Download American Water Heater 101 series Instruction manual

Instruction Manual
COMMERCIAL GAS WATER HEATERS
MODELS AHCG3/HCG3 60T 120
THROUGH AHCG3/HCG3 100T 250
SERIES 100 & 101
www.americanwaterheater.com
American Water Heater
Johnson City, TN 37605
INSTALLATION - OPERATION - SERVICE
- MAINTENANCE - LIMITED WARRANTY
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.
‡ 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.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
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This manual must remain with the
water heater.
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED 0912
198154-003
TABLE OF CONTENTS
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Gas Line Leak Testing 40
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Purging 40
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TEMPERATURE REGULATION 43
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Rough In Dimensions11
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Temperatures Menu47
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Insulation Blankets 13
Heater Information49
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Mixing Valves 15
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Thermal Expansion 15
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Temperature-Pressure Relief Valve 16
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LIGHTING THE WATER HEATER 56
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Lighting & Operation Labels 56
General Venting Information 22
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Operational Problems 60
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Momentary Ignition60
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Not Enough Or No Hot Water60
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Water Piping Diagrams 71
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2
SAFE INSTALLATION, USE AND SERVICE
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This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
CAUTION
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3
GENERAL SAFETY INFORMATION
PRECAUTIONS
HYDROGEN GAS FLAMMABLE
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Flammable hydrogen gases
may be present.
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Keep all ignition sources away
from faucet when turning on
hot water.
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GROUNDING INSTRUCTIONS
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Verify the power to the water heater is turned off before performing any service procedures.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Explosion Hazard
Overheated water can cause
water tank explosion.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
This manual must remain with the
water heater.
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
CAUTION
Improper installation, use and service may result
in property damage.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
4
Do not operate water heater if flood damaged.
Inspect anode rods regularly, replace if damaged.
Install in location with drainage.
Fill tank with water before operation.
Properly sized thermal expansion tanks are required on all
closed water systems.
Refer to this manual for installation and service.
GENERAL SAFETY INFORMATION
Fire or Explosion Hazard
Fire Hazard
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
For continued protection against
risk of fire:
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas
pressure.
Do not install water heater on
carpeted floor.
Do not operate water heater if
flood damaged.
Use only the gas shown on the water heater rating label.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended
periods of non-use.
Fire and Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Use joint compound or Teflon tape
compatible with propane gas.
Leak test before placing the
water heater in operation.
Disconnect gas piping and main
gas shutoff valve before leak
testing.
Install sediment trap in
accordance with NFPA 54.
Breathing Hazard - Carbon Monoxide Gas
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Fire and Explosion Hazard
Install water heater in accordance with
the instruction manual.
Do not use water heater with any gas
other than the gas shown on the rating
label.
Excessive gas pressure to gas valve can
cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
CAUTION
Property Damage Hazard
All water heaters eventually leak.
Do not install without adequate drainage.
Jumping out control circuits or components can
result in property damage, personal injury or death.
Electrical Shock Hazard
Turn off power to the water heater
before performing any service.
Label all wires prior to disconnecting
when performing service. Wiring errors
can cause improper and dangerous
operation.
Verify proper operation after servicing.
Service should only be performed by a qualified service
agent using proper test equipment.
Altering the water heater controls and/or wiring in any way
could result in permanent damage to the controls or water
heater and is not covered under the limited warranty.
Altering the water heater controls and/or wiring in any way
could result in altering the ignition sequence allowing gas to
flow to the main burner before the hot surface igniter is at
ignition temperature causing delayed ignition which can
cause a fire or explosion.
Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the appliance warranty.
Failure to follow these instructions can
result in personal injury or death.
5
INTRODUCTION
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QUALIFICATIONS
QUALIFIED INSTALLER OR SERVICE AGENCY
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6
FEATURES AND COMPONENTS
BLOWER/BURNER ASSEMBLY DETAIL
BASIC OPERATION
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120,000 & 150,000 Btu/hr MODELS
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10
INSTALLATION CONSIDERATIONS
ROUGH IN DIMENSIONS
SUPPLY GAS
CONNECTION
INTAKE AIR CONNECTION
3 INCH PVC
WATER OUTLET
HEIGHT
FRONT
I
BACK
T & P VALVE
E
F
B
H
D
CLEANOUT
VENT CONNECTION
3 INCH PVC
(exhaust elbow)
3/4” NPT DRAIN
1 1/2” NPT
WATER INLET
CONDENSATE
DRAIN CONNECTION
1/2 INCH PVC
C
A
G
These designs comply with the current edition of the American National Standard for Gas Water Heaters, Volume III, ANSI Z21.10.3 / CSA 4.3
as an automatic circulating tank water heater, and automatic storage water heaters.
35°
35°
120,000 & 150,000
Btu/hr
MODELS
TOP VIEWS
22°
V
3 I ENT
N
PV CH
C
V
3 I ENT
N
PV CH
C
64°
GA
S
68°
199,000 & 250,000
Btu/hr
MODELS
SUPPLY GAS
CONNECTION
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INTAKE AIR
3 INCH PVC
INTAKE AIR
3 INCH PVC
E
LV
E
LV
N
O
UT
VA
A
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CL
EA
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LE
P
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N
O
U
T
&
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VE
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&
VE
VAL
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FRONT
A
T
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WATER
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T
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WATER
OUTLET
18°
18°
45°
45°
45°
45°
* Center line of water outlet on top of the water heaters is approximately 7 inches from the front edge of the water heater.
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6+,3
6+,3
WEIGHT
WEIGHT
A
B
&
D
E
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H
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490/222
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555/252
595/270
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555/252
595/270
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555/252
595/270
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Figure 6
11
GAS LINE CONNECTION SIZE
STORAGE CAPACITIES
TABLE 1
TABLE 2
† MODEL
$+&*7
$+&*7
$+&*7
$+&*7
6(5,(6
100/101
100/101
100/101
100/101
1$785$/*$6
3/4 "NPT
3/4 "NPT
3/4 "NPT
3/4 "NPT
3523$1(*$6
3/4 "NPT
3/4 "NPT
3/4 "NPT
3/4 "NPT
MODEL
$+&*7
$+&*7
$+&*7
$+&*7
86*$//216
60
100
100
100
/,7(56
227
379
379
379
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GAS PRESSURE REQUIREMENTS
TABLE 3
MODEL
$+&*7
0$1,)2/'35(6685(
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3523$1(*$6
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RECOVERY CAPACITIES
TABLE 4
Type of
Gas
Natural
$+&*7
Propane
Natural
$+&*7
Propane
Natural
$+&*7
Propane
Natural
$+&*7
Propane
0RGHO
Input
Btu/hr
kW
35
44
58
73
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LPH
GPH
LPH
GPH
LPH
GPH
LPH
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461
1744
576
2179
767
2904
960
3632
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345
1308
432
1635
575
2178
720
2724
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276
230
197
173
154
138
126
115
1046
872
747
654
581
523
476
436
345
288
247
216
192
173
157
144
1308
1090
934
817
726
654
594
545
460
384
329
288
256
230
209
192
1743
1452
1245
1089
968
871
792
726
576
480
411
360
320
288
262
240
2179
1816
1557
1362
1211
1090
991
908
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106
402
133
503
177
670
221
838
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99
374
123
467
164
622
206
778
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LOCATING THE WATER HEATER
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CAUTION
Property Damage Hazard
Do not install without adequate drainage.
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Fire or Explosion Hazard
All water heaters eventually leak.
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Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas
pressure.
Use only the gas shown on the water heater rating label.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended
periods of non-use.
Read instruction manual before
installing, using or servicing
water heater.
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Do not obstruct water heater air intake
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Figure 7
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13
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
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death. Always read and understand instruction manual.
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14
MIXING VALVES
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Fire or Explosion Hazard
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pressure.
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above 10,000 feet (3,048 m) refer to high altitude
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MULTIPLE CONCENTRIC TERMINATION CLEARANCES
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32
MULTIPLE CONCENTRIC TERMINATION ARRANGEMENTS
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CONDENSATE DRAIN
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Figure 50
PVC PIPE NIPPLE
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THE FRONT OF THE
WATER HEATER FOR
SERVICE ACCESS
CONDENSATE TRAP DETAIL
Figure 51
38
SUPPLY GAS LINE INSTALLATION
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TABLE 8
Do not use water heater with any gas
other than the gas shown on the rating
label.
Excessive gas pressure to gas valve can
cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
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TEMPERATURE REGULATION
HIGH TEMPERATURE LIMIT CONTROL (ECO)
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120°F
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120°F
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TABLE 11
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TABLE 12
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Description
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TABLE 13
Menu
Description
Temperatures
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INITIAL START UP
REQUIRED TEST EQUIPMENT
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which air has entered.
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enter into confined areas or spaces where ignition can occur.
The area must be well ventilated and all sources of ignition
must be deactivated or removed.
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52
LIGHTING THE WATER HEATER
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Figure 57
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53
COMBUSTION
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SUPPLY GAS PRESSURE ADJUSTMENT
Breathing Hazard - Carbon Monoxide Gas
Fire and Explosion Hazard
Under no circumstances should
the input exceed the rate shown
on the water heater’s rating label.
Do not use water heater with any gas
other than the gas shown on the rating
label.
Excessive gas pressure to gas valve can
cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
Overfiring could result in damage to
the water heater and sooting.
Gas and carbon monoxide detectors
are available.
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MANIFOLD GAS PRESSURE ADJUSTMENT
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
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input exceed the rate shown on the
water heater’s rating label.
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explosion.
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available.
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CHECKING THE FIRING RATE
HIGH ALTITUDE INSTALLATIONS
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Fire and Explosion Hazard
Under no circumstances should the
input exceed the rate shown on the
water heater’s rating label.
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explosion.
Gas and carbon monoxide detectors are
available.
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3600
T
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x H = Btu/hr
Gas and carbon monoxide detectors
are available.
Example:
3600
12.6
Breathing Hazard - Carbon Monoxide Gas
x 1050 = 300,000 Btu/hr (87.9 kW)
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
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LIGHTING THE WATER HEATER
LIGHTING & OPERATION LABELS
7KHLQVWUXFWLRQODEHOEHORZLVDI¿[HGWRWKHZDWHUKHDWHU
VFRYHUHGE\WKLVPDQXDODWWKHIDFWRU\DQGPXVWEHIROORZHGZKHQOLJKWLQJ
DQGRSHUDWLQJWKHZDWHUKHDWHU
A/HCG3 60T 120 AND A/HCG3 100T 150 MODELS ONLY
FOR YOUR SAFETY READ BEFORE OPERATING
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.
telephone. Follow the gas supplier’s instructions.
%
B. BEFORE OPERATING smell all around the appliance area
for gas. Be sure to smell next to the floor because some
gas is heavier than air and will settle on the floor.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or
turn by hand, don’t try to repair it, call a qualified service
technician. Force or attempted repair may result in fire
or explosion.
“WHAT TO DO IF YOU SMELL GAS”
%
Do not try to light any appliance.
%
Do not touch any electrical switch; do not use any telephone
in your building.
%
Immediately call your gas supplier from a neighbor’s
If you cannot reach your gas supplier, call the fire
department.
D. Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect
the appliance and to replace any part of the control system
and any gas control which has been under water.
OPERATING INSTRUCTIONS
1.
7. Turn on all electrical power to the appliance.
STOP! Read the safety information above on this
label.
8. Set thermostat to desired setting.
2. Set thermostat to lowest setting.
9. If the appliance will not operate, follow the instructions
“To Turn Off Gas To Appliance” and call your service
technician or gas supplier.
3. Turn off all electrical power to the appliance.
F
L
O
W
4. This appliance is equipped with an ignition device which
automatically lights the burner. Do not try to light the
burner by hand.
REG
ADJUST
On/Off Switch
ON
6. Move “Off/On” switch to the “On” position.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electrical power to the appliance if service is to be performed.
3. MOve “Off/On” switch to the “Off” position. Do not force.
56
OFF
5. Move “Off/On” switch to the “Off” position.
Wait five (5) minutes to clear out any gas. If you then
smell gas,
STOP! Follow “B” in the safety information
above on
this label. If you don’t smell gas, go on to
the next step.
LIGHTING THE WATER HEATER
LIGHTING & OPERATION LABELS
7KHLQVWUXFWLRQODEHOEHORZLVDI¿[HGWRWKHZDWHUKHDWHU
VFRYHUHGE\WKLVPDQXDODWWKHIDFWRU\DQGPXVWEHIROORZHGZKHQOLJKWLQJ
DQGRSHUDWLQJWKHZDWHUKHDWHU
A/HCG3 100T 199 AND A/HCG3 100T 250 MODELS ONLY
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING
IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION
MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES
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.
telephone. Follow the gas supplier’s instructions.
?
B. BEFORE OPERATING smell all around the appliance area
for gas. Be sure to smell next to the floor because some
gas is heavier than air and will settle on the floor.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or
turn by hand, don’t try to repair it, call a qualified service
technician. Force or attempted repair may result in fire
or explosion.
“WHAT TO DO IF YOU SMELL GAS”
?
Do not try to light any appliance.
?
Do not touch any electrical switch; do not use any telephone
in your building.
?
Immediately call your gas supplier from a neighbor’s
If you cannot reach your gas supplier, call the fire
department.
D. Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect
the appliance and to replace any part of the control system
and any gas control which has been under water.
OPERATING INSTRUCTIONS
5. This appliance is equipped with an ignition device which
automatically lights the burner.
DO NOT TRY TO LIGHT THE BURNER BY HAND.
MODEL INFORMATION
Tank Temperature
Operating Set Point
103°F
120°F
UP
Status: Heating
6. Wait five (5) minutes to clear out any gas. If you then
smell gas,
STOP! Follow “B” in the safety information
above on
this label. If you don’t smell gas, go on to
the next step.
OFF
DN
GAS O
N
MENU
HELP
7. Turn on all electrical power to the appliance.
8. Set the ON/OFF switch on the control panel to
the “ON” position.
9. Set thermostat to desired setting.
CAUTION: Hotter water increases the risk of
scald injury. Consult the instruction
manual before changing temperature.
ON/OFF SWITCH
1.
STOP! Read the safety information above on this
label.
2. Set the ON/OFF switch on the control panel to
the “ON” position.
10. If the appliance will not operate, follow the instructions
“TO TURN OFF GAS TO APPLIANCE” and call your service
technician or gas supplier.
WARNING: TURN OFF ALL ELECTRICAL
POWER BEFORE SERVICING.
3. Set the thermostat to the lowest setting.
4. Set the ON/OFF switch on the control panel to the
“Off” position.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Set the ON/OFF switch on the control panel to the “OFF” position.
3. Turn off all electrical power to the appliance if service is to be performed.
57
TROUBLESHOOTING
INSTALLATION CHECKLIST
SEQUENCE OF OPERATION
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'UDLQ,QVWDOODWLRQRQSDJH
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SEQUENCE OF OPERATION FLOW CHART
If tank temperature drops below Operating Set Point minus
Differential setting a heating cycle is activated
Control System performs diagnostic checks
Normal State of all pressure switches and ECO are checked
Blower Prover pressure switch verified open
All other pressure switches and ECO are verified closed
NO
Control System Locks Out
Displays Fault Msg
Combustion Blower is energized
Pre-Purge cycle
Blower Prover switch contacts confirmed
closed by control system
NO
Control System Locks Out
“Blower Prover Open”
Fault Msg is displayed
Igniter is energized for warm up period
Does Control System sense minimum
Igniter amps?
NO
Control System Locks Out
“Low Igniter Current”
Fault Msg is displayed
24 Volt Gas Valve is energized
gas flows to Main Burner
2.0 minimum AC amps
Is flame sensed at the Main Burner ?
(control system monitors the flame sensor)
YES
NO
Water is heated to
set point
24 Volt Gas Valve
de-energized
24 Volt Gas Valve
de-energized
30 second
Inter-Purge cycle
30 second
Post-Purge cycle
Retries up to
two more times
Water heater goes
into standby mode
Control System
Locks Out
“Ignition Failure”
Fault Msg is
displayed
Figure 62
59
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OPERATIONAL PROBLEMS
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
MOMENTARY IGNITION
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CAUTION
Burn Hazard
The combustion chamber and burner sleeve
and housing become very hot during operation.
Do not reach into the burner housing or
combustion chamber if the water heater
is still hot.
Allow the water heater to cool and always use
gloves when handling the main burner.
INSTALLATION ERRORS
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NOT ENOUGH OR NO HOT WATER
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ROUGH STARTING, ROUGH OPERATION
Fire and Explosion Hazard
Do not use water heater with any gas
other than the gas shown on the rating
label.
Excessive gas pressure to gas valve can
cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
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60
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NOISY OPERATION
DIAGNOSTIC CHECKS
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Electrical Shock Hazard
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WATER LEAKAGE IS SUSPECTED
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REPLACEMENT PARTS
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Turn off power to the water heater
before performing any service.
Label all wires prior to disconnecting
when performing service. Wiring errors
can cause improper and dangerous
operation.
Verify proper operation after servicing.
Failure to follow these instructions can
result in personal injury or death.
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result in property damage, personal injury or death.
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Service should only be performed by a qualified service
agent using proper test equipment.
FAULT AND ALERT CONDITIONS
Altering the water heater controls and/or wiring in any way
could result in permanent damage to the controls or water
heater and is not covered under the limited warranty.
Altering the water heater controls and/or wiring in any way
could result in altering the ignition sequence allowing gas to
flow to the main burner before the hot surface igniter is at
ignition temperature causing delayed ignition which can
cause a fire or explosion.
FAULT CONDITIONS
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Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the appliance warranty.
FAULT AND ALERT MESSAGES
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POSSIBLE CAUSES - CHECK/REPAIR
DISPLAYED FAULT/ALERT MESSAGE
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AC Reversed
Fault occurred 2 mins ago
Power supply to water heater
has reversed polarity.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
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BACK
ADVANCED
Ignition Failure
Fault occurred 2 mins ago
The water heater has failed to
ignite the burner.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
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in the Heater Information menu - see Heater Information on page
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BACK
ADVANCED
Low Gas Pressure
Fault occurred 2 mins ago
The supply gas pressure to the
water heater is low.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
Low Igniter Current
Fault occurred 2 mins ago
Igniter current is low.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
Blocked Exhaust
Fault occurred 2 mins ago
The exhaust is blocked or
restricted. Ensure
condensate hose is draining.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
62
BACK
ADVANCED
FAULT AND ALERT MESSAGES (CONT)
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POSSIBLE CAUSES - CHECK/REPAIR
DISPLAYED FAULT/ALERT MESSAGE
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FRQWDFWVDUHFORVHGZKHQWKH\VKRXOGEHRSHQDWWKHEHJLQQLQJRI
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SDJHIRUVZLWFKORFDWLRQ
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‡ ([FHVVLYHQHJDWLYHDLUSUHVVXUHLQWKHLQVWDOOHGVSDFH
Blower Prover Failure
Fault occurred 2 mins ago
The blower prover switch is
closed out of sequence.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
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ADVANCED
Blower Prover Open
Fault occurred 2 mins ago
The blower prover switch remains
open after the blower has been
energized.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
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ADVANCED
Blocked Air Intake
Fault occurred 2 mins ago
The combustion air intake is
restricted.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
Energy Cut Out (ECO)
Fault occurred 2 mins ago
Tank temperature is excessive.
The water heater has been
disabled.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
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ADVANCED
Alert:
No Anode Voltage
Alert occurred 2 mins ago
No voltage detected from
Powered Anode(s).
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
MAINTENANCE
GENERAL
MAINTENANCE SCHEDULE
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PDWHULDOVJDVROLQHDQGRWKHUÀDPPDEOHYDSRUVDQGOLTXLGV6HH
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TABLE 14
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PRECAUTIONS
COMPONENT
Tank
Tank
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T&P Valve
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OPERATION
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Test Operation
INTERVAL
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Deposits
Test
Termination
6FUHHQV&OHDQ
Reseal/Repair
DRAINING AND FLUSHING
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DQG ÀXVKHG HYHU\ PRQWKV WR UHGXFH VHGLPHQW EXLOGXS 7KH
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CAUTION
Do not operate the water heater if it has
been exposed to or exhibits the following:
Flooding at or above the level of the burner or controls.
External damage.
Firing without water.
Sooting.
Do not operate the water heater until all corrective steps
have been made by a qualified service agent.
Burn harzard.
Hot water discharge.
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SDJH
Keep hands clear of drain
valve discharge.
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To drain the water heater storage tank:
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To Flush the tank perform the following steps:
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Overheated water can cause
water tank explosion.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
64
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FILLING THE WATER HEATER
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TABLE 15
TEMPERATURE-PRESSURE
RELIEF VALVE
UN-LIME® PROFESSIONAL DELIMER
Part Number
Description
9005416105
JDOORQFDVH
9005417105
1 - 5 gallon
POWERED ANODE RODS
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DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF
VALVE OPENING. THIS CAN CAUSE PROPERTY DAMAGE,
SERIOUS INJURY OR DEATH.
TEMPERATURE-PRESSURE RELIEF VALVE TEST
Explosion Hazard
Burn hazard.
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
Hot water discharge.
Properly sized temperaturepressure relief valve must be
installed in opening provided.
Keep clear of TemperaturePressure Relief Valve
discharge outlet.
Can result in overheating and
excessive tank pressure.
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Can cause serious injury or death.
VENT SYSTEM
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DIAGRAMS
CCB - CENTRAL CONTROL BOARD LAYOUT
CCB (CENTRAL CONTROL BOARD)
1
1
1
2
2
2
1
3
3
4
2
4
4
J3
5
J2
J4
J5
J1
J6
Spare
Retries
OPEN
Yes
Tstat
1
Use
Type
12
9
6
3
14
11
8
5
2
13
10
7
4
1
3
2 3 4
1 Retry
Ext
Input
15
No
Vent
Spare
S1 DIPSWITCH
J7
4
3
2
1
J9
J13
J10
1
3
2
4
J11
1
5
2
6
J15
3
7
1
4
8
2
J16
S1 DIPSWITCH DETAIL
Yes
Type
Tstat
Spare
OPEN
Use
2 3 4
Ext
Input
3
Retries
1
1 Retry
No
Vent
Spare
Dipswitch Operation:
Along one side of the dipswitch array there are numbers, 1-4. On the other side of the dipswitch
is the word “OPEN.” The dipswitches are rocker type switches, if one side of the rocker is down the
other side will be up. Pressing a rocker down on the side of the array labeled “OPEN,” opens the switch.
Pressing a rocker down on the side of the array labeled with the numbers 1-4 closes the dipswitch.
CHANGING NUMBER OF IGNITION TRIALS BEFORE LOCK OUT
NOTE: Always turn off power to the water heater before changing dipswitch settings.
Set dipswitch #4 to the open position for 1 trial for ignition before Ignition Failure lock out. Set dipswitch
#4 to the closed position for 3 trials for ignition before Ignition Failure lock out.
Figure 65
67
A/HCG3 120 & 150 WIRING DIAGRAM
24 VAC
GAS VALVE
LOW GAS
PRESSURE SWITCH
BLOCKED
AIR INTAKE
BLOWER
PROVER
BLOCKED
EXHAUST
1
J5 J4
UIM
J16
J6
13
2
15
4
14
5
10
6
7
8
11
ENABLE/DISABLE CIRCUIT
JUMPER WIRE BETWEEN PINS
8 AND 11 ON J6 PLUG
HOT SURFACE IGNITER
1 BLACK
2 WHITE
FLAME SENSOR
RED
1 RED (ECO)
3 BLACK
UPPER TEMPERATURE PROBE
4 RED (ECO)
1 BLACK
ANODE 1
2 BLACK
LOWER TEMPERATURE PROBE
1 GREEN
2 BLUE
ANODE 2
120 VAC 1 Ø POWER
1 BLACK
1
2
2 WHITE
COMBUSTION
BLOWER
1 2 RED
J3
2 GREEN
3 WHITE
GREEN
GREEN
GREEN
GREEN
1 BLACK120 VAC HOT
BLACK
RED
J1
WHITE
3 WHITE 120 VAC NEUTRAL
ON/OFF
SWITCH
4 YEL 24 VAC
4 YEL 24 VAC
GROUND STRIP
TRANSFORMER
50VA
BURNER GROUND
(BURNER BOLT)
INSIDE CCB
ENCLOSURE
Figure 66
68
JUNCTION
BOX
USER INTERFACE MODULE
J13
J2
J7
J15 J10
CCB (CENTRAL CONTROL BOARD)
2 BLACK
WHITE
BLACK
GROUND
N
L
120 VAC NEUTRAL
120 VAC HOT
A/HCG3 199 & 250 WIRING DIAGRAM
BLOCKED
AIR INTAKE
24 VAC
GAS VALVE
LOW GAS
PRESSURE SWITCH
BLOWER
PROVER
BLOCKED
EXHAUST
1
J5 J4
UIM
J16
J6
13
2
15
4
14
5
10
6
7
8
11
ENABLE/DISABLE CIRCUIT
JUMPER WIRE BETWEEN PINS
8 AND 11 ON J6 PLUG
HOT SURFACE IGNITER
1 BLACK
2 WHITE
FLAME SENSOR
RED
1 RED (ECO)
3 BLACK
UPPER TEMPERATURE PROBE
4 RED (ECO)
1 BLACK
ANODE 1
2 BLACK
LOWER TEMPERATURE PROBE
1 GREEN
2 BLUE
PWM (pulse width modulation)
SPEED INSTRUCTION SIGNAL
WIRES FROM CCB TO BLOWER
MOTOR VFD (variable frequency drive).
ANODE 2
NOTE: COMBUSTION BLOWER
ASSEMBLY CONSISTS OF
MOTOR, BLOWER AND INTEGRAL
VFD (variable frequency drive).
3 WHITE/GREEN
7 WHITE/BLUE
8 WHITE/BROWN
1 4 5
120 VAC 1 Ø POWER
1 BLACK
1
2
2 WHITE
COMBUSTION
BLOWER
1 2 RED
J3
2 GREEN
3 WHITE
GREEN
GREEN
GREEN
GREEN
1 BLACK120 VAC HOT
BLACK
RED
J1
WHITE
3 WHITE 120 VAC NEUTRAL
ON/OFF
SWITCH
4 YEL 24 VAC
4 YEL 24 VAC
GROUND STRIP
TRANSFORMER
50VA
BURNER GROUND
(BURNER BOLT)
INSIDE CCB
ENCLOSURE
Figure 67
69
JUNCTION
BOX
USER INTERFACE MODULE
J13
J2
J7
J15 J10
CCB (CENTRAL CONTROL BOARD)
2 BLACK
WHITE
BLACK
GROUND
N
L
120 VAC NEUTRAL
120 VAC HOT
CIRCULATION PUMP WIRING DIAGRAMS
CIRCULATING PUMP WIRING DIAGRAM
STORAGE TANK OR BUILDING RECIRCULATION
FIELD SUPPLIED TEMPERATURE CONTROL
INSTALLED IN THE STORAGE TANK
OR CIRCULATING LOOP RETURN LINE
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH WATER HEATER AS
THIS MAY CAUSE ELECTRICAL LINE
NOISE AND LEAD TO ERRATIC CONTROL
SYSTEM OPERATION.
L1 HOT
120 VAC
POWER
CIRC
PUMP
MOTOR
L2 NEUTRAL
Figure 68
CIRCULATING PUMP WIRING DIAGRAM
DISHWASHER LOOP WITH TOGGLE SWITCH
DISHWASHER
TOGGLE
SWITCH
FIELD SUPPLIED TEMPERATURE
CONTROL INSTALLED IN THE
CIRCULATING LOOP RETURN LINE
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH WATER HEATER AS
THIS MAY CAUSE ELECTRICAL LINE
NOISE AND LEAD TO ERRATIC CONTROL
SYSTEM OPERATION.
L1 HOT
120 VAC
POWER
CIRC
PUMP
MOTOR
L2 NEUTRAL
Figure 69
70
71
FINISHED FLOOR
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
ONE WATER HEATER, SINGLE TEMPERATURE
WITH BUILDING RECIRCULATION
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WATER PIPING DIAGRAMS
PIPE T&P TO
OPEN DRAIN
HOT WATER OUTLET
EXPANSION
TANK
COLD
WATER
SUPPLY
LINE TEMPERATURE
CONTROL
HOT WATER
RETURN
WATER FLOW SWITCH
TANK OR LINE TEMPERATURE
CONTROL
DRAIN
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
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72
EXPANSION
TANK
COLD WATER
SUPPLY
TEMPERED WATER
RETURN
LINE TEMPERATURE
CONTROL
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HOT WATER
RETURN
ONE WATER HEATER, TWO TEMPERATURE
WITH HIGH TEMPERAURE LOOP RECIRCULATION
WITH BUILDING RECIRCULATION
6HH7HPSHUDWXUH3UHVVXUH5HOLHI9DOYHRQSDJH
6HH'LVKZDVKLQJ0DFKLQHVRQSDJH
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WATER PIPING DIAGRAMS
TEMPERED
WATER
TO FIXTURES
LINE TEMPERATURE
CONTROL
12” TO 15”
MINIMUM
HOT
COLD
MIXING VALVE
HOT WATER
OUTLET
WATER FLOW SWITCH
DRAIN
PIPE T&P TO
OPEN DRAIN
TEMPERATURE GAGE
CHECK VALVE
MIXING VALVE
FULL PORT BALL VALVE
TANK OR LINE TEMPERATURE
CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
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73
HOT WATER
OUTLET
ALT. COLD WATER
CONNECTION
TANK TEMPERATURE
CONTROL
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
LINE TEMPERATURE
CONTROL
WATER FLOW SWITCH
TANK OR LINE TEMPERATURE
CONTROL
DRAIN
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
CIRCULATING PUMP
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NOTE:
The water heater’s Operating Set Point should be set 5° higher than the Tank Temperature Control in the auxiliary storage tank.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
ONE WATER HEATER, SINGLE TEMPERATURE
WITH VERTICAL STORAGE TANK FORCED RECIRCULATION
WITH BUILDING RECIRCULATION
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WATER PIPING DIAGRAMS
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74
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ALTERNATE TANK
TEMPERATURE
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TANK TEMPERATURE
CONTROL
HOT WATER
OUTLET
EXPANSION
TANK
WATER FLOW SWITCH
DRAIN
COLD WATER
SUPPLY
HOT WATER
RETURN
LINE TEMPERATURE
CONTROL
TEMPERATURE GAGE
CHECK VALVE
MIXING VALVE
FULL PORT BALL VALVE
TANK OR LINE TEMPERATURE
CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
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LEGEND
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NOTE:
The water heater’s Operating Set Point should be set 5° higher than the Tank Temperature Control in the auxiliary storage tank.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
ONE WATER HEATER, SINGLE TEMPERATURE
WITH HORIZONTAL STORAGE TANK FORCED RECIRCULATION
WITH BUILDING RECIRCULATION
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WATER PIPING DIAGRAMS
75
FINISHED
FLOOR
HOT WATER
OUTLET
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
PIPE T&P TO
OPEN DRAIN
TWO WATER HEATERS, SINGLE TEMPERATURE
WITH BUILDING RECIRCULATION
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WATER PIPING DIAGRAMS
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EXPANSION
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HOT WATER
RETURN
LINE TEMPERATURE
CONTROL
WATER FLOW SWITCH
TANK OR LINE TEMPERATURE
CONTROL
DRAIN
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
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76
FINISHED
FLOOR
HOT WATER
OUTLET
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
THREE WATER HEATERS, SINGLE TEMPERATURE
WITH BUILDING RECIRCULATION
6HH7HPSHUDWXUH3UHVVXUH5HOLHI9DOYHRQSDJH
6HH'LVKZDVKLQJ0DFKLQHVRQSDJH
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PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
LINE TEMPERATURE
CONTROL
WATER FLOW SWITCH
TANK OR LINE TEMPERATURE
CONTROL
DRAIN
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
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LEGEND
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77
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
HOT WATER
OUTLET
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
FOUR WATER HEATERS, SINGLE TEMPERATURE
WITH BUILDING RECIRCULATION
6HH7HPSHUDWXUH3UHVVXUH5HOLHI9DOYHRQSDJH
6HH'LVKZDVKLQJ0DFKLQHVRQSDJH
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OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
LINE TEMPERATURE
CONTROL
WATER FLOW SWITCH
TANK OR LINE TEMPERATURE
CONTROL
DRAIN
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
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