Instruction Manual RESIDENTIAL GAS WATER HEATERS POWER VENT/POWER DIRECT VENT GAS MODELS WITH HOT SURFACE IGNITION Ashland City, TN 37015 www.hotwater.com • 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. IF YOU ARE UNSUCCESSFUL, CALL THE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING.
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.
GENERAL SAFETY 3
GENERAL SAFETY 4
TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE............................2 GENERAL SAFETY..................................................................3 TABLE OF CONTENTS.............................................................5 INTRODUCTION.......................................................................5 Preparing for the Installation..............................................5 Get to Know Your Water Heater.........................................6 INSTALLATION CONSIDERATIONS......
GET TO KNOW YOUR WATER HEATER - GAS MODELS A Control Assembly B Blocked Inlet Switch C Blocked Outlet Switch D Fan Prover Switch E Blower Assembly F Burner Assembly G Flame Sensor H Hot Surface Igniter I Junction Box J Gas Control Valve Thermostat K Display Board L Top Plastic Enclosure M Display Enclosure ** N Exhaust Elbow Assembly ** O Condensate Tubing P Off/On Switch Q Display Label R Hot Water Outlet *S Electrical Outlet (120VAC) T Gas Supply U Main M
INSTALLATION CONSIDERATIONS ROUGH IN DIMENSIONS FIGURE 1A. Rough-In-Dimensions Model 100 Units A B C D E Inches cm F 68.50 49.25 22.00 15.75 3.00 8.00 174 125.09 55.88 40.00 7.62 20.32 Top/Side Inlet and Outlet: 3/4” NPT Gas Inlet: 1/2” NPT Capacity, Gas and Electrical Characteristics Model 100 Approximate Capacity Manifold Pressure Electrical Characteristics U.S. Gals. Liters Gas Type “WC kPA Volts/Hz Amperes 50 189 Nat.
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS For all side wall terminated, horizontally vented power vent, direct vent, and power direct 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 porch
WATER PIPING - MIXING VALVE USAGE * The side recirculation loop connections may not be used as the primary water inlet and outlet connections. For your convenience, plugs are installed in these fittings at the factory. Remove these plugs if needed for your specific installation. Otherwise (as with all connections) check for leaks while filling the tank with water and after completing the installation. FIGURE 2.
Facts to Consider About the 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.
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. for placement on the blanket directly over the existing labels. • Do inspect the insulation blanket frequently to make certain it does not sag, thereby obstructing combustion air flow. COMBUSTION AIR AND VENTILATION A gas water heater cannot operate properly without the correct amount of air for combustion.
a free area of one square inch per 1000 Btu/hr (22 cm2/kW) of the total input of all appliances in the enclosure, but not less than 100 square inches (645 cm2). enclosure, see Figure 9. If the confined space is within a building of tight construction, 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.
INSTALLING THE NEW WATER HEATER CHEMICAL VAPOR CORROSION CLOSED WATER SYSTEMS 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. 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.
Figures 2 and 10 show the typical attachment of the water piping to the water heater. The water heater is equipped with 3/4 inch NPT water connections. 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. NOTE: If using copper tubing, solder tubing to an adapter before attaching the adapter to the water heater connections.
HIGH ALTITUDE INSTALLATIONS The temperature-pressure relief valve must be manually operated at least once a year , see Figure 28. 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.
VENTING SEDIMENT TRAPS A sediment trap should be installed as close to the gas inlet of the water heater as practical at the time of water heater installation. The sediment trap should 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.
WARNING VENT HOOD(S) MAY BE EXTREMELY HOT DURING OPERATION. U.S. POWER VENT FIGURE 15A. 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. CANADIAN POWER VENT FIGURE 15B. 17 WARNING VENT HOOD(S) MAY BE EXTREMELY HOT DURING OPERATION.
U.S. DIRECT VENT WARNING VENT HOOD(S) MAY BE EXTREMELY HOT DURING OPERATION. FIGURE 15C. 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. CANADIAN DIRECT VENT FIGURE 15D. 18 WARNING VENT HOOD(S) MAY BE EXTREMELY HOT DURING OPERATION.
PLANNING THE VENT SYSTEM 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 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.
INSTALLATION OF VENT SYSTEM DIRECT VENTING Before beginning installation of piping system thoroughly read the section of this manual VENT PIPE PREPARATION. The air intake provided on the unit contains a mesh screen to prevent large particles from entering the unit. If you are installing your system so that it vents through roof, please refer to section titled INSTALLATION OF VERTICAL VENT SYSTEM. VENT TERMINAL INSTALLATION, SIDEWALL 1.
INSTALLATION SEQUENCE VERTICAL VENT TERMINAL INSTALLATION For installations in the City of Los Angeles, California Category IV PVC Pipe such as that manufactured by Brownline Pipe Company, must be used as vent pipe material. IMPORTANT WHEN TERMINATING THROUGH A ROOF, THE FOLLOWING SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE FOLLOWED. CAUTION VENT TERMINALS SUPPLIED WITH HEATER MUST BE USED. 1. Proper support must be provided for all pipe protruding through the roof.
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 blower it is time to complete the installation of the venting system for the sidewall installation. FIGURE 23.
This concentric vent termination kit may be used with 3 or 4 inch diameter pipe systems. When connecting to a 4 in. diameter pipe system a 3 x 4 inch field supplied reducer is to be installed at the intake and exhaust connection of the concentric vent termination kit. 1. Determine best location for termination kit. NOTE: Roof termination is preferred since it is less susceptible to damage, has reduced chances to intake contaminants, and less visible vent vapors. 2. Cut 1 hole (5 in.
NOTE: See the venting information (pages 16-20) in this 5. Secure assembly to roof structure as shown in Figure E using field supplied metal strapping or equivalent support material. NOTE: Ensure termination height is above the roof surface or anticipated snow level (1 ft. in U.S.A. or 1-1/2 ft. in Canada) as shown in Figure C. manual for additional vent location requirements. 2. Cut 1 hole (5 in. diameter) 3.
8. Operate heater through 1 heat cycle to ensure combustion-air and vent pipes are properly connected to concentric vent termination connections. Figure H. Concentric Vent Terminations for Horizontal Direct Venting. Figure g. MULTI-CONCENTRIC VENT TERMINATIONS When two or more appliances are directed vented with concentric vent terminations near each other, each appliance must be individually vented. NEVER common vent this appliance.
VENT PIPE PREPARATION PRIMER 1. INITIAL PREPARATION. 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. A.) Make sure the solvent cement you are planning to use is designed for the specific application you are attempting. B.
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. STEP B C.
CONTROLS AND SWITCHES open. When this switch prevents the unit from igniting, most likely the exhaust is blocked by some means. Check to see if the condensate is allowed to flow freely from the exhaust elbow and for obstructions in the exhaust venting and exhaust vent terminal. Also verify that the vent length does not exceed the maximum allowed as shown in the Vent Section of this manual. This model is provided with three pressure switches.
CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING. THIS WATER HEATER IS POLARITY SENSITVE. B EFO R E A PPLYI N G ELECTRICITY TO THIS HEATER BE CERTAIN THAT SUPPLY NEUTRAL WIRE TO GROUND CHECK INDICATES ZERO VOLTAGE. POWER VENT WIRING SCHEMATIC - FIGURE 24.
FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. BEFORE OPERATING: 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 • an ignition device which automatically lights the burner. Do NOT try to light the burner by hand. C. B. BEFORE OPERATING smell all around the appliance area for gas.
TEMPERATURE REGULATION 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. The water temperature is controlled using the Temperature Control on the Display at the front of the unit (See Figure 1).
USING THE ELECTRONIC CONTROLLER 1. Overview Interaction with the water heater controller is done through an up, a down, and three operation buttons. These buttons are illustrated to the right. Operation of the three lower buttons is defined immediately above them on the screen. The [UP] and [DN] buttons are used to navigate through the menus and make adjustments to the water heater.
2. Operating States In the main desktop screen, there are some specific Operating States that are indicated on the status line. These are summarized below: 3. Adjusting the Operating Set Point ACTION: From the Main Menu, press Select to enter the "Temperatures" screen. The Operating Set Point of this water heater determines the regulated temperature for the water in the tank. This parameter is adjusted in the Temperature menu.
3. Changing the Display Units 4. Fault Conditions The display interface to the heater has the option of selecting between degrees Fahrenheit and degrees Celsius for temperature displays. This can be found in the “Display Settings” menu. Also in this menu, you may adjust how the backlight operates and the contrast of the LCD screen. This water heater is equipped with electronic controls that have the ability to monitor almost all aspects of the water heater operation.
6. Viewing the Fault History ACTION: To get to the current fault information screen, press Menu. The controller for this water heater will store a history of ten of the last Fault conditions that occurred. This is stored in the Fault History. Along with all the information about the fault, including a estimate time of when the fault occurred, information regarding the advanced diagnostics for that fault can be accessed at any time. DISPLAY: ACTION: Press the DOWN button for more information.
FOR YOUR INFORMATION START UP CONDITIONS OPERATIONAL 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. 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.
PERIODIC MAINTENANCE Venting System Inspection 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 a visual inspection should be made of the main burner and the hot surface igniter assembly for proper flame characteristics and ignition sequences. You should also check for sooting.
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.
Service the water heater contact a qualified service agency. 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. 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. Read this manual first.
TROUBLESHOOTING GUIDELINES These guidelines should be utilized by a qualified service agent. PROBLEMS 1.) Blower will not run. a. “ON/OFF” control switch turned off. Turn switch to the “ON” position. b. Blower unplugged. Plug blower back into 115 VAC outlet. c. No power at outlet. Repair service to outlet. d. Thermostat defective. Replace thermostat. e. Control harness defective. Replace control harness. f. High limit control circuit open.
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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 furnish 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 war
500 Tennessee Waltz Parkway, Ashland City, TN 37015 Phone: 800-527-1953 Fax: 800-433-2515 www.hotwater.