Instructions / Assembly

ManualsBrandsPerfect Fit ManualsCommercial90 Gal. 3 Year 715,000 BTU Extreme High Input ASME Mass Code Natural Gas Water Heater

Printed in USA

FOR YOUR SAFETY!

— Do not store or use gasoline or other flammable

vapors or liquids or other combustible materials in

the vicinity of this or any other appliance. To do so

may result in an explosion or fire.

— 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.

•

Immediately call your gas supplier from a neighbor's

phone. Follow the gas supplier's instructions.

•

If you cannot reach your gas supplier, call the fire

department.

•

Do not return to your building until authorized by

the gas supplier or fire department.

— Improper installation, adjustment, alteration, service

or maintenance can cause injury, property dam-

age or death. Refer to this manual. Installation and

service must be performed by a qualified installer,

service agency or the gas supplier.

WARNING: If the information in these instructions are not followed exactly, a fire or explosion may result

causing property damage, personal injury or death.

NOTICE: This water heater is designed for use in a commercial application and the installation and maintenance of it should be per-

formed by a qualified, licensed service personnel. If the foregoing assumption is not appropriate, then we recommend that you obtain

and retain our Residential Use & Care Manual.

AP10386-18 (06/11)

WITH INSTALLATION INSTRUCTIONS FOR THE CONTRACTOR

Commercial Gas Water Heater

USE & CARE MANUAL

MULTI-FLUE COMMERCIAL MODELS

CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California to cause cancer, birth

defects or other reproductive harm.

Do Not Destroy this Manual. Please read carefully and

keep in a safe place for Future Reference.

Recognize this symbol as an Indication of Important

Safety Information!

*The Power Assist Burner and Xtreme Units use a system that requires a blower to deliver the air for combustion.

Standard

Burner Unit

Power Assist

Burner Unit *

CERTIFIED

GAS-FIRED

Unit *

TREME

Refer to page 9

for an impor tant

note regarding ini-

tial start-up of this

unit!

GNU:

Power Assisted *

Summary of content (28 pages)

PAGE 1
Commercial Gas Water Heater USE & CARE MANUAL WITH INSTALLATION INSTRUCTIONS FOR THE CONTRACTOR MULTI-FLUE COMMERCIAL MODELS Standard Burner Unit TREME Unit * GNU: Power Assisted * Power Assist Burner Unit * DESIGN GAS-FIRED CER TIFIED Refer to page 9 for an important note regarding initial start-up of this unit! ® CERTIFIED R *The Power Assist Burner and Xtreme Units use a system that requires a blower to deliver the air for combustion.
PAGE 2
! General Safety Precautions Be sure to read and understand the entire Use & Care Manual before attempting to install or operate this water heater. Pay particular attention to the following General Safety Precautions. Failure to follow these warnings could result in a fire or explosion, causing property damage, bodily injury or death . Should you have any problems understanding the instructions in this manual, STOP, and get help from a qualified installer or service technician or the gas supplier.
PAGE 3
! General Safety Precautions To meet commercial water use needs, the thermostat on this water heater is adjustable up to 180°F. However, water temperatures over 125°F. can cause severe burns instantly or death from scalds. This is the preferred starting point for setting the control for supplying general purpose hot water.
PAGE 4
Introduction NOTE: Auxiliary catch pan installation MUST conform to the applicable local codes. ! WARNING Read and Review this entire Manual with special emphasis on the Draft Hood and Venting Sections (Page 5) and Operation Section (Pages 8 - 11) prior to any installation work D.
PAGE 5
Introduction Large exhaust fans can lower the air pressure inside a building or room and interfere with proper venting and operation. Commercial kitchens or other locations that must maintain a high flow of exhaust air should have the water heater installed in a separate room with combustion and ventilation air supplied directly from outside as described above. photo processing labs, and storage areas for liquid and powdered bleaches or swim pool chemicals often contain such hydrocarbons.
PAGE 6
Installation NOTES: 1.) Heater's Outlet Piping must have upward slope, otherwise use Circulator 2.) If Vertical Tank is used, follow same layout. 3.) Figure depicts the “Power Assist Burner”, but all burner systems applies. 4.) The gas supply piping must be adequately supported and aligned to minimize loads (forces) on the water heater’s gas valve and burner system.
PAGE 7
Installation The pipe compound used should be resistant to the action of liquefied petroleum gases. LEAK TESTING — The water heater and its gas connections MUST be leak tested at normal operating pressure before it is placed in operation. Turn ON the manual gas shut-off valve near the water heater. Use a soapy water solution to test for gas leaks at all connections and fittings. Bubbles indicate a gas leak that must be corrected.
PAGE 8
Operation Before operating this water heater, be sure to read and follow the instructions on the label pictured below and all other labels on the water heater, as well as the warnings printed in this manual. Failure to do so can result in unsafe operation of the water heater resulting in property damage, bodily injury, or death. Should you have any problems reading or following the instructions in this manual, STOP, and get help from a qualified person.
PAGE 9
Operation Before operating this water heater, be sure to read and follow the instructions on the label pictured below and all other labels on the water heater, as well as the warnings printed in this manual. Failure to do so can result in unsafe operation of the water heater resulting in property damage, bodily injury, or death. Should you have any problems reading or following the instructions in this manual, STOP, and get help from a qualified person. Lighting Instructions for the Xtreme Unit Only. 1.
PAGE 10
Operation SAFETY PRECAUTIONS A. Do turn off manual gas shut-off valve if water heater has been subjected to over heating, fire, flood, physical damage or if gas supply fails to shut off. E. Do not allow combustible materials such as newspaper, rags or mops to accumulate near water heater. B. Do Not turn on water heater unless it is filled with water. F.
PAGE 11
Operation Small adjustments can be made by varying the manifold pressure from the designated settings mentioned above. 5. INTERMITTENT PILOT FLAME ADJUSTMENT — No adjustment is required with normal inlet gas pressures. The pilot flame adjustment valve is pre-set, and does not normally require re-adjustment. 6. HIGH ALTITUDE — Ratings of gas appliances are based on installation and operation at sea level of elevations of 2000 feet.
PAGE 12
Maintenance Burner and pilot assembly removal instructions specific to Xtreme models ONLY! For instructions on burner removal for standard and power assist models refer to page 13. To Remove Burner(s): Blower Protective Cage 1. Turn off gas and electric to unit. Remove the two (2) screws that hold the “blower protective cage” over blower. Remove “blower protective cage” and set aside to be reassembled later. Plenum Top Plate Grommet (hidden in this view) 2. Disconnect power cable to blower.
PAGE 13
Maintenance TO REMOVE BURNER TRAY: 2. The Temperature and Pressure Relief Valve must be free to operate properly. Check (at least once a year) by lifting the handle fully and allowing several gallons of water to flush through the discharge line. Make certain the discharged water is directed to a suitable drain. 1. Turn off manual gas shut-off valve. 2. Disconnect gas pipe union and wiring to gas valve, pilot, & blower(If so equipped.). 3.
PAGE 14
Maintenance 2. ANODE INSPECTION — The water supply in certain areas contains very aggressive elements. In these areas, periodic inspection of the anode is recommended to determine if replacement is necessary. The anode(s) supplied in this water heater is slowly consumed , thereby eliminating or minimizing corrosion and protecting the glass lined tank. The anode(s) should be replaced when more than 6 inches (15 cm) of core wire is exposed at either end. 4.
PAGE 15
“System Sentinel” Diagnostic System The “System Sentinel” Diagnostic system on this water heater provides the user or service technician with a visual representation of the operational status of the various sections of the water heater’s control system. A quick glance at the System Sentinel panel on the front of the heater will give an indication of where to begin trouble shooting of a non operational heater.
PAGE 16
“System Sentinel” Troubleshooting Guide Section 1... the “POWER” LED NO Is the “ON/OFF” Switch in the “ON” position? YES Is the “POWER” LED Illuminated? Turn switch to ON position. Is the Power LED now illuminated? NO YES Is 120 VAC power present at the branch circuit connections to Black wire of the switch and White wire of the transformer ? NO NO Check circuit breaker or fuse and field connection of branch circuit wiring to leads of switch. Repair or replace as required.
PAGE 17
“System Sentinel” Troubleshooting Guide Section 2... the “THERMOSTAT” LED Is the “THERMOSTAT” LED Illuminated? NO Ensure that power is being supplied to the water heater. Refer to “Section 1... the POWER LED” in this Troubleshooting Guide, and correct if necessary. Is the “THERMOSTAT LED” now illuminated. YES Thermostat is calling for heat, and 24 VAC power is being supplied to the Damper Assembly.
PAGE 18
NO YES NO YES NO *YES *NO *Is 24 VAC present between terminal 6 and Gray ground wire? *YES YES YES If all of the above components check okay, replace Ignition Control Module. NO YES Check continuity of Red and Gray wires between Damper Assembly and Ignition Control Module. Is continuity “good”? NO The Thermostat has called for heat, the Damper Assembly has fully opened, and 24 VAC power is being supplied to the Ignition Control Module and the ignition sequence will begin. 1.
PAGE 19
*Is there continuity across normally closed pole and common pole of pressure switch? *NO *NO *YES *Pressure switch is defective and must be replaced. *Relay is defective and must be replaced. *YES *NO *Is there 120 VAC across Brown wire and Blue wire of blower? *NO *Is blower operating? *YES *YES *Relay is defective and must be replaced. *Blower is defective and must be replaced. Repair or replace the Wiring Harness Ignition Control Module is defective and must be replaced.
PAGE 20
“System Sentinel” Troubleshooting Guide Section 4... the “PILOT VALVE” LED Is the "PILOT VALVE" LED illuminated? NO Is the Spark Ignitor operating? (Can sparking be heard?) YES NO The System Sentinel Panel is defective and must be replaced. 1. Remove Ignition Cable and check for good continuity, replace if necessary. 2. Check Ignitor Electrode gap for proper spacing (1/8” to 5/32”). Correct if necessary. 3. Examine Ceramic Insulator on Pilot Assembly for cracks. Replace if cracks are evident.
PAGE 21
“System Sentinel” Troubleshooting Guide Section 5... the “ECO” LED Is the “ECO” LED Illuminated? NO ECO is “open”. Allow tank to cool, and reset. If ECO again trips, the Thermostat/High limit is defective. Replace as required. YES The ECO (Energy Cut-Off device) is not tripped (open) and power is being supplied to the “PV” terminal on the Gas Control Valve. YES Is “ECO LED now illuminated? NO Is the Pilot Flame burning? The System Sentinel Panel is defective and must be replaced.
PAGE 22
Replacement Parts The following Gaskets are required for Normal Maintenance for all Models: SP5886 Tank Handhole Sealplate Gasket All other Parts can be ordered by providing the following information: 1. Description of Part(s), such as: Main Gas Valve Pilot Burner Main Burner Thermostat Damper / Draft Hood Assembly Anode Rod Or other parts as required. 2. Quantity of each part required. 3. Complete models number and name of the water heater. 4. Serial Number of water heater. 5.
PAGE 23
How to Obtain Service Assistance 1. Should you have any questions about your new water heater, or if it requires adjustment, repair, or routine maintenance, it is suggested that you first contact your installer, plumbing contractor or previously agreed upon service agency. In the event that the firm has moved, or is unavailable, refer to the telephone directory commercial listings or local utility for qualified service assistance.
PAGE 24
Wiring and Schematic Diagrams G Y- 3 Y-1 R-1 BL-1 COMM 24V IGN TH L1 DAMPER MOTOR BL-4 NORMAL OPERATION SEQUENCE INDICATED BY BOXED NUMERALS LED INDICATORS BR-3 120 V POWER BR-4 THERMOSTAT IGNITION BR-3 120V 24 V PILOT VALVE L1 L2 BR-4 THERMOSTAT AND LIMIT POWER LED 2 ECO MAIN VALVE BLACK DAMPER DRIVE COMM WHITE TRANSFORMER GRAY TH THERMOSTAT LED GY-1 MAIN VALVE LED GND GY-2 PV GND 24 GND MV MV / PV BR-1 BR-2 BR-3 GY-3 BR-1 BR-3 BL-2 W-1 PV PV MV MV GAS VALVE 4 MGV M
PAGE 25
Wiring and Schematic Diagrams G Y- 3 Y-1 R-1 BL-1 COMM 24V IGN TH L1 DAMPER MOTOR NORMAL OPERATION SEQUENCE INDICATED BY BOXED NUMERALS LED INDICATORS BL-4 BR-3 120 V POWER BR-4 THERMOSTAT IGNITION 120V BR-4 BR-3 THERMOSTAT AND LIMIT 24 V PILOT VALVE L1 L2 POWER LED 2 ECO DAMPER DRIVE MAIN VALVE BLACK COMM WHITE TRANSFORMER GRAY TH THERMOSTAT LED GY-1 MAIN VALVE LED GND GY-2 GND 24 PV GND MV BR-3 IGNITION CONTROL MV / PV BR-1 GY-3 TH D D W-2 GAS VALVE LIMIT R-3 3
PAGE 26
Wiring and Schematic Diagrams G Y- 3 Y-1 R-1 BL-1 COMM 24V IGN TH L1 DAMPER MOTOR BL-4 NORMAL OPERATION SEQUENCE INDICATED BY BOXED NUMERALS 120 V LED INDICATORS BR-3 3 M R POWER BR-4 L2 BLOWER THERMOSTAT IGNITION 120V BR-3 THERMOSTAT AND LIMIT L1 L2 BR-4 24 V PILOT VALVE ECO 2 MAIN VALVE BLACK DAMPER DRIVE WHITE ON 3 IGNITION CONTROL GY-2 4 PGV GND R-3 ECO LED PILOT VALVE LED BL-5 GY-1 IGNITION CONTROL 4 IGN. SCHEMATIC PILOT ELECTRODE ASS'Y.
PAGE 27
Wiring and Schematic Diagrams G Y- 3 Y-1 R-1 BL-1 L1 COMM 24V IGN TH NORMAL OPERATION SEQUENCE INDICATED BY BOXED NUMERALS DAMPER MOTOR LED INDICATORS BL-4 BR-3 IGNITION BR-3 BR-4 24 V PILOT VALVE L1 L2 POWER LED 2 ECO DAMPER DRIVE MAIN VALVE BLACK COMM WHITE GY-4 THERMOSTAT LED MAIN VALVE LED GND 24 MV/PV RELAY TH D D W-2 GAS VALVE GY-2 BL-6 PV C NC NO GND Y-5 LIMIT 3 PGV PV IGNITION CONTROL GND 24 Y-4 MV 5 MV / PV 4 GND ECO LED PILOT VALVE LED R-4 BR-1 BR-3 BL
PAGE 28
Wiring and Schematic Diagrams NOTE: If any of the original wire as supplied with this appliance must be replaced, it MUST be replaced with 18 GA., 600V, 105°C wire or its equivalent, unless otherwise noted. ! CAUTION! Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING! Figure 16. — Diagrams for units supplied with Honeywell VR8404M Gas Valve and Honeywell S8600M Ignition Control.