POWERED DIRECT VENT SERIES GAS-FIRED COMMERCIAL WATER HEATER 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. Do not touch any electrical switch; do not use any phone in your building.
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 and CAN/CGA 4.3-M (as indicated on the rating plate). These standards are available from CSA Standards Association, 5060 Spectrum Way Mississauga, Ontario L4W 5N6 CANADA. This water heater must be installed in accordance with local codes. In the absence of local codes, it must be installed in compliance with the National Fuel Gas Code (ANSI Z223.
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 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.
SECTION II: SPECIFICATIONS Figure 1 Model Description Capacity Input (BTU/hr) (Gal) Nat. LP 100 360,000 360,000 80 300,000 300,000 A (in.) 72 7/8 63 7/8 Dimensions for Figure 1 B C D (in.) (in.) (in.) 60 7/16 78 11/16 56 15/16 51 7/16 69 11/16 47 15/16 E (in.) 74 13/16 65 13/16 Model Description Capacity Input (kW/hr) (Liter) Nat. LP 378.5 105.5 105.5 302.8 88.0 88.0 A (cm) 185.1 162.3 Dimensions for Figure 1 B C D (cm) (cm) (cm) 153.5 199.9 144.7 130.7 177.0 121.8 E (cm) 190.0 167.
SECTION III: GENERAL INFORMATION FEATURES 1. Porcelain enamel lined tank provides corrosion protection with a tough glass lining on the interior of the tank. 2. Magnesium anodes provide an extra measure of protection and extends tank life. 3. Direct Vent design with an induced draft blower. Flue gases are exhausted and combustion air is taken from outside the building through coaxial vent pipe (exhaust flue pipe inside combustion air intake pipe). Maximum venting distance is 19 ½ feet with one elbow.
DISHWASHING MACHINE REQUIREMENTS All dishwashing machines meeting the National Sanitation Foundation requirements are designed to operate with water flow pressures between 15 and 25 pounds per square inch. Flow pressures above 25 pounds per square inch, or below 15 pounds per square inch, will result in improperly sanitized dishes. The National Sanitation Foundation also recommends circulation of 180°F water.
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.
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. After reading these Installation and Operating Instructions, select a location for the water heater where the floor is level and is easily accessible to water lines, gas supply (type identified on the rating plate), an adequate open drain, and within the maximum specified venting distance to an outside wall or roof for the direct vent terminal.
5. The minimum clearances to combustibles for this water heater are: two (2) inches (5.1 cm) from the sides and rear, two (2) inches (5.1 cm) from the front of the burner access box, sixteen (16) inches (40.6 cm) from the top jacket, zero (0) inch (0 cm) from the air intake boot and vent tubes and twelve (12) inches (30.5 cm) in any direction from the direct vent terminal. A minimum of 30 inches (76.2 cm) front clearance from the burner access panel is necessary for inspection and servicing. 6.
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 and Propane Installation Code (B149.1-00 latest edition). Failure to properly install the venting system could result in property damage, personal injury, or death.
Direct Vent Terminal Clearances Canadian Installations1 A= US Installations2 12 inches (30 cm) Clearance above grade, veranda, porch, deck or balcony 12 inches (30 cm) 36 inches (91 cm) 12 inches (30 cm) *b *b B= Clearance to widow or door that may be opened C= Clearance to permanently closed widow 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 12 inches (30 cm) *a 12 inches (30 cm) *a E
Horizontal And Vertical Direct Vent Lengths This Powered Direct Vent Gas Water Heater comes with one (1) direct vent kit. The venting system supplied with this water heater is a coaxial (pipe within a pipe) design with the flue discharge tube on the inside and combustion air supply on the outside. Optional direct vent components are available that can extend the horizontal length and/or vertical height of the direct vent system to the maximum distances listed in the table below.
Installation Procedure A. Determine where the vent terminal will exit through the wall or roof. 1. The supplied vent kit includes a horizontal (through the wall) vent terminal, an elbow, a condensate trap, vent connector clamps, and 6 1/2 ft. (2 m) of coaxial vent pipe. The 6 in. (15.3 cm) diameter venting system also is supplied with an 8 in. (20.3 cm) to 6 in. (15.3 cm) reducer for the water heater vent connection.
Figure 5 (c) Slide the outside wall plate over the vent terminal and fasten to the wall with 4 screws. Depending upon the wall construction, wall anchors may be required to reinforce the screws. (d) Install the flue cap over the outside of the angled flue discharge tube of the vent terminal. Rotate the cap so that the vent discharge opening is in line with the angled opening of the vent terminal. The vent and air intake openings must both be aligned to face the ground.
Figure 7 (Inside Wall) 2. Vertical Vent Terminal (Through the Roof - Optional) (a) Determine the exact location where the roof vent terminal will exit the roof, making sure the venting system clears all obstructions. For pitched roofs, the vent cap must be the distance above the roofline as specified in the local codes, or in the absence of local codes refer to the latest edition of the National Fuel Gas Code. The top of the roof terminal may extend up to 2 1/2 ft. (76.2 cm) above the roofline as needed.
C. Install Vent Piping Sections General Notes: 1) The coaxial vent pipe sections are designed to fit tightly together and seal with the integral flue pipe seal and supplied pipe clamps. No silicone caulk or special tools are required. (2) All venting sections and fittings come complete with silicone flue pipe gaskets and outside gasketed pipe clamps for making airtight connections between the venting pipe connections.
(d) Continue connecting pipe sections together with clamps and supporting with hangers. Follow the same procedure described in the previous steps for inserting and connecting the flue tubes inside the outer vent pipes. Install one section at a time with the outside pipe first, followed by the inside flue pipe. (e) The last pipe section may be cut to fit the distance required to reach the water heater vent connections.
SECTION VI: WATER CONNECTIONS NOTE: BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN WATER SUPPLY VALVE. After shutting off the main water supply, open a faucet to relieve the water line pressure to prevent any water from leaking out of the pipes while making the water connections to the water heater. After the pressure has been relieved, close the faucet. The COLD water inlet and HOT water outlet are identified on the top and front of the water heater.
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 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 B149.2 Propane Installation Code (Latest Edition). The minimum permissible gas supply pressure for the purpose of input adjustment is one (1.0) inch (0.25 kPa) water column above the operating manifold pressure. See the rating plate and gas valve for the manifold pressure and gas type.
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.
TYPICAL INSTALLATION 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.
SECTION IX: OPERATING INSTRUCTIONS Lighting and Shutdown Instructions 24
TEMPERATURE ADJUSTMENT 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 DANGER Hotter water increases the risk of scald injury. Scalding may occur within five (5) seconds at a temperature setting of 140F (60C).
Water Heater Display and Control Buttons Shown flashing in display only when temp is adjusted Sequence of operation Indicator Reads "Idle” or “Heating" Status Indicator Read "Operational" or "Service Needed" Temperature Up Button °F setpoint idle Status Operational SELECT SET Temperature Setpoint in Degrees F or Degrees C Range 70 - Max °F Range 21 - Max °C Temperature Down Button Set button Select button WARNING If the water heater display does not show “Operational” in the “Status” indicator, the
To Increase Setpoint Temperature Step 1: Depress and hold “Temperature Up” button until desired setpoint temperature appears in the display. °F idle Status Operational SELECT SET Step 1 Step 2: “Setpoint” indicator begins flashing in the display after pressing “Temperature Up” button. "Setpoint" flashes °F setpoint idle Status Operational SELECT SET Step 2 Step 3: Press “SET” button for new setting to take effect immediately. “Setpoint” will stop flashing.
To Decrease Setpoint Temperature Step 1: Depress and hold “Temperature Down” button until desired setpoint temperature appears in the display. °F idle Status Operational SELECT SET Step 1 Step 2: “Setpoint” indicator begins flashing in the display after pressing “Temperature Down” button. "Setpoint" flashes °F setpoint idle Status Operational SELECT SET Step 2 Step 3: Press “SET” button for new setting to take effect immediately. The setpoint will stop flashing.
To Change Temperature Format in Display from F to C or ˚C to ˚F: Step 1: Press “SELECT” button until F/C is displayed. °F °F/°C idle Status Operational SELECT Press select SET Step 1 Step 2: Press “SET” button to change temperature format. Symbol F/C will flash. °F °F/°C idle Status Operational SELECT SET °F/°C Flashes Step 2 Step 3a: Press “Temperature Up” button to change temperature format to C.
Step 3b: Press “Temperature Down” button to change temperature format to F. Changes to "°F" °F/°C Flashes °F °F/°C idle Status Operational SELECT SET Step 3b Step 4: Press “SET” button to confirm ˚F or ˚C format. F/C will stop flashing. Setpoint display will appear in the format selected (˚F or ˚C) in 10 seconds.
An automatic gas shut-off device (ECO) is incorporated in the sensor and control board which will shut off all gas supply to the burner and pilot if the water heater temperature exceeds 200°F (93°C). Should the ECO function (open), the water temperature should be reduced to approximately 120°F (49°C) and follow applicable Lighting Instructions to place the water heater in operation.
SECTION X: MAINTENANCE NOTICE The water heater should be inspected at a minimum annually by a qualified service technician for damaged venting system components and/or vent and combustion air supply joints not sealed. DO NOT operate this water heater if any part is found damaged or if any joint is found not sealed. 1. A qualified service technician should perform the following maintenance at the minimum periodic intervals suggested below.
To remove the burner rack assembly, follow the procedure outlined below: a) Shut off the gas and electrical supply to the water heater. b) Remove the pilot tube fittings at the gas valve and combustion box. c) Disconnect wires to gas valve. Open control box and disconnect pilot spark and flame sensor wires. Remove the wire raceway cover below the control box. d) Disconnect the gas pipe union below the gas valve.
TO FILL THE WATER HEATER 1. Close the water heater drain valve by turning the knob or valve stem clockwise. If alternative water connections are provided but not used, make certain they are plugged (i.e. rear connections). 2. Open the cold water supply shut-off valve. 3. Open several hot water faucets to allow air to escape from the system. 4. When a steady stream of water flows from the faucets, the water heater is filled.
SECTION XI: DIAGNOSTIC AND TROUBLESHOOTING GUIDE DIAGNOSTIC GUIDE FOR HONEYWELL INTEGRATED CONTROL SYSTEM SEQUENCE OF OPERATION FOR PDV MODELS 1. When the tank temperature drops below the temperature setpoint on the display, the control sends power to the induced draft blower to start the ignition sequence. 2. When blower reaches the full operating speed, the pressure switch closes, completing the 24 volt circuit to the safety circuit of the control.
ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY (FOR SERVICE PERSONNEL ONLY) The display has a “service mode” for changing the maximum setpoint and accessing information in aiding servicing of the water heater. This procedure is for service and installation personnel only. To enter the Service Mode, follow the steps illustrated below: WARNING The following procedure is for service and installation personnel only.
The following is the sequence of modes available in “Service Mode” by pressing the “Select” button: Error Code Number (Display/Reset). This is only shown if there is an operating error in the “User Mode”. Error Code Shown in Water Heater Display Status Service Needed SELECT Lockout RESET 1. Max Setpoint (Display/Change) Max Setpoint value Water Heater Display °F Max Setpoint idle Status Operational SELECT SET 2a.
2b. Water Temperature - Upper Sensor (Displays if there is an upper sensor – some models) °F idle Status Operational Upper Sensor SELECT SET 2c. Water Temperature - Lower Sensor (Displays if there are two sensors) °F idle Status Operational Lower Sensor SELECT SET 3.
4. Setpoint (Display/Change) °F setpoint idle Status Operational SELECT SET 5. ˚F/˚C (Display/Change) °F °F/C° idle Status Operational SELECT SET 6.
7. Software Version (Display only) Soft idle Status Operational SELECT SET 8. Error Code History (Displays if there are present error codes or up to 10 previous error codes). Water Heater Display will show -- if there are no error codes.
Step 2: Press “Set” button to enter setting mode. “Max Setpoint” will flash to indicate setting mode. "Max Setpoint" Flashes °F Max Setpoint idle Status Operational SELECT SET Step 3: Press the “UP” or “DOWN” buttons to change the maximum setpoint value. This will limit the maximum setpoint the user can select. Note: The maximum setpoint is approximately 180˚F.
Step 5: 30 Seconds after the last button press, the Water Heater Display will go back to “User Mode”. It will read “Max Setpoint” without showing a temperature value if the temperature setpoint is at the maximum setting. The Water Heater Display can be set back to the “User Mode” immediately by pressing both the “Temperature Up” and “Select” buttons together for 3 seconds.
Step 2: For water heaters using two temperature sensors, pressing the “Select” button again displays the Upper Sensor temperature reading. “Upper Sensor” will be displayed in the lower right side of the status window of the water heater display. °F idle Status Operational Upper Sensor SELECT SET Step 3: For water heaters using two temperature sensors, pressing the “Select” button again displays the Lower Sensor temperature reading.
To Display and Change Temperature Setpoint: Step 1: In “Service Mode” press the “Select” button until “Setpoint” is shown in the water heater display. °F setpoint idle Status Operational SELECT SET Step 2: Press the “Set” button to enter the setting mode. “Setpoint” will flash in the water heater display.
Step 4: To lower the temperature setpoint, press the “Temperature Down” button until the desired temperature is shown on the water heater display. "Setpoint" Flashes °F setpoint idle Status Operational SELECT SET Step 5: When the desired setpoint is reached on the water heater display, press the “Set” button to confirm the new setpoint. “Setpoint” stops flashing in the water heater display.
Step 2: Press “Set” button to change temperature format. “˚F/˚C” symbol will flash in the water heater display. "°F/°C" Flashes °F °F/C° idle Status Operational SELECT SET Step 3a: Press “Temperature Up” button to change temperature format to ˚C Changes to "°C" "°F/°C" Flashes °C °F/C° idle Status Operational SELECT SET Step 3b: Press “Temperature Down” button to change temperature format to ˚F.
Step 4: Press “Set” button to confirm ˚F or ˚C format. ˚F/˚C will stop flashing. "°F/°C" Symbol Stops Flashing °F °F/C° idle Status Operational SELECT SET Step 5: Pressing “Select” button will return display to setpoint in format selected (˚F or ˚C) immediately.
How to reset the control from Lockout Conditions: WARNING The following procedure is for service and installation personnel only. Resetting lockout conditions without correcting the malfunction can result in a hazardous condition. If an error code is displayed (except for #4, low flame sense current), the water heater will be in a “lockout condition” with the water heater display showing the error code number and “Service Needed” in the status section of the display window.
Error Codes and Error History Display: If there is an operating problem with the water heater, an error code number will appear on the water heater display with “Service Needed” to the right of the “Status” indicator. The error code label is located below the water heater display and the following section in this Installation and Operating Instruction Manual explains the error codes with corrective actions to repair the water heater.
Step 2: Press the “Temperature Down” button to select the error code index, starting with the most recent error code “10”. Error Code Index idle Status Operational SELECT SET Step 3: Press the “Select” button to view the error code for “code 10”. If there is a number displayed, note what the number is. The label next to the water heater display will identify the code number.
Step 4: Press the “Temperature Down” button to change to the previous code index, code #9. Error Code Index idle Status Operational SELECT SET Step 5: Press the “Select” button for code index #9 to view if there are any code numbers.
Step 6: Continue pressing the “Temperature Down” button to change to the next error code index and press “Select” to view the error code number, if any, for that index number. Continue on to index #1, the oldest error code index. The water heater display will store up to 10 error codes with the oldest code starting in code index #1 with the most recent code in code index #10. Step 7: 10 seconds after the last button press, the Water Heater Display will revert back to the current error code display.
Error Code Definition of Code 23 Flame Detected Before Ignition 24 31 32 57 58 59 Flame Detected After Heating Cycle Completes Upper Sensor Readings Faulty Lower Sensor Readings Faulty Flame Rod Shorted to Ground AC Line Frequency Error – Signal Too Noisy or Frequency Incorrect Line Voltage Too Low or High 61 DC Output Voltage Unstable 62 Maximum Number of Retries Detected 63 Maximum Number of Ignition Recycles Detected 64 Electronics Failure 65 High Water Temperature (Over 200˚F) Cause of
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 or lower sensor assembly, compare the resistance of the sensor terminals (blue leads for upper sensor, yellow and black lead for lower sensor) as measured by an ohmmeter to the water temperature as measured by an accurate thermometer.
SECTION XII: PARTS LIST 8” (20.
REPLACEMENT PARTS LIST FOR POWERED DIRECT VENT MODELS Contact your supplier, plumbing professional or the company listed on the rating plate of the water heater for replacement parts. Provide the part name as well as the model and serial number(s) of the water heater(s) when ordering parts. When applicable, the following information must be provided: type of gas, voltage and amperage, item number (from the following list) and description (from the following list). 56 PART NAME AND DESCRIPTION 1.
` SECTION XIII: INSTALLATION FOR POTABLE WATER AND SPACE HEATING THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION OF: GAS WATER HEATERS SUITABLE FOR WATER (POTABLE) HEATING AND SPACE HEATING 1. All piping components connected to this water heater for space-heating applications must be suitable for use with potable water. In Massachusetts, space heating piping length must not exceed 50 feet. 2.
` Suggested Piping Arrangement For Top & Side Connections Suggested Piping Arrangement For Top Connections 58
SECTION XIV: NOTES 59
NOTES 60
