sections describe
the inspection appropriate for each type.
NOTE: To check which type of anode is installed, refer to the Heater
Status menu of the UIM (user interface module). If the water heater
is equipped with a powered anode rod, this menu will display the
Anode Current, Anode Tank Voltage, and Anode Drive Voltage
statuses. If the Anode Current, Anode Tank Voltage, and Anode Drive
Voltage statuses are not displayed, the water heater is equipped
with sacricial anode(s). Refer to Features and Components (page
10) to locate the UIM and see Heater Status Menu (page 41) for
more information.
POWERED ANODE RODS
The anode rod is of a permanent design (non-sacricial) and does
not need to be replaced unless damaged. Periodic inspection of the
powered anode rod is not required.
A “No Water” or “Anode Shorted” fault displayed on the UIM indicates
a potentially damaged anode rod. If the powered anode rod has been
damaged, it should be removed and replaced from the water heater
tank. IMPORTANT: If the damaged powered anode rod has not
been replaced but has been removed permanently, this will void any
warranties. NOTE: Whether re-installing or replacing the powered
anode rod, check for any leaks and immediately correct if found.
To replace the powered anode:
1. Turn off electrical supply and gas supply to the water heater.
2. Shut off the water supply and open a nearby hot water faucet
to depressurize the water tank.
3. Drain approximately 5 gallons of water from tank (Refer to the
“Draining and Flushing” section for proper procedures). Close
drain valve.
4. Remove the wiring connection on the top of the powered anode
and remove the old powered anode rod.
5. Use Teon® tape or approved pipe sealant on threads and
install new anode rod.
6. Turn on water supply and open nearby hot water faucet to purge
air from water system. Check for any leaks and immediately
correct any if found.
Restart the water heater as directed in this manual.
SACRIFICIAL ANODE RODS
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 rate
of anode rod depletion. Once the anode rod is depleted, the tank
will start to corrode, eventually developing a leak.
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 sulde 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 ltration equipment
from a water conditioning company to successfully eliminate all
water odor problems.
Articially 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 inspected after a maximum of three years
and annually thereafter until the condition of the anode rod dictates
its replacement. Anode replacement is not covered by warranty.
NOTE: articially softened water requires the anode rod to be
inspected annually.
The following are typical (but not all) signs of a depleted anode rod:
• The majority of the rods diameter is less than 3/8”.
• Signicant sections of the support wire (approx. 1/3 or more of
the anode rod’s length) are visible.
If the anode rod show signs of either or both it should be replaced.
PERIODIC MAINTENANCE
54
NOTE: Whether re-installing or replacing the anode rod, check for
any leaks and immediately correct if found.
To replace 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. Drain approximately 5 gallons of water from tank. (Refer to
“Draining and Flushing” for proper procedures). Close drain valve.
4. Remove old anode rod.
5. Use Teon® tape or approved pipe sealant on threads and
install new anode rod.
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.
Restart the water heater as directed in this manual.
Figure 42
TEMPERATURE-PRESSURE RELIEF VALVE TEST
Burn hazard.
Hot water discharge.
Keep clear of Temperature-
Pressure Relief Valve
discharge outlet.
It is recommended that the Temperature-Pressure Relief Valve
should be checked to ensure that it is in operating condition every
6 months.
When checking the Temperature-Pressure Relief Valve operation,
make sure that (1) no one is in front of or around the outlet of the
Temperature-Pressure Relief Valve discharge line, and (2) that the
water discharge will not cause any property damage, as water may be
extremely hot. Use care when operating valve as the valve may be hot.
To check the temperature-pressure relief valve, lift the lever at the end of
the valve several times, Figure 43. 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 54. Replace the Temperature-
Pressure Relief Valve with a properly rated/sized new one, see
Temperature-Pressure Relief Valve on Page 22 for instructions
on replacement.
DISCHARGE PIPE
TEMPERATURE-PRESSURE
RELIEF VALVE
Figure 43
If the Temperature-Pressure Relief Valve on the water heater weeps
or discharges periodically, this may be due to thermal expansion.
NOTE: Excessive water pressure is the most common cause of
Temperature-Pressure Relief Valve leakage. Excessive water
system pressure is most often caused by “thermal expansion”
in a “closed system.” See Closed Water Systems and Thermal
Expansion on Page 21. The Temperature-Pressure Relief Valve
is not intended for the constant relief of thermal expansion.
Temperature-Pressure Relief Valve leakage due to pressure
build up in a closed system that does not have a thermal
expansion tank installed is not covered under the limited
warranty. Thermal expansion tanks must be installed on all
closed water systems.
DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF
VALVE OPENING. THIS CAN CAUSE PROPERTY DAMAGE,
SERIOUS INJURY OR DEATH.
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.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
DRAINING AND FLUSHING
It is recommended that the water heater storage tank be drained
and ushed every 6 months to reduce sediment buildup. The
water heater should be drained if being shut down during freezing
temperatures. See Figure 1B & Figure 1C in this manual for the
location of the water heater components described below.
Burn hazard.
Hot water discharge.
Keep hands clear of drain
valve discharge.
55
TO DRAIN THE WATER HEATER STORAGE TANK:
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.
3. Ensure the cold water inlet valve is open.
4. Open a nearby hot water faucet and let the water run until the
water is no longer hot.
5. 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.
9. Close the hot water faucet opened in Step 4.
10. If the water heater is going to be shut down for an extended
period, the drain valve should be left open.
TO FLUSH THE WATER HEATER STORAGE TANK:
1. Turn off the electrical supply to the water heater.
2. Ensure the cold water inlet valve is open.
3. Open a nearby hot water faucet and let the water run until the
water is no longer hot. Then close the hot water faucet.
4. Connect a hose to the drain valve and terminate it to an adequate
drain.
5. Ensure the drain hose is secured before and during the entire
ushing procedure. Flushing is performed with system water
pressure applied to the water heater.
6. Open the water heater drain valve to ush the storage tank.
7. Flush the water heater storage tank to remove sediment and
allow the water to ow until it runs clean.
8. Close the water heater drain valve when ushing is completed.
9. Remove the drain hose.
10. Fill the water heater - see Filling The Water Heater in this manual.
11. Turn on the electrical supply to place the water heater back in
operation.
12. Allow the water heater to complete several heating cycles to
ensure it is operating properly.
SERVICE
If a condition persists or you are uncertain about the operation of the
water heater contact a qualied service technician.
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.
If you are not thoroughly familiar with gas codes, your water heater,
and safety practices, contact your gas supplier or qualied installer
to check the water heater.
Read this manual rst. 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.
56
Never use this water heater unless it is completely lled with water.
To prevent damage to the tank, the tank must be lled with water.
Water must ow 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 (Not shown
in figure).
J. Condensate from the exhaust connection.
K. *The temperature probe fitting may be leaking.
Leakage from other water heaters, water lines, or ground seepage
should also be checked.
* To check where threaded portion enters tank, insert cotton
swab between jacket opening and tting. If cotton is wet, follow
“Draining” instructions in the “Periodic Maintenance” section and
then remove tting. Put pipe dope or teon tape on the threads
and replace. Then follow “Filling the Water Heater” instructions
in the “Installing the New Water Heater” section.
WATER LEAK PROTECTION
The water heaters covered by this manual have a water leak
protection feature that senses the buildup of water in vicinity of the
appliance, setting off an alarm to alert the end user.
To use this feature, contact your local distributor or call Technical
Support for assistance.
Kit number 100302557
LEAKAGE CHECKPOINTS
Figure 44
A:Inlet &
Outlet
K:Temperature
Probe
Connection
B:Anode
Rod
Connection
G:Recirculation
Connection
C:T & P
Connection
D:T & P Outlet
G:Recirculation
Connection
J:Flue Outlet
F:Drain Valve
Connection
H:Cleanout
E:Drain
Valve
57
TROUBLESHOOTING
SEQUENCE OF OPERATION
Read the Sequence of Operation section before attempting
to correct any operational problems. Refer to Features and
Components (page 10) for the location of various water heater
components described in this section. See also the Sequence Of
Operation Flow Chart (page 58).
1. When the control system is rst powered, during boot up, it will
display water heater model information during initialization.
After a few moments the control system LCD Touch Display
which is part of the UIM (user interface module) will display
the default screen known as the “Desktop” screen.
2. If the control system determines that the actual water
temperature inside the tank is below the programmed
Operating Set Point minus the Differential setting, a heating
cycle is activated.
3. The control system then performs selected diagnostic system
checks. This includes conrming the blocked exhaust, blocked
intake and ECO (energy cut out) switch contacts are closed.
4. If all diagnostic checks are successfully passed, the control
system energizes the Combustion Blower for pre-purge.
5. The control system energizes the Spark Ignition Transformer..
6. After a few seconds, the control system energizes the 24V
Gas Control Valve allowing gas to ow to the Main Burner.
7. The control system monitors the ame sensor to conrm a
ame is present at the Main Burner. If a ame is not veried
during the ignition trial period the control system will try for
ignition up to two more times. If ame can not be veried after
three trials for ignition, the control system will lock out and
display the “Ignition Failure” Fault message.
8. If a ame is veried, the control system will de-energize
the Spark Ignition Transformer and 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-volt gas valve and enter the post-purge
cycle (approximately 60 seconds).
9. The Combustion Blower will run for the duration of the
postpurge 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.
10. The control system now enters the standby mode while
continuing to monitor the internal storage tank water
temperature and the state of other system devices. If the tank
temperature drops below the Operating Set Point minus the
Differential setting, the control will automatically return to Step
2 and repeat the operating cycle.
INSTALLATION CHECKLIST
The list below represents some of the most critical installation
requirements that, when overlooked, often result in operational
problems, down time and needless parts replacement. This is not
a complete list. Before performing any troubleshooting procedures
use the list below to check for installation errors. Costs to correct
installation errors are not covered under the limited warranty.
Ensure all installation requirements and instructions in this manual
have been maintained and followed.
WATER HEATER LOCATION
1. Ensure proper clearances to combustibles are maintained and
there is sufcient room to service the water heater.
2. Ensure the area is free of corrosive elements and ammable
materials.
VENTING
3. Ensure the intake air and/or vent (exhaust) piping is the correct
size for the installed length.
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.
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.
7. If venting direct vent, ensure the screen located in air intake at
the water heater was removed.
GAS SUPPLY AND PIPING
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 and draining freely to a
suitable oor drain.
ELECTRICAL CONNECTIONS
10. 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.
11. Ensure the power supply connections to the water heater are
polarity correct.
58
SEQUENCE OF OPERATION FLOW CHART
YES NO
Water is heated to
set point
24 V Gas Valve
de-energized
60 second
Inter-Purge cycle
24 V Gas Valve
de-energized
Retries up to
two more times
60 second
Post-Purge cycle
Control System
Locks Out
“Ignition Failure”
Fault Msg is
displayed
Water heater goes
into standby mode
If tank temperature drops below Operating Set Point minus
Differential setting a heating cycle is activated
Spark Ignition Transformer is energized
24 V Gas Valve is energized
gas flows to Main Burner
Is flame sensed at the Main Burner ?
(control system monitors the flame sensor)
Control System Locks Out
Displays Fault Msg
NO
Combustion Blower is energized
Pre-Purge cycle
Control System performs diagnostic checks
Normal State of all pressure switches and ECO are checked
Pressure switches and ECO are verified closed
Figure 45
59
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:
• 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.
NOT ENOUGH OR NO HOT WATER
• No power to the water heater, check breaker, fuses.
• Enable/Disable switch in “disabled” position. Set to enable to
allow unit to operate.
• Hot water supply valve(s) to xtures closed.
• Operating Set Point is set too low, Differential setting is set too
high.
• Temperature Probe Offset setting is causing the heating cycles
to terminate prematurely.
• The heating capacity of the water heater has been exceeded,
the water heater is unable to meet demand.
• Colder incoming water temperature lengthening the time
required to heat water to desired temperature.
• Hot water piping leaks, open faucets, water heater drain valve
leaking or open.
• Sediment or lime scale accumulation may be affecting water
heater operation.
WATER IS TOO HOT
• Operating Set Point is set too high.
• Temperature Probe Offset improperly set.
• If installed check Thermostatic Mixing Valve settings.
• Lime build-up on temperature probe. Inspect and clean.
NOISY OPERATION
• Normal operating noise of electrical components; Combustion
Blower, transformer hum, relay contact closure.
REPLACEMENT PARTS
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 afxed to the water heater.
For more information or technical support call the phone number on
the warranty sheet supplied with this water heater.
OPERATIONAL PROBLEMS
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
This section of the manual is intended to be an aid in correcting
common operational problems, it is not all inclusive. The installer
may be able to observe and correct certain problems which might
arise when the water heater is rst put into operation or when it
is re-red after a prolonged shutdown. However, only qualied
service technician should perform any service procedures on the
water heater.
NOTE: For technical support or to locate a qualied service
technician in your area, call the phone number on the warranty
sheet supplied with this water heater.
ROUGH STARTING, ROUGH OPERATION
Fire and Explosion Hazard
Excessive gas pressure to gas valve can
cause serious injury or death.
Do not use water heater with any gas
other than the gas shown on the rating
plate.
Turn off gas lines during installation.
Contact a qualified installer or service
technician for installation and service.
• 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.
• Clogged/blocked intake air screen(s).
• Clogged/blocked the Main Burner.
MOMENTARY IGNITION
Burn Hazard
Do not reach into the burner housing or
combustion chamber if the water heater
is still hot.
•
Allow the water heater to cool and always use
gloves when handling the main burner.
•
•
The combustion chamber and burner sleeve
and housing become very hot during operation.
CAUTION
60
are operational problems. This is not a complete list. Along with
each of the Fault and Alert messages described there will be a list
of possible causes and things to check and repair.
Only qualied service technician, as dened in Qualications using
appropriate test equipment, should perform any service procedures
on the water heater.
NOTE: If you are not qualied and licensed or certied as required
by the authority having jurisdiction to perform a given task do not
attempt to perform any of the diagnostic or service procedures
described in the following section.
If you do not understand the instructions in the following section do
not attempt to perform any procedures.
For technical support or to locate a qualied service technician in
your area, call the phone number on the warranty sheet supplied
with this water heater.
FAULT AND ALERT CONDITIONS
FAULT CONDITIONS
When the control system declares a Fault condition it will display a
Fault message on the control system's LCD with an exclamation "!"
mark. The control system will lock out and disable heating operation
until the condition is corrected. The water heater must be serviced
by a qualied service technician before operation can be restored.
ALERT CONDITIONS
When the control system declares an Alert condition it will display
an Alert message on the control system's LCD with a question "?"
mark. The water heater will continue to operate during an Alert
condition but the water heater must be serviced by a qualied
service technician as soon as possible.
RESETTING CONTROL SYSTEM LOCK OUTS
To reset the control system from a lock out condition; turn off the
switch in front of the unit for approximately 20 seconds and then
back on. Keep in mind: if the condition that caused the Fault has
not been corrected, the control system will continue to lock out.
DIAGNOSTIC CHECKS
Turn off power to the water heater
before performing any service.
Electrical Shock Hazard
•
Label all wires prior to disconnecting
when performing service. Wiring errors
can cause improper and dangerous
operation.
•
Verify proper operation after servicing.
•
Failure to follow these instructions can
result in personal injury or death.
•
The following section, Fault And Alert Messages lists some of the
messages the control system will display on the LCD when there
FAULT AND ALERT MESSAGES
For technical support or to locate a qualied service technician in your area, call the phone number on the warranty sheet supplied with this
water heater.
Possible Causes - Check/Repair Displayed Fault/Alert Message
• Using a manometer, ensure that gas supply pressure is above
minimum requirement listed on heater’s data plate and does not
drop more than 1.5” W.C. when unit res.
• Ensure wire connections to gas valve are clean and tight.
• Ensure wire connections to ame sensor are clean and tight.
• Ensure wire connections to spark igniter are clean and tight.
• Inspect ame sensor, clean/replace as needed.
• Inspect spark igniter, realign igniter gap as needed
• Ensure adequate electrical ground to heater.
ADVANCEDBACK
0 days 0 hrs 0 mins ago
Error Code: B2-70
Ignition Failure
Flame not detected. Clean flame
rod. Check gas supply.
Press the Advanced button for
more information
• If Blocked Exhaust error occurs when blower is running, check for
restrictions in exhaust pipe, including exhaust elbow, condensate
drain, and outside termination. Also check exhaust pipe installation
(size/length) per manual.
• If Blocked Exhaust error occurs before blower runs, make sure
pressure switch connections are clean and tight. Check pressure
switch continuity/resistance. Switch should be closed (continuity/0
ohms). Replace switch if open (no continuity).
• Other possible causes: high wind conditions and excessive
negative air pressure in building.
ADVANCEDBACK
0 days 0 hrs 0 mins ago
Error Code: A8-1201
Blocked Exhaust
Restriction in exhaust pipe.
Check exhaust pipe and
termination for blockage.
Press the Advanced button for
61
FAULT AND ALERT MESSAGES (CONT)
For technical support or to locate a qualied service technician in your area, call the phone number on the warranty sheet supplied with this
water heater.
Possible Causes - Check/Repair Displayed Fault/Alert Message
• If Blocked Intake error occurs before blower runs, make sure
pressure switch connections are clean and tight. Check pressure
switch continuity/resistance. Switch should be closed (continuity/0
ohms). Replace switch if open (no continuity).
• If Blocked Intake error occurs when blower is running, check for
restrictions in intake pipe, including intake air connection, outside
termination, and inlet condensate drains (if installed).
• Other possible causes: High wind conditions, excessive negative
air pressure in building.
ADVANCEDBACK
0 days 0 hrs 0 mins ago
Error Code: A7-1201
Blocked Air Intake
Restriction in air intake.
Check intake pipe and
termination for blockage.
Press the Advanced button for
• Ensure wire connections to the temperature probe are clean and
tight.
• Using a thermometer, check the water temperature of the heater.
• Use a multi-meter and check for continuity between the two red
wires of the temperature probe.
• If the two red wires are open (no continuity) and water temperature
is below 160°F, replace the temperature probe.
• If the water temperature exceeds 195°F, turn off electric power and
gas supply and call Tech Support for further instructions.
ADVANCEDBACK
0 days 0 hrs 0 mins ago
Error Code: A5-401
High Temp Limit Exceeded
Energy Cut Off has shut off
water heater due to high tank
temperature.
Press the Advanced button for
• Conrm the water heater is full of water.
• Conrm the powered anode wire connections are tight and free of
debris or moisture (i.e. rust, solder, metal pipe shavings).
• Conrm proper electrical ground to the water heater.
• Inspect powered anode, clean/replace as needed.
NOTE: This Fault only applies to models with powered (non-
sacricial) anodes.
ADVANCEDBACKACCEPT
0 days 0 hrs 0 mins ago
Error Code: D6-8
No Water
No water detected by Powered
Anode.
The control indicates a problem
with the anode protection. By
• Conrm the anode rod is not bent and shorting to the tank.
• Conrm the powered anode is free of contamination between the
anode top and surrounding metal (i.e. solder, loctite, WD40).
• Conrm proper electrical ground to the water heater.
• Inspect powered anode, clean/replace as needed.
NOTE: This Fault only applies to models with powered (non-
sacricial) anodes.
ADVANCEDBACK
0 days 0 hrs 0 mins ago
Error Code: CC-B
Anode Shorted
The Powered Anode is shorted to
earth ground or the tank.
The control indicates a problem
with the anode
• Conrm that the lower probe cable is plugged into the CCB and the
lower probe connector.
• Measure resistance of probe to check for an open or shorted
circuit.
• Inspect lower probe cable for damage.
• Inspect the lower probe. Replace as needed.
ADVANCEDBACK
0 days 0 hrs 0 mins ago
Error Code: 48-0
Lower Temp Probe Open
The indicated temperature probe
may be shorted or open.
Check connector and resistance
of probe.
62
DIAGRAMS
CENTRAL CONTROL BOARD (CCB) LAYOUT
11
12
1
J16
J5
J3
J13
J4
J17
J10
J9
J14
J15
J1
J6
J12
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
4
5
5
5
5
5
5
6
6
6
6
6
6
7
78
8
8
9
9
7
10
8
Figure 46. Central Control Board Layout
63
WIRING DIAGRAM
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND
DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.
Figure 47: WIRING SCHEMATIC (Continued on next page).
Splice
Splice
Green
Green
Ferrite
Bead
Transformer
Secondary
White / Red
White / Blue
Transformer
Primary
Black
White
Transformer
Power
Supply J2
1 Blue
3 Orange
4 White/Green
Power
Supply J1
2 White
3 Black
Power
Supply
Central Control Board
(CCB)
Blower
1 Black
2 White
3 Green
120V OUT to
Blower
L1
Neutral
PE
1 White / Brown
2 White / Orange
4 White / Blue
Blower
Speed
5 White / Green
24Vureg
PWM Signal
Speed f-back
Dgnd
8 White
Field Box
HIGH Voltage
J1
7 Black
6 Red
5 Green
4 White
3 Black
2 Red
Green
Neutral
L1
Pump Common
Pump NO
AUX NO
AUX Common
AUX NC
PE
Junction Box
CCB J16
Low Voltage In
1 White/Red
2 White/Blue
4 Blue
5 Orange
6 White/Green
24VAC
24VAC
12VDC
5VDC
Dgnd
9 White
CCB J1
HIGH Voltage In
8 Black
7 Red
6 Green
3 Black
4 White
5
2 Red
1
Neutral
L1
Pump Common
Pump NO
AUX NO
AUX Common
AUX NC
PE
CCB J5
Blower Logic
1 White/Brown
2 White/Blue
4 White/Orange
5 White/Green
24Vureg
PWM Signal
Speed f-back
Dgnd
Green
Yellow
CCB J14
Limit String
1 Blue
2 Green
3 Yellow
4 Black
6 Black
7 Red
8 Black
9 Red
10 Black
11 Red
12 Black
Anode
Dgnd
Flame Rod
Condensate
Gas PS
Gas V Switch
Gas V 24V
24V Rtn
Condensate
Gas PS
Gas V Switch
1 Red
2 Black
CCB J6
120V Out
Neutral
120 to Spark
Red
Black
Red
Black
Upper Temperature
Probe / ECO
1 Red
2 Black
CCB J9
Upper Probe
ECO
Thermistor
4 Red
3 Black
ECO
Thermistor
Gas Valve
Ground Bar
Spark
Module
120V
Neutral
L1
Neutral
Protective
Earth
= multi-conductor power limited cable, 18AWG 80°C 300V UL category QPTZ
Connects
to burner
bolt
= Spark ignition wire, 220°C 25kVDC 8mm EMI suppression
Spark
Rod
Flame
Rod
CCB J17
Low Voltage Field
No factory
connections
Gas Valve
Power Switch
Splice
Blue
Blue
Anode
Rod
2 Red
3 Green
4 White/Brown
5 White/Blue
CCB J12
Configuration Key
SDA (data)
SCL (data)
Write protect
6 White/Orange
+5V
Dgnd
Configuration
Key
1 Black
2 Red
CCB J15
Pressure
Switches
Inlet return
Outlet return / Inlet power
4 Green
Outlet power
= 18AWG AWM wire 105°C 600V UL style 1015. Flame rod wire = 200°C 300V UL 1180.
1 Red
2 Black
3 Green
Ground
BURNER
BOLT
Outlet Pressure
Switch
Inlet Pressure
Switch
1 Blue
3 Yellow
4 Orange
Display J1
5 Violet
+5V
Data +
Data -
D gnd
1 Blue
3 Yellow
4 Orange
CCB J3
5 Violet
+5V
Data +
Data -
D gnd
Jumper
shorts
wires
64
Splice
Splice
Green
Green
Ferrite
Bead
Transformer
Secondary
White / Red
White / Blue
Transformer
Primary
Black
White
Transformer
Power
Supply J2
1 Blue
3 Orange
4 White/Green
Power
Supply J1
2 White
3 Black
Power
Supply
Central Control Board
(CCB)
Blower
1 Black
2 White
3 Green
120V OUT to
Blower
L1
Neutral
PE
1 White / Brown
2 White / Orange
4 White / Blue
Blower
Speed
5 White / Green
24Vureg
PWM Signal
Speed f-back
Dgnd
8 White
Field Box
HIGH Voltage
J1
7 Black
6 Red
5 Green
4 White
3 Black
2 Red
Green
Neutral
L1
Pump Common
Pump NO
AUX NO
AUX Common
AUX NC
PE
Junction Box
CCB J16
Low Voltage In
1 White/Red
2 White/Blue
4 Blue
5 Orange
6 White/Green
24VAC
24VAC
12VDC
5VDC
Dgnd
9 White
CCB J1
HIGH Voltage In
8 Black
7 Red
6 Green
3 Black
4 White
5
2 Red
1
Neutral
L1
Pump Common
Pump NO
AUX NO
AUX Common
AUX NC
PE
CCB J5
Blower Logic
1 White/Brown
2 White/Blue
4 White/Orange
5 White/Green
24Vureg
PWM Signal
Speed f-back
Dgnd
Green
Yellow
CCB J14
Limit String
1 Blue
2 Green
3 Yellow
4 Black
6 Black
7 Red
8 Black
9 Red
10 Black
11 Red
12 Black
Anode
Dgnd
Flame Rod
Condensate
Gas PS
Gas V Switch
Gas V 24V
24V Rtn
Condensate
Gas PS
Gas V Switch
1 Red
2 Black
CCB J6
120V Out
Neutral
120 to Spark
Red
Black
Red
Black
Upper Temperature
Probe / ECO
1 Red
2 Black
CCB J9
Upper Probe
ECO
Thermistor
4 Red
3 Black
ECO
Thermistor
Gas Valve
Ground Ba
r
Spark
Module
120V
Neutral
L1
Neutral
Protective
Earth
= multi-conductor power limited cable, 18AWG 80°C 300V UL category QPTZ
Connects
to burner
bolt
= Spark ignition wire, 220°C 25kVDC 8mm EMI suppression
Spark
Rod
Flame
Rod
CCB J17
Low Voltage Field
No factory
connections
Gas Valv
e
Power Switch
Splice
Blue
Blue
Anode
Rod
2 Red
3 Green
4 White/Brown
5 White/Blue
CCB J12
Configuration Key
SDA (data)
SCL (data)
Write protect
6 White/Orange
+5V
Dgnd
Configuration
Key
1 Black
2 Red
CCB J15
Pressure
Switches
Inlet return
Outlet return / Inlet power
4 Green
Outlet power
= 18AWG AWM wire 105°C 600V UL style 1015. Flame rod wire = 200°C 300V UL 1180.
1 Red
2 Black
3 Green
Ground
BURNER
BOLT
Outlet Pressure
Switch
Inlet Pressure
Switch
1 Blue
3 Yellow
4 Orange
Display J1
5 Violet
+5V
Data +
Data -
D gnd
1 Blue
3 Yellow
4 Orange
CCB J3
5 Violet
+5V
Data +
Data -
D gnd
Jumper
shorts
wires
Figure 47: WIRING SCHEMATIC (Continued from previous page).
65
NOTES
66
NOTES
67
NOTES
68
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