Installation Manual

39
GAS LINE CONNECTION
1. The water heaters covered by this manual are shipped from
the factory with a 1 1/2” supply gas connection, see Table 1
on page 10. Connect the supply gas line to the water heater's
24 VAC Gas Valve in accordance with all applicable local and
national code requirements. DO NOT use exible gas piping.
2. BTH 500 natural gas models require a 1 1/2” minimum supply
gas line. All other water heaters covered by this manual require
a 1 1/4” minimum supply gas line. See Table 5 on page 13.
3. Apply thread sealing compounds (pipe dope/ Teon tape)
sparingly and only to the male threads of the pipe joints. Do
not apply sealing compound to the rst two threads. Use pipe
dope or Teon tape marked as being resistant to the action of
liquid petroleum (LP/propane) gases.
4. Use only a smooth jaw adjustable wrench (such as a monkey
wrench) as a back up on the body of the 24 VAC Gas Valve
when tightening the rst pipe nipple into the body of the valve.
DO NOT use a standard pipe wrench (Stillson wrench) with
metal tooth jaws as this may permanently damage the valve.
5. Use a standard pipe wrench (Stillson wrench) as a back up
on the rst pipe nipple installed above when connecting other
ttings and pipe in the supply gas line to prevent the 24 VAC
Gas Valve on the water heater from twisting during installation.
6. To prevent damage, care must be taken not to apply too much
torque when connecting the supply gas line to the water heater.
7. Install a sediment trap (drip leg) as shown in Figure 48 on page 37.
8. Install a Main Gas Shutoff valve in the supply gas line as
shown in Figure 48 on page 38.
NOTE: Should overheating occur or the gas supply fail to shut
off, turn off the Main Gas Shutoff valve to the water heater.
GAS LINE LEAK TESTING
Fire and Explosion Hazard
Leak test before placing the
water heater in operation.
Disconnect gas piping and main
gas shutoff valve before leak
testing.
Install sediment trap in
accordance with NFPA 54.
Use joint compound or Teflon tape
compatible with propane gas.
Any time work is done on the gas supply system perform a leak
test to avoid the possibility of re or explosion.
1. For test pressures exceeding 1/2 psi (3.45 kPa) disconnect
the water heater and its Main Gas Shutoff Valve from the gas
supply piping system during testing, see Figure 48 on page
38. The gas supply line must be capped when disconnected
from the water heater.
2. For test pressures of 1/2 psi (3.45 kpa) or less, the water heater
need not be disconnected, but must be isolated from the supply
gas line by closing the Main Gas Shutoff Valve during testing.
3. Paint all supply gas line joints and connections upstream of
the water heater with a rich soap and water solution to test
for leaks. Bubbles indicate a gas leak. Do not use matches,
candles, ame or other sources of ignition for this purpose.
4. Repair any leaks before placing the water heater in operation.
ELECTRICAL WIRING
All electrical work must be installed in accordance with the
National Electrical Code, ANSI/NFPA 70 or the Canadian
Electrical Code, CSA C22.1 and local requirements.
When installed, the water heater must be electrically grounded in accordance
with local codes or, in the absence of local codes, with the National Electrical
Code, ANSI/NFPA 70 or the Canadian Electrical Code, CSA C22.1.
If any of the original wire as supplied with the water heater must
be replaced, it must be replaced with 105°C rated wiring or its
equivalent, except in the burner housing. In this case 200°C
rated wire must be used.
DEDICATED POWER WIRING AND BREAKERS
Dedicated power supply wires, ground wiring and dedicated
circuit breakers often prevent electrical line noise and are
required when installing the water heater.
POWER SUPPLY CONNECTIONS
Heater Wiring
(Factory Installed)
MOV
Ground
Ground T
erminal
Jumper Wires
L1
Neutral
Figure 49
Read the requirements for the Power Supply on page 13 before
connecting power.
Power supply connections must be made as follows:
1. Ensure the power supply is turned off at the breaker or disconnect switch.
2. Remove the junction box cover. See Figure 3 on page 8 for junction
box location.
3. Connect the 120VAC hot wire from the power supply to the black
jumper wire or the terminal block location marked "L1" inside of the
junction box located on top of the water heater. If the black jumper
wire is used, make the connection inside of the junction box with a
properly sized wire nut and wrap electrical tape around the wire nut
and wire end. See junction box Figure 49 and wiring diagram Figure
58 on page 64.
4. Connect the 120VAC neutral wire from the power supply to the white
jumper wire or the terminal block location marked "Neutral" inside of
the junction box located on top of the water heater. If the white jumper
wire is used, make the connection inside of the junction box with a
properly sized wire nut and wrap electrical tape around the wire nut
and wire end. See junction box Figure 49 and wiring diagram Figure
58 on page 64.
NOTE: If electrical connections are made directly to the terminal block
remove the jumper wires before making connection.
5. Connect the ground wire from the power supply to the green jumper
wire or the ground terminal location inside of the junction box located
on top of the water heater. If the green jumper wire is used, make
the connection inside of the junction box with a properly sized wire
nut and wrap electrical tape around the wire nut and wire end. See
junction box Figure 49 and wiring diagram Figure 58 on page 64.
6. Replace the junction box cover when connections are complete.
NOTE: Do not apply power to the water heater before installation
is complete and the water heater is lled with water.
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 hotwater.
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 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.
Connecting An External Supervisory Control
The enable/disable circuit is accessed from the CCB’s J17 plug inside
the CCB enclosure; see Figure 3 on page 8 to locate the CCB enclosure
and Figure 57 on page 63 for the CCB layout.
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.