A.O. Smith BPD-400 User Manual
AOS PREFERRE D-BPD 400 DIRE CT VENT
COMMERCIAL GAS W A TER HEA TER
GAS-FIRED INDUCED DRAFT
FOR DOMESTIC HOT W A TER
• INST ALLATION • OPERA TION • SER VICE • MAINTENANCE • LIMITED W ARRANTY
W ARNING: 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 OUTLINED 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. 0206 Part Number 197279-000
1
A DIVISION OF A.O. SMITH CORPORATION
Mc BEE, SOUTH CAROLINA
ROUGH-IN DIMENSIONS
TOP
GAS V AL VE PIPING
BPD -400 3/4" NPT
FRONT
Input Capacity SHIPPING
BTU Gallon
Model (kw-Hr.) (Liters) "A" "B" " C" "D" "E" "F" "G" "H" "I " LINE STD ASME
BPD - 400 390,000 95 82.25 80.25 30.25 8.75 4 or 6 21.75 63.50 2.25 58.00 1.00 900 lbs. 1100 lbs.
(114.3) (360) (209) (204) (77) (22) vent (55) (161) (8 ) (147) (2.54) 408 Kg 499 Kg
Table 1. RECOVER Y CAPACITIES - NA TURAL GAS
Input Capacity
BTU Gallon 30 F 40 F 50 F 60 F 70 F 80 F 90 F 100 F 110 F 120 F 130 F 140 F
Model (kw-Hr.) (Liters) 17 C 22 C 28 C 33 C 39 C 44 C 50 C 56 C 61 C 67 C 72 C
BPD - 400 390,000 95 1316 987 789 658 564 493 439 395 359 329 304 282
(114.3) (360) (4981) (3735) (2988) (2490) (2135) (1868) (1660) (1494) (1358) (1245) (1149) (1067)
DIMENSIONS IN INCHES (CM)
GAS WEIGHT
TEMPERA TURE RISE - DEGREES F - GALLONS PER HOUR (LPH)
78 C
Recovery capacities are based on heater performance at 83.5% thermal efficiency.
2
TYPICAL INST ALLATION
INTAKE FOR
COMBUSTION AIR
VENT TO
OUTDOORS
FLUE PRODUCTS
DISCHARGE PIPE
AIR INTAKE PIPE
TEMPERA TURE
PRESSURE RELIEF
VALVE
V ACUUM RELIEF REQUIRED BY SOME
CODES (REFER TO LOCAL CODES)
SHUTOFF V ALVE
COLD WA TER INLET
MIXING VALVE *
TEMPERED
WA TER OUTLET
HOT WA TER OUTLET
GAS
SUPPL Y
Installation Information: for Model BPD 400 100 Series
ELECTRICAL CLEARANCES PRESSURES ORIFICES INPUT
120/24VAC 60Hz 5A FRONT SIDES TOP NATURAL NATURAL NA TURAL 390kbtuh
UNIT IS POLARITY SENSITIVE 6" = (15 cm) 0 " 12 "= (30.5 cm) Manifold 4.50" WC Sea Level 0.126
Inlet 7.00" WC 4500' 0.126
Max. Inlet 14.00" WC 8000' 0.106
3
FOREWORD
These designs comply with the current version of the American National
Standard for Gas Water Heaters, Volume III, ANSI Z21.10.3 / CSA 4.3 as
automatic circulating tank water heaters, 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.
TABLE OF CONTENTS
PAGE PAGE
ROUGH-IN DIMENSIONS ................................................................... 2
TYPICAL INST ALLA TION .................................................................. 3
FOREWARD ...................................................................................... 4
GENERAL SAFETY INFORMA TION .................................................. 5
Precautions .................................................................................. 5
Chemical Vapor Corrosion........................................................... 5
Improper Combustion ................................................................... 5
Extended Nonuse Periods ........................................................... 5
Insulation Blankets ....................................................................... 5
High Altitude Installations ............................................................. 5
FEATURES ........................................................................................ 6
The Eliminator ............................................................................... 6
High Limit Switch (E.C.O.) ............................................................ 6
Circulating Pump........................................................................... 6
Dishwashing Machine Requirement ............................................ 6
Electronic Ignition Control ............................................................. 7
Pilot Assembly .............................................................................. 7
Gas Valve ..................................................................................... 7
Pressure Switch .......................................................................... 7
Step Down Transformer .............................................................. 8
Burner Tray Assembly ................................................................. 8
Burner Tray .................................................................................. 8
Burner .......................................................................................... 8
Burner Orifice .............................................................................. 8
Blower Assembly......................................................................... 8
High Limit Switch .......................................................................... 9
Shroud Assembly ......................................................................... 9
Temperature and Pressure Release Valve ................................. 9
INSTALLA TION INSTRUCTIONS ........................................................ 9
Required Ability ............................................................................ 9
Hard Water ................................................................................... 9
Locating the Heater...................................................................... 9
Leveling ........................................................................................ 9
Clearances ................................................................................... 10
Alcove Installation ........................................................................ 10
Air Requirements ......................................................................... 10
COMBUSTION AIR AND EXHAUST ................................................... 10
Venting Clearances ...................................................................... 10
Facts to Consider About the Location......................................... 11
Wire Fence ................................................................................... 11
Water Piping ................................................................................. 12
Temperature-Pressure Relief Valve ............................................ 12
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 Electric Code. The former is available from the Canadian Standards
Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131, and
both documents are available from the National Fire Protection Association,
1 Batterymarch Park, Quincy, MA 02269.
Filling the Water Heater................................................................ 13
Wiring ........................................................................................... 13
Venting ......................................................................................... 15
Venting Through Roof.................................................................. 19
GAS PIPING ....................................................................................... 20
Sediment Trap .............................................................................. 20
INST ALLATION CHECKLIST .............................................................. 21
Operating Instructions for Model 100-400 .................................. 22
Operational Sequence (Natural Gas Models Only) ..................... 22
Safety Sequence (Natural Gas Models Only) ............................. 22
Robertshaw Control System (Natural Gas) ................................ 22
FOR YOUR SAFETY......................................................................... 23
Operating Instructions ................................................................. 23
To Turn Off Gas to Appliance ...................................................... 23
T emperature Regulation ............................................................... 24
Temperature Adjustments ............................................................ 24
STAR T UP CONDITIONS.................................................................... 24
Condensation ............................................................................... 24
Smoke/Odor.................................................................................. 25
Thermal Expansion....................................................................... 25
Strange Sounds ........................................................................... 25
OPERATIONAL CONDITIONS ............................................................ 25
Smelly Water ................................................................................ 25
Air in Hot Water Faucets ............................................................. 25
Venting Manual Reset Switch...................................................... 25
High Temperature Shut Off System ............................................. 25
E.C.O. ........................................................................................... 25
Not Enough or No Hot Water........................................................ 25
Water Is Too Ho t ........................................................................... 26
Venting System Inspection .......................................................... 26
Burner Inspection ......................................................................... 26
Burner Cleaning ........................................................................... 26
Housekeeping .............................................................................. 27
Draining ........................................................................................ 27
Service ......................................................................................... 27
INSTALLA TION DIAGRAMS .............................................................. 28
Manifold Kits................................................................................. 33
Sediment Removal........................................................................ 34
Lime Scale Removal ..................................................................... 34
Anode Inspection and Replacement............................................ 34
Replacement Parts ....................................................................... 34
MODEL BPD 400 LIMITED WARRANTY............................................ 35
4
GENERAL SAFETY INFORMATION
PRECAUTIONS
DO NOT USE THIS APPLIANCE IF ANY P AR T 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.
IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO NOT OPERATE
HEATER UNTIL ALL CORRECTIVE STEPS HAVE BEEN MADE BY A
QUALIFIED SERVICEMAN.
1. EXTERNAL FIRE.
2. DAMAGE.
3. FIRING WITHOUT WA TER.
4. SOOTING.
CHEMICAL VAPOR CORROSION
DANGER
CORROSION OF THE FLUE AND VENT SYSTEM MAY OCCUR IF AIR
FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS. SUCH
CORROSION MAY RESUL T 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 (water softener salt), waxes, and process
chemicals are typical compounds which are potentially corrosive.
Do not store products of this sort 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. The limited warranty is
voided when failure of water heater is due to a corrosive
atmosphere. (Refer to the limited warranty for complete terms and
conditions.)
SERVED BY THIS HEA TER THA T HAS NOT BEEN USED FOR A LONG
PERIOD OF TIME (GENERALL Y TWO WEEKS OR MORE). HYDROGEN
GAS IS EXTREMELY FLAMMABLE.
these conditions, it is recommended that the hot water faucet be opened
for several minutes at the kitchen sink before using any electrical appliance
connected to the hot water system. If hydrogen is present, there will
probably be an unusual sound such as air escaping through the pipe as
the water begins to flow. THERE SHOULD BE NO SMOKING OR OPEN
FLAME NEAR THE FAUCET A T THE TIME IT IS OPEN.
To reduce the risk of injury under
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 90.1b-1999 standards
with respect to insulation and standby loss requirement making an
insulation blanket unnecessary.
DANGER
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 of the water heater, as this will
interfere with safe operation of venting components.
• Do not cover the gas valve or 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 not allow insulation to come within 2" (5 cm) of the burners, to
prevent blockage of combustion air flow to the burners.
• Do not allow insulation to come within 9" (23 cm) of floor, (within 2"
(5cm) of bottom cover) to prevent blockage of combustion air flow
to the burners.
IMPROPER COMBUSTION
DANGER
A TTIC AND/OR EXHAUST FANS OPERA TING ON THE PREMISES WITH A
WA TER HEA TER CAN RESUL T IN CARBON MONOXIDE POISONING AND
DEATH.
OPERATION OF THESE F ANS CAN PRODUCE A NEGA TIVE DRAFT IN THE
AREA OF THE WATER HEATER PREVENTING THE PRODUCTS OF
COMBUSTION FROM EXHAUSTING THROUGH THE CHIMNEY OR VENT PIPE.
The venting of the water heater should be inspected by a qualified service
technician at the time of installation and periodically thereafter to ensure
a down-draft condition does not exist.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILA TING AIR.
ADEQUATE AIR FOR COMBUSTION AND VENTILATION MUST BE PROVIDED
FOR SAFE OPERATION.
EXTENDED NONUSE PERIODS
DANGER
HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER SYSTEM
• Do inspect the insulation blanket frequently to make sure it does not
sag, thereby obstructing combustion air flow.
• Do obtain new labels from A.O. Smith for placement on the blanket
directly over the existing labels.
HIGH ALTITUDE INSTALLATIONS
DANGER
INSTALLATIONS ABOVE 2000 FEET (610 METERS) REQUIRE
REPLACEMENT OF THE BURNER ORIFICES IN ACCORDANCE WITH
SECTION 8.1.2 OF THE NATIONAL FUEL GAS CODE (ANSI Z223.1).
FAILURE TO REPLACE THE ORIFICES WILL RESUL T IN IMPROPER AND
INEFFICIENT OPERATION OF THE APPLIANCE RESULTING IN THE
PRODUCTION OF INCREASED LEVELS OF CARBON MONOXIDE GAS IN
EXCESS OF SAFE LIMITS WHICH COULD RESUL T IN SERIOUS PERSONAL
INJURY OR DEA TH.
You should contact your gas supplier for any specific changes which
may be required in your area.
As elevation above sea level is increased, there is less oxygen per cubic
5
foot of air. Therefore, the heater input rate should be reduced at high
altitudes for satisfactory operation with the reduced oxygen supply.
Failure to make this reduction would result in an over-firing of the
heater causing sooting, poor combustion and/or unsatisfactory heater
performance.
Ratings specified by manufacturers for most appliances apply for
elevations up to 2000 feet (610 m). For elevations above 2000 feet
(610), ratings must be reduced at the rate of 4% for each 1000 feet
(305m) above sea level. For example, if a heater is rated at 120,000
Btuh (35 Kwh) at sea level, to rate the heater at 4000 feet (1219 m),
you subtract 4 (once for each thousand feet) x 04 (4% input reduction)
x 120,000 (original rating) from the original rating. Therefore, to
calculate the input rating at 4,000 feet (121.9 m): 4 x .04 x 120,000 =
19,200 Btuh (5.6 Kwh), 120,000 (35 Kwh) - 19,200 (5.6 Kwh) = 100,800
Btuh (29.4 Kwh). At 6000 feet (1829 m) the correct input rating should
be 91,200 Btuh (26.7 Kwh).
Field conversion is not permitted.
FEATURES
THE ELIMINA T OR
(SELF-CLEANING S YSTEM)
• A malfunction in the thermostatic controls could 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.
These units include The Eliminator (Self-Cleaning System) installed in
the front water inlet, see Figure 2. The Eliminator must be oriented
correctly for proper function. There is a marked range on the pipe
nipple portion of the Eliminator, that must be aligned with the top of the
inlet spud. A label above the jacket hole has an arrow that will point to
the marked portion of the pipe nipple if the orientation is correct. If the
arrow does not point within the marked range on the pipe nipple,
adjust the pipe nipple to correct. A pipe union is supplied with the
Eliminator to reduce the probability of misaligning the Eliminator
accidentally while tightening the connection to the inlet water supply
line. Improper orientation of the Eliminator can cause poor performance
of the heater and can significantly reduce outlet water temperatures
during heavy draws.
FIGURE 1
HIGH LIMIT SWITCH (E.C.O.)
The dual bulb controller contains the high limit (energy cutoff) sensor,
see Figure 2. The high limit switch interrupts main burner gas flow
should the water temperature reach 205°F (96°C).
DUAL-BULB THERMOST AT
(SHOWN AT TOP WITH COVER ON AND AT BOTTOM
WITH COVER REMOVED)
FIGURE 2
Continued pilot outage preceded by higher than usual water temperature
is evidence of high limit switch operation. Contact your dealer or
servicer to determine the reason for operation.
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 in this manual for electrical hookup
information and install in accordance with the current version of
the National Electric Code ANSI/NFPA No. 70.
Only all bronze circulators are used with commercial water heaters.
Although circulators are oiled and operated by the manufacturer some
circulators must be oiled again before operating. Please refer to
manufacturer’s instructions.
In the event of high limit switch operation, the appliance cannot be
restarted unless the water temperature is reduced by at least 20°F
(11°C) and the high limit reset button on front of limit control is depressed,
see Figure 2.
Continued manual resetting of high limit control, preceded by higher
than usual water temperature is evidence of high limit switch operation.
The following is a possible reason for high limit switch operation.
DISHWASHING MACHINE REQUIREMENT
These appliances meet the National Sanitation Foundation St andard for
sanitary installations when used with the following leg kits, Part No’s.
6570-0 and 6570-7.
All dishwashing machines meeting the National Sanitation Foundation
requirements are designed to operate with water flow pressures
6
between 15 and 25 psi (103 kPa and 173 kPa). Flow pressures above 25
psi (173 kPa), or below 15 psi (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 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 takeoff to the dishwashing machine. Adjust flow by
means of the plug cock in the circulating line.
FIGURE 3
ROBERTSHAW SP715A IGNITION CONTROL MODULE
NATURAL GAS MODEL
ROBERT SHA W 47484A PILO T SENSOR
ROBERTS HA W DERHC-S7C NA TURAL 1" x 1" GAS V AL VE
ELECTRONIC IGNITION CONTROL
Each heater is equipped with an ignition control module (See figure 3
above). The solid state ignition control ignites the pilot burner gas by
creating a spark at the pilot assembly. Pilot gas is ignited and burns
during each running cycle. The main burner and pilot gases are cut off
during the OFF cycle. Pilot operation is proven by the pilot sensor.
Main burner ignition will not occur if the pilot sensor does not first
sense pilot operation.
PILOT ASSEMBL Y
The pilot assembly is mounted between the two middle burner
assemblies in the combustion chamber. The ignition sequence begins
with the ignition module sending voltage to the sparker located on the
front side of the pilot hood. Pilot gas flow is initiated after the sparker
begins to spark. The spark across the pilot gas flow ignites the pilot
gas. Once the pilot gas is ignited, the flame sensor senses the flame
through flame rectification (which means that the module's signal
changes from an AC current to a DC current because the current can
now flow through the flame to the pilot hood which is grounded to the
unit). Once the sensor senses flame, the signal is sent back to the
module to open up the gas valve for the main burners.
GAS VALVE
The gas valve is used to supply the gas to the unit during heat up periods.
The ignition control module monitors the thermostat's call for heat and
sends a signal to the gas valve when to open to allow gas flow.
PRESSURE SWITCH
The Blocked Outlet/Prover switch is set up to shut the unit off when a
pressure buildup in the exhaust vent pipe occurs. This switch is a
negative pressure switch that requires an increase in negative pressure
to change the electrical contacts from normally open to closed. The
switch is connected to the pressure tap connected to the housing of
the blower. When this switch prevents the unit from ignition, most
likely the exhaust is blocked by some means. Check for obstructions
in the exhaust vent terminal.
The Blocked Outlet/Prover switch has a second function. It is provided
on the heater to verify that the fan is operating. When the fan increases
in negative pressure, the electrical contacts close signaling that the
blower is operational and is at peak performance. The controller
requires that the electrical contacts on the switch close before it will
allow the burners to operate.
ROBERT SHA W #6S24-6 PILO T ASSEMBLY
MPL 9300VO AIR PRESSURE SWITCH
7
STEP DOWN TRANSFORMER
BURNER
The controls system utilizes a 120/24 VAC step down transformer.
Most of the control system utilizes 24 VAC for operation. See wiring
diagram for those components utilizing 24 VAC and 120 VAC.
P120/24 V AC STEP DOWN TRANSFORMER
BURNER TRA Y ASSEMBLY
The appliance is equipped with a user friendly burner tray assembly.
The assembly consists of a burner tray for mounting the burners,
manifold and orifices along with the gas valve and pilot assembly. It
can be easily removed by sliding the assembly in and out like a drawer
due to slide mounts in the combustion chamber.
The appliance is equipped with 8 burners mounted in a burner tray
assembly. The burners are tubular in design with two rows of small slit
burner ports. The natural gas burners are made of aluminized steel and
the LP version is a stainless steel material.
TUBULAR BURNER ASSEMBL Y
BURNER ORIFICE
The burner orifice regulates the input to the main burners.
BURNER TRAY ASSEMBL Y - NATURAL
BURNER TRA Y
The burner tray holds the burners in place and is used to slide the
entire assembly into the combustion chamber.
BURNER TRAY
BURNER ORIFICE
BLOWER ASSEMBL Y
The blower assembly functions by pulling in air from the outside of the
unit to supply the main burners located in the combustion chamber for
proper combustion. The blower pulls the air through the combustion
chamber and flue tubes where the flue gases then exit the exhaust vent.
FASCO BLOWER ASSEMBLY
8
HIGH LIMIT SWITCH
INSTALLATION INSTRUCTIONS
The surface mounted high limit switch monitors the flue gases escaping
through the blower assembly to ensure the temperatures do not exceed
the rating for the CPVC/PVC vent pipe utilized on the venting.
FIGURE 4
HIGH LIMIT SWITCH
SHROUD ASSEMBL Y
The shroud assembly protects the top of the appliance where the blower
and junction box are located.
SHROUD ASSEMBL Y
TEMPERA TURE AND PRESSURE RELIEF V AL VE
The temperature and pressure relief valve is a mechanical valve that
will open when the temperature or pressure in the tank exceeds
safe limits.
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.
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESUL T IN SERIOUS
PERSONAL INJURY OR DEA TH.
HARD W A 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 clean out procedure.
LOCA TING THE HEA TER
When installing the heater, consideration must be given to proper
location with adequate air supply and as centralized with the piping
system as possible.
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 ST ORED, OPERA TED OR REP AIRED. FLAMMABLE
VAPORS ARE HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE
IGNITED BY THE HEA TER’S PILOT OR MAIN BURNER FLAMES CAUSING
FIRE OR EXPLOSION. SOME LOCAL CODES PERMIT OPERA TION OF GAS
APPLIANCES IN SUCH AREAS IF THEY ARE INSTALLED 18” OR MORE
ABOVE THE FLOOR. THIS MA Y REDUCE THE RISK IF LOCA TION IN SUCH
AN AREA CANNOT BE AVOIDED.
DO NOT INST ALL THIS W ATER HEA TER DIRECTL Y ON A CARPETED FLOOR. A
FIRE HAZARD MA Y RESULT . Instead the water heater must be placed on a metal
or wood panel extending beyond the full width and depth by at least 3 inches (7.6
cm) in any direction. If the heater is installed in a carpeted alcove, the entire floor
shall be covered by the panel. Also, see the DRAIN REQUIREMENTS.
THE HEA TER SHALL BE LOCA TED OR PROTECTED SO IT IS NOT SUBJECT
TO PHYSICAL DAMAGE BY A MOVING VEHICLE.
TEMPERATURE AND PRESSURE RELIEF V AL VE
DRAIN VAL VE
The drain valve is used to drain the unit of water for servicing or replacement.
DRAIN V AL VE
WARNING
FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY OTHER
POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON
OR ADJACENT TO THE HEATER. OPEN CONTAINERS OR FLAMMABLE
MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM WITH
THE HEATER. THE HEA TER MUST NOT BE LOCA TED IN AN AREA WHERE IT
WILL BE SUBJECT TO FREEZING . LOCA TE IT NEAR A FLOOR DRAIN. THE
HEATER SHOULD BE LOCA TED 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 A VOIDED, A SUIT ABLE DRAIN P AN
SHOULD BE INSTALLED UNDER THE HEATER. Such pans should be fabricated
with sides at least 2" (5 cm) deep, with length and width at least 2" (5 cm)
greater than the diameter of the heater and must be piped to an adequate
drain. The pan must not restrict combustion air flow.
For appliance installation locations with elevations above
2000 feet (610 m), refer to HIGH ALTITUDE INSTALLATIONS section of this
manual for input reduction procedure.
LEVELING
If the unit is not level, insert the bolts which were used in crating into the
legs to correct this condition.
9
CLEARANCES
The unit is approved for installation on combustible flooring in an alcove
when the minimum clearance to combustibles is maintained per Figure 6
and the table below.
ABCD
(RIGHT SIDE) (LEFT SIDE) (BACK) (CEILING)
0" (0cm) 0" (0cm) 0" (0cm) 12" (30.5 cm)
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.
FIGURE 5
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, ventilation and draft hood dilution 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
When drawing combustion and dilution 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 INCHES (30.5 cm)
OF THE ENCLOSURE TOP AND ONE IN OR WITHIN 12 INCHES (30.5 cm)
OF THE ENCLOSURE BOTTOM. Each opening shall have a free area of at
least one square inch per 1000 Btuh (2,225mm²/Kw) of the total input of
all appliances in the enclosure, but not less than 100 square inches (645
square cm).
If the confined space is within a building of tight construction, air for
combustion, ventilation, and draft hood dilution must be obtained from
outdoors. When directly communicating with the outdoors or 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 (8,900mm²/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 (4,450mm²/Kw) of the total input of all appliances in the enclosure.
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 DRAWN INTO THE ROOM THROUGH THE HEATER'S
VENTING SYSTEM, CAUSING POOR COMBUSTION AND/OR SOOTING
WHICH MAY RESULT IN SERIOUS DAMAGE TO THE HEA TER AND RISK OF
FIRE OR EXPLOSION. IT CAN ALSO CREA TE A RISK OF ASPHYXIA TION.
FIGURE 6
ALCOVE INSTALLA TION (ACCEPT ABLE)
An alcove suitable for the installation of a water heater is a restricted
section of a room not separated from the room by a door or partition and
which meets the minimum clearances for the water heater.
*When the ceiling height exceeds 8 feet (2.4 m), you are only allowed to
consider 8 feet (2.4 m) when calculating the total volume of the enclosure.
AIR REQUIREMENTS
REFER TO THE CURRENT EDITION OF THE NA TIONAL FUEL GAS CODE
ANSI Z223.1/NFPA 54.
WARNING
KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE MA TERIALS,
GASOLINE AND OTHER FLAMMABLES, V APORS AND LIQUIDS.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION OR 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 AIR
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 CREA TES A RISK OF ASPHYXIA TION.
Where an exhaust fan is supplied in the same room with a heater, sufficient
openings for air must be provided in the walls. UNDERSIZED OPENINGS WILL
CAUSE AIR T O BE DRAWN INTO THE ROOM THROUGH THE CHIMNEY, CAUSING
POOR COMBUSTION. SOOTING MAY RESUL T IN SERIOUS DAMAGE TO THE
HEATER AND RISK OF FIRE OR EXPLOSION.
UNCONFINED SPACE
In buildings of conventional frame, brick, or stone construction, unconfined spaces
may provide adequate air for combustion, ventilation and draft hood dilution.
COMBUSTION AIR AND EXHAUST
WARNING
WHEN DETERMINING THE INSTALLATION LOCA TION FOR A POWER
DIRECT VENT WA TER HEA TER, SNOW ACCUMULA TION AND DRIFTING
SHOULD BE CONSIDERED IN AREAS WHERE APPLICABLE.
VENTING CLEARANCES
VENTING THROUGH AN OUTSIDE WALL-CLEARANCES
• 1" (2.5 cm) clearance for 4" or 6" PVC or CPVC piping from combustible
surfaces for outlet piping.
• 0" clearance for 4" or 6" PVC or CPVC piping from combustible surfaces
for inlet piping.
• 18" (46 cm) minimum in all directions from any obstruction, such as a wall,
that may interfere.
• 18" (46 cm) minimum from the ground and 9" from ceiling overhangs.
See Figure 7.
• The Power Direct Vent outlet terminal shall terminate a least 36" (91 cm)
above any forced air inlet located within 10 feet. See Figure 8.
• The Power Direct Vent outlet terminal shall terminate at least 36" (91 cm)
below, 36" (91 cm) horizontally from or 18" (46 cm) above any door,
window or gravity air inlet into the building. See Figure 8.
• 18" (46 cm) minimum from other natural draft (gravity) direct vent, power
vent or power direct vent appliance inlet and/or outlet vent(s) when directly
above or 135° to either side of center line. See Figure 9.
• 36" (91 cm) minimum from any appliance inlet and / or outlet vents when
directly below or 45° to either side of center line. See Figure 9.
• Vent termination must not be within 4 feet of any items such as gas
meters, gas valves or other gas regulating equipment.
• The venting system must be installed in a manner which allows inspection
of the installation of the venting pipes and joints as well as periodic
inspection after installation as required by ANSI Standards.
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WARNING
THE LOCATION SELECTED MUST PROVIDE CLEARANCES FOR SERVICING
AND PROPER OPERATION OF THE W A TER HEA TER.
WARNING
VENT TERMINA TION MUST NOT BE WITHIN 4 FEET OF ANY ITEMS SUCH AS GAS
METERS, GAS VAL VES OR OTHER GAS REGULATING EQUIPMENT .
WARNING
FAILURE TO HAVE REQUIRED CLEARANCES BETWEEN W A TER HEA TER
AND COMBUSTIBLE MATERIAL WILL RESUL T IN A FIRE HAZARD.
FIGURE 9
WIRE FENCE
When the water heater outlet terminal is low enough to be touched
accidentally, or is accessible to small children, a wire mesh chain link
fence (as shown in Figure 9) may be used. Care should be taken to
maintain adequate ventilation around the outlet terminal. If a chain link
fence is installed, it must not be used as a storage area for items that
may block proper ventilation.
FIGURE 7
FACTS TO CONSIDER ABOUT THE LOCA TION
VENTING THROUGH ROOF-CLEARANCES
• 1" (2.5 cm) clearance for 4" or 6" PVC or CPVC piping from
combustible surfaces for outlet piping.
• 0" clearance for 4" or 6" PVC or CPVC piping from combustible
surfaces for inlet piping.
• The Power Direct Vent inlet and outlet terminals shall terminate at
least 18" (46 cm) above the roof surface. See Figure 10.
• The venting system must be installed in a manner which allows
inspection of the installation of the venting pipes and joints as well as
periodic inspection after installation as required by ANSI Standards.
FIGURE 9
FIGURE 8 - DIRECT VENT TERMINAL CLEARANCES - US INSTALLA TION
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