Commercial Gas Water Heater USE & CARE MANUAL WITH INSTALLATION INSTRUCTIONS FOR THE CONTRACTOR MULTI-FLUE COMMERCIAL MODELS Standard Burner Unit Power Assist Burner Unit * TREME Unit * DESIGN CER TIFIED GAS-FIRED ® Refer to page 9 for an important note regarding initial start-up of this unit! CERTIFIED *The Power Assist Burner and Xtreme Units use a system that requires a blower to deliver the air for combustion.
! 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.
! 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.
Introduction ! WARNING NOTE: Auxiliary catch pan installation MUST conform to the applicable local codes. 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.
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. bleaches or swim pool chemicals often contain such hydrocarbons.
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.
Installation pressure increase in the water heater and system piping. This rapid pressure increase can quickly reach the safety setting of the relief valve, causing it to operate during each heating cycle. Thermal expansion, and the resulting rapid, and repeated expansion and contraction of components in the water heater and piping system can cause premature failure of the relief valve, and possibly the heater itself.
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.
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.
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. F. If there is any difficulty in understanding or following the OPERATION or MAINTENANCE instructions, it is recommended that a qualified person or serviceman perform the work. B.
Operation To insure accuracy for rating, clock enough cubic feet of gas so that the clocked time is at least 60 seconds. 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. ! WARNING 7.
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.
Maintenance TO REMOVE BURNER TRAY: ! CAUTION 1. Turn off manual gas shut-off valve. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING! 2. Disconnect gas pipe union and wiring to gas valve, pilot, & blower(If so equipped.). 2. The Temperature and Pressure Relief Valve must be free to operate properly.
4. Remove as much built-up scale from flue tubes and tank bottom as practical. Do not attempt to clean so thoroughly that the tool used damages the glass lining. tion 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. 5.
“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.
“System Sentinel” Troubleshooting Guide Section 1... the “POWER” LED Is the “ON/OFF” Switch in the “ON” position? YES Is the “POWER” LED Illuminated? NO 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 Check circuit breaker or fuse and field connection of branch circuit wiring to leads of switch. Repair or replace as required.
“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.
“System Sentinel” Troubleshooting Guide Section 3... the “IGNITION” LED YES Is the “IGNITION” LED Illuminated? NO Did the Damper Assembly fully open? 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. Is Spark Ignitor operating? (Can sparking be heard?) YES NO YES NO Check Damper for obstructions—remove if necessary.
“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 The Ignition Control Module is in the Ignition sequence, and is providing 24 VAC power to the ECO (Energy Cut-Off Device) inside of the Thermostat Is the Pilot Flame burning? YES YES NO NO The System Sentinel Panel is defective and must be replaced. 1.
“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.
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. Specify Type of Gas. 6.
Wiring and Schematic Diagrams G Y- 3 Y-1 R-1 BL-1 COMM 24V IGN TH NORMAL OPERATION SEQUENCE INDICATED BY BOXED NUMERALS L1 DAMPER MOTOR LED INDICATORS BL-4 BR-3 POWER BR-4 THERMOSTAT IGNITION BR-3 120V 24 V PILOT VALVE L1 L2 BR-4 THERMOSTAT AND LIMIT POWER LED 2 ECO DAMPER DRIVE MAIN VALVE BLACK COMM WHITE 24V Y-3 ON TRANSFORMER OFF SWITCH 1 TH BL-5 THERMOSTAT LED GY-1 MAIN VALVE LED 4 MGV GY-2 GND 24 PV GND MV MV / PV BR-2 BR-3 BR-1 GY-3 GND MV 24 MV/PV R-1 BR
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 BL-4 3 BLOWER M R BR-3 L2 120 V LED INDICATORS POWER BR-4 THERMOSTAT IGNITION BR-3 120V 24 V PILOT VALVE L1 L2 BR-4 THERMOSTAT AND LIMIT ECO 2 MAIN VALVE BLACK DAMPER DRIVE ON TRANSFORMER 24V THERM. GY-1 GY-4 MAIN VALVE LED 5 2 6 MGV RELAY GND PV IGNITION CONTROL MV 24 MV/PV GY-2 PV Y-5 BL-6 PRESS.
Wiring and Schematic Diagrams GY-3 Y-1 R-1 BL-1 COMM. 24V IGN TH THERMOSTAT AND HIGH LIMIT L1 3 POWER THERMOSTAT IGNITION PILOT VALVE ECO MAIN VALVE BL-4 L2 BR-3 BR-4 BLACK SWITCH R-1 TRANSFORMER OFF 1 GY-1 GY-4 R TH THERMOSTAT LED IGNITION CONTROL 2 C NC PRESS.
Supplement Sheet Commercial Heavy Duty Gas Water Heater Supplements the following Use & Care Manual: AP10386-16 The instructions in the Use & Care Manual supplied with the water heater should be followed in addition to the following Instructions for the GX90 High Altitude models. 1. HIGH ALTITUDE INSTALLATION – The following water heater models are certified for installations at elevations between 2,000 and 8,000 feet with no change in construction (i.e.
