Instruction Manual COMMERCIAL GAS WATER HEATERS INSTALLATION - OPERATION SERVICE - MAINTENANCE Low Lead Content WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS: • Do not try to light any appliance.
TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE..................3 Air From Other Indoor Spaces................................... 18 APPROVALS...................................................................3 Venting....................................................................... 19 Gas Piping................................................................. 20 GENERAL SAFETY INFORMATION...............................4 Sediment Traps........................................................
SAFE INSTALLATION, USE AND SERVICE The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual.
GENERAL SAFETY INFORMATION CAUTION Improper installation, use and service may result in property damage. • • • • • Do not operate water heater if any part has been exposed to flooding or water damage. Inspect anode rods regularly, replace when significantly depleted. 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.
INTRODUCTION PREPARING FOR THE INSTALLATION Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service. 1. Read the “General Safety” section, page 4 of this manual first and then the entire manual carefully. If you don’t follow the safety rules, the water heater will not operate properly. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.
INSTALLATION CONSIDERATIONS ROUGH-IN DIMENSIONS Figure 1. ROUGH-IN DIMENSIONS Table 1. DIMENSIONS AND RECOVERY RATINGS DIMENSIONS Model Units A B C D E F G H J K L M 75 Natural & LP Inches CM 61 7/8 157.2 59 3/8 150.8 29 15/16 76 26 1/2 67.3 14 3/16 36 4 10.2 14 7/8 39.4 16 40.6 1 7/8 4.8 1 NPT 1/2 NPT 12.0 30.5 100 Natural & LP Inches CM 69 7/8 177.5 67 3/8 171.1 31 1/2 80.0 27 3/4 70.5 14 1/8 35.9 4 10.2 15 5/8 39.7 16 40.6 1 7/8 4.
THERMOMETERS (NOT SUPPLIED) FACTS TO CONSIDER ABOUT THE LOCATION Thermometers should be obtained and field installed. Carefully choose an indoor location for the new water heater, because 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. This water heater is not for use in manufactured (mobile) homes or outdoor installation.
• Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected. • Sensors mounted in the drain pan that turn off the water supply to the entire home when water is detected in the drain pan. • Water supply shut-off devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater.
HIGH ALTITUDE Figure 2. AIR SHUTTER OPEN A correctly set burner should have a stable quiet flame. The flame will be blue with a well defined blue inner flame, Some yellow tipping is normal with LP gas. See Figure 3. Water heaters covered in this manual have been tested and approved for installation at elevations up to 7,700 feet (2,347 m) above sea level.
Figure 6. UNSTABLE FLAME Figure 8. VENTILATION CLEARANCES 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 or water heaters be installed so that combustion and ventilation air be taken from outside these areas.
• DO NOT apply insulation to the top of the water heater, as this will interfere with safe operation of the draft hood. See Figure 18 (page 20). • DO NOT cover the thermostat or the temperaturepressure relief valve. • DO NOT allow the insulation to come within 2 inches (5 cm) of the floor to prevent blockage of combustion air flow to the burner. • DO NOT cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.
INSTALLATION REQUIREMENTS GAS SUPPLY SYSTEMS SUPPLY GAS REGULATOR Low pressure building gas supply systems are defined as those systems that cannot under any circumstances exceed 14” W.C. (1/2 PSI Gauge). These systems do not require pressure regulation. Measurements should be taken to insure that gas pressures are stable and fall within the requirements stated on the water heater rating plate.
Table 3 shows the approximate time-to-burn relationship for normal adult skin. If anyone using hot water provided by the water heater being installed fits into one of these groups or if there is a local code or state law requiring a certain water temperature at the point of use, then special precautions must be taken.
TEMPERATURE-PRESSURE RELIEF VALVE Explosion Hazard Temperature-Pressure Relief Valve must comply with ANSI Z21.22CSA 4.4 and ASME code. Properly sized temperaturepressure relief valve must be installed in opening provided. Can result in overheating and excessive tank pressure. Can cause serious injury or death. This water heater is provided with a properly rated/ sized and certified combination temperature-pressure relief valve (T&P valve) by the manufacturer.
No valve or other obstruction is to be placed between the temperature-pressure relief valve and the tank. Do not connect discharge piping directly to the drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in adequate quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water flow may cause property damage.
AIR REQUIREMENTS UNUSUALLY TIGHT CONSTRUCTION In unconfined spaces in buildings, infiltration may be adequate to provide air for combustion, ventilation and dilution of flue gases. However, in buildings of unusually tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.) additional air must be provided using the methods described in that follows.
OUTDOOR AIR THROUGH ONE OPENING and free area are not known, it shall be assumed that wood louvers will have 25% free area and metal louvers and grilles will have 75% free area. Non motorized louvers and grilles shall be fixed in the open position. FRESH AIR OPENINGS FOR CONFINED SPACES The following instructions shall be used to calculate the size, number and placement of openings providing fresh air for combustion, ventilation and dilution in confined spaces.
OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS Figure 16. FRESH AIR FROM TWO VERTICAL DUCTS The confined space shall be provided with two permanent vertical ducts, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The vertical ducts shall communicate directly with the outdoors. See Figure 16. Figure 15.
The confined space shall be provided with two permanent openings, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. See Figure 17. Such temperatures may not be high enough to properly open thermally operated vent dampers. This would cause spillage of the flue gases and may cause carbon monoxide poisoning.
Be sure vent pipe is properly connected to prevent escape of dangerous flue gases which could cause deadly asphyxiation. Vent Draft Hood Draft Hood Screw Vent to outdoors or chimney Top of Heater Screw Figure 18. DRAFT HOOD ATTACHMENT The vent pipe from the water heater must be no less than the diameter of the draft hood outlet on the water heater and must slope upward at least 1/4 inch per linear foot (21 mm per meter). See Figure 19 (page 20).
Table 5. The sizes shown are for straight lengths of pipe GAS SUPPLY LINE SIZES (IN INCHES)* MAXIMUM CAPACITY OF PIPE IN CUBIC FEET PER HOUR at 0.5 in. W.C. pressure drop, which is considered normal for low pressure systems. Note: Fittings such as elbows, tees and line regulators will add to the pipe pressure drop. Also refer to the current editions of the National Fuel Gas Code (NFPA 54) or Natural Gas and Propane Installation Code (CAN/CSA B149.1). Table 4.
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).
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. FLAMMABLE BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A. This appliance has a pilot which is lit by a piezo- C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or electric spark gas ignition system.
TEMPERATURE REGULATION Short repeated heating cycles caused by small hot water uses can cause the temperature to exceed the thermostat setting by up to 30°F (16.7°C). If you experience this type of use you should consider using lower temperature settings to reduce scald hazards. NOTE: The temperatures indicated are approximates. The actual temperature of the heated water may vary. STANDARD MODE The controller adjusts the water heater to maintain the temperature set by the user.
FOR YOUR INFORMATION START-UP CONDITIONS Table 6. INPUT CHECK TIME REQUIRED TO CONSUME 1 CU. FT. OF GAS DRAFT HOOD OPERATION Check draft hood operation by performing a worst case depressurization of the building. With all doors and windows closed, and with all air handling equipment and exhaust fans operating such as furnaces, clothes dryers, range hoods and bathroom fans, a match flame should still be drawn into the draft hood of the water heater with its burner firing.
Do not remove the anode leaving the tank unprotected. By doing so, all warranty on the water heater tank is voided. 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. 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).
PERIODIC MAINTENANCE VENTING SYSTEM INSPECTION BURNER INSPECTION Flood damage to a water heater may not be readily visible or immediately detectable. However, over a period of time a flooded water heater will create dangerous conditions which can cause DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. Contact a qualified installer or service agency to replace a flooded water heater.
AIR SHUTTER ADJUSTMENT ANODE ROD INSPECTION CAUTION If the installation is at a high elevation and the burner flame exhibits flame lifting and/or noise, do the following: Property Damage Hazard 1. Use a screw driver to loosen the air shutter screw. • • 2. Adjust the air shutter by rotating the shutter. Counter clockwise to close and Clockwise to open. a. Close air shutter - to prevent noisy flames that are lifting from the burner ports. Avoid water heater damage.
operation, make sure that (1) no one is in front of or around the outlet of the temperature-pressure relief valve discharge line, and (2) that the water discharge will not cause any property damage, as the water may be extremely hot. Use care when operating valve as the valve may be hot. To check the relief valve, lift the lever at the end of the valve several times, see Figure 24. The valve should seat properly and operate freely.
PERIODIC REMOVAL OF LIME DEPOSITS FROM TANK TYPE COMMERCIAL WATER HEATERS The amount of calcium carbonate (lime) released from water is in direct proportion to water temperature and usage, see the chart (Figure 25). The higher the water temperature or water usage, the more lime deposits are dropped out of the water. This is the lime scale which forms in pipes, heaters and on cooking utensils.
c. Remove six (6) hex head screws securing tank cleanout plate and remove plate. DELIME USING FLO-JUG METHOD 1. Slide the hose clamp over end of hose and slide hose over the male adapter in the water heater drain opening and secure in place using hose clamp. d. Remove lime, scale, or sediment using care not to damage the glass lining. e. Inspect cleanout plate gasket, if new gasket is required, see the replacement parts list for item number. 2.
DRAINING AND FLUSHING TO FLUSH THE WATER HEATER STORAGE TANK: It is recommended that the water heater storage tank be drained and flushed every 6 months to reduce sediment buildup. The water heater should be drained if being shut down during freezing temperatures. See Figure 29 for the location of the water heater components described below. 1. Ensure the cold water inlet valve is open. 2. Open a nearby hot water faucet and let the water run until the water is no longer hot.
LEAKAGE TEST POINTS A. Water at the draft hood is water vapor which has condensed out of the combustion products. This is caused by a problem in the vent. Contact the gas utility. B. *Condensation may be seen on pipes in humid weather or pipe connections may be leaking. C. *The anode rod fitting may be leaking. D. Small amounts of water from temperature-pressure relief valve may be due to thermal expansion or high water pressure in your area. E.
Never use this water heater unless it is completely filled with water. To prevent damage to the tank, the tank must be filled with water. Water must flow GAS CONTROL/ TEMPERATURE KNOB from the hot water faucet before turning “ON” gas to the water heater. VAC IGNITER BUTTON Read this manual first. Then before checking the water heater make sure the gas supply has been turned “OFF”, and never turn the gas “ON” before the tank is completely full of water.
REPLACING THE GAS CONTROL VALVE/THERMOSTAT: 1. To replace the gas control valve/thermostat, reassemble in reverse order. When replacing the gas control valve/ thermostat, thread a 4” section of gas pipe into the inlet and use it to turn the gas control valve/thermostat (clockwise). DO NOT OVER TIGHTEN; damage may result. 2. Be sure to use approved Teflon® tape or pipe joint compound on the gas piping connections and fitting on the back of the gas control valve that screws into the tank. 3.
Table 7. STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART LED Status Problem Corrective Action 0 FLASHES (LED NOT LIT) Pilot light is not lit or Thermopile has not yet reached normal operating temperature. Turn Gas Control Valve/Thermostat knob to OFF. Wait 10 minutes, then attempt to relight Pilot by following the lighting instructions on the water heater’s label. Until the Thermopile reaches its normal operating temperature, the Status Light will not blink, even if the Pilot is lit.
Table 7. STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART LED Status Problem Corrective Action 5 FLASHES The temperature sensor (thermistor) is defective. Turn Gas Control Valve/Thermostat knob to OFF. Turn Main Gas Supply OFF. Replace the Gas Control Valve/ Thermostat. See Removing and Replacing the Gas Control Valve/Thermostat (page 34). 7 FLASHES Gas Control Valve failure. Turn Gas Control Valve/Thermostat knob to OFF. Turn Main Gas Supply OFF. Replace the Gas Control Valve/ Thermostat.
Table 8. GENERAL TROUBLESHOOTING GUIDELINES These guidelines should be used by a qualified service agent. Symptom WATER LEAKS LEAKING T&P VALVE SMELLY WATER PILOT WILL NOT LIGHT Problem Corrective Action Improperly sealed, hot or cold supply connection, relief valve, drain valve, or thermostat threads. Tighten threaded connections. Leakage from other appliances or water lines. Inspect other appliances near water heater. Condensation of flue products. See Condensation (page 25).
COLD COLD WATER SUPPLY DRAIN TANK TEMPERATURE CONTROL CIRCULATING PUMP PRESSURE RELIEF VALVE TEMPERATURE & PRESSURE RELIEF VALVE EXPANSION TANK COLD NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4.
COLD ALT. COLD WATER CONNECTION HOT WATER TO FIXTURES NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s). 5.
COLD HOT WATER TO FIXTURES DRAIN TANK TEMPERATURE CONTROL CIRCULATING PUMP PRESSURE RELIEF VALVE TEMPERATURE & PRESSURE RELIEF VALVE ALTERNATE LOCATION NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4.
LINE TEMPERATURE CONTROL HOT WATER RETURN TEMPERED WATER RETURN TEMPERED WATER OUTLET DRAIN PIPE T&P TO OPEN DRAIN MINIMUM 10´´ to 12´´ HOT COLD TANK TEMPERATURE CONTROL CIRCULATING PUMP PRESSURE RELIEF VALVE TEMPERATURE & PRESSURE RELIEF VALVE HOT WATER OUTLET NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit.
HOT COLD PIPE T&P TO OPEN DRAIN HOT COLD NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
HOT COLD EXPANSION TANK COLD WATER SUPPLY PIPE T&P TO OPEN DRAIN HOT WATER RETURN HOT NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
NOTES 45
COMMERCIAL WATER HEATER LIMITED WARRANTY EFFECTIVE WHAT'S NOT COVERED For 3 Years, in the event of a tank leak, we will repair or, at our discretion, replace the defective water heater.
