American Water Heater AHCG3-HCG360T120, AHCG3-HCG3100T250 User Manual

HIGH EFFICIENCY AHCG3/HCG360T120 thru AHCG3/HCG3100T250

COMMERCIAL GAS WATER HEATER

GAS-FIRED POWER BURNER

FOR DOMESTIC HOT WATER

• INSTALLATION • OPERATION • SERVICE • MAINTENANCE • LIMITED WARRANTY

WARNING: If the information in these

instructions is not followed exactly, a re

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

– Do not store or use gasoline or other

ammable 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 neighbor's phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier,

call the re department.

– Inst allation and serv ice mus t be performed by a qualified installer,

service agency or the gas supplier.

Thank you for buying this energy efcient water heater from American Water Heaters. We appreciate your condence in our products.

CAUTION

TEXT PRINTED OR UNDERLINED IN RED CONTAINS

INFORMATION RELATIVE TO YOUR SAFETY. PLEASE

READ THOROUGHLY BEFORE INSTALLING AND USING THIS APPLIANCE.

PO Box 1597, 500 Princeton Road

PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND

NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.

PRINTED 0608 198154-000

Johnson City, TN 37605

www.americanwaterheater.com

HIGH EFFICIENCY AHCG3/HCG360T120 thru AHCG3/HCG3100T250 ROUGH-IN-DIMENSIONS

GAS VALVE PIPING

AHCG3/HCG360T120 1/2" NPT AHCG3/HCG3100T150 thru 100T250 3/4" NPT

Table 1. RECOVERY CAPACITIES - NATURAL GAS / L.P.

Approx. TEMPERATURE RISE - DEGREES °F - GALLONS PER HOUR AHCG3/ Input Gas Gallon HCG3 BTU/Hr. Usage Capacity 30 40 50 60 70 80 90 100 110 120 130 140 60T120 120,000 nat/lp 60 461 345 276 230 197 173 154 138 126 115 106 99 100T150 150,000 nat/lp 100 576 432 345 288 247 216 192 173 157 144 133 123 100T199 199,900 nat/lp 100 767 575 460 384 329 288 256 230 209 192 177 164 100T250 250,000 nat/lp 100 960 720 576 480 411 360 320 288 262 240 221 206

AHCG3/ Gas Liter Approx. TEMPERATURE RISE - DEGREES C - Liters PER HOUR HCG3 kW-Hr Usage Capacity 17 22 28 33 39 44 50 56 61 67 72 78 60T120 35 nat/lp 227 1744 1308 1046 872 747 654 581 523 476 436 402 374 100T150 44 nat/lp 379 2179 1635 1308 1090 934 817 726 654 594 545 503 467 100T199 58 nat/lp 379 2904 2178 1743 1452 1245 1089 968 871 792 726 670 622 100T250 73 nat/lp 379 3632 2724 2179 1816 1557 1362 1211 1090 991 908 838 778

Recovery capacities are based on 95% thermal efciency.

FOREWORD

These designs comply with the current version of the American National Standard for Gas Water Heaters, Volume III, ANSI Z21.10.3 / CSA 4.3 as an automatic circulating tank water heater, and automatic storage water heaters.

Detailed installation diagrams are found in this manual. These diagrams will serve to provide the installer with a reference for the materials and methods of piping necessary. It is highly essential that all water, gas piping and wiring be installed as shown on the diagrams.

Particular attention should be given to the installation of thermometers at the locations indicated on the diagrams as these are necessary for checking the proper functioning of the heater.

In addition to these instructions, the equipment shall be installed in

accordance with those installation regulations in force in the local area where the installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.

In the absence of local codes, the installation must comply with the current editions of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and the National Electrical Code, NFPA 70 or CAN/CSA-B149.1, the Natural Gas and Propane Installation Code and CSA C22.1, the Canadian Electrical Code. All documents are available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131. NFPA documents are also available from the National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

PAGE

ROUGH-IN DIMENSIONS ................................................................. 2

FOREWORD ..................................................................................... 2

FEATURES ........................................................................................ 3,4

Water Temperature Control ........................................................... 3

High Limit Switch (E.C.O.) ............................................................ 4

Dishwashing Machine Requirement .............................................. 4

Circulating Pump ........................................................................... 5

INSTALLATION INSTRUCTIONS ..................................................... 4-12

Required Ability ............................................................................. 6

Insulation Blankets ........................................................................ 6

Locating The Heater ...................................................................... 5

Clearances .................................................................................... 5

Hard Water .................................................................................... 6

Air Requirements .......................................................................... 6

Mechanical Exhausting of Room Air ............................................. 6

Unconned Space ......................................................................... 6

Conned Space ............................................................................. 6

Chemical Vapor Corrosion ............................................................ 6

Venting .......................................................................................... 6

Vent Pipe Termination ................................................................... 6-10

Installation Requirements for the

Commonwealth of Massachusetts ............................................... 7

Direct Venting ................................................................................ 10

Direct Vent Terminal Installation (Sidewall) ................................... 10

Installation Sequence .................................................................... 10

Vertical Vent Terminal Installation ................................................. 11

Installation Sequence .................................................................... 11

Installation of Vent System ............................................................ 12

Vent Pipe Preparation ................................................................... 12

CONTROL AND SWITCHES ............................................................. 13

Blower Prover Switch .................................................................... 13

Blocked Outlet Prover Switch ........................................................ 13

Blocked Inlet Prover Switch .......................................................... 13

Low Gas Pressure Switch ............................................................. 13

On/Off Switch ................................................................................ 13

Hot Surface Igniter ........................................................................ 13

GAS PIPING ...................................................................................... 13

Connection of Gas Pipe ................................................................ 14

Purging .......................................................................................... 15

Gas Meter Size - City Gases Only ................................................ 15

Gas Pressure Regulation .............................................................. 15

TABLE OF CONTENTS

PAGE

Gas Valves .................................................................................... 15

SYSTEM CONNECTIONS ................................................................ 15

Thermometers ............................................................................... 15

Relief Valve ................................................................................... 15

Water Line Connections ............................................................... 15

Heater Wiring ............................................................................... 16

USING THE ELECTRONIC CONTROLLER .................................... 17

Overview ...................................................................................... 17

Operating States .......................................................................... 17

Adjusting the Operating Set Point ................................................ 18

Changing the Display Units .......................................................... 19

Fault and Warning Conditions ...................................................... 19

Access to the Current Fault or Warning ....................................... 19

Viewing the Fault History ............................................................. 20

PRIOR TO START-UP ...................................................................... 20

Required Ability ............................................................................ 20

OPERATING INSTRUCTIONS ......................................................... 21

Adjustment Procedure (Initial Start-Up) 120 and 150 Models ...... 21

Adjustment Procedure (Initial Start-Up) 199 and 250 Models ...... 21

Cathodic Protection ...................................................................... 22

Precautions .................................................................................. 22

GENERAL INFORMATION ............................................................... 22

Power Burner ............................................................................... 22

High Limit ..................................................................................... 22

High Altitude Installations ............................................................. 22

MAINTENANCE ............................................................................... 22

General ........................................................................................ 22

Maintenance Schedule ................................................................ 22

Flushing ........................................................................................ 26

Draining ........................................................................................ 26

Sediment Removal ....................................................................... 26

Lime Scale Removal .................................................................... 26

Anode Inspection and Replacement ............................................ 26,27

Drain Valve and Access Panels ................................................... 27

Relief Valve .................................................................................. 27

Circulating Pump .......................................................................... 27

Vent System ................................................................................. 27

INSTALLATION DIAGRAMS ............................................................ 28-32

Manifold Kits ................................................................................. 33

CHECKLIST AND SERVICE INFORMATION .................................. 34

TROUBLE-SHOOTING .................................................................... 34,35

LIMITED WARRANTY ...................................................................... 36

FEATURES

IMPORTANT

IT IS REQUIRED THAT A QUALIFIED SERVICE TECHNICIAN PERFORM THE INITIAL FIRING OF THE HEATER. AT THIS TIME THE USER SHOULD NOT HESITATE TO ASK THE TECHNICIAN ANY QUESTIONS WHICH HE MAY HAVE IN REGARD TO THE OPERATION AND MAINTENANCE OF THE UNIT.

A CHECKLIST AND SERVICE INFORMATION section are included at the rear of this manual. By using this checklist the user may be able to make minor operational adjustments and save himself unnecessary service calls. However, the user should not attempt repairs which are not listed in this section.

WATER TEMPERATURE CONTROL

TH I S WATER HE AT E R IS EQ U I P P E D WI T H AN AD J U S TA B L E

DANGER

THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT WATER TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHER AND LAUNDRY USE CAN CAUSE SCALD BURNS RESULTING IN SERIOUS PERSONAL INJURY AND/OR DEATH. THE TEMPERATURE AT WHICH INJURY OCCURS VARIES WITH THE PERSON’S AGE AND THE TIME OF THE EXPOSURE. THE SLOWER RESPONSE TIME OF CHILDREN, AGED OR DISABLED PERSONS INCREASES THE HAZARDS TO THEM. NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER TAP, OR TO DRAW THEIR OWN BATH WATER. NEVER LEAVE A CHILD OR DISABLED PERSON UNATTENDED IN A BATHTUB OR SHOWER.

THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET TEMPERATURES.

The water temperature is controlled using the Temperature Control Button on the Display at the front of the unit (See Figure 1). This control utilizes two temperature probes to determine the tank temperature. The primary temperature probe is located at the top of the tank and the other is near the water inlet.

The temperature may be adjusted from 90°F/32°C to 180°F/82°C. The thermostat was adjusted to 120°F/49°C before the heater was shipped from the factory. It is recommended that lower water temperature be used to avoid the risk of scalding. It is further recommended, in all cases, that the water

temperature be set for the lowest temperature which satises your hot water needs. This will also provide the most energy efcient operation of the water heater and minimize scale formation.

SETTING THE WATER HEATER TEMPERATURE AT 120°F/49°C WILL

REDUCE THE RISK OF SCALDS. Some states require settings at specic lower temperatures.

Figure 1 shows the approximate time-to-burn relationship for normal adult

skin. Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the thermostat setting by up to 20°F/11°C. If you experience this type of use, you should consider using lower temperature settings to reduce scald hazards.

Temperature Setting

180°F/82°C Nearly Instantaneous

170°F/77°C Nearly Instantaneous

160°F/71°C About 1/2 Second

150°F/66°C About 1-1/2 Seconds

140°F/60°C Less than 5 Seconds

130°F/54°C About 30 Seconds

120°F/49°C More than 5 Minutes

FIGURE 1.

Valves for reducing point-of-use temperature by mixing cold and hot water are available (see Figure 2). Also available are inexpensive devices that attach to faucets to limit hot water temperatures. Contact a licensed plumber or the local plumbing authority.

Time to Produce 2nd & 3rd

Degree Burns on Adult Skin

DISHWASHING MACHINE REQUIREMENT

All dishwashing machines meeting the National Sanitation Foundation requirements are designed to operate with water ow pressures between 15 and 25 pounds per square inch (103 Kpa and 173 Kpa). Flow pressures above 25 pounds per square inch (173 Kpa), or below 15 pounds per square inch (103 Kpa), will result in improperly sanitized dishes. Where pressures are high, a water pressure reducing or ow regulating control valve should be used in the 180°F (82°C) line to the dishwashing machine, and should be adjusted to deliver water between these limits.

The National Sanitation Foundation also recommends circulation of 180°F (82°C) water. Where this is done, the circulation should be very gentle so that it does not cause any unnecessary turbulence inside the water heater. The circulation should be just enough to provide 180°F (82°C) water at the point of take-off to the dishwashing machine. Adjust ow by means of the plug cock in the circulating line. (See installation diagrams.)

CIRCULATING PUMP

A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the heater. Refer to the piping diagrams at rear of manual for electrical hookup information and install in accordance with the current edition of the National Electrical Code, NFPA 70 or the Canadian Electrical Code, CSA C22.1.

All bronze circulators are recommended for used with commercial water heaters.

Although circulators are oiled and operated by the manufacturer some circulators must be oiled again before operated. Please refer to manufacturer's instructions.

FIGURE 2.

HIGH LIMIT SWITCH (E.C.O.)

The top immersion well of the dual bulb controller also contains the high limit (energy cutoff) sensor. The high limit switch interrupts the main burner gas ow should the water temperature reach approximately 202°F/94°C.

Should the high limit switch activate, the control system will automatically reset the unit once the water temperature in the tank falls below 140°F/60°C. If the unit is manually shut down and restarted, as long as the temperature in the tank is lower than 160°F/71°C, the unit will reset and initiate operation.

High limit switch operation is the likely cause when higher than normal water temperatures occur with a recurring need to restart the water heater. This could be due to a malfunctioning thermostat allowing the gas valve to remain open and the burner to continue ring even after water temperature in the tank has already reached the set point. Contact your dealer or servicer if continued high limit switch operation occurs.

INSTALLATION INSTRUCTIONS

REQUIRED ABILITY

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

INSULATION BLANKETS

Ins ul at io n blankets available to the general publ ic for external use on gas water heaters are not approved for use on your water heater. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank water heaters. Your water heater meets or exceeds the ASHRAE/IES 90.1 1999 standards with respect to insulati on and standby los s requirem en ts, making an insulation blanket unnecessary.

WARNING

Should you choose to apply an insulation blanket to this heater, you should follow these instructions. Failure to follow these instructions can result in re, asphyxiation, serious personal injury or death.

• Do not apply insulation to the top, or the upper 15" (38 cm) of the water heater, as this will interfere with safe operation.

• Do not cover the temperature & pressure relief valve.

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

• Do obtain new labels from manufacturer for placement on the blanket directly over the existing labels.

LOCATING THE HEATER

WARNING

THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH AS GAS WATER HEATERS IN ROOMS, GARAGES OR OTHER AREAS WHERE GASOLINE, OTHER FLAMMABLE LIQUIDS OR ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED, OPERATED OR REPAIRED. FLAMMABLE VAPORS ARE HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE IGNITED BY THE HEATER’S IGNITER OR MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION. SOME LOCAL CODES PERMIT OPERATION OF GAS APPLIANCES IF INSTALLED 18 INCHES (46 cm) OR MORE ABOVE THE FLOOR. THIS MAY REDUCE THE RISK IF LOCATION IN SUCH AN AREA CANNOT BE AVOIDED.

THE HEATER SHALL BE LOCATED OR PROTECTED SO IT IS NOT SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE.

DO NOT LOCATE THE HEATER WHERE NOISE FROM THE EXHAUST OR INTAKE WILL BE OBJECTIONABLE. THIS INCLUDES LOCATIONS CLOSE TO OR ACROSS FROM WINDOWS AND DOORS. AVOID ANCHORING THE VENT AND INTAKE PIPES DIRECTLY TO FRAMED WALLS, FLOORS OF CEILINGS UNLESS RUBBER ISOLATION PIPE HANGERS ARE USED. THIS PREVENTS ANY VIBRATIONS FROM BEING TRANSMITTED INTO THE LIVING SPACES.

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 ELBOW LOCATED AT THE BOTTOM OF THE UNIT. NOTE: IT IS IMPORTANT THAT THE CONDENSATE HOSE NOT BE ELEVATED ABOVE THE EXHAUST ELBOW (SEE FIGURE 3). THE CONDENSATE BUILD-UP WILL BLOCK THE EXHAUST OUTLET, WHICH WILL CAUSE IMPROPER OPERATION.

FIGURE 3.

WARNING

FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON OR ADJACENT TO THE HEATER. OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM WITH THE HEATER.

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

THE HEATER MUST NOT BE LOCATED IN AN AREA WHERE IT WILL BE SUBJECT TO FREEZING.

LOCATE IT NEAR A FLOOR DRAIN. THE HEATER SHOULD BE LOCATED IN AN AREA WHERE LEAKAGE FROM THE HEATER OR CONNECTIONS WILL NOT RESULT IN DAMAGE TO THE ADJACENT AREA OR TO LOWER FLOORS OF THE STRUCTURE.

When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance.

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-off device 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:

WARNING

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER. IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE APPLIANCE AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER.

CLEARANCES

These heaters are approved for installation on combustible ooring in an alcove when the minimum clearances from any combustion construction are followed as indicated in Figure 4.

In all installations the minimum combustible clearances from any vent piping shall be 0". Vent piping passing through a combustible wall or ceiling must be a continuous run (no joints).

A service clearance of 24" (61 cm) should be maintained from serviceable parts such as relief valves, ue bafes, ue damper devices, thermostats, cleanout openings or drain valves.

Always disconnect electrical power before servicing the unit.

• 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-off devices 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.

FIGURE 4.

*ILLUSTRATION OF MINIMUM COMBUSTIBLE CLEARANCES IN AN ALCOVE.

HARD WATER

Where hard water conditions exist, water softening or the threshold type of water treatment is recommended. This will protect the dishwashers, coffee urns, water heaters, water piping and other equipment.

See MAINTENANCE section for details of tank cleanout procedure.

AIR REQUIREMENTS

KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS.

DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATING AIR.

WARNING

FOR SAFE OPERATION PROVIDE ADEQUATE AIR FOR COMBUSTION AND VENTILATION. AN INSUFFICIENT SUPPLY OF AIR WILL CAUSE RECIRCULATION OF COMBUSTION PRODUCTS RESULTING IN CONTAMINATION THAT MAY BE HAZARDOUS TO LIFE. SUCH A CONDITION OFTEN WILL RESULT IN A YELLOW, LUMINOUS BURNER FLAME, CAUSING CARBONING OR SOOTING OF THE COMBUSTION CHAMBER, BURNERS AND FLUE TUBES AND CREATES A RISK OF ASPHYXIATION.

MECHANICAL EXHAUSTING OF ROOM AIR

Where an exhaust fan is installed in the same room with a heater, sufcient openings for air must be provided in the walls. UNDERSIZED OPENINGS WILL

CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE HEATER’S VENTING SYSTEM, CAUSING POOR COMBUSTION. SOOTING MAY RESULT IN SERIOUS DAMAGE TO THE HEATER AND RISK OF FIRE OR EXPLOSION. IT CAN ALSO CREATE A RISK OF ASPHYXIATION.

If the conned space is within a building of tight construction, air for combustion

and ventilation must be obtained from outdoors. When directly communicating with the outdoors 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 (6.5 cm²) per 4000 Btuh 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 (6.5 cm²) per

2000 Btuh of the total input of all appliances in the enclosure.

CHEMICAL VAPOR CORROSION

WARNING

CORROSION OF THE FLUE WAYS 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, waxes, and process chemicals are typical compounds which are potentially corrosive.

PRODUCTS OF THIS SORT SHOULD NOT BE STORED 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.

VENTING

WARNING

THE INSTRUC TIONS IN THIS SECT IO N ON VENTING MUS T BE FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULATION OF FLUE GASES. SUCH CONDITIONS CAUSE SOOTING OR RISKS OF FIRE AND ASPHYXIATION.

UNCONFINED SPACE

In buildings of conventional frame, brick or stone construction, unconned spaces may provide adequate air for combustion and ventilation.

If the unco nfi n ed space is wi thi n a buildi ng of tig ht const ruct ion (buildings 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 conned spaces in tightly constructed buildings must be followed to ensure adequate air supply.

CONFINED SPACE

When drawing combustion air from inside a conventionally constructed building to a conned space, such a space shall be provided with two permanent openings, ONE IN OR WITHIN 12" (31 cm) OF THE ENCLOSURE TOP AND ONE IN OR WITHIN 12" (31 cm) OF THE ENCLOSURE BOTTOM. Each opening shall have a free area of at least one square inch (6.5 cm²) per 1000 Btuh appliances in the enclosure, but not less than 100 square inches (645 cm²).

Heater must be protected from freezing downdrafts during shutdown periods.

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

NOTE: Before installing venting, determine place of vent pipe termination. See Figures 5a & b and 6a & b before proceeding.

CAUTION

DO NOT TERMINATE THE VENT ING WHERE NOISE FROM THE EXHAUST OR INTAKE WILL BE OBJECTIONABLE. THIS INCLUDES LOCATIONS CLOSE TO OR ACROSS FROM WINDOWS AND DOORS. AVOID ANCHORING THE VENT AND INTAKE PIPES DIRECTLY TO FRAMED WALLS, FLOORS OR CEILINGS UNLESS RUBBER ISOLATION PIPE HANGERS ARE USED. THIS PREVENTS ANY VIBRATIONS FROM BEING TRANSMITTED INTO THE LIVING SPACES.

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS

For all side wall terminated, horizontally vented power vent, direct vent, and power direct 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 nished grade in the

area of the venting, including but not limited to decks and porches, the following requirements shall be satised:

INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas

fueled equipment, the installing plumber or gastter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the oor level where the gas equipment is to be installed. In addition, the installing plumber or gastter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualied licensed professionals for the installation of hard wired carbon monoxide detectors.

In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent oor level.

In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and CSA certied.

SIGNAGE A metal or plastic identication plate shall be permanently mounted to the exterior of the building at a minimum

height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY

BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”

INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the

installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building, or structure used in whole or in part for residential purposes.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the ue gases, but identies “special venting systems,” the following requirements shall be satised by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation

instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting

instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or

equipment at the completion of the installation.

U.S. POWER VENT

FIGURE 5a.

CAUTION

TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE

IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN

THESE TWO TERMINALS IS RECOMMENDED.

CANADIAN POWER VENT

FIGURE 5b.

U.S. DIRECT VENT

FIGURE 6a.

CAUTION

TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE

IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN

THESE TWO TERMINALS IS RECOMMENDED.

CANADIAN DIRECT VENT

FIGURE 6b.

IMPORTANT

The vent system must terminate so that proper clearances are maintained as cited in local codes or the current editions of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the Natural Gas and Propane Installation Code,

CAN/CSA-B149.1.

Do not terminate the exhaust vent terminal over public area where condensate or vapor can cause nuisance or hazard.

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

Vent pipes serving power vented appliances are classied 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 CLEARANCES, and with National Fuel Gas Code and local Codes.

IMPORTANT

Plan the layout of the vent system backwards from the vent termination to the appliance.

FOR ALL MODELS

FIGURE 8.

IMPORTANT

WHEN LOCATING THE TERMINALS ON A SIDEWALL, THE FOLLOWING SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE FOLLOWED.

USE ONLY THE VEN T TERMINALS SUPPLI ED WITH THIS UNIT.

WARNING

TERMINATION OF A VENT SYSTEM WITH A DEVICE OTHER THAN TH E SUPP L IED VE NT TERMI N ATIO N S WILL A F FECT SYST E M PERFORMANCE AND RESULT IN A SAFETY HAZARD.

DIRECT VENTING

The air intake provided on the unit contains a mesh screen (see Figure 7) to prevent large particles from entering the unit.

FIGURE 7.

WARNING

WHEN THE UNIT IS TO BE SETUP AS A DIRECT VENT, THE MESH SCREEN MUST BE REMOVED. THE INLET VENT PIPE MAY THEN BE GLUED TO THE AIR INTAKE (see Figure 8) PROVIDED ON THE UNIT.

DIRECT VENT TERMINAL INSTALLATION

IMPORTANT

THIS UNIT CONSISTS OF TWO VENT TERMINALS - AN INTAKE VENT TERMINAL AND AN EXHAUST VENT TERMINAL. THE INTAKE VENT TERMINAL IS A 3" 45° PVC ELBOW WITH A DOME MESH WIRE SCREEN AND THE EXHAUST VENT TERMINAL IS A 3" 45°PVC ELBOW WITH A MESH WIRE SCREEN.

NOTE: TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN THESE TWO TERMINALS IS RECOMMENDED

1. The intake vent terminal and the exhaust vent terminal must terminate on the same exterior wall and must be located at a minimum of 24" (61cm) from the vertical centerline of the exhaust vent terminal (see Figure 9). In colder climates increasing the 24" (61cm) minimum will reduce possibility of frost over from side winds blowing exhaust vapors to the air intake of the direct vent.

2. The horizontal centerline of the intake vent terminal may not be located

lower than the horizontal centerline of the exhaust vent terminal

(see Figure 9).

INSTALLATION SEQUENCE

For installations in the City of Los Angeles, California Category IV PVC Pipe such as that manufactured by Brownline Pipe Company, must be used as vent pipe material

CAUTION

Vent terminals supplied with the heater must be used.

NOTE: BEFORE BEGINNING INSTALLATION OF ANY VENT PIPE READ THE VENT PIPE MANUFACTURER'S INSTALLATION INSTRUCTIONS.

1. After the points of termination have been determined, use the cover plates as templates to mark the holes for the vent pipes to be inserted through the wall. BEWARE OF CONCEALED WIRING AND PIPING INSIDE OF WALL.

2. If the vent terminals are being installed on the outside of a nished 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 holes as a centering point for the template.

3. A) MASONRY SIDE WALLS

Chisel an opening approximately 1/2" (1.3 cm) 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-all or sabre saw blade. Cut around the marked circle staying approximately one quarter inch outside of the line. (This will allow the vent pipe to easily slide through the opening. The resulting gap will be covered by the vent terminal cover plates.) Repeat this step on the inside wall if necessary.

4. Cut a length of 3" PVC pipe about 3.5" (8.9 cm) longer than the wall

thickness at the opening.

5. Glue the intake vent terminal to the section of the pipe.

VERTICAL VENT TERMINAL INSTALLATION

6. Slide the wall plate over the pipe to stop against intake vent terminal.

7. Place a bead of caulking (not supplied) around the gap between the pipe and the wall. Place some of the caulking on the back of the plate to hold it against the wall after installation.

8. 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 coupling on the other side of the wall, making sure that the vent terminal ends up pointed in the correct position (See Figure 9).

IMPORTANT

WH E N TERMINAT I N G TH R O U G H A RO O F, TH E FOLLOWING SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE FOLLOWED.

1. Proper support must be provided for all pipe protruding through the roof.

2. The vertical roof terminations should be sealed with a plumbing roof boot or equivalent ashing.

3. The intake vent termination and the exhaust vent termination must penetrate the same side of roof.

4. The center line of the intake vent termination and the center line of the exhaust vent termination must be no closer than 24" (61cm).

5. The intake vent terminal and the exhaust vent terminal must be oriented facing downward and the same direction.

The specications are displayed in Figure 10 & 11.

NOTE: Exhaust vent terminal is installed using the same procedure.

INSTALLATION SEQUENCE

NOTE: BEFORE BEGINNING INSTALLATION OF ANY VENT PIPE, READ “VENT PIPE PREPARATION” SECTION ON PAGE 12.

FIGURE 9.

1. After the points of termination have been determined, use the cover plates as templates to mark the holes for the vent pipes to be inserted through the roof.

2. Drill a pilot hole approximately 1/4" (6 mm) outside of the marked circle. This pilot hole is used as a starting point for a saws-all or sabre saw blade. Cut around the marked circle staying approximately one quarter inch outside the line. (This will allow the vent pipe to easily slide

through the opening). The resulting gap will be covered by the roof

boot/ashing.

3. Suspend the pipe through the center of the hole using proper support.

4. Slide roof boot or equivalent ashing over pipe and secure roof boot equivalent ashing to roof.

5. Seal around ashing.

6. Terminate intake terminal and exhaust vent terminal facing down as shown in Figure 11.

FIGURE 10.

FIGURE 11.

INSTALLATION OF VENT SYSTEM

Propane Installation Code which requires the vent system components be certied to ULC S636.

THE OPTIONAL INTAKE VENTING ARRANGEMENT AND THE EXHAUST

WARNING

VENTING ARRANGEMENT MUST BE INSTALLED TO RUN DIRECTLY TO THE OUTDOORS AND NOT IN ANY WAY BE CONNECTED TO ANOTHER VENTING SYSTEM (I.E. FURNACE, DRYERS OR SPACE HEATERS). IT IS CRUCIAL THAT THE VENTING ARRANGEMENT BE KEPT SEPARATE FROM OTHER VENTING SYSTEMS. IF THIS WARNING IS IGNORED, AND THE SYSTEM IS VENTED INCORRECTLY, IT MAY CAUSE IMPROPER OPERATION, FIRE, EXPLOSION, OR ASPHYXIATION.

1. Plan the route of the vent system from the vent termination to the planned location of the appliance. Layout the total vent system to use the minimum of vent pipe and elbows possible.

2. The installer may add up to a MAXIMUM OF FIFTY (50) EQUIVALENT FEET (15.2 m) of pipe to the exhaust venting arrangement. This addition of FIFTY (50) EQUIVALENT FEET (15.2 m) of pipe on both the intake venting arrangement and exhaust venting arrangement must include any 3" PVC elbows which equals (5) EQUIVALENT FEET (1.5 m) of pipe.

3. It is important that condensate not be allowed to buildup in the exhaust vent pipe. To prevent this from happening the pipe should be installed with a slight, 1/8" (3mm) per 5' (152 cm) of pipe maximum downward slope.

4. The vent system should be supported every 5' (152 cm) of vertical run and every 3' (91cm) of horizontal run of vent pipe length.

Table 2. VENT LENGTH TABLE

Number 3" 3" 4"

of 90° Minimum Maximum Maximum

Elbows Pipe (Ft./M.) Pipe (Ft./M.) Pipe (Ft./M.)

ONE (1) 7/2 45/13.7 115/35 TWO (2) 7/2 40/12.2 110/33.5 THREE (3) 7/2 35/10.7 105/32 FOUR (4) 7/2 30/9.1 100/30.5

FIVE (5) 7/2 --- 95/29

SIX (6) 7/2 --- 90/27.4

4" PVC may be used for a MAXIMUM intake of ONE HUNDRED TWENTY (120) EQUIVALENT FEET (36.6m) and a MAXIMUM exhaust of ONE HUNDRED TWENTY (120) EQUIVALENT FEET (36.6m). The maximum number of 90° elbows with the 4" venting is six (6) on the intake and six (6) on the exhaust. A 90° elbow is equal to ve (5) equivalent feet (1.5m) of pipe. One (1) 90° elbow is equal to two (2) 45° elbows. Any venting conguration using less than 50 equivalent feet should use 3" venting. See Table 2.

The 3 " ve n t i ng t e r mi nal s ( pr ovi d e d ) mu s t be u s ed w i t h th e

3" vent pipe. Two, approved 4" vent terminals (not provided) must be used with 4" vent pipe. See replacement parts list for terminals.

IMPORTANT

When multiple units are direct vented through a wall (3" or 4" venting), all intake vent terminals should be no lower than the highest exhaust vent terminal.

U.S. INSTALLATIONS

NOTE: This unit can be vented using only PVC (Class 160, ASTM D-2241

Schedule 40, ASTM D-1785 ; or Cellular Core Schedule 40 DWV, ASTM

F-891) , Schedule 40 CPVC (ASTM F-411), or ABS (ASTM D-2661) pipe.

The ttings, other than the TERMINATIONS should be equivalent to PVC-

DWV ttings meeting ASTM D-2665 (Use CPVC ttings, ASTM F-438 for CPVC pipe and ABS ttings, ASTM D-2661/3311 for ABS pipe. If CPVC or ABS pipe and ttings are used, then the proper cement must be used for all joints, including joining the pipe to the Termination (PVC Material). PVC Materials should use ASTM D-2564 Grade Cement; CPVC Materials should

use ASTM F-493 Grade Cement and ; ABS Materials should use ASTM

D-2235 Grade Cement.

CANADIAN INSTALLATIONS This water heater must comply with CAN/CSA B149.1 - Natural Gas and

This water heater has been design certied to be vented with PVC pipe certied and marked as complying with ULC S636. This water heater is supplied with a 2 inch 22.5 degree termination elbow that is a special tting that must be used with the appliance. Any outlet piping, ttings and glue used to vent this appliance that is not supplied by the manufacturer must comply with the ULC S636 requirements.

PVC Materials should use ASTM D-2564 Grade Cement; CPVC Materials should use ASTM F-493 Grade Cement and ABS Materials should use ASTM D-2235 Grade Cement.

If the water heater is being installed as a replacement for an existing power vented heater in pre-existing venting, a thorough inspection of existing venting system must be performed prior to any installation work. Verify that 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 joints between elbows and other ttings and straight runs of vent pipe. Check system for signs of sagging or other stresses in 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 installation and putting the water heater into service.

NOTE: for Water Heaters in locations with high ambient temperatures (above 100°F or 38°C) and/or insufcient dilution air, it is recommended that CPVC or

ABS pipe and ttings (MUST USE SUPPLIED VENT TERMINAL) be used.

NOTE: Stress levels in the pipe and ttings can be signicantly increased by improper installation. If rigid pipe clamps are used to hold the pipe in place, or if the pipe cannot move freely through a wall penetration, the pipe may be directly stressed, or high thermal stresses may be formed when the pipe heats up and expands. Install accordingly to minimize such stresses.

VENT PIPE PREPARATION

1. INITIAL PREPARATION

A. Make sure the solvent cement you are planning to use is designed

for the specic application you are attempting.

B. Know the physical and chemical characteristics and limitations of

the PVC, PVC cellular core, ABS or CPVC piping materials that you

are about to use.

C. Know the reputation of your pipe and cement manufacturer and

their products.

D. Know your own qualications or those of your contractor. The solvent

welding technique of joining PVC, PVC cellular core, ABS or CPVC

pipe is a specialized skill just as any other pipe tting technique.

E. Closely supervise the installation and inspect the nished job before

start-up.

F. Contact the manufacturer, supplier, or competent consulting agency

if you have any questions about the application or installation of

PVC, PVC cellular core, ABS or CPVC pipe.

G. Take the time and effort to do a professional job. Shortcuts will only

cause you problems and delays in start-up. The majority of failures in these systems are the result of shortcuts and/or improper joining

techniques.

2. SELECTION OF MATERIALS

PRIMER

It is recommended that Tetrahydrofuran (THF) be used to prepare the surfaces of pipe and ttings for solvent welding. Do not use water, rags, gasoline or any other substitutes for cleaning PVC cellular core, ABS or CPVC surfaces. A chemical cleaner such as MEK may be used.

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