GAS-FIRED COMMERCIAL WATER HEATER (Ultra Low NOx) INSTALLATION/OPERATION MANUAL WITH TROUBLESHOOTING GUIDE WARNING If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. DO NOT store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS DO NOT try to light any appliance.
SECTION I: IMPORTANT INFORMATION READ CAREFULLY This gas-fired water heater is design certified by CSA International under the American National Standard, Z21.10.3 (as indicated on the rating plate) and CAN/CGA 4.3-M (as indicated on the rating plate) available from CSA Standards Association, 5060 Spectrum Way, Mississauga, Ontario, CANADA L4W 5N6. This water heater must be installed in accordance with local codes.
DANGER DO NOT store or use gasoline or other flammable, combustible, or corrosive vapors and/or liquids in the vicinity of this or any other appliance. This water heater is equipped with an adjustable thermostat to control water temperature. Hot water temperatures required for automatic dishwasher and laundry use can cause scald burns resulting in serious personal injury and/or death. The temperature at which injury occurs varies with the person’s age and the time of exposure.
WARNING This water heater needs fresh air for safe operation and must be installed with provisions for adequate combustion and ventilation air. Insufficient air supply will cause a recirculation of combustion products resulting in contamination that may be hazardous to life. This will result in carboning or sooting of the combustion chamber, burner, and flue tubes and creates a risk of asphyxiation.
SECTION II: SPECIFICATIONS Figure 1 – Dimensional Layout Table 1 – Specifications Model Description Model Number Nominal Gal. Capacity BTU/Hr. Input US Imp. Gal Gal. UCG80H125 UCG80H199 UCG80H270 UCG80H399 UCG100H199 UCG100H270 UCG100H399 80 80 80 80 100 100 100 67 67 67 67 83 83 83 125,000 199,999 270,000 399,999 199,999 270,000 399,999 Dimensions (inches) GPH Recovery at Degree Rise B Jacket Dia. in. C Vent Size in. 40°F 100°F 140°F A Floor to Vent Conn. in. D Floor to T&P Conn. in.
SECTION III: GENERAL INFORMATION This water heater contains the following features: Main Power On/Off Switch The front panel of this water heater has an ON/OFF switch, which has markings when the main power is turned on to indicate power to the water heater. Combustion System This water heater is equipped with a self-compensating negative pressure pre-mix combustion system. As the blower operates, air is drawn in through the air intake and into a venturi, which pulls gas from the gas valve.
Temperature and Pressure Relief Valve WARNING Keep clear of combination temperature and pressure relief valve discharge line outlet. The discharge may be hot enough to cause scald injury. The water is under pressure and may splash.
SECTION IV: INSTALLATION INSTRUCTIONS WARNING INSTALLATION OF THIS WATER HEATER SHOULD BE DONE BY A TRAINED AND QUALIFIED PROFESSIONAL. PLUMBING, AIR SUPPLY, VENTING, GAS SUPPLY AND ELECTRICAL WORK ARE REQUIRED. DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE FOLLOWING: Liquefied petroleum gases/propane gas and natural gas have an odorant added by the gas supplier that aids in detection of the gas. Most people recognize this odor as a “sulfur” or “rotten egg” smell.
THIS WATER HEATER MUST BE INSTALLED INDOORS OUT OF THE WIND AND WEATHER. THIS WATER HEATER MUST NOT BE INSTALLED IN ANY LOCATION WHERE GASOLINE OR FLAMMABLE VAPORS ARE LIKELY TO BE PRESENT, UNLESS THE INSTALLATION IS SUCH TO ELIMINATE THE PROBABLE IGNITION OF GASOLINE OR FLAMMABLE VAPORS. The location of this water heater is of the utmost importance. Before installing this water heater, you should read the Installation section of these instructions.
Figure 2a – Minimum Clearance to Combustible Material Input Front “A” Sides, Rear “A” Less than or equal to 399,999 BTU/h 4 in. (10.2 cm) 0 in.
Remove Crate 1. Remove all banding and pry off crate sides carefully so as to not damage the water heater. 2. Carefully roll/lift the water heater from the crate base. CAUTION DO NOT drop water heater. DO NOT bump water heater jacket against floor. DO NOT bump exhaust vent pipe against crate or other objects. This will damage the heater and cause it to be inoperable or create nuisance problems. Moving the Water Heater to a Permanent Position 1.
WARNING The flue collar relief opening of the water heater and combustion air inlet must be in the same atmospheric pressure zone. Large exhaust fans in kitchens and other locations can lower the air pressure inside an enclosure and interfere with the proper operation and venting of the water heater. In these cases, the water heater should be installed in a separate room with the combustion and ventilation air supplied directly from outdoors as previously described. Unconfined Space 1.
SECTION V: VENTING WARNING The venting system must be installed properly following all local codes or in the absence of local codes, the latest edition of the National Fuel Gas Code (ANSI Z223.1- latest edition), or in Canada, The Natural Gas Installation Code (B149.1-00 latest edition) or CAN/CGA B149.2 Propane Installation Code (Latest Edition). Failure to properly install the venting system could result in property damage, personal injury, or death.
Optional Intake Venting DANGER The venting instructions must be followed to avoid restricted combustion or recirculation of flue gases. Such conditions cause sooting or risks of fire and asphyxiation. NOTICE Before beginning installation of any vent pipe, read the vent pipe manufacturer’s installation instructions. DO NOT install the water heater in any location where the ambient temperature may fall below freezing. Water heater must be protected from freezing downdrafts during shutdown periods.
Approved Intake Venting Materials For installations in the US only PVC Sch. 40 (ASTM D-1785, ULC 1738, ULC S636) DWV PVC Sch. 40 (ASTM-D2665) CPVC Sch. 40 (ASTM-F441, ASTM-D2846, ULC S636) Polypropylene (UL 1738, ULC S636) ABS Sch. 40 DWV (ASTM D2661) For installations in CANADA ULC S636 approved Sch.
Figure 3 – Intake Vent Terminal Clearances (Referencing Other Appliance Venting Locations) A= B= Canadian Installations1 US Installations2 Clearance above grade, veranda, porch, deck or balcony 12 inches (30 cm) 12 inches (30 cm) Clearance to window or door that may be opened 6 in (15cm) for appliances ≤10,000 Btuh (3kW); 12 in (30 cm) for appliances >10,000 Btuh (3kW) and ≤100,000 Btuh (30kW); 36 in (91 cm) for appliances >100,000 Btuh (30 kW) 4 feet (1.
Clearance to combustibles for all venting pipes and terminals For installations in the CANADA Refer to vent pipe and terminal manufacturer’s installation instructions for clearances to combustibles DO NOT place insulation or other materials in the required clearance spaces between the venting to combustible material unless otherwise specified.
Vertical Installation Vertical venting system must be supported every 5 ft (1.5 m) of vertical run and every 3 ft (.92 m) of horizontal run of vent pipe length. CAUTION Failure to properly support the vent piping with hangers and clamps may result in damage to the water heater or venting system.
Maximum Vent Length Table 2 – Maximum Intake Vent Length Model Number UCG100H199 UCG100H270 UCG100H399 UCG80H125 UCG80H199 UCG80H270 UCG80H399 Max 2” Vent Length (feet) 20 20 N/A 20 20 20 N/A Max 3" Vent Length (feet) 50 50 25 50 50 50 25 Max 4" Vent Length (feet) 75 75 50 75 75 75 50 Determining Required Vent Length 1. 2. 3. 4. Determine the total length of straight vent pipe (in feet) required for the intake. Add 5 ft (1.52 m) of venting for every 90° elbow. Add 2 ½ ft (.
Vent Pipe Preparation WARNING DO NOT attempt to start this water heater until vent pipe solvent fumes completely clear from the room and inside the vent piping. Vent Pipe Preparation and Joining Most failures in vent systems result from improper preparation and joining of pipe and fittings. The guidelines below must be followed when installing the venting system.
SECTION VI: WATER CONNECTIONS NOTE: BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN WATER SUPPLY VALVE. CAUTION If sweat fittings are to be used, DO NOT apply heat to the nipples on the side of the water heater. Sweat the tubing to the adapter before fitting the adapter to the water heater connections. It is imperative that heat is NOT applied to the nipples containing a plastic liner.
Alternate Space Heating Water Connections DANGER Toxic chemicals, such as those used for boiler treatment, must NOT be introduced into potable water used for space heating. This water heater must NOT be connected to an existing heating system or component(s) previously used with a non-potable water heating appliance. All piping components connected to this water heater for space heating applications must be suitable for use with potable water.
Figure 14 – Typical Plumbing Schematic for Zoned Heating SECTION VII: GAS CONNECTIONS The gas supply lines must meet all requirements of the National Fuel Gas Code (ANSI Z223.1-Latest Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B 149.2 Propane Installation Code (Latest Edition). The maximum permissible gas supply pressure is 14 in (3.5 kPa) W.C. for natural and propane gas. 1. Connect this water heater only to the type of gas as shown on the rating plate.
3. While checking for leaks care must be taken to prevent solution from contacting the electrical connections at the control. If electrical connections at the control become wet, they must be thoroughly dried before attempting to operate the water heater. Gas Meter Size – Natural Gases Only Be sure that the gas meter has sufficient capacity to supply the full rated gas input of the water heater as well as the requirements of all other gas fired equipment supplied by the meter.
SECTION VIII: ELECTRICAL CONNECTIONS WARNING Turn OFF or disconnect the electrical power supply to the water heater before servicing. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. All electrical wiring must be installed and grounded in accordance with local codes, or in the absence of local codes, the National Electrical Code, ANSI/NFPA 70 and/or CSA C22.2 Electrical Code.
Building Management System (BMS) The water heater can be equipped with a gateway kit that will facilitate a Building Management System (BMS) connection to Modbus or Bacnet®. This kit is sold separately and is not factory installed. A full installation, operation, and troubleshooting manual is provided with the gateway kit. CAUTION Before beginning any Troubleshooting operations listed below, please note that the gateway kit and BMS may need to be disconnected from the heater.
BMS Wiring Diagram NOTICE The Building Management System (BMS) is only compatible with units that have SOLA controllers.
SECTION IX: OPERATING INSTRUCTIONS WARNING Water heaters are heat-producing appliances. To avoid damage or injury there must be no materials stored against the water heater or vent system, and proper care must be taken to avoid unnecessary contact (especially by children) with the water heater and vent system.
Lighting and Shutdown Instructions Figure 16 – Lighting Instruction Label 29
Combustion Air/Gas Ratio This water heater is factory equipped with a gas valve/air mixing venturi system designed and set to maintain appropriate combustion excess air level (air/gas ratio) under normal operating conditions. When the excess air level is adjusted, an accurate and recently calibrated combustion gas analyzer, which correctly measures carbon monoxide (CO) and carbon dioxide (CO2) levels in the exhaust gas, as well as an accurate gas pressure manometer, are mandatory.
The water heater temperature setting is adjusted by using the control display mounted to the front of the water heater. The water heater thermostat is set at the lowest setpoint of 100F (37.8C) when shipped from the factory. The control display shows the temperature setpoint in degrees Fahrenheit (F) or degrees Celsius (C), and the status of the water heater (“Idle” or “Heating”). If the water heater is functioning normally, the display will also show “Operational”.
Display Control Water Heater Display and Control Buttons To Increase Temperature Setpoint Step 1. Press and hold “Temperature Up” button until desired setpoint temperature appears on the display. Step 2. Press “DONE” button for new setting to take effect immediately. If the “DONE” button is not pressed, the new temperature setting will take effect in approximately 10 seconds.
To Decrease Temperature Setpoint Step 1. Press and hold “Temperature Down” button until desired setpoint temperature appears on the display. Step 2. Press “DONE” button for new setting to take effect immediately. If the “DONE” button is not pressed, the new temperature setting will take effect in approximately 10 seconds. To View Combustion Rate Step 1. Select Next while viewing DHW Setpoint in User Mode to access Rate screen. Rate will only be displayed while the burner is operating. Step 2.
To Change Temperature Format in Display from F to C or ˚C to ˚F Step 1. Enter “Set-Up Mode” by pressing both UP/DOWN buttons together for 3 seconds. Step 2. Use the arrows to select between °F and °C Step 3. Press done to return to main screen or timeout/change will occur in one minute. Energy Cut Out (ECO) An automatic gas shut-off device (ECO) is incorporated in the sensor and control board which will shut off gas supply to the burner if the water heater temperature exceeds 207°F (97.2°C).
SECTION X: MAINTENANCE DANGER DO NOT attempt to repair gas valve. DO NOT attempt to repair ignition module. DO NOT attempt to repair venturi. DO NOT attempt to repair thermostat board. DO NOT attempt to repair transformer. DO NOT attempt to repair flow switch.
Maintenance Schedule Following are the instructions for performing some of the recommended maintenance. Unit inspection and adjustment should only be performed by a qualified technician. Table 7 – Suggested Maintenance Schedule Service Interval 1 Month: 1 Year: Component Operation Action Tank Condensate Line Powered Anode System Sediment removal Inspect & clean Check LED/inspect rods Relief Valve Function test Vent & Air Intake System Inspect Drain off several gallons of water.
Sediment and Lime Scale Removal Waterborne impurities consist of the particles of soil and sand, which settle out and form a layer of sediment on the bottom of the tank. The amount of calcium carbonate (lime) released from water is in direct proportion to water temperature and usage. The higher the water temperature or water usage, the more lime deposits are dropped out of the water. This is the lime scale which forms in pipes, water heaters, and on cooking utensils.
Temperature and Pressure Relief Valve At least twice a year, the temperature and pressure relief valve should be checked to ensure that it is in operating condition. To check the relief valve, lift the lever at the end of the valve several times. The valve should seat properly and operate freely. If water does not flow, remove and inspect for obstructions or corrosion. Replace with a new valve of the recommended size as necessary.
SECTION XI: SERVICE AND TROUBLESHOOTING GUIDE Sequence of Operations 1. Thermostat calls for heat. 2. Combustion blower starts at a “soft” start light off. 3. Blower pre-purge period of approximately 15 seconds. 4. Ignition control board runs an internal verification safety check for approximately 15 seconds. 5. Trial for ignition (approximately 5 seconds per trial, 3 trials total): a. Flame establishing period (3 seconds), gas valve opens, sparks from spark rod to burner surface to ignite the gas. b.
Additional Display Features Accessing Diagnostic Mode on the Water Heater Display (FOR SERVICE PERSONNEL ONLY) The display has a Diagnostic Mode to access information in aiding servicing of the water heater. This procedure is for service and installation personnel only. To enter the Diagnostic Mode, follow the steps illustrated below: WARNING The following procedure is for service and installation personnel ONLY.
Step 4. Press lower right “Next” button. The display will flash and show the number of any Lockout codes. If there are no lockouts, the display will show 00. If there are multiple lockout codes “Next” will scroll through them. Step 5. Press “Next”, the display will show “DHW MAX”. This is the maximum allowable temperature that the unit can get to before a lockout occurs. Step 6. Press Next, display will show “DELTA T DHW”, this is the real time temperature reading of the tank. Step 7.
NOTICE The ICON control system can produce soft and hard lockouts. Soft lockouts are displayed if active and are not stored in Diagnostic Mode history. The control will periodically attempt to resume normal operation when in soft lockout conditions. If the system resumes normal operation a soft lockout will clear instantly; hard lockouts will display if active and require manual reset. Up to ten previous Hard lockouts are logged chronologically (newest first) in Diagnostic Mode history.
Error Code Definition of Code 105 Flame detected out of sequence 109, 110 Ignition Failure Occurred. 122,123 Light-off Rate Proving Failed 172 Water temperature sensor resistance invalid NOTE Cause of Problem and Actions Taken to Correct Check to see if flame is present inside the combustion chamber before or after the ignition cycle. If so, check to make sure the gas valve is wired correctly. Check for voltage at the gas valve connection. Replace the gas valve if defective.
Procedure for Checking Thermostat Sensors Set the thermostat above water temperature (See temperature adjustment section) and observe system through one (1) complete cycle. Make sure system operates as desired. To check the upper sensor assembly, compare the resistance of the sensor terminals (yellow and black lead for upper sensor) as measured by an ohmmeter to the water temperature as measured by an accurate thermometer. Thermistor resistance increases as the temperature decreases.
Contact your local plumbing supplier or plumbing professional for replacement parts or contact the company at the address displayed on the rating plater of the water heater. For faster and better service, please provide the part name, model, and serial number(s) of the water heater(s) when ordering parts. READ THE WARRANTY FOR A FULL EXPLANATION OF THE LENGTH OF TIME THAT PARTS AND THE WATER HEATER ARE WARRANTED.
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