A.O. Smith 500A User Manual

CYCLONE Xi®

Model BTH 300A, 400A, 500A

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 no t us e any ph one in you r

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.

– Installation an d ser vic e must be performed by a qualified installer, service agency or the gas supplier.

Thank you for buying this energy efcient water heater from A.O. Smith Water Products Company. We appreciate your condence in our products.

CAUTION

TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ THOROUGHLY BEFORE INSTALLING AND USING

THIS APPLIANCE.

PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.

PRINTED 0307 197373-003

www.hotwater.com

ROUGH-IN-DIMENSIONS

GAS VALVE PIPING

BTH-300 1 1/4" NPT BTH-400 1 1/4" NPT BTH-500 1 1/2" NPT

TABLE 1 RECOVERY CAPACITIES.

TYPE OF INPUT Approx. F° 20F° 30F° 40F° 50F° 60F° 70F° 80F° 90F° 100F° 110° 120F° 130F° 140F° MODEL GAS BTUH KW Capacity C° 11C° 17C° 22C° 28C° 33C° 39C° 44C° 50C° 56C° 61C° 67C° 72C° 78C°

300,000 130 US Gals. GPH 1746 1164 873 699 582 499 436 388 349 318 291 269 250

BTH-300

88 492 Litres LPH 6610 4406 3304 2644 2203 1888 1652 1469 1322 1201 1102 1017 945 300,000 130 US Gals. GPH 1746 1164 873 699 582 499 436 388 349 318 291 269 250

BTH-300

88 492 Litres LPH 6610 4406 3304 2644 2203 1888 1652 1469 1322 1201 1102 1017 945

399,900 130 US Gals. GPH 2328 1552 1164 931 776 665 582 517 466 423 388 359 332

BTH-400

117 492 Litres LPH 8813 5875 4406 3525 2938 2518 2203 1958 1763 1602 1469 1356 1259

399,900 130 US Gals. GPH 2328 1552 1164 931 776 665 582 517 466 423 388 359 332

BTH-400

117 492 Litres LPH 8813 5875 4406 3525 2938 2518 2203 1958 1763 1602 1469 1356 1259 499,900 130 US Gals. GPH 2878 1919 1439 1151 959 822 720 640 576 523 480 443 411

BTH-500

146 492 Litres LPH 10894 7263 5447 4358 3631 3113 2724 2421 2179 1981 1816 1676 1556 499,900 130 US Gals. GPH 2878 1919 1439 1151 959 822 720 640 576 523 480 443 411

BTH-500

146 492 Litres LPH 10894 7263 5447 4358 3631 3113 2724 2421 2179 1981 1816 1676 1556

Recovery capacities are based on heater performance at 96% thermal efciency for BTH 300A, 400A, and 95% thermal efciency for BTH 500A.

NATURAL

PROPANE

NATURAL

PROPANE

NATURAL

PROPANE

U.S. Gallons/Hr and Litres/Hr at TEMPERATURE RISE INDICATED

FOREWORD

These designs comply with the current edition of the American Nati o n al S t a nd a r d f o r Gas Wat e r H ea t e rs , Volu m e II I , 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 wi th the cu rrent edition s of the Na tiona l Fuel Ga s Code, AN S I Z223.1/NFPA 54 an d th e National El e c t rical 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.

TABLE OF CONTENTS

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

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

FEATURES ................................................................................................ 3

Water Temperature Control ................................................................3-5

Water Temperature Setpoint Adjustment Procedure ............................. 5

High Limit Switch (E.C.O.) .................................................................... 5

Dishwashing Machine Requirement ...................................................... 5

Circulating Pump ...................................................................................6

INSTALLATION INSTRUCTIONS .............................................................6

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

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

Locating The Heater .............................................................................. 6

Clearances ............................................................................................ 7

Hard Water ............................................................................................7

Air Requirements .................................................................................. 7

Mechanical Exhausting of Room Air .....................................................7

Unconned Space .................................................................................7

Conned Space ..................................................................................... 7

Chemical Vapor Corrosion .................................................................... 7

Installation Requirements for the

Commonwealth of Massachusetts ........................................................8

VENTING ..............................................................................................8-11

Vent Pipe Termination .........................................................................11

Direct Venting ...................................................................................... 11

Direct Vent Terminal Installation ..................................................... 11-12

Installation Sequence ..........................................................................12

Vertical Vent Terminal Installation ....................................................... 12

Installation Sequence .....................................................................12-13

Installation of Vent System .................................................................. 13

Vent Pipe Preparation ......................................................................... 14

CONTROLS AND SWITCHES ................................................................ 14

Blower Prover Switch .......................................................................... 14

Blocked Outlet Prover Switch .............................................................. 14

Blocked Inlet Prover Switch ................................................................ 14

Low Gas Pressure Switch ................................................................... 14

On/Off Switch .................................................................................14-15

Hot Surface Igniter ..............................................................................15

GAS PIPING ............................................................................................ 15

Connection of Gas Pipe .................................................................15-16

Purging ................................................................................................16

Gas Meter Size - City Gases Only ......................................................16

Gas Valves ..........................................................................................16

SYSTEM CONNECTIONS ...................................................................... 16

Thermometers .....................................................................................16

Relief Valve ......................................................................................... 16

Water Line Connections ......................................................................16

Closed System ...............................................................................16-17

Water (Potable) Heating & Space Heating .......................................... 17

Heater Wiring .................................................................................17-19

OPERATION ............................................................................................ 20

Sequence of Operation .......................................................................20

ELECTRONIC CONTROL ....................................................................... 20

Overview .............................................................................................20

Operating States ............................................................................20-21

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

Changing the Display Units .................................................................22

Fault and Warning Conditions ........................................................22-23

Access to the Current Fault or Warning .............................................. 23

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

Viewing Information About the Heater .................................................24

PRIOR TO START-UP REQUIRED ABILITY ...........................................25

OPERATING INSTRUCTIONS ................................................................ 25

Adjustment Procedure (Initial Start-Up) .........................................25-26

Lighting Instructions ............................................................................26

Cathodic Protection .............................................................................27

Precautions .........................................................................................27

GENERAL INFORMATION ......................................................................27

Power Burner ......................................................................................27

High Limit ............................................................................................27

High Altitude Installations ....................................................................27

MAINTENANCE ......................................................................................27

General ............................................................................................... 27

Maintenance Schedule ........................................................................ 27

Flushing ............................................................................................... 28

Draining ...............................................................................................28

Sediment Removal ..............................................................................28

Lime Scale Removal ......................................................................28-29

Powered Anode System ...................................................................... 29

Drain Valve and Access Panels .......................................................... 29

Relief Valve ......................................................................................... 29

Vent System ........................................................................................29

INSTALLATION DIAGRAMS ..............................................................30-34

Multiple Unit Installations .................................................................... 35

CHECKLIST AND SERVICE INFORMATION ......................................... 36

Burner Operational Problems .............................................................. 36

Not Enough or No Hot Water ..............................................................36

Water Is Too Hot ..................................................................................36

Water Heater Makes Sounds .............................................................. 36

Water Leakage is Suspected ...................................................................36

TROUBLESHOOTING .......................................................................36-38

REPLACEMENT PARTS .........................................................................38

LIMITED WARRANTY ............................................................................. 39

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

DANGER

THIS WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT WA TER TEM P ERATUR ES REQU I RED FOR AUTOMA TIC DISHW ASHER AND LAUND RY 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 TIME OF 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 Up/Dn 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.

“AT A GLANCE” BTH 300/400/500

QUICK INSTALLATION TIPS

Horizontal Sidewall Venting Vertical Rooftop Venting

The temperature may be adjusted from 80°F/27°C to 180°F/82°C. The temperature was adjusted to 120°F/49°C before the heater was shipped from the factory. It is recommended that lower water temperatures 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.

WATER TEMPERATURE SETPOINT ADJUSTMENT

PROCEDURE

CAUTION

THE TEMPERATURE OF THE WATER AT THE TANK OUTLET MAY NOT CORRESPOND TO THE TEMPERATURE SETPOINT PROGRAMMED IN THE CONTROLLER. THE USER CAN EASILY CHANGE THE TEMPERATURE SETPOINT AT ANY TIME BY USING THE FOLLOWING PROCEDURE. IN ALL CASES, INPUT POWER MUST BE APPLIED TO THE CONTROLLER TO PERFORM ANY

PROGRAMMING OPERATIONS.

The Operating Set Point of this water heater determines the regulated

temperature for the water in the tank. This parameter is adjusted in the Temperature menu. Items in this menu allow you to monitor different temperature readings in the tank along with adjusting the Operating Set Point and Differential. To change the current programmed temperature setpoint value, see OPERATION section for details.

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 (11C°). If you experience this type of use, you should consider using lower temperature settings to reduce scald hazards.

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.

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 water temperature must drop below 140°F/60°C before the controller can be reset. The following is a possible reason for high limit switch operation.

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.

• A malfunction in the thermostatic controls would allow the gas valve to remain open causing water temperature to exceed the thermostat setting. The water temperature would continue to rise until high limit switch operation.

Contact your dealer or servicer if continued high limit switch operation occurs.

DISHWASHING MACHINE REQUIREMENT

All dish washing 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.

INSTALLATION INSTRUCTIONS

REQUIRED ABILITY

IN S TALLATI O N OR SERV I CE OF TH IS WATER HEATE R 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

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.

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.

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 EX HAUS T OR INTAKE WILL BE OBJEC TIONA BLE. THIS IN C LUDES LOC ATIONS CL O SE TO OR ACROSS FR O M WINDOWS AND DOORS. AVOID ANCHORING THE VENT AND INTAKE PIPES DIRECTLY TO FRAMED WALLS, FLOORS OF CEILINGS UNLESS RUBBER ISO LATION PIPE HANGERS

ARE USED. THIS PREVENTS ANY VIBRATIONS FROM BEING TRANSMITTED INTO THE LIVING SPACES.

WARNING

FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY OTHER POTENTIAL FIRE HAZARDOUS ARTIC LES 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 term ina tion points as practic abl e, 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.

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 BUILDUP WILL BLOCK THE EXHAUST OUTLET, WHICH WILL CAUSE

IMPROPER OPERATION.

• Do obtain new labels from A.O. Smith 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.

FIGURE 3.

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

MECHANICAL EXHAUSTING OF ROOM AIR

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, thermostats, cleanout openings, drain valves and venting connections.

Always disconnect electrical power before servicing the unit.

*ILLUSTRATION OF MINIMUM COMBUSTIBLE CLEARANCES IN AN ALCOVE.

FIGURE 4.

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.

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.

UNCONFINED SPACE

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

If the unconned 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 conned spaces in tightly constructed buildings must be followed to ensure adequate air supply.

CONFINED SPACE

When drawing combustion air from inside a conv entional ly constructed building to a conned space, such a space shall be provided with two permanent openings, ONE IN OR WITHIN 12 INCHES (31 cm) OF THE ENCLOSURE TOP AND ONE IN OR WITHIN 12 INCHES (31 cm) OF THE ENCLOSURE BOTTOM. Each opening shall have a free area of at least one square inch per 1000 Btuh (2,203mm2/kW) appliances in the enclosure, but not less than 100 square inches (645 cm²).

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 per 4000 Btuh (551mm2/kW) of the total input of all appliances in the enclosure. If horizontal ducts are used, each opening shall have a free area of not less than one square inch per 2000 Btuh (1,102mm2/kW) of the total input of all appliances in the enclosure.

AIR REQUIREMENTS

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

DO NOT OBSTRUCT THE FLOW OF COM BUSTION AND

VENTILATING AIR.

WARNING

FO R SAFE OP ERATIO N PROVID E 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 TUBE S AND CREATES A RIS K OF

ASPHYXIATION.

CHEMICAL VAPOR CORROSION

WARNING

CORROSION OF THE FLUE WAYS AND VENT SYSTEM MAY OCCUR IF A IR FOR COMBU STIO N CONTAI NS 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.

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

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.

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 floor 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.

MA N U FA C TURER REQ U I REMENTS - GA S 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.

MA N U FA C TURER REQ U I REMENTS - GA S 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.

VENTING

WARNING

THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST BE FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULATION OF FLUE GASES. SUCH CONDITIONS CAUSE

SOOTING OR RISKS OF FIRE AND ASPHYXIATION.

Heater must be prote cte d from freezing dow ndr afts during shutdown periods.

US DIRECT VENT

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

CAUTION

FIGURE 5.

US HORIZONTAL VENT

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 HORIZONTAL VENT

CAUTION

FIGURE 6.

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 Figure 5 and 6 before proceeding.

CAUTION

DO NOT TERMINATE THE VENTING WHERE NOISE FROM THE EXHAUST OR INTAKE WILL BE OBJECTIONABLE. THIS IN C LUDES LOC ATIONS CL O SE TO OR ACROSS FR O M WINDOWS AND DOORS. AVOID ANCHORING THE VENT AND INTAKE PIPES DIRECTLY TO FRAMED WALLS, FLOORS OR CEILINGS UNLESS RUBBER ISO LATION PIPE HANGERS

ARE USED. THIS PREVENTS ANY VIBRATIONS FROM BEING

TRANSMITTED INTO THE LIVING SPACES.

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.

WARNING

WHEN THE UNIT IS TO BE SETUP AS A DIRECT VENT, THE INTAKE GUARD AND THE BALANCE PLATE MUST BE

REMOVED. THE INLET VENT PIPE MAY THEN BE GLUED TO

THE AIR INTAKE (see Figure 8) PROVIDED ON THE UNIT.

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.

WARNING

USE ONLY THE VENT TERMINALS SUPPLIED WITH THIS UNIT. TERMINATION OF A VENT SYSTEM WITH A DEVICE OTHER THAN THE SUPPLIED VENT TERMINATIONS WILL AFFECT SYSTEM PERFORMANCE AND RESULT IN A SAFETY HAZARD.

DIRECT VENTING

The air intake provided on the unit contains an intake guard, see

Figure 7.

3"x 4" PVC REDUCER WITH INTAKE SCREEN

FIGURE 8.

DIRECT VENT TERMINAL INSTALLATION

IMPORTANT

4" VENT AND INTAKE TERMINALS ARE PROVIDED FOR NEW INSTALLATIONS. FOR REPLACEMENT OF PREVIOUS BTH 300 AND 400 WITH 3" TERMINALS, THE 4" TERMINALS ARE RECOMMENDED, BUT THE EXISTING 3" VENT/INTAKE

TERMINALS ARE PERMITTED.

NO T E : TO PREVENT EX H AUSTING PRODUC T S FR O M CIRCULATING TO THE AIR INTAKE IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN THESE TWO TERMINALS IS RECOMMENDED.

IMPORTANT

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

FIGURE 7.

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 to 48" (122 cm) will reduce possibility of frost over from side winds blowing exhaust vapors to the air intake of the direct the vent and is recommended for Canada.

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).

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.

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 10.

EXHAUST VENT TERMINAL

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 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.

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.

INTAKE VENT TERMINAL

FIGURE 10.

VERTICAL VENT TERMINAL INSTALLATION

IMPORTANT

WHEN TERMINATING THROUGH A ROOF, THE 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 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.

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.

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