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HEAT EXCHANGER RE-ASSEMBLY 1. Heat exchanger water header O-rings should be replaced with new ones. 2. Install inlet-outlet and return water headers and install header retainer nuts and torque nuts evenly. 3. Replace "V" baffles. 4. Install thermostat sensing bulbs in header wells and replace bulb retaining clips. 5. Install inlet and return pipes in water headers using pipe thread sealant. 6. Install water pressure relief valve, sensor probe, and low water cutoff devices if so equipped. 7. Open
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5. TROUBLE SHOOTING GUIDE IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions. SOLUTION(S) PROBLEM(S) CAUSE(S) 1)Check circuit b
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CATALOG NO. 3000.50D
Effective: 01-01-03
Replaces: 03- 01-97
INSTALLATION
AND OPERATING
INSTRUCTIONS
Models 090A, 135A, 195A
Type WH
ECONOPAK WATER
HEATERS
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors and liquids or other combustible
materials in the vicinity of this or any other appliance. To do so may result in an explosion or
fire.
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause
property damage, personal injury o
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3 1. RECEIVING EQUIPMENT Contents 3 2. GENERAL SPECIFICATIONS AND DIMENSIONS 4 General Safety Precautions 6 3. INSTALLATION PROCEDURES 6 - Code Requirements 6 - Mounting Base 6 - Clearance Requirements 6 - Combustion/Ventilation Air 7 - Venting Connections 8 - Common Vents 9 - Gas Supply Connections 10 - Water Connections & System Piping 11 - Electrical Wiring 12 - Wiring Diagrams 13 4. SERVICING PROCECURES 13 - General Locations of Controls 13 - Sequence of Operation 14 - Start Up Proce
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1. RECEIVING EQUIPMENT On receipt of your equipment it is suggested that you SPECIFICATIONS AND DIMENSIONS visually check for external damage to the carton. If the PIPING carton is damaged, it is suggested that a note be made K CONNECTIONS on the Bill of Lading when signing for equipment. Remove INPUT RECOVERY TANK VENT WATER GAS the heater from the carton and if it is damaged report the MODEL MBH GPH GAL.* A B DIA. NPT. NPT. WH-0090 90 90 80 11" 5-3/4 d
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General Safety Precautions Be sure to read and understand the entire Instruction Manual before attempting to install or operate this water heater. Pay particular attention to the following general Safety Precautions. Failure to follow these warnings could result in a fire or explosion, causing property damage, bodily injury or death. Should you have any problems understanding the instructions in this manual, STOP, and get help from a qualified installer or service technician or the gas suppli
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General Safety Precautions To meet commercial hot water requirements, the The following chart details the relationship of water tankstat is adjustable up to 190°F. However, water temperature and time with regard to scald injury and may temperatures over 125°F. can cause severe burns in- be used as a guide in determining the safest water stantly or death from scalds. This is the preferred temperature for your applications. starting point for setting the control for supplying general purpose hot
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3. INSTALLATION PROCEDURES operation and service (circulator replacement, control replacement, etc.) CODE REQUIREMENTS Installation must be in accordance with local CLEARANCE REQUIREMENTS codes, or, in the absence of local codes, with the latest 1) Minimum Clearances From Combustible Materials editions of the National Fuel Gas Code, ANSI Z223.1,/ Model Floor Front Back Right Left Top Flue NFPA 54, and the National Electrical Code, ANSI/ No. Vent NFPA 70. In Can
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2) If the heater room is located against an outside wall The discharge opening must be a minimum of two and air openings can communicate directly with the feet vertically from the roof surface and at least two (2) feet outdoors, the two openings on the outside wall higher than any part of the building within ten (10) feet. must each have a net free area, in square inches as Vent stack shall be at least five (5) feet in vertical height follows: above the drafthood outlet. The vent cap location s
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Fig.# 8191.1 WARNING: These heaters must not be connected into any portion of mechanical draft systems operating under positive pressure. To do so may cause the flue products to be discharged into the living space causing serious health injury. For connections to gas vents or chimneys, vent installations shall be in accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1, or applicable provisions of the local building codes. COMMON VENTS Manifolds that connect m
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At the time of removal of an existing heater, the GAS SUPPLY CONNECTIONS following steps shall be followed with each appliance The inlet gas connection of the heater gas valve is remaining connected to the common venting system 1/2". Provide an adequate gas piping supply line no placed in operation, while the other appliances remain- smaller than 1/2", according to the chart below: ing connected to the common venting system are not in operation. Maximum Equivalent Pipe Length (Feet) 1/2" P
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The gas valve is provided with pressure taps to measure gas pressure upstream of the gas valve and downstream which is the same as the manifold pressure. WATER CONNECTIONS & SYSTEM PIPING The pipe size and fittings between the heater and the tank should be at least 1" for model 90, and 1-1/4" for models 135 and 195. This is based on the tank being located as close to the heater as possible, as shown in the drawing below: T & P Relief Valve Hot Water Supply Thermometer Cold Water Recirculation
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ELECTRICAL WIRING The electrical power supply requirement for these heaters is 115 volts, 60 Hz. Field wiring connections and electrical grounding must comply with the local codes, or in the absence of local codes, with the latest edition of the National Electrical Code, ANSI/NFPA 70. Provide a separate fused circuit from the main electrical panel to the heater, and a disconnecting means within sight of the heater. Remove the control box cover and make the power supply connections in the fiel
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WIRING DIAGRAM: STANDING PILOT MODELS 90, 135 and 195 WARNING: SHOCK HAZARD LINE VOLTAGE IS PRESENT. BEFORE SERVICING TANKSTAT OR HEATER, TURN OFF ELECTRICAL POWER TO THE HEATER AT THE MAIN DISCONNECT OR CIRCUIT BREAKER. FAILURE TO DO SO COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH. WIRING DIAGRAM: INTERMITTENT IGNITION DEVICE (IID) MODELS 90, 135 and 195 *Field Installed WARNING: SHOCK HAZARD LINE VOLTAGE IS PRESENT. BEFORE SER- VICING TANKSTAT OR HEATER, TURN OFF ELECTRICAL POWER TO
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4. SERVICING PROCEDURES Circulator GENERAL LOCATION OF CONTROLS CONTROL BOX COMPONENT LOCATIONS Manual Reset Limit Pressure Relief Valve Field Wiring Compartment Ignition Module Temperature Sensor (Auto Ignition Only) Ignition Module (Auto Ignition Only) Transformer Roll-Out Sensor SEQUENCE OF OPERATION Gas Valve Fig.# 8195.3 INTERMITTENT IGNITION DEVICE (IID) Heaters equipped with the IID system will automati- cally light the pilot burner first and then the main burner, each
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START-UP PROCEDURES 8. Push in control knob all the way and hold in, SECTION 1. Filling the System immediately light the pilot with a match. Continue Fill system with water. Purge all air from the system to hold control knob in for about one minute after the using purge valve sequence. After system is purged of pilot is lighted, release knob and it will pop back up. air, lower system pressure. Pilot should remain lighted. If it goes out, repeat Flush system before putting into operation to
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8. Push down and hold the red reset button in, imme- C. Use only your hand to push in, move or turn the gas diately light the pilot with a match. Continue to hold control knob or lever. Never use tools. If the knob or lever down red reset button for about one minute after the will not push in, move or turn by hand, don't try to repair pilot is lighted. Release red reset button and it will it, call a qualified service technician. Force or attempted pop back up. Pilot should Remain lighte
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FOR INTERMITTENT IGNITION (IID) WITH HONEY- TO TURN OFF GAS TO HEATER WELL OR ROBERTSHAW GAS VALVE 1. Set the tankstat at the lowest setting. 1. STOP! Read the safety information above. 2. Turn off all the electric power to the heater if service 2. Set the tankstat to the lowest setting. is to be performed. 3. Turn off all electric power to the appliance. 3. For Honeywell Valve: 4. This heater is equipped with an ignition device Turn gas control knob clockwise to "Off". which automatically light
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INSPECTION PROCEDURES BURNERS Clean main burners and air louvers of dust, lint and debris. Keep heater area clear and free from combus- tibles and flammable liquids. Do not obstruct the flow of combustion and ventilating air. Make visual check of burner and pilot flame. Yellow flame indicates clogging of air openings. Lifting or blowing flame indicates high gas pressure. Low flame indicates low gas pressure. Fig.# 8935.0 Pilot Adjustment 4" ROBERTSHAW 7200 GAS VALVE Max. (Models 135 &
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BURNER DRAWER REMOVAL PROCEDURE FOR CLEANING FLUE GAS PASSAGE-WAYS 1. Shut off power and gas supply to the heater. Dis- connect union(s) and pilot tubing when present; Soot will clog areas behind fins and cause eventual then loosen and remove burner hold down screws. tube failure. Any sign of soot at base of burners or around 2. Disconnect wires at gas valve and slide burner outer jacket indicates a need for cleaning. drawer out. 1. Lift off draft hood and flue collector by removing MAIN BUR
