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

Important Safety Informa on .............................................................2

Ge ng Started ...................................................................................3

Installa on ..........................................................................................4

Maintenance ....................................................................................10

Speciﬁ ca ons: Wall Mount (42” Frame Width) ................................12

Speciﬁ ca ons: Wall Mount (62.81” Frame Width) ..........................14

Speciﬁ ca ons: Free Standing (41.54” Frame Width) ........................16

Speciﬁ ca ons: Free Standing (62.29” Frame Width) ........................18

Replacement Parts ...........................................................................20

1 Year Limited Parts Warranty ..........................................................24

Page

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

Do not store or use gasoline or other ﬂ ammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instruc ons.

• If you cannot reach your gas supplier, call the ﬁ re department.

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

INSTALLATION MUST BE PERFORMED BY QUALIFIED SERVICE PROFESSIONALS ONLY.

2000539909_100281805 (A)

March 2017

IMPORTANT SAFETY INFORMATION

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

SAFETY

This is the safety alert symbol. It is used to alert you to poten al physical injury hazards. Obey all safety mes- sages 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

WARNING

 on that, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situa on that, if not avoided, could result in death or serious injury.

CAUTION indicates a hazardous

CAUTION

NOTICE

WARNING! If the informa on in these instruc ons is not followed exactly, a ﬁ re or explosion may result causing property

damage, personal injury or death. Do not store or use gasoline or other ﬂ ammable 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 qualiﬁ ed service professionals.

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

situa on that, if not avoided, could result in minor or moderate injury.

NOTICE indicates prac ces not related to physical injury.

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 qualiﬁ ed 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:

ᴏ

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.

ᴏ

Keep the area around the water heaters clean. When dust collects on the ﬂ ame sensors, the water heaters will shut down and produce an error code.

ᴏ

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, that condensate be disposed of in a standard drain.

it is recommended

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.

it is recommended

GETTING STARTED

On-Demand Rack System • 3

INSTALLATION

Install 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 page 3.

• WARNING! The ﬂ oor or wall

INSTALLATION

Installation Requirements on

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.

ᴏ

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.

ᴏ

Ensure that you use ﬂ oor/ wall anchors with an adequate weight ra ng.

open, unroofed area with minimum clearances observed.

Wall Mounted Rack

A. Before you begin, read all warnings

and bullet points at the beginning of this sec on.

B. Determine your installa on

loca on, then conﬁ rm that the clearance requirements are met. (Refer to the water heater manual and applicable code.)

Figure 1: Lifting Brackets

Figure 2: Spreader Lifting Bar

NOTICE: Wall mount racks are shipped with li ing brackets in place. See Figure 1. These lifting brackets are actually wall mount brackets that have been rotated 90 degrees. They will allow you to hoist the rack without the use of straps. Use a spreader lifting bar as shown in Figure 2 to ensure that the lifting force is vertical.

C. A ach the rack to the wall, and

ensure that it is secure. The rack must be secured at each moun ng bracket. NOTE: The moun ng brackets can be moved along the channel to line up with the framing.

• 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

4 • On-Demand Rack System

ᴏ

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.

ᴏ

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 page 6).

Figure 3,

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 ﬂ oor at each

leg. It must be secure and must not allow movement.

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 ﬁ ve 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 ﬂ ows 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.

Install 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.)

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.

Install 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.

INSTALLATION

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.

• 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 ﬂ oor. 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

Figure 3: Cap open end of each manifold.

Cap*

Cap

INSTALLATION

Install 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: and regula ons, it is recommended that condensate be disposed of in a standard drain.

In the absence of local codes

Install 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 ﬂ ue gases

ŶĚĂƉ/ŶƐƚĂůůĂƟŽŶǆĂŵƉůĞ

Cold In

Cap*Hot out

ΎŽƉƉĞƌĞŶĚĐĂƉƐĂƌĞĮĞůĚƐƵƉƉůŝĞĚdŚĞǇĂƌĞŶŽƚ

ŝŶĐůƵĚĞĚǁŝƚŚƚŚĞĂƐƐĞŵďůǇ

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.

Install the Gas

Supply

• Conﬁ rm 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

Gas In

the NaƟ onal 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 InstallaƟ on 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, ﬂ ow 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 shutoﬀ 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.

• Conﬁ rm 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.

ᴏ

Each water heater and its individual shutoﬀ 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).

ᴏ

Each water heater must be

6 • On-Demand Rack System

isolated from the gas supply piping system by closing its manual shutoﬀ valve during any pressure tes ng of that system at test pressures equal to or less

than 1/2 psi (3.5 kPa).

Connect the

Power Supply

• Conﬁ rm 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

Figure 4: Controller Bracket

Installation for Wall

Mounted Systems.

Bracket Hole

T-B o lt

T-Channel Slot

T-B o lt

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

Heaters

1 to 7 15A 1

8 to 14 15A 2

15 to 20 15A 3

Breaker Size

(Amps)

Number of

• Refer to the water heaters’

Installation Manual and Owner’s Guide for instructions.

Configure the

System

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

A.) Place T-Bolt through bracket

ŚŽůĞĂƐƐŚŽǁŶĂƚůĞŌƚŚĞŶ

start nut on opposite side. Repeat for other bracket.

B.) Insert head of T-Bolt into

Bar

/ŶƐĞƌƚƚŚĞŶ

Rotate 90°

to lock.

DŽƵŶƟŶŐ

Nut

DŽƵŶƟŶŐ

Nut

Refer to the

dͲŚĂŶŶĞůƐůŽƚƚŚĞŶ

rotate it 90°. Tighten nut.

(Torque: 25 Nm +/- 5%)

ͿĞƚĞƌŵŝŶĞůŽĐĂƟŽŶ

ŽĨƐĞĐŽŶĚŵŽƵŶƟŶŐ

bar. It must align

ǁŝƚŚƚŚĞŵŽƵŶƟŶŐ

hole(s) on the

ŵƵůƟͲƵŶŝƚ ĐŽŶƚƌŽůůĞƌƐŇĂŶŐĞ

D.) Repeat steps A and B

to install the second

ŵŽƵŶƟŶŐďĂƌ

Breakers

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 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.

ᴏ

Wall mounted rack systems only: Install the bars onto either end as shown in Figure 4.

ᴏ

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 ﬁ eld supplied.