MODELS HW-120M, 160M, 200M, 225M

Transcription

1 MODELS HW-120M, 160M, 200M, 225M COMMERCIAL GAS COPPER HEAT EXCHANGER WATER HEATER BURKAY UP-FLOW MODELS Including Models with Intermittent Pilot Ignition (I.I.D.) Installation Operation Maintenance Limited Warranty LOW LEAD CONTENT WARNING: If the information in these instructions are 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. Do not touch any electrical switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor s phone. Follow the gas supplier s instructions. If you cannot reach your gas supplier, call the fire department. Installation and service must be performed by a qualified installer, service agency or the gas supplier. 500 Tennessee Waltz Parkway Ashland City, TN PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND TIFY OWNER TO KEEP FOR FUTURE REFERENCE PRINTED

2 GENERAL SAFETY 2

3 SAFE INSTALLATION, USE AND SERVICE Your safety and the safety of others is extremely important in the installation, use, and servicing of this water heater. Many safety-related messages and instructions have been provided in this manual and on the 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 boiler. 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. DANGER WARNING CAUTION CAUTION DANGER indicates an imminently hazardous situation which, if not avoided, will result in 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. 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. IMPORTANT DEFINITIONS Qualified Installer: A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing, electricity, air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired boilers. The qualified installer must have a thorough understanding of this instruction manual. Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing, electricity, air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired boilers. The service agency must also have a thorough understanding of this instruction manual, and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer. Gas Supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances within this application. The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the Natural Gas meter or Propane storage tank of a building. Many gas suppliers also offer service and inspection of appliances within the building. 3

4 ROUGH-IN-DIMENSIONS TABLE 1 - ROUGH-IN DIMENSIONS Models HW-120M HW-160M HW-200M HW-225M Dimensions Inches mm Inches mm Inches mm Inches mm A 49 3/ / / B 30 3/ / / /8 841 C 23 5/ / / /8 689 D 20 3/ / / /4 527 E 5 1/ / / /2 140 F G 11 13/ / / / H J 26 11/ / / / K 20 3/ / / /4 527 L 1 1/4 NPT 1 1/4 NPT 1 1/4 NPT 1 1/4 NPT M 1 NPT 1 NPT 1 NPT 1 NPT N 1/2 NPT 1/2 NPT 1/2 NPT 1/2 NPT W 1 3/ / / /4 44 Approx. Shipping 120 lbs. 54 Kg. 155 lbs. 70 Kg. 165 Lbs. 75 Kg. 175 lbs. 79 Kg. Weight HEATER PERFORMANCE DATA TE: To compensate for the effects of high altitude areas above 2000 feet, input rating, and therefore recovery ratings, should be reduced approximately 4% for each 1000 feet above sea level. TABLE 2 - RECOVERY CAPACITIES U.S. Gallons/Hrs. and Litres/Hr. at TEMPERATURE RISE INDICATED Input T F Model BTUH KW T C HW GPH LPH HW GPH LPH HW GPH LPH HW GPH LPH Recovery rating of models shown in chart above are obtained by actual efficiency test data by recognized Certification Agency. TABLE 3 - GAS AND ELECTRIC CHARACTERISTICS Manifold Pressure Maximum Supply Pressure Minimum Supply Pressure Model Type of Gas Inches W.C. kpa Inches W.C. kpa inches W.C. kpa HW-120M thru 225M NATURAL HW-120M thru 200M PROPANE Minimum Pressure must be maintained under both load and no load (static and firing) conditions. Electrical characteristics: 120 volts/60 Hz and less than 5 amps. 4

5 FOREWORD This design complies with the current edition of the ANSI Standard Z for gas water heaters Vol. III Storage Water Heaters with input ratings above 75,000 BTU per hour Circulating and Instantaneous. Detailed installation instructions are in this manual. These instructions will serve to provide the installer with a reference for the materials and method of piping suggested. IT IS ESSENTIAL THAT ALL WATER AND GAS PIPING AND THE ELECTRICAL WIRING BE INSTALLED AND CONNECTED AS SHOWN IN THE DIAGRAMS. You should thoroughly read and understand this manual before installation and operation of this unit. CHECK THE DIAGRAMS THOROUGHLY BEFORE STARTING INSTALLATION TO AVOID POSSIBLE ERRORS AND TO MINIMIZE TIME AND MATERIALS COST. Particular attention should be given to the installation of thermometers at the locations indicated in the diagrams as these are necessary for checking the operation of the heater. MAKE SURE THE GAS ON WHICH THE HEATER WILL OPERATE IS THE SAME AS THAT SPECIFIED ON THE HEATER MODEL AND RATING PLATE. TABLE OF CONTENTS PAGE GENERAL SAFETY INFORMATION... 2 ROUGH-IN DIMENSIONS... 4 FOREWORD... 5 Precautions Grounding Instructions... 6 Chemical Vapor Corrosion... 6 Propane Gas Models... 6 High Altitude Installations... 6 FEATURES... 7 Automatic Gas Shutoff Control... 7 Protector Switch (Coil High Limit)... 7 Thermal Balancer... 7 Intermittent Ignition Control Module Circulating Pump... 8 Tank Temperature Control (Not Supplied)... 8 Safety Flow Switch (Not Supplied) Drain Valve (Not Supplied)... 9 Thermometers (Not Supplied)... 9 INSTALLATION INSTRUCTIONS Important Required Ability Location Installation Clearances Levelling Air Requirements Venting Relief Valve Hard Water Closed Water Systems Thermal Expansion Water Line Connections Water (Potable) Heating The factory warranty will be void if the unit(s) have been improperly installed or operated. In addition to these instructions, the water heater(s) shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made. To comply with NSF Standard 5 installation requirements the bottom of the water heater must be sealed to the floor with a silicone based sealant or elevated 6 inches above the floor. In absence of local codes, the installation must comply with the latest editions. In the United States: The National Fuel Gas Code, ANSI Z223.1 and the National Electric Code, NFPA 70. In Canada: The Installation Code CAN/CGA B149.1 and.2 (latest edition) and the Canadian Electric Code, CSA C22.1. These are available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131, USA, or, Canadian Gas Association Laboratories, 55 Scarsdale Road, Don Mills, Ontario M3B 2R3, Canada. PAGE PIPING DIAGRAMS Gas Connections Electrical Information OPERATION Important General Filling Gas Line Leak Testing Purging Operating Instructions For I.I.D Models Checking And Adjusting The Input SERVICE INFORMATION Pilot And Main Burner Maintenance I.I.D. Pilot Burner Protector Switch (Coil High Limit-All Heaters) Tank Temperature Control Automatic Gas Shutoff Control Thermal Balancer Inspecting The Heat Exchanger And Venting System Gas Pressure Regulator Relief Valve Circulating Pump Electrical Service Replacement Parts PREVENTIVE MAINTENANCE Recommended Procedure For Periodic Removal Of Lime Deposits From Coil Type Commercial Water Heaters Deliming Solvents Removing Light Deposits Heavy Lime Deposits CHECKOUT LIMITED WARRANTY GENERAL SAFETY INFORMATION PRECAUTIONS DO T USE THIS WATER HEATER IF ANY PART HAS BEEN UNDER WATER. Immediately call a qualified service agent to inspect the water heater and to replace any part of the control system and any gas control which has been under water. IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO T OPERATE HEATER UNTIL ALL CORRECTIVE STEPS HAVE BEEN MADE BY A QUALIFIED SERVICE AGENT. 1. EXTERNAL FIRE. 2. DAMAGE. 3. FIRING WITHOUT WATER. 4. SOOTING KEEP THE HEATER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS. AREA AROUND HEATER MUST T CONTAIN OBSTRUCTING MATERIAL TO THE FLOW OF COMBUSTION AND VENTILATING AIR. 5

6 SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO THE WATER HEATER. Heater must be protected from freezing downdrafts during shutdown periods. GROUNDING INSTRUCTIONS This water heater must be grounded in accordance with the National Electric Code and/or local codes. These must be followed in all cases. This water heater must be connected to a grounded metal, 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. CHEMICAL VAPOR CORROSION WARNING CORROSION OF THE FLUEWAYS 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. (Refer to the limited warranty for complete terms and conditions.) PROPANE GAS MODELS Water heaters for propane or liquefied petroleum gas (LPG) are different from natural gas models. A natural gas heater will not function safely on LP gas and no attempt should be made to convert a heater from natural to LP gas. LP gas must be used with great caution. It is highly explosive and heavier than air. It collects first in low areas making odor difficult to detect at nose level. If LP gas is present or even suspected, do not attempt to find the cause yourself. Go to a neighbor s house, leaving your doors open to ventilate the house, then call your gas supplier or service agent. Keep area clear until a service call has been made. At times you may not be able to smell an LP gas leak. One cause is odor fade, which is a loss of the chemical odorant that gives LP gas its distinctive smell. Another cause can be your physical condition, such as having a cold or diminishing sense of smell with age. For these reasons, the use of a propane gas detector is recommended. IF YOU EXPERIENCE AN OUT-OF-GAS SITUATION, DO T TRY TO RELIGHT APPLIANCES YOURSELF. Only trained LP professionals should conduct the required safety checks in accordance with industry standards. HIGH ALTITUDE INSTALLATIONS WARNING INSTALLATIONS ABOVE 2000 FEET REQUIRE REPLACEMENT OF THE BURNER ORIFICE IN ACCORDANCE WITH THE NATIONAL FUEL GAS CODE (ANSI Z223.1). FOR CANADIAN INSTALLATIONS CONSULT CANADIAN INSTALLATION CODES AND CAN/CGA B149. FAILURE TO REPLACE THE ORIFICES WILL RESULT IN IMPROPER AND INEFFICIENT OPERATION OF THE APPLIANCE RESULTING IN THE PRODUCTION OF INCREASED LEVELS OF CARBON MOXIDE GAS IN EXCESS OF SAFE LIMITS WHICH COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH. You should contact your gas supplier for any specific changes which may be required in your area. As elevation above sea level is increased, there is less oxygen per cubic foot of gas. Therefore, the heater input rate should be reduced at high altitudes for satisfactory operation with the reduced oxygen supply. Failure to make this reduction could result in an overfiring of the heater, causing sooting, poor combustion and/or unsatisfactory heater performance. U.S. REQUIREMENTS Ratings specified by manufacturers for most appliances apply for elevations up to 2000 feet (610m). For elevations above 2000 feet (610m), ratings must be reduced at the rate of 4% for each 1000 feet (305m) above sea level. For example, if a heater is rated at 120,000 Btuh (35 Kwh) at sea level, to rate the heater at 4000 feet (1219m), you subtract 4 (once for each thousand feet) x.04 (4% input reduction) x 120,000 (original rating) from the original rating. Therefore, to calculate the input rating at 4,000 feet (121.9m): 4 x.04 x 120,000=19,200 Btuh (5.6 Kwh), 120,000 (35 Kwh) - 19,200 (5.6Kwh)=100,800 Btuh (29.4 Kwh). At 6000 feet (1829m) the correct input rating should be 91,200 Btuh (26.7 Kwh). The input reduction is primarily achieved by reducing the size of the main burner orifice. To do this, the main burner orifices require replacement with orifices sized for the particular installation elevation. Correct orifice sizing and parts may be obtained from A.O. Smith corporation. When ordering, be sure to state the model number and the altitude of the location where the water heater is being installed. Upon completion of derating of the heater, adjustment to the gas pressure regulator may be required. See CHECKING THE INPUT section in this manual for inlet and manifold pressure requirements. Also due to the input rating reduction required at high altitudes, the output rating of the appliance is reduced and should be compensated for in the sizing of the equipment for the application. 6

7 FEATURES TABLE 4. Control Device Factory Setting Field Adjustment F (90.5 C) cut out temp. Heater Automatic Gas Shutoff Control Fixed F (87.7 C) cut in temp. Non-adjustable F (121 C) cut out temp. Heater Protector Switch Fixed F (93.3 C) cut in temp. Non-adjustable Tank Temperature Control Field Supplied and Installed Adjust to Requirements Safety Flow Switch See Table 1 Field Adjustable AUTOMATIC GAS SHUTOFF CONTROL The automatic gas shutoff control, fig. 1, is an automatic safety device which activates at a water temperature of approximately F (90.5 C). This limits the water outlet temperature to a maximum of F (87.7 C). The device is wired in series with the gas valve. The control will automatically reset when the water temperature cools to approximately 190 o F (87.7 C). Should the automatic gas shutoff control activate during a heating cycle, the heater s gas valve will close; extinguishing the main burners. The pilot burner will also be extinguished. The circulating pump will continue operating as long as the storage tank thermostat continues to call for heat. When the water temperature in the heater drops to F (82.2 C) or below the control module will begin an ignition cycle which will relight the pilot burner and main burners. Re-ignition of the main burners will occur if the storage tank thermostat continues to call for heat. Otherwise, the normal operating cycle will resume on the thermostat s next call for heat. FIGURE 2 DO T RESET THIS SWITCH WITHOUT PERFORMING THE SYSTEM CHECKS OUTLINED UNDER PROTECTOR SWITCH IN THE SERVICE INFORMATION SECTION. ALSO, SEE CHART ONE UNDER THE CHECKOUT SECTION. IF NECESSARY, CALL A QUALIFIED SERVICE AGENT. Once the cause of the protector switch activation has been determined and corrected, it will be necessary to restart the heater following the LIGHTING AND OPERATING instructions. THERMAL BALANCER AUTOMATIC GAS SHUTOFF CONTROL FIGURE 1 The thermal balancer (standard on Models HW-200M and HW-225M, optional on Models HW-120M and HW-160M) is a delay relay used only on Cer-Temp 80 Recovery systems. It gives immediate pump start but delay of pump shutoff for approximately 2 minutes. Residual heat in the heat exchanger is then recovered after shutdown. This improves efficiency and balances heater temperature with tank temperature at shutdown. INTERMITTENT IGNITION CONTROL MODULE PROTECTOR SWITCH (Coil High Limit) This heater is equipped with a manually reset protector switch, Figure 2, located under the small cover on the side of the jacket. This device provides positive shutdown of the heater in the event of heater or system malfunction. Should the surface temperature of the copper tubing heat exchanger reach F (121.1 C), the protector switch will activate. The gas valve will close, and the pilot and main burners will be extinguished. To resume heater operation, the protector switch must be manually reset (remove the protector switch cover and push the reset button) after the coil surface temperature cools to less than F(93.3 C). 7 The Honeywell control module contain the electronic components of the system and also serve as a central wiring system for the controls mounted on the heater. The control module performs the following functions: 1. Checks for safe-start by sensing for a flame or false flame condition on start-up. 2. Generates a potential of 15,000 volts for spark ignition of the pilot burner. 3. Turns on or off power to the pilot valve.

8 4. Discontinues ignition spark when pilot flame is established. The S8600 / S8610 control used on propane gas models provides safety lockout if pilot fails to ignite within the pilot flame establishing period. The S-8600 / S-8610 control used on natural gas models continues trial for ignition until pilot flame is established. 5. After proof-of-pilot flame, opens the main valve. 6. On a power loss, shuts the heater down. When power is restored it will begin a new ignition cycle. 7. On a loss of flame, shuts off main gas and starts trial for pilot ignition. PLEASE SEE TROUBLE SHOOTING SECTION FOR MORE INFORMATION. INTERMITTENT IGNITION CONTROL MODULE (I.I.D.) FIGURE 3 CIRCULATING PUMP Constant circulating pump operation of the heater voids the warranty. Constant water flow through the unit will wash away the copper s natural protective coating. This is called velocity erosion. This erosion is not as great a problem when intermittent circulating operation is used per the recommended installation procedure. Constant circulation of water between the storage tank and the building is permissible as long as the water does not constantly flow through the heater. Only all bronze circulating pumps are used with commercial water heaters. Although circulating pumps are originally oiled and operated by the manufacturer, THEY MUST BE OILED AGAIN BEFORE OPERATED. Follow the manufacturer s instructions. See fig. 4. TYPICAL CIRCULATING PUMP FIGURE 4 Follow the same oiling procedure if a replacement circulating pump is installed into the system. TANK TEMPERATURE CONTROL (T SUPPLIED) DANGER USE ANTI-SCALD VALVE(S) in the hot water system to reduce the risks of scalds at points of use such as lavatories, sinks and bathing facilities. The tank temperature control is located in the lower portion of the hot water storage tank, see PIPING DIAGRAMS. It is the primary operating control of the system and regulates the water temperature in the tank. The storage tank thermostat should have contact ratings that exceed the maximum electrical requirements of the system. Typically, the thermostat should have motor full load and locked rotor current ratings which exceed the total amount of current required to drive the pump(s) controlled by the thermostat. The thermostat should have a temperature range of F (37.7 C) to F (82.2 C) or more. The preferred initial setting for the storage tank thermostat is F (48.8 C). However, for normal use, the thermostat should be adjusted to the lowest setting which produces an acceptable hot water supply temperature. This will always give the most energy efficient operation. Do not adjust the thermostat to achieve a storage temperature of 190 o F (87.7 C) or above. This action may cause the automatic gas shutoff control to activate shutting down the heater. Intermittent ignition device and circulating pump start and stop simultaneously as the tank thermostat contacts open and close. This basic action, water flowing whenever the burner operates, must not be altered. SAFETY FLOW SWITCH (T SUPPLIED) The safety flow switch is a safety device installed at the water outlet of the unit to prevent main burner operation in the event of inadequate water flow through the unit. An accessory package No containing a safety flow switch is available for this application. This switch may be mounted in a horizontal pipe line or a vertical pipe line with upward water flow. Do not install the switch where the water flow is downward. For proper performance mount the switch in a section of pipe where there is a straight run of at least 5 pipe diameters on each side of the flow switch (i.e. do not locate adjacent to valves, elbows, orifices, etc.). The flow switch shall be mounted in a standard 1 x 1 x 1 tee for a 1 pipe application. For larger pipe sizes use a reducing tee in order to keep the switch as close to the pipe as possible. Install the flow switch in the branch (top) opening of the reducing tee and provide adequate paddle length in the flow stream. For example in a 2 pipe installation use a 2 x 2 x 1 reducing tee. For 1, 2 or 3 pipe use the paddle segments as supplied. For other pipe sizes (i.e. 1 1/4, 1 1/2, and 2 1/2 ) trim the paddle to the proper pipe size, see fig. 5. If a standard tee is used, install a face or hex bushing in the top opening. The paddle must be adjusted or trimmed to the size of the pipe in which it will be installed. 8

9 CAUTION: The paddle must be trimmed at the dotted arc. It must not touch the pipe or any restrictions when installed. FIGURE 5 CAUTION Any part of the paddle must not touch the pipe or any restrictions in the pipe. Screw the flow switch in position so the flat of the paddle is at right angles to the flow. The arrow on the side case must point in the direction of the flow. The safety flow switch may be field adjusted to obtain higher minimum flow rates than those shown in Table 5. To adjust the flow rate setting: 1. Remove the flow switch cover. 2. For higher flow rate turn the range adjusting screw clockwise. 3. For lower flow rate turn the range adjusting screw counterclockwise. CAUTION The switch is factory set at approximately the minimum flow rate, see Table 5. It must not be set lower than the factory setting as this may result in the switch failing to return at a no flow condition. 4. Replace the flow switch cover. TABLE 5 - SAFETY FLOW SWITCH SETTINGS Minimum Flow Rate (GPM/LPM) Contacts (flow) Closed Contacts (no flow) Open Pkg. No. Model GPM LPM GPM LPM HW-120M, 160M HW-200M HW-225M The installer is cautioned to follow the manufacturer s instructions exactly when inserting this switch into a pipe tee. This is necessary in order to assure positive action of the switch with water flow. Once the minimum flow rate (Table 5) through the heater is reached, the safety flow switch contacts close and consequently, main burner operation is achieved. DRAIN VALVE (T SUPPLIED) A drain valve must be obtained and installed on each heater and tank for draining purposes, see installation diagrams in this manual. THERMOMETERS (T SUPPLIED) Thermometers should be obtained and field installed as shown in the installation diagrams. Thermometers are installed in the system as a means of detecting a possible liming condition in the heater. An increase of 5 0 F over the normal temperature rise through the heater is an indication that lime is present. The term temperature rise designates the difference between the heater inlet and outlet water temperatures. An increase of 5 0 F (3 C) above the recorded temperature rise may signify a liming condition in the coils or heat exchanger. Refer to PREVENTIVE MAINTENANCE section of this manual for deliming instructions. Record temperature rise at initial start-up for future reference. 9

10 INSTALLATION INSTRUCTIONS IMPORTANT Strict adherence to installation wiring diagrams shown in this manual is required to prevent constant pump operation when the system temperature control is satisfied, otherwise the warranty is void as stipulated under item 2a (6) of the LIMITED WARRANTY. REQUIRED ABILITY INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, GAS SUPPLY AND ELECTRICAL WORK ARE REQUIRED. LOCATION When installing the heater, consideration must be given to proper location. Location selected should be as close to the stack or chimney as practicable with adequate air supply, and as centralized with piping system as possible. THE HEATER SHOULD T BE LOCATED IN AN AREA WHERE IT WILL BE SUBJECT TO FREEZING. LOCATE IT NEAR A FLOOR DRAIN. THE HEATER SHOULD BE LOCATED IN AN AREA WHERE LEAKAGE FROM THE HEATER OR CONNECTIONS WILL T RESULT IN DAMAGE TO THE ADJACENT AREA OR TO LOWER FLOORS OF THE STRUCTURE. WHEN SUCH LOCATIONS CANT BE AVOIDED, A SUITABLE DRAIN PAN SHOULD BE INSTALLED UNDER THE HEATER. Such pans should be fabricated with sides at least 2 (50.8mm) deep, with length and width at least 2 (50.8mm) greater than the diameter of the heater and must be piped to an adequate drain. The pan must not restrict combustion air flow. Should the heater be installed in a garage, the heater must be located, or protected, so it is not subject to physical damage by a moving vehicle. For water heater installation in locations with elevations above 2,000 feet (610M), refer to HIGH ALTITUDE INSTALLATIONS section of this manual for input reduction procedure. INSTALLATION CLEARANCES These units are approved for installation in an alcove having minimum clearances from combustible construction of 44 (1,118mm) from top of the jacket, 6 (152.4mm) from sides, and 6 (152.4mm) from rear and vent connections. All models may be installed on combustible flooring. DO T INSTALL THIS WATER HEATER DIRECTLY ON A CARPETED FLOOR. A FIRE HAZARD MAY RESULT. Instead the water heater must be placed on a metal or wood panel extending beyond the full width and depth by at least 3 inches (76.2mm) in any direction. If the heater is installed in a carpeted alcove, the entire floor shall be covered by the panel. Also, see the DRAIN REQUIREMENTS. It is recommended that at least 24 (610mm) be provided on the left side and front of the unit for accessibility and proper servicing. In a utility room installation, the door shall be wide enough to allow the heater to enter or to permit the replacement of another appliance. LEVELLING Each unit should be checked after installation to be certain that it is level. If the unit is not level, obtain and insert metal shims under the base ring of the unit to correct this condition. UNCONFINED SPACE AIR REQUIREMENTS In buildings of conventional frame, brick, or stone construction, unconfined spaces may provide adequate air for combustion, ventilation and draft hood dilution. If the unconfined space is within a building of tight construction (buildings using the following construction: weather stripping, heavy insulation, caulking, vapor barrier, etc.), air for combustion, ventilation, and draft hood dilution must be obtained from outdoors. The installation instructions for confined spaces in tightly constructed buildings must be followed to ensure adequate air supply. 10

11 CONFINED SPACE When drawing combustion and dilution air from inside a conventionally constructed building to a confined space, such a space shall be provided with two permanent openings, ONE IN OR WITHIN 12 INCHES (30.5cm) OF THE ENCLOSURE TOP AND ONE IN OR WITHIN 12 INCHES (30.5cm) OF THE ENCLOSURE BOTTOM. Each opening shall have a free area of at least one square inch per 1000 Btuh (2,225mm 2 /Kw) of the total input of all appliances in the enclosure, but not less than 100 square inches (645 square cm). If the confined space is within a building of tight construction, air for combustion, ventilation and draft hood dilution must be obtained from outdoors. When directly communicating with the outdoors or communicating with the outdoors through vertical ducts, two permanent openings, located in the above manner, shall be provided. Each opening shall have a free area of not less than one square inch per 4000 Btuh (8,900mm 2 /Kw) of the total input of all appliances in the enclosure. If horizontal ducts are used, each opening shall have a free area of not less than one square inch per 2000 Btuh (4,450mm 2 /Kw) of the total input of all appliances in the enclosure. For Canadian installations consult CAN/CGA B149. Where an exhaust fan is installed in the same room with a heater, sufficient openings for air must be provided in the walls. UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE CHIMNEY, CAUSING POOR COMBUSTION. SOOTING MAY RESULT AND RISK OF ASPHYXIATION WILL OCCUR. VENTING PROPER VENT PIPE INSTALLATION FIGURE 6 Do not install without draft hood and do not install any damper in flueway. Be sure that the vent pipe does not extend beyond the inside wall of the chimney. 2. Where a continuous or intermittent back draft is found to exist, the cause must be determined and corrected. A special vent cap may be required. FAILURE TO CORRECT BACK DRAFTS MAY CAUSE AIR CONTAMINATION AND UNSAFE CONDITIONS. If the back draft cannot be corrected by the normal methods or if a suitable draft cannot be obtained, a blower type flue gas exhauster must be employed to assure proper venting and correct combustion. 3. Do not connect the heater to a common flue or chimney with solid fuel burning equipment. This practice is prohibited by many local building codes as is the practice of venting gas fired equipment to the duct work of ventilation systems. Where a separate vent connection is not available and the vent pipe from the heater must be connected to a common flue with an oil burning furnace, the vent pipe should enter the common flue or chimney at a point above the flue pipe from oil furnace. 4. Where two or more appliances vent into a common vent connector or manifold, the area of the common vent should at least equal the area of the largest flue or vent connector plus 50% of the areas of the additional draft hood outlets. 5. Refer to the National Fuel Gas Code for information pertaining to multiple heater venting. The ASHRAE HVAC SYSTEMS & EQUIPMENT HANDBOOK, as well as many manufacturers gas vent and chimney sizing handbooks contain information on multiple heater manifold venting. In the United States: Vent sizing, installation and termination shall be in accordance with current edition of the NATIONAL FUEL GAS CODE. ANSI Z Remove all soot or other obstructions from chimney which will retard free draft. 1. Install and size the vent pipe as necessary. The connection from the heater to the chimney should be run full size and should have a minimum pitch upward to the chimney of one quarter inch per foot length. 11 RELIEF VALVE An ASME-rated pressure relief valve (Supplied) must be installed in the hot water outlet line as near to the heater as possible. This pressure relief valve is rated in accordance with and complies with the current edition of the ANSI/ASME Boiler and Pressure Vessel Code, Section IV. A CSA design-certified and ASME-rated temperature and pressure relief valve (Not Supplied) must be installed on each and every water storage tank. This relief valve shall comply with the Standard for Relief Valves for Hot Water Supply systems, ANSI Z21.22 current edition. This relief valve should have a temperature rating of 210 F (98.8 C), a pressure rating not exceeding the lowest rated working pressure of any system component and a discharge capacity exceeding the total input of the water heaters supplying water to the storage tank. Select a relief valve with a discharge capacity exceeding the maximum heater input rating and a pressure rating not exceeding the working pressure shown on the rating plate of the heater. Locate the T & P relief valve in the top of the tank, or in the side of the tank on centerline within the upper 6 inches from the top of the tank. See installation diagrams. Tapping shall be threaded in accordance with the latest version of the Standard for Pipe Threads, General Purpose (inch), ANSI/ASME B Mark location with a Class III label.

12 Your local code authority may have other specific relief valve requirements not covered in this section. THE PURPOSE OF A RELIEF VALVE IS TO AVOID EXCESSIVE PRESSURE OR TEMPERATURE INTO THE STEAM RANGE, WHICH MAY CAUSE SCALDING AT FIXTURES, TANK EXPLOSION, SYSTEM OR HEATER DAMAGE. TO AVOID SCALDING OR WATER DAMAGE, A DRAIN LINE MUST BE CONNECTED TO A RELIEF VALVE TO DIRECT DISCHARGE TO A SAFE LOCATION. A DRAIN LINE MUST T BE REDUCED FROM THE SIZE OF THE VALVE OUTLET AND IT MUST T CONTAIN ANY VALVES BETWEEN THE HEATER AND THE RELIEF VALVE OR THE RELIEF VALVE AND THE DRAIN LINE EXIT. IN ADDITION, THERE SHOULD T BE ANY RESTRICTIONS IN A DRAIN LINE R SHOULD IT BE ROUTED THROUGH AREAS WHERE FREEZING CONDITIONS MIGHT OCCUR. DO T THREAD OR CAP THE DRAIN LINE EXIT. RESTRICTING OR BLOCKING A DRAIN LINE WILL DEFEAT THE PURPOSE OF THE RELIEF VALVE AND MAY CREATE AN UNSAFE CONDITION. INSTALL A DRAIN LINE WITH A DOWNWARD SLOPE SUCH THAT IT NATURALLY DRAINS ITSELF. Recommended locations of relief valves are shown in the installation diagrams. HARD WATER Where hard water conditions exist, water softening or the threshold type of water treatment is recommended. This will protect the dishwashers, coffee urns, water heaters, water piping and other equipment. When water softening or water treatment is not practical, a comparatively easy method of periodic lime removal from the heater may be employed by installing gate valves, drain valve and acid fill opening as shown in PREVENTIVE MAINTENANCE section of this manual. 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 flow 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 must 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. WATER LINE CONNECTIONS This manual provides detailed installation diagrams for typical methods of application. See piping diagrams. Cer-Temp 80 Recovery System (for one temperature water). These diagrams will serve to provide the installer with a reference for the materials and method of piping necessary for installation. It is essential that all water and gas piping, vent connections, electrical wiring and check and flow regulating valves be installed as shown on the diagrams. Consult the installation diagrams for appropriate locations to install the safety flow switch(es), drain valves, thermometers, relief valves and the circulating pump(s). Apply suitable pipe thread sealing compounds to only the male threads of parts to be connected. If any of these parts are being replaced in a functioning system, remember to shut off the manual gas and control valve(s) and close off the water inlet(s). Open a nearby faucet to relieve pressure and drain the heater and/or system before attempting to install the new parts. Check the diagrams thoroughly before starting installation to avoid errors and minimize time and material costs. If the system is to be filled with water for testing or other purposes during cold weather and before actual operation, care must be taken to prevent a downdraft entering the heater or freezing air from contacting the system. Failure to do so may cause the water in the system to freeze with resulting damage to the system. Damage due to freezing is not covered by the warranty. WATER (POTABLE) HEATING AND SPACE HEATING 1. All piping components connected to this unit for space heating applications shall be suitable for use with potable water. 2. Toxic chemicals, such as those used for boiler treatment, shall never be introduced into this system. 3. This unit may never be connected to any existing heating system or component(s) previously used with a non-potable water heating appliance. 4. When the system requires water for space heating at temperatures higher than required for domestic water purposes, a tempering valve must be installed. Please refer to installation diagrams on pages of this manual for suggested piping arrangements. 5. These water heaters cannot be used in space heating applications only. 12

13 PIPING DIAGRAMS DANGER TEMPERATURE SETTING SHOULD T EXCEED SAFE USE TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 20. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES. (USE THIS DIAGRAM FOR STRAIGHT RECOVERY SYSTEMS SUPPLYING HOT WATER AT ONE TEMPERATURE ONLY) FIGURE 7 13

14 DANGER TEMPERATURE SETTING SHOULD T EXCEED SAFE USE TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 20. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES. FIGURE 8 14

15 DANGER TEMPERATURE SETTING SHOULD T EXCEED SAFE USE TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 21. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES. FIGURE 9 15

16 GAS CONNECTIONS WARNING THE INLET GAS PRESSURE MUST T EXCEED THE VALUE SPECIFIED BY THE MANUFACTURER ON THE RATING PLATE (10.5 W.C. - NATURAL GAS, 13.0 W.C. - PROPANE GAS). EXPOSURE TO HIGHER GAS SUPPLY PRESSURE MAY CAUSE DAMAGE TO THE GAS VALVE WHICH COULD RESULT IN FIRE OR EXPLOSION. IF OVERPRESSURE HAS OCCURRED SUCH AS THROUGH IMPROPER TESTING OF GAS LINES OR EMERGENCY MALFUNCTION OF THE SUPPLY SYSTEM, THE GAS VALVE MUST BE CHECKED FOR SAFE OPERATION. MAKE SURE THAT THE OUTSIDE VENTS ON THE SUPPLY REGULATORS AND THE SAFETY VENT VALVES ARE PROTECTED AGAINST BLOCKAGE. THESE ARE PARTS OF THE GAS SUPPLY SYSTEM, T THE HEATER. VENT BLOCKAGE MAY OCCUR DURING ICE STORMS. IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING FROM CONTAMINANTS IN THE GAS WAYS. SUCH FOULING MAY CAUSE IMPROPER OPERATION, FIRE OR EXPLOSION. IF COPPER SUPPLY LINES ARE USED THEY MUST BE INTERNALLY TINNED AND CERTIFIED FOR GAS SERVICE. 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. SEE PIPING DIAGRAMS. THE SEDIMENT TRAP MUST BE READILY ACCESSIBLE AND T SUBJECT TO FREEZING CONDITIONS. INSTALL IN ACCORDANCE WITH THE CURRENT EDITION OF ANSI Z223.1 OF THE NATIONAL FUEL GAS CODE. To prevent damage, care must be taken not to apply too much torque when attaching gas supply pipe to gas valve gas inlet. Fittings and unions in the gas line must be metal to metal type. Apply joint compounds (pipe dope) sparingly and only to the male threads of pipe joints. Do not apply compound to the first two threads. Use compounds resistant to the action of liquefied petroleum gases. BEFORE PLACING THE HEATER IN OPERATION, CHECK FOR GAS LEAKAGE. Use soap and water solution or other material acceptable for the purpose in locating gas leaks. DO T USE MATCHES, CANDLES, FLAME OR OTHER SOURCES OF IGNITION FOR THIS PURPOSE. DISCONNECT THE HEATER AND ITS MANUAL GAS SHUTOFF VALVE FROM THE GAS SUPPLY PIPING SYSTEM DURING ANY PRESSURE TESTING OF THAT SYSTEM AT TEST PRESSURES IN EXCESS OF 1/2 PSIG. THE GAS SUPPLY LINE MUST BE CAPPED WHEN T CONNECTED TO HEATER. THE HEATER MUST BE ISOLATED FROM THE GAS SUPPLY PIPING SYSTEM BY CLOSING ITS MANUAL GAS SHUTOFF VALVE DURING ANY PRESSURE TESTING OF THE GAS SUPPLY PIPING SYSTEM AT TEST PRESSURES EQUAL TO OR LESS THAN 1/2 PSIG (3.44kPa). CORRECT GAS MAKE SURE the gas on which the heater will operate is the same as that specified on the heater model and rating plate. Do not install the heater if equipped for a different type gas - contact the heater supplier. SIZING GAS SUPPLY LINE The iron pipe or equivalent pipe sizes in Table 6 are derived from Table C-3 in the NATIONAL FUEL GAS CODE. The pipe sizes are based on a supply line gas pressure drop of 0.3 inches of water column from the gas meter to the point of installation of the heater(s). For natural gas, a heating value of 1050 Btu/ft 3 and a specific gravity of 0.60 has been assumed. A heating value of 2500 Btu/ft 3 and a specific gravity of 1.53 has been assumed for L.P. (propane) gas. Where it is necessary to use an excess number of pipe fittings, i.e., elbows, tees and valves, in the gas supply line, use pipe at least one size larger than that recommended in Table 6 to compensate for the increased pressure drop. If the service pressure is 4.5 inches W.C. (1.12kPa) for natural gas or (11 inches (1.74kPa) for L.P. gas) of water column or less, use pipe size larger than specified in Table 6 to minimize pressure drop in the line. GAS METER SIZE - City Gases Only Be sure that the gas meter has sufficient capacity to supply the full rated gas input of the heater as well as the requirements of all other gas fired equipment supplied by the meter. If gas meter is too small, ask the gas company to install a larger meter having adequate capacity. TABLE 6 GAS SUPPLY PIPE SIZES (IN INCHES) NATURAL GAS (1050 Btu/ft 3 ) PROPANE GAS (2500 Btu/ft 3 ) Distance To Heater From Meter (FT./M) HW-120M HW-160M HW-200M HW-225M HW-120M HW-160M HW-200M 10 (3M) 1/2 3/4 3/4 3/4 1/2 1/2 1/2 30 (9.1M) 3/4 3/ /2 3/4 3/4 50 (15.2M) 3/ /4 3/ (24.4M) /4 1 1/4 3/ (30.5M) 1 1 1/4 1 1/4 1 1/4 3/ (45.7M) 1 1 1/4 1 1/4 1 1/ /4 200 (61M) 1 1/4 1 1/4 1 1/4 1 1/ /4 1 1/4 16

17 A minimum gas supply pressure of 4.5 W.C. (1.12kPa) for natural gas and 11 W.C. (2.74kPa) for propane gas is required for purposes of input adjustment. ELECTRICAL INFORMATION ALL ELECTRICAL WORK MUST BE INSTALLED IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE IN THE UNITED STATES. The electrical connections must be made so that both the circulator and intermittent ignition device operate simultaneously when the storage tank temperature control calls for heat. The water heater, when installed, must be electrically grounded in accordance with local codes or, in the absence of local codes, in the United States with the NATIONAL ELECTRICAL CODE, ANSI/NFPA 70. A screw is provided in the heater junction box for a ground connection. All piping diagrams include an electrical wiring diagram to assist the installer in properly wiring of the additional components required to assure correct system operation. Figures 10 show the heater mounted controls as they are wired when the heater leaves the factory. Using the individual wiring diagrams on the installation diagrams, the installer connects his wiring to terminals in the heater(s) mounted junction box as shown. All wiring should be done such that the heater(s) will operate in the following manner: 1. When the tank temperature control calls for heat: The circulating pump starts to operate. Once the safety flow switch contacts close, intermittent ignition device is powered and sequence through steps as described for I.I.D. Control Module on Page When the tank temperature control is satisfied: The main burners should stop firing, but the circulating pump should continue to operate for about 2 minutes when equipped with a thermal balancer. 3. When the automatic gas shutoff control or coil protector switch operate (break electric circuit): The main burners should stop firing. Circulating pump should continue to operate. ELECTRICAL WIRING DIAGRAMS FOR THE HW-120M, 160M, 200M AND 225M WATER HEATERS I.I.D. SYSTEM FIGURE 10 17

18 OPERATION IMPORTANT Only qualified personnel shall perform the initial firing of the heater. At this time the user should not hesitate to ask the start-up technician any questions regarding operation and maintenance of the unit. Lighting and Operating instructions are included with this manual. By using these instructions, the user may be able to make minor operational adjustments and save unnecessary service calls. However the user should not attempt repairs, but should contact a service technician or gas supplier. GENERAL Never operate the water heater without first making sure the water heater and system are filled with water, in addition: Make sure a temperature and pressure relief valve is installed at the water heater and if used, the storage tank. Also check for leaks. Also be sure to check the gas piping for leaks before beginning the initial firing of the heater. FILLING 1. Close the systems drain valve by turning handle clockwise. 2. Open a nearby hot water faucet to permit the air in the system to escape. 3. Fully open the cold water inlet pipe valve allowing the heater and piping to be filled. 4. Close the hot water faucet as water starts to flow. 5. The heater is ready to be operated. GAS LINE LEAK TESTING Fire and Explosion Hazard Use joint compound or Teflon tape compatible with propane gas. 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. Any time work is done on the gas supply system perform a leak test to avoid the possibility of fire 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 21. 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 appliance need not be disconnected, but must be isolated from the supply gas line by closing the Main Gas Shutoff Valve during testing. 3. Coat all supply gas line joints and connections upstream of the water heater with a non-corrosive soap and water solution to test for leaks. Bubbles indicate a gas leak. Do not use matches, candles, flame or other sources of ignition for this purpose. 4. Repair any leaks before placing the water heater in operation. PURGING Gas line purging is required with new piping or systems in which air has entered. Purging should be performed per the current edition of NFPA 54 the National Fuel Gas Code. CAUTION BEFORE PROCEEDING WITH THE OPERATION OF THE UNIT, MAKE SURE HEATER AND SYSTEM ARE FILLED WITH WATER AND ALL AIR IS EXPELLED FROM HEATER AND PIPING. THE MAIN MANUAL GAS SHUTOFF VALVE AND THE PILOT ADJUSTING VALVE (WHEN APPLICABLE) MUST HAVE BEEN CLOSED FOR AT LEAST FIVE (5) MINUTES. THIS WAITING PERIOD IS AN IMPORTANT SAFETY STEP. ITS PURPOSE IS TO PERMIT GAS THAT MIGHT HAVE ACCUMULATED IN THE COMBUSTION CHAMBER TO CLEAR. IF YOU DETECT GAS AT THE END OF THIS PERIOD, DO T PROCEED WITH LIGHTING. RECOGNIZE THAT GAS ODOR, EVEN IF IT SEEMS WEAK MAY INDICATE PRESENCE OF ACCUMULATED GAS SOMEPLACE IN THE AREA WITH A RISK OF FIRE OR EXPLOSION. SEE THE FRONT PAGE FOR STEPS TO BE TAKEN. DO T USE THIS HEATER IF ANY PART HAS BEEN UNDER WATER. IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE HEATER AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER. Light the unit in accordance with the instructions on the lighting label attached to the water heater. These instructions are repeated in the following. 18