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Manuals - Lochinvar

1. nnns 10 Thermostat Adjustment nennen 11 Burner Flame Check sssrini 11 MAINTENANCE iiini 12 OPERATING amp TROUBLESHOOTING GUIDE 13 TEMPERATURE CONTROL CHECKOUT snn 16 INSTALLATION INSTRUCTIONS FOR POTABLE WATER AND SPACE HEATING 17 FAN INDUCED COMBUSTION rrr 18 GENERAL INFORMATION This gas fired water heater is design certified by the American Gas Association Laboratories under the applicable American National Standard Z21 10 1 or 221 10 3 as indicated on the rating plate available from the American Gas Association 1515 Wilson Blvd Arlington VA 22209 The warranty for this water heater is in effect only when the water heater is installed adjusted and operated in accordance with these Installation and Operating Instructions The warranty does not cover damage or injury caused by the use of any energy saving devices other than those authorized by the manufacturer in conjunction with this water heater The use of unauthorized energy saving devices may decrease the life of the water heater and endanger life and or property The manufacturer will not be liable for any damage injury or loss of life resulting from alteration and or failure to comply with these instructions This water heater has been equipped for use with one type of gas only Compare the information provided on the rating plate affixed to the front of the water heater making sure that the gas stated on the r
2. Na 100 199999 4 6519 538 456 23 6 2 6 m oso nw 55 wales 6 e sso 4500 6903 19 NA X 6 6 X Model Description Clearances Capacity Input kW hr Sides and Ceiling LITERS b m he ai es Rear cm cm ms ms m 12 12 53 sos Flue Damper Models Figure 2 Model Description Clearances am a u m i AEN re BTU hr in in in in Rear in Vent in in ne 4 4 6 un qp Model Description Clearances Capacity Input KW hr D Sides and Flue or Ceiling Liters cm cm cm cm Rear cm Vent cm cm 3 CGR I amp S Installation Minimum Clearances continued Figure 3 puis Figure 4 4 63 118 cm Flue Damper Models Figure 3 Model Description Clearances Capacity Input Sides and Flue or Ceiling D BTU hr m n Vent ad m 155 000 51 00 43 00 34 75 33 516 Model Description Clearances Capacity Input A B C D E Sides and Flue or Ceiling Liters hr cm cm cm cm cm Rear cm Vent cm cm 143 9 Flue Damper Models Figure 4 Model Description Clearances Capacity Input Sides and Flue or Ceiling GAL BTU hr li if i Rear in Vent in P 8 18000 7188 6438 6438 5600 53 f S399 ws Dx pes oes ae oe EC 25 000 82 8 15
3. After reading these Installation and Operating Instructions select a location for the water heater where the floor is level and is easily accessible to water lines gas supply type identified on the rating plate an adequate open drain and a chimney or exhaust gas vent DO NOT locate the water heater where water lines could be subjected to freezing temperatures Make sure the cold water pipes are not located directly above the gas control box or any other electrical control so that condensate during humid weather does not drip on the controls Adequate clearances shall be provided for easy access to controls by service personnel to enable proper cleaning servicing and operation of the water heater Under no circumstances is the front of the water heater to be placed in a position where the burner tray assembly can not slide out for removal when servicing Water heater corrosion and component failure can be caused by the heating and breakdown of airborne chemical vapors Examples of some typical compounds that are potentially corrosive are spray can propellants cleaning solvents refrigerator and air conditioning refrigerants swimming pool chemicals calcium and sodium chloride waxes and process chemicals These materials are corrosive at very low concentration levels with little or no odor to reveal their presence NOTE DAMAGE TO THE WATER HEATER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY THE WARRANTY DO NOT OPERATE THE WATE
4. BURNER FLAME CHECK At the time of installation and at periodic intervals about every 3 months a visual check of the pilot and burner flames should be made to determine if they are burning properly No adjustment to the air shutter should be required for this heater The burner flames should be blue with yellow tips A blue orange flame is characteristic of operation on liquefied petroleum LP gas If the burner flame does not appear as described an air shutter adjustment may be required The burner tube flames should light smoothly from the pilot IMPORTANT In the event of an emergency turn off the gas and electric if applicable to the appliance CGR I amp S Figure 7 MAIN BURNER FLAME PATTERN MAINTENANCE AX WARNING Water heaters are heat producing appliances To avoid damage or injury there shall be no materials stored against the water heater or vent system and proper care shall be taken to avoid unnecessary contact especially by children with the water heater and vent system UNDER NO CIRCUMSTANCES SHALL FLAMMABLE MATERIALS SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER VENT SYSTEM OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER OR VENT SYSTEM IMPORTANT The water heater should be inspected at a minimum annually by a qualified service technician for damaged components and or joints not sealed DO NOT operate this water heater if any part is foun
5. Reconnect all leads and check out system CGR I amp S TEMPERATURE CONTROL CHECKOUT PROCEDURE Set the thermostat above water temperature See page 10 and observe system through one 1 complete cyde Make sure system operates as desired To check the thermistor or thermistor ECO assembly compare it s resistance as measured by an ohmmeter to the water temperature as measured by an accurate thermometer Thermistor resistance increases as the temperature decreases The tables below show the correct sensor resistance at various temperatures In Degrees F Ee ou 14925 11308 9299 9078 8862 8653 7333 00 5827 10 4663 446 3758 3048 29 808 2752 2488 2043 160 1688 162 1509 10 0 1257 170 150 1129 110 10980 1071 1053 1035 1017 99 me c c mm c o gt co c a ec E gt 99 e oo 99 e ec A 99 e 1 oo ec un me me me Ww 3 ec RO wo Ww eS gt c c c un m oo c 1934 99 1333 587 _ 4660 20 3758 308 2488
6. appliances such as dishwashers and automatic clothes washer may require increased temperature water By setting the thermostat on this water heater to obtain the increased temperature water required by theses appliances you may create the potential for scald injury To protect against injury you should install an anti scaled tempering valve in the water system This valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines Such valves are available from the local plumbing supplier Please consult with a plumbing professional For information regarding space heating water connections and plumbing arrangements refer to page 16 Ay WARNING For protection against excessive temperatures and pressure install temperature and pressure protective equipment required by local codes but not less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials as meeting the requirements of the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems ANSI 221 22 or the Standard CAN1 4 4 Temperature and Pressure and the Standard CAN1 4 4 Temperature Pressure Temperature and Pressure Relief Valves and Vacuum Relief Valves The combination temperature and pressure relief valve shall be marked with a maximum set pressure not to exceed the maximum working
7. It will disappear when the tank becomes heated An automatic gas shut off device ECO is incorporated in the thermostat which will shut off all gas supply to the burner and pilot if the water heater temperature exceeds 200 F 93 C Should the ECO function open the water temperature should be reduced to approximately 120 F 49 C and follow applicable Lighting Instructions page 9 to place the water heater in operation If a problem exists contact your dealer for service It is recommended that all service work be performed by a qualified service agency If the water heater is to remain idle for 30 days or more or is subjected to freezing temperatures while shut off the water heater and piping should be fully drained See page 8 To Drain the Water Heater and the drain valve should be left fully open A WARNING Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time generally two weeks or more Hydrogen gas is extremely flammable To prevent the possibility of injury under these conditions we recommend the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance w hich is connected to the hot w ater system If hydrogen is present there w ill be an unsual sound such as air escaping through the pipes as hot water begins to flow Do not smoke or have open flame near the faucet at the time it is open
8. be liable for any damage or injury caused as a result of a cracked gas inlet as a result of excessive torque This water heater and its gas connection must be leak tested before placing the water heater in operation Check for gas leaks with a soap and water solution and a brush or a commercial leak detector fluid NEVER USE A MATCH OR OPEN FLAME FOR TESTING CGR I amp S A CAUTION The water heater and individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of the system at test pressures in excess of Y psi 3 5 kPa The water heater must be isolated from the gas supply piping system by closing its manual shutoff valve during any pressure testing of the gas supply system at test pressures equal to or less than psi 3 5 kPa The supply line must be capped when not connected to the water heater GENERAL OPERATION A WARNING Water heaters are heat producing appliances To avoid damage or injury there shall be no materials stored against the water heater or vent air intake system and proper care shall be taken to avoid unnecessary contact especially by children with the water heater and vent air intake system UNDER NO CIRCUMSTANCES SHALL FLAMMABLE MATERIALS SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER TO FILL THE WATER HEATER Close the water he
9. pressure of the water heater The combination temperature and pressure relief valve shall also have an hourly rated temperature steam BTU discharge capacity not less than the hourly rating of the water heater Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose on the water heater NOTE Some models may already be equipped or supplied with a combination temperature and pressure relief valve Verify that the combination temperature and pressure relief valve complies with local codes If the combination temperature and pressure relief valve does not comply with local codes replace it with one that does Follow the installation instructions above on this page Install a discharge line so that water discharged from the combination temperature and pressure relief valve will exit within six 6 inches 15 2 cm above or any distance below the structural floor and cannot contact any live electrical part The discharge line is to be installed to allow for complete drainage of both the combination temperature and pressure relief valve and the discharge line The discharge opening must not be subjected to blockage or freezing DO NOT thread plug or cap the discharge line Itis recommended that a minimum clearance of four 4 inches 10 2 cm be provided on the side of the water heater for servicing and maintenance of the combination temperature and pressure relief valve Do not place a va
10. should remain lit If pilot goes out repeat steps 4 thru 8 f knob does not pop up when released stop and immeadiately call your service technician or gas supplier f the pilot will not stay lit after several tries turn the gas control knob to OFF and call service technician or gas supplier Turn gas control knob counter clockwise to ON Turn on all electric power to the appliance Set the thermostat to desired setting TO TURN OFF GAS TO APPLIANCE Setthe thermostat to lowest setting Turn off all electric power to the appliace if service is to be performed Push in gas control knob slightly and turn dockwise 7 w to OFF Do not force life This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand 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 WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any telephone in your building Immediately call your gas supplier from a neighbor s telephone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department Useonly your hand to push in or turn the gas control knob If the knob Will not push in or turn by hand don t try to repair it call a qualified S
11. the pilot gas ignites the flame is sensed by the electrode or a flame sensing rod The flame sensing signal received by the ignition control causes the sparking to stop and the main gas valve to open The main burners ignite from the pilot flame The pilot flame is continually monitored by the flame sensing circuit If for any reason the pilot flame is not sensed by the electrode or flame sensing rod the main gas valve closes the spark electrode is re energized and the ignition trial period is reestablished The same sequence occurs during a power or gas supply interruption 5 The main burners continue to operate until the water temperature in the tank increases enough to cause the thermostat contacts to open When the thermostat contacts open the 120 volt power is interrupted to the induced draft blower and the primary transformer windings The gas valve closes causing the main and pilot burners to extinguish The damper on the blower outlet closes and the pressure switch contacts open CGR I amp S TROUBLESHOOTING PROCEDURE FOR WHITE RODGERS THERMOSTAT OPERATION CONDITION CHECK FOR Start Turn Induced draft Check to make sure 120 volt power is present at thermostat terminals to induced draft blower If not make sure thermostat to blower starts power is present at the terminal strip in the control box Make sure thermostat contacts close If not replace call for heat YES NO gt f thermostat If power is present to the bl
12. 16 MO EM In Degrees C Ii T 3 5 T5 2 3 33 ro 38 Sn 15 NOS 2888 15309 7019 B0 Z9 20979 60 288 2400 2316 2235 2157 2003 2011 1902 1876 1813 80 1056 1216 1177 140 1105 1070 103 1005 9M m n pue pep m wp oe om pm p 16 CGR I amp S THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION OF GAS WATER HEATERS SUITABLE FOR WATER POTABLE HEATING AND SPACE HEATING All piping components connected to this water heater for space heating applications must be suitable for use with potable water Toxic chemicals such as those used for boiler treatment shall not be introduced into potable water used for space heating This water heater shall not be connected to a existing heating system or component s previously used with a non potable water heating appliance When the system requires water for space heating at temperatures higher than required for other means such as a tempering valve shall be installed to temper the water for those uses in order to reduce the scald hazard potential Please refer to the illustrations below and on the following pages for suggested piping arrangements Suggested Piping Arrangement For Side Connections ANTI SCALD TEMPERING VALVE SUPPLY TO HEAT EXCHANGER Suggested Piping Arrangement For Side Connections If Applicable ANTI SCALD TEMPERING SHUT OFF VALVE COLD WATER INLET TEMPERED POTABLE
13. 38 15 38 00 EM 13 235 000 LP x0 199999 7550 1 216 Model Description Clearances Capacity Input C Sides and Flue or Ceiling Liters kW hr a m cm cm 1 Lis 5 8 pu 3110 13 3 211 1 97 1 92 171 5 1 50 8 68 9 LP m is iw i6 3i 53 CGR I amp S The following notes apply the tables accompanying Figures 1 4 1 All models with flue dampers and or above 400 000 Btu hr input employ a spark IID ignition system and requires 120 volt AC electric supply 2 Denotes minimum clearances to combustible material Some models may have different clearances Check the label on the front of the water heater to verify proper installation clearances VENTING A WARNING The vent system must be installed properly Failure to properly install the vent system could result in property damage personal injury or death This water heater must be connected to a masonry chimney or venting system approved by local codes or ordinances This vent connector used to attach the draft diverter outlet to the chimney or approved vent must be of the same diameter as the draft diverter outlet or larger For proper venting in certain installations a large vent connector may be needed Consult venting tables in ANSI standard Z223 1 latest edition National Fuel Gas Code and CAN CGA B149 1 or B149 2 latest editions or local code officia
14. BE REPLACED WITH 18 105 C THERMO PLASTIC AWM WIRE OR EQUIVALENT CGR l amp S 24V CLOCK AUGESSURY TRANSFORMER 120V AC INPUT 24N OUTPUT BLACK 115 VOLTS c THERMOSTAT BAS VIE WIE PN ERE W NW PY Y NV BR 1 NOTE IF ANY OF THE ORIGINAL WIRES AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT NUST BE REPLACED WITH 18 GA STRANDED 105 WIRE OR MS EQUIVALENT CGR I amp S LIGHTING AND SHUTDOWN INSTRUCTIONS Spark Ignition Pilot Models FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of Standing Pilot Models FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand 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 WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any telephone in your building mmediately call your gas supplier from a neighbor s telephone Follow the gas supplier s instructions If you cannot reach your gas s
15. CGR I amp S INSTALLATION amp SERVICE MANUAL GAS FIRED COMMERCIAL WATER HEATER A WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death FOR YOUR SAFETY Do not store or use gasoline or other flammable combustible or corrosive 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 telephone in your building Immediately call your gas supplier from a neighbor s telephone 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 For safety convenience and best performance w e recommend this w ater heater be installed and serviced by a plumbing professional TABLE OF CONTENTS GENERAL INFORMATION sssrinin 1 INSTALLATION 2 Locating The Water Heater enne 2 Minimum Clearances wuss 2 Venting 5 Combustion Air Supply nnns 5 Water Connections sssi 6 Gas Connections vss 7 GENERAL OPERATION sssrinin 8 Wiring Diagrams Standing Pilot Wiring Diagram 8 Spark Ignition Wiring Diagram 9 Lighting and Shutdown Instructions enne 10 Standing Pilot Models nnns 10 Spark Ignition Models
16. ET COLD WATER INLET CONTROL BOX GROUND JOINT UNION DRIP LEG CAP DRAIN PAN PIPE TO SUITABLE OPEN DRAIN Sequences of Normal Operation Standing Pilot with Milli volt Control With the pilot lit the pilot burner assembly power pile generates milli voltage to energize the magnet coil in the gas valve permitting gas flow through pilot and to the main gas ports of the valve Simultaneously milli voltage is also directed to the ECO energy cut off switches located in the thermostat Set the control knob on the gas valve on ON position Set the adjustable thermostat to desired water temperature As the water temperature decreases below the thermostat setting in the tank the contacts in the thermostat will close thereby energizing the circuit to the main valve permitting the flow of gas to the main burner Aslow opening feature of the gas valve will cause the burners to light slowly ata reduced manifold pressure After a few seconds allowing the combustion system to stabilize the manifold pressure will increase to the maximum setting of the gas valve The burners will continue to fire until the thermostat becomes satisfied where upon the contacts will open de energize the main valve circuit and the burners will extinguish If the temperature rises above fixed ECO energy cut off setting the ECO contacts will open simultaneously de energizing pilot and main valve circuits and the burners will be extinguished
17. Operating and Troubleshooting Guide Sequences of Normal Operation Electronic Thermostat w ith Intermittent Pilot Ignition The eledronic thermostat controls the 24 volt circuit to the ignition control When the thermostat contacts dose a 24 volt circuit is completed from the transformer through the thermostat relay to the ignition control module to ignite the ignition sequence On flue damper models the damper reaches then full open position the end switches in the damper close completing the 24 volt circuit to the ignition module gt HEAT TRAP ZIA 5 15 3 13 FLUE DAMPER aei VENT CONNECTOR TO CHIMNEY VENT PIPE 1 4 6 4 mm DRAFT DNERTER RISE PER LINEAR FOOT DIELECTRIC UNION HEAT TRAP 5 155 MIN COLD WATER SUPPLY MANUAL SHUT OFF VALVE TEMPERATURE AND PRESSURE RELIEF VALVE RELIEF VALVE DISCHARGE LINE PIPE TO SUITABLE OPEN DRAIN HAND HOLE CLEAN OUT 6 15 3 cm 3 The ignition control sends 24 volt power to the pilot valve PV terminals on the gas valve allowing pilot gas to flow to the pilot The ignition control also simultaneously sends high voltage low current electricity through the eledrode wire to the pilot electrode causing sparks at the pilot electrode to ignite the pilot gas If the pilot fails to ignite within 90 seconds the ignition control Stops the pilot gas and sparking for 15 seconds to allow gas to dissipate The i
18. R HEATER IF EXPOSURE HAS OR WILL OCCUR DO NOT STORE ANY POTENTIALLY CORROSIVE COMPOUNDS IN THE VICINITY OF THE WATER HEATER A WARNING Liquefied petroleum gases propane gasare heavier than air and will remain at floor level if there isa leak Basements crawl spaces closets and areas below ground level will serve as pockets for accumulation of leaking gas Before lighting smell all around the appliance area for gas Be sure to smell next to the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any telephone in your building Immediately call your gas supplier from a neighbor s telephone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department DO NOT OPERATE APPLIANCE UNTIL LEAKAGE IS CORRECTED A WARNING DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE FOLLOW ING Liquefied petroleum gases propane gas and natural gas have an odorant added by the gas supplier that aids in detection of the gas Most people recognize this odor as a sulfur or rotten egg smell Other conditions such as odorant fade can cause the odorant to diminish in intensity or fade and not be as readily detectable If you have a diminished sense of smell or are in any way unsure of the presence of gas immediately contact your gas supplier from a neighbor s telephone Gas detectors are available Contact your g
19. TO INSTALL AND MAINTAIN A NEW LISTED X 34 TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE MANUFACTURER FROM ANY CLAIM WHICH MIGHT RESULT FROM EXCESSIVE TEM PERATURE AND PRESSURES If this water heater is installed in a dosed water supply system such asthe one having a back flow preventer in the cold water supply provisions shall be made to control thermal expansion DO NOT operate this water heater in a dosed System without provisions for controlling thermal expansion Warranties do not cover damages from thermal expansions such as pressure bulges and or deformities Your water supplier or local plumbing inspector should be contacted on how to control this situation After installation of the water lines open the main water supply valve and fill the water heater While the water heater is filling open several hot water faucets to allow air to escape from the water system When a steady stream of water flows through the faucets close them and check all water connections for possible leaks NEVER OPERATE THE WATER HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER A CAUTION Keep clear of combination temperature and pressure relief valve discharge line outlet The discharge may be hot enough to cause scald injury The water is under pressure and may splash This water heater can deliver scalding temperature water at any faucet in the system Be careful whenever using hot water to avoid scalding injury Certain
20. WATER SUPPLY TO HEAT EXCHANGER RETURN FROM HEAT EXCHANGER Suggested Piping Arrangement COLD WATER INLET For Top Connections TEMPERED POTABLE WATER RETURN FROM HEAT EXCHANGER ANTI SCALD YEMPERING SHUT OFF VALVE COLD WATER INLET TEMPERED POTABLE WATER SUPPLY TO HEAT EXCHANGER RETURN FROM HEAT EXCHANGER CGR I amp S Induced Draft Commercial Water Heaters THIS INSTRUCTION SUPPLEMENT IS ONLY INTENDED TO GIVE INSTALLATION INSTRUCTIONS AND INFORMATION RELATED TO THE INDUCED DRAFT WATER HEATERS WHERE THESE MODELS DIFFER FROM THE ATMOSPHERICALLY VENTED MODELS IN THE GENERAL INSTALLATION INSTRUCTIONS REFER TO THE GENERAL INSTRUCTIONS FOR ALL APPLICABLE WARNINGS AND INSTALLATION PROCEDURES 928 Figure 8 1 NPT T amp 1 1 2 NPT FRONT WATER GQURSE OUT 1 1 2 NPT FRONT WATER COURSE IN SPECIFICATIONS AND DIMENSIONS Vent Dia Capacity Input AMP C BTU Hr Draw in in m num we wosjsspespom Capacity Input AMP C BTU Hr Draw in Vent Dia cm Clearances To Combustible M aterials Sides and Rear 6 in 15 2 cm 20 in 51 cm 6 in 15 2 m Notes 1 All models use an induced draft blower with integral damper and intermittent pilot ignition requiring 120 volt 60 Hz Electrical supply 2 May be installed on combustible flooring fe TOP OF BLOWER 1 NPT NAT 3 4 NPT LP 18 31 32 VENTING T
21. as supplier or plumbing professional for more information Proper venting practices must be considered when selecting a location for this water heater For exact venting specifications please consult the Venting section located on page 5 of these Installation and Operating Instructions This water heater must be located in an area where leakage of the tank water line connections or the combination temperature and pressure relief valve will not result in damage to the area adjacent to the water heater or to lower floors of the structure When such locations cannot be avoided a suitable drain pan must be installed under the water heater The drain pan must be no greater than 1 inches 3 8 cm deep and have a minimum length and width of at least four 4 inches 10 2 cm measured from the jacket of the water heater The drain pan as described above can be purchased from your plumbing professional The drain pan must be piped to an adequate drain The piping must be at least 34 inch 1 9 cm in diameter and pitched for proper drainage It is recommended that a minimum clearance of four 4 inches 10 2 cm be provided on the side of the water heater for servicing and maintenance of the combination temperature and pressure relief valve MINIMUM CLEARANCES A WARNING Failure to adhere to these installation and operating instructions may create a hazard to life and property and will nullify the warranty This installation shall allow ac
22. ater drain valve by turning the knob clockwise If alternative water connections are provided but not used make certain they are plugged i e rear connections Open the cold water supply shutoff valve Open several hot water faucets to allow air to escape from the system When steady stream of water flows from the faucets the water heater is filled Close the faucets and check for water leaks at the water heater drain valve combination temperature and pressure relief valve and the hot and cold water connections TO DRAIN THE WATER HEATER 5 hould it become necessary to completely drain the water heater make sure you follow the steps below 1 2 Rotate the thermostat dial dockwise to the PILOT LIGHTING position Rotate and partially depress gas control knob clockwise to the OFF position 3 Shut off the gas supply to the water heater Close the cold water supply shutoff valve 5 Open the drain valve on the water heater by turning the knob 6 counter clockwise The drain valve has threads on the end that will allow the connection of a standard hose coupling Open a hot water faucet to allow air to enter the system To refill the water heater refer to To Fill the Water Heater THERMOSTAT W RODGERS W JUMPER LEAD GAS VALVE ROBERTSHAW 7000BMVR 7000MVRHC NOTE PIEZO IGNITOR THERMOPILE IF ANY OF THE ORIGINAL WIRES AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST
23. ating plate is same as the gas to be used A CAUTION Do not attempt to use this water heater with any gas other than the type listed onthe rating plate Do not attempt to convert this water heater for use with a gas other than the type for which it is equipped Failure to use the proper gas can create an unsafe condition resulting in property damage bodily injury or death Consult your local gas supplier or Gas Company if there are any questions This water heater must be installed in accordance with local codes In the absence of local codes It must be installed in compliance with the National Fuel Gas Code ANS 2223 1 and Lastest Edition or in Canada CGA B149 1 Natural Gas Installation Code Latest Edition or CAN CGA B149 2 Propane Installation Code Latest Edition For installations in high altitude regions this water heater must be ordered from the supplier to the manufacturer s specifications for that particular altitude Contact the company listed on the rating plate when ordering high altitude constructed water heaters This water heater has been designed and certified for the purpose of heating potable water This installation and use of this water heater for any purpose other than the heating of potable water may cause damage to the water heater create a hazardous condition and nullify the warranty A CAUTION Incorrect operation of this appliance may create a hazard to life and property and will nullify the war
24. azardous to life Such a condition often will result in a yellow luminous burner flames causing carboning or sooting of the burners and flue tubes with possible damage to the heater Confined Spaces If the water hater is installed in a confined space volume is less that 50 ft 3 1000 Btu 15 m 3 0 29kW per hour of the total input rating of all gas appliances in that space air must be supplied through two permanent openings One opening shall be within 12 inches 30 5 cm from the top of the enclosure and one within 12 inches 30 5 cm of the bottom The openings must be protected by metal louvers or 14 6 4 mm min mesh meal screen The size of the openings are as follows CGR I amp S 1 If the openings communicate directly with an additional room s of sufficient volume each opening shall have a minimum free area opening of 1 in 2 1000 Btu 2 54 cm 0 29kW per hour of the total input rating of all gas appliances in the confirmed space but not less that 100 254 cm 2 2 If the openings communicate with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 in 2 2000 Btu 2 54 cm 0 59kW per hour of the total rating of all gas appliances the enclosure 3 If the openings communicate directly with the outdoors or through vertical ducts with outdoors each opening shall have a minimum free area of 1 in 2 4000 Btu 2 54 cm 1 18kW per hour of the total rating of all gas applian
25. ces in the enclosure A CAUTION The draft diverter relief opening of the water heater and combustion air inlet must be in the same atmospheric pressure zone Large exhaust fans in kitchens and other locations can lower the air pressure inside an enclosure and interfere with the proper operation and venting of the water heater In these cases the water heater should be installed in a separate room with the combustion and ventilation air supplied directly from outdoors as previously described All Air From Inside the Building The confined space shall be provided with two permanent openings communicating directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination Each opening shall have a minimum free area of 1 in 2 1000 Btu 2 54 cm 0 29kW per hour of the total input rating of all gas utilization equipment in the confined space but not less that 100 square inches 254 cm2 One opening Shall be within 12 inches 30 5 cm of the top and one within 12 inches 30 5 cm of the bottom of the endosure Unconfined Spaces In unconfined spaces in buildings infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases However in buildings of tight construction for example weather stripping heav
26. cess to the front of the water heater and adequate clearance shall be provided for servicing and operating this water heater The water heater may be installed on either a combustible or non combustible floor If the water heater is to be installed directly on carpeting it shall be installed on top of a metal or wood panel or equivalent extending beyond the full width and depth of the appliance by at least there 3 inches 7 6 cm in any direction or if the appliance is to be installed in alcove or closet the entire floor shall be covered by the panel The minimum clearances to combustibles for this water heater are given in the tables on pages 3 through 4 A minimum of 24 inches front clearance shall be provided for inspection and servicing CGR I amp S Ad CAUTION The National Fuel Gas Code ANSI 2233 1 or latest edition and CAN CGA B149 1 or latest edition expressly prohibits the follow ing a Installation of a water heater in a bathroom bedroom or any occupied room normally kept closed b Installation of a water heater in a garage unless the unit is installed so that the burner and ignition devices are at least eighteen 18 inches 45 8 cm above floor level and protected to avoid damage by a moving vehicle Figure 1 22 in Figure 2 59 4cm Flue Damper Models Figure 1 Model Description Clearances Capacity Input BTU hr Sides and Flue or Ceiling GAL in M 2 i Rear in Vent in in
27. d damaged or if any joint is found not sealed The following maintenance should be performed by a qualified service technician at the minimum periodic intervals suggested below In some installations the maintenance interval may be more frequent depending on the amount of use and the operating conditions of the water heater Regular inspection and maintenance of the water heater will help to ensure safe and reliable operation 1 Annual checks of the ignition systems mill volt and electronic temperature controls and any other water heater controls are necessary to ensure proper operation Also all safety shut off valves must be checked to verify proper operation and tightness The flow of combustion and ventilation air MUST NOT be restricted Clear the combustion air openings of any dirt dust or other restrictions WARNING The combustion ventilation system may be HOT At all times keep the water heater area clear and free from combustible materials gasoline and other flammable vapors and liquids Bi annually conduct a visual check of the pilot and burner flames to determine that they are burning properly See Burner Flame Check section on page 10 for example of proper burner flame pattern 5 Annually remove the main burner rack assembly to clean orifices and related parts of any dirt or other foreign material Inspect the burner ports for obstructions or debris and dean with a wire brush vacuum or use a mild detergen
28. djusted to its lowest setting when shipped from the factory The detent on the thermostat temperature scale shown below is the preferred starting point for setting the temperature control For energy efficient operation of your water heater the suggested initial temperature setting is approximately 130 F 55 C Households with small children or invalids may require a 120 F 49 C or lower temperature setting to reduce the risk of scald injury Some states require a lower temperature setting Full counterclockwise 77 rotation of the temperature selector Knob is the minimum temperature setting Full dockwise rotation of the temperature selector knob is the maximum temperature setting NOTE the lower the temperature setting the greater the energy efficiency both to heat the water and to maintain its temperature during standby periods Lower water temperatures also extend tank life Remember no water heating system will provide exact temperatures at all times Allow a few days of operation at this setting to determine the correct temperature setting consistent with you needs NOTE this water heater when set at a lower temperature setting is not capable of producing hot water of sufficient temperature for sanitizing purposes During winter season or any cold period you may desire a higher temperature setting to adjust for the colder incoming water This adjustment however may cause additional condensation to form on the cooler tan
29. ds electronic control module Measure at minimum temperature setting checks and check out system resistance of potentiometer with for short ohmmeter YES NO Potentiometer O K Replace electronic control module Reconnect all leads and check out system If water temperature is too cold or heater does not come on proceed as follows Test or Condition Result Action Taken Start Check voltage at 24 volt terminals of Is voltage between 21 5 and 28 5 Check power supply transformer Correct as necessary electronic control module of thermostat board f VAC YES N02 Are main burners operating or is pilot trying Check for voltage at N O thermostat Thermostat relay is not dosing Check Thermostat light sparking terminals terminal to meter to ground Is setting Refer to thermostat troubleshooting below YES NO voltage between 21 5 and 28 5 VAC YES NO 14 Troubleshooting Procedure for Electronic Thermostat continued CGR l amp S If water temperature is too cold or heater does not come on proceed as follows Test or Condition Are burners operating If power is not present at the NO terminal of the thermostat board and the heater operates if this wire is jumpered to the COM terminal above it then make the following checks to the thermostat circuit This procedure also applies if the burner s cyde on for short periods but the water temperature Seems low Sensors 0 check remote p
30. e operating manifold pressure See the rating plate and gas valve for the manifold pressure and gas type The maximum permissible gas supply pressure is fourteen 14 0 inches 3 5kPa water column for natural gas and liquefied petroleum gases propane gas 1 this water heater only to the type of gas Natural or Propane gas as shown on the rating plate Use clean black iron pipe or equivalent material approved by local codes and ordinances Dirt and scale from the pipe can enter the gas valve and cause it to malfunction The inlet gas line must have a minimum length of three 3 inches 7 6 cm drip leg sediment trap installed as dose to the water heater s gas valve as possible A ground joint union must be installed in the gas supply line as dose to the water heater as possible feeding the water heater to permit servicing of the water heater Compounds used on the threaded joints of the gas piping must be resistant to the action of liquefied petroleum gasses propane gas DO NOT apply pipe dope to the gas valve inlet and make certain that no pipe dope has become lodged in the inlet screen of the gas valve Extreme care shall be taken to ensure no pipe dope enters the gas valve and to avoid excessive torque when tightening the gas supply line to the gas valve Excessive torque may result in cracking of the gas valve housing The suggested maximum torque is 31 5 ft Ibs 4 4 kg m The manufacturer of this water heater will not
31. egs to the draft diverter and attach the draft diverter to the water heater per the instructions in the bag A CAUTION Modification to the flue damper or the draft diverter may result in personal injury property damage or death The flue damper and draft diverter are to be placed in position and operate exactly as stated in these instructions without modification Figure 5 DRAFT DIVERTER DAMPER COVER DAMPER VANE COLLECTOR OUTLET CONNECTOR PLUG ACKET TOP COMBUSTION AIR SUPPLY WARNING Liquefied petroleum gases propane gas are heavier than air and will remain at floor level if there is a leak Basements crawl spaces closets and areas below ground level will serve as pockets for accumulation of leaking gas Before lighting smell all around the appliance area for gas Be sure to smell next to the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical sw itch do not use any telephone in your building Immediately call your gas supplier from a neighbor s telephone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department DO NOT OPERATE APPLIANCE UNTIL LEAKAGE IS CORRECTED IMPORTANT The flow of combustion and ventilating air must not be obstructed Provide adequate air for combustion and ventilation An insufficient supply of air will cause recirculation of combustion products resulting in air contamination that may be h
32. er heater should be wired on a separate circuit and breaker GN CONTROL SP 845 WIRING DIAGRAM NOTE IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH 105 C OR ITS EQUIVALENT MAINTENANCE OF INDUCED DRAFT BLOWER The following maintenance should be performed by a qualified service technician at the minimum periodic interval listed below 1 Bi annually oil the induced draft motor in the ports of the front and rear motor bearings with 4 drops each of SAE 20 motor oil 2 Annually inspect the blower wheel for debris and clean as necessary 3 Inspect the venting system for corrosion and leaks Replace any defective sections of vent pipe 4 Inspect the blower vent damper for proper movement making sure the damper extends to the full open position after the blower reaches full speed see Figure 11 If the damper blade does not fully open remove the vent connector and make sure the blower wheel is clean and debris has not fallen on the damper blade or blower wheel If the damper binds replace the blower assembly DO NOT ATTEMPT TO REPAIR THE DAMPER OIL BEARINGS AT FRONT DAMPER SHOWN IN OPEN POSITION AND REAR 4 DROPS SAE20 EVERY 6 MONTHS Figure 11 Operating and Troubleshooting Guide Sequence of Normal Operation W hite Rodgers Thermostat with Intermittent Pilot Ignition mn Thermostat contacts dose on temperature drop in the tank causing the h
33. ervice technician Force or attempted repair may result in a fire or explosion 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 OPERATING INSTRUCTIONS Stop Read the safety information above on this label Setthe thermostat to lowest setting Turn off all electric power to the aplliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand CONTROL KNOB SHOWN IN OFF POSITION Turn gas control knob clockwise w to OFF Wait five 5 minutes to dear out any gas If you smell gas STOP Follow B in the safety information above on this lable If you don t smell gas go to the next step Turn knob on gas control counter dockwise w to ON Turn on all electric power to the appliance Setthe thermostat to lowest setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE Setthe thermostat to lowest setting Turn off all electric power to the appliace if service is to be performed Turn gas control knob clockwise w to OFF TEMPERATURE ADJUSTM ENT The temperature selector knob of the thermostat has been a
34. gnition control will then attempt 2 two more ignition trials as stated above If the pilot does not ignite after 3 three trials the ignition control will then go into lockout mode and the ignition system will remain shut down until the control is reset by interrupting power to the ignition module When the pilot gas ignites the flame is sensed by the electrode or a flame sensing rod The flame sensing signal received by the ignition control causes the sparking to stop and the main gas valve to open The main burners ignite from the pilot flame The pilot flame is continually monitored by the flame sensing circuit If for any reason the pilot flame is not sensed by the electrode or flame sensing rod the main gas valve closes the spark electrode is reenergized and the ignition trial period is reestablished The same sequence occurs during a lower or gas supply interruption The main burners continue to operate until the water temperature in the tank increases enough to cause the thermostat contacts to open When the thermostat contacts open 24 volt power is interrupted to the ignition control module and the gas valve closes The flue damper on D models closes If for some reason thermostat contacts fail to open then the high temperature limit ECO contacts in the thermostat sensor open and interrupts power to the pilot valve causing the pilot to extinguish The ignition module senses the pilot outage and attempts to re
35. he water hater models described above in this supplement are of the induced draft type which rely on an induced draft blow er to pull the combustion products through the flue tubes of the w ater heater An integral gravity damper on the induced draft blower outlet is forced open by the air pressure from the blower and closes at the end of each burner cycle NO ADDITIONAL VENT DAMPERS ARE TO BE ATTACHED TO THE OUTLET OF THESE APPLIANCES These water heaters have been approved for vertical venting through a lined masonry chimney or double wall vent pipe DO NOT VENT THESE WATER HEATERS HORIZONTALLY WITH THE VENT TERMINATING THROUGH THE WALL TO THE OUTSIDE ALL VENTING MUST TERMINATE THROUGH THE ROOF WITH A VERTICAL DISCHARGE The vent connector attached to the vent collar on the blower must be 8 20 cm in diameter The venting size was designed to produce a negative pressure inside the venting system when properly installed Horizontal piping must be sloped upward least inch per linear foot 2 1 cm m of length All vent piping must be well supported to avoid sagging or adding excessive weight onto the blower assembly This water heater may be commonly vented with another gas appliance providing the commonly shared vent is the proper 18 CGR l amp S Size to handle exhaust gases from both appliances This water heater must not have another gas appliance vented into the vent connector Consult the venting tables in the latest edition
36. igh voltage circuit through the thermostat to be completed to the transformer and induced draft blower When the induced draft blower comes up to operating speed the gravity damper on the blower outlet is pushed open by the air pressure The air pressure in the fuel collector chamber is reduced until the vacuum is sufficient to dose the pressure switch contacts 1 45 w c or 036 kPa 99 When the pressure switch contacts dose the 24 volt control circuit is completed to the TH or 24V terminals ignition control module The ignition control module may have a pre purge time delay of up to 45 seconds After the pre purge timing the ignition control sends 24 volt power through the thermostat ECO to the pilot valve PV terminals on the gas valve allowing pilot gas to flow to the pilot The ignition control also simultaneously sends high voltage low current electricity through the electrode wire to the pilot electrode causing sparks to ignite the pilot gas If the pilot gas fails to ignite within 90 seconds the ignition control stops the pilot gas and sparking The ignition control may allow the ignition sequence 21 CGR l amp S to retry upto 2 more attempts after a 5 minute delay before the control will lock out ignition attempts until the thermostat circuit is reset by interrupting power for 15 seconds The induced draft blower continues to operate as long as the thermostat contacts are closed 4 When
37. ily insulated caulked vapor barrier etc additional air may need to be provided using the methods described above under CONFINED SPEACES All Air From Outdoors or SPECIALLY ENGINEEERED INSTALLATIONS Specially Engineered Installations The requirements noted under CONFINED SPACES above shall not necessarily govern when special engineering approved by the authority having jurisdiction provides an adequate supply of air for combustion ventilation and dilution of flue gases WATER CONNECTIONS Note BEFORE PROCEEDING WITH THE INSTALLATION CLOSE THE MAIN WATER SUPPLY VALVE After shutting off the main water supply open a faucet to relieve the water line pressure to prevent any water from leaking out of the pipes while making the water connections to the water heater After the pressure has been relieved close the faucet The COLD water inlet and HOT water outlet are identified on the top and front of the water heater Make sure the dip tube is in place before making the cold water connection Make the proper plumbing connections between the water heater and the plumbing system to the house Install a shut off valve in the cold water supply line A CAUTION If sweat fittings are to be used DO NOT apply heat to the nipples top of the water heater Sweat the tubing to the adapter before fitting the adapter to the water connections Itisimperative that heat is not applied to the nipples containing a plastic liner A WARNING FAILURE
38. k surface This does not mean the tank is leaking During summer months the warmer incoming water temperatures will benefit the performance of your water heater and reduce the amount of condensation developed Condensation does not mean your tank is leaking Over 40 of reported tank leaks on installation are proven to be condensation To avoid unnecessary expense and inconvenience make sure the tank is leaking before calling a service person Figure 6 PREFERRED STARTING TEMPERATURE SET POINT CGR I amp S FN DANGER Hotter water increases the risk of scald injury Scalding may occur within five 5 seconds at a temperature setting of 135 F 57 C To protect against hot water injury install an anti scald tempering valve in the water System This valve will reduce point of discharge temperature by mixing cold and hot water in branch water lines A licensed plumbing professional or local plumbing authority should be consulted Note This water heater is equipped with an energy cut out device to prevent overheating Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance and call qualified service technician Note Whenever the water heater is filled with cold water condensate will form on the cool tank surface and drops of water will fall on the hot burner and combustion chamber surfaces producing a sizzling noise Condensation is normal and does not indicate a leak
39. light the pilot by reestablishing the sparking at the electrode as stated in paragraph 3 three above Since the pilot valve circuit is open the pilot will not ignite and the system will go into lockout mode after 3 three ignition trials In the lockout mode the ignition system will remain shutdown until the control is reset by interrupting power to the ignition module The ECO will not reset to close the contacts until the tank water temperature drops to between 100 F 38 C and 160 F 71 C If the ECO contacts open the cause for the high water temperature should be determined before resetting the ignition system CGR I amp S Troubleshooting Procedure for Electronic Thermostat If water temperature is too hot proceed as follows Test or Condition Result Action Taken Start Disconnect sensor leads from 15 resistance between 700 Sensor s may be shorted or open electronic control module and measure and 30K ohms see page 12 Check for loose broken or shorted wires resistance of sensor s with ohmmeter YESL N0 Replace sensing bulb s if necessary Sensors O K Disconnect ECO leads and 15 water temperature greater than 210 F Replace sensing bulb with ECO limit and check out measure resistance with ohmmeter 99 C and ECO resistance balance of system less than 10 ohms shorted YES NOL Disconnect potentiometer leads from 15 resistance greater than 4800 ohms Replace electronic control module Reconnect all lea
40. ls for proper application for your area Flue Damper Refer to Figure 5 and follow these instructions A CAUTION Do not turn on electrical pow er to water heater until flue damper is installed and water heater is filled with water 1 Remove the damper from the accompanying box shipped within the crate 2 Locate the collector outlet on top of the water heater Place the damper over the collector outlet and rotate as necessary to a position in which the damper wiring plug can be fully engaged with the connector on the side of the water heater 3 If applicable remove clip which holds damper vane closed This type of vent damper will then open by itself 4 Secure the flue damper to the jacket top with sheet metal screws Note Some dampers require an additional bracket to assure level installation 5 Connect the damper wiring plug to the connector on the side of the water heater Note The plug and connector can only be engaged one way polarized The Lighting and Operating instructions are outlined beginning on page 9 The damper must be in the open position when the water heater main burner is operating the arrow on the damper plate is in the up position when open Be certain the arrow is in a visible position when installed a Draft Diverter This water heater has been shipped with a draft diverter for which it was designed Remove the bag containing the legs and instructions from the draft diverter Attach the l
41. lve between the combination temperature and pressure relief valve and the tank A WARNING Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time generally two weeks or more Hydrogen gas is extremely flammable To prevent the possibility of injury under these conditions we recommend the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system If hydrogen is present there will be an unsual sound such as air escaping through the pipes as hot water begins to flow Do not smoke or have open flame near the faucet at the time it is open CGR I amp S BUAN Wolter iampersture over IPEF con cause Severs bums Instantly or Ceath trom sca de Children disablec and elderly ars at hi caet of beng scaldec See Instruct 5n manual be ore tempe atte at wate heater Fool water befor baling er OY Tem ocrature lim ting vos are 852 lable ee Marua GAS CONNECTIONS The gas supply lines must meet all requirements of the National Fuel Gas Code ANSI Z223 1 Latest Edition or in Canada CCGS B149 1 Natural Gas Installation Code Latest Edition or CAN CGA B149 2 propane installation code Lastest edition The minimum permissible gas supply pressure for the purpose of input adjustment is one 1 0 inch 0 25kPa water column above th
42. nd voltage is present between yellow wire and ground end switch in damper may be faulty Replace damper operator If the pilot valve will not open when voltage is present to the to the PV terminal and the common terminal PV MV wire has continuity to the module the gas valve may be defective If no voltage is present at PV on the ignition control and the ECO is closed power to 24V and 24V GND terminals of module the ignition control module may be defective Replace and recheck system Make sure pilot flame is steady and envelopes the electrode or flame sensor Turn pilot adjustment screw counter clockwise to increase size of pilot flame Make sure pilot shield is in place If pilot flame is stable check for voltage at the MV terminal at the ignition module and gas valve If no voltage is present at the ignition module replace control If voltage is present at the gas valve replace valve Sensor s may be shorted or open check continuity of wires for loose broken or shorted wires Replace sensing bulb or wire harness if necessary Disconnect potentiometer leads from electronic Replace potentiometer Reconnect all leads and check control module Measure resistance of potentiometer with ohmmeter Is resistance greater than 4800 ohms at the minimum temperature setting and less than 50 ohms at the maximum temperature setting checks for open or shorts YES N0O Potentiometer O K Replace electronic control module
43. o break deposits loose as this could damage the glass lining and shorten the life of the water heater After cleaning replace the cleanout tank cover and jacket cover and refill with water 10 A combination sacrificial anode rod hot water outlet nipple has been installed to extend tank life The anode rod should be inspected periodically every 2 years and replaced when necessary to prolong tank life Water conditions in your area will influence the time interval for inspection and replacement of the anode rod Contact the plumbing professional who installed the water heater or the manufacturer listed on the rating plate for anode replacement information The use of a water softener may increase the speed of anode consumption More frequent inspection of the anode is needed when using softened or phosphate treated water A CAUTION FOR YOUR SAFETY DO NOT ATEMPT REPAIR OF COMBINATION GAS CONTROL BURNERS OR GAS PIPING REFER REPAIRS TO A QUALIFIED SERVICE TECHNICIAN Contact your supplier plumbing professional or contact the company at the address given on the rating plate of the water heater for replacement parts Provide the part name as well as the model and serial number s of the water heater s when ordering parts 12 CGR l amp S TYPICAL INSTALLATION DIELECTRIC UNON ANTI SEALD TEMPERING VALVE qb HOT WATER OUTLET TO FIXTURES COLD WATER SUPPLY GAS SUPPLY MANUAL SHUT OFF GAS VALVE HOT WATER OUTL
44. o make sure the flue collector lid under the jacket top is tightly secured The gasket under the lid must be intact The gasket under the blower mounting flange must be secure and the joint between the blower mounting flange and blower transition duct must be caulked with high temperature sealant Dow RTV or equivalent Make sure the damper position rod is in the open position while the blower is operating If the damper sticks replace the blower Check the flue baffles to make sure scale or soot deposits have not accumulated and blocked the flue passageways Check the amp draw of the induced draft blower if vacuum to the pressure switch is low The normal running amps should be approximately 2 8 amps Does pilot spark without lighting pilot Make sure there is sufficient gas pressure at the gas valve inlet Check the nameplate for minimum gas supply pressures for the type of gas used Check to make sure 24 volts is present at PV wire on the gas valve If not check to make sure ECO high limit contacts on the two 2 bottom thermostat terminals are closed no voltage across terminals but voltage to ground ECO should reset after tank cools If not check for defective control Also make sure all terminal connections are tight If the pilot valve will not open when voltage is present to the PV terminal and the common terminal PV MV wire has continuity to the module the gas valve may be defective If no voltage is present at PV on the igni
45. of the National Fuel Gas Code ANS 2223 1 or in Canada CAN 1 B149 1 or B149 2 local code officials for proper application for your area For proper venting limit the number of elbows in the venting system All connections in the venting system must be securely fastened with sheet metal screws or other approved methods Consult local codes and ordinances Failure to install a proper venting system can result in fire injury or death See Figures 9 amp 10 for common venting connections VENT CAP Figure 9 TYPE B DOUBLE WALL GAS VENT USED AS CONNECTORS CONN RISE R Figure 10 d B DOUBLE WALL MASONRY CHIMNEY GAS VENT USED AS CONNECTORS CONN RISE R pw FOR PROPER COMMON VENTING PRACTICE REFER TO NATIONAL FUEL CAS CODE VENTING TABLES FOR PROPER SIZING OF VENTING SYSTEM CGR I amp S ELECTRICAL CONNECTIONS This water heater must be wired to a 115 volt 60 Hz power supply Refer to the wiring diagram on the water heater and with these supplemental instructions for proper field wiring connections to the terminal block All wiring and conduit must be installed and electrically grounded in accordance with the latest edition of the National Electric Code ANSI NFPA 70 or local applicable codes In Canada follow the latest edition of the Canadian Electrical Code Part 1 CSA C22 1 and all applicable local codes Refer to the nameplate for the total amp draw for this water heater The wat
46. otentiometer Result If pilot does not light and pilot is not sparking check to make sure flue damper is in the full open position Damper opens YES gt If damper opens but pilot does light or spark Does pilot spark without lighting pilot Make Sure there is sufficient gas pressure at the gas valve inlet Check the nameplate for minimum gas supply pressures for the type of gas used Check for plugged pilot orifice Check gas valve by measuring voltage from PV to ground If no voltage check continuity across ECO circuit of thermostat red wires If ECO is open it should reset after tank cools below 160 F 71 C If it does not reset replace sensing bulb with the ECO If ECO has opened there may be a problem with the thermostat Pilot lights but main gas does not come on Disconnect sensor leads from electronic control module and measure resistance of sensor s with ohmmeter Is resistance between 700 and 30K ohms see page 12 Measure water temperature from tank for an approximate correlation with the table YES 0 gt Action Taken Check flue damper wiring Check for 24 volts at yellow wire from thermostat to damper If damper still does not open check for 24 volts between red and white wires to damper If damper does not open when voltage is present and thermostat is closed replace damper operator Check black wire from damper for 24 volts to ground If no voltage is present but damper is open a
47. ower but will not operate check for continuity from the wires to the blower and the blower windings If no continuity check for broken wires If the wires are O K and blower still will not run replace the blower Pilot ignition Pilot ignites Does pilot spark after the pre purge period If not check to make sure the pressure switch contacts mounted after a 30 45 on outside of control box are closed by checking each terminal on the pressure switch through the voltmeter with second time the other lead to the ground lug There should be 24 volts from one terminal to ground Check the wiring by delay ignition making sure 24 volts is available at the TH or 24V terminals on the ignition control with the other lead of the controls with voltmeter to the ground lug inside the control box pre purge The vacuum at the pressure switch may be checked with a tee installed at the pressure switch tubing with a draft timings gauge or manometer connected Cold starting vacuum should be dose to 2 0 w c 49 kPa with a hot running YES N02 operation vacuum near 1 75 w c 44kPa The pressure switch contacts should close by 1 45 w c 36kPa and open in a drop of vacuum to 1 25 w c 31kPa If outside of these specs replace DO NOT LEAVE THE WATER HEATER OPERATING WITH THE PRESSURE SWITCH BYPASSED Make sure the pressure switch tubing fittings are snug but do not use tools to tighten the plastic nut on the pressure switch connection Check t
48. pe of gas used Remove burners and flue baffles and clean as needed Make sure gaskets are in good condition replace if necessary before reassembling lid Evaluate hot water usage to determine if hot water draw exceeds capacity of water heater 23 CGR I amp S 24 Printed in USA
49. ranty Ay DANGER Do not store or use gasoline or other flammable combustible or corrosive vapors and liquids in the vicinity of this or any other appliance IMPORTANT Before proceeding please inspect the water heater and components for possible damage DO NOTinstall any damaged components If damage isevident then please contact the supplier where the water heater was purchased or the manufacturer listed on the rating plate for replacement parts CGR I amp S INSTALLATION Locating The Water Heater WARNING Water heaters are heat producing appliances To avoid damage or injury there shall be no materials stored against the water heater or vent air intake system and proper care shall be taken to avoid unnecessary contact especially by children with the water heater and vent air intake components UNDER NO CIRCUMSTANCES SHALL FLAMMABLE MATERIALS SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER VENT AIR INTAKE SYSTEM OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER OR VENT AIR INTAKE SYSTEM This water heater must NOT be installed in any location where gasoline or flammable vapors are likely to be present unless the installation is such to eliminate the probable ignition of gasoline or flammable vapors The location of this water heater is of the utmost importance Before installing this water heater you should read the Installation section of these instructions
50. re and the joint between the blower mounting flange and blower transition duct must be caulked with high temperature sealant Dow RTV or equivalent The vacuum at the pressure switch may be checked with a tee installed at the pressure switch tubing with a draft gauge or manometer connected Cold starting vacuum should be dose to 2 0 w c 49 kPa with a hot running operation vacuum near 1 75 w c 44 kPa The pressure switch contacts should close by 1 45 w c 36 kPa and open in a drop of vacuum to 1 25 w c 31 kPa If outside of these specs replace DO NOT LEAVE THE WATER HEATER OPERATING WITH THE PRESSURE SWITCH BYPASSED Water heater Water heater Check water heater thermostat setting and adjust if necessary Make sure cyding is due to thermostat operates but cydes Setting check previous sections Also make sure high limit contacts are remaining dosed by measuring Water is not voltage from each lower thermostat terminal to ground hot enough Burners operate Check outlet water temperature from nearby faucet with a thermometer If the outlet water temperature continuously does not approximate the thermostat setting and the heater is otherwise functioning normally the thermostat may be out of calibration Remove from tank and replace Make sure there is sufficient gas supply pressure see nameplate Check burner manifold pressure outlet pressure tap on gas valve Check for proper orifice size for the ty
51. t solution to dean as needed NOTE It is imperative for proper operation of the water heater that the main burner rack be replaced in the original location A WARNING When lifting lever of the combination temperature and pressure relief valve hot water will be released under pressure Be careful that any released water does not result in bodily injury or property damage 7 least once a year check the combination temperature and pressure relief valve to ensure that the valve has not become encrusted with lime Lift the lever at the top of the valve several times until the valve seats properly without leaking and operates freely IMPORTANT If the combination temperature and pressure relief valve on the appliance discharges periodically this may be due to thermal expansion in a closed water supply system Contact the water supplier or local plumbing inspector on how to correct this situation Do not plug the combination temperature and pressure relief valve outlet 8 Monthly drain off a gallon of water to remove silt and sediment A WARNING THIS WATER MAY BE HOT 9 All models are equipped with a cleanout opening to aid in removal of hard water deposits from the tank bottom If this water heater operates under hard water conditions the following should be performed at least every 3 months drain the water heater Remove the cleanout jacket cover and tank cover When cleaning the tank care must be taken to avoid trying t
52. tion control the control may be defective Main burner Pilot ignites If pilot flame is present but main burners do not light no main burner gas check to make sure green ground ignition and main gas wire from module to control box ground lug has continuity Disconnecting the wire and measuring the resistance valve opens through both ends of the wire with an ohmmeter can verify this The reading should be 0 ohms with main Check to make sure pilot flame covers the electrode or flame sensing rod Check the electrode or flame sensing burners wire for continuity Replace wire if cracked lighting Check for cracked ceramic electrode insulator Clean electrode or flame sensing rod if carbon is present Make YES NO J sure vertical pilot draft shield is installed Pilot flame should be steady without wavering or blowing Check for voltage between the MV terminal of the ignition module and the ground lug If no voltage is present and above conditions ground pilot flame flame sensor wire leads are O K replace ignition control Check for voltage between MV and MV PV of the gas valve If voltage is present but valve does not open replace gas valve CGR I amp S TROUBLESHOOTING PROCEDURE FOR WHITE RODGERS THERMOSTAT OPERATION CONDITION CHECK FOR Main burners Main burners and If blower continues to operate but main burners cycle erratically check for proper grounding of the ignition operate until blower operate con
53. trol and continuity of the pilot electrode wire Make sure the pilot draft shield is in place The pilot adjustment thermostat is until thermostat screw should be adjusted to the full open position counter dockwise Make sure the pilot electrode is dean and satisfied is satisfied not damaged or bent The flame sensing current output from the pilot can be measured by connecting a microamp Blower and YES Checks 0 meter from the pilot flame sense lead to the sense terminal on the ignition control Replace the pilot if the burners stop NO electrode or wires have deteriorated or if the flame sense current is below 1 0 microamps Replace ignition control if problem persists and above checks proved satisfactory If the blower continues to operate but the burners cycle off check the ECO lower terminals of the thermostat If the ECO high limit trips the ignition will lock out requiring resetting Normally the thermostat should open before the high limit trips If the high limit opens before the thermostat replace the control Another possible cause for the burner to cycle is the pressure switch contacts are opening Make sure the pressure switch tubing fittings are snug but do not use tools to tighten the plastic nut on the pressure switch connection Check to make sure the flue collector lid under the jacket top is tightly secured The gasket under the lid must be intact The gasket under the blower mounting flange must be secu
54. upplier call the fire department Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or 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 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 LIGHTING INSTRUCTIONS Stop Read the safety information above on this label Turn the thermostat to lowest setting Turn off all electric power to the aplliance knob slightly and turn clockwise to off GAS CONTROL KNOB SHOWN IN OFF POSITI OSITION NOTE Knob can not be turned from PILOT to OFF unless knob is pushed in slightly Do not force Wait five 5 minutes to dear out any gas If you smell gas STOP Follow B in the safety information above on this lable If you don t smell gas go to the next step Find pilot follow metal tube from gas control The pilot is located in the center of the burner rack between two burner tubes Turn knob on gas control counter clockwise to PILOT J Push in control knob all the way and hold in Immediately light the pilot with a match Continue to hold the controL Knob in for about 1 minute after the pilot is lit Release knob and it will pop back up Pilot

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