Service manual

ManualsBrandsAmerican Standard ManualsBurnerD100-270

150158 Rev. 2 August - 2010

OPERATING, INSTALLATION AND SERVICE MANUAL

COMMERCIAL GAS WATER HEATER

WITH FLUE DAMPER AND ELECTRIC

IGNITION SYSTEM WITHOUT FAN MOTOR

REQUIRES 120V A.C. POWER SUPPLY

WARNING: If the information in these instructions is not followed exactly, a fire

or explosion may result causing property damage, personal injury or death.

THIS APPLIANCE SHALL NOT BE INSTALLED IN ANY LOCATION WHERE

FLAMMABLE LIQUIDS OR VAPORS ARE LIKELY TO BE PRESENT.

FLAMMABLE VAPORS MAY BE DRAWN TO THIS WATER HEATER FROM OTHER

AREAS OF THE STRUCTURE BY AIR CURRENTS.

CAUTION THIS WATER HEATER SHOULD NOT BE USED TO HEAT A SPA OR HOT TUB

THIS WATER HEATER SHALL NOT BE INSTALLED IN BATHROOMS, BEDROOMS,

OR ANY OCCUPIED ROOM NORMALLY KEPT CLOSED.

WARNING

This water heater is equipped for one type gas only. Check the data plate near the control access panel for the correct gas. DO NOT

USE THIS WATER HEATER WITH ANY GAS OTHER THAN THE ONE LISTED ON THE DATA PLATE. Failure to use the correct gas

can cause problems which can result in DEATH, SERIOUS BODILY INJURY OR PROPERTY DAMAGE. If you have any questions or

doubts consult your gas supplier or gas company. Water heaters for bottled, propane or liquefied petroleum gas (LPG) are different from

natural gas models. A natural gas heater will not function safely on bottled, propane or liquefied petroleum gas (LPG) and no attempt

should be made to convert a heater from natural gas to any other gas. An odorant is added to the gas used by this water heater.

IF YOU HAVE QUESTIONS THAT ARE NOT ANSWERED IN THE MANUAL YOU MAY CALL THE TOLL

FREE NUMBER 800 900-9063 OR CONTACT US BY EMAIL AT: engineering@waterheaters.com.

DO NOT CONTACT US BY TELEPHONE OR EMAIL FOR WARRANTY REGISTRATION. YOUR WATER

HEATER SERIAL NUMBER IS ALREADY ON FILE. THE WARRANTY IS ACTIVATED AT THE TIME OF

PURCHASE. KEEP YOUR RECEIPT TO SHOW TO SERVICE PERSON IF SERVICE IS REQUIRED.

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 neighborʼs phone. Follow the

gas supplierʼs 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.

Summary of content (27 pages)

PAGE 1
OPERATING, INSTALLATION AND SERVICE MANUAL COMMERCIAL GAS WATER HEATER WITH FLUE DAMPER AND ELECTRIC IGNITION SYSTEM WITHOUT FAN MOTOR REQUIRES 120V A.C. POWER SUPPLY 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 G Do not try to light any appliance.
PAGE 2
DANGER Vapors from flammable liquids will explode and catch fire causing death or severe burns. Do not use or store flammable products such as gasoline solvents or adhesives in the same room or area near the water heater. Keep flammable products: 1. far away from heater, 2. in approved containers, 3. tightly closed and 4. out of children’s reach. Water heater has a main burner and pilot flame. The pilot flame: 1. is on all the time and 2. will ignite flammable vapors Vapors: 1. cannot be seen, 2.
PAGE 3
INSTALLATION SAFETY WARNING L.P. UNITS, ANODES, MULTIPLE HEATER INSTALLATION..........7 HYDROGEN GAS, TEMPERATURE AND PRESSURE RELIEF VALVE...........................................................8 ELECTRICAL, FILLING HEATER WITH WATER, INSTALLATION CHECK LIST BEFORE PUTTING BURNER IN OPERATION.....................................................................................................................9 WIRING DIAGRAM..................................................................................
PAGE 4
CONSUMER RESPONSIBILITIES WARNING CLOSED WATER SYSTEMS THIS MANUAL HAS BEEN PREPARED TO ACQUAINT YOU WITH THE INSTALLATION, OPERATION AND MAINTENANCE OF YOUR GAS WATER HEATER AND TO PROVIDE IMPORTANT SAFETY INFORMATION. If the water supply system contains a check valve, back flow preventer or water pressure reducing valve you will have closed water system and the pressure will build up during the water heating cycle.
PAGE 5
IMPORTANT This water heater has been designed and manufactured for the express purpose of heating and storing potable water and space heating. See page 12 for space heating instructions. Any use other than this purpose will release the manufacturer from any liability or warranty claims stemming from the issue of this product. Consult local authorities. BEFORE PROCEEDING WITH THE INSTALLATION OF THIS WATER HEATER, READ AND THOROUGHLY UNDERSTAND THESE INSTALLATION AND OPERATION INSTRUCTIONS.
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REMEMBER: Flammable vapors may be drawn to this water heater from other areas of the structure by air currents.
PAGE 7
CAUTION PAN INSTALLATION AND CONSTRUCTION MUST CONFORM TO LOCAL CODES AND ORDINANCES. The draft diverter relief opening of the water heater and the combustion air inlet must be in the same atmospheric pressure zone. Large exhaust fans in kitchens or other locations can lower the air pressure inside an enclosure and interfere with proper operation and venting of the water heater.
PAGE 8
top cold water inlet as it may contain a nonmetallic dip tube. When making these connections, use a good grade of pipe joint compound. Be familiar with the location of the shut-off valve in the cold water line feeding the water heater (See Figure 5). If a valve is not present, one shall be installed as shown in Figure 5. CAUTION Do not turn on electrical power to water heater until flue damper is installed and the water heater is filled with water.
PAGE 9
TYPICAL INSTALLATION FIGURE 5 6 150158 Rev.
PAGE 10
MULTIPLE HEATER INSTALLATION After completing all gas connections, check each gas connection and fitting for leaks. Use a soap and water solution or a commercial leak detector fluid. NEVER USE MATCHES OR OPEN FLAME WHEN CHECKING FOR GAS LEAKS. INSTALLATION DIAGRAMS INSTALLATIONS WHERE HEATERS ARE MANIFOLDED The water heater and its individual gas shut off valve must be disconnected from the gas supply piping system during any pressure testing or that system at test pressures in excess of 1/2 psig (14” W.
PAGE 11
that no contact is made with any live electrical part. Do not connect discharge line directly to drain. (Figure 5) To prevent bodily injury, hazard to life or damage to property, the relief valve must be allowed to discharge water in the event of excessive temperature or pressure developing in the water heater. The function of the temperature and pressure relief valve is to discharge water in large quantities should circumstances demand.
PAGE 12
ELECTRICAL JUNCTION BOX 120 VAC LESS THAN 5 AMPS When installed, this appliance must be electrically grounded in accordance with local codes or in the abscence of local codes, with the National Electrical Code, ANSI/NFPA NO. 70-Latest Edition and Canadian Electrical Code CSA #22.2. Electrical ON-OFF control must be located near heater in accordance with local code. CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.
PAGE 13
FIGURE 10 WIRING DIAGRAM 10 150158 Rev.
PAGE 14
FIGURE 11 11 150158 Rev.
PAGE 15
OTHER THAN THE ONE LISTED ON THE RATING PLATE (Figure 5). Failure to use the correct gas can cause problems which result in DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. If you have any DAMPER OPERATION SEQUENCE questions or doubts consult your gas supplier or gas company. NATURAL GAS MODELS LEGEND DM Damper Motor F Fuse TH Thermostat ES Endswitch CM Control Module R Relay Coil R1 N/C Relay Contact R2 N/O Relay Contact SS1 N/C Safety Switch Contact SS2 N/O Safety Switch Contact IF YOU SMELL GAS: 1.
PAGE 16
COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM When using this heater as a source of heat for a combination space heating/potable water heating system, be sure to follow manual(s) shipped with air handler system. Refer to figure 15 page 19. Note the following warnings: Toxic chemicals, such as those used for boiler treatment, shall NEVER be introduced into this system.
PAGE 17
THIS OPERATING INSTRUCTIONS ARE ONLY FOR D80-512 AS MODEL FOR YOUR SAFETY READ BEFORE LIGHTING 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 is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. B. BEFORE OPERATING smell all around the appliance area for gas.
PAGE 18
BEFORE PLACING THIS WATER HEATER IN OPERATION SEE “CONDENSATION” ON PAGE 12 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 is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. • If you cannot reach your gas supplier, call the fire department. C.
PAGE 19
HI-TEMPERATURE LIMIT EMERGENCY SHUTDOWN INSTRUCTIONS The thermostat on this water heater is equipped with a high temperature limit switch (ECO). The ECO will shut off the gas supply to the burner and pilot in the event the water temperature exceeds 190 degrees F. Main burner operation can be reset by pressing the reset button on the ECO after the water temperature has returned to normal (see Fig. 12).
PAGE 20
WATER HEATER SOUNDS DRAINING 1. Possible noises due to expansion and contraction of some metal parts during periods of heat-up and cool-down do not represent harmful or dangerous conditions. 2. Sediment buildup in the tank bottom will create varying amounts of noise, and left in the tank, will cause premature tank failure. 3. Condensation causes sizzling and popping within the burner areas during heating and cooling periods and should be considered normal. See Condensation.
PAGE 21
COMMON COMPLAINTS (continued) Flame burns at orifice Pilot will not remain lit High operating costs Insufficient hot water Slow water recovery Drip from relief valve Thermostat fails to close Condensation Combustion Odors Smoking and carbon formation Pilot flame too small Pilot flame too large Low gas pressure Defective thermostat Low gas pressure Defective thermostat No gas Dirt in gas lines Pilot line clogged Improper calibration Thermostat set too high Sediment or lime in tank Heater too small for
PAGE 22
REPLACEMENT PARTS LIST (SEE PAGE 18) PARTS REPLACEMENT MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR GAS SUPPLIER The following parts may be ordered through your plumber, a local plumbing supply company, or direct from the factory. Parts will be shipped at prevailing prices and will be billed accordingly. Refer to warranty for company address.
PAGE 23
REPLACEMENT PARTS ILLUSTRATION STANDARD MODEL SHOWN FIGURE 14 20 150158 Rev.
PAGE 24
COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM FIGURE 15 21 150158 Rev.
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NOTES 22 150158 Rev.
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NOTES 23 150158 Rev.
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NOTES 24 150158 Rev.