Rheem Commercial Power Direct Vent Water heater Water Heater User Manual
Contents
1. o 24 MV PV PGV PV o n GND ECO LED a Q PILOT VALVE LED 1 IGN PV o ANY REPLACEMENT WIRE MN MUST BE RATED FOR 250 C PILOT ELECTRODE ASSY GAS VALVE CONNECTION DIAGRAM SCHEMATIC Figure 14 Diagrams for units supplied with Honeywell VR8304P or VR8304M Gas Valve and Honeywell S8600M Ignition Control Honeywell Thermo stat and Temperature Limiting Switch for vent pipe NOTICE If any of the original wire as supplied with this appliance must be replaced it MUST be replaced with 18 GA 600V 105 C wire or its equivalent unless otherwise noted CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation VERIFY PROPER OPERATION AFTER SERVICING NORMAL OPERATIONSEQUENCE L1 INDICATEDBY BOXED NUMERALS 120v 2 Cay wy BLOWER NA LED BL 4 ela BR 3 BR 4 120V THERMOSTAT THERMOSTAT O IGNITION m 12 I O PILOT VALVE ms xc AND 5 5 e IGNITION HIGH LIMIT BLACK I O MAIN VALVE LED J SWITCH WHITE N 4 1 TRANSFORMER o 7 M N NSW A GRAY gt m SR 1 e2. n THERMOSTAT LED IGNITION nu 4 CONTROL MAIN VALVELED 6 MGV o GND MV o o 24 MV PV DIT BIS o PGV P o GND ECO LED O PILOT VALVE LED 5 IGN ine ANY REPLACEMENT WIRE MUST BE RATED FOR 250 C PILOT ELECTRODE ASSY MVO GAS VALVE CONNECTION DIAGRAM SCHEMATIC Figure 14 Diagrams for units supplied with Honeywell VR8304P or VR8304M Gas Valve and Honeywell S8600M Ignition Control White Rodgers Thermostat and Temperature Limiting Switch for vent pipe 26 Wiring and Schematic Diagrams NORMAL OPERATION SEQUENCE NOTICE If any of the original wire as supplied INDICATED BY BOXED NUMERALS with this appliance must be replaced it MUST be 120V replaced with 18 GA 600V 105 C wire or its equiv alent unless otherwise noted LED INDICATORS THERMOSTAT AND LIMIT 1 T IGNITION LED n IGNITION CONTROL H ECO LED n PILOT VALVE BL 2 p dd ANY REPLACEMENT WIRE MUST BE RATED FOR 250 C ELECTRODE ASSY CONNECTION DIAGRAM SCHEMATIC 6 CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation VERI FY PROPER OPERATION AFTER
3. Figure 10 Draining the Condensate 4 JOINING PIPES AND FITTINGS All pipe fittings solvent cement primers and procedures must conform to Ameri can National Standards Institute and American Society for Testing and Materials ANSI ASTM standards CEMENTING JOINTS All joints in the vent piping must a natural bristle brush or the dauber supplied with the can be properly sealed and we recommend using the following mate The proper brush size is one inch rial 12 FOR PROPER INSTALLATION A CAUTION 6 DO NOT use solvent cement that has become curdled lumpy or thickened DO NOT thin solvent cement Observe shelf precautions printed on the containers For applications below 32 F use only low temperature type solvent cement Avoid skin or eye contact Observe all cautions and warnings on material containers WIRING A polarized 120V 50 60 Hz power supply with suitable disconnect means must be connected to the black and white leads provided The current draw by the Power Direct Vent unit is 1 5 Amps The water heater when installed must be electrically grounded in ac cordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 in the United States or CSA C22 1 Electrical Code in Canada Refer to Fig 14 on page 26 amp 27 of this manual for water heater internal wiring diagrams Appropriate so
4. The unit may be vented horizontally through a wall or vertically through the roof Pipe runs must be adequately supported along both vertical and horizontal runs Maximum unsupported span is recommended to be no more than 4 feet It is imperative that the first hanger be located on the horizontal run immediately adjacent to the first 90 degree elbow from the vertical rise or at the blower outlet in the case of a horizontal blower position Support method used should isolate the vent pipe from floor joists or other structural members to help prevent the transmission of noise and vibration Do not support pin or otherwise secure the vent ing system in a way that restricts the normal thermal expansion and contraction of the chosen venting material If the water heater is being installed as a replacement for an existing power vented water heater a thorough inspection of the existing venting system must be performed prior to any installation work Verify that the correct materials as detailed above have been used and that the mini mum or maximum vent length and terminal locations as detailed in this manual have been met Carefully inspect the entire venting system for any signs of cracks or fractures particularly at the joints between elbows or other fittings and the straight runs of vent pipe Check the system for signs of sagging or other stresses in the joints as a result of misalignment of any components in the system If any of these condi
5. L8N 3P3 Phone 1 800 268 6966 When contacting the manufacturer the following information should The following Gaskets are required for Normal Maintenance for all Models SP5886 Tank Handhole Sealplate Gasket All other Parts can be ordered by providing the following information 1 Description of Part s such as Main Gas Valve Pilot Burner Main Burner Thermostat Blower Assembly Anode Rod Or other parts as required 2 Quantity of each part required 3 Complete models number and name of the water heater 4 Serial Number of water heater 5 Specify Type of Gas 6 Address Parts Orders to your distributor or dealer 28
6. DO NOT try to light any appliance DO NOT touch any electrical switch DO NOT use any phone in your building Leave the house immediately and make sure your fam ily and pets leave also Leave the doors open for ventilation and contact the gas supplier a qualified service agency or the fire department Keep the area clear until the service call has been made the leak is corrected and a qualified agency has determined the area to be safe A WARNING Both LP and natural gas have an odorant added to help detection Some people may not physically be able to smell or recognize this odorant If unsure or unfamiliar about the smell associated with LP or natural gas ask the gas supplier Other conditions such as Odorant Fade which causes the odorant to fade or diminish in inten sity can also hide or camouflage a gas leak A DANGER Waiter heaters utilizing Liquefied Petroleum gas LP are different from natural gas models A natural gas heater will not function safely on LP gas and vice versa No attempt should ever be made to convert a heater from natural gas to LP gas To avoid possible equipment damage personal injury or fire DO NOT connect this water heater to a fuel type not in accordance with unit data plate Propane for propane units Natural gas for natural gas units These units are not certified for any other type fuel A WARNING LP appliances should not be installed below grade for example in a base
7. 25 Wiring Diagrams 26 27 How to Obtain Service Assistance 28 READ THE SAFETY INFORMATION Your safety and the safety of others are very impor tant There are many important safety messages in this manual and on your appliance Always read and obey all safety messages This is the safety alert symbol Recognize this symbol as an indication of Important Safety Information This symbol alerts you to potential hazards that can kill or hurt you and others All safety messages will follow the safety alert sym bol and either the word DANGER WARNING CAUTION or NOTICE These words mean A DANGER An imminently hazardous situation that will result in death or serious injury WARNING A potentially hazardous situation that could result in death or serious injury and or damage to property CAUTION A potentially hazardous situation that may result in minor or moderate injury Notice Attention is called to observe a specified procedure or maintain a specific condition A General Safety Precautions To meet commercial water use needs the thermostat on this water heater is adjustable up to 180 F However water temperatures over 125 F can cause severe burns instantly or death from scalds This is the preferred starting point for setting the control for supplying general purpose hot water Safety and energy conservation are factors to be considered when setting the water tempe
8. Refer to Section 5 of Troubleshooting Guide When illuminated this red LED indicates that the Ignition Control Module is supplying 24 VAC power to the MV Main Valve terminal on the Gas Control Valve Refer to Section 6 of Troubleshooting Guide System Sentinel Troubleshooting Guide Section 1 the POWER LED Is the POWER LED Illuminated Turn switch to ON position Is the Power is Power LED now illuminated being supplied to the heater the ON OFF Switch is func tioning and the 24V AC Transformer is functioning Is the ON OFF Switch in the ON position Is 120 VAC power present at the Check circuit breaker or fuse and field connec branch circuit connections to Black tion of branch circuit wiring to leads of switch wire of the switch and White wire of Repair or replace as required Is POWER LED the transformer now illuminated Is 120 VAC power present between Replace Switch then verify that the Black and White wires to the power is present Is POWER LED transformer now illuminated Is 24 VAC power present between Replace Transformer then verify the Yellow and Gray wires from the that power is present Is POWER transformer LED now illuminated The System Senti nel Panel is defective and must be replaced A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation
9. Screen Inside Outside of Building Wall Sheet Metal Shield on Brick or Masonry Walls Vent Terminal with 7 Mesh Protective Outside of Building Wall Installation Figure 6 Outlet bea outlet Additional Considerations See Figure 9 1 Do Not install vent terminal under any patio or deck 2 To help prevent moisture from freezing on walls and under eaves do not locate vent terminal on the side of a building with prevailing winter winds 3 Do Not terminate vent pipe directly on brick or masonry surfaces Use a rust resistant sheet metal backing plate behind vent See Figure 9 4 Do Not locate vent terminal too close to shrubbery since flue gases may damage them 5 Caulk all cracks seams and joints within six 6 feet of vent terminal 6 All painted surfaces should be primed to lessen the chance of physical damage Painted surfaces will require maintenance 7 Insulate vent pipe exposed to cold conditions attics crawl spaces etc to help prevent moisture from accu mulating in vent pipe A WARNING Moisture in the flue gas will condense as it leaves the vent terminal In cold weather this condensate can freeze on the exterior wall under the eaves and on surrounding objects Some discoloration to the exterior of the building is to be expected Ho
10. APPLIANCE IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE PILOT DO NOT TRY TO LIGHT THE PILOT BY HAND 5 TURN THE GAS COCK KNOB CLOCKWISE TO OFF WAIT FIVE 5 MINUTES TO CLEAR OUT ANY GAS IF YOU THEN SMELL GAS STOP FOLLOW B IN THE SAFETY INFORMATI ON ABOVE ON THIS LABEL IF YOU DON T SMELL GAS GO TO NEXT STEP TURN GAS COCK KNOB COUNTER CLOCKWISE Y TO ON TURN ON ALL ELECTRIC POWER TO THE APPLIANCE SET THERMOSTAT TO DESIRED SETTING 10 IF THE APPLIANCE WILL NOT OPERATE FOLLOW THE INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE AND CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLIER TO TURN OFF GAS TO APPLIANCE APPLIANCE IF SERVICE IS TO BE PERFORMED SET THE THERMOSTAT TO LOWEST SETTING 3 TURN THE GAS COCK KNOB CLOCKWISE b TURN OFF ALL ELECTRIC POWER TO THE TO OFF Operation Before operating this water heater be sure to read and follow the instructions on the label pictured below and all other labels on the water heater as well as the warnings printed in this manual Failure to do so can result in unsafe operation of the water heater resulting in prop erty damage bodily injury or death Should you have any problems reading or following the instructions in this manual STOP and get help from a qualified person 1 LIGHTING PROCEDURE Lighting procedures are outlined on the label pictured below This label is also located on the water heater near th
11. VERIFY PROP ER OPERATION AFTER SERVICING 20 System Sentinel Troubleshooting Guide Section 2 the THERMOSTAT LED Is the LED Illuminated YES Ensure that power is being supplied to Thermostat is calling for the water heater Refer to Section 1 the heat and 24 VAC power POWER LED in this Troubleshooting Guide and correct if necessary Is the THERMO STAT LED now illuminated Is Thermostat set at a tempera Adjust ture higher than the water tem Thermostat to a higher setting perature in tank Is Thermostat LED now illumi nated Ensure that power is being supplied to Is 24 VAC the water heater Refer to Section 1 the power present at Yellow Wire POWER LED in this Troubleshooting Guide Terminal inside Thermostat and correct if necessary Is the THERMO STAT LED now illuminated Is 24 VAC power present at Blue Wire Terminal inside Ther mostat Thermostat is defective or out of calibration and must be replaced A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation VERIFY PROP ER OPERATION AFTER SERVICING 21 System Sentinel Troubleshooting Guide Section 3 the IGNITION LED Is the Ignition LED Illuminated The Thermostat has called for heat the Blower is running and 24 VAC power is being supplied to Is Spark Ignitor operating
12. be protected from freezing No valve of any type restriction or reducer coupling should be installed in the discharge line Local codes shall govern the installation of relief valves GAS SUPPLY The inlet gas pressure to the water heater must not exceed 10 5 w c 2 6 kPa for Natural gas For purposes of input adjust ment the minimum inlet gas pressure with main burner on is shown on the rating plate Check to see if high or low gas pressure is present and then contact the gas company for correction The gas line should be of adequate size to prevent undue pressure drop Sizing based upon Table 1 on pg 13 is recommended No ad ditional allowance is necessary for an ordinary number of fittings A ground joint union and manual shutoff valve should be installed in the gas line near the water heater so that the burner assembly may be easily removed The shut off valve must be readily accessible for turning on or off See Fig 4 on page 7 A sediment trap must be installed at the bottom of the gas line See Fig 4 on page 7 LEAK TESTING The water heater and its gas connections MUST be leak tested at normal operating pressure before it is placed in op eration Turn ON the manual gas shut off valve near the water heater Use a soapy water solution to test for gas leaks at all connections and fittings Bubbles indicate a gas leak that must be corrected The water heater factory connections to the gas valve should also be lea
13. been sub jected to over heating fire flood physical damage or if gas supply fails to shut off B Do Not turn on water heater unless it is filled with water C Do Not turn on water heater if cold water supply shut off valve is closed D Do Not store or use gasoline or other flammable vapors and liquids such as adhesives or paint thinner in vicinity of this or any other appliance If such flammables must be used open doors and win dows for ventilation and all gas burning appliances in vicinity should be shut off including their pilot lights to avoid vapors igniting NOTICE Flammable vapors may be drawn by air currents from sur rounding areas to the water heater 2 TEMPERATURE SETTINGS The thermostat is adjusted to its lowest temperature position when shipped from the factory To meet com mercial water use needs it is adjustable up to 180 F 82 C How ever water temperatures over 125 F 52 C can cause severe burns instantly or death from scalds This is the preferred starting point for setting the control for supplying general purpose hot water Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat The most energy ef ficient operation will result when the temperature setting is the lowest that satisfies the needs consistent with the application Hotter water increases the Potential for Hot Water SCALDS A DANGER To adjust the water temperatur
14. must be replaced Refer to Section 3 the IGNITION LED and Section 4 the PILOT VALVE LED of Troubleshoot ing Guide Repair or replace components as required Section 6 the MAIN VALVE LED Is the MAIN VALVE LED Illuminated The Ignition Control Module is providing 24 VAC between the MV and MV PV terminals on Gas Control Valve and Main Burn er should be operating Is the Pilot Flame burning Is 24 VAC present between Blue wire on Is the Spark Ignitor operating MV Terminal and White wire on MV PV Can sparking be heard terminal on the Ignition Control Module The System Sentinel Panel is defective and must be replaced Is the inlet gas pressure at or below the maximum as specified on the rating plate Is 24 VAC present between Blue YES wire on MV Terminal and White wire on MV PV terminal on gas valve aNG Main Gas Valve is inoperative and must be replaced Ignition Control Module is inoperative and must be replaced Check Continuity of Blue and White wires between Ignition Control Module and Gas Control Valve Repair or replace as required to restore power to gas valve A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation VERIFY PROP ER OPERATION AFTER SERVICING oA Replacement Parts Instructions For Placing a Parts Order All parts o
15. recommend that it be drained This unit is provided with a special fitting on the blower that allows for the Cleaner Primer and Medium Body Solvent Cement draining of condensate formed in the vent The drain hose should have two 2 loops formed to act as traps Before operation of the water 1 Cut pipe end square remove jagged edges and burrs Cham heater both loops should have water placed in them Support the traps fer end of pipe then clean fitting socket and pipe joint area so that they remain horizontal Condensate is known to be acidic refer of all dirt grease or moisture to local state or federal codes for proper handling methods 2 After checking pipe and socket for proper fit wipe socket and pipe with cleaner primer Apply a liberal coat of primer to inside surface of socket and outside of pipe Do not allow primer to dry before applying cement 3 Apply a thin coat of cement evenly in the socket Quickly apply a heavy coat of cement to the pipe end and in sert pipe into fitting with a slight twisting motion until it bottoms out NOTICE Cement must be fluid if not recoat Hold the pipe fitting for 30 seconds to prevent the tapered socket from pushing the pipe out of the fitting 5 Wipe all excess cement from the joint with a rag Allow 15 minutes before handling Cure time will vary according to fit temperature and humidity NOTICE Stir the solvent cement frequently while using Use
16. the entire floor must be covered by the panel The water heater should not be located in an area where leakage of the tank or connections will result in damage to the area adjacent A CAUTION to it or to lower floors of the structure When such areas cannot be avoided it is recommended that a suitable catch pan adequately drained be installed under the water heater The pan MUST NOT restrict the flow of combustion air flow to bottom of water heater NOTICE Auxiliary catch pan installation MUST conform to the ap plicable local codes D RESTAURANTS If the water heater is to be installed in a restau rant or other location where the floor is frequently cleaned it must be elevated to provide at least six inches 15 cm of clearance from the floor to comply with NSF International recommendations E CORROSIVE ATMOSPHERES The heater should not be installed near an air supply containing halogenated hydrocarbons For example the air in beauty shops dry cleaning establishments photo processing labs and storage areas for liquid and powdered bleaches or swim pool chemicals often contain such hydrocarbons The air there may be safe to breathe but when it passes through a gas flame corrosive elements are released that will shorten the life of any gas burning appliance Propellants from common spray cans or gas leaks from refrigeration equipment are highly corrosive after passing through a flame The lim ited warranty is vo
17. the white wire of the transformer Relay is Is 24 defective VAC present and must be across coil replaced of relay Recheck all connections should have power at blower motor Review pressure switch circuit NO on this page A CAUTION Wiring harness is defec tive and must be replaced Check Con tinuity of the Red wire from the Ignition Module to the Pressure Switch Is continuity Power should be at 24 VAC of Ignition Module Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation VERIFY PROP ER OPERATION AFTER SERVICING 22 System Sentinel Troubleshooting Guide Section 4 the PILOT VALVE LED NO Is the PILOT VALVE LED Illuminated YES The Ignition Control Module is in Is the Pilot Flame burning the Ignition sequence and is pro viding 24 VAC power to the ECO Energy Cut Off Device inside of ad the Thermostat Is the Spark Ignitor operating Can sparking be heard The System Sentinel Panel is defective and must be replaced Remove Ignition Cable and check for good conti nuity replace if necessary Check Ignitor Electrode gap for proper spacing 1 8 to 5 32 Correct if necessary Is 24 VAC present between the Brown wire on PV Examine Ceramic Insulator on Pilot Assembly Terminal and White wire on PV MV Terminal on for cracks Replace if cracks are evident th
18. 60 seconds Small adjustments can be made by varying the manifold pressure from the designated settings mentioned above 5 INTERMITTENT PILOT FLAME ADJUSTMENT No adjustment is required with normal inlet gas pressures The pilot flame adjustment valve is pre set and does not normally require re adjustment 6 HIGH ALTITUDE Ratings of gas appliances are based on installation and operation at sea level of elevations of 2000 feet Factory prepared high altitude models are available and are specifically rated for installation at elevation up to 8000 feet Refer to rating plate on the front of the water heater for number and altitude specifications Also refer to the supplement sheet for information on venting high altitude models 7 EMERGENCY SHUTDOWN WARNING Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance A WARNING DO NOT use this appliance if any part has been under water Imme diately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water If the water heater has been subjected to fire or physical damage turn off gas at the manual gas control shut off valve Do not operate the water heater again until it has been checked out by a qualified service technician Maintenance Properly maintained this water heater will prov
19. C pipe and fit Venting Information for 4 Vents tings Use only the vent terminals supplied withthe water heater Number of 90 Elbows with TETEE euer HORIZONTAL VENT TERMINAL LOCATION The location of the Vent Terminal i Length Required Pipe Length vent terminal depends on the minimum clearances and consider Ft Ft ations shown in the charts on pages 11 and 12 m m wo wo Wes men mss zT D Vent lengths for the inlet and the outlet pipes should not have a differ ence of more than five 5 equivalent feet NOTICE 3 and 4 vent pipe should not be mixed other than to reduce the 4 vent for the 3 PVC Vent Terminal This unit is supplied with two 2 3 inch Schedule 40 PVC 45 vent terminals The 4 vent pipe can use up to 16 inches of 3 PVC preceding the vent terminal This unit uses the same vent terminals sup plied with the unit for both 3 and 4 pipe 4 to 3 reducer will be required to go from 4 to 3 pipe 9 Mortar or Silicone Caulk From Water Heater Mortar or Silicone Caulk 4x3 Reducer Coupling ge 4 Vent 205209 4x3 Reducer 3 Vent Coupling Pipe From _ LZZ LOLOL Water Heater Mortar or Silicone Caulk 4 Vent Pipe cO Ss Seo 4 Vent From Water Heater Vent Terminal with Mesh Protective Screen Inside Outside of Building Wall Masonry Walls a Sheet Metal Shield on Brick or 8 Vent Terminal with Mesh Protective
20. Can sparking be heard Is the Blower Operating the Ignition Control Module and the ignition sequence will begin Is there 120 VAC across Black wire and White wire of blower The System Sentinel Panel is defective and must be replaced Is 24 VAC present between the Gray ground wire and the Red 24 V wire connected to the Igni tion Control Module Is there 24 VAC present between the common and Normally open terminal of pressure switch 1 Is there 120 VAC between Blower is defective and must be the black wire at the relay and the white wire on the replaced transformer 1 Remove Ignition Cable and check for good continuity replace if necessary 2 Check Ignitor Electrode s gap for proper spacing 1 8 to 5 32 Correct if neces sary 3 Examine Ceramic Insulator on Pilot Assembly for cracks Replace if cracks are evident Check con tinuity of yellow wires to pressure switches and between switches Check continuity Check continuity of black wire to of black wire from relay relay to blower motor and white If all of the above components check okay wire to motor CORN replace Ignition Control Module good Is continuity good Pressure Switch is defective and must be replaced Check Is continuity wire con nections Wire is defec tive and must be replaced Is there 120 between the black wire on the relay power going to blower and
21. Commercial Power Direct Vent Water Heater USE amp CARE MANUAL WITH INSTALLATION INSTRUCTIONS FOR THE CONTRACTOR MULTI FLUE COMMERCIAL MODELS I IH dc CE Recognize this symbol as an Indication of Important A Do Not Destroy this Manual Please read carefully and Safety Information keep in a safe place for Future Reference NOTICE This water heater is designed for use in a commercial application and the installation and maintenance of it should be per formed by a qualified licensed service personnel If the foregoing assumption is not appropriate then we recommend that you obtain and retain our Residential Use amp Care Manual A CALIFORNIA PROPOSITION 65 WARNING This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING If the information in these instructions are not followed exactly a fire or explosion may result causing property damage personal injury or death A FOR YOUR SAFETY Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions Do not store or use gasoline or other flammable vapors or liquids or other combustible materials in you cannot reach your gas Supplier call tie Tire the vicinity of this or any other appliance To do so department FEQ TESIEN AN Do not return to your building
22. SERVICING Figure 14 Diagrams for units supplied with Honeywell VR8304P or VR8304M Gas Valve and Honeywell S8600M Ignition Control 27 How to Obtain Service Assistance 1 Should you have any questions about your new water heater or if it be made available requires adjustment repair or routine maintenance it is suggested that you first contact your installer plumbing contractor or previously Model and serial numbers of the water heater as shown on the rating agreed upon service agency In the event that the firm has moved or plate attached to the jacket of the heater is unavailable refer to the telephone directory commercial listings or local utility for qualified service assistance b Address where water heater is located and can be seen 2 Should your problem not be solved to your complete satisfaction you should then contact the Manufacturer s National Service Department at one of the following address c Name and address of installer and any service agency who performed service on the water heater In The U S A d Date of original installation and dates any service work was per Rheem Manufacturing Co Water Heater Division formed 2600 Gunter Park Drive Montgomery Alabama 36109 1413 e Details of the problem as you can best describe them Phone 1 800 432 8373 l f List of people with dates who have been contacted regarding your In CANADA problem Rheem Canada Ltd Lt e P O Box 2846 Hamilton
23. To install the vent terminals a short length of 3 inch maximum of 16 inches long pipe will need to be used Refer to Figure 9b on page 10 The GP100 250 model can only be vented using 4 inch Schedule 40 PVC pipe and fittings The 4 inch pipe can be connected directly to the blower coupling and 4 inch tee MINIMUM AND MAXIMUM VENT LENGTHS Charts for installation from 0 2000 ft elevation ONLY Please see supplement sheet for installations above 2000 feet NOTICE Be sure to mount inlet vent terminal 6 inches higher than the outlet vent terminal Vent terminals need to be a minimum of 7 inches center to center horizontally apart and a maximum of 24 inches apart GP100 150 amp GP100 200 GP100 250 Venting Information for 3 Vents Venting Information for 4 Vents Number of 90 Elbows with Minimum Pipe Maximum Length Required Pipe Length Ft Number of 90 Elbows with Kobe Minimum Pipe Maximum Vent Terminal Length equired Pipe Length 45 Elbows Inlet Vent Outlet Vent One 1 One 1 Vent Terminal Number of 45 Elbows Fi Ft Four a Foura 25 0 Vent lengths for the inlet and the outlet pipes should not have a iff f than fi ivalent feet Vent lengths for the inlet and the outlet pipes should not have a dif ve xa etian uo ference of more than five 5 equivalent feet One 1 One 1 Two 2 Two 2 Two 2 Two 2 meo mea T GP100 250 can only be vented with four 4 inch PV
24. al injury or loss of life A This appliance is equipped with an ignition device which automatically lights the pilot DO NOT try to light the pilot by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department C Use only your hand to turn the gas control knob Never use tools If the knob will not turn by hand don t try to repair it call a qualified service technician Force or attempt to repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified ser vice technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP READ THE SAFETY INFORMATI ON ABOVE ON THIS LABEL USING A SLOTTED SCREW DRIVER INSERT INTO TEMPERATURE ADJUSTMENT OPEN ING TURN SCREW CLOCKWISE y TO THE LOWEST SETTING THERMOSTAT GAS COCK KNOB GAS VALVE TEMPERATURE ADJUSTMENT SCREW TURN OFF ALL ELECTRIC POWER TO THE APPLIANCE THIS
25. any pressure test ing of the gas supply piping at pressures equal to or less than 1 2 psi 14 w c 3 5 kPa 5 VENTING WARNING The water heater must be vented to the outdoors as described in these instructions DO NOT connect this water heater to an existing Vent or Chimney it must be vented separately from all other appliances WARNING Failure to properly vent the water heater to the outdoors as outlined above and in the following section can result in unsafe operation of the water heater causing bodily injury explosion fire or death A WARNING To avoid the risk of fire explosion or asphyxiation from carbon monoxide NEVER operate this water heater unless it is properly vented and has an adequate air supply for proper operation The vent pipe must overlap a minimum of 7 on each connection It is important that the vent pipe engages fully into any pipe fitting and be kept in that position until the adhesive has fully cured DO NOT drill or punch holes in the plastic pipe or fittings NOTICE This unit can be vented using only the following recommended pipe material Use only 3 or 4 inch diameter pipe PVC Schedule 40 ASTM D 1785 CPVC Schedule 40 ASTM F 441 ABS Schedule 40 ASTM D 2661 The fittings other than the VENT TERMINAL should be equiva lent to the following PVC Schedule 40 DWV ASTM D 2665 CPVC Schedule 40 DWV ASTM F 438 ABS Schedule 40 DWV ASTM D 2661
26. arried some distance from where their liquids are being used or stored The open flame of the water heater s intermittent pilot or main burner can ignite these vapors causing an explosion or fire which may result in severe burns or death to those in range as well as property damage For these reasons installation of a gas fired water heater in a garage is not desirable A WARNING If a location in a garage is the only alternative the gas water heater Should be installed so that the open flame of the pilot and main burner are no less than 18 inches above the garage floor The water heater must be located or protected so it is not subject to physical damage by moving vehicles or area flooding Raising the gas fired water heater will reduce BUT NOT eliminate the possibility of light ing the vapor of any flammable liquids which may be improperly stored or accidentally spilled C All models are certified for installation on combustible floors and in alcoves The minimum side and top clearance to walls and ceiling for providing protection of combustible materials are shown on the water heater s rating label A front clearance of 18 inches 46 cm should be provided for adequate inspection and servicing If the water heater must be installed on carpeting place a metal or wood panel beneath water heater extending beyond its full width and depth at least 3 inches 7 6 cm in all directions If the water heater is installed in an alcove
27. as control which has been under water OPERATING INSTRUCTIONS STOP READ THE SAFETY INFORMATION ABOVE ON THIS LABEL 2 REMOVE OUTER COVER USING A SLOTTED SCREWDRIVER INSERT INTO SLOT IN CENTER OF DIAL TURN DIAL COUNTERCLOCKWISE TOTHE LOWEST SETTING Honeywell THERMOST AT TEMPERATURE Index ADJUSTMENT DIA NOTE Thermostat shown with cover removed GAS VALVE 3 TURN OFF ALL ELECTRIC POWER TO THE APPLIANCE 4 THIS APPLIANCE IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE PILOT DO NOT TRY TO LIGHT THE PILOT BY HAND 5 TURN THE GAS CONTROL KNOB CLOCK WISE N TO OFF WAIT FIVE 5 MINUTES TO CLEAR OUT ANY GAS IF YOU THEN SMELL GAS STOP FOL LOW B IN THE SAFETY INFORMATION ABOVE THIS LABEL IF YOU DON T SMEL L GAS GO TO NEXT STEP TURN THE GAS CONTROL KNOB COUNTER CLOCKWISE TO ON TURN ONALL ELECTRIC POWER TO THE APPLIANCE SET THERMOSTAT TO DESIRED SETTING INSTAL L OUTER COVER IF THE APPLIANCE WILL NOT OPERATE FOL LOW THE INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE AND CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLIER TO TURN OFF GAS TO APPLIANCE TURN OFF ALL ELECTRIC POWER TO THE 3 TURN THE GAS CONTROL KNOB CLOCK APPLIANCE IF SERVICE IS TO BE PERFORMED 2 SET THE THERMOSTA T TO LOWEST SETTING WISE WO Operation SAFETY PRECAUTIONS A Do turn off manual gas shut off valve if water heater has
28. ation regarding this subject If a recirculation line is installed the return connection should be made to a tee close to the inlet connection on the water heater A check valve should always be installed in the recirculation line to prevent cold water from entering WATER CONNECTIONS This water heater may be connected indi vidually in multiples with others or with an external hot water storage tank Inlet water connections are made to the lower coupling on the heater and outlet water connections are made to the upper coupling Each water heater is supplied with the necessary components Diffuser tubes to make the water connections that will ensure proper perfor mance The components are supplied in a bag attached to the water heater If special instructions are required for any specific water heater they will be included in the bag Cap or plug unused connections Use only clean new galvanized steel copper or approved plastic pipe for water connections Local codes or regulations shall govern the exact type of material to be used The installation of unions on the inlet and outlet water lines and a shut off valve in at least the cold water inlet line is recommended so the water heater may be easily disconnected for servicing Dielectric unions are not required for protection of water heater When this water heater is supplying general purpose hot water require ments for use by individuals a thermostatically controlled mixi
29. e insert a small straight screwdriver into slotted screw in hole in front of ther mostat and turn wheel to desired setting Thermostat is adjustable up to 180 F CAUTION Hotter water increases the risk of SCALDING Honeywell White Rodgers Figure 11 Thermostat adjustment E Do not allow combustible materials such as newspaper rags or mops to accumulate near water heater If there is any difficulty in understanding or following the OPERA TION or MAINTENANCE instructions it is recommended that a qualified person or serviceman perform the work A CAUTION Hydrogen gas can be produced in a hot water system served by this water heater that has not been used for a long period of time generally two weeks or more HYDROGEN GAS IS EXTREMELY FLAMMABLE To dissipate such gas and to reduce risk of injury it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance connected to the hot water system If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow Do not smoke or use an open flame near the faucet at the time it is open A WARNING When this water heater is supplying general purpose hot water requirements for individuals a thermostatically controlled mixing valve for reducing point of use water temperature is recommend ed Contact a licensed pl
30. e Gas Control Valve Is 24 VAC present between the Brown wire on PV Terminal and Gray Ground wire on Ignition Control Module Is the inlet gas pres sure at or below the maximum as speci Gas Control Valve fied on the rating is inoperable and must plate m be replaced Is the IGNITION LED illuminated Is the ECO LED illuminated YES Check continuity of Brown wire between ECO Device inside of Ther mostat and PV Terminal on Gas Control Valve Repair or replace wire as needed to restore power to PV Termi nal on gas valve Refer to Section 3 the IGNI Refer to Section 5 the ECO LED in TION LED in the Troubleshooting Guide the Troubleshooting Guide A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation VERIFY PROP ER OPERATION AFTER SERVICING Ignition Control Module is inoperable and must be replaced System Sentinel Troubleshooting Guide Section 5 the ECO LED Is the ECO LED Illuinated ECO is open Allow tank to cool The and reset If ECO again trips the ECO Energy Cut Off device is Thermostat High limit is defective not tripped open and power is Replace as required being supplied to the PV termi ea nal on the Gas Control Valve Is LED now illuminated 15 the Pilot Flame burning The System Sentinel Panel is defective and
31. e gas tem perature is above permissible limits The switch is a manual reset type A CAUTION Label all wires prior to disconnection when servicing controls Wir ing errors can cause improper and dangerous operation VERIFY PROPER OPERATION AFTER SERVICING G RELIEF VALVE The Temperature and Pressure Relief Valve must be free to operate properly Check at least once a year by lifting the handle fully and allowing several gallons of water to flush through the discharge line Make certain the discharged water is directed to a suitable drain A DANGER Before manually operating the relief valve make certain no one will be exposed to the danger of coming in contact with the hot water released by this valve The water may be hot enough to cre ate a SCALD hazard The water released should be directed to a suitable drain to prevent injury or damage NOTICE If the temperature and pressure relief valve on the water heater discharges periodically this may be due to thermal expansion in a closed water system Contact the water supplier or local plumbing inspector on how to correct this DO NOT plug the relief valve outlet H TANK Good maintenance requires that the tank be cleaned of de posits Unless the water supply is soft 0 to 5 grains hardness scale or lime deposits will accumulate in the tank Hard water scale is de posited at an increasingly high rate in proportion to increased water temperature Accumula
32. e thermostat NOTICE The Gas Valve supplied with this water heater may vary from the one pictured on the label below but the Lighting Instructions are the same for all types of valves supplied with this model water heater FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing propertydamage personal injury or loss of life A This appliance is equipped with an ignition 1 1 device which automatically lights the pilot DO NOT try to light the pilot by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only your handtoturnthe gas control knob Never use tools If the knobwill not turn by hand don ttry to repair it call a qualified service technician Force or attemptedrepair may result in a fire or explosion Donot use this appliance if any part has been under water Immediately call a qualified ser vice technician to inspect the appliance and to replace any part of the control system and any g
33. e water heater was shipped from the factory The illustration below illustrates the thermostat and how to adjust the water tem perature To adjust the water temperature insert a small straight screwdriver into slotted screw in hole in front of ther mostat and turn wheel to desired setting Thermostat is adjustable up to 180 F CAUTION Hotter water increases the risk of SCALDING Honeywell Honeywell White Rodgers NOTICE Each water heater will contain one 1 of the above ther mostats Refer to actual unit to determine which one A DANGER Hotter water increases the Potential for Hot Water SCALDS NOTICE Mixing valves are available for reducing point of use water temperature by mixing and cold water in branch water lines Contact a licensed plumber or the local plumbing authority for further information A General Safety Precautions Be sure to read and understand the entire Use amp Care Manual before attempting to install or operate this water heater Pay particular attention to the following General Safety Precautions Failure to follow these warnings could result in a fire or explosion causing property damage bodily injury or death Should you have any problems understanding the instructions in this manual STOP and get help from a qualified installer or service technician or the gas supplier A WARNING Gasoline as well as other flammable materials and liquids adhesives solvents etc a
34. ermine the vent terminal height and cut vent pipe ac cordingly Refer to Fig 8 for proper vent terminal height Connect vent elbow onto vertical pipe through roof Connect short piece of vent pipe approximately 3 long to elbow then join terminal to the short piece of vent pipe VERTICAL VENT TERMINAL LOCATION The location of vertical vent terminal depends on the following considerations see Figure 8 1 Minimum twelve 12 inches above roof 2 Minimum twelve 12 inches above anticipated snow level AIR SUPPLY INLET Horizontal Vent Terminal Location V VENT TERMINAL 3 Maximum twenty four 24 inches above roof level without additional support for vent pipe 4 Four 4 feet from any gable dormer or other roof structure with building interior access i e vent window etc 5 Ten 10 feet from any forced air inlet to the building Any fresh or make up air inlet such as a dryer or furnace area is considered to be a forced air inlet 6 The inlet is a minimum of six 6 inches vertically above the outlet 7 Terminals are a minimum of seven 7 inches horizontally apart with a maximum of twenty four 24 inches VENT INSTALLATION Before proceeding make certain you understand the procedure and cautions covered in the section Joining Pipes and Fittings 22 A 0022222222222 LLL LLL LENCE 222 S NN Z AREA WHERE TERMINAL IS NOT PERMITTED The f
35. g diodes on the panel are arranged from top to bottom based on their function in the normal sequence of operation and their function is explained as follows POWER When illuminated this green LED indicates that 120VAC power is being supplied to the heater the ON OFF switch is functioning and the 24V transformer is functioning properly Refer to Section 1 of Troubleshooting Guide THERMOSTAT IGNITION PILOT VALVE MAIN VALVE MAIN VALVE THERMOSTAT When illuminated this red LED indicates that the ther mostat is functioning calling for heat and 24VAC power is being supplied to the relay to turn on the blower and the N C terminal of the pressure switch with N C and N O terminals Refer to Section 2 of Troubleshooting Guide IGNITION When illuminated this red LED indicates that 24 VAC power is being supplied to the Ignition Control Module and the ignition sequence has begun The N O side of the pressure switch with N C and N O terminals closes Refer to Section 3 of Troubleshooting Guide PILOT VALVE When illuminated this red LED indicates that the Ignition Control Module is supplying 24 VAC power to the ECO Energy Cut Off device or High Limit Refer to Section 4 of Troubleshooting Guide ECO When illuminated this red LED indicates that the ECO Energy Cut Off device or High Limit is closed and 24 VAC power is being supplied to the PV Pilot Valve ter minal on the Gas Control Valve
36. he main burner and pilot flames Water heater has a main burner and pilot flame The pilot flame 1 which can come on at any time and 2 will ignite flammable vapors Vapors 1 cannot be seen 2 are heavier than air 3 go a long way on the floor and 4 can be carried from other rooms to the pilot flame by air currents are at least 18 above the floor This will reduce but not eliminate the risk of vapors being ignited by the main burner or pilot flame Read and follow water heater warnings and instructions If owners manual is missing contact the retailer or manufacturer DANGER LIQUEFIED PETROLEUM MODELS Propane or LP gas must be used with great caution It is heavier than air and will collect first in lower areas making it hard to detect at nose level Make sure to look and smell for LP leaks before attempting to light appliance Use a soapy solution to check all gas fittings and connections Bubbling at a connection indicates a leak that must be corrected When smelling to detect an LP leak be sure to sniff near the floor too Gas detectors are recommended in LP applications and their installation should be in accordance with the manufacturer s recommendations and or local laws rules regulations or customs It is recommended that more than one method be used to detect leaks in LP applications IF LP GAS IS PRESENT OR SUSPECTED DO NOT attempt to find the cause yourself
37. ide years of dependable trouble free service It is strongly suggested that a regular routine main tenance program be established and followed by the owner It is further recommended that a periodic inspection of the blower thermostat burner relief valve internal flueway draft hood damper assembly and venting system should be made by service technicians qualified in gas appliance repair 1 ROUTINE PREVENTIVE MAINTENANCE A BURNERS Visually inspect the main burner flame and the pilot flame at least every three months Refer to Figures 12 and 13 for normal flame pattern Fallen scale can usually be dislodged from the tops of the burners with a thin rod then vacuumed or brushed from the bottom of the burner box If a more thorough cleaning is deemed necessary to restore a normal flame pattern the burner tray assembly should be removed and the burners cleaned individually amp CAUTION For your safety removal and cleaning of burner tray and individual burners should be performed ONLY by a qualified service techni cian as it involves disconnection of gas piping and leak testing Figure 12 Pilot Flame Pattern 17 TO REMOVE BURNER TRAY 1 Turn off manual gas shut off valve 2 Disconnect gas pipe union and wiring to gas valve and pilot 3 Remove retaining screws from plate on the same side as the gas valve 4 Slide burner tray assembly out When reinstalling the burner tray assembly make certain i
38. ided when failure of water heater is due to a corrosive atmosphere Refer to the Certificate of Limited Warranty for complete terms and conditions Installation WARNING The manufacturer s warranty does not cover any damage or defect caused by installation or attachment or use of any special attach ment such as energy saving devices other than those authorized by the manufacturer into onto or in conjunction with the water heater The use of such unauthorized devices may shorten the life of the water heater and may endanger life and property The manufacturer disclaims any responsibility for such loss or injury resulting from the use of such unauthorized devices 1 INSPECT SHIPMENT for possible damage The manufacturer s responsibility ceases upon delivery of goods to the carrier in good condition Any claims for damage shortage in shipments or non de livery must be filed immediately against carrier by consignee THERMAL EXPANSION Determine if a check valve exists in the inlet water line It may have been installed in the cold water line as a separate back flow preventer or it may be part of a pressure reduc ing valve water meter or water softener A check valve located in the cold water inlet line can cause what is referred to as a closed water system A cold water inlet line with no check valve or back flow prevention device is referred to as an open water system As water is heated it ex
39. k tested after placing the water heater in operation ion Installat yue uoisuedx3 euueu y JO seui epinf sepoo 220 01 2 ejs s 1euJng pue seb sJojeou eu uo se910J eziuuiuiu 0 pue peuoddns Ajayenbape eq isn Buidid Ajddns seb eu SALON ji yue uoisuedx3 euilau leju zd p109 men ante Jo inus 10H Buimeig uonejeisu jedidAL p 4 suorjonrjsur S 1o1njovjnueur pug 220 Jad jjejsur jy DARA JPY 9 deo aly 5 eJnyejeduie siu ul 8 uo uonoes 529 deg aQ den wawipas Le wc A uoun 3ulof punog yesow13y JO Inus seg enuen Installation A WARNING NEVER use open flame to test for gas leaks as bodily injury or property damage could result PRESSURE TESTING THE GAS SUPPLY SYSTEM The water heater and its manual gas shut off valve MUST be disconnect ed from the gas supply piping system during any high pressure testing of that system at pressures in excess of 1 2 psi 14 w c 3 5 kPa The water heater MUST be isolated from the gas piping system by closing the manual gas shut off valve during
40. ll connections and fittings for possible gas leak Gas Company inspected installation if required Relief Valve Discharge line run to open drain Discharge line protected from freezing Venting All pipe connections are secure at blower vent terminals and for each pipe joint connection Vent terminals mounted properly and in correct location Condensate tube has water in both loops Operation Before operating this water heater be sure to read and follow the instructions on the label pictured below and all other labels on the water heater as well as the warnings printed in this manual Failure to do so can result in unsafe operation of the water heater resulting in prop erty damage bodily injury or death Should you have any problems reading or following the instructions in this manual STOP and get help from a qualified person 1 LIGHTING PROCEDURE Lighting procedures are outlined on the label pictured below This label is also located on the water heater near the thermostat NOTICE The Gas Valve supplied with this water heater may vary from the one pictured on the label below but the Lighting Instructions are the same for all types of valves supplied with this model water heater F FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage person
41. lvent and cleaner must be used for NOTICE DO NOT use in conjunction with a GFCI the type of vent pipe used PVC CPVC or ABS A WARNING DANGER OF FIRE OR BODILY INJURY Solvent cements and primers are highly flammable Pro vide adequate ventilation and do not assemble near heat source or open flame Do not smoke Installation Check List A Water Heater Location C Gas Supply Close to area of vent Indoors and protected from freezing temperatures LJ Proper clearance from combustible surfaces observed and water heater not installed on carpeted floor Air supply free of corrosive elements and flammable vapors Provisions made to protect area from water damage Sufficient room to service heater B Water Supply Water heater completely filled with water Water heater and piping air vented Water connections tight and free of leaks TABLE 1 Maximum Capacity of Pipe in Cubic Feet of Gas per Hour for Gas Pressures of 0 5 psig or Less and a Pressure Drop of 0 3 Inch Water Column Based on a 0 60 Specific Gravity Natural Gas If 1 5 Specific Gravity L P Gas is used multiply capacity by 0 63 Nominal Internal Length of Pipe Feet Iron Pipe Size Diameter 10 20 30 40 50 1001 125 Inches Inches Gas line equipped with shut off valve union and sediment trap drip leg Approved pipe joint compound used Soap and water solution used to check a
42. ment if such installation is prohibited by federal state and or local laws rules regulations or cus toms Introduction A WARNING Read and Review this entire Manual with special emphasis on the Venting Sections Pages 8 12 and Operation Section Pages 14 17 prior to any installation work LOCAL INSTALLATION REGULATIONS This water heater must be installed in accordance with these instructions local codes utility company requirements and or in the absence of local codes the latest edition of the National Fuel Gas Code ANSI Z223 1 in the United States or CGA CAN B149 Installation Codes in Canada LOCATION A This water heater is of the direct vent design All air for combustion and all products of combustion are routed through the venting system directly from and to the outside of the building The water heater should be installed in a clean dry location as close as practical to the gas vent terminals Long hot water lines should be insulated to conserve water and energy The water heater and water lines should be protected from exposure to freezing temperatures B Agas fired water heater should not be installed in a space where liquids which give off flammable vapors are to be used or stored Such liquids include gasoline LP gas butane and propane paint or adhesives and their thinners solvents or removers Because of natural air movement in a room or other enclosed space flammable vapors can be c
43. nd the vapors they produce are extremely dangerous DO NOT handle use or store gasoline or other flammable or combustible materials any where near or in the vicinity of a water heater Be sure to read and follow the warning label pictured below and other labels on the water heater as well as the warnings printed in this manual Failure to do so can result in property dam age bodily injury or death A DANGER Failure to properly vent the water heater to the outdoors as outlined in the Venting Section of this manual can result in unsafe operation of the water heater To avoid the risk of fire explosion or asphyxiation from carbon monoxide never operate this water heater unless it is properly vented and has an adequate air supply for proper operation Be sure to inspect the vent system for proper installation at initial start up and at least annually thereafter Refer to Maintenance section of this manual for more information regarding vent system inspections A DANGER A Vapors from flammable liquids will explode and catch fire causing death or severe burns Do not use or store flammable products such as gasoline solvents or adhesives in the same room or area near the water heater Keep flammable products 1 far away from heater 2 in approved containers 3 tightly closed and 4 out of children s reach Installation Do not install water heater where flammable products will be stored or used unless t
44. ng valve is recommended to reduce the risk of scald injury Contact a licensed plumber or the local plumbing authority for further information Thermometer s should be installed so that they indicate the tempera ture of the water at or near the outlet of the water heater and storage tank s if provided See Fig 4 on page 7 RELIEF VALVE A new factory installed combination pressure and temperature relief valve complying with the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems ANSI Z21 22 or Standard CAN1 4 4 Temperature Pressure Tempera ture and Pressure Relief Valves and Vacuum Relief Valves is provided with the water heater No valve is to be placed between the relief valve and the water heater For a circulating tank installation the separate storage tank s must have similar protection The pressure rating of the relief valve must not exceed 150 psi 160 psi for ASME models the maximum working pressure as marked on front of the water heater The Btu h rating of the relief valve must equal or exceed the Btu h input of the water heater as marked on its rating plate Connect the outlet of the relief valve to a suitable open drain The discharge line must pitch downward from the valve to allow complete draining by gravity of the relief valve and discharge line and be no smaller than the outlet of the valve The end of the discharge line should not be threaded or concealed and should
45. nmechanical air supply 6 inches 15 for appliances lt 10 000 4 feet 1 2 m below or to side of opening inlet to the combustion air inlet to any Btuh 3 kW 12 inches 30 for appli 1 foot 300 mm above opening building or other appliance ances gt 10 000 Btuh 3kW and lt 100 000 Btuh 30kW 36 inches 91 cm for appliances gt 100 000 Btuh 30kW K Clearance to mechanical ait supply 6 feet 1 83 m 3 feet 91 cm above if within 10 feet inlet 3 m horizontally L Clearance above paved side walk or 7 feet 2 13 m 7 feet 2 13 m paved driveway located on public property M Clearance under veranda porch deck Not Allowed Not Allowed or balcony 1 In accordance with current CAN CGA B149 Installation Codes 2 In accordance with current ANSI Z223 1 NFPA 54 National Fuel Gas Code A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings If clearances are not specified then follow local installation codes and the requirement of the gas supplier DRAINING THE CONDENSATE In certain conditions PVC materials should use ASTM D 2564 grade cement installations in unconditioned space or having long horizontal or vertical CPVC materials should use ASTM F 493 grade cement runs may accumulate condensate In order to prevent condensate from ABS materials should use ASTM D 2235 grade cement draining back into the blower we
46. ollowing information should be used for determining the proper location of the vent terminal for direct vent water heaters Canadian Installations 1 US Installations 2 A Clearance above grade veranda 12 inches 30 cm above anticipated 12 inches 30 cm above anticipated porch deck or balcony snow level snow level B Clearance to window or door that may 6 inches 15 cm for appliances lt 10 000 Btuh 3 kW 12 inches 30 cm for appli ances gt 10 000 Btuh 3kW and lt 100 000 Btuh 30kW 36 inches 91 for appli ances 7 100 000 Btuh 30kW be opened 6 inches 15 for appliances lt 10 000 Btuh 3 kW 9 inches 23 for appli ances gt 10 000 Btuh 3 kW and lt 50 000 Btuh 15 kW 12 inches 30 em for appliances gt 50 000 Btuh 15 kW C Clearance to permanently closed window D Vertical Clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet 61 cm from the center line of the terminal 3 feet 91 cm 3 feet 91 cm G Clearance to inside corner 18 inches 46 cm 18 inches 46 cm Figure 9 Horizontal Vent Terminal Location 11 Canadian Installations US Installations H Clearance to each side of center line 3 feet 91 cm within a height 15 feet 4 57 extended meter regulator assembly m above the meter regulator assembly above I Clearance to service regulator vent 3 feet 91 cm outlet J Clearance to no
47. pands in volume and creates an increase in the pressure within the water system This action is referred to as thermal expansion In an open water system expanding water which exceeds the capacity of the water heater flows back into the city main where the pressure is easily dissipated A closed water system however prevents the expanding water from flowing back into the main supply line and the result of thermal expansion can create a rapid and dangerous pressure increase in the water heater and system piping This rapid pressure increase can quickly reach the safety setting of the relief valve causing it to oper ate during each heating cycle Thermal expansion and the resulting rapid and repeated expansion and contraction of components in the water heater and piping system can cause premature failure of the relief valve and possibly the heater itself Replacing the relief valve will not correct the problem The suggested method of controlling thermal expansion is to install an expansion tank in the cold water line between the water heater and the check valve The expansion tank is designed with an air cushion built in that compresses as the system pressure increases thereby relieving the over pressure condition and eliminating the repeated operation of the relief valve Other methods of controlling thermal expansion are also available Contact your installing contractor water supplier or plumbing inspector for additional inform
48. rature on the thermostat The most energy efficient operation will result when the temperature setting is the lowest that satisfies the needs consistent with the application A DANGER Water temperature over 125 F can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before setting temperature at water heater Feel water before bathing or showering Temperature limiting valves are available see manual Maximum water temperatures occur just after burner has shut off To find hot water temperature being delivered turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications Temperature Time to Produce Serious Burn 120 F More than 5 minutes 125 F 11 2 to 2 minutes 130 F About 30 seconds About 10 seconds Less than 5 seconds Less than 3 seconds About 11 2 seconds About 1 second Table courtesy of Shriners Burn Institute TIME TEMPERATURE RELATIONSHIPS IN SCALDS The temperature of the water in the heater can be regulated by setting the temperature dial on front of the thermostat To comply with safety regulations the thermostat was set at its lowest setting befor
49. rders should include A CAUTION For your safety DO NOT attempt repair of gas piping gas control thermostat burners vent con nectors or other safety devices Refer repairs to qualified service personnel The model and serial number of the water heater from the rating plate Specify type of gas natural or LP as marked on the rating plate Part description as noted below and number of parts desired 2 Blower Assembly 4 T amp P Valve Handhole Sealplate Gasket SP5886 Thermostat Beneath Cover Ignition Control Assembly w Relay Drain Valve Gas Valve Burner Assembl a d Pilot Ignitor zc Assembly Some assembly components are available individually Control Module Transformer and ON OFF Switch 25 Wiring and Schematic Diagrams NORMAL OPERATIONSEQUENCE INDICATEDBY BOXED NUMERALS 120V 3 wy BLOWER Ney LED INDICATORS POWER THERMOSTAT THERMOSTAT AND IGNITION HIGH LIMIT e PILOT VALVE ECO IGNITION MAIN VALVE LED H 1 4 TRANSFORMER m N C S W a o o R GRAY E M Ir n THERMOSTAT LED IGNITION a CONTROL MAIN VALVELED 6 MGV o GND MV
50. s are preferred cautiously follow the instructions supplied with the cleaner DO NOT use a muriatic or hydrochloric acid HCI base cleaner 2 ANODE INSPECTION The water supply in certain areas contains very aggressive elements In these areas periodic inspection of the anode is recommended to determine if replacement is necessary The anode s supplied in this water heater is slowly consumed thereby eliminating or minimizing corrosion and protecting the glass lined tank The anode s should be replaced when more than 6 inches 15 cm of core wire is exposed at either end 3 SEASONAL OPERATION If the water heater is to remain idle for an extended period 60 days or more the heater should be turned off The water heater and piping should be drained if they might be subjected to freezing temperatures It is recommended that the water heater s operation is thoroughly checked by a qualified service technician before it is placed back in service NOTICE Refer to Hydrogen Gas caution notation on page 16 System Sentinel Diagnostic System The System Sentinel Diagnostic system on this water heater provides the user or service technician with a visual representation of the operational status of the various sections of the water heater s control system A quick glance at the System Sentinel panel on the front of the heater will give an indication of where to begin trouble shooting of a non operational heater The LED s light emittin
51. t is pushed in all the way so that the plate lines up with the holes in the plenum side Then reinstall the retain ing screws 5 Reconnect gas pipe union and wiring to gas valve and pilot turn on manual gas shut off valve and test for gas leak B VENTING SYSTEM Inspect venting system at least yearly to make certain the passageways are free and unobstructed and that the vent connector from the water heater s blower assembly is properly posi tioned and securely attached Remove any obstructions in vent con nector or vent terminal C CONTROLS The manifold pressure and controls should be checked at least yearly by a qualified service technician Figure 13 Pilot amp Main Burner Flame Pattern Maintenance D BLOWER Clean the blower periodically to remove any buildup of lint or dirt Remove the inlet plate and blow out any lint or dirt on the wheel and on the screen of the inlet plate Before operation re install the inlet plate to the blower E PRESSURE SWITCH Inspect the inlet to the pressure switch and the tubing for debris or blockage Clean out the tubing periodically to prevent buildup of debris F EMERGENCY CUT OFF This water heater is equipped with a com bination thermostat temperature limiting device ECO that should be checked annually by qualified service personnel G THERMAL CUTOFF SWITCH Some units equipped with a thermal cutoff switch which will shut down the unit if the flu
52. tion of these deposits may reduce efficiency and shorten the life of the water heater Any new installation should have a tank inspection program set up initially for frequent inspection The first inspection should be within a six month period Once the scaling tendencies have been established the inspection program can be modified to suit the water conditions Cleaning should be performed if the scale has accumulated above the drain valve opening 18 A wet dry shop vac with a nozzle fashioned from 1 and or 3 4 poly ethylene pipe makes a good tool for scraping and removing scale TO CLEAN OR INSPECT TANK 1 Shut off gas valve and drain tank 2 Remove tank clean out cover on jacket and with pocket knife cut and remove a circular plug of insulation the full size of jacket open ing 3 Loosen nut on seal plate assembly enough to twist yoke sideways Hold assembly securely and push inward then remove from tank 4 Remove as much built up scale from flue tubes and tank bottom as practical Do not attempt to clean so thoroughly that the tool used damages the glass lining 5 Clean the seal plate and install a new gasket Wipe clean the inte rior surface of the tank that contacts the gasket Reinstall the seal plate and tighten in position Fill tank with water and check for leaks If no leaks are found install insulation plug and clean out cover on jacket and re light the water heater If chemical lime dissolving cleaner
53. tions are found they must be corrected in accordance with the venting instructions in this manual before completing the installation and putting the water heater into service VENT PIPE CONNECTION Outlet Vent Connection Vent Connection Figure 5 Vent Pipe Connection Locations The blower assembly is preinstalled at the factory so all that is required for connecting the vent system is attaching the vent pipe to the blower and the PVC Tee Before starting the vent installation careful planning should be given to the routing and termination of the vent pipe The length of the vent pipe inlet and outlet should be kept to a minimum Also see page 10 amp 12 for vent terminal placement The GP100 150 amp GP100 200 model can be vented using either 3 inch or 4 inch Schedule 40 PVC pipe and fittings To use 3 inch PVC you can connect directly to the blower outlet rubber coupling provided for outlet connection and PVC Tee Make sure that clamps on rubber coupling are tight after the pipe is installed The inlet vent pipe should be cemented into the PVC Tee If 4 inch PVC pipe is going to be used then it will be necessary to have short piece at least 3 inches long of 3 inch PVC pipe to join into the coupling and tee Then a 4 X 3 reducer would need to be joined to the short piece of pipe so that the 4 inch pipe could be used The 4 inch pipe will then need to be stepped back down using a 4 X 3 reducer to 3 inch PVC
54. umber or the local plumbing authority for further information Outlet water temperature will vary during normal operating cycles Reli able temperature readings should be taken shortly after main burner cycles off during a period of little or no use 3 GAS MANIFOLD PRESSURE With the gas valve supplied with this water heater main burner ignition occurs at a low or step manifold pressure which will then automatically build up to its normal operat ing level The rated operating manifold pressure is listed on the water heater rating plate For purposes of input adjustment the minimum inlet gas pressure with main burner on is also shown on the rating plate A 1 8 NPT tapping is provided on the outlet side of the gas valve for connecting a manometer to check this pressure If necessary adjust the pressure to the proper value by turning regulator adjustment screw clockwise to increase pressure or counterclockwise to decrease pres sure 4 CHECK INPUT Consult the local Gas Company to determine the heating value of the gas supplied Check input by clocking gas meter with all other gas appliances turned off Use the following formula 3 600 x Heating Value x Number of Cubic Feet Timed Seconds Clocked INPUT btu h A WARNING DO NOT exceed Input shown on the water heater s rating plate Operation To insure accuracy for rating clock enough cubic feet of gas so that the clocked time is at least
55. until authorized by WHATTO DO IFYOU SMELL GAS the gas supplier or fire department Improper installation adjustment alteration service Do not try to light any appliance or maintenance can cause injury property dam age or death Refer to this manual Installation and service must be performed by a qualified installer service agency or the gas supplier Do not touch any electrical switch do not use any phone in your building Printed in USA AP13463 3 02 07 TABLE OF CONTENTS Safety Information Safety Precautions 3 4 16 Introduction Local Installation Regulations 5 Water Heater Location 5 Installation Instructions Inspect Shipment 6 Water Supply Connections 6 Gas 6 Typical Installation 7 Vent Installation 8 12 Wiring 13 Installation Checklist 13 Operating Instructions Lighting Instructions 14 15 Water Temperature 16 Emergency Shut Down 17 Care and Cleaning Burner Inspection 17 Venting Inspection 17 Routine Maintenance 18 Anode Inspection 18 Seasonal Operation 18 Troubleshooting System Sentinel Diagnosis 20 24 Customer Service Parts Lisl 2
56. wever improper location or installation can result in se vere damage to the structure or exterior finish of the building Short Piece of Vent Pipe Min 12 Above Roof Vent Pipe Min 12 Above Anticipated Through Roof Snow Level Max 24 Above Roof Without Additional Support Elbows Figure 8 Vertical Vent Terminal Location HORIZONTAL VENT INSTALLATION Once the vent terminal location has been determined make a hole through the exterior wall to accommodate the vent pipe Vent pipe must exit exterior wall horizontally only See Figures 9a and 9b Insert a small length of vent pipe through the wall and connect the coupling as shown in Figure 9 Connect terminal as shown to the vent pipe on the exterior of the building Seal any opening around the vent pipe or fittings with mortar or silicone caulk as shown in Figures 9a and 9b Complete the rest of the vent pipe installation to the water heater s vent connector fitting on the blower outlet If necessary support horizontal run as previously mentioned Installation VERTICAL VENT INSTALLATION Once the vent termi nal location has been determined make a hole through the roof and interior ceiling to accommodate the vent pipe Com plete the vent pipe installation to the water heater s vent connector fitting on the blower outlet Support vertical or horizontal runs as previously mentioned Install adequate flashing where the vent pipe passes through the roof Det
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