Instructions / Assembly
7
The pipe compound used should be resistant to the action of lique-
fied petroleum gases.
LEAK TESTING — The water heater and its gas connections MUST
be leak tested at normal operating pressure before it is placed in
operation. Turn ON the manual gas shut-off valve near the water
heater. Use a soapy water solution to test for gas leaks at all con-
nections and fittings. Bubbles indicate a gas leak that must be
corrected. The water heater factory connections to the gas valve
should also be leak tested after placing the water heater in opera-
tion.
NEVER use open flame to test for gas leaks, as bodily injury or
property damage could result.
PRESSURE TESTING THE GAS SUPPLY SYSTEM — The water
heater and its manual gas shut-off valve MUST be disconnected
from the gas supply piping system during any high pressure test-
ing of that system at pressures in excess of 1/2 psi (14” w.c. / 3.5
kPa).
The water heater MUST be isolated from the gas piping system by
closing the manual gas shut-off valve during any pressure testing
of the gas supply piping at pressures equal to or less than 1/2 psi
(14” w.c. / 3.5 kPa).
5. RELIEF VALVE — A new factory installed combination pressure
and temperature relief valve, complying with the Standard for Re-
lief Valves and Automatic Gas Shutoff Devices for Hot Water Sup-
ply Systems, ANSI Z21.22, or Standard CAN1-4.4, Temperature,
Pressure, Temperature and Pressure Relief Valves and Vacuum
Relief Valves is provided with the water heater. No valve is to be
placed between the relief valve and the water heater. For a cir-
culating tank installation, the separate storage tank(s) must have
similar protection. The pressure rating of the relief valve must not
exceed 150 psi (160 psi for ASME models), the maximum working
pressure as marked on front of the water heater.
The Btu/h rating of the relief valve must equal or exceed the Btu/h
input of the water heater as marked on its rating plate.
Connect the outlet of the relief valve to a suitable open drain. The
discharge line must pitch downward from the valve to allow com-
plete draining (by gravity) of the relief valve and discharge line, and
be no smaller than the outlet of the valve. The end of the discharge
line should not be threaded or concealed and should be protected
from freezing. No valve of any type, restriction or reducer coupling
should be installed in the discharge line. Local codes shall govern
the installation of relief valves.
6. THERMAL EXPANSION — Determine if a check valve exists in
the inlet water line. It may have been installed in the cold water line
as a separate back flow preventer, or it may be part of a pressure
reducing valve, water meter or water softener. A check valve located
in the cold water inlet line can cause what is referred to as a ”closed
water system”. A cold water inlet line with no check valve or back
flow prevention device is referred to as an ”open” water system.
As water is heated, it expands in volume and creates an increase
in the pressure within the water system. This action is referred to as
”thermal expansion”. In an ”open” water system, expanding water
which exceeds the capacity of the water heater flows back into the
city main where the pressure is easily dissipated.
A ”closed water system”, however, prevents the expanding water
from flowing back into the main supply line, and the result of ”thermal
expansion” can create a rapid, and dangerous pressure increase in
the water heater and system piping. This rapid pressure increase can
quickly reach the safety setting of the relief valve, causing it to oper-
ate during each heating cycle. Thermal expansion, and the resulting
rapid, and repeated expansion and contraction of components in the
water heater and piping system can cause premature failure of the
relief valve, and possibly the heater itself.Replacing the relief valve
will not correct the problem!
The suggested method of controlling thermal expansion is to install an
expansion tank in the cold water line between the water heater and the
check valve. The expansion tank is designed with an air cushion built in
that compresses as the system pressure increases, thereby relieving
the over pressure condition and eliminating the repeated operation of
the relief valve. Other methods of controlling thermal expansion are
also available. Contact your installing contractor, water supplier, or
plumbing inspector for additional information regarding this subject.
If a recirculation line is installed, the return connection should be
made to a tee close to the inlet connection on the water heater. A
check valve should always be installed in the recirculation line to
prevent cold water from entering.
WATER CONNECTIONS — This water heater may be connected
individually, in multiples with others, or with an external hot water
storage tank.
Inlet water connections are made to the lower coupling on the
heater, and outlet water connections are made to the upper cou-
pling or, if desired on models so equipped, the optional top con-
nections may be utilized.
Cap unused connections. Use only clean, new galvanized steel,
copper or approved plastic pipe for water connections. Local
codes or regulations shall govern the exact type of material to
be used. The installation of unions on the inlet and outlet water
lines and a shut-off valve in at least the cold water inlet line is
recommended, so the water heater may be easily disconnected
for servicing.
When this water heater is supplying general purpose hot water
requirements for use by individuals, a thermostatically controlled
mixing valve is recommended to reduce the risk of scald injury.
Contact a licensed plumber or the local plumbing authority for
further information.
Thermometer(s) should be installed so that they indicate the tem-
perature of the water at or near the outlet of the water heater and
storage tank(s) if provided. See Fig. 4 or 5 on page 6.
7. WIRING — A polarized 120V 50/60 Hz power supply, with suit-
able disconnect means, must be connected to the black and white
leads provided. The current draw by the Standard Burner Unit is
0.3 Amps, 1.5 Amps on the Power Assist Burner unit, and 2.5
amps on the Xtreme unit. The water heater, when installed, must
be electrically grounded in accordance with local codes, or, in the
absence of local codes, with the National Electrical Code, ANSI/
NFPA 70 in the United States; or CSA C22.1 Electrical Code, in
Canada. Refer to Fig. 12, 13, 14, 15, or 16 on pages 24-28 of this
manual for water heater internal wiring diagrams.
Installation
WARNING
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