A.O. Smith HYB-90N manual

Installation and Operating Manual PRINTED IN U.S.A. 0610 316888-000 Rev . 00 KEEP THIS MANUAL IN THE POCKET ON HEA TER FOR FUTURE REFERENCE WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED. POWER VENT GAS MODELS ALL TECHNICAL AND W ARRANTY QUESTIONS: SHOULD BE DIRECTED T O THE LOCAL DEALER FROM WHOM THE W A TER HEA TER W AS PURCHASED. HYBRID [...]

2 www .hotwater .com T ABLE OF CONTENTS SAFE INST ALLA TION, USE AND SERVICE 3 GENERAL SAFETY 4 INTRODUCTION 6 Get T o Know Y our Water Heater - Gas Models . . . . . 8 Replacement Parts And Deliming Products . . . . . . . 8 INST ALLA TION CONSIDERA TIONS 9 Rough In Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 9 W ater Piping - Mixing [...]

www .hotwater .com 3 Y our safety and the safety of others is extremely important in the installation, use and servicing of this water heater . Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instru[...]

4 www .hotwater .com GENERAL SAFETY[...]

www .hotwater .com 5 GENERAL SAFETY Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual. • Install vent system In accordance with codes. • Do not operate water heater if flood damaged. • Special Consideration must be taken with installations above 1 1,000' (3,352m) for standard models.[...]

6 www .hotwater .com Thank Y ou for purchasing this water heater . Properly installed and maintained, it should give you years of trouble free service. Abbreviations Found In This Instruction Manual: • CSA - Canadian Standards Association • ANSI - American National Standards Institute • NFP A - National Fire Protection Association • ASME - [...]

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8 www .hotwater .com FIGURE 1 GET TO KNOW YOUR W A TER HEA TER - GAS MODELS REPLACEMENT PARTS AND DELIMING PRODUCTS Replacement parts and recommended delimer may be ordered through authorized servicers or distributors. When ordering parts, provide complete model and serial numbers (see rating plate), quantity and name of part desired. Standard hard[...]

www .hotwater .com 9 Capacity , Gas and Electrical Characteristics Model Approx. Capacity Input Ga s Ty p e Gas Supply Pressure Manifold Pressure Electrical Characteristics U.S. Gals. Litres BTU/hr Max. in. WC (kPa) Min. in. WC (kPa) in. WC (kPa) V olts/Hz Amperes HYB-90N 25 94.6 100,000 Nat. 14.0 (3.49) 5.0 (1.25) 4.2 (1.05) 120/60 2. 5 Minimum ga[...]

10 www .hotwater .com For all side wall terminated, horizontally vented power vent, gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above fi[...]

www .hotwater .com 1 1 FIGURE 3 W A TER PIPING - MIXING V AL VE USAGE This appliance has been design certi fi ed as complying with ANSI Z21.10.3/CSA 4.3 (latest revision) for water heaters and is considered suitable for: W ater (Potable) Heating: All models are considered suitable for water (potable) heating. Please note the following: The system [...]

12 www .hotwater .com groups or if there is a local code 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 satis fi es your hot water needs, a means such as a Mixing V alve, should be used at the hot water taps used by t[...]

www .hotwater .com 13 HANDLE INST ALLA TION For ease of handling and carrying, plugs are provided in the side of the shroud that can be removed and pipe handles inserted (see Figure 4). • Remove plastic plugs from shroud side panels. • Screw a short length of 3/4” NPT pipe into the sides of the water heater . • Use the handles to move the w[...]

14 www .hotwater .com When installing the heater , consideration must be given to proper location. Location selected should be as close to the wall as practicable and as centralized with the water piping system as possible. FIGURE 5 Minimum clearances between the water heater and combustible construction are 0 in. at the sides and rear , 0 in. (0cm[...]

www .hotwater .com 15 Screws Screws To p Casing (Front) FIGURE 7 Screws FIGURE 8 FIGURE 9 After the heater has been positioned and the earthquake straps have been installed, re-assemble the shroud in the reverse order .[...]

16 www .hotwater .com COMBUSTION AIR AND VENTILA TION A gas water heater cannot operate properly without the correct amount of air for combustion. Do not install in a con fi ned area such as a closet, unless you provide air as shown in the “Facts to Consider About Location” section. Never obstruct the fl ow of ventilation air . If you have an[...]

www .hotwater .com 17 FIGURE 1 1 B. ALL AIR FROM OUTDOORS: (See Figures 12, 13 and 14) The con fi ned space should be provided with two permanent openings, one commencing within 12 in. (30cm) of the top and one commencing within 12 in. (30cm) from the bottom of the enclosure. The openings should communicate directly , or by ducts, with the outdoor[...]

18 www .hotwater .com 6 . Louvers and Grilles: In calculating free area, consideration should be given to the blocking effect of louvers, grilles or screens protecting openings. Screens used should not be smaller than 1/4 in. (0.64cm) mesh. If the free area through a design of louver or grille is known, it should be used in calculating the size ope[...]

www .hotwater .com 19 limited warranty . Thermal expansion can also cause intermittent temperature-pressure relief valve operation: water discharged from the valve due to excessive pressure build up. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This condition is not covered under the limited wa[...]

20 www .hotwater .com The temperature-pressure relief valve must be installed directly into the fi tting of the water heater designed for the relief valve. Must terminate a maximum of 6 in. (15cm) above a fl oor drain or external to the building. In cold climates, it is recommended that the discharge pipe be terminated at an adequate drain inside[...]

www .hotwater .com 21 GAS PIPING Make sure gas supplied is same type listed on model rating plate. The inlet gas pressure must not exceed 14 in. WC (3.5 kPa) for natural and propane gas (L.P .). The minimum inlet gas pressure shown on rating plate is that which will permit fi ring at rated input. All gas piping must comply with local codes and ord[...]

22 www .hotwater .com a sediment trap) must be incorporated in the piping. The drip leg must be readily accessible. Install in accordance with the “Gas Piping” section. Refer to the current edition of the National Fuel Gas Code (ANSI Z223.1/NFP A 54). GAS LINE PURGING Air may be present in the gas lines and could prevent the burner from lightin[...]

www .hotwater .com 23 VENT PIPE TERMINA TION STREET ELBOW NORMAL ELBOW PREFERRED PRACTICE: 90° LONG SWEEP ELBOW (LESS RESTRICTIVE) BACK T O BACK ELBOWS 90° SHORT SWEEP ELBOW (MORE RESTRICTIVE) 6 in. (15 cm) min. NOT RECOMMENDED: FIGURE 19 VENT LENGTH LESS THAN OR EQUAL TO 20 EQUIV ALENT FEET (6.1m) USE THIS SCREEN. VENT LENGTH GREA TER THAN 20 EQ[...]

24 www .hotwater .com V ent piping must slope up from heater to termination a minimum of 1/8 in. (0.3cm) rise per 4 ft. (1.2m) of vent piping TERMINA TION ELBOW RODENT SCREEN (INST ALL INT O ELBOW) GROUND LEVEL OR MAXIMUM SNOW LINE* STRAP 6 in. (15cm) MIN. 90° ELBOW Example for calculating equivalent feet. Section “A” . . . . 0.5 ft. . . (0.15[...]

www .hotwater .com 25 CONDENSA TE This water heater is a condensing unit and requires a drain to be located in close proximity to allow the condensate to drain safely . The condensate drains from the unit at the exhaust tee located at the bottom of the unit (see Figure 22). Condensate from this water heater is mildly acidic. Please note that some l[...]

26 www .hotwater .com SEQUENCE OF INST ALLA TIONS Cut a length of PVC pipe about 3.5 in. (9cm) longer than the wall thickness at the opening. Glue the vent terminal to this section of pipe. Slide the wall plate over the pipe to stop against the vent terminal. Place a bead of caulking (not supplied) around the gap between the pipe and cover plate. A[...]

www .hotwater .com 27 VENT PIPING TO BE SLOPED (DOWN) TOW ARD HEA TER TO PREVENT WA TER FROM COLLECTING. 6 in. (15 cm) MIN. LENGTH A TT ACH 45° TERMINA TION ELBOW RODENT SCREEN (INST ALL INTO ELBOW) SEALANT 12 in. (30 cm) min. * WHERE SNOW COVER IS NORMAL DURING WINTER, ENSURE SUFFICIENT VENT CLEARANCE TO PREVENT BLOCKAGE OR ICE BUILDUP . SEALANT [...]

28 www .hotwater .com FIGURE 28 A VENT USED IN A SPECIAL VENTING SYSTEM WITH POSITIVE VENT PRESSURE AND P ASSING THROUGH A ROOF SHALL EXTEND A T LEAST 450mm (18 in.) ABOVE THE HIGHEST POINT WHERE IT P ASSES THROUGH THE ROOF SURF ACE AND ANY OTHER OBSTRUCTION WITHIN A HORIZONT AL DIST ANCE OF 450mm (18 in.). A VERTICAL VENTING SYSTEM MUST BE SUPPORT[...]

www .hotwater .com 29 PRIMER It is recommended that T etrahydrofuran (THF) be used to prepare the surfaces of pipe and fi ttings for solvent welding. Do not use water , rags, gasoline or any other substitutes for cleaning PVC or CPVC surfaces. A chemical cleaner such as MEK may be used. CEMENT The cement should be a bodied cement of approximately [...]

30 www .hotwater .com D. Inspection, cleaning, priming Visually inspect the inside of the pipe and fi tting sockets and remove all dirt, grease or moisture with a clean dry rag. If wiping fails to clean the surfaces, a chemical cleaner must be used. Check for possible damage such as splits or cracks and replace if necessary . Depth-of-entry Markin[...]

www .hotwater .com 31 W ARNING VENT HOOD(S) MA Y BE EXTREMEL Y HOT DURING OPERA TION. FIGURE 31 CAUTION TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULA TING TO THE AIR INT AKE IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DIST ANCE BETWEEN THESE TWO TERMINALS IS RECOMMENDED.[...]

32 www .hotwater .com ELECTRICAL CONNECTIONS The water heater must be connected to a properly grounded electrical branch circuit. A dedicated circuit is preferred. Do not use a GFI outlet. Refer to the rating plate attached to the water heater to determine the electrical requirements for the heater . Ensure the circuit provided is correct for these[...]

www .hotwater .com 33 OPERA TING INSTRUCTIONS Changing the Standby Status When the Standby Button is pressed, the Status changes to normal operation and all the LEDs on the display will light up for a period of 1 second to verify operation. The button can toggle the status between Normal operation and Standby . Key Lock NOTE: This is a tamper resis[...]

34 www .hotwater .com Numeric Display Numeric information such as temperature set-point, maintenance codes and error codes are displayed using a large yellow LED display . Up and Down Buttons T wo buttons (with “Up” and “Down” arrows) are used for adjusting the data on the display . Other secondary functions such as turning the Key Lock “[...]

www .hotwater .com 35 WIRING DIAGRAM Obey local codes and electric utility requirements when you install or service the water heater . This appliance must be electrically grounded in accordance with local codes or , in the absence of local codes, with the National Code ANSI/NFPA No 70 (current edition) and/or the CSA C22.1 electrical Code (current [...]

36 www .hotwater .com LIGHTING INSTRUCTIONS 1 . S et the ther most at to the lowest set ting. 2. Set th e ON/O FF switch o n the c ontrol pane l to the “O FF” position. 3. T urn of f all electric al power to the appliance if ser vice is to be per forme d. T O TURN OFF GAS T O APPLIANCE 1. STOP! Read the sa fety info rmati on above on this label[...]

www .hotwater .com 37 HEA T CYCLE DEFINITIONS ST A TE DESCRIPTION Pre-purge If the heat engine initial call-for-heat is successful (all checks are passed), the combustion fan is energized. The fan is started at a high speed for several seconds and the system veri fi es the fan speed. Input signals (from other parts of the water heater) are veri ?[...]

38 www .hotwater .com TEMPERA TURE REGULA TION FIGURE 35 It is recommended that lower water temperatures be used to avoid the risk of scalding. It is further recommended, in all cases, that the water temperatures be set for the lowest temperature which satis fi es your hot water needs. This will also provide the most energy ef fi cient operation [...]

www .hotwater .com 39 W ater T emperature T ime for 1st Degree Burn (Less Severe Burns) T ime for Permanent Burns 2nd & 3rd Degree (Most Severe Burns) 1 10°F (44°C) (normal shower temp.) 1 16°F (47°C) (pain threshold) 1 16°F (47°C) 35 minutes 45 minutes 122°F (50°C) 1 minute 5 minutes 131°F (55°C) 5 seconds 25 seconds 140°F (60°C) 2[...]

40 www .hotwater .com W ater Circulation Pump A circulation pump is integrated into the heat engine for the Hybrid application. The pump serves to push water through the heat engine at a rate that supports optimum recovery time and maximum heat output. The control provides 120V ac, 60Hz line power to the pump to enable operation. W ater Flow Measur[...]

www .hotwater .com 41 Line V oltage Monitor The control monitors the line voltage provided to the system. If the line voltage is too low , the system components may not operate properly . For diagnostic purposes, the display panel should indicate that the cause was power-related. • If line power is below 102V ac, the water heater will enter the f[...]

42 www .hotwater .com CONST ANT OUTPUT TEMPERA TURE CONTROL While the temperature regulation in the previous section describes the features of temperature monitoring and regulation, your water heater goes beyond the on/off control implied there and implements a gas, air and water fl ow modulation scheme to provide a constant water delivery tempera[...]

www .hotwater .com 43 HOUSEKEEPING V acuum around base of water heater for dust, dirt, and lint on a regular basis. VENTING SYSTEM INSPECTION At least once a year a visual inspection should be made of the venting system. Y ou should look for: Obstructions which could cause improper venting. The combustion and ventilation air fl ow must not be obst[...]

44 www .hotwater .com ANODE ROD REPLACEMENT T o replace the anode: T urn off gas supply to the water heater . Shut off the water supply and open a nearby hot-water faucet to depressurize the water tank. Drain approximately 5 gallons (20 litres) of water from tank (Refer to “DRAINING THE T ANK” for proper procedures.) Close drain valve. Remove o[...]

www .hotwater .com 45 Remove the fi lter: • Disconnect the electrical power to the water heater . • Close the shutoff valves on both the hot-water and cold-water lines. • Unlock the door by rotating the side lock counter- clockwise with a wide, slot screwdriver . • Pop the top and bottom door pins by pushing the pins out, using a small scr[...]

46 www .hotwater .com • Disconnect electrical power to the water heater . • Remove the pail of cleaning solution and replace it with a pail of clean water . • Rinse the cleaning solution from the water heater as follows: • Connect the electrical power to the water heater and run the heat engine. • Allow the clean water to fl ow through t[...]

www .hotwater .com 47 DIAGNOSTIC DISPLA Y By simultaneously pressing the “Mode” and “down arrow” buttons for 3 seconds the unit will allow access to the diagnostic mode. In diagnostic mode, using the up/down arrow allows for cycling between diagnostic codes. The numeric display will show the diagnostic code for 1 second, followed by the act[...]

48 www .hotwater .com If an error code is displayed, or odd behavior of the unit occurs, the fi rst corrective action should be to “Cycle the Power”: Unplug the 120V ac power cord and after 5 seconds plug it in again. If this doesn’t clear the fault, proceed with the “Remedy” in the following table (T able 5). If wire harness checking is[...]

www .hotwater .com 49 Fault Code Displayed Description Cause Lockout type Remedy E15 Blower speed abnormal. Blower speed is 200RPM below the target speed for 20 seconds. Soft Check the blower wire harness. Change the blower . Change the board. 1. 2. 3. E16 Blower speed is 500RPM above the target speed for 6 seconds. E17 Machine starts or normal com[...]

50 www .hotwater .com Fault Code Displayed Description Cause Lockout type Remedy E30 Blower Error . Locked Rotor . Soft Check the blower wire harness. Change the blower . Change the board. 1. 2. 3. E33 W ater Flow V alve Closed. The water valve did not open when attempting to establish fl ow . Soft Check the water valve wire harness. Change the bo[...]

www .hotwater .com 51 These guidelines should be utilized by a quali fi ed service agent. Problem Possible Cause(s) What to do NOT ENOUGH HOT WA TER ST ANDBY button turned of f. Press switch to turn heater on. No power at outlet. Repair service to outlet. Error Code being displayed Refer to “F AUL T INDICA TION AND ERROR CODES” section and T a[...]

52 www .hotwater .com Problem Possible Cause(s) What to do WHEN THE T AP IS OPENED, THERE IS NO HOT W A TER OR THE HOT W A TER TURNS COLD AND ST A YS COLD. a. The hot water fi xture is not suf fi ciently open to draw the water through the heater . b. The unit display is an error code. c. There is an external recirculation system installed, or the[...]

www .hotwater .com 53 SERVICE If a condition persists or you are uncertain about the operation of the water heater contact a quali fi ed service agency . LEAKAGE CHECKPOINTS Use this guide to check a “Leaking” water heater . Many suspected “Leakers” are not leaking tanks. Often the source of the water can be found and corrected. If you are[...]

54 www .hotwater .com P ARTS IDENTIFICA TION ITEM # DESCRIPTION A Baf fl e, Flue B Hot W ater Outlet Nipple (w/ Anode, Heat T rap) C T&P Relief V alve D Cold W ater Inlet Nipple (w/ Dip T ube, Heat T rap) E Cover , Back-Flue Gas Return F T op Insulation G Flue Gas Return Duct Assy H Shroud, Back-T ank Assembly I Shroud, Right Side-T ank Assemb[...]

www .hotwater .com 55 R O NM L K J I H G F E D C B A T Q S P 12 U 10 7 6 5 4 3 2 1 Z Y X W V 11 9 8 13[...]

56 www .hotwater .com REPLACEMENT P ARTS DESCRIPTION KIT # Drain valve 9000058015 T&P relief valve 9003741005 Anode/MG/NIP/HT 9004333005 Anode/AL/NIP/HT 9006827005 Circulation pump assembly 9007173005 Inlet/outlet thermistor (T emp sensor) 9007174005 PCB assembly w/ base 9007175005 12” Hose (braided) 9007176005 T ank thermistor 9007177005 NIP[...]

www .hotwater .com 57 LIMITED RESIDENTIAL GAS W ARRANTY THIS W ARRANTY IS APPLICABLE T O THE ORIGINAL OWNER ONL Y If the glass lined tank in this water heater shall prove upon examination by (the warrantor) to have leaked during the warranty period in normal residential use, due to natural corrosion from potable water therein, the warrantor will fu[...]

58 www .hotwater .com NOTES[...]

www .hotwater .com 59 NOTES[...]

500 TENNESSEE W AL TZ P ARKWA Y ASHLAND CITY , TN 37015 PHONE: 1-800-433-2545 F AX: 1-800-433-2515 www .aosmithwaterheaters.com / email: parts@hotwater .com[...]