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17

INSTALLATION REQUIREMENTS

GAS SUPPLY SYSTEMS

Low pressure building gas supply systems are defined as those 

systems  that  cannot  under  any  circumstances  exceed  14” 

W.C. (1/2 PSI Gauge). These systems do not require pressure 

regulation.  Measurements  should  be  taken  to  insure  that  gas 

pressures are stable and fall within the requirements stated on 

the  water  heater  rating  plate.  Readings  should  be  taken  with 

all gas burning equipment off (static pressure) and with all gas 

burning equipment running at maximum rate (dynamic pressure). 

The  gas  supply  pressure  must  be  stable  within  1.5”  W.C. 

from  static  to  dynamic  pressure  to  provide  good  performance. 

Pressure drops that exceed 1.5” W.C. may cause rough starting, 

noisy  combustion  or  nuisance  outages.  Increases  or  spikes  in 

static pressure during off cycles may cause failure to ignite or in 

severe cases damage to water heater gas control valves. If your 

low  pressure  system  does  NOT  meet  these  requirements,  the 

installer is responsible for the corrections.
High pressure building supply systems use pressures that exceed 

14” W.C. (1/2 PSI Gauge). These systems must use field supplied 

regulators  to  lower  the  gas  pressure  to  less  than  14”  W.C.  (1/2 

PSI Gauge). Water heaters require gas regulators that are properly 

sized for the water heater input and deliver the rating plate specified 

pressures.  Gas  supply  systems  where  pressure  exceeds  5  PSI 

often  require  multiple  regulators  to  achieve  desired  pressures. 

Systems in excess of 5 PSI building pressure should be designed 

by gas delivery professionals for best performance. Water heaters 

connected to gas supply systems that exceed 14” W.C. (1/2 PSI 

Gauge) at any time must be equipped with a gas supply regulator. 
All  models  require  a  minimum  gas  supply  pressure  of  3.5” 

W.C.(0.87  kPa)  for  natural  gas  and  8.0”  W.C.  (1.99  kPa)  for 

propane.  The  minimum  supply  pressure  is  measured  while  gas 

is not flowing (static pressure) AND while gas is flowing (dynamic 

pressure). The supply pressure (static and dynamic) should never 

fall below 3.5” W.C.(0.87 kPa) for natural gas or 8.0” W.C. (1.99 

kPa) for propane. The supply pressure should be measured with 

all gas fired water heaters connected to the common main firing 

at full capacity. If the supply pressure drops more than 1.5” W.C. 

(0.37 kPa) as gas begins to flow to the water heater then the supply 

gas  system  including  the  gas  line  and/or  the  gas  regulator  may 

be  restricted  or  undersized.  See  Supply  Gas  Regulator  on  page 

17 and Supply Gas Line Installation on page 31. The gas control 

valve on all models has a maximum gas supply pressure limit of 

14”  W.C.(3.48  kPa) The  maximum  supply  pressure  is  measured 

while gas is not flowing (static pressure) AND while gas is flowing 

(dynamic pressure).

SUPPLY GAS REGULATOR

The maximum allowable gas supply pressure for this water heater 

is 14 inches W.C. (3.5 kPa). Install a positive lock-up gas pressure 

regulator in the gas supply line if inlet gas pressure can exceed 14 

inches W.C. (3.5 kPa) at any time. Regulators must be sized/used 

according to manufacturer’s specifications.
If a positive lock-up regulator is required follow these instructions:

1. 

Positive  lock-up  gas  pressure  regulators  must  be  rated  at  or 

above the input Btu/hr rating of the water heater they supply.

2. 

Supply gas regulators shall have inlet and outlet connections not 

less than the minimum supply gas line size for the water heater 

they supply

3. 

Positive  lock-up  gas  pressure  regulator(s)  should  be  installed 

no closer than 3 feet (1 meter) and no farther than 8 feet (2.4 

meters) from the water heater’s inlet gas connection.

4. 

After installing the positive lock-up gas pressure regulator(s) an 

initial nominal supply pressure setting of 7.0” W.C.(1.74 kPa) for 

Natural Gas and 11.0” W.C. (2.74 kPa) for Propane (LP) while 

the water heater is operating is recommended and will generally 

provide good water heater operation. Some additional adjustment 

may be required later to maintain a steady gas supply pressure. 

5. 

When installing multiple water heaters in the same gas supply 

system  it  is  recommended  that  individual  positive  lock-up  gas 

pressure regulators be installed at each unit.

All gas piping must comply with local codes and ordinances or with 

the current editions National Fuel Gas Code (ANSI Z223.1/ NFPA-

54) or the Natural Gas and Propane Installation Code (CAN/CSA 

B149.1)  whichever  applies.  Copper  or  brass  tubing  and  fittings 

(except tin lined copper tubing) shall not be used.
If the gas control valve is subjected to pressures exceeding 1/2 psi 

(3.5 kPa), the damage to the gas control valve could result in a fire 

or explosion from leaking gas.

If the main gas line Shut-off serving all gas water heaters is used, 

also turn off the gas at each water heater. Leave all gas appliances 

shut off until the water heater installation is complete.
A gas line of sufficient size must be run to the water heater. Consult 

the current edition of National Fuel Gas Code (ANSI Z223.1/NFPA 

54) or the Natural Gas and Propane Installation Code (CAN/CSA 

B149.1) and your gas supplier concerning pipe size.

There must be:
• 

A readily accessible manual shut off valve in the gas supply 

line serving the water heater, and

• 

A sediment trap ahead of the gas control valve to help prevent 

dirt and foreign materials from entering the gas control valve.

• 

A ground joint union of proper size between the manual shut 

off 

valve and gas control valve to permit servicing of the unit.

Be sure to check all the gas piping for leaks before lighting the 

water  heater.  Use  a  soapy  water  solution,  not  a  match  or  open 

flame. Rinse off soapy solution and wipe dry.

POWER SUPPLY

The water heaters covered in this manual require a 120 VAC, 

1Ø (single phase), 60Hz, 7 amp power supply and must also be 

electrically grounded in accordance with local codes or, in the 

absence of local codes, with the National Electrical Code, ANSI/

NFPA 70 or the Canadian Electrical Code, CSA C22.1.
If any of the original wire as supplied with the water heater must 

be replaced, it must be replaced with 105°C rated wiring or its 

equivalent,  except  in  the  burner  housing.  In  this  case  200°C 

rated wire must be used.

DEDICATED POWER WIRING AND BREAKERS

Dedicated power supply wires, ground wiring and dedicated 

circuit  breakers  often  prevent  electrical  line  noise  and 

should be considered when installing the water heater.

POWER FLUCTUATIONS AND ELECTRICAL NOISE

The  water  heater’s  control  system  requires  a  source  of  stable 

clean electricity for proper operation. Connecting the water heater 

to a branch circuit that is subject to fluctuations in voltage level or 

Содержание BSS

Страница 1: ...tly 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 WH...

Страница 2: ...take Moisture Protection 25 Horizontal Vent Terminal Installation 25 Vertical Vent Terminal Installation 26 Termination Clearances Sidewall Direct Vent 27 Direct Vent Installation Diagrams 28 Concentr...

Страница 3: ...ot follow the safety message and how to avoid the risk of injury DANGER WARNING CAUTION CAUTION DANGER indicates an imminently hazardous situation which if not avoided will result in injury or death T...

Страница 4: ...Explosion Hazard Overheated water can cause water tank explosion Properly sized Temperature Pressure Relief Valve must be installed in the opening provided Verify the power to the water heater is tur...

Страница 5: ...5 GENERAL SAFETY INFORMATION...

Страница 6: ...nderstand instruction manual Breathing Hazard Carbon Monoxide Gas Property Damage Hazard All water heaters eventually leak Do not install without adequate drainage CAUTION Fire and Explosion Hazard Le...

Страница 7: ...tally vented gas fueled heating appliance or equipment The sign should read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS INSPECTION The s...

Страница 8: ...These diagrams will serve to provide the installer with a reference It is essential that all venting water piping gas piping and wiring be installed as shown Particular attention should be given to th...

Страница 9: ...8 1 2 22 15 3 4 40 1 2 41 6 3 8 5 1 2 6 5 8 cm 123 19 55 88 40 102 87 104 14 16 19 13 97 16 82 50 130 Inches 62 3 8 22 15 3 4 54 1 2 55 6 3 8 5 1 2 6 5 8 cm 165 7 55 88 40 138 43 139 7 16 19 13 97 16...

Страница 10: ...pressure must be maintained under both load and no load dynamic and static conditions Table 3 RECOVERY CAPACITIES Input Recovery Capacities Rating Btu hr Rating kW Temp Rise F 30 40 50 60 70 80 90 100...

Страница 11: ...at the bottom of heater behind the Access Doors 1 30 11 15 2 3 23 34 33 CAUTION HARNESS HAS 120 VAC IN OPERATION See Venting Installation and Condensate Piping for more information Figure 2 34 GALLON...

Страница 12: ...ation 50 GALLON UNIT FEATURES AND COMPONENTS CONT Figure 3 50 GALLON UNIT This is a view of the area at the bottom of heater behind the Access Doors 1 2 3 15 32 27 33 29 32 24 26 20 19 12 11 25 13 28...

Страница 13: ...ndensate Drain Outlet 13 Enable Disable Switch 14 Hot Water Outlet 15 Gas Supply 16 Main Manual Gas Shutoff Valve 17 Union 18 Inlet Water Shutoff Valve 19 Cold Water Inlet 20 T P Relief Valve 21 Ratin...

Страница 14: ...pressure switch that requires an increase in negative pressure to change the electrical contacts from normally closed to open The switch is connected to the pressure tap on the PVC pipe connected to...

Страница 15: ...ater heater close to a 120 VAC power supply See Power Supply on Page 18 for requirements 8 Locate the water heater where an adequate supply of fresh air for combustion and ventilation can be obtained...

Страница 16: ...ter heater Do not cover the outer door thermostat or temperature pressure relief valve Do not cover the instruction manual Keep it on the side of the water heater or nearby for future reference Doobta...

Страница 17: ...d at or above the input Btu hr rating of the water heater they supply 2 Supply gas regulators shall have inlet and outlet connections not less than the minimum supply gas line size for the water heate...

Страница 18: ...4 Water Temperature F C Time for 1st Degree Burn Less Severe Burns Time for Permanent Burns 2nd 3rd Degree Most Severe Burns 110 43 3 normal shower temp 116 46 7 pain threshold 116 46 7 35 minutes 45...

Страница 19: ...ed in the cold water supply line an expansion tank must be installed between the check valve and the water heater s cold water inlet Set storage tank temperature five degrees lower than the water heat...

Страница 20: ...ature Pressure Relief Valve on the water heater each remote storage tank that may be installed and piped to a water heating appliance must also have its own properly sized rated and approved Temperatu...

Страница 21: ...the building In cold climates it is recommended that the discharge pipe be terminated at an adequate drain inside the building Shall not have any valve or other obstruction between the temperature pr...

Страница 22: ...bustion air intake and the exhaust vent terminal Refer to Horizontal Vent Terminal Installation on Page 25 and Vertical Vent Terminal Installation on Page 26 GENERAL VENTING INSTRUCTIONS The following...

Страница 23: ...e personal injury death or substantial property damage Installations must comply with applicable national state and local codes For Canadian installation Polypropylene vent must be listed as a ULC S63...

Страница 24: ...000 ft 610 m to 7 700 ft 2 347 m IMPORTANT Do not use vent elbows in this vent pipe installation See Figure 12 90 Short Sweep Elbow 90 Long Sweep Elbow 45 Sweep Elbow Correct Fittings Incorrect Fittin...

Страница 25: ...hat it vents through the roof please refer to Vertical Vent Terminal Installation on Page 26 1 A f t e r t h e p o i n t s o f t e r m i n a t i o n h a v e b e e n determined see Vent Pipe Terminatio...

Страница 26: ...nings above anticipated snow levels FLAT ROOF INSTALLATION On flat roof installations the air intake and the exhaust vent terminations must be a minimum of 24 inches 60 cm above any parapet vertical w...

Страница 27: ...ir supply inlet into building or combustion air inlet to any other appliance 6 in 15 cm for appliances 10 000 Btuh 3 kW 12 in 30 cm for appliances 10 000 Btuh 3 kW and 100 000 Btuh 30 kW 36 in 91 cm f...

Страница 28: ...uations See the section on Direct Vent Air Intake Moisture Protection on page 25 Figure 24 SIDEWALL VENT INSTALLATION ALL MODELS See Note 3 See Note 3 Drain Pan Piped To Adequate Drain See Note 1 See...

Страница 29: ...t of a qualified installer or qualified service technician see Page 8 All precautions in the literature on tags and labels attached to the unit must be observed Follow all safety codes Wear safety gla...

Страница 30: ...ARIS UNITS 175 000 199 000 BTU HR MODELS When using two water heaters with inputs of 175 000 BTH HR or above install vent terminations using either Method A or Method B below Figure 33 When using thre...

Страница 31: ...pany will have to install a properly sized gas meter Make sure the gas supplied is the same type listed on the water heaters rating label The gas piping must be installed according to all local and st...

Страница 32: ...y of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases at 11 inches water column pressure Based on a Pressure Drop of 0 5 Inch Water Column Additional tables are available in th...

Страница 33: ...ay coil to this circuit This will damage the CCB circuit board and is not covered under the limited warranty CONNECTING AN EXTERNAL SUPERVISORY CONTROL The enable disable circuit is accessed from the...

Страница 34: ...or state law requiring a certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot wat...

Страница 35: ...120 F Status Heating MENU HELP GAS OFF O N Figure 38 HIGH TEMPERATURE LIMIT CONTROL ECO This water heater is equipped with an ECO energy cut out non adjustable high temperature limit switch The ECO i...

Страница 36: ...ion of the various operational states The Desktop screen also displays animated Status Icons to convey operational information see Table 12 on Page 37 for descriptions of the Status Icons OVERVIEW The...

Страница 37: ...control system or when the Enable Disable switch located at the base of the water heater is in disable position The Combustion Blower is being energized The Spark Igniter is being energized See Spark...

Страница 38: ...ot reset the control system if the condition that caused the Fault has not been corrected Heating Disabled The heating is disabled by the Enable Disable switch located at the base of the water heater...

Страница 39: ...will be displayed Tank Temperature 71 F Operating Setpoint 120 F Status Standby HELP MANUFACTURER MODEL INFORMATION MENU The Main Menu is where all control system menus are listed see Table 14 on page...

Страница 40: ...fferential Adjustment on page 39 Temperatures HELP BACK Operating Setpoint 120 F Differential 8 F Tank Temperature 120 F Tank Probe Offset 0 F HEATER STATUS MENU DESCRIPTION ACTION DISPLAY Press Heate...

Страница 41: ...ersion Software version for user interface module Use External Enable Enables Disables the external enable circuit External Enable Status Displays whether or not the external enable circuit has been a...

Страница 42: ...last nine 9 Fault andAlert messages with a time stamp The newest event will replace the oldest Press the Fault to view details for each Fault or Alert message stored Fault History HELP BACK 1 Upper T...

Страница 43: ...to Yes and press ACCEPT to save the new setting NOTE The Access Code at the bottom of the Service Contact Information screen is for manufacturing engineering purposes only There are no user settings...

Страница 44: ...Sequence of Operation See the Sequence of Operation Flow Chart on page 49 Ensure the water heater is properly grounded Flame sensing requires an adequate earth ground If the water heater is not proper...

Страница 45: ...42 On the water heaters covered by this manual there are test ports for supply and manifold gas pressure readings on the gas control valve Using a small flat tip pocket screw driver open the needle v...

Страница 46: ...t a t s o m r e h t e h t t e S o t s e t u n i m 5 e v i f t i a W s a g y n a t u o r a e l c s a g l l e m s n e h t u o y f I n i B w o l l o F P O T S u o y f I l e b a l s i h t n o e v o b a n...

Страница 47: ...The display CCB and other electrical components will still be energized and the display will read Water Heating Disabled 3 Close Main Gas Shutoff Valve see Figure 37 on page 31 GAS INPUT RATE The gas...

Страница 48: ...represents some of the most critical installation requirements that when overlooked often result in operational problems down time and needless parts replacement This is not a complete list Before pe...

Страница 49: ...setting a heating cycle is activated Igniter is energized 24 V Gas Control Valve is energized gas flows to Main Burner 24 V Gas Control Valve de energized 24 V Gas Control Valve de energized Is flame...

Страница 50: ...e to have the complete water heater Model Number Serial Number and Series Number available This information can be found on the rating plate affixed to the water heater For more information or technic...

Страница 51: ...l continue to lock out DIAGNOSTIC CHECKS Turn off power to the water heater before performing any service Electrical Shock Hazard Label all wires prior to disconnecting when performing service Wiring...

Страница 52: ...continuity when the blower is off and closed shorted when the blower is on Replace the switch if necessary ADVANCED BACK 0 days 0 hrs 0 mins ago Error Code A7 1201 Blocked Air Intake Restriction in ai...

Страница 53: ...the valve being slightly opened Not shown in Figure 46 F The drain valve may be leaking at the tank fitting Not shown in Figure 46 G Leakage from recirculation plug or pipe connection Not shown in Fig...

Страница 54: ...n the hose clamp at the adaptor rubber boot and slide the plastic pipe out and away from the adaptor rubber boot See Figure 14 in Integrated Filter Installation Remove the adaptor rubber boot containi...

Страница 55: ...ter heater drain valve and terminate it to an adequate drain 7 Open the water heater drain valve and allow all the water to drain from the storage tank 8 Close the water heater drain valve when all wa...

Страница 56: ...CONTROL BOARD LAYOUT 11 12 1 J16 J5 J3 J13 J4 J17 J10 J9 J14 J15 J1 J6 J12 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 8 8...

Страница 57: ...iolet CCB J3 5V Data Data D gnd SDA data SCL data Write protect 5V Dgnd CCB J12 2 Red 3 Green 4 White Brown 5 White Blue 6 White Orange Key Gas Valve L1 Neutral Protective Earth MAIN INPUT 3 CIRCUIT B...

Страница 58: ...POWER WITH APPLIANCE AS THIS MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION Figure 50 CIRCULATING PUMP WIRING DIAGRAM DISHWASHER LOOP WITH TOGGLE SWITCH FIELD SUPPLIED TE...

Страница 59: ...s Mixing Valve Metal Drain Pan 6 15 2cm Air Gap Max Adequate Drain set to 120 F 48 8 C or lower Mixing Valve Figure 52 TYPICAL ONE TEMPERATURE SYSTEM PIPING INSTALLATION All Models Figure 53 SAMPLE MI...

Страница 60: ...ixing Valve Manual Shut Off Valve Typ Mixing Valve 180 F Max Figure 54 AIR HANDLER PIPING INSTALLATION All Models Figure 55 POLARIS WITH AUXILLARY STORAGE TANK One or Two Temperature System With or Wi...

Страница 61: ...61 NOTES...

Страница 62: ...62 NOTES...

Страница 63: ...For Tech Support please call PGC models 1 800 456 9805 SPC models 1 800 365 0024 BSS BTS models 1 800 527 1953 Copyright 2016 A O Smith Corporation All rights reserved...

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