INDIRECT-FIRED WATER HEATER A Spanish language version of these instructions is available by contacting the manufacturer listed on the rating plate. La version espanola de estas instruccions se puede obtener al escribirle a la fábrica cuyo nombre aparece in la placa de especificaciones.
CONGRATULATIONS! You have purchased one of the finest water heaters on the market today! This installation, operation, and instruction manual will explain in detail the installation and maintenance of your new indirect water heater. We strongly recommend that you contact a plumbing professional for the installation of this water heater. We require that you carefully read this manual, as well as the enclosed warranty, and refer to it if questions arise.
CAUTION The maximum boiler water supply temperature to the indirect heat exchanger must NOT exceed 240°F (115°C). NOTICE Insulation blankets are not required for this water heater. This water heater meets or exceeds the ASHRAE/IES 90.1b standards with respect to insulation and standby loss requirements. SECTION I IMPORTANT INFORMATION -READ CAREFULLYThe equipment must be installed in accordance with those installation regulations required in the area where the installation is to be made.
Important Information continued- DANGER DO NOT store or use gasoline or other flammable, combustible, or corrosive vapors and/or liquids in the vicinity of this or any other appliance. IF YOU SMELL GAS: • DO NOT try to light any appliance. • DO NOT touch any electric switch; DO NOT use any telephone in your building. • Immediately call your gas supplier from a telephone in another building. Follow the gas supplier’s instructions.
Important Information continued- WARNING Installation is not complete unless a pressure and temperature relief valve is installed into the side of the water heater. See the Water Connections section of this manual for details. This water heater contains very hot water under high pressure. Do NOT unscrew any pipe fittings or attempt to disconnect any components of this water heater without positively assuring the water is cool and has no pressure.
Important Information continued- WARNING It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete. DO NOT operate the water heater with jumpered or absent controls or safety devices. DO NOT tamper with or alter the water heater and/or controls. DO NOT operate the water heater if any external part has been under water.
SECTION II SPECIFICATIONS Figure 1 – Tank Layout Table 1: Water Heater Dimension (Inches) Model 30-Gal. / Res. 40-Gal. “R” / Res. 50-Gal. “R” / Res. 65-Gal. / Res. 65-Gal. / Com. 80-Gal. / Res. 80-Gal. / Com. 120-Gal. / Res. 120-Gal. / Com.
Specifications continued- Table 2: Water Heater Capacities Model 30-Gal. / Res. 40-Gal. “R” / Res. 50-Gal. “R” / Res. 65-Gal. / Res. 65-Gal. / Com. 80-Gal. / Res. 80-Gal. / Com. 120-Gal. / Res. 120-Gal. / Com. Tank Coil Volume Dry Weight Capacity (Gal) (Lbs) (Gal) 29 2.7 140 37 2.7 172 43 2.7 180 57 2.7 196 54 5.0 265 71 2.7 224 67 5.0 293 110 2.7 355 107 5.0 415 Wet Weight (Lbs) 404 486 576 704 768 861 920 1324 1370 Table 3: AHRI Certified Water Heater Ratings Model 30-Gal. / Res. 40-Gal. “R” / Res.
Specifications continued- Table 4: Water Heater Performance Model 30-Gal. / Res. 40-Gal. “R” / Res. 50-Gal. “R” / Res. 65-Gal. / Res. 65-Gal. / Com. 80-Gal. / Res. 80-Gal. / Com. 120-Gal. / Res. 120-Gal. / Com. Maximum First Hour Rating (Gal/Hr) @ Continuous Draw Rating (Gal/Min) @ 140°F 226 235 244 258 396 272 408 309 445 140°F 115°F 3.3 5.2 3.3 5.2 3.3 5.2 3.3 5.2 5.7 8.8 3.3 5.2 5.7 8.8 3.3 5.2 5.7 8.
Specifications continued- NOTICE If the boiler takes longer to heat up from a cold start than the water availability as noted above, hot water shortage may occur. Hot water availability is based off drawing 80% of the heated tank volume at 4 gallons per minute flow rate. The maximum heat transfer through the coil (heat input) of the water heater at 240°F boiler water supply temperature and 210°F potable water temperature is 94,100 Btu/hr for residential models and 180,300 Btu/hr for commercial models.
ADJUSTABLE AQUASTAT – The thermostat can read from 40°F to 180°F. The temperature may be adjusted from 80°F to 160°F with installed factory stops. The aquastat (thermostat) was adjusted to 120°F before the heater was shipped from the factory. It is recommended that lower temperatures be used to avoid the risk of scalding. Refer to the “Warnings” and the section on SCALDING in “Section VII – Operating Instructions.
General Information continued- WARNING Install a discharge line so that water discharged from the temperature and pressure relief valve will exit within six (6) inches above, or any distance below, the structural floor and cannot contact any live electrical part. The discharge line is to be installed to allow for complete drainage of both the temperature and pressure relief valve and the discharge line. The discharge opening must not be subjected to blockage or freezing.
Pre-installation continued- IMPORTANT DECISIONS REQUIRED BEFORE INSTALLATION SIZING 1. Boiler DOE Heating Capacity – The indirect-fired water heater will provide the rated performance only if used in conjunction with a heat source with a DOE heating capacity (Boiler Output) at least as much as the minimum noted in Table 3. If the heat source has less capacity, the output of the tank will be reduced.
Pre-installation continued- SYSTEM ZONE CONTROL The indirect-fired water heater must be installed as a zone separate from the space heating system. The domestic hot water zone’s piping and circulator must be sized for a minimum flow rate with all zones in use and a maximum flow rate with only the water heater in use. For this reason, the preferred method of zone control is with circulators. 1.
Pre-installation continued- COMPONENT LOCATION CAUTION This water heater must be located in an area where leakage of the tank, water line connections, or the temperature and pressure relief valve will not result in damage to the area adjacent to the water heater or to lower floors of the structure. When such locations cannot be avoided, a suitable drain pan must be installed under the water heater.
Pre-installation continued- APPLIANCE LOCATION 1. Boiler Location – Locate the indirect-fired water heater as close to the boiler as practical. 2. Fixture Locations – For fastest delivery of hot water, place the indirect-fired water heater close to points of use. ADDITIONAL RECOMMENDED COMPONENTS 1. Shut-off Valves – Allows isolation of water heater from domestic water system and/or boiler system during service. 2.
SECTION V WATER CONNECTIONS WARNING FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE MANUFACTURER FROM ANY CLAIM WHICH MIGHT RESULT FROM EXCESSIVE TEMPERATURE AND PRESSURES. Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time. HYDROGEN GAS IS EXTREMELY FLAMMABLE.
Water Connections continued- INSTRUCTIONS FOR POTABLE CONNECTIONS 1. BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN WATER SUPPLY VALVE. After shutting off the main water supply, open a faucet to relieve the water line pressure to prevent any water from leaking out of the pipes while making the water connections to the water heater. After the pressure has been relieved, close the faucet. The COLD water inlet and HOT water outlet are identified on the top of the water heater.
Water Connections continued- CONNECT WATER BOILER SUPPLY PIPING 1. For a space heating system that utilizes ZONE VALVES, refer to Figure 2. The indirect-fired water heater connection labeled “FROM BOILER SUPPLY” should be piped to the boiler supply piping. Mount the circulator making sure the flow arrow points toward the water heater. The use of shut-off valves and unions are recommended for future service convenience. The use of an air separator and vent is recommended to eliminate air in the system.
Water Connections continued- Figure 3 - Water Boiler Piping with Circulators CONNECT STEAM BOILER SUPPLY PIPING Figure 4 represents a typical steam boiler connection diagram. Refer to the boiler installation manual or contact the boiler manufacturer for an appropriate piping diagram. The use of a union, shut-off valves, and a drain valve is recommended for future service convenience. The use of an in-line “Y”-style strainer is required to prevent accumulation of sludge in the water heater’s coil.
Water Connections continued- NOTICE Typical steam boiler without connections available below the water line is not recommended due to insufficient water temperature, especially during warmer months when the space heating system is not operational. Boiler water temperature at the bottom of a steam boiler can be 50°F lower than the boiler’s water temperature limit setting during such periods. FILL BOILER SYSTEM 1.
SECTION VI ELECTRICAL CONNECTIONS Install electric wiring in accordance with National Electric Code or the Canadian Electrical Code and local regulations. See the boiler’s installation manual for wiring diagrams. DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the water heater or building. Lock out all electrical boxes with padlock once power is turned off.
Electrical Connections continued- Figure 5 - Aquastat Control SECTION VII OPERATING INSTRUCTIONS WARNING Water heaters are heat-producing appliances. To avoid damage or injury there must be no materials stored against the water heater, and proper care must be taken to avoid unnecessary contact (especially by children) with the water heater.
Electrical Connections continued- SEQUENCE OF OPERATIONS 1. Aquastat senses stored water temperature drops below desired setting. a. Domestic hot water priority only: Normally closed contacts open to interrupt space heating. 2. Aquastat satisfied. a. Aquastat contacts open, turning off domestic hot water circulator and de-energizing relay. b. Normally open contacts open, stopping boiler operation. c.
Electrical Connections continued- Table 8 details the approximate relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.
Electrical Connections continued- 3. After the water heater completes a heat-up cycle, check the water temperature at a faucet. Allow enough water to flow to ensure that the water temperature reflects the tank temperature. Adjust the water heater’s temperature setting as necessary. a. Adjusting to a lower temperature setting will not immediately affect water temperature. Draw sufficient water or allow the water heater to remain idle until a heat-up cycle is initiated. Repeat step 3. b.
Maintenance continued- CAUTION Before manually operating the valve, make sure that a drain line has been attached to the valve to direct the discharge to an open drain. Failure to take this precaution could mean contact with extremely hot water discharging from the valve during this checking operation.
Maintenance continued- To inspect or replace an anode: The anodes on this water heater are easily accessible from the top of the heater making replacement simple and quick. a. Turn the water heater electricity OFF for the zone containing the indirect-fired heater. Flow water until the discharge is cool or allow enough time for the potable water to cool naturally. Connect a hose to the drain valve. Locate the hose’s discharge in an area where any remaining hot water will not cause any damage or injury. b.
SECTION IX TROUBLESHOOTING GUIDE PROBLEM CAUSE Boiler does not operate Circulator does not operate No hot water at faucet Improper aquastat setting or calibration Zone valve does not open (if used) Electrical problem (relay, wiring, etc.) Scale build-up Clogged cold water filter or boiler supply strainer (if used) 29 SOLUTION Refer to boiler installation instructions. Check main service switch. Check fused disconnect. Check power supply. Replace as necessary.
Troubleshooting Guide continued- PROBLEM CAUSE Aquastat set too high Water at faucet too hot Improper system plumbing Improper system wiring Aquastat setting too low Insufficient hot water Boiler cycles more than 5 times per day in summer Undersized boiler with no priority to domestic hot water Peak use of hot water is greater than tank storage capacity Faulty tank aquastat SOLUTION Lower aquastat setting. See Section VII. Compare plumbing to Section V: Water Connections.
SECTION X PARTS LIST PART NAME & DESCRIPTION 1. Aquastat Control 7. Drain Valve 2. Aquastat Well 8. Jacket Head Pan 3. Anode 9. Hole Closure 4. Diptube 10. Heat Exchanger Escutcheon 5. Outlet Nipple 11. Drain Escutcheon 6. T&P Relief Valve 12.
Contact your supplier or plumbing professional for replacement parts or contact the company at the address given on the rating plate of the water heater. Provide the part name, model, and serial numbers of the water heater when ordering parts. READ THE WARRANTY FOR A FULL EXPLANATION OF THE LENGTH OF TIME THAT PARTS AND THE WATER HEATER ARE WARRANTED.
