A.O. Smith BTX-80 User Manual

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MODEL BTX-80

COMMERCIAL GAS WATER HEATER

Glass-LinedTank-TypeWater Heater

Thank you for buying this energy efficient water heater.

We appreciate your confidence in our products.

You should thoroughly read this manual before installation and/ or operation of this water heater. Please pay particular attention to the important safety and operating instructions as well as the WARNING and CAUTIONS.

TABLE OF CONTENTS

 

PAGE

GET TO KNOW YOUR WATER HEATER

2-3

GENERAL SAFETY INFORMATION

4-5

INSTALLATION

5-16

OPERATION

16-18

MAINTENANCE AND

18-21

TROUBLESHOOTING

TROUBLESHOOTING WITH THE LED

22

LIMITED WARRANTY

23

CAUTION

TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION

RELATIVE TO YOUR SAFETY. PLEASE READ THOROUGHLY

BEFORE INSTALLING AND USING THIS APPLIANCE.

A DIVISION OF A.O. SMITH CORPORATION

McBEE, SOUTH CAROLINA, U.S.A.

www.aosmithwaterheaters.com

KEEP THIS MANUAL IN THE POCKET ON THE HEATER FOR FUTURE REFERENCE

WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

PRINTED IN THE U.S.A. 0406

PART NO. 197086-000

1

ROUGH-IN-DIMENSIONS

Rough-In-Dimensions

Model

 

Units

 

A

B

 

C

D

 

E

F

G

H

 

J

 

K

BTX-80

 

Inches

 

70.62

68.20

 

51.90

20.90

 

9.15

12.00

22.00

8.00

 

15.81

 

26.92

 

cm

 

179.37

173.23

 

131.83

53.09

 

23.24

30.48

55.88

20.32

 

40.16

 

68.38

 

 

 

 

 

 

 

Top/Side Inlet and Outlet: 3/4" NPT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Gas Inlet: 1/2" NPT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Capacity and Gas and Electrical Characteristics

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Model

 

 

Approximate Capacity

 

 

 

Manifold Pressure

 

Electrical Characteristics

 

U.S. Gals.

Liters

 

Gas Type

 

“WC

 

 

kPA

Volts/Hz

 

 

Amperes

 

 

 

 

 

 

 

 

 

BTX-80

 

 

50

189

 

 

 

Nat.

 

4.00

 

 

0.99

120/60

 

 

<5

All models - Maximum Supply Pressure: 14 inches W.C. (3.48kPa) Minimum Supply Pressure Natural Gas: 5.0 inches W.C. (1.24kPa)

Minimum Pressure must be maintained under both load and no load (static and dynamic) conditions.

Recovery Capacities - U.S. Gallons/Hr. and Liters/Hr. at Temperature Rise Indicated

M odel

Input

 

 

 

 

 

 

Recovery Capacities

 

 

 

 

 

 

Rating

Rating

Tem p.

 

30

40

50

60

70

80

 

90

100

110

120

130

140

 

(Btu/hr)

(kW )

Rise

 

17

22

28

33

39

44

 

50

56

61

67

72

78

BTX-80

76,000

22.25

G PH

 

275

206

165

138

118

104

 

92

83

75

69

64

59

LPH

 

1041

780

625

522

447

394

 

348

314

284

261

242

223

 

 

 

 

 

Recovery capacity based on 90% thermal efficiency.

2

TYPICAL INSTALLATION

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. (See Replacement Parts Insert for list of part numbers and descriptions.) Standard hardware items may be purchased locally.

(A)

VENT PIPE

(W)

DRAIN PAN

(B)

ANODE

(X)

CONTROL

(C)

HOT WATER OUTLET

(Y)

CONTROL HARNESS*

(D)

OUTLET (120 VAC)

(AA) MOTOR & BLOWER

(F)

GAS SUPPLY

(CC) CONDENSATE FITTING

(G)

MAIN MANUAL GAS

 

(4 Places as Shown)**

 

SHUT OFF VALVE

(DD) PLASTIC TOP

(H)

GROUND JOINT UNION

(EE) ON/OFF SWITCH

(J)

DIRT LEG

(FF)

EXHAUST TEE

(K)

OUTER DOOR

(GG) ELBOW

(L)

UNION

(HH) BUSHING

(M)

INLET WATER SHUT

(II)

NIPPLE

 

OFF VALVE

(JJ)

CONDENSATE TEE

(N)

COLD WATER INLET

(KK) HOSE BARB

(O)

INLET DIP TUBE

(LL)

PLUG

(P)

TEMPERATURE AND

(MM) VENT PIPE ASSEMBLY #1

 

PRESSURE RELIEF VALVE

(NN) VENT PIPE ASSEMBLY #2

(Q)

RATING PLATE

(OO) VENT PIPE ASSEMBLY #3

(R)

INSULATION

(PP) SIDE RECIRCULATION

(S)

VENT TERMINAL

 

LOOP INLET***

(T)

DRAIN VALVE

(QQ) SIDE RECIRCULATION

(U)

IGNITER AND MAIN

 

LOOP OUTLET*** (not shown)

 

BURNER

(RR) VENT ATTENUATION

 

 

 

ASSEMBLY (VAA) (Optional)

CONDENSATE ASSEMBLY

(U)NATURAL GAS MAIN BURNER WITH IGNITER ASSEMBLY

SIDE VIEW

*CAUTION HARNESS HAS 120 VAC. IN OPERATION.

**See "PLANNING THE VENT SYSTEM", "CONDENSATE" and "PREPARATION OF BLOWER ASSEMBLY" in the "INSTALLATION" section for more information.

***The side recirculation loop connections may not be used as the primary water inlet and outlet connections. For your convenience, plugs are installed in these fittings at the factory. Remove these plugs if needed for your specific installation. Otherwise (as with all connections) check for leaks while filling the tank with water and after completing the installation.

VACUUM RELIEF

(X)

TEMPERATURE INDICATORS

VALVE

 

 

 

 

*INSTALL PER LOCAL CODES

TEMPERATURE ADJUSTMENT BUTTONS

FIGURE 1

3

GENERAL SAFETY INFORMATION

EXTERNAL DAMAGE

Do not operate the water heater until it has been fully checked out by a qualified technician, if the water heater:

Has been exposed to fire or damage.

Displays evidence of sooting.

Produces steam or unusually hot water.

If the water heater has been subject to flooding it must be replaced.

CHEMICAL VAPOR CORROSION

WARNING

CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS. SUCH CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION.

Spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride (water softener salt), waxes, and process chemicals are typical compounds which are potentially corrosive.

Do not store products of this sort near the heater. Also, air which is brought in contact with the heater should not contain any of these chemicals. If necessary, uncontaminated air should be obtained from remote or outside sources. The limited warranty is voided when failure of water heater is due to a corrosive atmosphere. (See limited warranty for complete terms and conditions).

IMPROPER COMBUSTION

WARNING

ATTIC AND/OR EXHAUST FANS OPERATING ON THE PREMISES WITH A WATER HEATER CAN RESULT IN CARBON MONOXIDE POISONING AND DEATH.

OPERATION OF THESE FANS CAN PRODUCE A NEGATIVE DRAFT IN THE AREA OF THE WATER HEATER PREVENTING THE PRODUCTS OF COMBUSTION FROM EXHAUSTING THROUGH THE VENT PIPE.

The venting of the water heater should be inspected by a qualified service technician at the time of installation and periodically thereafter to ensure a down-draftcondition does not exist.

DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATING AIR. ADEQUATE AIR FOR COMBUSTION AND VENTILATION MUST BE PROVIDED FOR SAFE OPERATION.

LIQUID PETROLEUM MODELS

WARNING

Water heaters for propane or liquefied petroleum gas (LPG) are different from natural gas models. A natural gas heater will not function safely on LP gas and no attempt should be made to convert a heater from natural gas to LP gas.

LP gas must be used with great caution. It is highly explosive and heavier than air. It collects first in the low areas making its odor difficult to detect at nose level. If LP gas is present or even suspected, do not attempt to find the cause yourself. Go to a neighbor's house, leaving your doors open to ventilate the house, then call your gas supplier or service agent. Keep area clear until a service call has been made.

At times you may not be able to smell an LP gas leak. One cause is odor fade, which is a loss of the chemical odorant that gives LP gas its distinctive smell. Another cause can be your physical condition, such as having a cold or a diminishing sense of smell with age. For these reasons, the use of a propane gas detector is recommended.

IF YOU EXPERIENCE AN OUT-OF-GASSITUATION, DO NOT TRY TO RELIGHT APPLIANCES YOURSELF. Ask your LP delivery person to relight pilots for you. Only trained LP professionals should conduct the required safety checks in accordance with industry standards.

EXTENDED NON-USEPERIODS

WARNING

HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER SYSTEM SERVED BY THIS HEATER THAT HAS NOT BEEN USED FOR A LONG PERIOD OF TIME (GENERALLY TWO WEEKS OR MORE). HYDROGEN GAS IS EXTREMELY FLAMMABLE.To reduce the risk of injury under these conditions, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance connected to the hot water system. If hydrogen is present, there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow. THERE SHOULD BE NO SMOKING OR OPEN FLAME NEAR THE FAUCETAT THE TIME IT IS OPEN.

INSULATION BLANKETS

Insulation blankets available to the general public for external use on gas water heaters are not necessary with this water heater. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. Your water heater meets and exceeds the Energy Policy Act standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary.

WARNING

Should you choose to apply an insulation blanket to this heater, you should follow these instructions (See Figure 1 for identification of components mentioned below). Failure to follow these instructions can restrict the air flow required for proper combustion, potentially resulting in fire, asphyxiation, serious personal injury or death.

Do not cover the gas valve or temperature & pressure relief valve.

Do not allow insulation to come within 2" of the blower.

Do not allow insulation to come within 2" of the floor to prevent blockage of combustion air flow to the burner.

4

Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.

Do obtain new warning and instruction labels for placement on the blanket directly over the existing labels.

Do inspect the insulation blanket frequently to make certain it does not sag, thereby obstructing combustion air flow.

INSTALLATION

REQUIRED ABILITY

INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE FIELD INVOLVED. PLUMBING, ELECTRICAL AIR SUPPLY, VENTING AND GAS SUPPLY ARE REQUIRED.

GENERAL

The heater is designed to operate on natural or propane gases. HOWEVER, MAKE SURE the gas on which the heater will operate is the same as that specified on the heater model and rating plate.

The installation must conform to these instructions and the local code authority having jurisdiction. In the absence of local codes, the installation must conform to the current edition of National Fuel Gas Code ANSI Z223.1/NFPA 54 and the National Electrical Code, NFPA 70. The former is available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131, and both documents are available from the National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

GROUNDING

The water heater, when installed, must be grounded in accordance with local codes, or in the absence of local codes:

The National Electrical Code, NFPA 70

HIGH ALTITUDE INSTALLATION

CAUTION

INSTALLATIONSABOVE 2000 FT. REQUIRE REPLACEMENT OF THE BURNER ORIFICE INACCORDANCE WITH THE NATIONAL FUEL GAS CODE (ANSI Z223.1/NFPA 54). FAILURE TO REPLACE THE ORIFICE COULD RESULT IN IMPROPER AND INEFFICIENT OPERATION OF THE APPLIANCE, PRODUCING CARBON MONOXIDE GAS IN EXCESS OF SAFE LIMITS, WHICH COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH. CONTACT YOUR GAS SUPPLIER FOR ANY SPECIFIC CHANGES WHICH MAY BE REQUIRED IN YOUR AREA.

SOME MODELS ARE SPECIFICALLY BUILT FOR HIGH ALTITUDE SERVICE.

PLEASE CHECK THE RATING PLATE BEFORE MAKING CHANGES.

LOCATION OF HEATER

When installing the heater, consideration must be given to proper location. Location selected should be as close to the wall as practicable with adequate air supply and as centralized with the water piping system as possible.

The heater is designed for installation on combustible flooring in a closet having minimum clearances from combustible material of: 0" clearance from sides and rear, 5.5" from the front and 12" from the top. (Standard clearance.) If clearances stated on the

heater differ from standard clearances, install water heater according to clearances stated on heater.

A minimum clearance of 4" must be allowed for access to replaceable parts such as the thermostats, drain valve and relief valve. A top clearance of 24" should be allowed for blower assembly service.

Adequate clearance for servicing this appliance should be considered before installation, such as changing the anodes, etc. Minimum clearances for proper operation are given above.

WARNING

In cold climates provide protection against freeze-up.

Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak, the flow will not cause damage to the structure. For this reason, it is not advisable to install the water heater in an attic or upper floor. When such locations cannot be avoided, a suitable drain pan should be installed under the water heater. Drain pans are available at your local hardware store. Such a drain pan must have a minimum length and width of at least 2 inches (51 mm) greater that the water heater dimensions and must be piped to an adequate drain. The pan must not restrict combustion air flow.

Water heater life depends upon water quality, water pressure and the environment in which the water heater is installed. Water heaters are sometimes installed in locations where leakage may result in property damage, even with the use of a drain pan piped to a drain. However, unanticipated damage can be reduced or prevented by a leak detector or water shut-offdevice used in conjunction with a piped drain pan. These devices are available from some plumbing supply wholesalers and retailers, and detect and react to leakage in various ways:

Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected.

Sensors mounted in the drain pan that turn off the water supply to the entire home when water is detected in the drain pan.

Water supply shut-offdevices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater.

Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply.

WARNING

DO NOT INSTALL THIS WATER HEATER DIRECTLY ON A CARPETED FLOOR. A FIRE HAZARD MAY RESULT. Instead the water heater must be placed on a metal or wood panel extending beyond the full width and depth by at least 3 inches (76.2 mm) in any direction. If the heater is installed in a carpeted alcove or closet, the entire floor shall be covered by the panel.

AIR REQUIREMENTS

In calculating the free area of a vent opening, the blocking effect of screens, louvers and grills should be considered. Screens shall not be of a mesh smaller than 1/4 inch square. If the free area is not known, the current edition of National Fuel Gas Code ANSI Z223.1 recommends using figures of 20-25percent free area for wood louvers or60-75percent for metal grills or louvers.

UNCONFINED SPACE

In buildings of conventional frame, brick or stone construction, unconfined spaces may provide adequate air for combustion and ventilation air for the power venter.

5

If the unconfined space is within a building of tight construction (building using the following construction: weather stripping, heavy insulation, caulking, vapor barrier, etc.), air for combustion and ventilation must be obtained from outdoors. The installation instructions for confined spaces must be followed.

CONFINED SPACE

When drawing combustion air from inside a conventionally constructed building to a confined space, such a space shall be provided with two permanent openings. ONE WITHIN 12 INCHES OF THE ENCLOSURE TOP AND ONE WITHIN 12 INCHES OF THE ENCLOSURE BOTTOM. Each opening shall have a free area of one square inch per 1000 Btu/hr of the total input of all appliances in the enclosure, but not less than 100 square inches.

If the confined space is within a building of tight construction, air for combustion and ventilation must be obtained from outdoors. When directly communicating with the outdoors or communicating through vertical ducts, two permanent openings, located in the above manner, shall be provided. Each opening shall have a free area of not less than one square inch per 4000 Btu/hr of the total input of all appliances in the enclosure. If horizontal ducts are used, each opening shall have a free area of not less than one square inch per 2000 Btu/hr of the total input of all appliances in the enclosure.

WATER CONNECTIONS

Refer to figure 1 for typical installation. A suitable pipe thread sealant must be used to prevent leakage. Please note that the side connection plugs are not factory installed. Plugs are supplied in a kit with the water heater.

WATER (POTABLE) HEATING AND SPACE HEATING

1.All piping components connected to this unit for space heating applications shall be suitable for use with potable water.

2.Toxic chemicals, such as those used for boiler treatment, shall NEVER be introduced into this system.

3.This unit may NEVER be connected to any existing heating system or component(s) previously used with a non-potablewater heating appliance.

4.When the system requires water for space heating at temperatures higher than required for domestic water purposes, a tempering valve must be installed. Please refer to Fig. 2 for suggested piping arrangement.

FIGURE 2

CLOSED WATER SYSTEM

A closed system will exist if a back-flowpreventer (check valve), pressure reducing valve, or other similar device is installed in the cold water line between the water heater and the street main (or well). Excessive pressure may develop due to the thermal expansion of heated water causing premature tank failure or intermittent relief valve operation. This type of failure is not covered by the limited warranty. An expansion tank may be necessary in the cold water supply to alleviate this situation, see Fig. 1. Contact the local plumbing authority.

If the temperature and pressure relief valve on the appliance discharges periodically, this may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct situation. DO NOT PLUG THE TEMPERATURE AND PRESSURE RELIEF VALVE.

GAS CONNECTIONS

The minimum gas supply pressure for input adjustment is 5.0" W.C. for natural gas.

THE HEATER IS NOT INTENDED FOR OPERATION AT HIGHER THAN 14" WATER COLUMN SUPPLY PRESSURE. EXPOSURE TO HIGHER GAS SUPPLY PRESSURE MAY CAUSE DAMAGE TO THE CONTROL WHICH COULD RESULT IN FIRE OR EXPLOSION. If overpressure has occurred such as through improper testing of gas lines or emergency malfunction of the supply system, the control must be checked for safe operation. Make sure that the outside vents on the supply regulators and the safety vent valves are protected against blockage. These are parts of the gas supply system not the heater. Vent blockage may occur during ice storms.

IT IS IMPORTANT TO GUARD AGAINST CONTROL FOULING FROM CONTAMINANTS IN THE GAS WAYS. SUCH FOULING MAY CAUSE IMPROPER OPERATION, FIRE OR EXPLOSION.

All gas piping must comply with local codes and ordinances or with the National Fuel Gas Code (ANSI Z223.1 / NFPA-54)whichever applies.

6

WARNING

VENT HOOD(S) MAY BE

EXTREMELY HOT

DURING OPERATION.

FIGURE 3

REFER TO FIG. 1 FOR CONNECTION DETAILS. BEFORE ATTACHING THE GAS LINE BE SURE THAT ALL GAS PIPE IS CLEAN ON THE INSIDE.

TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS SUPPLY LINE, A DIRT LEG (SOMETIMES CALLED DRIP LEG) MUST BE INCORPORATED IN THE PIPING, FIGURE 1. The dirt leg must be readily accessible. Install in accordance with recommendations of serving gas supplier. Refer to the current edition of ANSI Z223.1.

To prevent damage, care must be taken not to apply too much torque when attaching gas supply pipe to thermostat gas inlet. The thermostat inlet has a pad for use with a backup wrench.

Apply joint compounds (pipe dope) sparingly and only to the male threads of pipe joints. Do not apply compound to the first two threads. Use compounds resistant to the action of liquefied petroleum gases. Do not use teflon tape on thermostat fittings.

CONNECTION OF GAS PIPE

1.When connecting gas pipe to unit, apply wrench to flange only. Note: Do not use wrench on gas valve or gas valve bracket.

2.PERFORM THE GAS LEAK TEST ANY TIME WORK IS DONE ON A GAS SYSTEM TO AVOID THE POSSIBILITY OF FIRE OR EXPLOSION WITH PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE.

The Gas Leak Test is performed as follows: Paint pipe connections upstream of gas control with a rich soap and water solution to test for leaks before operating main burner. Bubbles indicate gas leak. To stop leak, tighten pipe connections. After piping connections are checked, turn on main burner. (See Lighting and Operating Instructions in this manual or on water heater.) With main burner in operation, paint pipe joints (including flanges), and control inlet and outlet with rich soap and water solution. Bubbles indicate gas leak. To stop leak, tighten

flange screws, joints and pipe connections. Replace part if leak can't be stopped.

DISCONNECT THE APPLIANCEAND ITS INDIVIDUAL SHUT OFF VALVE FROM THE GAS SUPPLY PIPING SYSTEM DURING ANY SUPPLY PRESSURE TESTING EXCEEDING 1/2 PSI (3.5 kPa). GAS SUPPLY LINE MUST BE CAPPED WHEN DISCONNECTED FROM THE HEATER. FOR TEST PRESSURES AT 1/2 PSI (3.5 kPa) OR LESS, THE APPLIANCE NEED NOT BE DISCONNECTED, BUT MUST BE ISOLATED FROM THE SUPPLY PRESSURE TEST BY CLOSING THE MAIN MANUAL GAS VALVE.

BEFORE PLACING THE HEATER IN OPERATION, CHECK FOR GAS LEAKAGE. USE SOAP AND WATER SOLUTION OR OTHER MATERIAL ACCEPTABLE FOR THIS PURPOSE. DO NOT USE MATCHES CANDLES, FLAME OR OTHER SOURCES OF IGNITION TO LOCATE GAS LEAKS.

RELIEF VALVE

A NEW TEMPERATURE AND PRESSURE RELIEF VALVE COMPLYING WITH THE STANDARD FOR RELIEF VALVES AND AUTOMATIC GAS SHUT OFF DEVICES FOR HOT WATER SUPPLY SYSTEMS, ANSI Z21.22 (CURRENT EDITION) MUST BE INSTALLED IN THE HEATER IN THE MARKED OPENING PROVIDED. THE VALVE MUST BE OF A SIZE (INPUT RATING) THAT WILL BE ADEQUATE FOR YOUR SIZE HEATER.

Check the metal tag on the relief valve and compare it to the heater’s rating plate. The pressure rating of relief valve must not exceed the working pressure shown on the rating plate of the heater. In addition the hourly Btu rated temperature steam discharge capacity of the relief valve shall not be less than the input rating of the heater. NO VALVE IS TO BE PLACED BETWEEN THE RELIEF VALVE AND TANK. DO NOT PLUG THE RELIEF VALVE.

7

The drain line connected to this valve must not contain a reducing coupling or other restriction and must terminate near a suitable drain to prevent water damage during valve operation. The discharge line shall be installed in a manner to allow complete drainage of both the valve and line. DO NOT THREAD, PLUG OR CAP THE END OF THE DRAIN LINE.

VENT PIPE ASSEMBLY

There are three parts of the vent pipe assembly that connect the water heater exhaust (located on the lower back side of the water heater) to the inlet of the blower assembly (mounted on top of the water heater) as shown in Figure 1. These parts will need to be assembled according to the instructions in the VENT PIPE PREPARATION section of this manual. These PVC parts should be assembled with ASTM D-2564grade cement.

Assemble Vent Pipe Assemblies #1, #2 and #3 (See Figure 1) prior to cementing. The preferred orientation of Vent Pipe Assembly #1 (Condensate U-Assembly)is shown in Figure 4. However this assembly may be rotated to a different orientation as needed for the specific installation requirements. Note the rotational orientation of each part by marking a line several inches long across the joints. The long tube of Vent Pipe Assembly #2 should be approximately vertical. If it is found that either of the two pieces of pipe in Vent Pipe Assembly #2 are too long for properfit-up,then remove as little material as possible to improve thefit-up.Keep in mind that the pipes will insert slightly further into the elbows when cement is applied as it acts as a lubricating agent. The vertical distance from the bottom of the CondensateU-Assemblyto the floor that supports the water heater should be approximately 0.25" (See Figure 4). Disassemble the parts and cement back together using the alignment marks. After the cement dries, attach the assembly to the blower and the water heater exhaust using the supplied rubber boots and hose clamps.

A condensate trap is incorporated in the bottom of this vent pipe assembly. See the CONDENSATE section of this manual for further details.

VENTING

WARNING

NEVER OPERATE THE HEATER UNLESS IT IS VENTED TO THE OUTDOORS AND HAS ADEQUATE AIR SUPPLY TO AVOID RISKS OF IMPROPER OPERATION, FIRE, EXPLOSION OR ASPHYXIATION.

VENT PIPE TERMINATION

The first step is to determine where the vent pipe will terminate. See Figures 3, 8 and 9. The vent may terminate through a sidewall as shown in Figure 8 or through the roof as shown in Figure 9.

IMPORTANT

The vent system must terminate so that proper clearances are maintained as cited in local codes or the current edition of the National Fuel Gas Code, ANSI Z223.1, 12.9.1 through 12.9.4.

Instructions on proper installation through a sidewall are provided in Figure 3.

Plan the vent system layout so that proper clearances are maintained from plumbing and wiring.

Vent pipes serving power vented appliances are classified by building codes as "vent connectors". Required clearances from

combustible materials must be provided in accordance with information in this manual under LOCATION OF HEATER and INSTALLATION OF VENT SYSTEM, and with the National Fuel Gas Code and local codes.

PLANNING THE VENT SYSTEM

Plan the route of the vent system from the discharge of the blower to the planned location of the vent terminal.

1.Layout the total vent system to use a minimum of vent pipe and elbows.

2.This water heater is capable of venting the flue gases the equivalent of twenty-five(25) feet of 2 inch pipe,sixty-five(65) feet of 3 inch pipe, orone-hundredtwenty-eight(128) feet of 4 inch pipe as listed in Table 1.

TABLE 1

Number of

2" Maximum

3" Maximum

4" Maximum

90° Elbows

Pipe (Feet)

Pipe (Feet)

Pipe (Feet)

1

20

60

120

2

15

55

112

3

10

50

104

4

--

45

96

5

--

40

88

6

--

35

80

The minimum vent lengths for each of the pipe sizes is one 90° on top of the unit plus 2' of straight pipe and the appropriate termination.

NOTE: The equivalent feet of pipe listed above are exclusive of the termination. That is, the termination, with an installed screen, is assumed to be in the system and the remainder of the system must not exceed the lengths discussed above.

3.The blower discharge adapter is made to accept only straight sections of 2" pipe. To start, a minimum of 2 inches of 2" pipe must be attached to the blower discharge (See figure 5).

If using 2" inch vent pipe:

A minimum of 2 inches must be attached to the blower before the first elbow. After the first elbow add the additional venting required for the installation. The total system cannot exceed the lengths discussed above, where each elbow is equal to 5 feet of straight pipe.

If using 3" or 4" inch vent pipe:

Two inches of pipe must be attached to the blower discharge before adding a reducer to acquire the desired pipe diameter. An appropriately sized 45 degree elbow (supplied locally – a schedule 40 DWV) vent terminal must be obtained with an equivalent screen (supplied in vent kit). The total system cannot exceed the equivalent pipe lengths discussed above where each elbow is equal to 5 feet of straight pipe (3" vent pipe) or 8 feet of straight pipe (4" vent pipe).

NOTE: This unit can be vented using only PVC (Class 160, ASTMD-2241;Schedule 40, ASTMD-1785;or Cellular Core Schedule 40 DWV, ASTMF-891),Schedule 40 CPVC/ ASTMF-441),or ABS/ASTMD-2661)pipe. The fittings, other than the TERMINATION should be equivalent to PVCDWV fittings meeting ASTMD-2665(Use CPVC fittings, ASTMF-438for CPVC pipe and ABS fittings, ASTM D- 2661/3311 for ABS pipe. If CPVC or ABS pipe and fittings are used, then the proper cement must be used for all

8

joints, including joining the pipe to the Termination (PVC Material). If local codes do not allow the use of the PVC termination when a material other than PVC is used for venting, then an equivalent fitting of that material may be substituted if the screen in the PVC terminal is removed and inserted into the new fitting.

PVC Materials should useASTM D-2564Grade Cement; CPVC Materials should use ASTMF-493Grade Cement and ABS Materials should use ASTMD-2235Grade Cement.

If the water heater is being installed as a replacement for an existing power vented heater in pre-existingventing, a thorough inspection of the existing venting system must be performed prior to any installation work. Verify that the correct material as detailed above has been used, and that the minimum or maximum vent lengths and terminal location as detailed in this manual have been met. Carefully inspect the entire venting system for any signs of cracks or fractures, particularly at the joints between elbows and other fittings and the straight runs of vent pipe. Check the system for signs of sagging or other stresses in the joints as a result of misalignment of any components in the system. If any of these conditions are found, they must be corrected in accordance with the venting instructions in this manual before completing the installation and putting the water heater into service.

NOTE: A. For water heaters in locations with high ambient temperatures (above 100°F) it is recommended that CPVC or ABS pipe and fittings be used.B. A 22.5 degree elbow (2" vent pipe) or a 45 degree elbow (3" and 4" vent pipe) with an installed screen VENT TERMINALmust be used in all cases.

4.There will be some installations where condensate will be formed in the horizontal runs of the vent system. This condensate will run into the condensate boot attached to the blower and out the fitting. The water heater is shipped with condensate hose that attaches to the fitting on the condensate boot. No other Tee or fitting is required. See Figures 5, 8 and 9.

CONDENSATE

WARNING

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 4) AND FROM TWO PLACES ON THE BLOWER ASSEMBLY (SEE FIGURE 5). Condensate from this water heater is mildly acidic. Please note that some local codes require that condensate is treated by using a pH neutralizing filter prior to disposal.

NOTE: IT IS IMPORTANT THAT THE CONDENSATE HOSE ON THE BOTTOM OF THE UNIT IS NOT INSTALLED ELEVATED ABOVE THE CLAMP THAT IS SECURED TO THE SIDE OF THE JACKET, SEE FIGURE 4. THIS MUST BE TRUE FOR THE ENTIRE LENGTH OF THE HOSE FROM THE CLAMP TO THE EXIT INTO AN APPROPRIATE DRAIN. If these instructions are not followed or if the condensate hose is blocked, water will spill from the condensate trap. As with every water heater installation, a drain pan should be used to prevent water damage to the surrounding area. If necessary, a condensate pump with

an incorporated reservoir may be used to pump the water to an appropriate drain. To avoid condensate spillage, select a pump with an overflow switch.

CAUTION MUST BE USED TO ENSURE THAT THE DRAIN IS FREE AND CLEAR OF DEBRIS AND WILL NOT ALLOW BACKFLOW THROUGH THE CONDENSATE HOSE. CONSIDERATION MUST BE GIVEN TO AVOID FREEZING OF THE CONDENSATE LINES WHICH COULD RESULT IN EXCESSIVE BUILD UP OF CONDENSATE INSIDE THE WATER HEATER. Waterproof heat tape may be required to prevent freezing of the condensate lines. Please ensure that the outlet of the condensate drain does not create a slippery condition which could lead to personal injury.

The condensate trap may be primed by filling the CONDENSATE U-ASSEMBLYwith tap water using the supplied hose while the water heater is not operating. The system is fully primed when the hose is lowered below the hose clamp on the side of the water heater and water begins to flow out of the hose. In most installations the water heater willself-primethe condensate trap during the first fullheat-upcycle. IF A SOUND OF AIR BUBBLING THROUGH WATER (GURGLING) IS HEARD WHILE THE BLOWER IS OPERATING AFTER THE FIRSTHEAT-UPCYCLE, THEN TURN THE UNIT OFF AND CONTACT YOUR PLUMBER OR SERVICE REPRESENTATIVE.

IF THESE INSTRUCTIONS ARE NOT FOLLOWED, THE CONDENSATE BUILD-UPWILL BLOCK THE EXHAUST OUTLET, WHICH WILL CAUSE IMPROPER OPERATION.

CONDENSATE SYSTEM - FIGURE 4

Condensate is likely to form in the venting system attached to this water heater. The vent pipe should be sloped downward away from the blower assembly (not less than 1/8" (3.2 mm) nor greater than 1/2" (12.7 mm) per foot maximum). If the vent piping is vented level or sloped upwards away from the blower assembly, then adequate means for draining and disposing of the condensate needs to be made by the installer. In either case, a 3/8" drain hose should be connected to the built-indrain port. Prior to operating the water heater, make sure the removable cap is installed on the second drain port (See Figure 5).

PREPARATION OF BLOWER ASSEMBLY

1.Check to make sure that the wire harness is attached to the gas valve and blower control box.

2.Make sure no material is still attached to the outside or inside of blower assembly.

9

WARNING

CONDENSATE ALSO DRAINS FROM TWO LOCATIONS ON THE BLOWER ASSEMBLY AS SHOWN IN FIGURE 5. A CONDENSATE HOSE MUST BE SECURED TO FORM A "TRAP" AS SHOWN IN FIGURE 5 FOR THESE CONDENSATE DRAIN CONNECTIONS. THESE TWO HOSES MAY BE CONNECTED TOGETHER. THE HOSE(S) SHOULD BE ROUTED TO A SUITABLE DRAIN. A fitting that may be used to join the two hoses from the blower assembly is included in a supplied kit.

FIGURE 5

3.Make sure that plastic tubing is still attached to the pressure switch and fan housing. Also make sure that wiring connector from motor to control box is securely attached.

4.Do not plug in power cord until vent system is completely installed. The Power Vent operates on 110-120Vac. therefore a grounded outlet must be within reach of the 6 foot flexible power cord supplied with the vent (see fig.1). The power cord supplied may be used on a unit only where local codes permit. If local codes do not permit use of flexible power supply cord:

A.Make sure the unit is unplugged from the wall outlet. Remove the plastic top cap. Remove screws and open panel on the front of the control box on the blower.

B.Cut the flexible power cord, leaving enough to be able to make connections. Remove the strain relief fitting from the box.

C.Install a suitable conduit fitting inside the enclosure.

D.Splice field wiring into existing wiring using code authorized method (wire nuts, etc).

E.Be certain that neutral and line connections are not reversed when making these connections.

F.Ground heater properly. This water heater must be grounded in accordance with the National Electrical Code NFPA 70 and/or local codes. These must be followed in all cases.

The water heater must be connected to a grounded metal, permanent wiring system; or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the water heater, see Figure 7.

G.Close the panel on the control box. Make sure that the access panel is secured shut.

5.The blower discharge boot is made to accept only straight sections of 2" pipe. To start off with an elbow, a short section of the furnished pipe, a minimum of 2 inches, must be cut and glued into the end of the elbow that will mount on the discharge boot.

INSTALLATION OF VENT SYSTEM

Before beginning installation of piping system thoroughly read the section of this manual VENT PIPE PREPARATION.

If you are installing your system so that it vents through roof, please refer to section titled INSTALLATION OF VERTICAL VENT SYSTEM.

VENT TERMINAL INSTALLATION, SIDEWALL

1.Install the vent terminal by using the cover plate as a template to mark the hole for the vent pipe to pass through the wall. BEWARE OF CONCEALED WIRING AND PIPING INSIDE THE WALL.

2.If the Vent Terminal is being installed on the outside of a finished wall, it may be easier to mark both the inside and outside wall. Align the holes by drilling a hole through the center of the template from the inside through to the outside. The template can now be positioned on the outside wall using the drilled hole as a centering point for the template.

3.A) MASONRY SIDE WALLS

Chisel an opening approximately one half inch larger than the marked circle.

B) WOODEN SIDE WALLS

Drill a pilot hole approximately one quarter inch outside of the marked circle. This pilot hole is used as a starting point for a saws-allor sabre saw blade. Cut around the marked circle staying approximately one quarter inch outside of the line. (This will allow the vent to easily slide through the opening. The resulting gap will be covered up by the Vent Terminal cover plate.) Repeat this step on inside wall if necessary.

SEQUENCE OF INSTALLATIONS, FIGURE 6

Cut a length of PVC pipe about 3.5 inches 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. Apply enough to fill some of the gap between the pipe and wall. Place some of the caulking on the back of the plate to hold it against the wall after installation. If the vent pipe is installed up to the wall, with a coupling on the end against the wall opening, the pipe with the vent terminal can be prepared for gluing before inserting through the wall. Slide the pipe through the wall and insert into the coupling on the other side of the wall, making sure that the vent terminal ends up pointed in the correct position, see Figure 6.

VENT TERMINATION - FIGURE 6

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