Index Commercial Gas Water Heater Installation Instructions and Use & Care Guide for models with prefix DCG and ADCG To obtain technical, warranty or service assistance during or after the installation of this water heater, call toll free: 1-800-456-9805 When calling for assistance, please have the following information ready: 1. Model number 2. 7 digit product number 3. Serial number 4. Date of installation 5. Place of purchase Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . .
what can happen if the instructions are not followed. Table of Contents Water Heater Safety . . . . . . . . . . . . . Installation Instructions . . . . . . . . . . . Unpacking the Water Heater . Installation Requirements . . . Site Location . . . . . . . . . . . . . Clearances and Accessibility . Combustion Air Supply and Ventilation Water System Piping . . . . . . . . . . . . . Gas Supply and Piping . . . . . . . . . . . Electrical Connections . . . . . . . . . . . . Wiring Diagram . . . . . . . . . . .
Index INSTALLATION INSTRUCTIONS Consumer Information This water heater is design-certified by CSA International as a Category I, non-direct vented water heater which takes its combustion air either from the installation area or from air ducted to the unit from the outside. This water heater must be installed according to all local and state codes, or in the absence of local and state codes, with the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)- latest edition.
Index Site Location • • FLAMMABLES FLAMMABLE VAPORS 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. This water heater has a main burner and an automatic ignition system. The ignition system: 1.
Index Important: The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure. Due to the normal corrosive action of the water, the tank will eventually leak after an extended period of time. A suitable metal drain pan should be installed under the water heater as shown below, to help protect the property from damage which may occur from leaks in the piping connections or tank.
Index COMBUSTION/VENT PIPE SYSTEM Carbon Monoxide Hazard Follow all instructions to locate and install the vent pipe system. Instructions can be found in this manual, in state or local codes (or the authority having jurisdiction), or in the absence of such, the National Fuel Gas Code, ANSI Z223.1, NFPA 54, Latest Edition. Canadian installations must be performed in accordance with CAN/CSA-B149.
Index Air Requirements An adequate air supply shall be provided for combustion and ventilation of this water heater. An insufficient supply can result in poor combustion and possible sooting of the burner, combustion chamber or flue passageway. This may present a potential fire hazard or could create a serious health hazard by producing carbon monoxide. General Where an exhaust fan or any other air consuming appliance (Eg. Clothes dryer, furnace, etc.
Index Air Opening Requirements (a) EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM INSIDE THE BUILDING. Two permanent openings (top and bottom) shall be provided connecting the confined space (e.g., closet/small room) with the unconfined space. Each opening shall have a free area of one square inch per 1,000 BTU/hour (22 cm²/kW) input of all appliances in the confined space, but not less than 100 square inches (645 cm²).
Index Draft Hood/Damper Installation Flue Outlet Reducer Do not operate water heater with damper in closed position, it must be in the open position during water heater operation. Do not negate the action of any existing safety or operational controls. Some units are shipped with a flue outlet reducer (See Figure 3B). Use only the flue outlet reducer supplied with this unit. The flue outlet reducer should be connected to the top of the flue damper and sealed by high temperature silicon.
Index WATER SYSTEM PIPING Piping Installation 10 Piping, fittings, and valves should be installed according to the installation drawing (Figure 4). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation. Water supply pressure should not exceed 80% of the working pressure of the water heater. The working pressure is stated on the water heater’s data plate.
Index Figure 6: Commercial Unit with Auxiliary Booster Heater Two Temperature (With or Without Building Recirculation) Outlet Boosted Temperature Hot Water to Fixtures Thermometer Shut-off valve Thermometer Shut-off valve Temperature and Pressure Relief Valve Temperature and Pressure Relief Valve Check Valve Typical Booster Heater Pre-Heater Thermal Expansion Tank Shut-off valve 1 1/2” Cold water supply Shut-off valve Pre-Heated Water to the Booster Pressure Reducing Valve Note: Install a vac
Index Figure 8: Commercial Unit with Auxiliary Storage Heater - Forced Circulation With or Without Building Recirculation - Top Inlet/Outlet Connections Thermometer Outlet Boosted Temperature Thermometer Thermal Expansion Tank Hot Water to Fixtures Pre-Heated Water to the Booster Pressure Reducing 1 1/2” Cold Valve water supply Shut-off valve Check valve Temperature and Pressure Relief Valve Typical Booster Heater Shut-off valve Temperature and Pressure Relief Valve Pre-Heater Note: Install a v
Index Temperature and Pressure Relief Valve Explosion Hazard If the temperature and pressure relief valve is dripping or leaking, have a qualified service technician replace it. • Do not plug valve. • Do not remove valve. Failure to follow these instructions can result in death or explosion. Figure 9: T&P Relief Valve must not exceed the working pressure of the water heater as stated on the data plate. Important: Only a new temperature and pressure relief valve should be used with this water heater.
Index GAS SUPPLY AND PIPING Explosion Hazard Use a new AGA or CSA approved gas supply line. Install a shut-off valve. Do not connect a natural gas water heater to a L.P. gas supply. Do not connect a L.P. gas water heater to a natural gas supply. Failure to follow these instructions can result in death, explosion, or carbon monoxide poisoning. Gas Requirements Read the data plate to be sure the water heater is made for the type of gas being used.
Index Gas Pressure Testing Important: This water heater and its gas connection must be leak tested before placing the appliance in operation. • If the code requires the gas lines to be tested at a pressure of 14” W.C. or greater, the water heater and its manual shut-off valve must be disconnected from the gas supply piping system and the line capped. • If the gas lines are to be tested at a pressure less than 14” W.C.
Index ELECTRICAL CONNECTIONS Electrical Installation If you lack the necessary skills required to properly install the electrical wiring to this water heater, do not proceed but have a qualified service technician perform the installation. When making the electrical connections, always make sure: • The voltage and frequency correspond to that specified on the water heater data plate on the front of the water heater. • The electrical supply has the proper overload fuse or breaker protection.
Index WIRING DIAGRAM 17 17
Index INSTALLATION CHECKLIST Water Heater Location Requirements • • • • • Centrally located with the water piping system. Located as close to the gas piping and vent pipe system as possible. Located indoors and in a vertical position. Protected from freezing temperatures. Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor. Sufficient room to service the water heater. Provisions made to protect the area from water damage.
Index OPERATING YOUR WATER HEATER Read and understand these directions thoroughly before attempting to operate the water heater (see Lighting Instructions on page 20). Check the data plate on the front of the water heater for the correct gas. Do not use this water heater with any gas other than the one listed on the data plate. If you have any questions or doubts, consult your gas supplier or gas utility company. L.P.
Index OPERATING INSTRUCTIONS 1. STOP! Read the safety information above on this label. 2. Turn off all electric power to the appliance. 3. Set the thermostat to the lowest setting. 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 clockwise to the “OFF” position. Do not force. 6. Wait ten (10) minutes to clear any gas.
Index Emergency Shut Down Important: If overheating occurs or the gas supply fails to shut off, close the manual gas supply valve and turn the gas control knob to the off position. Turn off the electrical supply to the unit and close the cold water supply valve. Do not operate the water heater again until it has been thoroughly checked by a qualified service technician. Checking the Draft Burn Hazard Do not touch vent. Doing so can result in burns.
Index MAINTENANCE OF YOUR WATER HEATER Draining and Flushing It is recommended that the tank be drained and flushed every 6 months to remove sediment which may buildup during operation. Note: Warranty is null and void in the event lime & scale deposits are allowed to exceed two inches in depth. The water heater should be drained if being shut down during freezing temperatures. To drain the tank, perform the following steps: 1.
Index Pilot Burner and Main Burner Assembly Inspection To access the pilot burner and main burner for inspection: 1. Turn off gas at main shutoff valve and turn off electrical power. 2. Disconnect the gas supply line from the gas valve. 3. Remove the 2 screws holding the Pilot & Main Burner Assembly in place. See Figure 17 for location of screws. Figure 17: Pilot/Burner Assembly Removal 6. When replacing the gas valve, use an approved Teflon® or pipe joint compound on the pipe threads. 7.
Index DCG3 SERIES COMMERCIAL GAS DAMPERED WATER HEATERS High water temp. YES Will ECO light reset once temp. in tank cools? NO No Hot Water NO Repair power problem YES Replace gas valve Power to heater? Is ECO light on? YES Check for 24V between PV & PV/MV terminals on gas valve NO When thermostat NO is turned up does pilot spark? YES NO Does pilot light? YES Does sparking stop? Replace ICM Check gas supply YES NO Clean flame sensor - check ground.
Index DCG3 SERIES THERMOSTAT TROUBLESHOOTING FLOW CHART No voltage or low voltage from purple wire between thermostat board & ECO board Replace bad sensor(s) With an ohm meter set at X1, check NO orange wires on set pot.
Index REPAIR PARTS ILLUSTRATION When ordering repair parts always give the following information: 1. Model, serial, and product number 2. Type of gas 3. Item number 4. Parts description Repair Parts List No.