A.O. Smith 101, 100 User Manual
CYCLONE Xi Model BTH 120-250(A)
SERIES 100 AND 101
COMMERCIAL GAS WATER HEATER
GAS-FIRED POWER BURNER
FOR DOMESTIC HOT W A TER
• INST ALLATION • OPERA TION • SER VICE • MAINTENANCE • LIMITED W ARRANTY
WARNING: 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 neighbor's 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 .
Thank you for buying this energy efficient water heater from
A.O. Smith Water Products Company. We appreciate your
confidence 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.
PLACE THESE INSTRUCTIONS ADJACENT TO HEA TER AND
NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED IN U.S.A. 0307 PART NO. 197727-000
1
A DIVISION OF A.O. SMITH CORPORATION
Mc BEE, SOUTH CAROLINA
CYCLONE Xi BTH 120 - 250A ROUGH-IN-DIMENSIONS
GAS VAL VE PIPING
BTH-120, 199 & 250 1/2" NPT
BTH-150 3/4" NPT
T able 1. RECOVERY CAP ACITIES - NA TURAL GAS / L.P.
Approx.
Input Gas Gallon TEMPERA TURE RISE - DEGREES °F - GALLONS PER HOUR
Model BTU/Hr. Usage Capacity 30 40 50 60 70 80 90 100 110 120 130 140
BTH 120 120,000 nat/lp 60 461 345 276 230 197 173 154 138 126 115 106 99
BTH 150 150,000 nat/lp 100 576 432 345 288 247 216 192 173 157 144 133 123
BTH 199 199,900 nat/lp 100 767 575 460 384 329 288 256 230 209 192 177 164
BTH 250 250,000 nat/lp 100 960 720 576 480 411 360 320 288 262 240 221 206
Approx.
Gas Liter TEMPERATURE RISE - DEGREES C - Liters PER HOUR
Model kW-Hr Usage Capacity 17 22 28 33 39 44 50 56 61 67 72 78
BTH 120 35 nat/lp 227 1744 1308 1046 872 747 654 581 523 476 436 402 374
BTH 150 4 4 nat/lp 379 2179 1635 1308 1090 934 817 726 654 594 545 503 467
BTH 199 5 8 nat/lp 379 2904 2178 1743 1452 1245 1089 968 871 792 726 670 622
BTH 250 7 3 nat/lp 379 3632 2724 2179 1816 1557 1362 1211 1090 991 908 838 778
Recovery capacities are based on 95% thermal efficiency.
FOREWORD
These designs comply with the current edition of the American National
Standard for Gas W ater Heaters, V olume 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, NFP A 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 V alley Road, Cleveland, OH 44131. NFP A document s are also
available from the National Fire Protection Association, 1 Batterymarch
Park, Quincy, MA 02269.
2
TABLE OF CONTENTS
PAGE 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
INSTALLA TION 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
Unconfined Space ........................................................................ 6
Confined 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
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
OPERATIING 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 INFORMA TION ................................................................ 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
INSTALLA TION DIAGRAMS............................................................. 28-32
Manifold Kits................................................................................ 33
CHECKLIST AND SERVICE INFORMATION ...................................... 34
TROUBLE-SHOOTING...................................................................... 34,35
LIMITED WARRANTY....................................................................... 36
FEATURES
IMPORT ANT
IT IS REQUIRED THA T A QUALIFIED SER VICE TECHNICIAN PERFORM THE
INITIAL FIRING OF THE HEA TER. A T THIS TIME THE USER SHOULD NOT
HESITATE TO ASK THE TECHNICIAN ANY QUESTIONS WHICH HE MA Y
HAVE IN REGARD TO THE OPERATION AND MAINTENANCE OF THE UNIT.
A CHECKLIST AND SERVICE INFORMA TION 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.
WA TER TEMPERA TURE CONTROL
DANGER
THIS WA TER HEATER IS EQUIPPED WITH A N ADJUST ABLE THERMOSTA T
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 H AVE 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
3
water temperature be set for the lowest temperature which satisfies your
hot water needs. This will also provide the most energy efficient operation
of the water heater and minimize scale formation.
SETTING THE WATER HEA TER TEMPERA TURE A T 120°F/49°C WILL REDUCE
THE RISK OF SCALDS. Some states require settings at specific 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 Time to Produce 2nd & 3rd
Setting Degree Burns on Adult Skin
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.
DISHWASHING MACHINE REQUIREMENT
All dishwashing machines meeting the National Sanitation Foundation
requirements are designed to operate with water flow 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 flow 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 flow by means of the
plug cock in the circulating line. (See installation diagrams.)
CIRCULA TING 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, NFP A 70 or the Canadian Electrical Code,
CSA C22.1.
All bronze circulators are recommended for used with commercial
water heaters.
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 flow 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 firing 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.
Although circulators are oiled and operated by the manufacturer
some circulators must be oiled again before operated. Please
refer to manufacturer's instructions.
INSTALLATION INSTRUCTIONS
REQUIRED ABILITY
INST ALLATION OR SERVICE OF THIS WA TER 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.
INSULA TION BLANKETS
Insulation blankets available to the general public for external use on gas
water heaters are not approved for use on your A.O. Smith water heater.
The purpose of an insulation blanket is to reduce the standby heat loss
encountered with storage tank water heaters. Your A.O. Smith water
heater meets or exceeds the ASHRAE/IES 90.1 1999 standards with
respect to insulation and standby loss requirements, making an insulation
blanket unnecessary.
Should you choose to apply an insulation blanket to this heater, you should
follow these instructions. Failure to follow these instructions can result in
fire, 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 A.O. Smith for placement on the blanket
directly over the existing labels.
WARNING
4
LOCA TING 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, OPERA TED OR REP AIRED. FLAMMABLE
VAPORS ARE HEA VY AND TRA V EL ALONG THE FLOOR AND MAY BE
IGNITED BY THE HEA TER’S IGNITER OR MAIN BURNER FLAMES CAUSING
FIRE OR EXPLOSION. SOME LOCAL CODES PERMIT OPERA TION OF GAS
APPLIANCES IF INST ALLED 18 INCHES (46 cm) OR MORE ABOVE THE
FLOOR. THIS MA Y REDUCE THE RISK IF LOCA TION IN SUCH AN AREA
CANNOT BE A VOIDED.
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 LOCA TIONS CLOSE TO
OR ACROSS FROM WINDOWS AND DOORS. AVOID ANCHORING THE VENT
AND INTAKE PIPES DIRECTL Y T O FRAMED WALLS, FLOORS OF CEILINGS
UNLESS RUBBER ISOLATION PIPE HANGERS ARE USED. THIS PREVENTS
ANY VIBRATIONS FROM BEING TRANSMITTED INTO THE LIVING SP ACES.
WARNING
FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY OTHER
POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON
OR ADJACENT TO THE HEA TER. OPEN CONT AINERS 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 LOCA TED IN AN AREA WHERE IT WILL BE
SUBJECT TO FREEZING .
LOCA TE IT NEAR A FLOOR DRAIN. THE HEA TER SHOULD BE LOCA TED IN
AN AREA WHERE LEAKAGE FROM THE HEA TER OR CONNECTIONS WILL
NOT RESULT IN DAMAGE TO THE ADJACENT AREA OR TO LOWER FLOORS
OF THE STRUCTURE.
WARNING
THIS WA TER HEA TER IS A CONDENSING UNIT AND REQUIRES A DRAIN
TO BE LOCATED IN CLOSE PROXIMITY TO ALLOW THE CONDENSATE
TO DRAIN SAFEL Y. THE CONDENSATE DRAINS FROM THE UNIT A T THE
EXHAUST ELBOW LOCATED A T THE BOTT OM OF THE UNIT. NOTE: IT IS
IMPORT ANT THA T THE CONDENSATE HOSE NOT BE ELEV A TED ABOVE
THE EXHAUST ELBOW (SEE FIGURE 3). THE CONDENSA TE BUILD-UP
WILL BLOCK THE EXHAUST OUTLET , WHICH WILL CAUSE IMPROPER
OPERATION.
FIGURE 3.
WARNING
DO NOT USE THIS APPLIANCE IF ANY PA RT HAS BEEN UNDER WA TER.
IMMEDIATEL Y CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE
APPLIANCE AND TO REPLACE ANY PA RT OF THE CONTROL SYSTEM AND
ANY GAS CONTROL WHICH HAS BEEN UNDER W ATER.
CLEARANCES
These heaters are approved for installation on combustible flooring 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).
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:
• 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.
A service clearance of 24" (61 cm) should be maintained from serviceable
parts such as relief valves, flue baffles, flue damper devices, thermostats,
cleanout openings or drain valves.
Always disconnect electrical power before servicing the unit.
FIGURE 4.
*ILLUSTRATION OF MINIMUM COMBUSTIBLE CLEARANCES IN AN
ALCOVE.
5
HARD WA TER
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 MA TERIALS,
GASOLINE AND OTHER FLAMMABLE V APORS AND LIQUIDS.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILA TING AIR.
WARNING
FOR SAFE OPERA TION PROVIDE ADEQUA TE AIR FOR COMBUSTION AND
VENTILATION. AN INSUFFICIENT SUPPLY OF AIR WILL CAUSE
RECIRCULATION OF COMBUSTION PRODUCTS RESULTING IN
CONT AMINATION THA T MAY BE HAZARDOUS TO LIFE. SUCH A CONDITION
OFTEN WILL RESUL T IN A YELLOW , LUMINOUS BURNER FLAME, CAUSING
CARBONING OR SOOTING OF THE COMBUSTION CHAMBER, BURNERS
AND FLUE TUBES AND CREATES A RISK OF ASPHYXIA TION.
MECHANICAL EXHAUSTING OF ROOM AIR
Where an exhaust fan is installed in the same room with a heater, sufficient
openings for air must be provided in the walls. UNDERSIZED OPENINGS
WILL CAUSE AIR TO BE DRA WN INTO THE ROOM THROUGH THE HEATER’S
VENTING SYSTEM, CAUSING POOR COMBUSTION. SOOTING MAY RESUL T
IN SERIOUS DAMAGE TO THE HEA TER AND RISK OF FIRE OR EXPLOSION.
IT CAN ALSO CREA TE A RISK OF ASPHYXIA TION.
UNCONFINED SP ACE
In buildings of conventional frame, brick or stone construction, unconfined
spaces may provide adequate air for combustion and ventilation.
If the unconfined space is within a building of tight construction (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 confined spaces
in tightly constructed buildings must be followed to ensure adequate air
supply.
CONFINED SPACE
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 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 V APOR CORROSION
WARNING
CORROSION OF THE FLUE WA YS AND VENT SYSTEM MA Y OCCUR IF AIR
FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS. SUCH
CORROSION MAY RESULT IN F AILURE AND RISK OF ASPHYXIA TION.
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 ST ORED NEAR THE HEA TER.
ALSO, AIR WHICH IS BROUGHT IN CONTACT WITH THE HEATER
SHOULD NOT CONT AIN ANY OF THESE CHEMICALS. IF NECESSARY,
UNCONT AMINATED AIR SHOULD BE OBTAINED FROM REMOTE OR OUTSIDE
SOURCES.
VENTING
WARNING
THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST BE FOLLOWED
TO A VOID CHOKED COMBUSTION OR RECIRCULA TION OF FLUE GASES.
SUCH CONDITIONS CAUSE SOOTING OR RISKS OF FIRE AND
ASPHYXIATION.
Heater must be protected from freezing downdrafts during shutdown periods.
WARNING
NEVER OPERATE THE HEA TER UNLESS IT IS VENTED TO THE OUTDOORS
AND HAS ADEQUATE AIR SUPPLY TO AVOID RISKS OF IMPROPER
OPERA TION, FIRE, EXPLOSION OR ASPHYXIA TION.
VENT PIPE TERMINATION
NOTE: Before installing venting, determine place of vent pipe termination.
See Figures 5a & b and 6a & b before proceeding.
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 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).
CAUTION
DO NOT TERMINA TE THE VENTING WHERE NOISE FROM THE EXHAUST OR
INTAKE WILL BE OBJECTIONABLE. THIS INCLUDES LOCATIONS CLOSE T O
OR ACROSS FROM WINDOWS AND DOORS. A VOID ANCHORING THE VENT
AND INTAKE PIPES DIRECTL Y TO FRAMED WALLS, FLOORS OR CEILINGS
UNLESS RUBBER ISOLA TION PIPE HANGERS ARE USED. THIS PREVENTS
ANY VIBRATIONS FROM BEING TRANSMITTED INTO THE LIVING SP ACES.
6
INST ALLA TION REQUIREMENTS FOR THE COMMONWEAL TH 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 finished
grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:
INST ALLA TION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled
equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and
battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or
gasfitter 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 qualified 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 floor 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 certified.
SIGNAGE A metal or plastic identification 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 NFP A 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 p art s for venting the flue gases, but
identifies “special venting systems,” the following requirements shall be satisfied 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.
7
U.S. POWER VENT
FIGURE 5a.
CAUTION
TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULA TING TO THE AIR INT AKE
IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN
THESE TWO TERMINALS IS RECOMMENDED.
CANADIAN POWER VENT
FIGURE 5b.
8
U.S. DIRECT VENT
FIGURE 6a.
CAUTION
TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULA TING TO THE AIR INT AKE
IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DIST ANCE BETWEEN
THESE TWO TERMINALS IS RECOMMENDED.
CANADIAN DIRECT VENT
FIGURE 6b.
9
IMPORT ANT
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 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 CLEARANCES, and with National Fuel
Gas Code and local Codes.
FOR ALL
MODELS
FIGURE 8.
IMPORT ANT
IMPORT ANT
Plan the layout of the vent system backwards from the vent termination to
the appliance.
WARNING
USE ONL Y THE VENT TERMINALS SUPPLIED WITH THIS UNIT. TERMINA TION
OF A VENT SYSTEM WITH A DEVICE OTHER THAN THE SUPPLIED VENT
TERMINATIONS WILL AFFECT SYSTEM PERFORMANCE AND RESUL T 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 T O BE SETUP AS A DIRECT VENT , THE MESH SCREEN
MUST BE REMOVED. THE INLET VENT PIPE MA Y THEN BE GLUED TO THE
AIR INTAKE (see Figure 8) PROVIDED ON THE UNIT .
DIRECT VENT TERMINAL INST ALLATION
IMPORT ANT
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 CIRCULA TING T O
THE AIR INTAKE IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL
DISTANCE BETWEEN THESE TWO TERMINALS IS RECOMMENDED.
WHEN LOCA TING THE TERMINALS ON A SIDEW ALL, THE FOLLOWING
SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE
FOLLOWED.
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).
INST ALLATION 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 INST ALLATION OF ANY VENT PIPE READ THE
VENT PIPE MANUFACTURER'S INST ALLA TION 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 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 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.
10
5. Glue the intake vent terminal to the section of the pipe.
VERTICAL VENT TERMINAL INST ALLA TION
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).
IMPORT ANT
WHEN TERMINA TING THROUGH A ROOF , THE FOLLOWING SPECIFICATIONS
PERT AINING 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 flashing.
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 specifications are displayed in Figure 10 & 11.
NOTE: Exhaust vent terminal is installed using the same procedure.
INST ALLATION SEQUENCE
NOTE: BEFORE BEGINNING INSTALLA TION OF ANY VENT PIPE, READ
“VENT PIPE PREPARA TION” SECTION ON P AGE 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/flashing.
3. Suspend the pipe through the center of the hole using proper support.
4. Slide roof boot or equivalent flashing over pipe and secure roof boot
equivalent flashing to roof.
5. Seal around flashing.
6. Terminate intake terminal and exhaust vent terminal facing down as
shown in Figure 11.
FIGURE 10.
FIGURE 11.
11
INST ALLA TION OF VENT SYSTEM
WARNING
THE OPTIONAL INT AKE VENTING ARRANGEMENT AND THE EXHAUST
VENTING ARRANGEMENT MUST BE INST ALLED TO RUN DIRECTL Y TO THE
OUTDOORS AND NOT IN ANY WA Y BE CONNECTED TO ANOTHER VENTING
SYSTEM (I.E. FURNACE, DRYERS OR SPACE HEA TERS). IT IS CRUCIAL
THAT THE VENTING ARRANGEMENT BE KEPT SEPA RATE FROM OTHER
VENTING SYSTEMS. IF THIS WARNING IS IGNORED, AND THE SYSTEM IS
VENTED INCORRECTL Y , I T MA Y CAUSE IMPROPER OPERA TION, FIRE,
EXPLOSION, OR ASPHYXIA TION
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.
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 five (5) equivalent feet (1.5m) of
pipe. One (1) 90° elbow is equal to two (2) 45° elbows. Any venting
configuration using less than 50 equivalent feet should use 3" venting. See
T able 2.
The 3" venting terminals (provided) must be used with the
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.
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 fittings, other than the TERMINATIONS should be equivalent to PVCDWV fittings meeting ASTM D-2665 (Use CPVC fittings, ASTM F-438 for
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
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.
NOTE: for Water Heaters in locations with high ambient temperatures
(above 100°F or 38°C) and/or insufficient dilution air, it is recommended that
CPVC or ABS pipe and fittings (MUST USE SUPPLIED VENT TERMINAL) be
used.
4. 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.
5. The vent system should be supported every 5' (152 cm) of vertical run
and every 3' (91cm) of horizontal run of vent pipe length.
NOTE: Stress levels in the pipe and fittings can be significantly 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 PREP ARATION
1. INITIAL PREPARA TION
A. Make sure the solvent cement you are planning to use is designed
for the specific 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 qualifications 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 fitting technique.
E. Closely supervise the installation and inspect the finished 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 fittings 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.
CEMENT
The cement should be a bodied cement of approximately 500 to 1600
centipoise viscosity containing 10-20% (by weight) virgin PVC material
solvated with tetrahydrofuran (THF). Small quantities of dimethyl formamide
(DMF) may be included to act as a retarding agent to extend curing time.
Select the proper cement; Schedule 40 cement should be used for Schedule
40 pipe. Never use all-purpose cements, commercial glues and adhesives
or ABS cement to join PVC or CPVC pipe and fittings.
SAFETY PRECAUTION: PRIMERS AND CEMENTS ARE EXTREMELY
FLAMMABLE AND MUST NOT BE STORED OR USED NEAR HEAT OR
OPEN FLAME. ALSO, USE ONL Y IN A WELL-VENTILA TED AREA.
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