INDIRECT-FIRED WATER HEATER A Spanish language version of these instructions is available by contacting the manufacturer listed on the rating plate. La version espanola de estas instruccions se puede obtener al escribirle a la fábrica cuyo nombre aparece in la placa de especificaciones. WARNING To avoid damage or injury, there must be no materials stored against the indirect water heater and proper care shall be taken to avoid unnecessary contact (especially by children) with the indirect water heater.
CONGRATULATIONS! You have just purchased one of the finest water heaters on the market today! This installation, operation, and instruction manual will explain in detail the installation and maintenance of your new indirect water heater. We strongly recommend that you contact a plumbing professional for the installation of this water heater. We require that you carefully read this manual, as well as the enclosed warranty, and refer to it if questions arise.
SECTION I IMPORTANT INFORMATION -READ CAREFULLYThe equipment must be installed in accordance with those installation regulations required in the area where the installation is to be made. These regulations must be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made.
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. IF YOU SMELL GAS: DO NOT try to light any appliance. DO NOT touch any electric switch; do not use any telephone in your building. Immediately call your gas supplier from a telephone in another building. Follow the gas supplier’s instructions.
WARNING Installation is not complete unless a pressure and temperature relief valve is installed into the side of the water heater. See the Water Connections section of this manual for details. This water heater contains very hot water under high pressure. Do not unscrew any pipe fittings or attempt to disconnect any components of this water heater without positively assuring the water is cool and has no pressure.
WARNING It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete. DO NOT operate the water heater with jumpered or absent controls or safety devices. DO NOT tamper with or alter the water heater and/or controls. DO NOT operate the water heater if any external part has been under water.
CAUTION The maximum boiler water supply temperature to the indirect heat exchanger must not exceed 240°F (115°C). NOTICE Insulation blankets are not required for this water heater. This water heater meets or exceeds the ASHRAE/IES 90.1b standards with respect to insulation and standby loss requirements. TABLE OF CONTENTS IIIIIIIVVVIVIIVIIIIXX- IMPORTANT INFORMATION…………….….. SPECIFICATIONS………………………………. GENERAL INFORMATION……………………. PRE-INSTALLATION…………………………… WATER CONNECTIONS………………………..
SECTION II SPECIFICATIONS Figure 1 – Tank Layout Table 1: Water Heater Dimension (Inches) MODEL 40-Gal. / Res. 50-Gal. / Res. 65-Gal. / Res. 80-Gal. / Res. 120-Gal. / Com.
Table 2: Water Heater Capacities MODEL Tank Coil Capacity Volume (Gal) (Gal) 40-Gal. / Res. 50-Gal. / Res. 65-Gal. / Res. 80-Gal. / Res. 120-Gal. / Com. 40 50 60 75 114 Dry Weight (Lbs) Wet Weight (Lbs) 168 196 196 224 415 514 623 704 861 1370 2.7 2.7 2.7 2.7 5.0 Table 3: Water Heater Performance MODEL 40-Gal. / Res. 50-Gal. / Res. 65-Gal. / Res. 80-Gal. / Res. 120-Gal. / Com.
NOTICE If the boiler takes longer to heat up from a cold start than the water availability as noted above, hot water shortage may occur. Hot water availability is based off drawing 80% of the heated tank volume at 4 gallons per minute flow rate. The maximum heat transfer through the coil (heat input) of the water heater at 240°F boiler water supply temperature and 210°F potable water temperature is 94,100 Btu/hr for residential models and 180,300 Btu/hr for commercial models.
SECTION III GENERAL INFORMATION FEATURES This water heater contains the following features: HEAT EXCHANGER -- The heat exchanger (coil) has 1” NPT female fittings. These water heaters with single-wall heat exchangers meets the Uniform Plumbing Code for installation in all potable water systems provided that: • • • • • The boiler water (including additives) is practically nontoxic, having toxicity rating of class of 1 as listed in Clinical Toxicology of Commercial Products.
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.
WARNING Install a discharge line so that water discharged from the temperature and pressure relief valve will exit within six (6) inches above, or any distance below, the structural floor and cannot contact any live electrical part. The discharge line is to be installed to allow for complete drainage of both the temperature and pressure relief valve and the discharge line. The discharge opening must not be subjected to blockage or freezing. DO NOT thread, plug, or cap the discharge line.
SECTION IV PRE-INSTALLATION UNPACKING INSPECT SHIPMENT carefully for any signs of damage. If damage is noted, do not install the product. Contact the shipper or manufacturer. All equipment is carefully manufactured, inspected, and packed. Our responsibility ceases upon delivery of the packaged heater to the carrier in good condition. NOTE: Any claims for damage or shortage in shipment must be filed immediately against the carrier by the consignee. IMPORTANT DECISIONS REQUIRED BEFORE INSTALLATION SIZING 1.
Answer: New Rating = 162 gal/hr x (80,000 BTU/h)/(106,000 BTU/h) = 162 gal/hr x 0.755 = 122 gal/hr NOTICE Increasing the boiler DOE heating capacity above the values listed in Table 3 will not increase the rating of the water heater. 2. Circulator Sizing – Refer to Table 4 for the corresponding pressure drop through the coil for the given model. Calculate the pressure drop of all straight pipe and fittings on the supply and return of the water heater at the selected flow rate.
1. 2. 3. Circulators – With space heating zones using circulators, the indirect-fired heater should be added as an additional zone with a circulator. Zone Valves – Select a valve with a low-pressure drop to assure adequate flow through the water heater. Hybrid – The space heating zone can be zoned using zone valves and the indirect-fired heater zoned with a circulator. DOMESTIC HOT WATER PRIORITY Two options are available, Priority and Non-Priority. 1.
Component Location CAUTION This water heater must be located in an area where leakage of the tank, water line connections, or the temperature and pressure relief valve will not result in damage to the area adjacent to the water heater or to lower floors of the structure. When such locations cannot be avoided, a suitable drain pan must be installed under the water heater.
Appliance Location 1. Boiler Location – Locate the indirect-fired water heater as close to the boiler as practical. 2. Fixture Locations – For fastest delivery of hot water, place the indirect-fired water heater close to points of use. Additional Recommended Components 1. Shut-off Valves – Allows isolation of water heater from domestic water system and/or boiler system during service. 2. Unions – Allows water heater movement during service if adequate clearance cannot be provided. 3.
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. HYDROGEN GAS IS EXTREMELY FLAMMABLE.
INSTALL TEMPERATURE AND PRESSURE RELIEF VALVE (if not factory installed) WARNING Temperature and pressure relief valve discharge piping must be piped near the floor to eliminate potential of severe burns. Do not pipe in any area where freezing could occur. Do not install any shut-off valves, plugs or caps to the temperature and pressure relief valve or piping. INSTRUCTIONS FOR POTABLE CONNECTIONS 1. BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN WATER SUPPLY VALVE.
streams of water flow through the faucets, close them and check all water connections for possible leaks. 4. NEVER OPERATE THE WATER HEATER WITHOUT FIRST BEING CERTAIN THAT IT IS FILLED WITH WATER. INSTRUCTIONS FOR BOILER CONNECTIONS The indirect-fired heater connection labeled “To Boiler Return” should be piped to the boiler return piping as close to the boiler as possible and especially after any flow control or check valves in the space heating return piping.
Figure 2 - Water Boiler Piping with Zone Valves 2. For a space heating system that utilizes CIRCULATORS, refer to Figure 3. The indirect-fired heater connection labeled “FROM BOILER SUPPLY” should be piped to the boiler supply piping. Mount the circulator making sure the flow arrow points toward the water heater. The use of shutoff valves and unions are recommended for future service convenience. The use of an air separator and vent is recommended to eliminate air in the system.
CONNECT STEAM BOILER SUPPLY PIPING Figure 4 represents a typical steam boiler connection diagram. Refer to the boiler installation manual or contact the boiler manufacturer for an appropriate piping diagram. The use of a union, shut-off valves, and a drain valve is recommended for future service convenience. The use of an in-line “Y”-style strainer is required to prevent accumulation of sludge in the water heater’s coil.
SECTION VI ELECTRICAL CONNECTIONS Install electric wiring in accordance with National Electric Code or the Canadian Electrical Code and local regulations. See the boiler’s installation manual for wiring diagrams. DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the water heater or building. Lock out all electrical boxes with padlock once power is turned off.
complete, secure the aquastat cover back in place. AT NO TIME SHOULD WATER HEATER OPERATION TAKE PLACE WITHOUT THE COVER ON THE CONTROL.
SECTION VII OPERATING INSTRUCTIONS WARNING Water heaters are heat-producing appliances. To avoid damage or injury there must be no materials stored against the water heater, and proper care must be taken to avoid unnecessary contact (especially by children) with the water heater. UNDER NO CIRCUMSTANCES SHALL FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THE WATER HEATER OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER.
WATER TEMPERATURE ADJUSTMENT 1. The aquastat controls the maximum water temperature in the tank. The differential is a fixed 5°F with a 160°F maximum setting, set at the factory to 120°F. WARNING SCALDING This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. By setting the aquastat on this water heater to obtain an increased water temperature, you may create the potential for scald injury.
2. For the most energy efficient operation, adjust the aquastat for the minimum water temperature necessary to meet domestic hot water needs. Refer to Figure 7. Use a small flat screwdriver to rotate the temperature dial through the hole directly below the temperature indication window. The temperature setting is aligned with the notch in this window. IT IS NOT NECESSARY TO REMOVE THE COVER TO ADJUST THE TEMPERATURE SETTING.
SECTION VIII MAINTENANCE This indirect-fired water heater is intended to provide a service life of many years. Components that require service, however, may be subject to failure. Failure to use the correct procedures or parts in these circumstances may make the water heater unsafe. The owner should arrange to have the following inspections and simple maintenance procedure performed by qualified service personnel at the frequencies suggested. 1.
If the temperature–pressure relief valve on the heater discharges periodically or continuously, it may be due to thermal expansion of water in a closed water supply system, or it may be due to a faulty relief valve. Thermal expansion is the normal response of water when it is heated. In a closed system, thermal expansion will cause the system pressure to build until the relief valve actuation pressure is equaled. Then the relief valve will open, allowing some water to escape, slightly lowering the pressure.
4. 5. discharge in an area where any remaining hot water will not cause any damage or injury. b. Open the drain valve to flush any sediment out of the bottom to the heater. c. Shut off the cold water supply. Make sure all hot water fixtures and circulating pumps are turned off. d. Wait for water flow from the hose to stop. Remove the anode using a socket of the appropriate size. Do not use an impact wrench. e. Inspect and replace the anode as required. Use pipe tape or sealant when reinstalling the anode.
SECTION IX TROUBLE SHOOTING GUIDE PROBLEM No hot water at faucet CAUSE Boiler does not operate Circulator does not operate Improper aquastat setting or calibration Zone valve does not open (if used) Electrical problem (relay, wiring, etc.
TROUBLE SHOOTING GUIDE (CONT.) PROBLEM CAUSE SOLUTION Insufficient hot water Aquastat setting too low Undersized boiler with no priority to domestic hot water Peak use of hot water is greater than tank storage capacity Faulty tank aquastat Excessive demand Adjust aquastat to higher setting.
SECTION X PARTS LIST 1. 2. 3. 4. 5. 6. PART NAME & DESCRIPTION Aquastat Control 7. Drain Valve Aquastat Well 8. Jacket Head Pan Anode 9. Hole Closure Diptube 10. Heat Exchanger Escutcheon Outlet Nipple 11. Escutcheon T & P Relief Valve 12.
Contact your supplier or plumbing professional for replacement parts or contact the company at the address given on the rating plate of the water heater. Provide the part name, model, and serial numbers of the water heater when ordering parts. READ THE WARRANTY FOR A FULL EXPLANATION OF THE LENGTH OF TIME THAT PARTS AND THE WATER HEATER ARE WARRANTED. Manufactured under one or more of the following U.S.
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