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
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
CAUTION
• Do not try to light any appliance.
• Do not touch any electrical switch;
TEXT PRINTED OR OUTLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ
THOROUGHLY BEFORE USING APPLIANCE.
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.
A DIVISION OF A.O. SMITH CORPORATION
McBEE, SOUTH CAROLINA, USA
RENTON, WA, USA
STRATFORD, ONTARIO, CANADA
— Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
VELDHOVEN, THE NETHERLANDS
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER
AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE
PART NO. 212626-000
PRINTED IN U.S.A. 0905
SUPERSEDES PART NO. 192011-000 REV.4
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ROUGH-IN-DIMENSIONS
TABLE 1 - ROUGH-IN DIMENSIONS
Models
Dimensions Inches
HW-120M
HW-160M
Inches
HW-200M
Inches
53 1/4
33 1/8
27 1/8
20 3/4
5 1/2
10
11 13/16
7
HW-200M
Inches
mm
1254
772
600
527
140
254
300
152
678
527
mm
1273
772
600
527
140
254
300
178
678
527
mm
1353
841
689
527
140
254
300
178
678
527
mm
1524
841
689
527
140
254
300
178
678
527
A
B
C
D
E
F
G
H
49 3/8
30 3/8
23 5/8
20 3/4
5 1/2
10
11 13/16
6
50 1/8
30 3/8
23 5/8
20 3/4
5 1/2
10
11 13/16
7
60
33 1/8
27 1/8
20 3/4
5 1/2
10
11 13/16
7
J
K
26 11/16
20 3/4
26 11/16
20 3/4
26 11/16
20 3/4
26 11/16
20 3/4
L
M
1 1/4 NPT
1 NPT
1 1/4 NPT
1 NPT
1 1/4 NPT
1 NPT
1 1/4 NPT
1 NPT
N
1/2 NPT
1/2 NPT
1/2 NPT
1/2 NPT
W
1 3/4
44
1 3/4
44
1 3/4
44
1 3/4
44
Approx.
Shipping
Weight
120 lbs.
54 Kg. 155 lbs. 70 Kg. 165 Lbs. 75 Kg.
175 lbs.
79 Kg.
HEATER PERFORMANCE DATA
NOTE: 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
Btuh
F°
20F° 30F° 36F° 40F°
50F° 54F° 60F° 70F° 72F° 80F° 90F° 100F° 108F° 110F° 120F° 126F° 130F° 140F°
Model
KW C° 11.1C° 16.6C° 20C° 22.2C° 27.7C° 30C° 33.3C° 38.8C° 40C° 44.4° 50C° 55.5C° 60C° 61.1C° 66.6C° 70C° 72.2C° 77.7C°
120,000
160,000
199,000
225,000
GPH 605
35 LPH 2290 1527 1272 1145
GPH 777 518 432 388
47 LPH 2941 1961 1634 1471
GPH 987 658 548 494
58 LPH 3737 2491 2076 1869
GPH 1096 731 609 548
66 LPH 4149 2766 2305 2074
403
336
303
242
916
311
224
848
288
202
763
259
980
329
173
654
222
840
282
168
636
216
817
274
151
573
194
735
247
934
274
134
509
173
654
219
830
244
121
458
155
588
197
747
219
830
112
242
144
545
183
692
203
768
110
416
141
535
179
679
199
754
101
382
129
490
165
623
183
691
96
93
86
HW-120M
364
123
467
157
593
174
659
352
120
452
152
575
169
638
327
111
420
141
534
157
593
HW-160M
1176 1089
395 366
HW-200M
1495 1384 1246 1068 1038
438 406 365 313 304
HW-2250M
1659 1537 1383 1185 1152 1037 922
Recovery rating of models shown in chart above are obtained by actual efficiency test data by recognized Certification Agency.
NOTE: Recovery rate shown on each models rating plate is based on the requirements of ANSI Standard Z21.10.3, which stipulates
the data to be based on energy efficiency of 75%.
TABLE 3 - CAPACITY AND GAS AND ELECTRIC CHARACTERISTICS
Manifold Pressure
Maximum Supply Pressure Electrical Characteristics
Model
Type of Gas
Inches W.C.
kPa
0.87
2.49
Inches W.C.
10.5
kPa
2.61
3.23
Volts/Hz
120/60
120/60
Amperes
HW-120M thru 225M
HW-120M thru 200M
NATURAL
PROPANE
3.5
10
<5
<5
13.0
Minimum Supply Pressure, Natural Gas: 4.5 inches W.C. (1.12 kPa)
Minimum Supply Pressure, Propane Gas: 11.0 inches W.C. (1.74 kPa)
Minimum Pressure must be maintained under both load and no load (static and dynamic) conditions.
2
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FOREWORD
The factory warranty will be void if the unit(s) have been improperly
installed or operated.
This design complies with the latest edition of the ANSI Standard
Z21.10.3 for gas water heaters Vol. III Storage Water Heaters
with input ratings above 75,000 BTU per hour Circulating and
Instantaneous.
In addition to these instructions, the boiler(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.
Detailed installation diagrams are in this manual. These diagrams
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
INSTALLEDAND CONNECTEDAS SHOWN IN THE DIAGRAMS.
In absence of local codes, the installation must comply with the
latest editions.
You should thoroughly read and understand this manual before
installation and operation of this unit.
In the United States:
The National Fuel Gas Code, ANSI Z223.1 and the National
Electric Code, NFPA 70.
CHECK THE DIAGRAMS THOROUGHLY BEFORE STARTING
INSTALLATION TO AVOID POSSIBLE ERRORS AND TO
MINIMIZE TIME AND MATERIALS COST.
In Canada:
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.
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.
MAKE SURE THE GAS ON WHICH THE HEATER WILL
OPERATE IS THE SAMEAS THAT SPECIFIED ON THE HEATER
MODEL AND RATING PLATE.
TABLE OF CONTENTS
PAGE
PAGE
ROUGH-IN DIMENSIONS ..................................................................
FOREWORD .......................................................................................
GENERAL SAFETY INFORMATION ..................................................
2
3
3
PIPING DIAGRAMS ............................................................................ 11-13
Gas Connections ........................................................................... 14-15
Electrical Information ..................................................................... 15-16
Precautions .................................................................................... 3-4
OPERATION ........................................................................................
Important .......................................................................................
General ...........................................................................................
Filling ..............................................................................................
Purging Of Gas Line ......................................................................
Operating Instructions For I.I.D Models. .......................................
Checking And Adjusting The Input .................................................
SERVICE INFORMATION ..................................................................
Pilot And Main Burner Maintenance ...............................................
17
17
17
17
17
18
19
20
20
Grounding Instructions ...................................................................
Chemical Vapor Corrosion .............................................................
Liquid Petroleum Models ................................................................
High Altitude Installations ...............................................................
FEATURES .........................................................................................
Automatic Gas Shutoff Control .......................................................
Protector Switch (Coil High Limit) ...................................................
Thermal Balancer ...........................................................................
4
4
4
4
5
5
5
5
Intermittent Ignition Control Module ................................................ 5-6
I.I.D. Pilot Burner ........................................................................... 20-21
Circulating Pump ............................................................................
Tank Temperature Control (Not Supplied) ......................................
Safety Flow Switch (Not Supplied) ................................................. 6-7
6
6
Protector Switch (Coil High Limit-All Heaters) ...............................
Tank Temperature Control ..............................................................
Automatic Gas Shutoff Control .....................................................
Thermal Balancer ...........................................................................
21
21
21
21
Drain Valve (Not Supplied) .............................................................
Thermometers (Not Supplied) ........................................................
INSTALLATION INSTRUCTIONS .......................................................
Important ........................................................................................
Required Ability ..............................................................................
Location .........................................................................................
Installation Clearances ...................................................................
Levelling .........................................................................................
7
7
8
8
8
8
8
8
Inspecting The Heat Exchanger And Venting System .................. 21-22
Gas Pressure Regulator ................................................................
Relief Valve ...................................................................................
Circulating Pump ............................................................................
Electrical Service ...........................................................................
Replacement Parts ........................................................................
PREVENTIVE MAINTENANCE ...........................................................
Recommended Procedure For Periodic Removal Of Lime
22
22
22
22
22
22
Air Requirements ........................................................................... 8-9
Venting ...........................................................................................
Relief Valve .................................................................................... 9-10
Hard Water .....................................................................................
Closed Water System ....................................................................
Water Line Connections ................................................................
Water (Potable) Heating ................................................................
9
Deposits From Coil Type Commercial Water Heaters ................. 22-23
Deliming Solvents ..........................................................................
Removing Light Deposits ..............................................................
23
23
10
10
10
10
Heavy Lime Deposits ................................................................... 23-24
CHECKOUT ........................................................................................ 24-27
LIMITED WARRANTY ........................................................................
28
GENERAL SAFETY INFORMATION
3. IF DAMAGED.
PRECAUTIONS
4. FIRING WITHOUT WATER.
5. SOOTING.
If the unit is exposed to the following, do not operate heater until
all corrective steps have been made by a qualified serviceman:
KEEP THE HEATER AREA CLEAR AND FREE FROM
COMBUSTIBLE MATERIALS, GASOLINE AND OTHER
FLAMMABLE VAPORSAND LIQUIDS. AREAAROUND HEATER
MUST NOT CONTAIN OBSTRUCTING MATERIAL TO THE
FLOW OF COMBUSTION AND VENTILATING AIR.
1. FLOODING TO LEVEL OF BURNER OR CONTROLS OR
HIGHER.
2. EXPOSURE TO FIRE.
3
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SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL
TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL
VALVE TO THE APPLIANCE.
HIGH ALTITUDE INSTALLATIONS
WARNING
INSTALLATIONSABOVE 2000 FEETREQUIRE REPLACEMENT
OF THE BURNER ORIFICE IN ACCORDANCE WITH SECTION
8.1.2 OFTHE NATIONALFUEL 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
MONOXIDE GAS IN EXCESS OF SAFE LIMITS WHICH COULD
RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
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.
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.
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.
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)=100,000 Btuh (29.4 Kwh). At 6000
feet (1829m) the correct input rating should be 91,200 Btuh (26.7
Kwh).
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.)
CANADIAN REQUIREMENTS
LIQUID PETROLEUM MODELS
Appliances with inputs up to and including 400,000 BTU (117.2
Kw) must be factory equipped with orifices for operation at specific
elevations. Standard (sea level) orifices permit operation up to
2000’ (610m) elevation. For operation between 2000’ (610m)
and 4500’ (1370m) specify “HIGHALTITUDE OPERATION” when
ordering the heater(s). For operation above 4500’ (2370m) consult
factory before ordering.
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.
Field conversion for operation at altitudes other than that
specified on the heater rating plate is not permitted.
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 Water Products Company. When ordering, be sure
to state the model number and the altitude of the location where
the water heater is being installed.
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.
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.
IF YOU EXPERIENCE AN OUT-OF-GAS SITUATION, DO NOT
TRY TO RELIGHT APPLIANCES YOURSELF. Only trained LP
professionals should conduct the required safety checks in
accordance with industry standards.
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.
4
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FEATURES
TABLE 4.
Control Device
Factory Setting
Field Adjustment
1950F (90.5°C) cut out temp.
Fixed 1900F (87.7°C) cut in temp.
2500F (121°C) cut out temp.
Fixed 2000F (93.3°C) cut in temp.
Field Supplied and Installed
Heater Automatic Gas Shutoff Control
Non-adjustable
Heater Protector Switch
Tank Temperature Control
Safety Flow Switch
Non-adjustable
Adjust to Requirements
Field Adjustable
See Table 1
AUTOMATIC GAS SHUTOFF CONTROL
The automatic gas shutoff control, fig. 1, is an automatic safety
device which activates at a water temperature of approximately
1950F (90.5°C). This limits the water outlet temperature to a
maximum of 2000F (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 190oF (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 1800F (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 NOT 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 SERVICEMAN. 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
The thermal balancer (standard on Models HW-200M and
HW-225M, optional on Models HW-120M and HW-160M) is a
snap-acting single-pole thermal 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.
AUTOMATIC GAS SHUTOFF CONTROL
FIGURE 1
INTERMITTENT IGNITION CONTROL MODULE
The Honeywell S-8600 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:
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 2500F (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 2000F(93.3°C).
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. Opens the pilot valve.
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4. Discontinues ignition spark when the pilot flame is established. Follow the same oiling procedure if a replacement circulator is
The S-8600 control used on propane gas models provides installed into the system.
safety lockout if the pilot fails to ignite within the pilot flame
establishing period. The S-8600 control used on natural gas
models continues trial for ignition until pilot flame is established.
TANK TEMPERATURE CONTROL
(Not Supplied)
5. After proof-of-pilot flame, opens the main valve.
DANGER
6. On a power loss, shuts the heater down. When power is
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
restored it will begin a new ignition cycle.
bathing facilities.
7. On a loss of flame, shuts off main gas and starts trial for pilot
ignition.
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 1000F
(37.7°C) to 1800F (82.2°C) or more. The preferred initial setting
for the storage tank thermostat is 1200F (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 190oF (87.7°C)
INTERMITTENT IGNITION CONTROL MODULE (I.I.D.)
FIGURE 3
or above. This action may cause the automatic gas shutoff control
to activate shutting down the heater.
Intermittent ignition device and circulator 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.
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.
SAFETY FLOW SWITCH
(Not 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.
Only all bronze circulators are used with commercial water heaters.
An accessory package A.O.S. No. 211480 containing a safety
flow switch is available for this application.
Although circulators are oiled and operated by the manufacturer,
THEY MUST BE OILED AGAIN BEFORE OPERATED. Oil the
three oil cups (2 on the motor, 1 on the pump) as instructed by
manufacturer. See fig. 4.
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.
Thereafter, lubricate the three oil cups at least once every 4
months.
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
TYPICAL CIRCULATING PUMP
FIGURE 4
Use 2 or 3 teaspoonsful in bearing oil cups, and 10 or 12 drops in adjusted or trimmed to the size of the pipe in which it will be
the motor oil cups. Use no. 20 non-detergent motor oil. installed.
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CAUTION: The paddle must be trimmed at the dotted arc. It must not touch the pipe or any restrictions when installed.
FIGURE 5
The installer is cautioned to follow the manufacturer’s instructions
CAUTION
exactly when inserting this switch into a pipe tee. This is necessary
Any part of the paddle must not touch the pipe or any restrictions
in order to assure positive action of the switch with water flow.
in the pipe. Screw the flow switch in position so the flat of the
Once the minimum flow rate (Table 5) through the heater is
paddle is at right angles to the flow. The arrow on the side case
reached, the safety flow switch contacts close and consequently,
must point in the direction of the flow.
main burner operation is achieved.
The safety flow switch may be field adjusted to obtain higher
minimum flow rates than those shown in Table 5.
DRAIN VALVE (Not Supplied)
To adjust the flow rate setting:
A drain valve must be obtained and installed on each heater and
tank for draining purposes, see installation diagrams in this
manual.
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.
THERMOMETERS (Not Supplied)
Thermometers should be obtained and field installed as shown
in the installation diagrams.
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.
Thermometers are installed in the system as a means of detecting
a possible liming condition in the heater. An increase of 50F 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.
4. Replace the flow switch cover.
TABLE 5 - SAFETY FLOW SWITCH SETTINGS
Minimum Flow Rate (GPM)
An increase of 50F (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.
Contacts Close
GPM LPM
Contacts Close
GPM
0.3
Pkg.
No.
Model
HW-120M,160M
HW-200M
LPM
1.1
0.6
4.2
2.3
211480
211480
15.9
2.5
9.5
HW-225M
5.8
22.0
3.7
14.0
211480
Record temperature rise at initial start-up for future reference.
7
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INSTALLATION INSTRUCTIONS
For appliance installation in locations with elevations above 2,000
feet (600M), refer to HIGH ALTITUDE INSTALLATIONS section
of this manual for input reduction procedure.
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.
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.
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.
All models may be installed on combustible flooring.
DO NOT 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.
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.
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.
THE HEATER SHOULD NOTBE LOCATED INANAREAWHERE
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 NOT RESULT IN DAMAGE
TO THE ADJACENT AREA OR TO LOWER FLOORS OF THE
STRUCTURE.
LEVELLING
Each unit should be checked after installation to be certain that it
is level.
WHEN SUCH LOCATIONS CANNOT BEAVOIDED, ASUITABLE
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.
If the unit is not level, obtain and insert metal shims under the
base ring of the unit to correct this condition.
AIR REQUIREMENTS
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.
WARNING
FOR SAFE OPERATION AN AMPLE SUPPLY OF AIR MUST BE
PROVIDED FOR PROPER COMBUSTIONAND VENTILATION.
AN INSUFFICIENT SUPPLY OF AIR WILL RESULT IN A
YELLOW/LUMINOUS BURNER FLAME, CAUSING CARBONING
OR SOOTING OF THE FINNED HEAT EXCHANGER AND
CREATING A RISK OF ASPHYXIATION. DO NOT OBSTRUCT
THE FLOW OF COMBUSTION AND VENTILATION AIR.
WARNING
THERE IS A RISK IN USING FUEL BURNING APPLIANCES
SUCH AS HEATERS IN ROOMS OR AREAS WHERE
GASOLINE, OTHER FLAMMABLE LIQUIDS OR ENGINE
DRIVEN EQUIPMENT OR VEHICLES ARE STORED,
OPERATED OR REPAIRED. FLAMMABLE VAPORS ARE
HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE
IGNITED BY THE IGNITER OR MAIN BURNER FLAMES
CAUSING FIRE OR EXPLOSION. SOME LOCAL CODES
PERMIT OPERATION OF GAS APPLIANCES IN SUCH AREAS
IF THEY ARE INSTALLED 18 INCHES OR MORE ABOVE THE
FLOOR. THIS MAY REDUCE THE RISK IF LOCATION IN SUCH
UNCONFINED SPACE
In buildings of conventional frame, brick, or stone construction,
unconfined spaces may provide adequate air for combustion,
ventilation and draft hood dilution.
AN AREA CANNOT BE AVOIDED.
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.
WARNING
FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY
OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST
NEVER BE PLACED ON OR ADJACENT TO THE HEATER.
OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD
NOT BE STORED OR USED IN THE SAME ROOM WITH THE
HEATER.
8
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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.
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 2. Where a continuous or intermittent back draft is found to exist,
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 (2,225mm2/Kw)of the total input of all
appliances in the enclosure, but not less than 100 square inches
(645 square cm).
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 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 (8,900mm2/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 (4,450mm2/Kw) of the total input
of all appliances in the enclosure. For Canadian installations
consult CAN/CGA B149.
•
If the back draft cannot be corrected by the normal methods
or if a suitable draft cannot be obtained, ablower 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.
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.
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.
VENTING
5. Refer to the National Fuel Gas Code for information pertaining
to multiple heater venting. The ASHRAE HVAC SYSTEMS &
EQUIPMENT HANDBOOK 2000, as well as many
manufacturers’ gas vent and chimney sizing handbooks
contain information on multiple heater manifold venting.
WARNING
THE INSTRUCTIONS IN THIS SECTION ON VENTING THE
HEATER MUST BE FOLLOWED TO AVOID CHOKED
COMBUSTION OR RECIRCULATION OF FLUE GASES. SUCH
CONDITIONS CAUSE SOOTING OR RISKS OF FIRE AND
ASPHYXIATION.
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 comply with
the ANSI/ASME Boiler and Pressure Vessel Code, Section IV
(“Heating Boilers”), 1989 edition (or latest edition).
In the United States:
Vent sizing, installation and termination shall be in accordance
with the NATIONAL FUELGAS CODE.ANSI Z223.1-1999 or most
recent edition.
In Canada:
A C.S.A 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 andAutomatic Gas Shutoff Devices
for Hot Water Supply systems, “ANSI Z21.22-1986 or latest
edition”. This relief valve should have a temperature rating of
2100F (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.
With Canadian Installation Code CAN/CGA B149 (latest edition)
Type B venting may be used with these heaters. All local and
utility regulations on venting should be followed.
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.
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 B1.20.1. Mark
location with a Class III label. See ANSI Z21.10.1, Part 1,
MARKING.
PROPER VENT PIPE INSTALLATION
FIGURE 6
9
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Your local code authority may have other specific relief valve
requirements not covered in this section.
WATER LINE CONNECTIONS
This manual provides detailed installation diagrams for typical
methods of application. See piping diagrams.
THE PURPOSE OF A RELIEF VALVE IS TOAVOID EXCESSIVE
PRESSURE OR TEMPERATURE INTO THE STEAM RANGE,
WHICH MAY CAUSE SCALDING AT FIXTURES, TANK
EXPLOSION, SYSTEM OR HEATER DAMAGE.
•
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.
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
NOT BE REDUCED FROM THE SIZE OF THE VALVE OUTLET
AND IT MUST NOT CONTAIN ANY VALVES BETWEEN THE
HEATERAND THE RELIEF VALVE OR THE RELIEF VALVEAND
THE DRAIN LINE EXIT. IN ADDITION, THERE SHOULD NOT
BE ANY RESTRICTIONS IN A DRAIN LINE NOR SHOULD IT
BE ROUTED THROUGH AREAS WHERE FREEZING
CONDITIONS MIGHT OCCUR. DO NOT 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.
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.
Recommended locations of relief valves are shown in the
installation diagrams.
Check the diagrams thoroughly before starting installation to
avoid errors and minimize time and material costs.
HARD WATER
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.
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.
WATER (POTABLE) HEATING
CLOSED WATER SYSTEM
1. All piping components connected to this unit for space
heating applications shall be suitable for use with potable
water.
A closed system will exist if a back-flow prevention device (check
valve), pressure reducing valve, or other similar device is installed
in the cold water line between the water heater and the street
main (or well). Excessive pressure may develop due to the
thermal expansion of heated water causing premature tank
failure or intermittent relief valve operation. This is not a warranty
failure. An expansion tank may be necessary in the cold water
supply to alleviate this situation. Contact the local plumbing
authority.
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.
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PIPING DIAGRAMS
DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT
FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 19. 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
11
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DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE
TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL
WARNING ON PAGE 19. IF HIGHER PREHEAT TEMPERATURES ARE
NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN
ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
FIGURE 8
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DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE
AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON
PAGE 19. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO
OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR
HOT WATER SUPPLIED TO FIXTURES.
FIGURE 9
FIGURE 10
13
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acceptable for the purpose in locating gas leaks. DO NOT USE
MATCHES, CANDLES, FLAME OR OTHER SOURCES OF
IGNITION FOR THIS PURPOSE.
GAS CONNECTIONS
WARNING
THE INLET GAS PRESSURE MUST NOT 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, NOT THE HEATER. VENT
BLOCKAGE MAY OCCUR DURING ICE STORMS.
DISCONNECTTHE HEATERAND ITS MANUALGAS 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 NOT 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
IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING
FROM CONTAMINANTS IN THE GAS WAYS. SUCH FOULING
MAY CAUSE IMPROPER OPERATION, FIRE OR EXPLOSION.
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.
IF COPPER SUPPLY LINES ARE USED THEY MUST BE
INTERNALLY TINNED AND CERTIFIED FOR GAS SERVICE.
SIZING GAS SUPPLY LINE
BEFOREATTACHING THE GAS LINE BE SURE THATALLGAS
PIPE IS CLEAN ON THE INSIDE.
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/ft3 and a
specific gravity of 0.60 has been assumed. A heating value of
2500 Btu/ft3 and a specific gravity of 1.53 has been assumed for
L.P. (propane) gas.
TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS
SUPPLY LINE, A DIRT LEG (SOMETIMES CALLED SEDIMENT
TRAP OR DRIP LEG), MUST BE INCORPORATED IN THE
PIPING. SEE PIPING DIAGRAMS. THE DIRT LEG MUST BE
READILY ACCESSIBLE AND NOT SUBJECT TO FREEZING
CONDITIONS.
INSTALL IN ACCORDANCE WITH
RECOMMENDATIONS OF SERVING GAS SUPPLIERS. IN THE
UNITED STATES REFER TO ANSI Z223.1-1999 OR MOST
RECENT EDITION OF THE NATIONAL FUEL GAS CODE. IN
CANADA, THE CANADIAN INSTALLATION CODE CAN/CGA
B 149 (LATEST EDITION).
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 2 to
compensate for the increased pressure drop.
If the service pressure is 4.5 inches W.C. (1.12kPa) (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.
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.
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
BEFORE PLACING THE HEATER IN OPERATION, CHECK FOR too small, ask the gas company to install a larger meter having
GAS LEAKAGE. Use soap and water solution or other material adequate capacity.
TABLE 6
GAS SUPPLY PIPE SIZES (IN INCHES)
NATURAL GAS (1050 Btu/ft3)
PROPANE GAS (2500 Btu/ft3)
Distance To Heater
From Meter (FT./M) HW-120M
HW-160M
3/4
HW-200M
3/4
HW-225M HW-120M
HW-160M
HW-200M
10 (3M)
30 (9.1M)
1/2
3/4
3/4
1
3/4
1
1
1 1/4
1 1/4
1 1/4
1 1/2
1/2
1/2
3/4
3/4
3/4
1
1/2
3/4
3/4
1
1
1
1/2
3/4
1
1
1
3/4
1
1
1 1/4
1 1/4
1 1/4
1
1
50 (15.2M)
80 (24.4M)
100 (30.5M)
150 (45.7M)
200 (61M)
1 1/4
1 1/4
1 1/4
1 1/4
1
1
1 1/4
1 1/4
1 1/4
1
1 1/4
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Aminimum gas supply pressure of 4.5" W.C. (1.12kPa) for natural
gas and 11" W.C. (1.74kPa) for propane gas is required for
purposes of input adjustment.
Figures 11 and 12 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.
ELECTRICAL INFORMATION
All wiring should be done such that the heater(s) will operate in
the following manner:
ALL ELECTRICAL WORK MUST BE INSTALLED IN
ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE IN
THE UNITED STATES AND IN CANADA MUST CONFORM TO
LOCAL REGULATIONS OR THE CANADIAN ELECTRICAL
CODE CSA C22.
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 5.
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 appliance, when installed, must be electrically grounded in
accordance with local codes or, in the absence of local codes, in
the United States with the NATIONALELECTRICAL CODE,ANSI/
NFPA 70. In Canada with the CANADIAN ELECTRIC CODE,
CSA C22.
2. 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.
A screw is provided in the heater junction box for a ground
connection.
3. When the automatic gas shutoff control or coil protector switch
operate (break electric circuit):
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.
•
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 (NATURAL)
FIGURE 11
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ELECTRICAL WIRING DIAGRAMS FOR THE HW-120M, 160M, AND 200M WATER HEATERS
I.I.D. SYSTEM (PROPANE)
FIGURE 12
NOTES:
16
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OPERATION
CAUTION
PURGING SHOULD BE PERFORMED BY PERSONS
EXPERIENCED IN THIS TYPE GAS SERVICE. TOAVOID RISK
OF FIRE OR EXPLOSION, PURGE DISCHARGE MUST NOT
ENTER CONFINED AREAS OR SPACES WHERE IGNITION
CAN OCCUR. THE AREA MUST BE WELL VENTILATED AND
ALL SOURCES OF IGNITION MUST BE INACTIVATED OR
REMOVED.
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 the 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.
BEFORE PLACING THE WATER HEATER IN OPERATION,
CHECK FOR GAS LEAKAGE. USE A SOAP AND WATER
SOLUTION OR OTHER MATERIAL ACCEPTABLE FOR THE
PURPOSE OF LOCATING GAS LEAKS. DO NOT USE
MATCHES, CANDLES, FLAME OR OTHER SOURCES OF
IGNITION FOR THIS PURPOSE.
GENERAL
Never operate the water heater without first making sure the water
heater and system are filled with water, in addition:
CAUTION
BEFORE PROCEEDING WITH THE OPERATION OF THE UNIT,
MAKE SURE HEATERAND SYSTEMARE FILLED WITH WATER
AND ALL AIR IS EXPELLED FROM HEATER AND PIPING.
•
Make sure a temperature and pressure relief valve is installed
at the water heater and if used, the storage tank. Also check
for leaks.
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 NOT 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.
•
Also be sure to check the gas piping for leaks before beginning
the initial firing of the boiler.
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.
DO NOT 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.
4. Close the hot water faucet as water starts to flow.
5. The heater is ready to be operated.
PURGING OF GAS LINE
Light the unit in accordance with the instructions on the lighting
label attached to the boiler. These instructions are repeated in
the following.
Gas line purging is required with new piping or systems in which
air has entered.
17
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OPERATING INSTRUCTIONS FOR I.I.D. MODELS
The I.I.D. models have an automatic intermittent spark ignition system, figure 3, mounted on the jacket at the front of the heater which
ignites the pilot gas whenever system controls call for heat.
Start the unit in accordance with the instructions on the operating label attached to the heater. These instructions are repeated in the
following.
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS
EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING
PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
A.
B.
THIS APPLIANCE IS EQUIPPED WITH AN IGNITION C.
DEVICE WHICH AUTOMATICALLY LIGHTS THE
PILOT. DO NOT TRY TO LIGHT THE PILOT BY HAND.
USE ONLY YOUR HAND TO TURN THE GAS
CONTROL KNOB . NEVER USE TOOLS. IF THE KNOB
WILL NOT TURN BY HAND, DON’T TRY TO REPAIR
IT. CALL A QUALIFIED SERVICE TECHNICIAN.
FORCE OR ATTEMPTED REPAIR MAY RESULT IN A
FIRE OR EXPLOSION.
BEFORE OPERATING SMELL ALL AROUND THE
APPLIANCE AREA FOR GAS . BE SURE TO SMELL
NEXT TO THE FLOOR BECAUSE SOME GAS IS
HEAVIER THAN AIR AND WILL SETTLE ON THE
FLOOR.
D.
DO NOT USE THIS APPLIANCE IF ANY PART HAS
BEEN UNDER WATER. IMMEDIATELY CALL A
QUALIFIED SERVICE TECHNICIAN TO INSPECT THE
APPLIANCE AND TO REPLACE ANY PART OF THE
CONTROL SYSTEM AND ANY GAS CONTROL
WHICH HAS BEEN UNDER WATER.
WHAT TO DO IF YOU SMELL GAS
• DO NOT TRY TO LIGHT ANY APPLIANCE.
• DO NOT TOUCH ANY ELECTRIC 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.
E.
DO NOT OPERATE APPLIANCE UNLESS UNIT IS
FILLED WITH WATER AND INLET LINES AFTER
FULLY OPEN.
• IF YOU CANNOT REACH YOUR GAS SUPPLIER,
CALL THE FIRE DEPARTMENT.
HONEYWELL VR8304P GAS CONTROL
OPERATING INSTRUCTIONS
1.
STOP! READ THE SAFETY INFORMATION
ABOVE ON THIS LABEL.
8.
9.
TURN ON ALL ELECTRICAL POWER TO THE
APPLIANCE.
2.
3.
SET THERMOSTAT TO LOWEST SETTING.
SET THERMOSTAT TO DESIRED SETTING. PILOT
WILL BE IGNITED BY ELECTRONIC SPARK. WHEN
PILOT IGNITION IS SENSED, THE MAIN BURNERS
WILL IGNITE.
TURN OFF ALL ELECTRIC POWER TO THE
APPLIANCE.
4.
5.
6.
THIS APPLIANCE IS EQUIPPED WITH AN IGNITION
DEVICE WHICH AUTOMATICALLY LIGHTS THE
PILOT. DO NOT TRY TO LIGHT THE PILOT BY HAND.
10. IF MAIN BURNER FAILS TO IGNITE, REMOVE
BURNER ACCESS DOOR AND FOLLOW SMALL
METAL TUBE FROM GAS VALVE TO PILOT. REPEAT
STEPS 2 THRU 9. MAKE SURE PILOT IS BURNING.
IF PILOT FAILS TO IGNITE, CHECK FOR PILOT
IGNITION SPARK.
TURN GAS VALVE CONTROL KNOB CLOCKWISE
TO “OFF” (FIG. A) A SLIGHT INDENT CAN BE FELT
IN THE “OFF” POSITION.
IF APPLIANCE WILL NOT OPERATE, FOLLOW THE
INSTRUCTIONS “TO TURN OFF GAS TO
APPLIANCE” AND CALL YOUR SERVICE
TECHNICIAN OR GAS SUPPLIER.
WAIT FIVE (5) MINUTES TO CLEAR OUT ANY GAS.
THEN SMELL FOR GAS, INCLUDING NEAR THE
FLOOR. IF YOU THEN SMELL GAS.
STOP! FOLLOW “B” IN THE SAFETY
INFORMATION ABOVE IN THIS LABEL.
IF YOU DON’T SMELL GAS. GO TO NEXT
STEP.
7.
TURN GAS CONTROL KNOB COUNTERCLOCKWISE
TO “ON” (FIG. B) UNTIL KNOB SNAPS INTO “ON”
POSITION.
TO TURN OFF GAS TO APPLIANCE
1. SET THE THERMOSTAT TO LOWEST SETTING.
2. TURN OFF ALL ELECTRIC POWER TO THE APPLIANCE IF SERVICE IS TO BE PERFORMED.
3. TURN GAS VALVE CONTROL KNOB CLOCKWISE
ABOVE.
TO “OFF”. REFER TO STEP 5 OF “OPERATING INSTRUCTIONS”
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2. Attach a pressure gauge or a manometer to the outlet pressure
tap, figure 14 and refer to table 3 for correct manifold pressure.
3. Fire the heater by turning the gas valve control knob to “ON”.
4. Use this formula to “clock” the meter. Be sure that other gas
consuming appliances are not operating during this interval.
DANGER
HOT WATER TEMPERATURES REQUIRED FOR AUTOMATIC
DISHWASHER AND LAUNDRY USE CAN CAUSE SCALD
BURNS RESULTING IN SERIOUS PERSONAL INJURY AND/
OR DEATH. THE TEMPERATUREAT WHICH INJURY OCCURS
VARIES WITH THE PERSON’SAGEAND TIME OF EXPOSURE.
THE SLOWER RESPONSE TIME OF CHILDREN, AGED OR
DISABLED PERSONS INCREASES THE HAZARDS TO THEM.
NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER
TAP, OR TO DRAW THEIR OWN BATH WATER. NEVER LEAVE
ACHILD OR DISABLED PERSON UNATTENDED INABATHTUB
OR SHOWER.
3600
T
x H = Btuh
T = Time (in seconds) to burn one cubic foot of gas.
H = Heating value of gas (in Btu’s per cubic foot of gas).
Btuh = Actual heater input (in Btuh).
EXAMPLE: (Using HW-120M heater)
T = 31.5 seconds/ft3
THE WATER HEATER SHOULD BE LOCATED IN AN AREA
WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS
TO SET TEMPERATURES.
H = 1050 Btu/ft3
Btuh = ?
3600 x 1050 = 120,000 (compare with the ratings in
31.5 Table 5).
Should it be necessary to adjust the gas pressure to the burners
to obtain the full input rate, the steps below should be followed.
5. Remove the regulator adjustment sealing cap, fig. 14, and
adjust the pressure by turning the adjusting screw with a
screwdriver.
It is recommended in domestic hot water applications that lower
water temperature be used to avoid the risk of scalding. It is
further recommended, in all cases, that the water temperature be
set for the lowest temperature which satisfies the user’s hot water
needs. This will also provide the most energy efficient operation
of the boiler and minimize scale formation in the heat exchanger,
thus prolonging the life of the boiler.
• Clockwise
to increase gas pressure and input rate.
• Counterclockwise
rate.
to decrease gas pressure and input
DO NOT turn the adjusting screw in past the point of little or no
manifold pressure change or fully bottom the adjusting screw.
SETTING THE WATER HEATER TEMPERATURE AT 120°F
(49°C) WILL REDUCE THE RISK OF SCALDS. Some states
require settings at specific lower temperatures. The table below
shows the approximate time-to-burn relationship for normal adult
skin.
6. “Clock” the meter as in step 4 above.
7. Repeat steps 5 and 6 until the specified input rate is achieved.
8. Turn the gas valve control knob to “OFF”. Replace the regulator
adjustment sealing cap and remove the pressure gauge or
manometer from the outlet pressure tap. Using an allen
wrench, replace the set screw in the outlet pressure tap.
Temperature
Setting
Over 170°F (77°C)
160°F (71°C)
150°F (66°C)
140°F (60°)
Time to Produce 2nd & 3rd
Degree Burns on Adult Skin
Nearly instantaneous
About 1/2 seconds
9. Turn the gas valve control knob to “ON”.
About 1-1/2 seconds
Less than 5 seconds
About 30 seconds
If gas pressure regulator cannot be equipped to give the full input
rating with sufficient gas pressure at the valve, re-orifice the main
burners.
130°F (54°)
120°F (49°C) or less
More than 5 minutes
Table 7
IMPORTANT
UNDER NO CIRCUMSTANCES SHOULD THE GAS INPUT
EXCEED THE INPUT SHOWN IN TABLE 2. OVERFIRING
COULD RESULT IN DAMAGE OR SOOTING OF THE HEATER.
USE ANTI-SCALD VALVE(S) in the hot water system to reduce
the risks of scalding at points of use such as lavatories, sinks and
bathing facilities.
When the heater is operating at full capacity, or full gas input, it
should consume 1 cu. ft. of gas in approximately the amount of
time indicated in table 8.
CAUTION
IN THE EVENT OF ELECTRIC POWER FAILURE, DO NOT
ATTEMPT TO OPERATE THE HEATER.
TABLE 8 — TIME REQUIRED TO CONSUME 1 CUBIC FT. OF GAS
(Heater operating at full input or full capacity.
Does not apply to high altitude installations.)
CHECKING AND ADJUSTING THE INPUT
The maximum inlet gas pressure must not exceed the value
specified by the manufacturer (10.5" W.C. - natural gas,
13.0" W.C. - propane gas). The minimum value listed on the
Rating Plate is for the purposes of input adjustment.
Heating
Value
(Btu/
Total Time Required (Seconds)
MODEL
Type of
Gas
Cu. Ft.)
HW-120M
HW-160M HW-200M HW-225M
Natural
1050
2500
31.5
78.3
23.6
56.3
19.0
45.2
16.8
- - -
Propane
1. Turn the gas valve control knob to “OFF”, (See page 18).
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SERVICE INFORMATION
The installer may be able to observe and correct certain problems
which may arise when the unit is put into operation. HOWEVER,
it is recommended that only qualified service personnel, using
appropriate test equipment, be allowed to service the heater.
5. Restore electrical power and gas supply to heater.
•
Check for gas leaks and proper heater and vent operation.
I.I.D. PILOT BURNER
Any safety devices used in conjunction with this appliance should
receive periodic (at least twice a year) inspection to assure proper
operation. All relief valves should be inspected and manually
operated every six months.
Servicing of the pilot burner includes cleaning the burner head
and the orifice of the pilot burner, fig. 15.
The pilot flame should envelop 3/8 to 1/2 in. of the tip of the
insulated rod on the igniter-sensor. If adjustment is required, it is
necessary to establish pilot flame without main burner operation.
For this to happen, perform the following steps.
PILOT AND MAIN BURNER MAINTENANCE
At least twice a year, check the pilot burner, fig. 15 and the main
burners, fig 13, for proper operation.
1. Follow “TO TURN OFF GAS TO APPLIANCE” steps in the
“OPERATING INSTRUCTIONS FOR I.I.D. MODELS”.
The burners should display the following characteristics:
2. Carefully disconnect the wire terminal connected to the
MV terminal of the S8600 module, fig. 3.
•
•
Provide complete combustion of gas.
Cause rapid ignition and carryover of flame across entire
burner.
Give reasonably quiet operation during ignition, burning and
extinction.
3. Turn gas valve control knob counterclockwise to “ON”.
4. Turn on all electric power to the heater.
•
•
Cause no excessive lifting of flame from burner ports.
5. Set tank temperature control to call for heat. Pilot will operate
without the main burners igniting.
If the preceding burner characteristics are not evident, check for
accumulation of lint or other foreign material that restricts or blocks
the air openings to the burners or heater.
6. Remove the pilot adjustment cover screw, fig. 14, and turn the
inner adjustment screw clockwise
to decrease or
Also check for good flow of combustion and ventilating air to the
unit. Maintain a clear area around the heater at all times.
counterclockwise to increase the pilot flame. Be sure to
replace cover screw after adjustment to prevent possible gas
leakage.
Qualified servicers should follow this procedure when the heater’s
burners need cleaning.
7. Repeat step 1.
1. Turn off the electrical power and close the main manual gas
shutoff valve.
8. Carefully reconnect the MV wire terminal to the S8600 module.
Be sure the terminal is securely connected.
9. Follow “OPERATING INSTRUCTIONS FOR I.I.D. MODELS”
to put heater back into operation.
• Allow heater parts to cool before disassembly.
2. Remove main burner manifold assembly from heater.
If the pilot burner ignites but the main burner fails to light, check
for gas flow to the main burner.
•
Refer to parts list supplied with this manual for disassembly
aid.
Check for good terminal connections at the igniter-sensor
connector (fig. 15) and at the S8600 module.
3. Remove any loose foreign material such as dust or lint with a
vacuum. Check all ports, orifices and air openings for blockage.
Dislodge any foreign material causing blockage. Do not use
sharp metal objects to clean blocked orifices as they will
damage the soft brass orifice. Remove any soot or carbon
deposits with a rag making sure to remove any lint left on burner
by vacuuming again.
For further assistance see Chart 2, “S8600 INTERMITTENT PILOT
SYSTEM TROUBLESHOOTING”.
MAIN BURNER FOR HW HEATERS
FIGURE 13
HONEYWELL GAS VALVE FOR I.I.D. SYSTEM (TOP VIEW)
FIGURE 14
4. Reinstall the burner manifold assembly on heater.
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If control is out of calibration, replace control.
AUTOMATIC GAS SHUTOFF CONTROL
The automatic gas shutoff control, fig. 1, is an automatic device
which is wired in series with the gas valve and intermittent ignition
control module.
The control settings are fixed at 1950F (90.5°C) cut-out and 1900F
(87.7°C) cut-in. Reduced water flow due to lime scale
accumulation is one cause of frequent automatic gas shutoff
control operations. Refer to “PREVENTIVE MAINTENANCE”
section for deliming instructions. If this non-adjustable control is
out of calibration, replace control.
PILOT BURNER USED ON I.I.D. SYSTEMS
FIGURE 15
THERMAL BALANCER
PROTECTOR SWITCH
(Coil High Limit - All Heaters)
Figure 16 shows the internal wiring of the thermal balancer. The
device may be tested after disconnecting the four leads from their
respective terminals on the unit.
If the protector switch, fig 2, should shut off unit, check for the
following conditions:
1. Apply a test light to the yellow and red leads:
• The lamp should light as the contact in this circuit is normally
closed when the resistor is cool.
1. No water in heater.
2. Restricted water flow through the heater.
3. Excessive liming.
4. Improper wiring (automatic gas shutoff control acting as primary
control).
5. Pump failure.
2. Apply the light to the black and yellow leads.
•
The lamp should not light as the contact in this circuit is
normally open when the resistor is cool.
3. Remove the test light.
After correcting failure condition, remove the protector switch cover
and depress reset button. Button will not reset until water
temperature in heater coil is down to 2000F. Restart heater,
following the “OPERATING INSTRUCTIONS FOR I.I.D.
MODELS” , PAGE 18.
4. Apply 120 volts to the white and red leads which power the
1900 ohm resistor.
•
After warming period, the contacts of the thermal balancer
should change position.
5. Remove the 120 volt power source.
PROTECTOR SWITCH CONTINUITY TEST
6. Apply the test light as described in steps 1 and 2.
Do not depress the protector switch reset button prior to testing.
The leads from the switch are removed at the point farthest from
the switch.
•
While the resistor is still warm, the lamp indications should
be the opposite as described above. If this is not the case,
replace the thermal balancer.
Attach the leads from a test flashlight to the switch leads.
The Model N22T test kit (combination flashlight and continuity
tester) is manufactured by the Ray-O-Vac Company, Madison,
WI and available through your local suppliers.
With the flashlight turned on, the lamp should light. If the lamp
lights, the protector switch circuit is closed and in proper working
order. If the lamp does not light, the reasons could be:
1. Protector switch contacts open.
•
Depress reset button on switch (switch cannot be reset until
water temperature in the heater coil drops below 2000F).
Lamp should light.
THERMAL BALANCER SCHEMATIC DIAGRAM
FIGURE 16
INSPECTING THE HEAT EXCHANGER
AND VENTING SYSTEM
2. Defective protector switch or bad leads.
•
If lamp does not light when reset button is depressed, attach
the test flashlight leads to the protector switch terminals. If
Every 6 months, inspect the venting system (including the
lamp does not light, switch is defective and must be replaced. chimney) for blockages which will retard free draft and points of
flue gas leakage. Remove any obstructions and replace any
damaged or deteriorated vent pipe.
•
If lamp does not light, the leads are bad and must be repaired
or replaced.
Check the heat exchanger to be sure it is not blocked by dirt or
soot. It is not sufficient to only look through the flue outlet with
the draft hood removed. Examination should also be made using
a mirror and light through the burner opening, viewing the entire
bottom area of the exchanger.
TANK TEMPERATURE CONTROL
The tank temperature control is the primary operating control of
the system. The sensing element is mounted on the hot water
storage tank. A change of temperature lower than the control
setting will cause the element to activate the electrical switch and
start the heater.
Qualified servicers should follow this procedure when the heater’s
external heating surfaces need cleaning.
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with sufficient gas pressure at the valve, replace with new gas
valve.
CAUTION
DO NOT USEANYLON BRUSH OR OTHER STATIC CREATING
MATERIAL TO CLEAN DUSTAND CARBON DEPOSITS FROM
HEATING SURFACES AND VENT.
RELIEF VALVE
At least twice a year the system relief valves should be checked
to ensure that they are in operating condition. To check a relief
valve, lift the lever at the end of the valve several times. The
valve should seat properly and operate freely.
SUCH DEPOSITS ARE FLAMMABLE AND MAY BE IGNITED
BY STATIC ELECTRICITY. USE AMETAL BRUSH TO MINIMIZE
THE DANGER OF EXPLOSION.
1. Turn off the electrical power and main manual gas shutoff valve.
CAUTION
•
Allow heater parts and vent to cool before disassembly.
BEFORE MANUALLY OPERATING A RELIEF VALVE, MAKE
SURE THAT A DRAIN LINE HAS BEEN ATTACHED TO THE
VALVE TO DIRECT DISCHARGE TO AN OPEN DRAIN.
FAILURE TO TAKE THIS PRECAUTION COULD MEAN
CONTACT WITH EXTREMELY HOT WATER EXITING THE
VALVE DURING THE CHECK OPERATION.
2. Remove the heater draft diverter and vent pipe running to the
chimney.
•
Check parts and chimney for obstructions and clean as
necessary.
•
Replace any damaged or deteriorated parts of the venting
system.
If a relief valve discharges periodically or continuously, it may be
due to thermal expansion of water in a closed water supply system,
or, it may be due to a faulty relief valve.
3. Remove burners from heater and other metal parts as required
to clean and vacuum the heat exchangers and combustion
coils.
Thermal expansion is the normal response of water when it is
heated. In a closed system, thermal expansion will cause the
system pressure to build until the relief valve actuation pressure
is equaled. Then the relief valve will open allowing some water to
escape, slightly lowering the pressure.
•
Refer to parts list supplied with this manual for disassembly
aid.
4. Reinstall the parts removed in steps 2 and 3.
Be sure the vent pipe has a minimum upward pitch of one
•
quarter inch per foot of length and is sealed as necessary. Installation of a properly sized thermal expansion tank will usually
correct this problem. Contact your water supplier or local plumbing
5. Restore electrical power and gas supply to heater.
Check for gas leaks and proper heater and vent operation.
inspector for information on how to best correct this situation.
•
ABOVE ALL DO NOT PLUG ANY RELIEF VALVE. THIS IS NOT
A SOLUTION AND CAN CREATE A HAZARDOUS SITUATION.
Upon reassembly, a negative draft must be produced by the
system. Check for proper draft by holding a lit match near the
draft hood opening while the heater is operating. The flame should
be drawn into the draft hood opening indicating proper draft.
CIRCULATING PUMP
The circulating pump may require occasional lubrication. Refer
to circulator manufacturer’s instructions for lubrication procedures,
and lubrication frequency.
GAS PRESSURE REGULATOR
The gas pressure regulator is included in the combination gas
valve, fig.14, and is set to operate on the gas specified on the
heater model and rating plate.
ELECTRICAL SERVICE
CAUTION
Periodically check main burner, fig. 13, and pilot flame, fig. 15, for
proper operation. This should be checked every six months.
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN
SERVICING CONTROLS. WIRING ERRORS CAN CAUSE
IMPROPER AND DANGEROUS OPERATION.
Do not subject the gas valve to inlet gas pressure of more than
10.5" W.C. - natural gas, 13.0" W.C. - propane gas. If higher gas
pressures are encountered, a service regulator is necessary.
VERIFY PROPER OPERATION AFTER SERVICING.
REPLACEMENT PARTS
Check for a minimum inlet gas pressure value shown on the Rating
Plate before making any adjustment of the regulator.
Replacement parts may be ordered through A. O. Smith dealers,
authorized servicers or distributors. Refer to the Yellow Pages
for where to call or contact the A. O. Smith Water Products
Company, 5621 West 115th Street, Alsip, IL 60803,
ordering parts be sure to state the quantity, part number and
description of the item including the complete model and serial
number as it appears on the product. Refer to the parts list for
Attempts to adjust the regulator during periods of low gas supply
pressure could result in overfiring of the heater when the gas
supply pressure returns to normal.
DO NOT INCREASE PRESSURE ABOVE THAT SPECIFIED AS
OVERFIRING WILL RESULT IN DAMAGE TO THE HEATER
.
If gas pressure regulator cannot be adjusted to correct pressure more information.
PREVENTIVE MAINTENANCE
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.
RECOMMENDED PROCEDURE FOR PERIODIC
REMOVAL OF LIME DEPOSITS FROM COIL
TYPE COMMERCIAL WATER HEATERS
Lime accumulation not only reduces the life of the equipment,
but also reduces efficiency of the heater and increases fuel
consumption.
The amount of calcium carbonate (lime) released from water is in
direct proportion to water temperature and usage, see fig. 17.
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The usage of water softening equipment greatly reduces the
hardness of the water. However, this equipment does not always
remove all of the hardness (lime). For this reason it is
recommended that a regular schedule for deliming be maintained.
The time between cleaning will vary from weeks to months
depending upon water conditions and usage. A change of
approximately 50F in the normal temperature rise through the
heater is usually an indication that scale should be removed. For
long life, copper or brass is recommended for all valves, pipe and
fittings used between gate valves “A” and “B” and the heater, see
fig. 18.
Heater failure due to excessive lime build-up voids the warranty
DELIMING THE HW WATER HEATER
FIGURE 18
6. Continue to fill until foaming action stops.
7. When foaming action has stopped completely, allow 10 to 15
minutes for UN•LIME to dissolve any remaining scale in the
heater.
8. Open the drain valve and drain all UN•LIME from the heater.
9. Remove standpipe and drain hose assembly from tees. Install
fittings originally removed into openings. Open valve “A”,
allowing fresh water to flow through heater and out drain valve
for 3 to 5 minutes.
10.Close drain valve and open valve “B”. Heater is now ready for
operation.
HEAVY LIME DEPOSITS
.
If the solvent does not readily pass through the clogged coils or
heat exchanger, it will be necessary to use a deliming pump or
contact a service agency for proper cleaning.
FIGURE 17
DELIMING SOLVENTS
A. O. Smith part no. 4930 motorized deliming pump kit, complete
with pump, hoses, fittings, container and instructions, is available
from your dealer, distributor or A. O. Smith Water Products
Company.
A. O. Smith recommends the use of UN•LIME® for deliming.
UN•LIME is a patented food grade acid which is safe to handle
and does not create the harmful fumes which are associated with
other products.
A. O. Smith Form No. 4778, entitled “AllAbout Deliming Coil Type
Water Heaters”, describes heater cleaning methods and
equipment required. UN•LIME and the booklet may be obtained
through your dealer, distributor or A. O. Smith Water Products
Company.
UN•LIME may be obtained from your dealer, distributor or the
A. O. Smith Water Products Company. Order part no. 4763
(1 gal.), packed 4 gallons per case, or part no. 4813 (5 gal.
container).
CAUTION
Observe handling instructions on label of product being used.
REMOVING LIGHT DEPOSITS
1. Shut off electric and gas supply to the burner.
2. Close gate valves “A” and “B”.
3. Install drain hose assembly in upper deliming tee. Open drain
cock and drain heater. Install standpipe in lower deliming tee
or in tee from which pressure relief valve has been removed.
4. Close drain valve.
5. Slowly pour 3 gallons of UN•LIME into heater through
standpipe. Direct solution into suitable container with a hose,
see fig. 18.
FIGURE 19
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•
The part no. 4920 pump contained in the deliming kit is
equipped with a titanium shaft. This shaft will not withstand
ammonium bifluoride solutions and must be replaced with a
stainless steel shaft, part no. 4926.
REMOVING SILICATE
Ammonium bifluoride flakes (NH4FlHF) are used in conjunction
with A. O. Smith UN•LIME delimer and pump type deliming kit,
part no. 4930, to delime and remove siliceous materials from
copper coil water heaters.
Ammonium bifluoride flakes should be purchased locally from
chemical suppliers. Contact your dealer, distributor or
A. O. Smith Water Products Company for additional information.
CHECKOUT
examined before using the checkout procedure. Be sure to refer
to the correct piping - wiring diagram and checkout for the type of
system that is installed.
The checkout sequence should be used as an on-the-job trouble-
shooting guide to identify the cause of incorrect system operation
and suggest a remedy for its correction.
The system should be filled with water, purged of air, valves
properly set and utilities connected and ready to operate.
Because improper piping and wiring can result in unsatisfactory
system performance, it is suggested that the installation be
CHART 1 - CER-TEMP 80 RECOVERY SYSTEM CHECKOUT PROCEDURE
(Use this checkout for Cer-Temp 80 Recovery Systems)
SYSTEM OPERATION
Checkout Sequence
Contact
Incorrect
Cause
Remedy
Set tank temperature
control 20° (11°C) below
tank water temperature
Circulating pump
and burner shut
off.
Pump and burner
remain on.
Tank temperature control
differential wide.
Reduce differential.
With thermal
Tank temperature control
defective.
Replace.
balancer, pump off
delay of approx-
imately 2 minutes.
System wiring is incorrect.
Correct wiring.
Correct wiring.
Circulating pump
on.
Pump wired for continuous
operation.
Burner on.
See intermittent pilot system troubleshooting chart 2.
Gas valve stuck or defective.
System wiring in incorrect.
Correct or replace valve.
Correct wiring.
Set tank temperature
control 20° (11°C) above
tank water temperature.
Circulating pump
and burner on.
Circulating pump
on.
Automatic gas shutoff
control calibrated too low
or differential too wide.
Replace. (If problem
proven to be at this
control by applying
jumper to terminals.)
If system has been in
extended use it may
have lime build-up.
See preventive
maintenance.
System wiring is incorrect.
Correct wiring.
Gas valve or wiring
defective.
Check wiring repair or
replace valve.
See intermittent pilot system trouble-shooting chart 2.
Circulating pump
and burner off.
Tank temperature control
differential too great.
Reduce differential. A 5°
differential is generally
used.
Power off or system wiring
is incorrect.
Check power supply and
wiring.
Tank temperature control
defective.
Replace.
See intermittent pilot system trouble-shooting chart 2.
System wiring is incorrect. Replace.
See intermittent pilot system trouble-shooting chart 2.
Burner on.
Heater outlet water
temperature exceeds
210°F.
Circulating pump
on.
Circulating pump
and burner on.
Automatic gas shutoff
control defective.
Replace.
See intermittent pilot system trouble-shooting chart 2.
Set tank temperature
control for desired water
temperature.
System maintains.
desired water
temperature.
24
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CHART 2
S8600 (NATURAL GAS AND LP GAS)
INTERMITTENT PILOT SYSTEM TROUBLESHOOTING
NO SPARK AT PILOT BURNER
Turn gas supply off.
NO
Replace ignition module.
Is voltage (24 Vac) across the 24 V terminals on “Call for heat”?
YES
Is voltage (24 Vac) across the PV & MV/PV terminals on
“call for heat”?
NO
NOTE: (FOR LP MODELS ONLY) Pilot valve will be de-energized
if module goes into lockout condition. Reset system by turning
electrical power off or by turning system controller to “OFF” or
down below “Call for heat”. Wait one minute then turn system on.
YES
Turn on gas supply.
turn on power supply.
Turn off power supply.
NO
Is ignition cable firmly plugged into module?
Securely connect cable
and/or ground wire.
Is green ground wire firmly attached to mounting screw
and GND terminal on module?
YES
Ensure ground strap is the closest metal to the igniter/sensor
rod (electrode) to prevent the spark from shorting out
to other metal parts (pilot screen, pilot shield, etc.).
NO
NO
Carefully bend downward
top of ground strap
to achieve 1/8”
Ignition cable must not touch metal surfaces or
current carrying wires.
spark gap.
Is there a 1/8” gap between ground strap and electrode?
YES
Are the ceramic insulators surrounding the electrode
cracked or broken?
Replace ignition
module.
YES
Replace pilot burner assembly or bus bar.
25
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CHART 2
S8600 (NATURAL GAS AND LP GAS)
INTERMITTENT PILOT SYSTEM TROUBLESHOOTING
SPARK AT PILOT BURNER BUT PILOT WILL NOT LIGHT
Ensure all manual shutoff valves are fully open; All filters are
clean; All gas connections are gas tight; Pilot tubing is not
damaged, obstructed or kinked; and pilot orifice is unclogged.
Check for air in gas line, purge (bleed) line if necessary.
NO
NO
Are the wires securely attached to the pilot operator on the gas
control and to the PV & MV/PV terminals on the ignition module?
Attach wires firmly.
YES
Install a pressure gauge in the pilot tubing line between the gas
control and the pilot burner assembly. Ensure that the pilot
adjustment screw (under cap) is adjusted to a position that will
permit gas to flow.
Replace gas valve.
Is pilot gas flowing during ignition attempt?
YES
Turn on power supply
Turn off power supply.
Is ignition cable firmly plugged into module?
NO
Securely connect
cable and/or ground
wire.
Is green ground wire firmly attached to mounting screw
and GND terminal on module?
YES
NO
Replace pilot burner
and/or ground wire.
Is pilot burner ignition cable in good condition (not brittle, burnt, or cracked)?
YES
Ensure ground strap is the closest metal to the igniter/sensor
rod (electrode) to prevent the spark from shorting out to
other metal parts (pilot screen, pilot shield, etc.).
NO
Carefully bend down-
wards top of ground
strap to achieve
Ignition cable must not touch metal surfaces or
current carrying wires.
1/8” spark gap.
Is there a 1/8” gap between ground strap and electrode?
YES
NO
Are the ceramic insulators surrounding the electrode in good
Replace pilot burner.
condition (not cracked or broken)?
YES
NO
Replace ignition
module.
Is there excessive draft conditions that may cause pilot
burner ignition problems?
YES
Correct draft problems in a manner that would ensure
adequate combustion and ventilation air and proper
pilot burner performance.
26
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CHART 2
S8600 (NATURAL GAS AND LP GAS)
INTERMITTENT PILOT SYSTEM TROUBLESHOOTING
PILOT BURNER LIGHTS BUT MAIN BURNER DOES NOT LIGHT
Correct the situation by consulting the
installation or user’s manual on how to
adjust pilot flame.
NO
NO
Does the pilot flame cover 3/8” to 1/2”
of igniter/sensor rod?
YES
Replace
ignition
module.
NO
NO
Does spark stay on for more than 30 seconds
after the pilot is “proven” (lit)?
Is voltage (24 Vac) across terminals
MV & MV/PV?
Are the wires securely attached to the main
valve operator on the gas control and to
terminals MV & MV/PV on ignition module?
Attach
wires
firmly.
YES
Replace main gas valve.
NO
NO
Is the pilot burner ignition cable in good
condition (not brittle, burnt, or cracked)?
Replace pilot burner.
Replace pilot burner.
YES
Are the ceramic insulators surrounding the
igniter/sensor rod in good condition
(not broken or cracked)?
YES
Are the igniter/sensor rod in good
condition (not worn, corroded, sooted
or damaged)?
NO
Clean rod or replace
pilot burner if necessary.
YES
Replace ignition module.
27
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MODEL HW LIMITED WARRANTY
A. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this water heater.
1. If within FIVE years after initial installation of this water heater, a heat exchanger, coil or gas burner shall prove upon examination by the warrantor
to be defective in material or workmanship, the warrantor, at his option will exchange or repair such part or portion.
a.
This warranty is extended to the owner for all other parts or portion during the FIRST year following initial installation of this water heater.
b.
The warranty on the repair or replacement of the part or portion will be limited to the unexpired term of the original warranty.
2. CONDITIONS AND EXCEPTIONS
This warranty shall apply only when the water heater is installed in accordance with local plumbing and building codes, ordinances and regulations,
the printed instructions provided with it and good industry practices. In addition, a temperature and pressure relief valve, certified by A.G.A. and
approved by the American Society of Mechanical Engineers, must have been installed.
a.
This warranty shall apply only when the heater is:
(1) used at temperatures not exceeding the maximum calibrated setting of its thermostat;
(2) used at water pressure not exceeding the working pressure shown on the heater;
(3) filled with potable water, free to circulate at all times and with the tank free of damaging water sediment or scale deposits;
(4) used in a non-corrosive and non-contaminated atmosphere;
(5) in its original installation location;
(6) in the United States, its territories or possessions, and Canada;
(7) sized in accordance with proper sizing techniques for commercial and/or residential water heaters;
(8) bearing a rating plate which has not been altered, defaced or removed, except as required by the warrantor;
(9) operated with properly installed dirt leg;
(10) fired with the fuel for which it was factory built;
(11) fired at the factory rated input;
b.
c.
Any accident to the water heater, any misuse, abuse (including freezing) or alteration of it, any operation of it in a modified form, or any
attempt to repair tank leaks will void this warranty.
This warranty is void if a device acting as a backflow prevention device (check valves etc.) is installed in the cold water supply the heater
is connected to, unless an effective method of controlling thermal expansion is also installed at the heater(s) and operational at all times.
The relief valve installed on the heater is not an acceptable method.
3. SERVICE AND REPAIR EXPENSES
Under the limited warranty the warrantor will provide only a replacement water heater or part thereof. The owner is responsible for all other costs.
Such costs may include but are not limited to:
a.
b.
Labor charges for service removal, repair or reinstallation of the water heater or any component part;
Shipping, delivery, handling, and administrative charges for forwarding the new heater or replacement part from the nearest distributor and
returning the claimed defective heater or part to such distributor.
c.
All cost necessary or incidental for any material and/or permits required for installation of the replacement heater or part.
4. LIMITATIONS ON IMPLIED WARRANTIES
Implied warranties, including the warranty of merchantability imposed on the sale of this heater under state law are limited to one (1) year duration
for the heater or any of its parts. Some states do not allow limitation on how long an implied warranty lasts, so the above limitation may not apply
to you.
5. CLAIM PROCEDURE
Any claim under the warranty should be initiated with the dealer who sold the heater, or with any other dealer handling the warrantor’s products. If
this is not practicable, the owner should contact:
U.S. Customers
Canadian Customers
A. O. Smith Corporation
500 Tennessee Waltz Parkway
Ashland City, TN 37015
A. O. Smith Enterprises Ltd.
P. O. Box, 310 - 768 Erie Street
Stratford, Ontario N5A 6T3
a.
b.
The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by
the warrantor.
Dealer replacements are made subject to in-warranty validation by warrantor.
6. DISCLAIMERS
NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE ON BEHALF OF THE WARRANTOR WITH RESPECT TO THE
MERCHANTABILITY OF THE HEATER OR THE INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF THE HEATER. THE
WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE
TO PERSONAL PROPERTY OR OTHER CONSEQUENTIAL DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS
WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER
ARISING IN CONTRACT OR IN TORT.
a.
Some states do not allow the exclusion or limitation of the incidental or consequential damage, so the above limitations or exclusions may
not apply to you.
b.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Fill in the following for your own reference. Keep it. Registration is not a condition of warranty. The model and serial number are found on the heater’s
rating plate.
Model No.
Dealer’s Name__________________________________________________________________________________________________________
Dealer’s Address ________________________________________________________________ _ Phone No.____________________
______ Serial No.
________________________________ Date Installed ________________
City and State_____________________________________________________________________________ Zip _________________________
KEEP THIS WARRANTY POSTED ADJACENT TO THE HEATER FOR FUTURE REFERENCE.
28
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