A.O. Smith ACI-CRS-24B2B-N, ACI-CRS-24B2B-P, ACI-CRS-34B2B-N, ACI-CRS-34B2B-P, ACI-CRS-36B2B-N Installation Manual

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A.O. Smith ACI-CRS-24B2B-N, ACI-CRS-24B2B-P, ACI-CRS-34B2B-N, ACI-CRS-34B2B-P, ACI-CRS-36B2B-N Installation Manual

ON DEMAND RACK SYSTEM

INSTALLATION MANUAL

FREE STANDING (BACK-TO-BACK)

FREE STANDING

(IN-LINE)

 

WALL MOUNT

 

Table of Contents Page

 

 

 

Page

Important Safety Informa on.............................................................

2

Ge ng Started ...................................................................................

3

Installa on..........................................................................................

4

Maintenance ....................................................................................

10

Specifica

ons: Wall Mount (42” Frame Width)................................

12

Specifica

ons: Wall Mount (62.81” Frame Width) ..........................

14

Specifica

ons: Free Standing (41.54” Frame Width)........................

16

Specifica

ons: Free Standing (62.29” Frame Width)........................

18

Replacement Parts ...........................................................................

20

1 Year Limited Parts Warranty..........................................................

24

ADDITIONAL INFORMATION IS PROVIDED IN THE WATER HEATER’S INSTALLATION MANUAL AND OWNER’S GUIDE. A COPY IS PROVIDED WITH EACH WATER HEATER IN THE ASSEMBLY.

WARNING: If the informa on in these instruc ons 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 instruc ons.

If you cannot reach your gas supplier, call the fire department.

Installa on and service must be performed by a qualified installer, service agency or the gas supplier.

INSTALLATION MUST BE PERFORMED BY QUALIFIED SERVICE PROFESSIONALS ONLY.

2000539909_100281805 (A) March 2017

SAFETY

IMPORTANT SAFETY INFORMATION

Read and follow all safety messages and instruc ons in this manual.

This is the safety alert symbol. It is used to alert you to poten al physical injury hazards. Obey all safety messages that follow this symbol to avoid possible property damage, serious injury or death. Do not remove any

permanent instruc ons, labels, or the data plate from either the outside of the water heater or on the inside of the access panels. Keep this manual near the water heater.

 

 

 

DANGER indicates hazardous situa-

 

DANGER

 

 

 

on that, if not avoided, will result

 

 

in death or serious injury.

 

 

 

 

 

 

 

 

 

 

WARNING indicates a hazardous

 

WARNING

 

 

situa on that, if not avoided, could

 

 

result in death or serious injury.

 

 

 

 

 

 

 

CAUTION indicates a hazardous

 

CAUTION

 

 

situa on that, if not avoided, could

 

 

result in minor or moderate injury.

 

 

 

 

 

 

 

NOTICE indicates prac ces not

 

NOTICE

 

 

related to physical injury.

 

 

 

 

 

 

 

 

 

 

 

WARNING! If the informa on in these instruc ons 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.

An odorant is added by the gas supplier to the gas used by this water heater. This odorant may fade over an extended period of me. Do not depend upon this odorant as an indica on of leaking gas. We recommend installing a fuel gas and carbon monoxide

detector.

Installa on includes the connec on of gas lines, water lines, valves and electricity. Knowledge of applicable na onal, state, and local codes is necessary. Therefore, installa on must be performed only by qualified service professionals.

Read and follow all instruc ons, cau ons, and warnings in the water heaters’ Installa on Manuals/Owner’s Guides.

2 • On-Demand Rack System

GETTING STARTED

WARNING

Follow all local codes during installation. In the absence of local codes, follow the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 (current edition) in the USA, or in Canada, follow CAN/CSA B149.1, Natural Gas and Propane Installation Code (current edition). Failure to do

so may cause death, personal injury, or property damage.

Product Registration

The rack system itself does not require registration. However, each water heater within the system should be registered. To do so, fill out and return the registration card for each water heater. (Each water heater is provided with its own manual and registration card.) Alternatively, you may register through the website listed on the registration card.

General Information

The On-Demand Rack System includes both wall-mounted and free standing configurations, and several options are available within each type. Refer to the

Specifications section.

For questions regarding general operation, refer to the water heaters’ manuals.

Venting

Venting components are not supplied with the rack system and must be obtained separately. For venting instructions, refer to the water heaters’ installation manuals/owner’s guides.

Installation

Requirements

Observe the water heaters’

installa on requirements as outlined in their installa on manual.

Installa on and service must be performed by a qualified service professional, such as a licensed plumber or gas fi er. Otherwise, the warranty will be void.

The installer is responsible for the correct installa on of the water heater and for compliance with all code requirements.

Place the water heaters in a loca on that provides easy access for service and maintenance.

Do not Install the system in a pit or loca on where gas and water can accumulate.

Do not allow the vent terminals to point toward any opera ng window, door, or opening into a building.

Do not install the system next to any source of airborne debris that can cause debris to be trapped inside the combus on chambers (unless the system is direct vented).

The power supply must be 120 VAC (60 Hz) and must be properly grounded.

Indoor Models

Do not install indoor models outdoors.

• Due to safety concerns, a c installa ons are not recommended. If you install the system in an a c:

Make sure the water heaters will have enough combus on air and proper ven la on. Refer to the installa on manual for the water heaters.

Keep the area around the water heaters clean. When dust collects on the flame sensors,

the water heaters will shut down and produce an error code.

A drain pan, or other means of protec on against water damage, is required to be

installed under the water heaters in case of leaks.

It is recommended to direct vent the water heaters.

Ensure that the surrounding areas are protected from poten al water damage (i.e., condensate discharge, etc.). In the absence of local codes and regula ons, it is recommended that condensate be disposed of in a standard drain.

Outdoor Models

Do not install outdoor models indoors.

Outdoor models must be installed only in an area with a mild, temperate climate. Also, refer to the water heaters’ manual for freeze

protec on informa on.

Ensure that the installa on is in an open, unroofed area with minimum clearances observed.

Ensure that the surrounding areas are protected from poten al water damage (i.e., condensate discharge, etc.). In the absence of local codes and regula ons, it is recommended that condensate be disposed of in a standard drain.

GETTING STARTED

On-Demand Rack System • 3

INSTALLATION

INSTALLATION

1Install the Rack(s)

When installing the rack(s), you must comply with the water heaters’ installation requirements. Refer to the Installation Manual and Owner’s Guide.

See also Installation Requirements on page 3.

WARNING! The floor or wall must be able to support the rack system in a secure and safe manner. Follow local and state code requirements. Failure to do so can lead to loss of life, personal injury, and/or property damage.

Areas prone to earthquakes may have addi onal code requirements. Prior to installa on, contact the local authority having jurisdic on over installa on requirements.

Ensure that you use floor/ wall anchors with an adequate weight ra ng.

This rack system and its water heaters must be installed according to all local and state codes or, in the absence of local and state codes, the “Na onal Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edi on.

Install the rack(s) in a loca on where the proper amount of combus ble air will be available to

it at all mes without obstruc ons. (Refer to the water heaters’

Installation Manual and Owner’s Guide.)

The system must be installed in a loca on that provides easy access for service and maintenance.

Outdoor Systems:

Ensure that the installa on is in an

open, unroofed area with minimum

NOTICE: Wall mount racks are

clearances observed.

shipped with li ing brackets in

Wall Mounted Rack

place. See Figure 1. These lifting

brackets are actually wall mount

A. Before you begin, read all warnings

brackets that have been rotated

and bullet points at the beginning of

90 degrees. They will allow you to

this sec on.

hoist the rack without the use of

B. Determine your installa on

straps. Use a spreader lifting bar

loca on, then confirm that the

as shown in Figure 2 to ensure that

clearance requirements are met.

the lifting force is vertical.

(Refer to the water heater manual

C. A ach the rack to the wall, and

and applicable code.)

ensure that it is secure. The rack

 

 

must be secured at each moun ng

Figure 1: Lifting Brackets

bracket. NOTE: The moun ng

 

brackets can be moved along the

 

channel to line up with the framing.

Figure 2: Spreader Lifting Bar

4 • On-Demand Rack System

The clearance hole in each moun ng bracket is 1/2-inch in diameter. Fasteners must be appropriate for the weight of the rack and the material to which it is being mounted. When

in doubt, consult a licensed structural engineer.

Use a leveling tool to make sure that the assembly is level. To operate properly, the assembly must be level and the water heaters must be in an upright posi on (as shown in Figure 3, page 6).

Free Standing Rack

A.Before you begin, read all warnings and bullet points at the beginning of this sec on.

B.Place the rack and ensure that it is level.

NOTICE:

You may need to use straps to ensure that the li ing force is ver cal.

C.Verify that the clearance requirements are met. (Refer to the water heater manual and applicable code.)

D.Anchor the rack to the floor at each leg. It must be secure and must not allow movement.

NOTICE: The clearance hole in each leg is 1/2-inch in diameter. Fasteners must be appropriate for the material to which the rack is being mounted. When in doubt, consult a licensed structural engineer.

Mul -Unit Controller

If your installation includes more than four water heaters, you will need to install a multi-unit controller. See the configuration section on page 7 for more information.

Piping Requirements

Piping for up to six water heaters:

A rack system is designed with piping to handle up to six water heaters. If the job requires four to six heaters in more than one format, then you can use two racks that provide the sum total of the required number of heaters. For example, if you needed five heaters total, you could install a rack with three heaters and another with two heaters. The water lines and gas line can be joined on site.

Piping for six or more water heaters: If the job requires mul ple racks that total more than six water heaters, refer to the piping diagram on page 9. Mul ple rack systems require a reverse return setup to balance flows across the system. Size the hot and cold headers that supply the rack systems so that they can accommodate the water volume that is required. (These headers will be larger than the rack system piping.) The gas supply lines should be sized to supply the maximum input of the total number of water heaters. Follow proper trade

prac ces and refer to ANSI Z223.1/ NFPA 54 (current edi on) for proper sizing.

2Install the Water Supply

Once flow direction has been determined and the inlet and outlet sides are known, cap the open end of each manifold. See Figure 3 on page 6. (Copper end

caps are not furnished.)

INSTALLATION

Install the water supply in reverse

 

return format. The flow direction

 

must preserve the “last in, first out”

 

principle of a reverse return. See

 

Figure 5 on page 9.

 

Flush the water line at each water

 

heater to remove debris, then purge

 

the air from each line. Failure to do

 

so may cause damage to the water

 

heaters.

 

3Install the Pressure Relief Discharge Lines

The discharge lines must be installed according to the water heaters’ Installation Manual and Owner’s Guide.

The discharge piping for each pressure relief valve must be directed so that the hot water cannot splash on anyone or on nearby equipment.

A ach each discharge pipe to the pressure relief valve and run the end of the tube to a maximum of 6 in. (152 mm) from the floor. This discharge tube must allow free and complete drainage without any restric ons.

For indoor installa on, a drain pan, or other means of protec on against water damage, is required to be installed under the water heaters in case of leaks.

Follow all applicable code requirements.

On-Demand Rack System • 5

INSTALLATION

Figure 3: Cap open end of each manifold.

ŶĚ ĂƉ /ŶƐƚĂůůĂƟŽŶ džĂŵƉůĞ

Cap*

Hot out

Cap

Cold In

Cap*

Gas In

Ύ ŽƉƉĞƌ ĞŶĚ ĐĂƉƐ ĂƌĞ ĮĞůĚ ƐƵƉƉůŝĞĚ͘ dŚĞLJ ĂƌĞ ŶŽƚ ŝŶĐůƵĚĞĚ ǁŝƚŚ ƚŚĞ ĂƐƐĞŵďůLJ͘

4Install the Condensate

Drain Lines

Install a condensate drain line at each water heater to dispose of condensate. Refer to the water heaters’ Installation Manual and Owner’s Guide for specific instructions.

NOTICE: In the absence of local codes and regula ons, it is recommended that condensate be disposed of in a standard drain.

5Install the Venting

WARNING

Improper ven ng of this appliance can result in excessive levels of carbon monoxide which can result in severe personal injury or death.

Improper installa on can cause nausea or asphyxia on, severe injury or death from carbon monoxide and flue gases

poisoning. Improper installa on will void the product warranty.

Install venting according to the

Installation Manual and Owner’s Guide for the water heaters.

Follow all local codes during installation. In the absence of local codes, follow the National Fuel Gas Code, ANSI Z223.1/NFPA 54 (current edition) in the USA, or in Canada, follow CAN/CSA B149.1,

Natural Gas and Propane Installation Code (current edition). If you install thimbles, fire stops or other

protective devices and they penetrate any combustible or noncombustible construction, be sure to follow all applicable national and local codes.

6Install the Gas Supply

Confirm that the water heaters are rated for the type of gas that is supplied.

The means of gas supply must comply with local codes. In the absence of local codes, follow

the NaƟonal Fuel Gas Code, ANSI Z223.1/NFPA 54 (current edi on) in the USA, or in Canada, follow CSA B149.1, Natural Gas and Propane InstallaƟon Code (current edi on).

Ensure that the gas supply pipe is sized appropriately. It must be able to supply the necessary volume of gas required for the water heaters. Otherwise, flow capabili es and output temperatures will be limited. Refer to local codes, ANSI Z223.1/ NFPA 54 in the USA, or CSA B149.1 in Canada.

A 1-½ inch union and an end cap is supplied with each rack unit. Install these items onto the rack’s piping as required. See Figure 3. Prior to opera on, check for leaks and correct any that are found.

Each water heater has its own manual gas shuto valve already installed. Each gas supply line shall be checked for leaks using code approved methods.

Purge the gas line of any debris and/or water before connec ng to the gas inlet.

Confirm that the gas inlet pressure is within limits.

When the gas connec ons are completed, perform a gas leak test by either applying soapy water to all gas fi ngs and looking for bubbles or by using a gas leak detec on device.

Each water heater and its individual shuto valve must be disconnected from the gas supply piping system during any pressure tes ng of that system at test pressures in excess of 1/2 psi (3.5 kPa).

Each water heater must be

6 • On-Demand Rack System

isolated from the gas supply piping system by closing its manual shuto valve during any pressure tes ng of that system at test pressures equal to or less than 1/2 psi (3.5 kPa).

7Connect the Power Supply

Confirm that the installa on complies with local electrical code requirements. In the absence of such requirements, follow the

Na onal Electrical Code ANSI/NFPA 70 (current edi on) in the U.S. or CSA C22.1 Canadian Electrical Code, Part 1 (current edi on) in Canada.

Indoor models include a factory installed, 6-foot (1.83m) long power cord.

Outdoor models must be hard wired.

The water heaters require 120 VAC, 60 Hz electrical power supply that is properly grounded.

The electrical connec on must

provide a means of disconnec on (to terminate power to the water heaters for servicing and safety purposes).

Also, the water heaters must be electrically grounded. Do not a ach the ground wire to either the gas or water piping. Installa on must comply with all code requirements.

Power Requirements

One 15 amp breaker can adequately protect up to seven water heaters. Example:

Number of

Breaker Size

Number of

Heaters

(Amps)

Breakers

1 to 7

15A

1

8 to 14

15A

2

 

 

 

15 to 20

15A

3

 

 

 

Refer to the water heaters’

Installation Manual and Owner’s Guide for instructions.

8Configure the System

If your rack system contains up to four water heaters, configure it with the Easy-Link System. Refer to the

Figure 4: Controller Bracket

 

 

A.) Place T-Bolt through bracket

Installation for Wall

 

 

ŚŽůĞ ĂƐ ƐŚŽǁŶ Ăƚ ůĞŌ͕ ƚŚĞŶ

Mounted Systems.

 

B

start nut on opposite side.

 

 

Repeat for other bracket.

 

 

/ŶƐĞƌƚ͕ ƚŚĞŶ

 

 

Rotate 90°

B.) Insert head of T-Bolt into

 

 

to lock.

 

 

d ŚĂŶŶĞů ƐůŽƚ͕ ƚŚĞŶ

 

 

 

 

 

 

rotate it 90°. Tighten nut.

 

 

 

(Torque: 25 Nm +/- 5%)

 

 

DŽƵŶƟŶŐ

 

 

Bar

 

Bracket Hole

͘ ĞƚĞƌŵŝŶĞ ůŽĐĂƟŽŶ

 

A

Nut

 

ŽĨ ƐĞĐŽŶĚ ŵŽƵŶƟŶŐ

T-Bolt

 

 

 

bar. It must align

 

 

 

 

 

 

ǁŝƚŚ ƚŚĞ ŵŽƵŶƟŶŐ

T-Channel Slot

hole(s) on the

 

 

 

ŵƵůƟ ƵŶŝƚ

 

 

 

ĐŽŶƚƌŽůůĞƌ͛Ɛ ŇĂŶŐĞ͘

 

 

DŽƵŶƟŶŐ

 

 

Bar

D.) Repeat steps A and B

T-Bolt

 

C

 

to install the second

 

 

Nut

ŵŽƵŶƟŶŐ ďĂƌ͘

 

 

 

water heaters’ Installation Manual and Owner’s Guide for instructions.

However, if your rack system contains five or more water heaters, you must install and configure a multi-unit controller (part number 100112691).

• A multi-unit controller can connect

INSTALLATION

 

up to 20 water heaters, making it

 

 

 

easy to use multiple racks.

 

The mul -unit controller is available

 

 

as an accessory item. It can be

 

 

ordered along with the rack system

 

 

or later through your local service

 

 

agency/installer.

 

If a mul -unit controller is ordered

 

 

with a wall mount or free standing

 

 

(in-line) system, it can be installed

 

 

on either end of the assembly.

 

 

However, a controller-moun ng

 

 

kit is necessary to complete

 

 

the installa on. This kit is sold

 

 

separately and must be installed

 

 

on site by the installing contractor.

 

 

(Kit part number: 100211495.) The

 

 

moun ng kit includes two 14-in. long

 

 

moun ng bars and two moun ng

 

 

brackets.

 

 

Wall mounted rack systems only:

 

 

 

Install the bars onto either end

 

 

 

as shown in Figure 4.

 

 

Free standing rack systems: The

 

 

 

mul -unit controller may be

 

 

 

mounted on either side of the

 

 

 

rack or on a nearby wall. The

 

 

 

moun ng hardware must be

 

 

 

field supplied.

 

See also Piping Requirements, p. 5.

9Final Installation Checklist

WARNING

• Do not install outdoor systems indoors.

On-Demand Rack System • 7

INSTALLATION

Do not install indoor systems outdoors.

Improper installa on can cause nausea or asphyxia on, severe injury or death from carbon monoxide and flue gases poisoning. Improper installa on will void the product warranty.

Power Supply:

Confirm that the power supply is 120 VAC (60 Hz) and that the circuit is properly grounded.

Refer to the Power Requirements table on page 7.

Does the electrical connec on provide a means of disconnec on (to terminate

power to the water heaters for servicing and safety purposes)?

Make sure that the installa on complies with local electrical code requirements. In the absence of such requirements, follow the Na onal Electrical Code ANSI/NFPA 70 (current edi on) in the U.S. or CSA C22.1 Canadian Electrical Code, Part 1 (current edi on) in Canada.

Gas Supply:

Confirm that the water heaters are rated for the type of gas that is supplied.

Ensure that the gas supply line is equipped with a manual gas shut-o valve.

Ensure that air and debris are purged from the gas line.

Check the gas lines for leaks. Correct any that are found.

Verify that the gas inlet pressure is within limits.

Make sure that the installa on complies with all local codes. In the absence of local codes,

follow the NaƟonal Fuel Gas Code, ANSI Z223.1/NFPA 54 (current edi on) in the USA, or in Canada, follow CAN/CSA B149.1,

Natural Gas and Propane InstallaƟon Code (current edi on).

Water Supply:

Before opera on, flush the water line at each water heater to remove debris, then purge the air from each line.

Ensure that water hardness levels do not exceed 7 grains per gallon (120 ppm) for single family domes c applica ons or more than 4 grains per gallon (70 ppm) for all other types

of applica ons. Avoid hard water scaling by proper water treatment, if necessary.

Ensure that no pool water, spa water, or chemically treated water is introduced into the water supply. Only potable water can be used with these water heaters. Refer to the water heaters’ manuals for more informa on.

Ensure that water pH levels are between 6.5 and 8.5.

Is the water supply taken from a well? If so, the water should be treated.

Damage caused by water quality is not covered by the warranty.

Ven ng, Air Supply, and Clearances:

Ensure that the water heaters are not subject to corrosive agents in the air. Also, ensure that the area around the water heaters is dustand debris-free.

Ensure that ven ng is installed according to the water heaters’ installa on manuals

and the vent manufacturer’s instruc ons.

Are water heater clearances observed? (Refer to the water heaters’ Installation Manual and Owner’s Guide.)

Are vent termina on and air intake clearances observed? (Refer to the water heaters’

Installation Manual and Owner’s Guide.)

Verify that adequate combustion air will be available to the water heaters at all times. Refer to the water heaters’ Installation Manual and Owner’s Guide. Installation must also comply with local codes. In the absence of

local codes, comply with the

NaƟonal Fuel Gas Code, ANSI Z223.1/NFPA 54 (current

edi on) in the USA, or in Canada, CAN/CSA B149.1,

Natural Gas and Propane InstallaƟon Code (current edi on).

Control System:

If your installa on includes up to four water heaters, make sure that the Easy-Link System is configured properly. Refer to the water heaters’ Installation Manual and Owner’s Guide for instructions.

If your installa on includes five or more water heaters, make sure that the mul -unit controller is installed and configured properly. (Refer to the Multi-Unit Controller Installation Manual.)

When installa on is complete, verify proper opera on. If you have ques ons or need assistance, please call toll-free: 877-737-2840.

8 • On-Demand Rack System

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