ULTRA HIGH EFFICIENCY COMMERCIAL GAS WATER HEATER 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. DO NOT install any damaged venting system components. If damage is evident then please contact the supplier where the water heater was purchased, or the manufacturer listed on the rating plate for replacement parts. Use only vent terminals provided or factory authorized terminals for venting this water heater.
WARNING This water heater needs fresh air for safe operation and must be installed so there are 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, burners, and flue tubes and creates a risk of asphyxiation. This water heater requires its own separate venting system.
SECTION II: SPECIFICATIONS Figure 1 - Dimensional Layout Table 1 - Specifications DIMENSIONS (INCHES) Storage B Input C Capacity A Floor to Model No. Rate Jacket U.S. Height Top of BTU/h Dia.
SECTION III: GENERAL INFORMATION This water heater contains the following features: Main Power On/Off Switch The front panel of this water heater has a lighted ON/OFF switch, which is illuminated 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.
General Information continued- Temperature and Pressure Relief Valve WARNING Keep clear of the 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.
General Information continued- Figure 2 - Condensate Elbow with Trap Cleanout All models are equipped with a cleanout opening to aid in removal of hard water deposits from the tank bottom. If this water heater operates under hard water conditions, the following should be performed at least every 3 months: Turn OFF water supply and drain the water heater. Remove the cleanout jacket cover and tank cover.
SECTION IV: INSTALLATION INSTRUCTIONS WARNING INSTALLATION OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE FIELD INVOLVED. 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.
Installation Instructions continued- Unpacking 1. Inspect carefully for any signs of damage. 2. All equipment is carefully manufactured, inspected and packed. 3. Any claims for damage or shortage in shipment must be filed immediately with the shipper and noted on the Bill of Lading. 4. Remove all venting components from the combustion assembly compartment by removing the latches.
Installation Instructions continued- Figure 3b - Recommended Minimum Clearances For Service Access Remove Crate 1. Remove all banding and pry off crate sides carefully 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.
Installation Instructions continued- Location WARNING KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS. This water heater must be located in an area where the general public does NOT have access to set temperatures. Air Requirements 1. Do NOT obstruct the flow of combustion and ventilating air. 2. For safe operation, adequate air is needed for combustion and ventilation.
Chemical Vapor Corrosion Corrosion of the flue ways and vent system will occur if air for combustion contains certain chemical vapors. Such corrosion may result in poor combustion and create a risk of asphyxiation, as well as reducing the life of the water heater. Spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes and process chemicals are corrosive.
Installation Instructions continued- Figure 7 - Typical Three Water Heater Connection Figure 8 - Typical Four Water Heater Connection 14
SECTION V: WATER CONNECTIONS WARNING Failure to install and maintain a new, listed temperature and pressure relief valve will release the manufacturer from any claim, which might result from excessive temperature and pressures. Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time (generally two weeks or more). HYDROGEN GAS IS EXTREMELY FLAMMABLE.
Water Connections continued- Table 2 Approximate Time/Temperature Scald Chart APPROXIMATE TIME/TEMPERATURE RELATIONSHIPS IN SCALDS 120°F (49°C) More than 5 minutes 125°F (52°C) 1½ to 2 minutes 130°F (54°C) About 30 seconds 135°F (57°C) About 10 seconds 140°F (60°C) Less than 5 seconds 145°F (63°C) Less than 3 seconds 150°F (66°C) About 1½ seconds 155°F (68°C) About 1 second Alternate Space Heating Water Connections DANGER Toxic chemical, such as those used for boiler treatment, must not be introduced int
Water Connections continued- Figure 10 - Typical Plumbing Schematic for Zoned Heating SECTION VI: VENTING This water heater has a certified category IV, per latest ANSI Z 21.10.3-2019.CSA 4.3-2019 revision. Refer to the latest edition of the National Fuel Gas Code (ANSI Z223.1-latest edition), or in Canada, the Natural Gas and Propane installation Code (B149.1-00 latest edition). WARNING The vent system must be properly installed.
Venting continued- NOTICE For installations in Canada, field supplied vent piping must comply with CAN/CGA B149.1 (latest edition) and be certified to the Standard For Type BH, Class II, 65°C, Gas Venting Systems, ULC S636. Components of this listed system shall not be interchanged with other vent systems or unlisted pipe/fittings.
Venting continued- CAUTION All intake and exhaust venting components must have the same diameter size. DO NOT use a different size on the intake and exhaust venting. For 2 in (5.1 cm) or 4 in (10.2 cm) venting, use the supplied 3 in (7.6 cm) vent terminals. If a 2 in (5.1 cm) vent terminal is preferred, use 2 in (5.1 cm) terminal (p/n 239-39831-00). This terminal is available from your supplier. Be sure the condensate runs freely to a drain and does NOT accumulate inside the water heater.
NOTICE If 2 in (5.1 cm) pipe is used, then use a 2 in to 3 in reducer to adapt to the 3 in (7.6 cm) vent terminal size. If a 2 in (5.1 cm) vent terminal is preferred, this terminal is available from your supplier.
Figure 11b - Direct Vent and Powered Direct Vent Terminal Clearances Clearance above grade, veranda, porch, deck or balcony Clearance to window or door that may be opened A= B= Clearance to permanently closed window C= 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 D= E= Clearance to unventilated soffit F= Clearance to outside corner Clearance to inside corner G= Canadian Installations1 US I
Venting continued- The vent system must terminate so that proper clearances are maintained as cited in local codes or the latest edition of the National Fuel Gas Code, ANSI Z223.1: 1. Do not terminate near soffit vents or crawl space or other area where condensate or vapor could create a nuisance or hazard or cause property damage. 2.
Venting continued- WARNING! DO NOT USE 2” VENT WITH 100T250/300 MODELS Figure 12 - Typical Horizontal Direct Vent System Vertical Installation Vertical venting system must be supported every 5 ft of vertical run and every 3 ft 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. Stress levels in the pipe and fittings can be significantly increased by improper installation.
Venting continued- WARNING! DO NOT USE 2” VENT WITH 100T250/300 MODELS Figure 13 - Typical Vertical Direct Vent System Installation (Note: Intake and exhaust terminals may be on different outside walls.) Through the Wall Venting with Low Ground Clearance: When venting cannot exit through the wall at a height greater than or equal to 12 in (30.5 cm) (and above expected snow level) from the ground, then the installation must be modified as shown below (see Figure 14).
Venting continued- Maximum Vent Length Table 3 - Maximum Vent Length (Combined Maximum Length for Intake and Exhaust) 60T125 2” Vent Pipe Max. Intake Length Max. Exhaust Length 3” Vent Pipe Max. Intake Length Max. Exhaust Length 4” Vent Pipe Max. Intake Length Max. Exhaust Length Power Direct Vent 15 ft (4.5 m) 15 ft (4.5 m) Power Vent N/A 30 ft (9.2 m) Max. Intake Length Max. Exhaust Length 60T150 100T199 Power Power Direct Vent Vent 50 ft N/A (15.2 m) 50 ft 100 ft (15.2 m) (30.
Venting continued- Determining Required Vent Length 1. 2. 3. 4. 5. Determine the total length of straight vent pipe (in feet) required for both the intake and the exhaust. Add 5 ft of venting for every 90° elbow. Add 2 1/2 ft of venting for every 45° elbow. Total vent length cannot exceed “Max Vent Length” in Table 3. Air intake cannot exceed exhaust by more than 30 ft in any venting situation.
Venting continued- WARNING! DO NOT USE 2” VENT WITH 100T250/300 MODELS. Figure 15 - Typical Horizontal Power Vent System Vertical Installation Vertical venting must be supported every 5 ft of vertical run and every 3 ft of horizontal run of vent pipe length. Stress levels in the pipe and fittings can be significantly increased by improper installation.
Venting continued- Through The Wall Venting With Low Ground Clearance When venting cannot exit through the wall at a height greater than or equal to 12 in (30.5 cm) (and above expected snow level) from the ground, then the installation must be modified as shown below (see Figure 17). Refer to Tables 3 or 4 for maximum venting lengths using 2 in (5.1 cm), 3 in (7.6 cm), 4 in (10.2 cm), or 6 in (15.2 cm) diameter plastic pipe. WARNING! DO NOT USE 2” VENT WITH 100T250/300 MODELS.
NOTE: When installing multiple intake/exhaust terminals on the same wall of a building, the nearest intake terminal must be at least 5 ft (1.5 m) from the nearest exhaust terminal. Spacing requirements are the same for roof installation. Venting continued- Concentric Vent Terminal Installation Procedure WARNING Improper installation, adjustment, service, or maintenance can cause property damage, personal injury, or death.
Venting continued- Figure 19 - Dimensional Layout of Concentric Vent Kits Concentric Vent Size 2 in 3 in 4 in (A) Nominal Pipe Size 2 in 3 in 4 in (B) in inches 3 ½ in 4 ½ in 6 5/8 in Figure 20 - Concentric Vent Kit Part Identification Concentric Vent Size 2 in 3 in 4 in (A) in inches 2 in 3 in 4 ½ in (B) in inches 3 ½ in 4 ½ in 6 5/8 in 2. Determine the best location for the termination kit. 3. Cut the recommended 3 ½ in (8.9 cm) diameter hole for 2 in (5.1 cm) vent termination, 6 5/8 in (16.
Venting continued- 5. Install concentric Y fitting and pipe assembly through the structure’s hole and field-supplied roof boot/flashing. Do not allow insulation or other materials to accumulate inside pipe assembly when installing through the hole. 6. Secure assembly to roof structure as shown in Figure 22 using field-supplied metal strapping or equivalent support material. NOTICE Ensure termination height is above the roof surface or anticipated snow level (see Figure 22).
Venting continued- 3. Cut the recommended 3 ½ in (8.9 cm) diameter hole for 2 in (5.1 cm) vent terminations, 6 5/8 in (16.9 cm) diameter hole for 4 in (10.2 cm) vent termination, or 4 ½ in (11.5 cm) for 3 in (7.6 cm) vent termination. 4. Partially assemble vent kit. a. Cement Y concentric fitting to larger diameter kit pipe (see Figure 20). b. Cement rain cap to smaller diameter kit pipe (see Figure 21). 5.
Venting continued- Low Profile Side Wall Termination Kit The IPEX Low Profile side wall termination kits are fully certified for use with IPEX product only. IPEX System 636 PVC Low Profile vent kits are made from certified compound and IPEX System 1738 PVC Low Profile vent kits are made from a UL1738 certified PVC compound. Both are rated to a maximum temperature of 149°F (65°C).
Venting continued- Figure 24 – Typical Side Wall Termination Figure 25 – Approved Installation Orientation Figure 26 – Side Wall Termination Assembly Figure 27 – Minimum Clearances: Multiple Side Wall Terminations 34
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 VII: GAS CONNECTIONS WARNING Connect this water heater ONLY to the type of gas as shown on the rating plate. Use clean black iron pipe or equivalent material approved by local codes and ordinances (dirt and scale from the pipe can enter the gas valve and cause it to malfunction). The inlet gas line must have at least a 3 in (7.6 cm) drip leg (sediment trap) installed as close to the water heater’s gas valve as possible.
Gas Connections continued- 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. If the gas meter is too small, ask the gas company to install a larger meter having adequate capacity.
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 direct vent system, and proper care must be taken to avoid unnecessary contact (especially by children) with the water heater and direct vent system.
Lighting & Shutdown Instructions 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. 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. B. BEFORE OPERATING smell all around the appliance for gas.
Temperature Adjustment Table 5 Approximate Time/Temperature Scald Chart APPROXIMATE TIME/TEMPERATURE RELATIONSHIPS IN SCALDS 120°F (49°C) More than 5 minutes 125°F (52°C) 1½ to 2 minutes 130°F (54°C) About 30 seconds 135°F (57°C) About 10 seconds 140°F (60°C) Less than 5 seconds 145°F (63°C) Less than 3 seconds 150°F (66°C) About 1½ seconds 155°F (68°C) About 1 second CAUTION This water heater, when set at a lower temperature setting, is NOT capable of producing hot water of sufficient temperature for sani
WARNING Setting the water temperature to the maximum set point can result in scalding hot water delivered to the faucets. It is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the installation. See following section to change the maximum setpoint limit (max setpoint). Make sure the water heater control display is not in a public area that can result in the temperature settings being improperly adjusted.
ICON System Control Only 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. An energy cut out (ECO) is incorporated in the sensor and control board which will shut off all gas supply to the burner if the water heater temperature exceeds 207°F (93°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 pressure switch. General NOTE: KEEP APPLIANCE AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS. Water heater maintenance includes periodic tank flushing and cleaning, and removal of lime scale.
Maintenance Schedule WARNING Water heaters are heat producing appliances. To avoid damage or injury there must be no materials stored against the water heater or vent-air intake system, and proper care must be taken to avoid unnecessary contact (especially by children) with the water heater and vent-air intake system.
Maintenance Schedule continued- Filling Water Heater 1. Close the water heater drain valve. This water heater utilizes a ball valve; when closing the valve, the stem will spin indefinitely. Confirm it is closed by ensuring the slot on the stem is perpendicular to the valve body. If alternative water connections are provided but not used, make certain they are plugged (i.e. space heating & alternate top connections). 2. Open the cold water supply shut-off valve. 3.
Maintenance Schedule continued- Powered Anode System All models are equipped with a powered anode system. The powered anode system provides corrosion protection to the tank by supplying a low voltage current to the titanium anode rods and then periodically comparing this current with the potential between the anode rod and tank wall to make corrections. The powered anode system is designed to extend the tank life without requiring anode rod replacement.
Maintenance Schedule continued- 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.
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 Cause of Problem and Actions Taken to Correct • • Water temperature sensor fault 93 • • Appears after alert 172, defined below. Check the water temperature sensor wire harness from the sensor to the control module. Make sure there are no loose connections to the control plug. Check the resistance reading from each of the outside wires to the center (common) wire. Measure the tank temperature and compare with the chart below.
Service Error Codes and Troubleshooting Procedures 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 sensor assembly, compare the resistance of the sensor wires (either outside black to center wire with yellow marking) as measured by an ohmmeter to the water temperature as measured by an accurate thermometer.
Customer must specify complete model number and serial number when ordering service parts. Manufactured under one or more of the following U.S.
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