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A.O. Smith HYB-90N Instruction Manual

1. 2 Open front door of the heater and remove the front cover of the heat engine 3 Checkthat or set DIP switch 4 is in the calibrate ON or down position 4 Generate a 5 minute minimum water draw from the heater 5 Repeatthe calibration procedure NOTE If changes are made to the vent system or the heater is re located the Calibration Procedure must be repeated 32 www hotwater com OPERATING INSTRUCTIONS DISPLAY PANEL STANDBY LED GREEN STANDBY ON OFF l BUTTON A l ENERGY SAVER VACATION A L MODE BUTTON i x OOO I BURNER IN MODE LEDs 3 OPERATION 4 FAULT INDICATOR TEMPERATURE UNITS OF MEASURE NUMERIC DISPLAY I UP HOTTER BUTTON LILI iL I I 1 I I I KEY LOCK i DOWN COLDER BUTTON FIGURE 33 Changing the Standby Status When the Standby Button is pressed the Status changes to normal operation and all the LEDs on the display will light up for a period of 1 second to verify operation The button can toggle the status between Normal operation and Standby Key Lock NOTE This is a tamper resistant feature The Key Lock is considered On or Off Key Lock is turned On after one minute without a key press by the user e Key Lock can then be turned Off for one minute by simultaneously pressing the Up Button and the Down Button for three seconds When the keys are locked the Temperature Set point ca
2. www hotwater com 15 COMBUSTION AIR AND VENTILATION A gas water heater cannot operate properly without the correct amount of air for combustion Do not install in a confined area such as a closet unless you provide air as shown in the Facts to Consider About Location section Never obstruct the flow of ventilation air If you have any doubts or questions at all call your gas supplier Failure to provide the proper amount of combustion air can result in a fire or explosion and cause death serious bodily injury or property damage A WARNING Install water heater in accordance with the instruction manual and NF PA54 or CAN CSA B149 1 To avoid injury combustion and ventilation air must be taken from outdoors Do not place chemical vapor emitting products near water heater Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual 12 MAX 30 5 cm 100 sq in 7 6 cm 645 sg cm AIR DUGT 12 MAX 30 5 cm FRONT VIEW OF DOOR FIGURE 10 If this water heater will be used in beauty shops barber shops cleaning establishments or self service laundries with dry cleaning equipment it is imperative that the water heater s be installed so that all air for combustion and ventilation is taken from outdoors Note Vent length should be long enough that the outside air will not freeze the water heater Propellants of aerosol sprays and volati
3. ADANGER e Burnhazard e Hot water discharge e Keep clear of relief valve discharge outlet TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE FIGURE 36 The temperature pressure relief valve lever must be operated at least once a year to ensure that the water ways are clear When checking the temperature pressure relief valve operation make sure that 1 No one is in front of or around the outlet of the temperature pressure relief valve discharge line 2 The water discharge will not cause any property damage as the water may be extremely hot 3 Adischarge line is connected to this valve directing the flow of hot water from the valve to a proper placement for disposal If water does not flow freely when the lever is in the open position replacement of the valve is required Turn off the cold water inlet heater and call a qualified service man If after manually operating the valve see Figure 36 it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions and replace the temperature pressure relief valve with a new one If the temperature pressure relief valve on the appliance weeps or discharges periodically this may be due to thermal expansion You may have a check valve installed in the water line or a water meter with a check valve Consult your local water supplier or a qualified service age
4. section CALIBRATION The water heater must be calibrated as follows before being put into service The Calibration Procedure examines and measures certain details of your installation and automatically sets some control parameters Before starting the Calibration Procedure the heater must be properly installed and connected to the water piping and the vent system Ensure all panels covers and doors are in place To avoid a possible end of call for heat and consequent interruption of the Calibration Procedure a continuous water draw from the heater is recommended during the calibration This procedure assumes that the heater is installed with DIP switch 4 in the calibration ON or down position see Figure 33a To calibrate the heater 1 Plug the power cord into a 120Vac 60Hz outlet 2 Press the Standby Button to turn on the heater and initiate the Calibration Procedure 3 The Calibration Procedure will last about 6 minutes Do not interrupt this procedure once it has started Aftera successful calibration the heater will go into standby mode During the calibration if the call for heat ends the calibration was not completed and the E36 error message will be shown on the display If this occurs unplug the power cord and repeat steps 1 and 2 To put the heater into service after a successful calibration 1 Unplug the power cord from the 120Vac 60Hz outlet 2 Open plastic front door of the heater an
5. National Fire Protection Association ASME American Society of Mechanical Engineers GAMA Gas Appliance Manufacturer s Association UL Underwriters Laboratories Inc This gas fired water heater is design certified by CSA International under American National Standard CSA Standard for Gas Water Heaters ANSI Z21 10 3 CSA 4 3 current edition PREPARING FOR THE INSTALLATION 1 Read the General Safety section of this manual first and then the entire manual carefully If you don t follow the safety rules the water heater will not operate properly It could cause DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE This manual contains instructions for the installation operation and maintenance of the gas fired water heater You must read and be aware of the warnings placed throughout the manual All warnings and all instructions are essential to the proper operation of the water heater and your safety Since we cannot put everything on the first few pages READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER The installation must conform with these instructions and the local code authority having jurisdiction In the absence of local codes the installation must comply with the current editions of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and the National Electrical Code NFPA 70 Documents are available from Canadian Standards Association 5060 Spectrum Way Mississauga Ontari
6. Strange Sounds Possible noises due to expansion and contraction of some metal parts during periods of heat up and cool down do not necessarily represent harmful or dangerous conditions Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal See CONDENSATE section OPERATIONAL CONDITIONS Smelly Water In each water heater there is installed at least one anode rod see parts section for corrosion protection of the tank Certain water conditions will cause a reaction between this rod and the water The most common complaint associated with the anode rod is one of a rotten egg smell in the hot water The smell is a result of four factors which must all be present for the odor to develop a Aconcentration of sulfate in the supply water b Little or no dissolved oxygen in the water c A sulfate reducing bacteria which has accumulated within the water heater this harmless bacteria is nontoxic to humans d Anexcess of active hydrogen in the tank This is caused by the corrosion protective action of the anode Smelly water may be eliminated or reduced in some water heater models by replacing the anode s with one of less active material and then chlorinating the water heater tank and all water lines Contact the local water heater supplier or a qualified service agency for further information concerning an Anode Replacement Kit and this c
7. Cut around the marked circle staying approximately 1 4 in 0 64cm outside of the line This will allow the vent to easily slide through the opening The resulting gap will be covered up by the Vent Terminal cover plate Repeat this step on inside wall if necessary www hotwater com 25 SEQUENCE OF INSTALLATIONS Cut a length of PVC pipe about 3 5 in 9cm longer than the wall thickness at the opening Glue the vent terminal to this section of pipe Slide the wall plate over the pipe to stop against the vent terminal Place a bead of caulking not supplied around the gap between the pipe and cover plate Apply enough to fill some of the gap between the pipe and wall Place some of the caulking on the back of the plate to hold it against the wall after installation If the vent pipe is installed up to the wall with a coupling on the end against the wall opening the pipe with the vent terminal can be prepared for gluing before inserting through the wall Slide the pipe through the wall and insert into the coupling on the other side of the wall making sure that the vent terminal ends up pointed in the correct position see Figure 23 WALL PLATE OPTIONAL MORTAR OR SILICONE CAULK PVC VENT TERMINAL WITH MESH PROTECTIVE SCREEN INSIDE FROM WATER HEATER 1 FOOT MIN OUTSIDE OF PVC COUPLING BUILDING WALL VENT TERMINATION FIGURE 23 INSTALLATION SEQUENCE For installations in the City of Los Angeles Calif
8. NMOUS m ST t m 19j 043u02 01W sw 29S ANAIX NOW ama vt J9UL10JSUEJ J9MOd Jamojg MO0 J 1832M ct 9AJeA 3M L l Aa Re awe asny ewsayl asny ewsoyL m YA E k E B E Om EEFT f ZW i ama f MOTISAT sosit Na TI AJLA 493 JeMo g poy asuas awej m 35 FIGURE 34 www hotwater com LIGHTING INSTRUCTIONS BEFORE LIGHTING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A This appliance does not have a pilot It is equipped with f you cannot reach your gas supplier call the fire an ignition device which automatically lights the burner department Do NOT try to light the burner by hand C Do not use this appliance if any part has been under B BEFORE OPERATING smell all around the appliance water Immediately contact a qualified installer or area for gas Be sure to smell next to the floor because service agency to replace a flooded water heater Do some gas is heavier than air and will settle on the floor not attempt to repair the unit It must be replaced 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 jaja SAVER MN N EK VACATION STOP Read the safety information above on 6 If the green light above the stand by button is flashing this label press the stand by button If the g
9. Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently A DANGER hazardous situation which if not avoided will result in injury or death WARNING indicates a potentially hazardous A situation which if not avoided could result WARNING in injury or death purum CAUTION indicates a potentially hazardous A situation which ifnotavoided could result CAUTION in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous CAU TI O N situation which if not avoided could result in property damage All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances listed IMPORTANT DEFINITIONS Qualified Installer or Service Agency Installation and service of this water heater requires ability equivalent to that of a Qualified Agency as defined
10. WATER HEATER l FURNACE WI NLET air DUCT ENDS 1 300 mm ABOVE FLOOR FIGURE 13 When ducts are used they should be of the same cross sectional area as the free area of the openings to which they connect The minimum short side dimension of rectangular air ducts should not be less than 3 in 7 6cm see Figure 14 Alternatively a single permanent opening may be used when communicating directly with the outdoors or with spaces that freely communicate with the outdoors The opening should have a minimum free area of 1 square inch per 3 000 BTU per hour 8 3 cm kW of total input rating of all equipment in enclosure see Figure 15 FIGURE 15 www hotwater com 17 6 Louvers and Grilles In calculating free area consideration should be given to the blocking effect of louvers grilles or screens protecting openings Screens used should not be smaller than 1 4 in 0 64cm mesh If the free area through a design of louver or grille is known it should be used in calculating the size opening required to provide the free area specified If the design and free area is not known it may be assumed that wood louvers will be 20 25 percent free area and metal louvers and grilles will have 60 75 percent free area Louvers and grilles should be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation 7 Spec
11. included with the heater usedin a water supply with less than 12 grains per gallon 200 mg L of hardness is not acidic or otherwise impure Problems resulting from scale formation are not covered by the warranty Any accident to the water heater or any part thereof including freezing fire floods or lightning any misuse abuse or alteration of it any operation of it in a modified form or any attempt to repair tank leaks or parts will void this warranty SERVICE AND LABOR RESPONSIBILITY UNDER THIS LIMITED WARRANTY THE WARRANTOR WILL PROVIDE ONLY A REPLACEMENT WATER HEATER OR PART THEREOF LABOR IS ALSO INCLUDED FOR 1 YEAR AFTER THAT PERIOD THE OWNER IS RESPONSIBLE FOR ALL OTHER COSTS Such costs may include but are not limited to a Labor charges for service removal or reinstallation of the water heater or part thereof b Shipping and delivery charges for forwarding the new water heater or replacement part from the nearest distributor and returning the claimed defective heater or part to such distributor except in the state of California where such charges are the manufacturer s responsibility C All cost necessary or incidental for handling and administrative charges and for any materials and or permits required for installation of the replacement heater or part LIMITATION ON IMPLIED WARRANTIES Implied warranties including any warranty of merchantability imposed on the sale of this heater under state law are limi
12. 3 ft 91cm of horizontal run All piping and fittings must be joined by the proper procedures as described under VENT PIPE PREPARATION INSTALLATION OF VERTICAL VENT SYSTEM A proper flashing or BOOT should be used to seal the pipe where it exits the roof The total vent system should not exceed the equivalent feet of pipe as listed in Table 1 Provide support for all pipe protruding through the roof All piping should be properly secured The vent system piping should be supported every 5 ft 1 5m of vertical run and every 3 ft 91cm of horizontal run All piping and fittings must be joined by the proper procedures as described under VENT PIPE PREPARATION www hotwater com 27 MIN 18 46cm ABOVE ROOF OR MIN 18 46cm ABOVE ANTICIPATED SNOW LEVEL MAXIMUM EQUIVALENT FEET SEE TABLE 1 ALL PIPE PROTRUDING THROUGHTH SHOULD BE PROPERLY SUPPORTED FIGURE 28 TERMINATION MAY BE 45 ELBOW ORA T ELBOW A ai A VENT USED IN A SPECIAL SCREEN VENTING SYSTEM WITH POSITIVE INSTALL VENT PRESSURE AND PASSING INTO THROUGH A ROOF SHALL ELBOW EXTEND AT LEAST 450mm 18 22 in ABOVE THE HIGHEST POINT WHERE IT PASSES THROUGH THE ROOF SURFACE AND ANY OTHER OBSTRUCTION WITHIN A HORIZONTAL DISTANCE OF 450mm 18 in A VERTICAL VENTING SYSTEM MUST BE SUPPORTED EVERY 1 5m 5 ft 3 in 7 6cm MIN LENGTH ROOF n po ad LINE RSS ouu SE Be L S FIGURE 29 IMPORTANT Th
13. 500 1 067 1 981 9007439005 6 501 8 500 1 981 2 591 9007440005 8 501 11 000 2 591 3 352 9007441005 Rated inputs are suitable up to 11 000 ft 3 352m elevation Consult the factory for installation at altitudes over 11 000 ft 3 352m WARNING THIS HIGH EFFICIENCY WATER HEATER IS CERTIFIED FOR USE AT AN ALTITUDE OF 11 000 Ft 3 352 METERS HOWEVER FOR USE AT ALTITUDES OVER 3 500 Ft 1 067m THE PCB MUST BE CHANGED Some gas utility companies derate their gas for altitude making it unnecessary to modify the water heater for high altitude installations Call the local gas or utility company to verify BTU content FLOODING FREEZING If this water heater has been exposed to flooding freezing fire or any unusual condition do not put it into operation until it has been inspected and approved by a qualified service technician These conditions can result in unseen internal damage and are not subject to warranty coverage FILLING THE WATER HEATER CAUTION Avoid water heater damage Filltank with water before operating Never use this water heater unless it is completely full of water To prevent damage to the tank the tank must be filled with water Open the nearest hot water faucet to allow air to escape Water must flow from the hot water faucet before turning ON gas to the water heater To fill the water heater with water 1 Close the water heater drain valve by turning the handle to
14. AND ONE WITHIN 12 in 30cm OF THE ENCLOSURE BOTTOM Each opening should have a free area of 1 square inch per 1000 Btu hr 22 cm kW of the total input of all appliances in the enclosure but not less than 100 square in 645 cm If the confined space is within a building air for combustion and ventilation must be obtained from outdoors When directly communicating with the outdoors or communicating through vertical ducts two permanent openings located in the above manner should be provided Each opening should have a free area of not less than 1 square inch per 4000 Btu hr 5 5 cm kW of total input of all appliances in the enclosure If horizontal ducts are used each opening should have a free area of not less than 1 square inch per 2000 Btu hr 11 cm kW of the total input of all appliances in the enclosure A ALLAIR FROM INSIDE BUILDINGS See Figures 10 amp 11 The confined space should 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 should be considered in making this determination Each opening should have a minimum free area of 1 square inch per 1 000 Btu per hour 22 cm KW of the total input rating of all gas utilization equipment in the confined space but not less than 100 square in 645
15. Failure to follow instructions and safety messages could result in death or serious injury Instruction manual must remain with water heater Never use this water heater unless it is completely filled with water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater A Condensation may be seen on pipes in humid weather or pipe connections may be leaking B Small amounts of water from temperature pressure relief valve may be due to thermal expansion or high water pressure in your area C The temperature pressure relief valve may be leaking at the tank fitting D Water from a drain valve may be due to the valve being slightly opened E The drain valve may be leaking at the tank fitting F Water in the water heater bottom or on the floor may be from condensation loose connections or the relief valve DO NOT replace the water heater until a full inspection of all possible water sources is made and necessary corrective steps taken G The hose from the tank to the heat engine may be leaking at the tank fitting H The fittings at the circulation pump may be leaking Leakage from other appliances water lines or ground seepage should also be checked To check where threaded portions enter the tank insert cotton swab between jacket opening and fitting If cotton is wet follow Draining The Tank section
16. G Cleanup and joint movement Remove all excess cement from around the pipe and fitting with a dry cotton rag This must be done while the cement is still soft The joint should not be disturbed immediately after the cementing procedure and sufficient time should be allowed for proper curing ofthe joint Exact drying time is difficult to predict because it depends on variables such as temperature humidity and cement integrity For more specific information you should contact your solvent cement manufacturer STEP G CONNECTION TO VENT PIPE The vent system connects to the vent pipe with and elbow or rubber coupling This coupling includes gear clamps These connections must be properly seated and tightened to prevent the leakage of flue gases into the installation area With 2 in venting the straight rubber adapter is used forthe connection to the vent pipe With 3 in venting a transition adapter is required to change from the 2 in vent pipe to the 3 in vent size Clean and lightly sand the end of the vent piping that will connect to the rubber coupling Loosen the upper clamp on the rubber adapter and insert the sanded end of the vent pipe and tighten the gear clamp NOTE Do not glue or seal in the rubber coupling Check the venting system to ensure that there is no stress on the connection or the vent pipe which will create a twisting or bending UPPER GEAR n FAN LOWER b O D GEAR CLAMP RUBBER COUPL
17. P valve HOT WATER ODORS refer to High sulfate or mineral content in Drain and flush heater thoroughly cathodic protection water supply then refill Bacteria in water supply Chlorinate water supply HOT WATER TOO HOT Thermostat set too high Refer to TEMPERATURE REGULATION section WATER HEATER SOUNDS Condensation dripping on burner Refer to CONDENSATE above SIZZLING RUMBLING NOISE Sediment at bottom of heater tank Clean sediment from tank Refer to DRAINING SOOTING Improper combustion Refer to Air Requirements BURNER WILL NOT STAY LIT High ambient room temperature Contact a qualified service agency to GOES OUT 4 5 SECONDS determine cause Defective Control board Replace Control board Damaged Flame Sensor Replace Flame Sensor Error code E35 VENT GAS ODORS Lack of air supply Shut off water heater immediately Improperly installed vent piping and contact a qualified service Downdraft agency to determine cause Poor Combustion THERE IS NO WATER AT ALL The unit display is flashing an error Check if there is any error code WHEN THE HOT WATER TAP IS code flashing on the remote controller OPENED TABLE 6 www hotwater com 51 Possible Cause s What to do WHEN THE TAP IS OPENED a The hot water fixture is not Check if there is any error code on THERE IS NO HOT WATER OR THE sufficiently open to draw the water the display HOT WATER TURNS COLD AND through the heater STAYS COLD b The unit display
18. SUPPORTED EVERY 4 ft 1 2m TO PREVENT VIBRATION USE Ol S YA ISOLATION PADS WHEN ATTACHING STRAPS TO FLOOR JOISTS WALLS OR CEILINGS TIITII Ng lieu E e TERMINATION x STRAP RODENT SCREEN INSTALL INTO Example for calculating equivalent feet ELBOW Section A 0 5 ft 0 15m 90 elbow 7 0 ft 2 13m minimum of 1 8 in 0 3cm SectionB 1 0 ft 0 31m rise per 4 ft 1 2m of vent 45 elbow 4 0 ft 1 21m piping Vent piping must slope up from heater to termination a GROUND LEVEL OR 24 Section C 1 5 ft 0 46m 45 elbow 4 0 ft 1 21m Section D 4 57m Total Equivalent 33 0 ft 10 04m MAXIMUM SNOW LINE DE Based on this example use the fully open rodent A A JA screen for vent length greater than 20 equivalent w N ft 6 1 equivalent metres FIGURE 21 If using 3 inch vent pipe Install the rubber reducing coupling 2 in to 3 in and gear clamps supplied at the end of the section of vent pipe installed on the heater Continue building the vent system or connect the existing vent system to the coupling The total system must not exceed the equivalent pipe lengths discussed above where each long radius elbow is equal to 5 ft 1 5m of 3 in diameter straight vent pipe The elbow and rodent Screen supplied in the vent kit must be used as the vent termination NOTE This unit can be vented with PVC pipe materials DW
19. VENT LENGTH LESS THAN OR VENT LENGTH GREATER THAN 20 EQUAL TO 20 EQUIVALENT FEET EQUIVALENT FEET 6 1m USE THIS 6 1m USE THIS SCREEN SCREEN FIGURE 20 The first step is to determine where the vent pipe will terminate see Figures 24 29 8 31 The vent may terminate through a sidewall as shown in Figure 24 or through the roof as shown in Figure 29 The vent system must terminate so that proper clearances are maintained as cited in local codes or the current edition of the National Fuel Gas Code ANSI Z223 1 12 9 1 through 12 9 4 Instructions on proper installation through a sidewall are provided in Figures 31 Plan the vent system layout so that proper clearances are maintained from plumbing and wiring Vent pipes serving power vented appliances are classified by building codes as vent connectors Required clearances from combustible materials must be provided in accordance with information in this manual under FACTS TO CONSIDER ABOUT LOCATION AND INSTALLING THE WATER HEATER and with the National Fuel Gas Code and local codes PLANNING THE VENT SYSTEM Plan the route of the vent system from the exhaust elbow to the planned location of the vent terminal 1 Layouttotal vent system to use a minimum of vent pipe and elbows 2 This water heater is capable of venting flue gases a maximum distance equivalent to 50 ft 15 2m of 2 in pipe or 100 ft 30 5m of 3 in pipe The use of elbows reduces the maximum d
20. at any time and Do not use or store 2 the spark will ignite flammable products such as flammable vapors gasoline solvents or adhe sives in the same room or Vapors area near the water heater 1 cannot be seen 2 are heavier than air Keep flammable products 3 go along way on the floor 4 1 far away from heater and 2 in approved containers can be carried from other 3 tightly closed and rooms to the the 4 out of children s reach electodes by air currents Installation Do not install the water heater where flammable products will be stored or used AWARNING Fire Hazard For continued protection against risk of fire Do not install water heater on carpeted floor Do not operate water heater if flood damaged This water heater must not be installed directly on carpeting Carpeting must be protected by metal or wood panel beneath the appliance extending beyond the full width and depth of the appliance by at least 3in 7 6cm in any direction or if the appliance is installed in an alcove or closet the entire floor must be covered by the panel Failure to heed this warning may result in a fire hazard A WARNING Fire or Explosion Hazard Read instruction manual before installing using or servicing water heater e Improper use may result in fire or explosion e Maintain required clearances to combustibles www hotwater com 13 When installing the heater consideration mu
21. by ANSI below in the field involved Installation skills such as plumbing air supply venting gas supply electrical supply are required in addition to electrical testing skills when performing service ANSI Z223 1 2006 Sec 3 3 83 Qualified Agency Any individual firm corporation or company that either in person or through a representative is engaged in and is responsible for a the installation testing or replacement of gas piping or b the connection installation testing repair or servicing of appliances and equipment that is experienced in such work that is familiar with all precautions required and that has complied with all the requirements of the authority having jurisdiction Gas Supplier The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances within this application The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the Natural Gas meter or Propane storage tank of a building www hotwater com 3 GENERAL SAFETY AWARNING AWARNING Read and understand instruction manual and safety messages For continued protection against before installing operating or risk of fire servicing this water heater e Do not install water heater on Failure to follow instructions and carpeted floor safety messages could result in An Do not operate water heater if death or serious injury flood da
22. cm One opening should commence within 12 in 30cm ofthe top and one commencing within 12 in 30cm of the bottom of the enclosures 16 www hotwater com FIGURE 11 B ALLAIR FROM OUTDOORS See Figures 12 13 and 14 The confined space should be provided with two permanent openings one commencing within 12 in 30cm ofthe top and one commencing within 12 in 30cm from the bottom of the enclosure The openings should communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors 1 When directly communicating with the outdoors each opening should have a minimum free area of 1 square inch per 4 000 Btu per hour 5 5 cm kW of total input rating of all equipment in the enclosure see Figure 12 VENTILATION LOUVERS SJ OUTLET AIR WATER HEATER LiL FURNACE ALT INLET INLET AIR DUCT AIR VENTILATION LOUVERS FIGURE 12 2 When communicating with the outdoors through vertical ducts each opening should have a minimum free area of 1 square inch per 4 000 Btu per hour 5 5 cm kW of total input rating of all equipment in the enclosure see Figure 13 3 When communicating with the outdoors through horizontal ducts each opening should have a minimum free area of 1 square inch per 2 000 Btu per hour 11 cm kW of total input rating of all equipment in the enclosure see Figure 14 VENTILATION LOUVERS EACH END OF ATTIC AIR OUTLET
23. foreign material in the gas supply line a drip leg sometimes called www hotwater com 21 a sediment trap must be incorporated in the piping The drip leg must be readily accessible Install in accordance with the Gas Piping section Refer to the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 GAS LINE PURGING Air may be present in the gas lines and could prevent the burner from lighting on initial start up The gas lines should be purged of air by a qualified service technician after installation of the gas piping system HIGH ALTITUDE INSTALLATIONS A WARNING Special consideration must be taken with installations above 11 000 3 352m Please contact an AO Smith qualified Service agent to obtain proper setup and instructions before lighting Failure to implement the proper setup will result in improper and inefficient operation of the appliance resulting in production of increased levels of carbon monoxide gas in excess of the safe limits which could result in serious personal injury or death Always read and understand instruction manual The heater is set at the factory to operate at altitudes from sea level to 3 500 ft 1 067 m Accessory kits are available to allow the heater to operate at altitudes higher than 3 500 ft 1 067m These accessory kits are listed in the table below Instructions for installing these accessories are included in the kits Alitude f m 3 501 6
24. instructions in the Maintenance section and then remove fitting Put pipe dope or teflon tape on the threads and replace Then follow the instructions in Filling the Water Heater section www hotwater com 53 PARTS IDENTIFICATION ITEM DESCRIPTION Baffle Flue B Hot Water Outlet Nipple w Anode Heat Trap Cold Water Inlet Nipple w Dip Tube Heat Trap Hose 12 Braided Heat Engine Cold In Tank Thermistor Probe Front Door Lock Hook Cam Air Inlet Cover Direct Vent Air Inlet Cover Gasket Direct Vent PCB Circuit Board Assembly w Base Water Inlet Fitting Flange Inlet Water Filter Return Fitting Flange Barbed Fitting Heat Exchanger 54 www hotwater com sz y nim co NC S A A l SK CC Wc www hotwater com REPLACEMENT PARTS Drain valve T amp P relief valve Anode MG NIP HT Anode AL NIP HT Circulation pump assembly Inlet outlet thermistor Temp sensor 12 Hose braided Tank thermistor NIP DIP TBO HT Hi limit 85 ECO Diptube J 3 4 return Transformer Hi limit Fuse Switch High Temp 56 www hotwater com LIMITED RESIDENTIAL GAS WARRANTY THIS WARRANTY IS APPLICABLE TO THE ORIGINAL OWNER ONLY If the glass lined tank in this water heater shall prove upon examination by the warrantor to have leaked during the warranty period in normal residential use due to natural corrosion from potable water therein the warrantor will furnis
25. is not covered by the unit s warranty Disconnect electrical power to the water heater Close the shutoff valves on both the hot water and cold water lines Drain the tank using the instructions in the Draining The Tank section Disconnect the hoses joining the tank and the heat engine upper hose is water outlet and lower hose is water inlet Connect addition length of hose not provided to existing hoses Note The heat engine hose is a 3 4 NPT thread which is different for a garden hose thread 5 gallon pail of virgin food grade white vinegar or virgin food grade citric acid Hot Water Line Cold Water FIGURE 39 Connect a pump to the hose running to the heat engine water inlet lower fitting We recommend a submersible utility pump for the circulating pump Note If a submersible pump is not used connect a hose from the circulating pump to the cleaning solution Pourapproximately 4 gallons 15 litres of virgin food grade white vinegar or citric acid into a 5 gallon or greater pail Place the intake and output hoses into the pail of cleaning solution If a submersible utility pump is used place the pump into the pail of cleaning solution Plugin the circulating pump Connect the electrical power to the water heater and run the heat engine Operate the heat engine to circulate the cleaning solution through the system for at least 45 minutes Note L
26. is set to the last temperature The default setting is 105 F 41 C in the Energy Saver Mode Outlet Temperature Limit Control Your water heater is designed to provide a constant outlet water temperature The water heater takes into account dynamic conditions of the heat engine such as the inlet water temperature flow rate gas flow adjustment etc and establishes the optimum performance The control will end the call for heat if the outlet thermistor temperature exceeds the set point by a fixed amount The call for heat may be restored if the outlet thermistor temperature drops below the set point by 5 4 F 3 C or more Inlet Temperature Limit Control To add protection to the system an over temperature comparison is made on the inlet water temperature The water heater will end the call for heat if the inlet thermistor temperature is above the set point The call for heat may be restored if the inlet thermistor temperature drops below the set point www hotwater com 41 CONSTANT OUTPUT TEMPERATURE CONTROL While the temperature regulation in the previous section describes the features of temperature monitoring and regulation your water heater goes beyond the on off control implied there and implements a gas air and water flow modulation scheme to provide a constant water delivery temperature from the heat engine for the duration of the call for heat Heat Needed during Normal Operation The amount of heat needed is based
27. should be used at the hot water taps used by these people or at the water heater Mixing valves are available at plumbing supply or hardware stores see Figure 3 Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat read the Temperature Regulation section in this manual Never allow small children to use a hot water tap or to draw their own bath water Never leave a child or handicapped person unattended in a bathtub or shower The water heater should be located in an area where the general public does not have access If a suitable area is not available a cover should be installed over the thermostat to prevent tampering The water temperature setting was factory set at the lowest temperature THIS WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE THERMOSTAT TO CONTROL WATER TEMPERATURE HOT WATER TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHER AND LAUNDRY USE CAN CAUSE SCALD BURNS RESULTING IN SERIOUS PERSONAL INJURY AND OR DEATH THE TEMPERATURE AT WHICH INJURY OCCURS VARIES WITH THE PERSON S AGE AND THE TIME OF THE EXPOSURE THE SLOWER RESPONSE TIME OF CHILDREN AGED OR DISABLED PERSONS INCREASES THE HAZARDS TO THEM NEVERALLOW SMALL CHILDREN TO USE A HOT WATER TAP OR TO DRAW THEIR OWN BATH WATER NEVER LEAVE A CHILD OR DISABLED PERSON UNATTENDED INA BATHTUB OR SHOWER THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE THE GENERAL PUBLIC DOES NOT HAV
28. size than the outlet pipe size of the valve or have any reducing couplings or other restrictions Shall not be plugged or blocked Shall be of material listed for hot water distribution Shall be installed so as to allow complete drainage of both the temperature pressure relief valve and the discharge pipe Shall terminate a maximum of 6 in 15cm above a floor drain or external to the building In cold climates it is recommended that the discharge line be terminated at an adequate drain inside the building Shall not have any valve between the relief valve and tank ADANGER Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting The temperature pressure relief valve must be manually operated at least once a year see Figure 17 Caution should be taken to ensure that 1 no one is in front of or around the outlet of the temperature pressure relief valve discharge line and 2 the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE FIGURE 17 If after manually operating the valve
29. the harmful effects of thermal expansion Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank CAUTION Avoid water heater damage Install thermal expansion tank if necessary Do not apply heat to water fittings Contact qualified installer or service agency NOTE If using copper tubing solder tubing to an adapter before attaching the adapter to the water heater connections Do not solder the water lines directly to the water heater connections It will harm the dip tube and damage the tank SHUT OFF VALVE Tq Yi COLD WATER TEMPERED INLET POTABLE WATER MIXING VALVE OPTIONAL PIPE INSULATION RECOMMENDED FIGURE 16 NOTE To protect against untimely corrosion of hot and cold water fittings it is strongly recommended that di electric unions or couplings be installed on this water heater when connected to copper pipe see Figure 3 also Figures 3 and 16 show the typical attachment of the water piping to the water heater The water heater is equipped with 3 4 NPT water connections HARD WATER We highly recommend installing water filtering system or a water softener before the water heater system If you are installing a water filtering system use a 5 micron filter to reduce particles that can potentially cause nuisance shutdown problems and prolong the maintenance of the water heater s inlet filter A water softener can affec
30. the right clockwise The drain valve is on the lower front of the water heater 2 Openthecold water supply valve to the water heater tank NOTE The cold water supply valve must be left open when the water heater is in use 3 To insure complete filling of the tank allow air to exit by opening the nearest hot water faucet Allow water to run until a constant flow is obtained This will let air out of the water heater and the piping 4 Check all water piping and connections for leaks Repair as needed VENTING A WARNING all vent system in accordance with codes not operate water heater if flood damaged all water heater in accordance with the instruction manual not operate if soot buildup not obstruct water heater air intake with insulating et not place chemical vapor emitting products near er heater Gas and carbon monoxide detectors are available Never operate the heater unless it is vented to the outdoors and has adequate air supply to avoid risks of improper operation fire explosion or asphyxiation Analyze the entire vent system to make sure that condensate will not become trapped in a section of vent pipe and therefore reduce the open cross sectional area of the vent Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual 22 www hotwater com VENT PIPE TERMINATION 90 SHORT SWEEP ELBOW MORE RESTRICTIVE
31. this type of cutter is used the flare on the end must be completely removed NOTE Power saws should be specifically designed to cut plastic pipe B Deburring Use a knife plastic pipe deburring tool or file to remove burrs from the end of small diameter pipe Be sure to remove all burrs from around the inside as well as the outside of the pipe A slight chamfer bevel of about 10 15 should be added to the end to permit easier insertion of the pipe into the end of the fitting Failure to chamfer the edge of the pipe may remove cement from the fitting socket causing the joint to leak 3 32 2 5MM PI STEP B C Test dry fit of the joint Tapered fitting sockets are designed so that an interfaced fit should occur when the pipe is inserted about 1 3 to 2 3 of the way into the socket Occasionally when pipe fitting dimensions are at the tolerance extremes it will be possible to fully insert dry pipe to the bottom of the fitting socket When this happens a sufficient quantity of cement must be applied to the joint to fill the gap between the pipe and fitting The gap must be filled to obtain a strong leak free joint www hotwater com 29 30 D Inspection cleaning priming Visually inspect the inside of the pipe and fitting sockets and remove all dirt grease or moisture with a clean dry rag If wiping fails to clean the surfaces a chemical cleaner must be used Check for possible damage such as splits or c
32. this manual have been met Carefully inspect the entire venting system for any signs of cracks or fractures particularly at joints between elbows and other fittings and straight runs of vent pipe Check system for signs of sagging or other stresses in joints as a result of misalignment of any components in the system If any of these conditions are found they must be corrected in accordance with the venting instructions in this manual before completing installation and putting the water heater into service NOTE A For water heaters in locations with high ambient temperatures above 100 F 38 C it is recommended that CPVC or ABS pipe and fittings be used B A 22 5 degree elbow 2 in vent pipe or a 45 degree elbow 3 in vent pipe with an installed screen VENT TERMINAL must be used in all cases There will be some installations where condensate will be formed in the horizontal runs of the vent system This condensate will run into the condensate trap The water heater is shipped with a condensate tube that attaches to the condensate trap No other tee or fitting is required www hotwater com CONDENSATE This water heateris a condensing unit and requires a drain to be located in close proximity to allow the condensate to drain safely The condensate drains from the unit at the exhaust tee located at the bottom of the unit see Figure 22 Condensate from this water heater is mildly acidic Please note that some local c
33. Btu hr input rate as shown on the water heater s rating plate For safe operation of the water heater the relief valve must not be removed from its designated opening nor plugged www hotwater com 19 The temperature pressure relief valve must be installed directly into the fitting of the water heater designed for the relief valve Must terminate a maximum of 6 in 15cm above a floor drain or external to the building In cold climates it is recommended that the discharge pipe be terminated at an adequate drain inside the building Be certain that no contact is made with any live electrical part The discharge opening must not be blocked or reduced in size under any circumstances Excessive length over 30 ft 9 14m or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve see Figures 3 amp 19 No valve or other obstruction is to be placed between the relief valve and the tank Do not connect tubing directly to discharge drain unless a 6 in 15cm air gap is provided To prevent bodily injury hazard to life or property damage the relief valve must be allowed to discharge water in quantities should circumstances demand If the discharge pipe is not connected to a drain or other suitable means the water flow may cause property damage CAUTION Temperature pressure relief valve discharge pipe must terminate at adequate drain The Discharge Pipe Shall not be smaller in
34. E ACCESS TO SET TEMPERATURES 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 water temperature is controlled using the Temperature Control on the Display at the front of the unit see Figure 3 This control utilizes a temperature probe to determine the tank temperature The primary temperature probe is located at the top of the tank The temperature may be adjusted from 90 F 32 C to 158 F 70 C The thermostat was adjusted to 105 F 43 C before the heater was shipped from the factory It is recommended 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 your hot water needs This will also provide the most energy efficient operation of the water heater and minimize scale formation Valves for reducing the point of use temperature by mixing cold and hot water are available see Figure 2 Also available are inexpensive devices that attach to faucets to limit hot water temperatures Contact a licensed plumber or the local plumbing authority The table below shows the approximate time to burn relationship for normal adult skin Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the thermostat setting by up to 20 F 11 C If you expe
35. ENCE WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED PRINTED IN U S A 0610 316888 000 Rev 00 TABLE OF CONTENTS SAFE INSTALLATION USE AND SERVICE 3 GENERAL SAFETY 4 INTRODUCTION 6 Get To Know Your Water Heater Gas Models 8 Replacement Parts And Deliming Products 8 INSTALLATION CONSIDERATIONS 9 Rough In Dimensions 9 Water Piping Mixing Valve Usage 11 Facts To Consider About Location 12 Handle Installation 13 Earthquake Zones 14 Combustion AirAnd Ventilation 16 Appliances In Unconfined Spaces 16 Appliances In Confined Spaces 16 Chemical Vapor Corrosion 18 Water Piping IAA NIA wa 18 Closed Water Systems 18 Thermal Erkpansion 18 Hard Water cese b eed eee att e eby 19 Temperature pressure Relief Valve 19 Gas PIPINGs 2 hacia oh eM eye vekse Rb kata as 21 Sediment Traps 21 Gas Line Purging 2000 e eee eee 22 High Altitude Installations 22 Flooding freezing 22 Filling The Water Heater 22 Venting co gi ome ened AE AW eL bee es 22 Vent Pipe Termination o 23 Planning The Vent System 23 Condensate 25 In
36. GURE 25 INSTALLATION OF VENT SYSTEM SIDEWALL With the route of the venting system and selection of materials completed as discussed in the section of this manual titled Planning The Vent System the through the wall vent terminal in place and the first section of piping up to first elbow installed at the rubber coupling it is time to complete the installation of the venting system for the sidewall installation MAXIMUM EQUIVALENT FEET SEE TABLE 1 VENT TERMINAL L ji MIN 12 30cm ABOVE GRADE ANTICIPATED SNOW LEVEL FIGURE 26 ATTACH 45 TERMINATION ELBOW RODENT EQUIVALENT SCREEN VENT LENGTH INSTALL WADI MEASURED INTO Ue FROM THIS ELBOW Pa POSITION 12 in NEN 30 cm min RISER C L HM GROUND W VENT LEVEL PIPING TO BE SLOPED DOWN TOWARD HEATER TO WHERE SNOW COVER IS NORMAL DURING WINTER PREVENT ENSURE SUFFICIENT VENT CLEARANCE TO PREVENT WATER FROM BLOCKAGE OR ICE BUILDUP COLLECTING FIGURE 27 Before completing the installation of the venting system be sure to read the sections of this manual discussing the proper method of cutting and cementing PVC pipe and fittings in the Vent Pipe Preparation section It is recommended that the completion of the venting system start at the rubber coupling and run to the coupling on the inside wall of the vent terminal see Figure 23 The vent system piping should be supported every 5 ft 1 5m of vertical run and every
37. ING RUBBER ADAPTER 2 in to ADAPTER 2 3 FIGURE 30 U S POWER VENT www hotwater com A WARNING VENT HOOD S MAY BE EXTREMELY HOT DURING OPERATION Minimum 18 in 45 72 cm Minimum 3 ft 91 cm within a height of 15 ft 4 6 m above 12 in 30 cm meter regulator assembly ee above grade or RU 2 expected snow fall 12 in 30 cm to side or Minimum 3 ft 91cm clearance from soffit 12 in 30 cm to service regulator vent outlet above door Minimum Minimum Minimum 12 in 30 cm 7 fi 23 m 1 E ft 61 em under veranda porch above rom outside deck or balcony public Sidewalk corner see footnote 1 or pave driveway Minimum 3 ft 91 cm above a mechanical air supply inlet within 10 ft 3 m horizontally see footnote 2 Minimum WC ki 12 in 30 cm Minimum 4 ft 1 2 m from sides of from side of window S Minimum 4 ft 1 2 m below or side of 12 in 30 cm above non mechanical permanently that may be open Minimum 4 i 1 2im Minimum 4 Te 1 4 m air supply inietingo rape or closed window elow a window tha rom side of window appliance or Minimum 9 in 23 cm mum gin 30m ove Say be open thtmay bs open naneo M OR nto _to 50 000 btuh 15 Kw inputs and 12 V VENT TERMINAL X AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED in 30 cm for appliances greater than 50 000 btuh 15 Kw to an air supply inlet to a direct vent a
38. Installation and Operating Manual e Smith www hotwater com CSA 4 3b 2008 ANSI Z21 10 3b 2008 EFFICIENCY RATING CERTIFIED ama WARNING If the information in these instructions is 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 DOIF YOU SMELL GAS e Donottry to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e f 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 HYBRID GAS WATER HEATERS POWER VENT GAS MODELS AWARNING Read and understand instruction manual and safety messages before installing operating or servicing this water heater Failure to follow instructions and safety messages could result in death or serious injury Instruction manual must remain with water heater e For Your Safety AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFER
39. N REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS For all side wall terminated horizontally vented power vent gas fueled water heaters installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the sidewall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery ba
40. NOTE Barbed fitting not required if hard piping is used to drain condensate VENTING ELBOW BARBED FITTING CONDENSATE TRAP DRAIN PAN ROUTE TO SUITABLE DRAIN FIGURE 22 INSTALLATION OF VENT SYSTEM Before beginning installation of piping system thoroughly read the Vent Pipe Preparation section of this manual If you are installing your system so that it vents through roof please refer to the section titled Installation Of Vertical Vent System Ensure the vent length is long enough that the outside air will not cause the water heater to freeze VENT TERMINAL INSTALLATION SIDEWALL 1 Install the vent terminal by using the cover plate as a template to mark the hole for the vent pipe to pass through the wall BEWARE OF CONCEALED WIRING AND PIPING INSIDE THE WALL 2 If the Vent Terminal is being installed on the outside of a finished wall it may be easier to mark both the inside and outside wall Align the holes by drilling a hole through the center of the template from the inside through to the outside The template can now be positioned on the outside wall using the drilled hole as a centering point for the template 3 A MASONRY SIDE WALLS Chisel an opening approximately 1 2 in 1 3cm larger than the marked circle B WOODEN SIDE WALLS Drill a pilot hole approximately 1 4 in 0 64cm outside of the marked circle This pilot hole is used as a starting point for a saws all or sabre saw blade
41. TALLATION CONSIDERATIONS ROUGH IN DIMENSIONS Left Side View FIGURE 2 Capacity Gas and Electrical Characteristics Approx Capacity Capacity Input Gas Supply Pressure Manifold Pressure Electrical Characteristics Type en S Gals pue BTU hr Max Min in WC kPa Volts Hz Amperes in WC kPa in WC kPa HYB 90N E 000 14 0 3 49 5 0 1 25 4 2 1 05 120 60 Minimum gas supply pressure must be maintained under both load and no load dynamic and static conditions Manifold Pressure is preset on the gas valve by the manufacturer DO NOT ATTEMPT TO ADJUST Thermal efficiency is 90 If the hardness of your water supply is more than of 12 grains per gallon 200 mg L if your water supply is acidic or otherwise impure the water supply must be treated with approved methods in order to ensure full warranty coverage Problems resulting from the forma tion of scale are not covered by the warranty o o o o o 0 remrem w This appliance must be installed in accordance with local codes or in the absence of local codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the Natural Gas and Propane Installation Code CAN CSAB149 1 Not for installation in a Manufactured Home Mobile Home This water heater is suitable for water potable heating only This water heater is suitable for installation in a closet or alcove www hotwater com 9 10 INSTALLATIO
42. TION 6 Burner Fault FIGURE 35 It is recommended that lower water temperatures be used to avoid the risk of scalding It is further recommended in all cases that the water temperatures be set for the lowest temperature which satisfies your hot water needs This will also provide the most energy efficient operation of the water heater ADANGER Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting HOT WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes washing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water from this heater fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve
43. V ASTM D2665 Schedule 40 80 120 ASTM D1785 or SDR Series ASTM D2241 CPVC pipe materials CPVC41 ASTM D2846 Schedule 40 80 ASTM F441 or SDR Series ASTM F442 ABS pipe materials Schedule 40 DWV ASTM D2661 The fittings other than the TERMINATION should be equivalent to PVC DWV fittings meeting ASTM D 2665 Use CPVC fittings ASTM F 438 for CPVC pipe and ABS fittings ASTM D 2661 3311 for ABS pipe If CPVC or ABS pipe and fittings are used then proper cement must be used for all joints including joining the pipe to Termination PVC Material If local codes do not allow the use of the PVC termination when a material other than PVC is used for venting then an equivalent fitting of that material may be substituted if the screen in the PVC terminal is removed and inserted into the new fitting This water heater is supplied with a 45 degree termination elbow that is a special fitting that must be used with the appliance PVC Materials should use ASTM D 2564 Grade Cement CPVC Materials should use ASTM F 493 Grade Cement and ABS Materials should use ASTM D 2235 Grade Cement If the water heater is being installed as a replacement for an existing power vented heater in pre existing venting a thorough inspection of existing venting System must be performed prior to any installation work Verify that correct material as detailed above has been used and that the minimum or maximum vent lengths and terminal location as detailed in
44. VC pipe about 3 5 in 9cm longer than the wall thickness at the opening Glue the intake vent terminal to the section of the pipe Slide the wall plate over pipe to stop against intake vent terminal Place a bead of caulking not supplied around the gap between the pipe and the wall Place some of the caulking on the back of the plate to hold it against the wall after installation If the vent pipe is installed up to the wall with a coupling on the end against the wall opening the pipe with the vent terminal can be prepared for gluing before inserting through the wall Slide the pipe through the wall and insert into coupling on the other side of the wall making sure that the vent terminal ends up pointed in the correct position see Figure 24 MORTAR OR METAL PLATES SILICONE 2 CAULK PVC VENT TERMINAL WITH MESH PROTECTIVE SCREEN INSIDE EXHAUST VENT TERMINAL g FROM EATER OUTSIDE HEATER PVC BUILDING COUPLING WALL EXHAUST VENT TERMINAL ALL MODELS FIGURE 24 26 www hotwater com Gin 15 cm MIN LENGTH ATTACH 45 TERMINATION ELBOW M a zh pr d SEALANT AI VENT PIPING TO BE 74 H SLOPED DOWN ee jel TOWARD HEATER a 21 TO PREVENT WATER FROM COLLECTING INTO er ELBOW SEALANT INSTALL 12 in 30 cm min GROUND LEVEL WHERE SNOW COVER IS NORMAL DURING WINTER ENSURE SUFFICIENT VENT CLEARANCE TO PREVENT BLOCKAGE OR ICE BUILDUP FI
45. Vacation Initial conditions after starting up the control is determined by evaluation of the stored set point Vacation Mode is selected if the Temperature Set point value is less than 100 F 38 C Boost Mode is selected if the Temperature Set point value is greater than or equal to 140 F 60 C Energy Saver Mode is selected for all other Temperature set point values Three LED s are used to indicate the Operating Mode Selection Vacation Mode Yellow LED Energy Saver Mode Green LED Boost Mode Orange LED The Operating Modes have the following characteristics Vacation mode Fixed temperature setting of 90 F 32 C Energy Saver mode Temperature range from 100 F to 135 F 38 C to 57 C in increments of 1 F or 1 C Boost mode Temperature range from 140 F to 158 F 60 C to 70 C in increments of 1 F or 1 C Switching between operation modes is done by pressing the Mode Button when the Key Lock is Off When a mode is active the corresponding LED is turned on Pressing the Mode button will cycle between the three possible modes of operation Each time the Mode Button is changed by the user the controller display is to respond with the following actions 1 The Temperature Set point changes to the lowest temperature for the respective mode e g 100 F 38 C for Energy Saver and 140 F 60 C for Boost mode and is communicated to the master device 2 The LED corresponding to the
46. a visual inspection should be made of the main burner and spark generator assembly for proper flame characteristics and ignition sequences You should also check for sooting Soot is not normal and will impair proper combustion Soot build up indicates a problem that requires correction before further use Turn OFF gas to water heater and leave off until repairs are made because failure to correct the cause of the sooting can result in a fire causing death serious injury or property damage A DANGER Do not obstruct combustion air openings at the bottom of the water heater Do not use or store flammable vapor products such as gasoline solvents or adhesives in the same room or area near water heater or other appliance Can cause serious injury or death INSTALLED IN SUITABLE AREA To insure sufficient ventilation and combustion air supply proper clearances from the water heater must be maintained See Facts to Consider About Location section Combustible materials such as clothing cleaning materials or flammable liquids etc must not be placed against or adjacent to the water heater which can cause a fire ANODE ROD INSPECTION CAUTION Avoid water heater damage nspectionand replacement ofanode rod required The anode rod is used to protect the tank from corrosion Most hot water tanks are equipped with an anode rod The submerged rod sacrifices itself to protect the tank Instead
47. as control valve is subjected to pressures exceeding 1 2 psi 3 5 kPa the damage to the gas control valve could result in a fire or explosion from leaking gas If the main gas line shut off serving all gas appliances is used also turn off the gas at each appliance Leave all gas appliances shut off until the water heater installation is complete Agas line of sufficient size must be run to the water heater Consult the current edition of National Fuel Gas Code ANSI Z223 1 NFPA 54 and your gas supplier concerning pipe size There must be Areadily accessible manual shut off valve in the gas supply line serving the water heater and Adrip leg sediment trap ahead of the gas control valve to help prevent dirt and foreign materials from entering the gas control valve Aflexible gas connector or a ground joint union between the shut off valve and control valve to permit servicing of the unit The appliance and its gas connections must be leak tested before placing the appliance in operation Use a leak test solution not a match or open flame NOTE An alternate location for the gas line entry is possible Drill a suitable hole centered on the crosshairs on the left side panel AWARNING e Use joint compound or tape compatible with propane Leak test before operating heater Disconnect gas piping and shut off valve before pressure testing system Use pipe joint compound or Teflon tape
48. ater s igniter or main burner The resulting flashback and fire can cause death or serious burns to anyone in the area Also the water heater must be located and or protected so it is not subject to physical damage by a moving vehicle 12 www hotwater com A WARNING Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Avoid all ignition sources if you smell gas Do not expose water heater control to excessive gas pressure Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use A Read instruction manual before installing using or servicing water heater HANDLE INSTALLATION For ease of handling and carrying plugs are provided in the side of the shroud that can be removed and pipe handles inserted see Figure 4 Remove plastic plugs from shroud side panels Screw a short length of 3 4 NPT pipe into the sides of the water heater Use the handles to move the water heater to the desired location Remove the handles Reinstall the plastic plugs in the shroud side panels Handle FIGURE 4 ADANGER FLAMMBLEp Flammable Vapors 4Avapors from flammable Water heater has a main liquids may explode and burner and spark generator catch fire causing death or The spark generator severe burns 1 can be triggered
49. aw or Pipe Cutter Deburring Tool Knife File or Beveling Machine 2 in and above Brush Pure Bristle Rag Cotton Not Synthetic Primer and Cleaner Solvent Cement PVC for PVC Components and CPVC for CPVC Components Containers Metal or Glass to hold Primer and Cement Select the type of PVC or CPVC materials to be used on the basis of their application with respect to chemical resistance pressure rating temperature characteristics etc Insertion Tool Helpful for larger diameter pipe and fittings 6 in 15cm and above 28 www hotwater com A WARNING Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Avoid all ignition sources if you smell gas Do not expose water heater control to excessive gas pressure Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use A Read instruction manual before installing using or servicing water heater PRIMER It is recommended that Tetrahydrofuran THF be used to prepare the surfaces of pipe and fittings for solvent welding Do not use water rags gasoline or any other substitutes for cleaning PVC or CPVC surfaces A chemical cleaner such as MEK may be used CEMENT The cement should be a bodied cement of approximately 500 to 1600 centipoise visco
50. be a continuous lockout Blocked Exhaust Gas Outlet Detection If the exhaust air passage is obstructed the control is to enter a fault state and initiate a controlled shut down This is an overall safety feature of the control system Igniter The control has an integrated direct spark ignition which can turn on by means ofarelay This feature is integrated onto the controller board By default the control will allow for three ignition retries after a failed ignition Flame Sensor An active flame is sensed through a flame rod located in the burner assembly in the region of the burners flame The flame sense input will be monitored by the control and respond to the presence of the flame Combustion Chamber Temperature Protection Thermal Fuse If in any conditions when the temperature increases over 287 6 F 142 C the High Limit Temperature Fuse melts This function disconnects the power supply controller and must be replaced 40 www hotwater com Line Voltage Monitor The control monitors the line voltage provided to the system If the line voltage is too low the system components may not operate properly For diagnostic purposes the display panel should indicate that the cause was power related If line power is below 102Vac the water heater will enter the fault state and initiate a controlled shut down The fault will automatically clear if the voltage is restored to 102Vac or above If line power is ab
51. ck up may be installed on the next adjacent floor level In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and CSA certified SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 EXEMPTIONS The following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the
52. code of HO1 and the value of 105 is the inlet water temperature measurement The display will continue to show the diagnostic code and the measurement value unless the up or down arrows are pressed to switch to the next item see Table 4 If no buttons are pressed for 30 seconds the unit will revert back to operation mode where the set point temperature is displayed Diagnostic Code H01 H02 H03 H05 H06 H07 H08 H09 H10 Description Inlet Water Temperature Storage tank temperature flow rate Heat Engine Rated Output Current Error Code See Fault Code Table Error Code History From the Most Recent to the Least Recent See Fault Code Table Software Release Number CWHCB H12 H20 Configuration File Number H22 Software Release H22 xxx xxx Number UIM Heat engine outlet water temperature Heat engine water Total Heating H08 xxx xxx hours 001 234 1234 hours Time 51 41 days Ed Total Cycles heating cycles 000 459 Code and Measurement Display Displayed characters Example of Units Example of Format Se HO1 xxx C or F 041 or 105 41 C or 105 F C LED or F LED turned ON 041 or 105 41 C or 105 F C LED or F LED turned ON litres minute 056 5 6 litres minute 1 litre 0 264 Gallons 1 gallon 3 78 litres rom 006_511 6511 rpm rom rotations per minute mA 001 456 1456 mA mA milliampers 1 456A C LED or F LED turne
53. d ON 1 48 Gallons minute 459 heating cycles Hxx XXX TABLE 4 Proper operation No error 78 002 025 002 009 Software release For the display number 2 09 board 000 006 Configuration file number 6 The most recent error corresponds to H12 and the least recent to H20 For the main controller board Ignition failure Software release number 2 25 H23 xxx XXX www hotwater com 47 Ifan error code is displayed or odd behavior of the unit occurs the first corrective action should be to Cycle the Power Unplug the 120Vac power cord and after 5 seconds plug it in again If this doesn t clear the fault proceed with the Remedy in the following table Table 5 Ifwire harness checking is required examine the integrity of wires themselves the connector housings the integrity of the terminals as well as condition of the crimps Fault Code Displayed E01 E02 E07 E08 E09 13 14 Description Invalid Rated KBtu Model Type Main Valve Relay Out Of Sequence Flame Detected ECO switch is open High temperature 120Vac too high 120Vac gt Overvoltage Limit 120Vac too low 48 Blower Current abnormal Vent Switch Open Control detects that the configuration selected is not defined or the configuration has never been set Control detects that a relay used to enable the Main Valve has failed in either the open or closed position Flame detected whe
54. d remove the cover ofthe heat engine The DIP switches are located on the PCB which is mounted on the right hand side of the heat engine 3 Set DIP switch 4 in the normal OFF or up position see Figure 33a 4 Reinstall the front cover ofthe heat engine close and latch the front door of the heater 5 Plug the power cord into the 120Vac 60Hz outlet 6 Press the Standby Button to turn on the heater and start the unit 3123456 ti DIP ve DIP Switch 4 in DIP Switch 4 in normal mode calibration mode OFF up ON down FIGURE 33a The E36 calibration error occurs in the following situations e Calibration switch DIP switch 4 is in the calibrate ON or down position and an end call for heat occurs before the Calibration Procedure is finished e Calibration switch DIP switch 4 is in the calibrate ON or down position there is no call for heat within 6 minutes of turning on the power e Calibration switch DIP switch 4 is in the calibrate ON or down position and the unit is calibrated but the DIP switch is not set to the normal OFF or up within 6 minutes after the Calibration Procedure is finished Calibration switch DIP switch 4 is in the normal OFF or up position and the unit is not calibrated and 1 minute or more passes after turning on the power If an E36 error message is displayed 1 Unplug the power cord from 120Vac 60Hz outlet
55. dication of whether there is sufficient flow through the heat exchanger for normal heating 3 If the water is less than 0 58 gal min 2 2 l min the unit stops and will start again when the flow is above 0 78 gal min 2 7 l min Water Flow Restriction Valve A motorized valve is placed in series with the circulation pump and the heat exchanger of the heat engine This valve serves to limit the amount of flow through the heat engine such that a variable rate of flow can be achieved from the fixed speed pump Gas Delivery Safety String The release of gas into the combustion chamber is of critical importance to the safe operation of the heater The control is a combination of hardware and software that measure and ensure the gas is released only when appropriate for combustion The term safety string applies to those devices or components that directly control the power applied to the gas valves as well as the gas valves themselves The components are main gas valve solenoid stage 1 and 2 gas valve solenoids exhaust vent high temperature switch energy cut out ECO temperature switch Exhaust Vent High Temperature Switch The water heater is designed for plastic vent piping typically used in high efficiency appliances To ensure the water heater will not release exhaust gasses at temperatures that would cause the vent piping to melt a bimetallic switch is mounted on the assembly The switch used is a normally closed
56. ds the unit will allow access to the maintenance mode 34 www hotwater com WIRING DIAGRAM awey o Ve si o umog apow 309201 e 15008 efwiou0s3 yeyuaey lewon 4o uo snisie a 2 uonipe Juan epo e2i29Je T ZZI WSO 94 Jo pue uonipe Juan OZ ON Vd4N ISNV 9p02 BUONeN ay YIM sepoo evo DNIDIAYAS AILIV Mwen Jo SoUBSqe au ul 4O sapoo e20 UJIM DIUEPJOIJE NOLIVAYIJO YAdOUd AJTYIA NOLIVAIJO ul pepunoub A BLLUJJB 3 aq SNW BOUBI dde siu SNOUAJINYA ANY AAJOUdWI JS vo Jozsiuoauj xue NVO StOU3 ONIYIM STOHINOO Jejeay Jejem ay asia Jo amp 3sui noA uaym SNIOIAS3S NIHM NOLLO3NNOOSIG squawesinbas Ayjin ou229 a pue sepoo e20 Aaqo OL YOTYd SIAYIM TV 138V1 NOILQVO S AJLA SEY doud puz IST Uew N3349 daub 4 a MI dund 31IHM MONA MOTIIA FONVYO FINVYO FAM FAM JOVIS ama NOUS ame A385 MONA EPA 1349 1349 ama TE vis yva o vis N33u5 31IHM bunes piw duung ay IMS PRNO dae N3349 A T t aay Jen ozI E mo o woyzsuesL MS dwaj u6iH NOUS V V V V V 3e UI NMOSS JeAOZIJ9MOd Jd YWAX 093 saA eA seo TTC SJOISIWOUL al Ka Lt 9TC JegiubT Ano Aseijixny TTC i ec SJO3SIuI9U VIE
57. e Inlet Water Filter 44 Cleaning The Heat Engine 45 Flushing The Heat Exchanger Lime Build up 45 Draining The Tank o 46 Fault Indication And Error Codes 46 Diagnostic Display 47 TROUBLESHOOTING 51 SGRVICB iu sod lad eA ai ante tales eite e a ote Bate hig 53 Leakage Checkpoints 53 Parts Identification 54 Replacement Parts 56 LIMITED RESIDENTIAL GAS WARRANTY 57 NOTES ee eere Ei eir pa 58 Fill out and keep with water heater IMPORTANT INFORMATION Model Number Serial Number Installation Information Date Installed Company s Name Street or P O Box City State and Zip Code Phone Number Plumber s Name 2 www hotwater com SAFE INSTALLATION USE AND SERVICE Your safety and the safety of others is extremely important in the installation use and servicing of this water heater Many safety related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard Read and obey all safety messages and instructions throughout this manual It is very important that the meaning of each safety message is understood by you and others who install use or service this water heater This is the safety alert symbol It is used to alert you to potential personal injury hazards
58. e vent system must terminate so that proper clearances are maintained as cited in local codes or the current edition of the National Fuel Gas Code ANSI Z223 1 and as listed below 1 Vent Termination must extend a minimum of 18 in 46cm above roof or 18 in 46cm above the anticipated snow level to prevent blockage of the vent termination as shown in Figures 28 and 29 VENT PIPE PREPARATION 1 INITIAL PREPARATION A Make sure the solvent cement you are planning to use is designed for the specific application you are attempting B Know the physical and chemical characteristics and limitations of the PVC and CPVC piping materials that you are about to use C Know the reputation of your manufacturer and their products D Know your own qualifications or those of your contractor The solvent welding technique of joining PVC and CPVC pipe is a specialized skill just as any other pipe fitting technique E Closely supervise the installation and inspect the finished job before start up F Contact the manufacturer supplier or competent consulting agency if you have any questions about the application or installation of PVC and CPVC pipe G Take the time and effort to do a professional job Shortcuts will only cause you problems and delays in start up By far the majority of failures in PVC and CPVC systems are the result of shortcuts and or improper joining techniques 2 SELECTION OF MATERIALS e Cutting Device S
59. ection between igniter and igniter rod for proper contact Outlet Outlet Temperature Temperature is lt minimum defined Probe is Open temperature circuit Outlet Outlet Temperature Temperature is gt maximum defined Probe is Short temperature circuit Inlet Temperature Inlet Temperature is Check temperature probes wire Probe is Open lt minimum defined Soft hamess circuit temperature R Replace themperature probe Inlet Temperature Inlet Temperature Change the board Outlet water Outlet water temperature lt Check the outlet temperature probe temperature too setting temperature 15 C 2 Change the board low for 60 seconds after flame detected TABLE 5 www hotwater com 49 gou Lockout Code Description A Displayed yP Blower Error Locked Rotor Water Flow Valve The water valve did not Closed open when attempting to establish flow 1 Check the blower wire harness 2 Change the blower 3 Change the board 1 Check the water valve wire harness 2 Change the board 3 Change the water valve Proportional Valve The closed loop control PV Response of the proportional valve Too Slow is not functioning properly control error or the valve is responding slowly valve failure Repeated Flame Low Gas Inlet Pressure Loss Fault Check the proportional gas valve wire harness change the board change the gas valve assembly Check the flame rod wire harness check li
60. ermont s legislation Act 193 requirement of a weighted average maximum of 0 25 lead www hotwater com www hotwater com GET TO KNOW YOUR WATER HEATER GAS MODELS kkk A Mixing Valve B Hot Water Outlet Tempered C Pipe Insulation D Inlet Water Shutoff Valve E Cold Water Inlet F Expansion Tank G Vent Termination Elbow H Access Door Heat Engine Earthquake Strap J Power Cord K Main Manual Gas Shutoff Valve L Gas Supply M Sediment Pocket N Condensate Tube O Drain Pan P Drain Valve Q Heat Engine Hose Cold In R Casing Door Plastic S Display Enclosure Plastic T Heat Engine Hose Hot Out oar W q z e ii T gje CS mm Dr CI N IN SI oS Y U Side Casing Plastic V Top Casing Enclosure Plastic W Exhaust Elbow Assembly X T amp P Relief Valve Y Anode Z Inlet Dip Tube CAUTION HARNESS HAS 120 VAC IN OPERATION See Planning the Vent System Installation of Vent System and Condensate for more information These items not included REPLACEMENT PARTS AND DELIMING PRODUCTS Replacement parts and recommended delimer may be ordered through authorized servicers or distributors When ordering parts provide complete model and serial numbers see rating plate quantity and name of part desired Standard hardware items may be purchased locally amp 0 0009 D m a e pm MM tar as FIGURE 1 www hotwater com INS
61. h the ORIGINAL OWNER a replacement water heater of equivalent size and current model or a replacement part for any component part which fails in normal use in accordance with the warranty terms and conditions specified below THE WATER HEATER REPLACEMENT MODEL OR PART WILL BE WARRANTED FORONLYTHE UNEXPIRED PORTION OF THE ORIGINAL WARRANTY The warranty period will be determined by the original installation date of the water heater PROOF OF PURCHASEAND PROOF OF INSTALLATION ARE NECESSARY TO VALIDATE THIS WARRANTY This warranty is not transferable WARRANTY PERIOD Product Line HEAT ENGINE amp TANK PARTS HYB 90N 6 YEARS 6 YEARS When the water heater has been used for other than single family residential application 1 The Tank warranty shall be reduced to 1 year on 6 year models 2 The parts warranty shall be reduced to 1 year for all models Returned parts which meet any of the following conditions are not covered by this warranty 1 improper installation or removal 2 damaged by other than normal wear 3 replaced for cosmetic purposes or 4 returned with defaced date codes CONDITIONS AND EXCEPTIONS This warranty shall apply only when the water heater is installed and operated in accordance with 1 all local fire codes and plumbing codes ordinances and regulations 2 the printed instructions provided with it 3 good industry practices and 4 proper safety practices such as but not limited to a properly sized drain pan if instal
62. hlorination treatment If the smelly water persists after the anode replacement and chlorination treatment we can only suggest that chlorination or aeration of the water supply be considered to eliminate the water problem Do not remove the anode leaving the tank unprotected By doing so all warranty on the water heater tank is voided Air In Hot Water Faucets AWARNING Flammable hydrogen gases may be present Keep all ignition sources away from faucet when turning on hot water HYDROGEN GAS Hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable and explosive To prevent the possibility of injury under these conditions we recommend the hot water faucet located farthest away be opened for several minutes before any electrical appliances which are connected to the hot water system are used such as a dishwasher or washing machine If hydrogen gas is present there will probably be an unusual sound similar to air escaping through the pipe as the hot water faucet is opened There must be no smoking or open flame near the faucet at the time it is open 42 www hotwater com MAINTENANCE HOUSEKEEPING Vacuum around base of water heater for dust dirt and lint on a regular basis VENTING SYSTEM INSPECTION At least once a year a visual inspection should be made of the venting system You should l
63. ial Conditions Created by Mechanical Exhausting or Fireplaces operation of exhaust fans ventilation systems clothes dryers or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment CHEMICAL VAPOR CORROSION CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS SUCH CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION Spray can propellants cleaning solvents refrigerator and air conditioning refrigerants swimming pool chemicals calcium and sodium chloride water softener salt waxes and process chemicals are typical compounds which are potentially corrosive Do not store products of this sort near the heater Also air which is brought in contact with the heater should not contain any of these chemicals If necessary uncontaminated air should be obtained from remote or outside sources The limited warranty is voided when failure of water heater is due to a corrosive atmosphere See limited warranty for complete terms and conditions WATER PIPING ADANGER Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe te
64. ict combustion air flow See Figure 1 Water heater life depends upon water quality water pressure and the environment in which the water heater is installed Water heaters are sometimes installed in locations where leakage may result in property damage even with the use of a drain pan piped to a drain However unanticipated damage can be reduced or prevented by a leak detector or water shut off device used in conjunction with a piped drain pan These devices are highly recommended and are available from some plumbing supply wholesalers and retailers and detect and react to leakage in various ways Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected Sensors mounted in the drain pan that turn off the water supply to the entire building when water is detected in the drain pan Water supply shut off devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply AVOIDAREAS WHERE FLAMMABLE LIQUIDS VAPORS ARE LIKELY TO BE PRESENT OR STORED GARAGES STORAGE AND UTILITY AREAS ETC Flammable liquids such as gasoline solvents propane LP or butane etc and other substances such as adhesives etc emit flammable vapors which can be ignited by a gas water he
65. ire harness Change the blower Change the board www hotwater com pout Lockout Code Description Cd Displayed yP Blower speed is 200RPM below the target speed for 20 seconds Blower speed is 500RPM above the target speed for 6 seconds Check the blower wire harness Change the blower Change the board Blower speed Machine starts or normal abnormal combustion but Blower speed 0 for last 3sec Have Blower s output signal but the Blower speed 0 for last 400ms Blower speed stuck gt 3000 rpm Proportional valve Current Proportional Minimum valve PV current unusual Proportional valve Current Maximum Check the proportional gas valve wire harness Change the board Change the gas valve assembly Probe is Short is maximum defined circuit temperature Tank Temperature Tank Temperature Probe is Open is minimum defined Circuit temperature Tank Temperature Tank Temperature Probe is Short is gt maximum defined circuit temperature Ignition failure After a failure to detect the flame during ignition the control will retry the specified number of times After the maximum failed attempts this fault is declared Check the igniter wire harness 2 Check igniter 120Vac voltage supply during the ignition time Check the ignition rod If it looks dirty clean it using isopropyl alcohol and a clean cloth Check the high voltage wiring conn
66. is an error code c There is an external recirculation system installed or there is a check valve on the recirculation return line d Improper sized dip tube e Water heater disconnected from electrical power THE WATER IS NOT HOT The temperature is set too low a Check unit s temperature setting ENOUGH b Check for cross plumbing between cold and hot water lines CANNOT OPEN DOOR Door pins locked in place a Ensure the door lock is unlocked b Ensure the top and bottom door pins are released by using a small screwdriver to pry the pins in the direction of the door opening TABLE 6 52 www hotwater com SERVICE If a condition persists or you are uncertain about the operation of the water heater contact a qualified service agency LEAKAGE CHECKPOINTS Use this guide to check a Leaking water heater Many suspected Leakers are not leaking tanks Often the source of the water can be found and corrected If you are not thoroughly familiar with gas codes your water heater and safety practices contact your gas supplier or qualified installer to check the water heater Read this manual first Then before checking the water heater make sure the gas supply has been turned OFF and never turn the gas ON before the tank is completely full of water FIGURE 40 AWARNING Read and understand instruction manual and safety messages before installing operating or servicing this water heater
67. istance see Table 1 NOTE The lengths of pipe listed are exclusive of the termination The termination elbow with an installed screen is required and uses the equivalent of 7 ft 2 1m of vent pipe length Therefore the remainder of the vent system must not exceed the lengths listed NOTE Do NOT use Cellcore venting PVC outer layer foamcore type material for middle layer and then PVC inside layer Maximum vent Maximum vent length for 2 in pipe length for 3 in pipe ft m ft m Number of 90 Elbows 1 43 13 1 45 36 10 8 40 122 29 8 8 35 10 6 9 13 7 30 9 1 22 67 15 4 5 25 7 6 65 19 8 75 22 8 TABLE 1 3 The exhaust elbow assembly comes with a straight section of 2 in pipe installed To continue the vent system a rubber coupling must be attached The venting must extend 6 in 15cm vertically from the top of the heater before installing an elbow If using 2 inch vent pipe Install the rubber coupling and gear clamps supplied at the end of the section of vent pipe installed on the heater Continue building the vent system or connect the existing vent system to the coupling The total vent system must not exceed the lengths discussed above where each short radius elbow is equal to 7 equivalent feet 2 1m of straight pipe The elbow and rodent screen supplied in the vent kit must be used as the vent termination www hotwater com 23 NOTE VENT PIPE MUST BE
68. it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions and replace the temperature pressure relief valve with a new one T amp P Valve and Pipe Insulation if supplied Remove insulation for T amp P valve and pipe connections from carton FIGURE 18 Fit pipe insulation over the incoming cold water line and the hot water line Make sure that the insulation is against the top cover of the heater Fit T amp P valve insulation over valve Make sure that the insulation does not interfere with the lever of the T amp P valve Secure all insulation using tape 20 www hotwater com GAS PIPING A4 WARNING Do not use water heater with any gas other than the gas shown on the rating plate Excessive pressure to gas contral valve can cause serious injury or death Turn off gas lines during installation Contact qualified installer or service agency Make sure gas supplied is same type listed on model rating plate The inlet gas pressure must not exceed 14 in WC 3 5 kPa for natural and propane gas L P The minimum inlet gas pressure shown on rating plate is that which will permit firing at rated input All gas piping must comply with local codes and ordinances or with the National Fuel Gas Code ANSI Z223 1 NFPA 54 Copper or brass tubing and fittings except tin lined copper tubing should not be used If the g
69. lace when significantly depleted i Label all wires prior to disconnection when servicing a controls Wiring error can cause improper and dangerous Install in location with drainage Bj f Ga operation Verify proper operation after servicing Fill tank with water before operation Properly sized thermal expansion tanks are required on all Failure to do this could result in death serious bodily closed water systems injury or property damage Refer to this manual for installation and service A WARNING AA DANGER Breathing Hazard Carbon Monoxide Gas Install vent system In accordance with codes Do not operate water heater if flood damaged Special Consideration must be taken with installations above 11 000 3 352m for standard models Do not operate if soot buildup is present Do not obstruct water heater air intake with insulating jacket Do not place chemical vapor emitting products near water heater Gas and carbon monoxide detectors are 4AVapors from flammable Water heater has a main available liquids may explode and burner and spark generator No vent damper installation is compatible with catch fire causing death or The spark generator this power vented water heater severe burns 1 can be triggered at any DO not elevate the condensate hose on the time and bottom of the water heater above the bracket ill inni attached to the side of the unit This must be true Do not use o
70. le compounds cleaners chlorine based chemicals refrigerants etc in addition to being highly flammable in many cases will also react to form corrosive hydrochloric acid when exposed to the combustion products of the water heater The results can be hazardous and also cause product failure APPLIANCES IN UNCONFINED SPACES UNCONFINED SPACE is space whose volume is not less than 50 cubic feet per 1 000 Btu per hour 4 8 cubic meters per kW of the aggregate input rating of all appliances installed in that space Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors are considered a part of the unconfined space 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 heavily insulated caulked vapor barrier etc additional air may need to be provided using the methods described in Appliances in Confined Space that follows APPLIANCES IN CONFINED SPACES CONFINED SPACE is a space whose volume is less than 50 cubic feet per 1 000 Btu per hour 4 8cm per kW of the aggregate input rating of all appliances installed in that space When drawing combustion air from inside a building to a confined space such a space should be provided with two permanent openings ONE WITHIN 12 in 30cm OF THE ENCLOSURE TOP
71. led in an area where leakage from connections of the tank would result in damage to the area adjacent to the heater In addition a new temperature and pressure relief valve certified by the Canadian Standards Association must have been properly installed and piped to the nearest drain This warranty shall apply only when the heater is owned by the original purchaser used at temperatures not exceeding the maximum calibrated setting of its thermostat e not subjected to excessive water pressure fluctuations and not subject to an operating pressure greater than 150 P S I filled with potable water free to circulate at all times and with the tank free of damaging water sediment or scale deposits used in a non corrosive and non contaminated atmosphere used with factory approved anode s installed in its original installation location in the United States and its territories or possessions or Canada sized in accordance with proper sizing techniques for residential water heaters bearing a rating plate which has not been altered defaced or removed except as required by the warrantor used in an open system or in a closed system with a properly sized and installed thermal expansion tank fired at the factory rated input using the fuel stated in the face of the rating plate operated with the inner and outer combustion chamber doors in place maintained in accordance with the instructions printed in the manual
72. ll installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the installation www hotwater com WATER PIPING MIXING VALVE USAGE SUGGESTED PIPING ARRANGEMENT FOR TOP CONNECTIONS SHUT OFF VALVE TEMPERED POTABLE WATER TEMPERED POTABLE WATER COLD WATER INLET l pe en EXPANSION TEMPERATURE PRESSURE MIXING RELIEF VALVE VALVE DISCHARGE OPTIONAL PIPE DO NOT CAP OR PLUG PIPE INSULATION RECOMMENDED METAL DRAIN PAN gan 15cm DRAIN VALVE MAX AIR GAP TO SUITABLE DRAIN DRAIN FIGURE 3 This appliance has been design certified as complying with ANSI Z21 10 3 CSA 4 3 latest revision for water heaters and is considered suitable for Water Potable Heating All models are considered suitable for water potable heating ADANGER Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting Please note the following The system should be installed only with piping
73. ly bent inwards thus allowing the straps to exit the shroud see Figure 9 In order to access the tabs and install the earthquake straps it is necessary to remove the top front and side panels of the shroud as follows see Figures 6 8 Door opening 1 Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver 2 Release the top and bottom door pins by prying the pins out using a small screwdriver 3 Open the door the door remains fastened to the left side panel Remove the top casing front 1 Use a screwdriver to remove the six screws securing the top casing 2 Lift up and remove casing top front Remove the right side panel 1 Use a screwdriver to remove the screw from the bottom front of the right side panel Remove the three screws from the right side panel towards the rear of the unit Remove the screw from the top of the unit Push the panel back and lift out Remove the left side panel Use a screwdriver to remove the screw from the bottom front of the left side panel Remove the three screws from the left side panel towards the rear of the unit Remove the screw from the top of the unit Push the panel back and lift out Top Casing Access To Front X Door Pins Door Lock FIGURE 6 14 www hotwater com FIGURE 9 After the heater has been positioned and the earthquake straps have been installed re assemble the shroud in the reverse order
74. maged Instruction manual must remain with water heater Water temperature over 125 F A DANG ER 52 C can cause severe burns A WA RN N G i resulting in severe injury or Explosion Hazard Children the elderly and the physically or mentally disabled are at highest risk for scald injury Overheated water can cause water tank explosion Feel water before bathing or S showering A E Properly sized temperature Temperature limiting valves are and pressure relief valve available must be installed in opening Read instruction manual for safe provided temperature setting A WARNING Fire or Explosion Hazard Donot store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Avoid allignition sources if you smell gas Do not expose water heater control to excessive gas pressure Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use Read instruction manual before installing using or servicing water heater 4 www hotwater com GENERAL SAFETY CAUTION A WARNING Improper Installation use and service may result zi 1 y A Before servicing the water heater make sure the blower In property damage assembly is unplugged or the electrical supply to the Do not operate water heater if flood damaged Wet S tumed EE Inspect anode rods regularly rep
75. marked as being resistant to the action of petroleum Propane L P gases The appliance and its gas connection must be leak tested before placing the appliance in operation The appliance and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of the system at test pressures in excess of 1 2 psi 3 5 kPa It shall be isolated from the gas supply piping system by closing its individual manual shut off valve during the pressure testing the gas supply piping system at test pressures equal to or less than 1 2 psi 3 5 kPa is considered isolated IMPORTANT MAKE SURE THE GAS LINE IS PIPED WITH HARD PIPE AVOID FLEX LINE CONSTRUCTION FOR GAS DUE TO POSSIBLE GAS FLOW PROBLEMS SEDIMENT TRAPS AWARNING e Contaminants in gas lines can cause fire or explosion Clean all gas piping before installation e Install drip leg in accordance with NFPA54 or CAN CSA B1491 A sediment trap shall be installed as close to the gas inlet of the water heater as practical at the time of water heater installation The sediment trap shall be either a tee fitting with a capped nipple in the bottom outlet or other device recognized as an effective sediment trap Contaminants in the gas lines may cause improper operation of the gas control valve that may result in fire or explosion Before attaching the gas line be sure that all gas pipe is clean on the inside To trap any dirt or
76. most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions A copy of a
77. mperature setting HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes washing dish washing cleaning and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the physically or developmentally disabled If anyone using hot water fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater see Figure 3 Valves for reducing point of use temperature by mixing cold and hot water are also available Consult a Qualified Installer or Service Agency Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat read the Temperature Regulation section in this manual A WARNING Toxic Chemical Hazard Do not connect to non potable water system This water heater should not be connected to any heating systems or component s used with a non potable water heating appliance All piping components connected to this u
78. n no flame was expected Control detects that the ECO switch is open preventing power to the Main Valve Control detects that the High Temperature Vent Switch is open preventing power to the Main Valve 120Vac lt Undervoltage Limit Blower Current meets requirements for a completely blocked flue Blower Current meets requirements for a partially blocked flue Blower Current meets requirements for a non heating blocked flue evaluation TABLE 5 Lockout type Auto Reset Change the main controller board board Change the board Check the flame rod Check the flame wire harness Change the board Measure the water temperature ECO switch open temperature is 854 5 C 185414 F and close temperature is 65 5 C 149414 F Check the ECO switch Check the ECO wire harness Change the board Measure the water temperature High Vent Switch open temperature is 7442 8 C 165 5 F and close temperature is 5742 8 C 135 5 F Check the switch Check the High Vent Switch wire harness Change the board Nominal voltage is 120Vac Overvoltage limit is 132Vac Undervoltage limit is 102Vac Check the power cord Check the wall outlet Measure the voltage at the board connector J7 between pin1 and pin 3 If the voltage is between limits change the board Check the venting system If the venting system is clear recalibrate the unit Check the blower w
79. ncrease the set point so that a calibration sequence not call for heat occurs initiated because of lack of Drain the tank in order to lower the call for heat or the unit water temperature so that a call has been never calibrated for heat is generated or Calibration is successful Set DIP switch 4 to OFF position but DIP switch 4 not set to Recalibrate the unit normal Change the board 50 www hotwater com TROUBLESHOOTING These guidelines should be utilized by a qualified service agent Possible Cause s What to do NOT ENOUGH HOT WATER STANDBY button turned off Press switch to turn heater on No power at outlet Repair service to outlet Error Code being displayed Refer to FAULT INDICATION AND ERROR CODES section and Table 5 or call service agency or dealer Leaking hot water pipes of fixtures Have plumber check and repair leaks CONDENSATION Water on the floor under heater See CONDENSATE section WATER LEAKS Improperly sealed hot or cold supply Check for leaks See Figure 40 connections relief valve drain valve or thermostat threads Leakage from other appliances or Inspect other appliances near water water lines heater Condensation of flue products Refer to CONDENSATE section LEAKING T amp P Thermal expansion in closed water Install thermal expansion tank Do system not plug T amp P valve Improperly sealed valve Check relief valve for proper operation Do not plug T amp
80. ncy for further information Do not plug the temperature pressure relief valve MOTORS Motors are permanently lubricated and do not need periodic lubrication Keep fan and motor free of dust and dirt by cleaning annually SNOW ACCUMULATION Keep the area around flue terminal free of snow and ice The appliance will not function properly if the intake air or exhaust is impeded blocked or partially blocked by obstructions CLEANING THE INLET WATER FILTER The cold water inlet filter must be cleaned on a regular basis The frequency of this cleaning is dependent on the quality of your local water supply You will need to prepare a bucket to collect some of the draining water The cold water inlet filter is located inside the door on the left hand side of the heat engine To access the inlet filter Access To Door Pins FIGURE 37 44 www hotwater com Remove the filter Disconnect the electrical power to the water heater Close the shutoff valves on both the hot water and cold water lines Unlock the door by rotating the side lock counter clockwise with a wide slot screwdriver Pop the top and bottom door pins by pushing the pins out using a small screwdriver Open the door Open a nearby hot water faucet to depressurize the water tank Drain the tank following the instructions in the Draining The Tank section Unscrew the filter and clean by rinsing it under a faucet and scrubbing with a brush if
81. ne gas pressure If it is above 5 WC check the flame rod and if it looks dirty clean it up using isopropyl alcohol and a clean cloth change the flame rod change the board Check the water inlet on the heat engine Make a water draw during first 60 seconds after putting the unit in ON mode to evacuate possible air from the heat engine water passage Check wire harness for pump water valve and water flow sensor Check the pump 120Vac voltage supply the pump shall be energized during the heating mode Clean or change the water filter Change board Change pump No Water Flow The heater could not start because the water flow was not established This can be caused by an air bubble or a blockage in the heat engine water passage a failed flow sensor or a failed circulation pump Change water valve Board Failure An internal diagnostic check TABLE 5 Lockout types Continuous Needs Cycle the Power or service to restart Soft Will try to automatically recover and restart after 20 minutes Auto Will automatically restart when voltage returns to acceptable parameters Alert Will only display an error code in diagnostic mode Soft Soft Soft Soft Soft Soft oft ES EN B B E36 Calibration error Calibration sequence Unplug the power cord check the incomplete because end DIP switch 4 position and put it in of call for heat during ON position the calibration time or I
82. new mode is turned on UNIQUE HYBRID FEATURES Temperature Measurement Temperature Probes The water heater has support for three independent temperature probes 1 Water Inlet Temperature Probe The water inlet temperature probe contains a thermistor and measures the temperature of the water entering the heat engine enclosure 2 Water Outlet Temperature Probe The water outlet temperature probe contains a thermistor and measures the temperature of the water leaving the heat engine enclosure This supply of hot water is delivered to the top of the storage tank in close proximity to the outlet fitting 3 Tank Temperature Probe The tank probe contains a thermistor and measures the temperature of the water in the storage tank at a specific location between the top and the bottom of the tank www hotwater com 39 Water Circulation Pump A circulation pump is integrated into the heat engine for the Hybrid application The pump serves to push water through the heat engine at a rate that supports optimum recovery time and maximum heat output The control provides 120Vac 60Hz line power to the pump to enable operation Water Flow Measurement 1 Water Flow Sensor The Water Flow Sensor uses a sensor for the detection of the water flow When water flows the sensor rotates and a transistor is switched on and off producing a pulsing signal with a frequency related to flow rate 2 Water Flow Detection Flow detection is an on off in
83. nit should be suitable for use with potable water Toxic chemicals such as those used for boiler treatment should not be introduced into this system When the system requires water for space heating at temperatures higher than required for domestic water purposes a mixing valve must be installed Please refer to Figure 3 for suggested piping arrangement CLOSED WATER SYSTEMS Water supply systems may because of code requirements or such conditions as high line pressure among others have installed devices such as pressure reducing valves check valves and back flow preventers Devices such as these cause the water system to be a closed system THERMAL EXPANSION As water is heated it expands thermal expansion In a closed system the volume of water will increase As the volume of water increases there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the 18 www hotwater com limited warranty Thermal expansion can also cause intermittent temperature pressure relief valve operation water discharged from the valve due to excessive pressure build up The temperature pressure relief valve is not intended for the constant relief of thermal expansion This condition is not covered under the limited warranty A properly sized thermal expansion tank should be installed on all closed systems to control
84. nnot be increased and the Operating Mode cannot be changed The set point may be decreased while the keys are locked The On Off Button is not affected by the Key Lock feature All other buttons are locked when the Key Lock is On The Key Lock icon will be displayed if the water heater is either in the lock or unlock condition The Icon is composed of 3 components the base a locked and an unlocked arc Operating Modes Operating modes are Boost for peak demand Energy Saver and Vacation Three LEDs are used to indicate the Operating Mode Vacation Mode Yellow LED Energy Saver Mode Green LED Boost Mode Orange LED The Operating Modes have the following characteristics Vacation mode Fixed temperature setting of 90 F 32 C Set point Difference is 14 F 8 C Tank Set point Differential is 22 F 12 C Energy Saver mode Temperature range from 100 F to 135 F 38 C to 57 C in increments of 1 F or 1 C Set point Difference is 14 F 8 C Tank Set point Differential is 14 F 8 C Boost mode Temperature ranges from 140 F to 158 F 60 C to 70 C in increments of 1 F or 1 C Set point Difference is 14 F 8 C Tank Set point Differential is 9 F 5 C Switching between operating modes is done by pressing the Mode Button when the Key Lock is Off When a mode is active the corresponding LED is turned on Pressing the Mode button will cycle be
85. ntil it is no longer hot 3 CLOSE the cold water inlet valve to the water heater 4 Connect a hose to the drain valve and terminate to an adequate drain 5 OPEN the water heater drain valve to allow for tank draining NOTE If the water heater is going to be shut down and drained for an extended period the drain valve should be left open with hose connected allowing water to terminate to an adequate drain 6 CLOSE the drain valve 7 Follow instructions in the Filling The Water Heater section 8 Follow the lighting instructions on the label or see Lighting Instructions in this manual to restart the water heater FAULT INDICATION AND ERROR CODES A red fault LED lighting a large red exclamation point should be present on the display panel if a fault condition exists A history of the last 9 error codes along with the current error code is stored in memory and can be accessed via the maintenance mode If the current error code is zero E00 shall be displayed see Table 4 46 www hotwater com DIAGNOSTIC DISPLAY By simultaneously pressing the Mode and down arrow buttons for 3 seconds the unit will allow access to the diagnostic mode In diagnostic mode using the up down arrow allows for cycling between diagnostic codes The numeric display will show the diagnostic code for 1 second followed by the actual measurement displayed for 3 seconds For example H01 105 represents the diagnostic
86. o Canada L4W 5N6 NFPA documents are also available from National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 The water heater when installed must be grounded in accordance with the local codes or in the absence of local codes the National Electrical Code NFPA 70 If after reading this manual you have any questions or do not understand any portion of the instructions call the local gas utility or the manufacturer whose name appears on the rating plate 5 Carefully plan the place where you are going to put the water heater Correct combustion vent action and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and fires see Figures 1 and 3 Examine the location to ensure the water heater complies with the Facts to Consider About Location section in this manual For California installation this water heater must be braced anchored or strapped to avoid falling or moving during an earthquake See instructions for correct installation procedures Instructions may be obtained from California Office of the State Architect 400 P Street Sacramento CA 95814 Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248 CMR 2 00 State Plumbing Code and 248 CMR 5 00 See page 8 Complies with SCAQMD rule 1146 and districts having equivalent NOx requirements Complies with California s legislation AB1953 and V
87. odes require that condensate is treated by using a pH neutralizing filter prior to disposal Caution must be used to ensure that the drain is free and clear of debris and will not allow backflow through the condensate tube Consideration must be given to avoid freezing of the condensate lines which could result in excessive build up of condensate inside the water heater Waterproof heat tape may be required to prevent freezing of the condensate lines Please ensure that the outlet of the condensate drain does not create a slippery condition which could lead to personal injury To operate properly and prevent exhaust gases from escaping through the condensate trap the trap must contain some water Before being started for the first time water must be added to the trap Remove the condensate tube if installed and add water to the trap through the hole for the condensate tube until it flows from the hole Re install the condensate tube CONDENSATION WARNING THIS WATER HEATER IS A CONDENSING UNIT AND REQUIRES A DRAIN TO BE LOCATED IN CLOSE PROXIMITY TO ALLOW CONDENSATE TO DRAIN SAFELY THE CONDENSATE DRAINS FROM UNIT AT THE EXHAUST ELBOW LOCATED AT BOTTOM OF UNIT NOTE IT IS IMPORTANT THAT THE CONDENSATE TUBE NOT BE ELEVATED ABOVE THE CONDENSATE TRAP OUTLET SEE FIGURE 22 CONDENSATE BUILD UP WILL BLOCK THE EXHAUST OUTLET WHICH WILL CAUSE IMPROPER OPERATION WITH SOME INSTALLATIONS IT IS RECOMMEND TO INSTALL A CONDENSATE PUMP
88. of corroding the tank water ions attack and eat away the anode rod This does not affect the water s taste or color The rod must be maintained to keep the tank in operating condition Anode deterioration depends on water conductivity not necessarily water condition A water softener can affect the life of the anode installed in this water heater A corroded or pitted anode rod indicates high water conductivity and should be checked and or replaced more often than an anode rod that appears to be intact Replacement of a depleted anode rod can extend the life of your water heater Inspection should be conducted by a qualified technician and at a minimum should be checked annually after the warranty period www hotwater com 43 ANODE ROD REPLACEMENT To replace the anode 1 Turn off gas supply to the water heater 2 Shut off the water supply and open a nearby hot water faucet to depressurize the water tank 3 Drain approximately 5 gallons 20 litres of water from tank Refer to DRAINING THE TANK for proper procedures Close drain valve 4 Remove old anode rod 5 Use Teflon tape or approved pipe sealant on threads and install new anode rod 6 Turn on water supply and open nearby hot water faucet to purge air from water system 7 Restart the water heater as directed under Operating Your Water Heater See the Parts Reference Illustration for anode rod location TEMPERATURE PRESSURE RELIEF VALVE OPERATION
89. on the amount of water flowing through the heater and the amount of temperature rise that needs to be generated to meet your demands The system will calculate the amount of heat needed The temperature regulation will prevent the inlet temperature from reaching the temperature set point Detection of Failure to Maintain Desired Constant Temperature This check can be used to detect a failure of the stage 2 gas valve In this case an insufficient amount of heat would be applied This check can also serve to diagnose failures or mis wiring of the water flow restriction valve If the valve fails to restrict the flow of water the system may not be able to sufficiently heat the water passing through the heat engine A failure to maintain the desired constant temperature is determined by the outlet water temperature remaining 15 degrees lower than the set point for one minute while the flame is established If this condition is detected while in the heating state for normal modes an Alert message is provided to the display panel START UP CONDITIONS Smoke Odor It is not uncommon to experience a small amount of smoke and odor during the initial start up This is due to burning off of oil from metal parts and will disappear in a short while NOTE If there is a discharge from the temperature pressure relief valve refer to the THERMAL EXPANSION section of this manual NOTE Do not plug the temperature pressure relief valve
90. ook for 1 Obstructions which could cause improper venting The combustion and ventilation air flow must not be obstructed 2 Damage or deterioration which could cause improper venting or leakage of combustion products Be sure the vent piping is properly connected to prevent escape of dangerous flue gasses which could cause deadly asphyxiation Obstructions and deteriorated vent systems may present serious health risk or asphyxiation Chemical vapor corrosion of the flue and vent system may occur if air for combustion contains certain chemical vapors Spray can propellants cleaning solvents refrigerator and air conditioner refrigerants swimming pool chemicals calcium and sodium chloride waxes bleach and process chemicals are typical compounds which are potentially corrosive If after inspection of the vent system you found sooting or deterioration something is wrong Call the local gas utility to correct the problem and clean or replace the flue and venting before resuming operation of the water heater BURNER OPERATION AND INSPECTION Flood damage to a water heater may not be readily visible or immediately detectable However over a period of time a flooded water heater will create dangerous conditions which can cause DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE Contact a qualified installer or service agency to replace a flooded water heater Do not attempt to repair the unit It must be replaced At least once a year
91. ornia Category IV PVC Pipe such as that manufactured by Brownline Pipe Company must be used as vent pipe material CAUTION Vent terminals supplied with heater must be used NOTE BEFORE BEGINNING INSTALLATION OF ANY VENT PIPE READ THE VENT PIPE MANUFACTURER S INSTALLATION INSTRUCTIONS 1 After the points of termination have been determined use the cover plates as templates to mark the holes for the vent pipes to be inserted through the wall BEWARE OF CONCEALED WIRING AND PIPING INSIDE OF WALL If the vent terminals are being installed on the outside of a finished wall it may be easier to mark both the inside and outside wall Align the holes by drilling a hole through the center of the template from the inside through to the outside The template can now be positioned on the outside wall using the drilled holes as a centering point for the template A MASONRY SIDE WALLS Chisel an opening approximately 1 2 in 1 3cm larger than the marked circle B WOODEN SIDE WALLS Drill a pilot hole approximately 1 4 in 0 64cm outside of the marked circle This pilot hole is used as a starting point for a saws all or sabre saw blade Cut around the marked circle staying approximately 1 4 in 0 64cm outside of the line This will allow the vent pipe to easily slide through the opening The resulting gap will be covered by the vent terminal cover plates Repeat this step on the inside wall if necessary Cuta length of 3 in P
92. ou must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a Mixing Valve should be used at the hot water taps used by these people or at the water heater see Figure 3 Mixing valves are available at plumbing supply or hardware stores Consult a Qualified Installer or Service Agency Follow the mixing valve manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat read the Temperature Regulation section in this manual FACTS TO CONSIDER ABOUT LOCATION Carefully choose an indoor location for the new water heater because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance This water heater is not for use in manufactured mobile homes or outdoor installation Whether replacing an old water heater or putting the water heater in a new location the following critical points must be observed 1 Select a location indoors as close as practical to the vent terminal or location to which the water heater vent piping is going to be connected and as centralized with the water piping system as possible 2 Apressure reducing valve and or an expansion tank may be required for installations where the water pressure is high The pressure reducing valve should be located on the supply to the entire house in orde
93. ove 132Vac the water heater will enter the fault state and initiate a controlled shut down The fault will automatically clear if the voltage is restored to 132Vac or below TEMPERATURE REGULATION Temperature regulation is the process by which the controller determines when the water heater is to heat water as well as when to stop the heating process This section defines how the water heater is to regulate the temperature Temperature Units of Measure The water heater control will display the temperatures in either C or F as per selected unit of measure The main temperature unit is C and all the calculations within the control system are done using temperature values in C The display has the capability to perform a conversion from C to F The resulting temperatures in F will be rounded off to the nearest degree Temperature Set point The adjustable temperature set point is used to determine the desired outlet temperature of the water heater The water outlet of the heat engine feeds the outlet of the storage tank although some mixing does occur with the water at the top of the storage tank For this reason the temperature of water delivered is considered equivalent to the heat engine output temperature This value is to be set within the acceptable range of 90 F 32 C and 158 F 70 C when selecting the operating modes As a safety measure the control is to ensure that the set point cannot be adjusted out
94. ower the temperature below 104 F 40 C or to vacation mode Warning Water will become hot very quickly www hotwater com 45 Disconnect electrical power to the water heater Remove the pail of cleaning solution and replace it with a pail of clean water Rinse the cleaning solution from the water heater as follows Connect the electrical power to the water heater and run the heat engine Allow the clean water to flow through the heat engine for 5 minutes Disconnect electrical power to the water heater and circulating pump Disconnect the hoses from the heat engine Disconnect hoses and circulating pump draining the cleaning solution into the pail Reconnect the original hoses to the tank Remove the in line filter at the cold water inlet and clean out any residue Assemble the filter back into the unit Openthe shutoff valves on both the hot water and cold water lines Fill the tank with water Connect the electrical power to the water heater Restart water heater following lighting instructions DRAINING THE TANK ADANGER Burn hazard Hot water discharge Keep hands clear of drain valve discharge The water heater should be drained if being shut down during freezing temperatures Also periodic draining and cleaning of sediment from the tank may be necessary 1 Set the power switch to the OFF position 2 OPEN anearby hot water faucet and let the water run u
95. peed Input signals from other parts of the water heater are verified before completion of pre purge including fan current verification If one of the checks fails then the unit moves into the post purge mode followed by the hard lockout mode and the appropriate error is displayed see Error Code List and Clear out Procedure If the flame presence is detected the control delays a pre determined amount of time keeping the spark igniter energized If flame presence is not detected within 5 seconds from the moment the gas was allowed in the combustion chamber three ignition trials then the control will initiate an ignition re try for two more times If flame presence cannot be verified within the given timing and after the ignitions re try if applicable the system enters the post purge mode and the gas flow is turned off The heat engine gas valve is now turned off and the fan speed is changed to high speed for a predetermined time followed by a change of fan speed to a low value for the remaining duration of the post purge mode The control will also verify that the proper conditions are maintained and there is no flame current sensed from the flame rod If during the first stage of the post purge mode high speed fan operation conditions for a new call for heat are met then the system will allow the state change to Initial call for heat only after the first stage of the post purge mode is complete After successful completion of post pu
96. ppliance 1 Permitted only if veranda porch deck or balcony is fully opened on a minimum of two sides beneath the floor 2 A vent shall not terminate above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings FIGURE 31 A CAUTION TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE IN WINDY COLD AREAS THE MAXIMUM PRACTICAL DISTANCE BETWEEN THESE TWO TERMINALS IS RECOMMENDED www hotwater com 31 ELECTRICAL CONNECTIONS The water heater must be connected to a properly grounded electrical branch circuit A dedicated circuit is preferred Do not use a GFI outlet Refer to the rating plate attached to the water heater to determine the electrical requirements for the heater Ensure the circuit provided is correct for these requirements Important Do not use an extension cord to connect the water heater to an electrical outlet Important The electrical controls used inside the gas control of this water heater are polarity sensitive Ensure the electrical supply is connected correctly in the receptacle box Failure to connect correctly will prevent the unit from functioning properly When all the water gas and venting connections have been correctly made fill the tank as directed in the section FILLING THE WATER HEATER When the tank has been filled connect the electrical power and proceed with starting the water heater as directed in the CALIBRATION
97. r to maintain equal hot and cold water pressure 3 Selected location must provide adequate clearances for servicing and proper operation of the water heater 4 Avoid locations that could cause the water heater to freeze from outside air 5 Selected location must provide access to a properly grounded electrical branch circuit A dedicated circuit is preferred Do not use a GFI outlet Important Do not use an extension cord to connect the water heater to an electrical outlet Important The electrical controls used inside the gas control of this water heater are polarity sensitive Ensure the electrical supply is connected correctly in the receptacle box Failure to connect correctly will prevent the unit from functioning properly CAUTION Allwater heaters eventually leak Donotinstall without adequate drainage Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak the flow will not cause damage to the structure For this reason it is not advisable to install the water heater in an attic or upper floor When such locations cannot be avoided a suitable metal drain pan should be installed under the water heater Drain pans are available at your local hardware store Such a drain pan must have a clearance of atleast 1 0 in 2 5cm greater than any point on the water heater s outer jacket and must be piped to an adequate drain The pan must not restr
98. r store 2 the spark will ignite for the entire length of the hose including the exit flammable products such as flammable vapors into an appropriate drain gasoline solvents or adhe Condensate lines must be free and clear of debris sives in the same room or Vapors and must not allow back flow through the hose area near the water heater 1 cannot be seen The condensate lines must be able to flow freely are heavier than air 2 to an appropriate drain Keep flammable products 3 go along way on the floor 4 on Flammable Vapors Do not allow condensate lines to become crimped 1 far away from heater and closed 2 in approved containers Can be carried from other Analyze the entire vent system to make sure that 3 tightly closed and rooms to the the condensate will not become trapped in a section 4 out of children s reach electodes by air currents of vent pipe and therefore reduce the open cross sectional area of the vent Installation Do not install the water heater where flammable Breathing carbon monoxide can cause brain damage or death products will be stored or used Always read and understand instruction manual www hotwater com 5 INTRODUCTION Thank You for purchasing this water heater Properly installed and maintained it should give you years of trouble free service Abbreviations Found In This Instruction Manual CSA Canadian Standards Association ANSI American National Standards Institute NFPA
99. racks and replace if necessary Depth of entry Marking the depth of entry is a way to check if the pipe has reached the bottom of the fitting socket in Step F Measure the fitting depth and mark this distance on the pipe O D You may want to add several inches to the distance and make a second mark as the primer and cement will most likely destroy your first one Apply primer to the surface of the pipe and fitting Socket with a natural bristle brush This process softens and prepares the PVC or CPVC for the solvent cementing step Move quickly and without hesitation to the cementing procedure while the surfaces are still wet with primer Application of solvent cement Apply the solvent cement evenly and quickly around the outside of the pipe at a width a little greater than the depth of the fitting socket Apply a light coat of cement evenly around the inside of the fitting socket Avoid puddling Apply a second coat of cement to the pipe end STEPE Joint assembly Working quickly insert the pipe into the fitting socket bottom and give the pipe or fitting a 1 4 turn to evenly distribute the cement Do not continue to rotate the pipe after it has hit the bottom of the fitting socket A good joint will have sufficient cement to make a bead all the way around the outside ofthe fitting hub The fitting will have a tendency to slide back while the cement is still wet so hold the joint together for about 15 seconds STEPF
100. reen light is turned off then the water heater will automatically light the burners 7 Set the display to the desired setting CAUTION Hotter water increases the risk of scald injury Consult the instruction manual before changing temperature 8 If the appliance will not operate follow the instructions TO TURN OFF GAS TO APPLIANCE and call your gas STOP Follow B in the safety technician or gas supplier information above on this label If you don t DANGERI smell gas A Hotter water increases the risk of scald injury Consult the instruction 5 Turn on all electrical power to the appliance manual before changing temperature 2 Ensure tank is filled with water and the gas line is connected 3 This appliance is equipped with a device which automatically lights the burner DO NOT TRY TO LIGHT THE BURNER BY HAND 4 Wait five 5 minutes to clear out any gas If you smell 1 Set the thermostat to the lowest setting 3 Turn off all electrical power to the appliance if service is 2 Set the ON OFF switch on the control panel to the OFF to be performed position 36 www hotwater com HEAT CYCLE DEFINITIONS STATE DESCRIPTION Inter Purge Post Purge Standby Mode Lockout mode Proven Ignition If the heat engine initial call for heat is successful all checks are passed the combustion fan is energized The fan is started at a high speed for several seconds and the system verifies the fan s
101. required Heat Engine Cabinet m E x Water Inlet Filter Water Inlet Fitting Ee WI PO FIGURE 38 Install the filter Install the clean filter Close the drain valve Open the shutoff valves on both the hot water and cold water lines Fill the tank following the instructions in the Filling The Water Heater section in this Manual Close and lock the door Reconnect the electrical power to the water heater Restart the water heater following the Lighting Instructions found in the Operating Manual CLEANING THE HEAT ENGINE It is imperative that the control compartment burner and circulating air passageways of the appliance is kept clean Turn off and disconnect the electrical power Allow to cool Remove and clean the water inlet filter See Cleaning The Inlet Water Filter section Remove the front panel e Use a low air pressure to remove dust from the main burner heat exchanger and blower Do not use a wet cloth or spray cleaners on the burners NOTE Do not use volatile substances such as benzene and thinners They may ignite or fade the paint FLUSHING THE HEAT EXCHANGER LIME BUILD UP The heat exchanger must be cleaned on a regular basis to reduce lime build up The frequency of this cleaning is dependent on the quality of your local water supply Failure to flush the appliance will cause damage to the heat exchanger Damage caused by lime build up
102. rge the fan is turned off and the control will wait until the determined conditions for a call for heat are met In standby mode the unit continually monitors the input and output conditions and if abnormal conditions are detected the unit will enter in a lockout mode If a call for heat is required and all checks are passed the control will return to the initial call for heat state This is a non operational mode following the detection of an error in the system In this stage the system displays an error message and continuously monitors input and output parameters The system can move from this state into the stand by mode only if the error is cleared typical values for input and output parameters are recorded Once the power is turned on the self inspection is getting a normal status water is turned on and fan s current is normal then the ignition process will start for 5 seconds If ignition is successful the heater will go to normal combustion state and the ignition sparking will stop after 3 seconds If ignition fails the control will attempt to cycle through the heating stage three times and then attempt to re ignite the gas If ignition cannot be achieved the control will end ignition attempts and prevent any more heating cycles close the gas valve turn the blower on and display the E28 error message to the user TABLE 2 www hotwater com 37 TEMPERATURE REGULATION BOOST LI c7 NmimimE ENERGY e Li Li Li F a VACA
103. rience this type of use you should consider using lower temperature settings to reduce scald hazards 38 www hotwater com Time for Permanent Burns 2nd 8 3rd Degree Most Severe Burns Time for 1st Degree Burn Less Severe Burns 110 F 44 C normal shower temp 116 F 47 C pain threshold Water Temperature HOF AFC 22 F 50 C U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 TABLE 3 Setting Desired Temperatures 1 Set the key lock to the Off position 2 Select the desired mode button vacation energy saver or boost 3 Using the arrow buttons select the desired temperature Key Lock NOTE This is a tamper resistant feature The Key Lock is considered On or Off Key Lock is turned On one minute after the unit has been plugged in Key Lock can then be turned Off for one minute by simultaneously pressing the Up Button and the Down Button for three seconds When the keys are locked the Temperature Set point cannot be increased or decreased and the Operating Mode cannot be changed The On Off Button is not affected by the Key Lock feature All other buttons are locked when the Key Lock is On A lock or unlock LED icon will display the condition The Icon will be composed of 3 components the base a locked and an unlocked arc Operating Mode Selection Operation modes are Boost peak demand Energy Saver and
104. side of this range If the water flow is turned off and then is turned on the controller remembers and automatically resets to the last temperature If a power outage occurs or the unit is energized de energized by the STANDBY symbol for re booting the controller resets to the last temperature setting After clearing a continuous lockout error code the unit will always go back to the factory default temp setting and mode Storage Tank Set point The control is required to maintain a storage tank set point differential temperature Storage Tank Call For Heat The storage tank call for heat is generated when the tank thermistor temperature drops below the storage tank set point minus the fixed storage tank differential At the end of a call for heat the tank thermistor s temperature is equal to or greater than the storage tank set point Temperature Control Modes The temperature control functions can operate under one of the pre defined user selected control modes The temperature control mode serves to limit the range of the heat engine temperature set point and the storage tank differential Please reference the Operating Mode Selection for details of how the set point and differentials are adjusted for the different modes In brief three modes are provided Vacation Mode Energy Saver Mode and Boost Mode The temperature control mode will be maintained after a power loss Upon restoring power the temperature set point
105. sity containing 10 20 by weight virgin PVC material solvated with tetrahydrofuran THF Small quantities of dimethyl formamide DMF may be included to act as a retarding agent to extend curing time Select the proper cement Schedule 40 cement should be used for Schedule 40 pipe Never use all purpose cements commercial glues and adhesives or ABS cement to join PVC or CPVC pipe and fittings A WARNING Primers and cements are extremely flammable and must not be stored or used near heat or open flame Also use only in a well ventilated area APPLICATORS Select a suitable pure bristle type paint brush Use a proper width brush or roller to apply the primer and cement see chart below Speedy application of cement is important due to its fast drying characteristics IMPORTANT NOTE A dauber type applicator should only be used on pipe sizes 2 in and below For larger diameter pipe a brush or roller must be used RECOMMENDED BRUSH SIZE FOR PRIMER AND CEMENT APPLICATIONS Nominal Pipe IPS Size Brush Width 1 5in 2 0 1 5 2 5 in 3 8cm 6 4cm USE ONLY NATURAL BRISTLE 3 MAKING THE JOINT A Cutting Pipe must be squarely cut to allow for the proper interfacing of the pipe end and the fitting socket bottom This can be accomplished with a miter box saw or wheel type cutter Wheel type cutters are not generally recommended for larger diameters since they tend to flare the corner of the pipe end If
106. st be given to proper location Location selected should be as close to the wall as practicable and as centralized with the water piping system as possible TOP VIEW OF CLOSET WITHOUT DOOR 0 MIN TOP VIEW OF CLOSET WITH DOOR WATER HEATER 07 MIN Filo MIN FIGURE 5 Minimum clearances between the water heater and combustible construction are 0 in at the sides and rear 0 in Ocm from the front and 2 in 5 08cm from the top see Figure 5 If clearances stated on the heater differ from these distances install water heater according to clearances stated on the heater Adequate top clearance of 24 in 61cm for servicing this appliance such as changing the anodes etc should be considered before installation A minimum front clearance of 20 in 51cm and 10 in 26cm of side clearance must be allowed for access to replaceable parts EARTHQUAKE ZONES In Earthquake Zones the water heater must be braced anchored or strapped to avoid moving during an earthquake Contact local utilities for code requirements in your area The Spacemaker TSE25 Bear Claw Water Heater Strap is suitable for bracing the Hybrid water heater Follow the manufacturer s instructions for installing the braces Be sure to wear protective goggles and gloves when handling any kind of sheet metal product Tabs have been provided on each side of the rear portion of the shroud The top and bottom of each tab must be cut and gent
107. stallation Of Vent System 25 Vent Terminal Installation Sidewall 25 Sequence Of Installations 26 Installation Sequence 26 Installation Of Vent System Sidewall 27 Installation Of Vertical Vent System 27 Vent Pipe PreparatiON 28 Connection To Vent Pipe 30 U S PowerVent 31 Electrical Connections 32 CALIBRATION dst 32 OPERATING INSTRUCTIONS 33 Display Panel 2 2 aaa erea e 33 Wiring DIagram veee eee A 35 Lighting Instructions 36 Heat Cycle DefinitionS 37 Temperature Regulation 38 Unique Hybrid Features 39 Temperature Regulation 41 Constant Output Temperature Control 42 Start Up ConditiOnS 42 Operational Conditions 42 MAINTENANCE 43 Housekeeping 43 Venting System Inspection 43 Burner Operation And Inspection 43 Anode Rod Inspection 43 Anode Rod Replacement 44 Temperature pressure Relief Valve Operation 44 MOS 24 ki oo oad Ode e ae metrik sa pena ra pet Ad 44 Snow Accumulation 44 Cleaning Th
108. switch which will open when the temperature reaches the maximum design temperature for the venting used This switch should reset to the closed position when the vent pipe temperature cools sufficiently Opening Temperature is approximately 165 F 74 C 5 F 2 8 C Closing Temperature is approximately 135 F 57 C 5 F 2 8 C The power for the main gas valve is to be routed through the Exhaust Vent High Temperature Switch causing the main gas valve to be de energized immediately when the switch opens The status of the Exhaust Vent High Temperature switch should be continually monitored by the controller If an open switch is detected the control should declare a fault and respond according to the fault The fault is a continuous lockout Energy Cut Out ECO Temperature Switch The heat exchanger of the heat engine is equipped with a surface mounted bimetallic switch which opens when the water temperature exceeds the safe operating temperature for the water heater Opening Temperature is 185 F 9 F 85 C 5 C Closing Temperature is 149 F 6 F 65 C 3 C The power from the main gas valve is to be routed through the ECO switch causing the main gas valve to be immediately de energized when the switch opens The status of the ECO switch should be continually monitored by the controller If an open switch is detected the control should declare a fault and respond according to the fault This will
109. t the life of the anode installed in this water heater Refer to Anode Rod Inspection section in this manual Clean the filter on the water inlet as frequently as required by the quality of your local water Refer to Cleaning The Inlet Water Filter section of this manual One additional filter is supplied with your water heater TEMPERATURE PRESSURE RELIEF VALVE AWARNING e Temperature pressure relief valve must comply with ANSI Z21 22 CSA 4 4 and ASME code Properly sized temperature relief valve must be installed in opening provided e Can result in overheating and excessive tank pressure Can cause serious injury or death This heater is provided with a properly certified combination temperature pressure relief valve by the manufacturer The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production oflisted equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems ANSI Z21 22 CSA 4 4 and the code requirements of ASME If replaced the valve must meet the requirements of local codes but not less than a combination temperature and pressure relief valve certified as indicated in the above paragraph The valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater 150 psi 1 035 kPa and a discharge capacity not less than the water heater
110. ted to one year duration for the heater or any of its parts Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you CLAIM PROCEDURE Any claim under this warranty should be initiated with the dealer who sold the heater or with any other dealer handling the warrantor s products 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 PROOF OF PURCHASE AND PROOF OF INSTALLATION DATES ARE REQUIRED TO SUPPORT WARRANTY FOR CLAIM FROM ORIGINAL OWNER THIS FORM DOES NOT CONSTITUTE PROOF OF PURCHASE OR PROOF OF INSTALLATION DISCLAIMERS NO EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE MERCHANTABILITY OF THE HEATER OR THE INSTALLATION OPERATION REPAIR OR REPLACEMENT OF THE HEATER OR PARTS THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE LOSS OF USE OF THE UNIT INCONVENIENCE LOSS ORDAMAGE TO PERSONAL PROPERT Y 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 Some states do not allow the limitation or exclusion of incidental or consequential damages so the above limitation or exclusion ma
111. that is suitable for potable drinkable water such as copper CPVC PEX or polybutylene DO NOT use PVC water piping DO NOT use any pumps valves or fittings that are not compatible with potable water DO NOT use valves that may cause excessive restriction to water flow Use full flow ball or gate valves only DO NOT use any lead based solder in potable water lines Use appropriate tin antimony or other equivalent material DO NOT tamper with the gas control thermostat igniter flammable vapor sensor or temperature and pressure relief valve Tampering voids all warranties Only qualified service technicians should service these components DO NOT use with piping that has been treated with chromates boiler seal or other chemicals DO NOT add any chemicals to the system piping which will contaminate the potable water supply HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes washing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children and the physically or developmentally disabled If anyone using hot water from this heater fits into one of these www hotwater com 11 groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then y
112. tween the three possible modes of operation www hotwater com 33 Numeric Display Numeric information such as temperature set point maintenance codes and error codes are displayed using a large yellow LED display Up and Down Buttons Two buttons with Up and Down arrows are used for adjusting the data on the display Other secondary functions such as turning the Key Lock Off are described in other sections Temperature Set point change Two buttons with Up and Down arrows are used to adjust the desired temperature set point When the Temperature Set point is displayed and the Key Lock Is Off pressing the Up Button will increase the set point and pressing the Down button will decrease the set point NOTE The Temperature Set point cannot be adjusted beyond the limits of the current Mode selected Burner in Operation When the burners are in operation and flame is detected by the flame sensor the flame symbol is illuminated Switching Between Units of Measure Switching between temperature units of measure F C Two yellow LEDs will be used to light up the current unit mode F or C To switch units of measure simultaneously press the Mode button and the Up button Fault Indication A red fault LED lighting a large red exclamation point should be present on the display panel Maintenance mode By simultaneously pressing the Mode and down arrow buttons for 3 secon
113. y not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Should governmental regulations or industry standards prohibit the Manufacturer from furnishing a comparable model replacement under this warranty the Owner will be furnished with the closest comparable water heater meeting the current governmental regulations and industry standards A supplementary fee may be assessed to cover the additional cost associated with the changes made to meet applicable regulations and standards www hotwater com 57 58 NOTES www hotwater com NOTES www hotwater com 59 fe Smith 500 TENNESSEE WALTZ PARKWAY ASHLAND CITY TN 37015 PHONE 1 800 433 2545 FAX 1 800 433 2515 www aosmithwaterheaters com email parts hotwater com

A.O. Smith HYB-90N Instruction Manual

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