Shield SNR150-100 Supplement

Installation & Service

Manual

Models: SNR150-100, SNR200-100,

SNA285-125, SNA400-125, AND

SNA500-125

This manual must only be used by a

qualified heating installer / service

technician. Read all instructions in this

manual before installing. Perform steps

in the order given. Failure to comply

could result in severe personal injury,

death, or substantial property damage.

WARNING

Save this manual for future reference.

-- 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 near by phone.

Follow the gas supplier’s 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.

WARNING: If the information in these instructions is not

followed exactly, a fire or explosion may result causing property

damage, personal injury or death.

SWH-I-S Rev F

Contents

PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . 3

Hazard Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

THE SHIELD -- HOW IT WORKS . . . . . . . . . . . . . . . . . 4-6

RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. DETERMINE WATER HEATER LOCATION

Closet and Alcove Installations . . . . . . . . . . . . . . . . . . . . 8

Provide Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Flooring and Foundation . . . . . . . . . . . . . . . . . . . . . . . . 10

Remove Water Heater from Wood Pallet . . . . . . . . . . . 10

Prevent Combustion Air Contamination . . . . . . . . . . . . 10

Using an Existing Vent System to Install a New Water

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Removing Water Heater From Existing Common Vent . 11

Combustion & Ventilation Air Requirements . . . . . . . . . 12

2. GENERAL VENTING

Direct Venting Options . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

Venting and Combustion Air . . . . . . . . . . . . . . . . . . . . . 17

PVC/CPVC Vent Piping Materials . . . . . . . . . . . . . . . . . 17

Requirements for Installation in Canada . . . . . . . . . . . . 17

Installing Vent and Air Piping . . . . . . . . . . . . . . . . . . . . 17

PVC/CPVC Air Intake/Vent Connections . . . . . . . . . . . . 18

Air Inlet Pipe Materials . . . . . . . . . . . . . . . . . . . . . . . . . 19

Stainless Steel Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Stainless Steel Air Intake/Vent Connections . . . . . . . . 20

Min./Max. Allowable Combustion Air & Vent Piping . . . 20

Vent & Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3. SIDEWALL DIRECT VENTING . . . . . . . . . . . . . . . . 22-28

4. VERTICAL DIRECT VENTING . . . . . . . . . . . . . . . . 29-32

5. CONVENTIONAL AND SIDEWALL VENTING . . . . 33

6. SYSTEM PIPING

General Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Scalding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Water Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Piping Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-38

7. GAS CONNECTIONS

Connecting Gas Supply Piping . . . . . . . . . . . . . . . . . . . 39

Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Pipe Sizing for Natural Gas . . . . . . . . . . . . . . . . . . . 40

Natural Gas Supply Pressure Requirements . . . . . . 40

Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Pipe Sizing for Propane Gas . . . . . . . . . . . . . . . . . . 40

Propane Supply Pressure Requirements . . . . . . . . 40

Check Inlet Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . 41-42

Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Gas Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . 42

8. FIELD WIRING

Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 43

Power Cord Connection . . . . . . . . . . . . . . . . . . . . . . . . . 43

Runtime Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Alarm Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

9. CONDENSATE DISPOSAL

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

10. START-UP

Check for Gas Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Inspect/fill Condensate System . . . . . . . . . . . . . . . . . . . . 47

Final Checks Before Starting the Water Heater . . . . . . . 47-50

11. OPERATING INFORMATION

How the Water Heater Operates . . . . . . . . . . . . . . . . . . . 51

Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Water Heater Temperature Regulation . . . . . . . . . . . . . . 52

Adjustable Control Parameters . . . . . . . . . . . . . . . . . . . . 52

Saving Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 53

The Shield Control Module . . . . . . . . . . . . . . . . . . . . . . . 54

Status Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 55-56

12. MAINTENANCE

Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 57

Address Report Problems . . . . . . . . . . . . . . . . . . . . . 58

Inspect Water Heater Interior . . . . . . . . . . . . . . . . . . . 58

Clean Condensate Trap . . . . . . . . . . . . . . . . . . . . . . . 58

Check All Piping for Leaks . . . . . . . . . . . . . . . . . . . . . 58

Flue Vent System and Air Piping . . . . . . . . . . . . . . . . 59

Check Water System . . . . . . . . . . . . . . . . . . . . . . . . . 59

Check Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . 59

Check Water Heater Relief Valve . . . . . . . . . . . . . . . 59

Inspect Ignition & Flame Sense Electrodes . . . . . . . . 60

Check Ignition Ground Wiring . . . . . . . . . . . . . . . . . . 60

Check All Water Heating Wiring . . . . . . . . . . . . . . . . . 60

Check Control Settings . . . . . . . . . . . . . . . . . . . . . . . 60

Perform Startup & Checks . . . . . . . . . . . . . . . . . . . . . 60

Check Burner Flames . . . . . . . . . . . . . . . . . . . . . . . . 60

Check Flame Signal . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Review with Owner . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Handling Ceramic Fiber Materials . . . . . . . . . . . . . . . 60-61

Cleaning Water Heater Heat Exchanger . . . . . . . . . . 61

Oiled Bearing Circulators . . . . . . . . . . . . . . . . . . . . . . 61

Magnesium Anode Rod Inspection . . . . . . . . . . . . . . 61

Check Delta T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

13. TROUBLESHOOTING

Before Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Troubleshooting Chart - No Display . . . . . . . . . . . . . . 63

Checking Temperature Sensors . . . . . . . . . . . . . . . . . 64

Troubleshooting Chart - Noisy System . . . . . . . . . . . 65

Troubleshooting Chart - Fault Messages Displayed . 66-71

Combustion Analysis Procedure . . . . . . . . . . . . . . . . . . . 72

Gas Valve Adjustment Procedure . . . . . . . . . . . . . . . . . . 73

14. DIAGRAMS

Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Please read before proceeding

Installer – Read all instructions, in this

manual before installing. Perform steps in

the order given.

Have this water heater serviced/inspected by a

qualified service technician, at least annually.

Failure to comply with the above could result

in severe personal injury, death or substantial

property damage.

Failure to adhere to the guidelines on this

page can result in severe personal injury,

death, or substantial property damage.

Water heater operation –

• Do not block flow of combustion or ventilation air to

the water heater.

• Should overheating occur or gas supply fail to shut off,

do not turn off or disconnect electrical supply to

circulator. Instead, shut off the gas supply at a location

external to the appliance.

• Do not use this water heater if any part has been under

water. The possible damage to a flooded appliance can

be extensive and present numerous safety hazards. Any

appliance that has been under water must be replaced.

When calling or writing about the water

heater – Please have the water heater model

and serial number from the water heater

rating plate.

Consider piping and installation when

determining water heater location.

Any claims for damage or shortage in

shipment must be filed immediately against

the transportation company by the

consignee.

Factory warranty (shipped with unit) does

not apply to units improperly installed or

improperly operated.

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

• 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 near by phone. Follow the

gas supplier’s 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.

WARNING

NOTICE

WARNING

Installation & Service Manual

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels

or to important information concerning the life of the product.

DANGER

WARNING

CAUTION

CAUTION

NOTICE

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious

injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious

injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate

injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not

avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not

related to personal injury or property damage.

When servicing the water heater –

• To avoid electric shock, disconnect electrical supply

before performing maintenance.

• To avoid severe burns, allow the water heater to cool

before performing maintenance.

The Shield - How it works...

1. Access cover - front

Provides access to the gas train and heat exchanger.

2. Air intake adapter

Allows for the connection of the PVC air intake pipe to

the water heater.

3. Air pressure switch

The air pressure switch detects blocked inlet conditions.

4. Air shroud (500-125 Model Only_Not Shown)

The air shroud directs air and gas flow into the blower.

5. Blower

The blower pulls in air and gas through the venturi

(item 5). Air and gas mix inside the blower and are pushed into

the burner, where they burn inside the combustion chamber.

6. Burner (not shown)

Made with metal fiber and stainless steel construction,

the burner uses pre-mixed air and gas and provides a

5 to 1 firing rate.

7. Condensate drain connection

Connects the condensate drain line to 1/2" PVC.

8. Electronic Control Module

The electronic control responds to internal and external signals

and controls the blower, gas valve, and pumps to meet the

demand.

9. Electronic display

The electronic display consists of 7 buttons and a dual line 32-

character liquid crystal display.

10. Flame inspection window

The quartz glass window provides a view of the burner

surface and flame.

11. Flame sensor

Used by the control module to detect the presence of burner

flame.

12. Flue gas sensor (not shown)

This sensor monitors the flue gas exit temperature. The control

module will modulate and shut down the water heater if the

flue gas temperature gets too hot. This protects the flue pipe

from overheating.

13. Gas connection pipe

Threaded pipe connection, either 1/2", 3/4", or 1",

depending on the model. This pipe should be connected

to the incoming gas supply for the purpose of delivering

gas to the water heater.

14. Gas shutoff switch (150-100 - - 285-125 Models Only)

An electrical switch designed to cut power from the gas valve to

prevent gas flow to the burner.

15. Gas shutoff valve (400-125 -- 500-125 Models Only)

Manual valve used to isolate the gas valve from the gas supply.

16. Gas valve

The gas valve senses the negative pressure created by the

blower, allowing gas to flow only if the gas valve is

powered and combustion air is flowing.

17. Heat exchanger access cover

Allows access to the combustion side of the heat

exchanger coils.

18. Heat exchanger inlet temperature sensor

This sensor monitors the inlet water temperature to the heat

exchanger.

19. Heat exchanger outlet temperature sensor

This sensor monitors heat exchanger outlet water temperature.

20. High limit sensor

Device that monitors the outlet water temperature. If the

temperature exceeds its setting, it will break the control circuit,

shutting the water heater down.

21. Ignition electrode

Provides direct spark for igniting the burner.

22. Line voltage junction box

The junction box contains the connection points for the line

voltage power.

23. Low voltage connection board

The connection board is used to connect external low voltage

devices.

24. Low voltage wiring connections (knockouts)

Conduit entryway for the low voltage

connection board.

25. Power cord

Six foot cord allows for quick connection to 120V supply.

26. Pump

Circulates water between the tank and the heat exchanger.

27. Pump relay

Switches power to the pump.

28. Relief valve discharge pipe

Protects the heat exchanger from over pressure and

temperature conditions. The relief valve is set at 150 PSI.

29. Stainless steel heat exchanger

Allows water to flow through specially designed

coils for maximum heat transfer, while providing

protection against flue gas corrosion. The coils are

encased in a jacket that contains the combustion process.

30. Tank sensor

Used by the control to monitor the temperature of the tank.

31. Top panel

Removable panel to gain access to the internal components.

32. Vent pipe connection

Allows for the connection of the PVC/CPVC vent pipe system

to the water heater.

33. Venturi

The venturi controls air and gas flow into the burner.

34. Water heater drain valve

Location from which the water heater can be drained.

35. Water inlet

Copper sweat connection for cold water supply that returns

water from the system to the heat exchanger, either 1-1/2" or 2",

depending on the model.

36. Water outlet

Male NPT water connection that supplies hot water to the

system, either 1-1/2" or 2", depending on the model.

Installation & Service Manual

Front View - Models SNR150-100 -- SNA285-125

Left Side (inside unit) -- Models SNR150-100 -

SNA285-125

Right Side (inside unit) -- Models SNR150-100 - SNA285-125

The Shield - How it works... (continued)

Rear View - Models SNR150-100 -- SNA285-125

Models SNR150-100 -- SNA285-125

Installation & Service Manual

The Shield - How it works...

Rear View - Model SNA400-125

Rear View - Model SNA500-125 Right Side (inside unit) - Model SNA500-125

Right Side (inside unit) - Model SNA400-125

Model SNA400-125

Model SNA500-125

Installation & Service Manual

Ratings

Notes:

1. Shield water heaters require special gas venting. Use

only the vent materials and methods specified in the

Shield Installation and Service Manual.

2. Standard Shield water heaters are equipped to operate

from sea level to 4,500 feet only with no adjustments.

The water heater will de-rate by 4% for each 1,000 feet

above sea level up to 4,500 feet.

3. High altitude Shield water heaters are equipped to

operate from 3,000 to 12,000 feet only with no field

adjustments. The water heater will de-rate by 2% for

each 1,000 feet above 3,000 feet. High altitude models

are manufactured with a different control module for

altitude operation, but the operation given in this

manual remains the same as the standard models. A

high altitude label (as shown in FIG. A) is also affixed

to the unit.

Maximum allowed working pressure is located on the rating plate.

Model Number

Note: Change “N” to

“L” for L.P. gas models.

CSA

Input Modulation Btu/hr

(Note 2)

Water Content

Gallons

Water

Connections

Gas

Connections

Vent/Air Size

Min Max (Note 1)

SNR150-100 30,000 - 150,000 92 1-1/2" 1/2" 3"

SNR200-100 40,000 - 199,999 93 1-1/2" 1/2" 3"

SNA285-125 57,000 - 285,000 124 2" 3/4" 4"

SNA400-125 80,000 - 399,999 125 2" 1" 4"

SNA500-125 100,000 - 500,000 126 2" 1" 4"

NOTICE

Figure A High Altitude Label Location

UNIT EQUIPPED FOR

3,000 FT. TO 12,000 FT.

HIGH ALTITUDE

Installation & Service Manual

The Shield water heater gas manifold and

controls met safe lighting and other

performance under tests specified in

ANSI Z21.10.3 – latest edition.

Failure to keep water heater area clear and

free of combustible materials, gasoline,

and other flammable liquids and vapors

can result in severe personal injury, death,

or substantial property damage.

Installation must comply with:

• Local, state, provincial, and national codes, laws,

regulations, and ordinances.

• National Fuel Gas Code, ANSI Z223.1 – latest edition.

• National Electrical Code.

• For Canada only: B149.1 Installation Code, CSA C22.1

Canadian Electrical Code Part 1 and any local codes.

Before locating the water heater, check:

1. Check for nearby connection to:

• Water piping

• Venting connections

• Gas supply piping

• Electrical power

2. Locate the appliance so that if water connections should

leak, water damage will not occur. When such locations

cannot be avoided, it is recommended that a suitable

drain pan, adequately drained, be installed under the

appliance. Under no circumstances is the manufacturer

to be held responsible for water damage in connection

with this appliance, or any of its components.

3. Check area around the water heater. Remove any

combustible materials, gasoline and other flammable

liquids.

4. The Shield water heater must be installed so that gas

control system components are protected from dripping

or spraying water or rain during operation or service.

WARNING This appliance is certified as an indoor

appliance. Do not install the appliance

outdoors or locate where the appliance will

be exposed to freezing temperatures or to

temperatures that exceed 100°F.

Failure to install the appliance indoors

could result in severe personal injury,

death, or substantial property damage.

Provide clearances:

Clearances from combustible materials

1. Hot water pipes—at least 1" from combustible materials.

2. Vent pipe – at least 1" from combustible materials.

3. See FIG.’s 1-1 and 1-2 on page 9 for other clearance

minimums.

Clearances for service access

1. See FIG.’s 1-1 and 1-2 on page 9 for recommended

service clearances. If you do not provide the minimum

clearances shown, it may not be possible to service the

water heater without removing it from the space.

Closet and alcove installations

This appliance requires a special venting

system. The vent connection to the

appliance must be made with the CPVC

pipe section installed in the appliance. The

field provided vent fittings must be

cemented to the CPVC pipe section. Use

only the vent materials, primer and cement

specified in this manual to make the vent

connections. Failure to follow this

warning could result in fire, personal

injury, or death.

For closet and alcove installations as

shown in FIG.’s 1-1 and 1-2, CPVC vent

material must be used inside the structure.

The ventilating air openings shown in

FIG.’s 1-1 and 1-2 are required for this

arrangement. Failure to follow this

warning could result in fire, personal

injury, or death.

WARNING

NOTICE WARNING

1 Determine water heater location

Installation & Service Manual

A closet is any room the water heater is installed in which is

less than 455 cubic feet for SNR150-100 and SNR200-100

models and 671 cubic feet for the SNA285-125 through

SNA500-125 models.

An alcove is any room which meets the criteria for a closet

with the exception that it does not have a door.

Example: Room dimensions = 6 feet long, 6 feet wide, and

9 foot ceiling = 6 x 6 x 9 = 324 cubic feet. This would be

considered a closet for a Shield Water Heater.

OPEN

FRONT

1" MINIMUM CLEARANCE

AROUND HOT WATER

PIPES AND VENT PIPE

Figure 1-2 Alcove Installation - Minimum Required Clearances

1" MINIMUM CLEARANCE

AROUND HOT WATER

PIPES AND VENT PIPE

CLOSED DOOR

VENTILATING

AIR OPENING

VENTILATING

AIR OPENING

*AREAOF EACH OPENING:

1 SQ. INCH PER 1000 BTU PER HOUR INPUT

WITH A MINIMUM OF 100 SQ. INCHES

Figure 1-1 Closet Installation - Minimum Required Clearances

WARNING For closet installations, CPVC

material MUST BE used in a closet

structure due to elevated

temperatures. Failure to follow this

warning could result in fire,

personal injury, or death.

1 Determine water heater location (continued)

RECOMMENDED SERVICE

CLEARANCES:

Top - 18" (457 mm)

Right Side - 24" (610 mm)

Front - 24" (610 mm)

RECOMMENDED SERVICE

CLEARANCES:

Top - 18" (457 mm)

Right Side - 24" (610 mm)

Front - 24" (610 mm)

Installation & Service Manual

WARNING For alcove installations, CPVC

material MUST BE used in an

alcove structure due to elevated

temperatures. Failure to follow this

warning could result in fire,

personal injury, or death.

Do not install the water heater on carpeting

even if foundation is used. Fire can result,

causing severe personal injury, death, or

substantial property damage.

When local codes require compliance with NSF 5, the heater

must be sealed to the floor with a food grade silicone to prevent

debris and harborage of vermin under the heater.

If flooding is possible, elevate the water heater sufficiently to

prevent water from reaching the water heater.

Flooring and foundation

Flooring

The Shield water heater is approved for installation on

combustible flooring, but must never be installed on carpeting.

Prevent combustion air contamination

Install air inlet piping for the Shield water heater as described in

this manual. Do not terminate vent/air in locations that can

allow contamination of combustion air. Refer to Table 1A, for

products and areas which may cause contaminated combustion

air.

Ensure that the combustion air will not

contain any of the contaminants in Table 1A.

Contaminated combustion air will damage

the water heater, resulting in possible severe

personal injury, death or substantial

property damage. Do not pipe combustion

air near a swimming pool, for example. Also,

avoid areas subject to exhaust fumes from

laundry facilities. These areas will always

contain contaminants.

WARNING

1 Determine water heater location

Products to avoid:

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents

found in household laundry rooms

Adhesives used to fasten building products and other similar

products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Table 1A Corrosive Contaminants and Sources

Remove water heater from wood pallet

1. Remove the sides and the top of the crate.

2. Remove the blocks on the base of the crate to allow for easier

removal.

3. The water heater can then be slid off the base of the crate for

installation.

Do not drop the water heater or bump the

jacket on the floor or pallet. Damage to the

water heater can result.

NOTICE

Installation & Service Manual

This manual suits for next models

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