Giant UGC120S-100 Installation & Maintenance Manual Download Page 52

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GI-IM048En-1013

MAINTENANCE NOTES

Summary of Contents for UGC120S-100

Page 1: ...eserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature NOTE TO CONSUMER PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE This manual must only be used by a qualified heating installer service technician Read and understand all instructions in this manual before installing Perform steps in the order given Failure to co...

Page 2: ...NITY 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 provided by a qualified installer s...

Page 3: ...In some circumstances the property owner or his her agent assumes the role and at government installations the commanding officer or departmental official may be the AHJ NOTE GIANT Inc reserves the right to modify product technical specifications and components without prior notice FOR THE INSTALLER This water heater must be installed by qualified and licensed personnel The installer should be gui...

Page 4: ... 11 2 INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE 11 F PREVENT COMBUSTION AIR CONTAMINATION 11 G REMOVING A HEATER FROM A COMMON VENT SYSTEM 12 H WATER CHEMISTRY 13 PART 4 HEATER PIPING 15 A GENERAL PIPING INFORMATION 15 B SCALDING 16 C TEMPERATURE AND PRESSURE RELIEF VALVE 16 D BACKFLOW PREVENTER 16 E POTABLE EXPANSION TANK 16 F WATER PIPING 17 G AUXILIARY CONNECTIONS 17 H ...

Page 5: ...SATE OUTPUT 38 C LOW VOLTAGE OUTDOOR SENSOR INPUT 38 D INTERNAL WIRING DIAGRAM 39 PART 7 GAS CONNECTIONS 41 A GAS PIPING 41 B GAS TABLE 41 C GAS VALVE 42 PART 8 START UP PROCEDURE 43 A OPERATING INSTRUCTIONS 43 B OVERALL WATER HEATER AND CONTROL OPERATION 43 C STATUS MENU 43 D OUTDOOR RESET 44 E TEST MODE 45 F MAINTENANCE 45 PART 9 SHUTDOWN 46 A SHUTDOWN PROCEDURE 46 B VACATION PROCEDURE 46 C FAIL...

Page 6: ...E IF ANY PART HAS BEEN SUBMERGED IN WATER Immediately call a qualified service technician The appliance MUST BE replaced if it has been submerged Attempting to operate an appliance that has been submerged could create numerous harmful conditions such as a potential gas leakage causing a fire and or explosion or the release of mold bacteria or other harmful particulates into the air Operating a pre...

Page 7: ...eater is fired combustion gases heat the combustion chamber walls transferring heat directly into the surrounding water These hot gases are blown into secondary heat exchanger coils where more heat is transferred into the water removing even more heat from the gases Modulating Combustion System Modulation during water heating operation is based on tank temperature The control monitors the system t...

Page 8: ...P 212 It is also very important not to expose the condensate line to freezing temperatures or any type of blockage Plastic tubing must be the only material used for the condensate line Steel brass copper or other materials will be subject to corrosion or deterioration A second vent may be necessary to prevent condensate line vacuum lock on a long horizontal run Also an increase in pipe size may be...

Page 9: ...tdoor air for combustion Such heaters must be installed using room air for combustion Indoor air will have a much lower relative humidity and hence potential corrosion will be minimized This heater is certified for indoor installations only Do not install the heater outdoors Failure to install this heater indoors could result in substantial property damage severe personal injury or death 2 Check f...

Page 10: ... garage to ensure the burner and ignition devices are well off the floor When raising the heater fully support the entire bottom of the water heater Locate or protect the heater so it cannot be damaged by a moving vehicle E EXHAUST VENT AND INTAKE PIPE The heater is rated ANSI Z21 10 3 Category IV pressurized vent likely to form condensate in the vent and requires a special vent system designed fo...

Page 11: ...l fuel burning appliances installed in that space Rooms connected directly to this space through openings not furnished with doors are considered part of the space See Figure p 36 for details Confined space is space with volume less than 50 cubic feet per 1 000 Btu hour 4 8 cubic meters per kW of the total input rating of all fuel burning appliances installed in that space Rooms connected directly...

Page 12: ...r proper size and horizontal pitch to determine if there is blockage leakage corrosion or other deficiencies that could cause an unsafe condition 3 If practical close all building doors windows and doors between the space in which the water heater remains connected to the common venting system and other spaces in the building Turn on clothes dryers and any appliances not connected to the common ve...

Page 13: ...on about water hardness CLASSIFICATION MG L OR PPM GRAINS GAL Soft 0 17 1 0 1 Slightly Hard 17 1 60 1 3 5 Moderately Hard 60 120 3 5 7 0 Hard 120 180 7 0 10 5 Very Hard 180 and over 10 5 and over If the hardness of the water exceeds the maximum level of 7 grains per gallon water should be softened to a hardness level no lower than 5 grains per gallon Water softened as low as 0 to 1 grain per gallo...

Page 14: ...gure 3 All dimensions are approximate A suffix of LP denotes propane gas LP 179 B UNCRATING HEATER Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee ...

Page 15: ... 000 96 GPH 582 468 392 335 294 263 237 213 196 181 169 GPM 9 7 7 8 6 5 5 6 4 9 4 4 4 3 6 3 3 3 2 8 LPH 2203 1772 1484 1268 1113 996 897 806 742 685 640 LPM 36 7 29 5 24 7 21 1 18 6 16 6 15 13 4 12 4 11 4 10 7 Table 2 Recovery on rating plate is based at 94 thermal efficiency at 70o F 39o C rise as required by ANSI PERFORMANCE EQUATIONS Rated Input x 9 GPM Temp Rise o F x 500 GPH GPM x 60 PART 4 H...

Page 16: ...and heater or in the discharge line Do not plug or place any obstruction in the discharge line Test the operation of the relief valve after filling and pressurizing the system by lifting the lever Make sure the valve discharges freely If the valve fails to operate correctly immediately replace with a new properly rated relief valve Test T P valve at least once annually to ensure the waterway is cl...

Page 17: ...or equivalent with pipe sealant compound In the branch of the 1 2 5 cm or a 1 3 8 cm brass tee install a copper male adapter to match your copper plumbing system For convenience you may install a sweat shut off valve and a union in the cold inlet piping to ease future servicing If there is a back flow preventer or any type of a no return valve in the system you must install an additional tee here ...

Page 18: ... should have an integral flow check 5 Check with air handler manufacturer for proper sizing 6 This drawing is meant to demonstrate system piping only The installer is responsible for all equipment and detailing required by local codes NOTES FOR AIR HANDLER APPLICATION 1 ALL WATER PIPING MUST BE INSULATED 2 YOU MUST INSTALL A VACUUM RELIEF VALVE PER 248 CMR NOTE THIS DRAWING IS MEANT TO DEMONSTRATE...

Page 19: ...uld have an integral flow check 5 Check with air handler manufacturer for proper sizing 6 This drawing is meant to demonstrate system piping only The installer is responsible for all equipment and detailing required by local codes NOTES FOR AIR HANDLER APPLICATION 1 ALL WATER PIPING MUST BE INSULATED 2 YOU MUST INSTALL A VACUUM RELIEF VALVE PER 248 CMR NOTE THIS DRAWING IS MEANT TO DEMONSTRATE SYS...

Page 20: ...ized and installed within this piping system between the backflow preventer and the cold water inlet 3 Gas line must be rated to the unit maximum input capacity Unit must have 10 3 m of pipe after gas regulator 4 All circulators should have an integral flow check 5 Check with air handler manufacturer for proper sizing 6 This drawing is meant to demonstrate system piping only The installer is respo...

Page 21: ...n this piping system between the backflow preventer and the cold water inlet 3 Gas line must be rated to the unit maximum input capacity Unit must have 10 3 m of pipe after gas regulator 4 All circulators should have an integral flow check 5 Check with brazed plate manufacturer for correct plate connections and orientation 6 This drawing is meant to demonstrate system piping only The installer is ...

Page 22: ...g system between the backflow preventer and the cold water inlet 3 Gas line must be rated to the unit maximum input capacity Unit must have 10 3 m of pipe after gas regulator 4 All circulators should have an integral flow check 5 Drains and check valve between unit and storage tank will assist in purging air from system 6 This drawing is meant to demonstrate system piping only The installer is res...

Page 23: ...et 3 Gas line must be rated to the unit maximum input capacity Unit must have 10 3 m of pipe after gas regulator 4 All circulators should have an integral flow check 5 Drains and check valve between unit and storage tank will assist in purging air from system 6 This drawing is meant to demonstrate system piping only The installer is responsible for all equipment and detailing required by local cod...

Page 24: ...vere personal injury or death NOTE To avoid contamination often contained in indoor air it is best to pipe all intake combustion air directly to the outdoors NOTE If exhaust vent pipe system passes through an unheated space such as an alcove or attic the space must be heated or the pipe must be insulated The insulation must have an R value sufficient to prevent freezing of the condensate Improper ...

Page 25: ... air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air C REQUIREMENTS FOR INSTALLATION IN CANADA 1 Installations must be made with a vent pipe system certified to ULC S636 IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC S636 Additionally you may use AL29 4C stainless steel venting to comp...

Page 26: ...r heater is 10 25 cm center to center Minimum distance between exhaust vents and intake pipes on multiple water heaters is 10 25 cm center to center NOTE Due to potential moisture build up sidewall venting may not be the preferred venting option Carefully consider venting installation and location to save time and cost The building owner is responsible for keeping the exhaust and intake terminatio...

Page 27: ...to provide a minimum total vent length of 16 equivalent feet 5 m could result in property damage and improper product operation F LONGER VENT RUNS The maximum total equivalent length can be extended by increasing the diameter of both exhaust vent and intake pipe equally However the transitions should begin a minimum of 15 total equivalent feet 4 6 m from the water heater a The maximum total equiva...

Page 28: ...r damage to vehicles and machinery 8 Due to potential moisture build up sidewall venting may not be the preferred venting option To save time and cost carefully consider venting installation and location 9 Horizontal lengths of exhaust vent must slope back towards the water heater not less than 6 3 mm per foot to allow condensate to drain from the vent pipe 10 The exhaust vent must terminate where...

Page 29: ... termination methods must all comply with the methods and limits given in the Venting section Part 5 of this manual When installing a combustion air intake from outdoors care must be taken to utilize uncontaminated combustion air NOTE To prevent combustion air contamination see Table 1 Contaminant Table Take extra precaution to adequately support the weight of vent pipes terminating through the ro...

Page 30: ...30 GI IM048En 1013 Figure 11 Sidewall Venting NOTE This drawing is meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes LP LP ...

Page 31: ...31 GI IM048En 1013 Figure 12 Concentric Venting NOTE This drawing is meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes LP LP ...

Page 32: ...32 GI IM048En 1013 Figure 13 LP 179 F NOTE This drawing is meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes LP ...

Page 33: ...tched a minimum of 6 3 mm per foot back to the heater to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within one 1 foot 30 cm of the water heater and the balance at four 4 foot 1 2 m intervals on the vent pipe Heater venting must be readily accessible for visual inspection for the first three 3 feet 91 cm from the heater 2 VENTING THROUGH AN E...

Page 34: ... properly sealed to ensure that all combustion air is drawn properly and exhaust does not leak from the system Failure to properly seal the venting system will result in property damage severe personal injury or death NOTES A For every 1 2 5 cm of overhang the exhaust vent must be located 1 2 5 cm vertical below overhang overhang means top of building structure and not two adjacent walls corner of...

Page 35: ...cient combustion air based on the water heater input Never obstruct the supply of combustion air to the water heater If the water heater is installed in areas where indoor air is contaminated see Figure 17 it is imperative that the water heater be installed as direct vent so that all combustion air is taken directly from the outdoors into the water heater intake connection Unconfined space is spac...

Page 36: ...36 GI IM048En 1013 Figure 18 LP LP ...

Page 37: ...s used increase the condensate line to a minimum of 1 2 5 cm ID and place a tee in the line after the condensate neutralizer to properly reduce vacuum lock in the drain line 2 Plastic pipe should be the only material used for condensate line Steel brass copper and other metals will be subject to corrosion or deterioration 3 NEVER install condensate lines outside It is very important that the conde...

Page 38: ...cluded with the outdoor sensor to correctly mount the sensor on the exterior surface of the building It is preferable to mount the sensor on the north side in an area that will not be affected by direct sunlight but will be exposed to varying weather conditions Connect the outdoor sensor to terminals marked Outdoor Figure 20 Low Voltage Wiring Label all wires prior to disconnecting them when servi...

Page 39: ...39 GI IM048En 1013 D INTERNAL WIRING DIAGRAM Figure 21 Wiring Diagram LP ...

Page 40: ...40 GI IM048En 1013 Figure 22 LP 179 L LP ...

Page 41: ...maximum gas inlet pressure you must isolate the heater from the gas line to continue leak testing To do this you must turn off the factory and field installed gas cocks This will minimize the possibility of damaging the gas valve Failure to do so may damage the gas valve In the event the gas valve is exposed to a pressure greater than PSI 14 water column 35 6 cm the gas valve must be replaced Neve...

Page 42: ...NEW LP installations and also in empty tank situations This can also occur when a utility company shuts off service to an area to provide maintenance to their lines The gas valve must not be replaced with a conventional gas valve under any circumstances As an additional safety feature the gas valve in this water heater has a flanged connection to the swirl plate and blower C GAS VALVE Figure 24 Ga...

Page 43: ...te purging open all hot water faucets Ensure the water heater is full of water before firing the burner Failure to do so will damage the heater Such damage IS NOT covered by warranty and could result in property damage serious personal injury or death 2 Adjust the temperature set point of the heater to the desired level The factory default setting is 119o F 48 o C If changes are necessary follow O...

Page 44: ... you set the temperature press S3 until you exit the menu 3 Setting the outdoor reset curve change only the functions in the descriptions below a Press and hold S3 and S4 together for five 5 seconds b Use S1 and S2 to adjust flashing 000 to code 975 Press S3 until you enter the menu c Use S3 to scroll to Function 8 to adjust minimum outdoor temperature Use S1 and S2 to adjust temperature to desire...

Page 45: ...t is exceeded It is recommended to draw water out of the tank to lower temperature so tests can be performed After ten 10 minutes Test Mode stops automatically To exit Test Mode manually press S1 and S2 key together for one 1 second COMBUSTION SETTINGS HIGH FIRING RATES and LOW FIRING RATES ON ALL MODELS NATURAL GAS PROPANE LP Low High Low High Carbon Monoxide CO 0 10 ppm 0 20 ppm 0 10 ppm 0 20 pp...

Page 46: ... connection section If the burner does not light after the third ignition trial the control will enter a lockout state This lockout state indicates that a problem exists with the water heater the controls or the gas supply Under such circumstances a qualified service technician should be contacted immediately to properly service the water heater and correct the problem If a technician is not avail...

Page 47: ...fan speed less than 70 of expected 60 Sec 1 Check the combustion air fan wiring 2 Replace the combustion air fan 3 Replace the control board E14 Heater combustion air fan speed is more than 130 of expected 60 Sec 1 Check the combustion air fan wiring 2 Replace the combustion air fan 3 Replace the control board LEO Water Level in Tank is Low Until Corrected 1 Be sure all air is bled from system 2 I...

Page 48: ...a code other than F01 follow the troubleshooting guide for that code 7 If the flue temperature increases to over 190 o F 88 o C consult GIANT for further assistance F02 Interrupted or shorted upper temperature sensor 1 Check the electrical connection to the appropriate temperature sensor 2 If connection is okay replace bad sensor F03 Interrupted or shorted lower temperature sensor F05 Upper temper...

Page 49: ...49 GI IM048En 1013 Figure 26 LP 179 J LP ...

Page 50: ...50 GI IM048En 1013 Figure 27 LP 179 H LP ...

Page 51: ... Safeties Temperatures Verify safe settings on heater or Anti Scald Valve Temperatures Verify programmed temperature settings ELECTRICAL Connections Check wire connections Make sure they are tight Smoke and CO detector Verify devices are installed and working properly Change batteries if necessary Circuit Breakers Check to see that the circuit breaker is clearly labeled Exercise circuit breaker CH...

Page 52: ...52 GI IM048En 1013 MAINTENANCE NOTES ...

Page 53: ...nstallation Address Date of Installation Installer s Code Name Product Serial Number s Comments Installer s Phone Number Signed by Installer Signed by Customer IMPORTANT Customer Please only sign after the installer has reviewed the installation safety proper operation and maintenance of the system In the case that the system has any problems please call the installer If you are unable to make con...

Page 54: ...54 GI IM048En 1013 Giant Factories Inc Telephone 514 645 8893 Toll free 1 800 363 9354 General fax 514 640 0969 Customer Service fax 514 645 8413 www giantinc com ...

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