A. O. Smith BT-100 Service Manual

MODELS BT- 80 AND 100
COMMERCIAL GAS WATER HEATER
Glass-Lined Tank-Type W ater Heater
Thank you for buying this energy efficient water heater from A.O. Smith Water Products Company. We appreciate your confidence in our products.
PRINTED IN U.S.A. 1004
TEXT IN BLACK BOLD TYPE OR UNDERLINED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY. INST ALLING AND USING THIS APPLIANCE.
PLACE THESE INSTRUCTIONS ADJACENT TO HEA TER
AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
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PLEASE READ THOROUGHLY BEFORE
A DIVISION OF A.O. SMITH CORPORA TION
McBEE, SOUTH CAROLINA, USA
www.aosmithwaterheaters.com
CAUTION
P ART NO. 196158-001
ROUGH-IN DIMENSIONS
FIGURE 1.
DIMENSIONS
Model Units A B C D E F G H J K L M
BT-80 Inches 61 1/8 58 1/2 29 11/16 26 1/2 15 3/16 4 14 1/2 16 1 1/4 1 1/2 11 15/16
Natural & LP C M 155.25 148.6 75.4 67.3 38.6 10.2 39.4 40.6 3.2 NPT NPT 30.3
BT-100 Inches 69 3/4 66 1/2 29 11/16 26 1/2 15 3/16 4 14 1/2 16 1 1/4 1 1/4 1/2 11 15/16 Natural C M 177.2 168.9 75.4 67.3 38.6 10.2 39.4 40.6 3.2 NPT NPT 30.3
BT-100 Inches 68 5/8 66 1/2 30 15/16 27 3/4 15 3/16 4 15 3/4 1 6 1 1/4 1 1/4 1/ 2 11 15/16
LP CM 174.3 168.9 78.59 70.5 38.6 10.2 40.0 40.6 3.2 NPT NPT 30.3
RECOVERY RA TINGS
Input Approx. Approx.
Model Rating Rating Gal. Liter T emp. C° 17 22 28 33 39 44 50 56 61 67 72 78
Btu/Hr kW Cap. Cap. Rise F° 30 40 50 60 70 80 90 100 1 10 120 130 140
BT- 80 75,100 22.0 74 280 GPH 243 182 146 121 104 91 81 73 66 61 56 52
LPH 916 686 550 456 392 343 305 275 249 230 211 196
BT -100 75,100 22.0 98 371 GPH 243 182 146 121 104 91 81 73 66 61 5 6 52
LPH 916 686 550 456 392 343 305 275 249 230 211 196
Recovery ratings based on 80% thermal efficiency.
FOREWORD
The design of models BT-80 and 100 comply with the latest version of ANSI Z21.10.3-CSA 4.3 as automatic storage or automatic circulating tank type water heaters.
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.
Installation diagrams are found in this manual. These diagrams will serve to provide the installer with a reference for the materials and method of piping necessary. It is highly essential that all water and gas piping be installed as shown on the diagrams.
In addition to these instructions, the equipment shall be installed in accordance with those installation regulations in force in the
The installation must conform to these instructions and the local code authority having jurisdiction. In the absence of local codes, the installation must comply with the latest editions of the National Fuel Gas Code, ANSI Z223.1/NFP A 54. This publication is available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131, or the National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.
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TABLE OF CONTENTS
Page
ROUGH-IN DIMENSIONS ....................................................................... 2
FOREWORD .......................................................................................... 2
GENERAL SAFETY INFORMA TION ...................................................... 3-4
Precautions....................................................................................... 3
Chemical Vapor Corrosion ............................................................... 3
Improper Combustion........................................................................ 3
Liquid Petroleum Models................................................................... 3-4
Extended Non-use Periods .............................................................. 4
Insulation Blankets............................................................................ 4
Circulating Pump ............................................................................... 4
INSTALLA TION INSTRUCTIONS ............................................................ 4-9
Required Ability................................................................................. 4
Locating The Heater ......................................................................... 4-5
High Altitude Installations .................................................................. 5
Clearances ....................................................................................... 5
Hard Water ....................................................................................... 5
Air Requirements.............................................................................. 5-6
Water (Potable) Heating and Space Heating ................................... 6
Venting.............................................................................................. 6-7
Thermometers (Not Supplied) .......................................................... 7
Relief Valve....................................................................................... 7
Gas Piping......................................................................................... 8-9
Gas Pressure Regulator .................................................................. 9
OPERATION.......................................................................................... 9-13
Page
To Operate The Water Heater......................................................... 9
Purging............................................................................................. 9
Lighting Instructions ........................................................................10-11
T emperature Regulation .................................................................. 12
Check Venting .................................................................................12-13
High Temperature Limit Switch........................................................ 13
SERVICE INFORMA TION ......................................................................13-14
Pilot and Main Burner....................................................................... 13
Checking Gas Input .........................................................................13-14
Vent System .................................................................................... 14
Relief Valve...................................................................................... 14
Hot Water Odor ............................................................................... 14
Anode Rod Inspection ..................................................................... 14
Winter Protection ............................................................................. 14
Replacement Parts .......................................................................... 14
PREVENTIVE MAINTENANCE ..............................................................15-16
Recommended Procedure For Periodic Removal Of Lime
Deposits From Tank Type Commercial Water Heaters ................... 15
Deliming Solvents ............................................................................ 15
Tank Cleanout Procedure ................................................................15-16
CHECKLIST ..........................................................................................16-17
LIMITED WARRANTY............................................................................ 18
GENERAL SAFETY
INFORMATION
PRECAUTIONS
DO NOT USE THIS APPLIANCE IF ANY P ART 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 OPERA TE HEA TER UNTIL ALL CORRECTIVE STEPS HA VE BEEN MADE BY A QUALIFIED SERVICEMAN.
1. EXTERNAL FIRE.
2. DAMAGE.
3. FIRING WITHOUT WA TER.
4. SOOTING
CHEMICAL VAPOR CORROSION
WARNING
CORROSION OF THE FLUEWA YS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONT AINS 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 (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.)
IMPROPER COMBUSTION
WARNING
ATTIC AND/OR EXHAUST F ANS OPERA TING ON THE PREMISES WITH A WA TER HEA TER CAN RESUL T IN CARBON MONOXIDE POISONING AND DEATH.
OPERA TION OF THESE FANS 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 VENTILATING AIR. ADEQUATE AIR FOR COMBUSTION AND VENTILATION MUST BE PROVIDED FOR SAFE OPERA TION.
LIQUID PETROLEUM MODELS
Water heaters for propane or liquefied petroleum gas (LPG) are different from natural gas models. A natural gas heater will not function safely on LP gas and no attempt should be made to convert a heater from natural gas to LP gas.
LP gas must be used with great caution. It is highly explosive and heavier than air. It collect s first in the low areas making its odor difficult to detect at nose level. If LP gas is present or even suspected, do not attempt to find the cause yourself. Go to a neighbor's house, leaving your doors open to ventilate the house, then call your gas supplier or service agent. Keep area clear until a service call has been made.
At times you may not be able to smell an LP gas leak. One cause is odor fade, which is a loss of the chemical odorant that gives LP gas its distinctive smell. Another cause can be your physical condition, such as having a cold or diminishing sense of smell with age. For these reasons, the use of a propane gas detector is recommended.
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IF YOU EXPERIENCE AN OUT -OF-GAS SITUATION, DO NOT TR Y TO RELIGHT APPLIANCES YOURSELF, ask your LP delivery person to
relight pilots for you. Only trained LP professionals should conduct the required safety checks in accordance with industry standards.
INSTALLATION INSTRUCTIONS
REQUIRED ABILITY
EXTENDED NON-USE PERIODS
WARNING
HYDROGEN GAS CAN BE PRODUCED IN A HOT W A TER SYSTEM SERVED BY THIS HEA TER THA T HAS NOT BEEN USED FOR A LONG PERIOD OF TIME (GENERALLY TWO WEEKS OR MORE). HYDROGEN GAS IS EXTREMEL Y FLAMMABLE. T o reduce the risk
of injury under 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 AT THE TIME IT IS OPEN.
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 90.1b-1999 standards with respect to insulation and standby loss requirement 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 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 the draft hood.
• Do not cover the outer door, thermostat or temperature & pressure relief valve.
• Do not allow insulation to come within 2" (5cm) of the floor to prevent blockage of combustion air flow to the burner.
• Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.
• Do obtain new warning and instruction labels from A.O. Smith for placement on the blanket directly over the existing labels.
• Do inspect the insulation blanket frequently to make certain it does not sag, thereby obstructing combustion air flow.
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. Install the system in accordance with the latest 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.
INSTALLA TION OR SERVICE OF THIS W A TER HEATER REQUIRES ABILITY EQUIVALENT TO THA T OF A LICENSED TRADESMAN IN THE FIELD INVOL VED. PLUMBING , AIR SUPPL Y, VENTING AND GAS SUPPLY WORK ARE REQUIRED.
GENERAL
The heater is designed to operate on natural or propane gases. HOWEVER, MAKE SURE the gas on which the heater will operate is the same as that specified on the heater model and rating plate.
LOCATING THE HEATER
When installing the heater, consideration must be given to proper location. Location selected should be as close to the stack or chimney as practicable, 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 WA TER HEA TERS IN ROOMS, GARAGES OR OTHER AREAS WHERE GASOLINE, OTHER FLAMMABLE LIQUIDS OR ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED, OPERA TED OR REPAIRED. FLAMMABLE VAPORS ARE HEAVY AND TRAVEL ALONG THE FLOOR AND MA Y 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 IF INSTALLED 18" (46CM) OR MORE ABOVE THE FLOOR. THIS MA Y REDUCE THE RISK IF LOCATION IN SUCH AN AREA CANNOT BE AVOIDED.
DO NOT INSTALL THIS WATER HEATER DIRECTLY ON A CARPETED FLOOR. A FIRE HAZARD MAY RESULT.
water heater must be placed on a metal or wood panel extending beyond the full width and depth by at least 3" (76.2mm) in any direction. If the heater is installed in a carpeted alcove or closet, the entire floor shall be covered by the panel. Also, see the drain requirements.
THIS HEATER SHALL BE LOCATED OR PROTECTED SO IT IS NOT SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE.
WARNING FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY OTHER POTENTIAL FIRE HAZARDOUS ARTICLES 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.
THE HEATER MUST NOT BE LOCATED IN AN AREA WHERE IT WILL BE SUBJECT TO FREEZING.
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, A SUITABLE DRAIN PAN SHOULD BE INSTALLED UNDER THE HEATER. Such pans should be fabricated with sides at least 2" (5cm) deep, with length and width at least 2" (5cm) greater than the diameter of the heater and must be piped to an adequate drain. The pan must not restrict combustion air flow.
Instead the
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Drain pans suitable for these heaters are available from your distributor or A. O. Smith Water Products Company, 5621 West 115th Street, Alsip, IL 60803.
Water heater life depends upon water quality, water pressure and the environment in which the water heater is installed. Water heat­ers are sometimes installed in locations where leakage may re­sult in property damage, even with the use of a drain pan piped to a drain. However, unanticipated damage can be reduced or pre­vented by a leak detector or water shutoff device used in conjunc­tion with a piped drain pan. These devices are available from some plumbing supply wholesalers and retailers, and detect and react to leakage in various ways:
• Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected.
• Sensors mounted in the drain pan that turn off the water supply to the entire home when water is detected in the drain pan.
• Water supply shutoff devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater.
• Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply.
For appliance installation locations with elevations above 2000' (610m), refer to HIGH ALTITUDE INSTALLATIONS section of this manual for input reduction procedure.
HIGH AL TITUDE INSTALLATIONS
state the model number and the altitude of the location where the water heater is being installed.
Upon completion of derating of the heater, adjustment to the gas pressure regulator may be required. See CHECKING THE INPUT section in this manual for inlet and manifold pressure requirements.
Also due to the input rating reduction required at high altitudes, the recovery rating of the appliance is also reduced and should be compensated for in the sizing of the equipment for application.
CLEARANCES
These heaters are approved for installation on combustible flooring in a closet having a ceiling 12" (30.5cm) above top cover and with clearances to combustible construction of 6" (15.2cm) from flue or vent connector, 0" (0cm) at the sides and rear and 4" (10.1cm) to front to prevent a possible fire hazard condition. A minimum of 4" (10.1cm) shall be allowed for installation of serviceable parts.
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 PREVENTIVE MAINTENANCE section for details of tank cleanout procedure.
WARNING
INSTALLA TIONS ABOVE 2000' (610m) REQUIRE REPLACEMENT OF THE BURNER ORIFICE IN ACCORDANCE WITH SECTION 8.1.2 OF THE NATIONAL FUEL GAS CODE (ANSI Z223.1). F AILURE TO REPLACE THE ORIFICE WILL RESULT IN IMPROPER AND INEFFICIENT OPERATION OF THE APPLIANCE RESUL TING IN THE PRODUCTION OF INCREASED LEVELS OF CARBON MONOXIDE GAS IN EXCESS OF SAFE LIMITS WHICH COULD RESUL T IN SERIOUS PERSONAL INJURY OR DEATH.
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 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 overfiring 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 (610m). For elevations above 2000 feet (610m), 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 75,100 Btu/Hr (22.0 kW) at sea level, to rate the heater at 4000 feet (1219m), you subtract 4 (once for each thousand feet) x 0.04 (4% input reduction) x 75,100 Btu/Hr (original rating) from the original rating. Therefore, to calculate the input rating at 4000 feet (1219m): 4 x 0.04 x 75,100 Btu/Hr = 12,016 Btu/Hr (3.5 kW); 75,100 Btu/Hr (22.0 kW) - 12,016 Btu/Hr (3.5 kW) = 63,084 Btu/Hr (18.5 kW). At 6000 feet (1829m) the correct input rating should be 57,076 Btu/Hr (16.7 kW).
The input reduction is primarily achieved by reducing the size of the main burner orifices. To do this, the main burner orifices require replacement with orifices sized for the particular installation elevation. Correct orifice sizing and parts may be obtained from A.O. Smith Water Products Company. When ordering, be sure to
AIR REQUIREMENTS
REFER TO THE LA TEST EDITION OF THE NA TIONAL FUEL GAS CODE ANSI Z223.1/NFP A 54.
KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLES, VAPORS AND LIQUIDS.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION OR VENTILATING AIR.
WARNING FOR SAFE OPERATION PROVIDE ADEQUATE AIR FOR COMBUSTION AND VENTILA TION. AN INSUFFICIENT SUPPL Y OF
AIR WILL CAUSE RECIRCULA TION OF COMBUSTION PRODUCTS RESULTING IN AIR CONTAMINA TION THA T MA Y 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 ASPHYXIATION.
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 MA Y RESUL T IN SERIOUS DAMAGE TO THE HEA TER 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.
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.
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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 " (305mm) OF THE ENCLOSURE TOP AND ONE IN OR WITHIN 12" (305mm) OF THE ENCLOSURE BOTTOM. Each opening shall have a free area of at least one square inch per 1000 Btu/Hr (2203mm
2
/kW) of the total input of all appliances in
the enclosure, but not less than 100 square inches (645cm2). 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
2
square inch per 4000 Btu/Hr (551mm
/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
2
per 2000 Btu/Hr (1102mm
/kW) of the total input of all appliances
in the enclosure.
WATER (POTABLE) HEATING AND SPACE
HEATING
1. All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
2. Toxic chemicals, such as those used for boiler treatment, shall
NEVER be introduced into this system.
3. This unit may NEVER be connected to any existing heating
system or component(s) previously used with a non-potable water heating appliance.
4. When the system requires water for space heating at
temperatures higher than required for domestic water purposes, a tempering valve must be installed, see Figure 4.
CAUTION
A closed system will exist if a check valve (without bypass), pressure reducing valve (without bypass), or a water meter (without bypass) is installed in the cold water line between the water heater and street main (or well).
Excessive pressure may develop in such closed systems, causing premature tank failure or intermittent relief valve operation. a similar device is required in the inlet supply line between the appliance and the meter or valve to compensate for the thermal expansion of the water .
This is not a warranty failure. An expansion tank or
Heater must be protected from freezing downdrafts. Remove all soot or other obstructions from the chimney that will
retard a free draft. Type B venting is recommended with these heaters. This water heater must be vented in compliance with all local
codes, the current edition of the National Fuel Gas Code ANSI-Z223.1 and with the Category I Venting Tables.
If any part of the vent system is exposed to ambient temperatures below 35° F (2° C) it must be insulated to prevent condensation.
• Do not connect the heater to a common vent or chimney with any oil-fired or solid fuel burning equipment. This practice is prohibited by many local building codes as is the practice of venting gas fired equipment to the duct work of ventilation systems.
FIGURE 2.
DRAFT HOOD
The draft hood furnished with this heater must be installed without alteration. Provision must be made if it is installed in confined space or a small room to accommodate draft hood spillage and avoid risks described in previous steps. The upper air opening called for in the AIR REQUIREMENTS section of this manual is for this purpose.
Locate the 3 brackets and 6 screws in the installation instruction bag. Secure each bracket to the draft hood leg with the screws furnished. Place the draft hood on the water heater so that legs of the draft hood fit into the slots on the jacket top, see Figure 3. Once the draft hood (with brackets attached) is in place, drill a small pilot hole through bracket hole into the jacket top. WARNING, DO NOT PENETRATE THE JACKET T OP BY MORE THAN 1/4". Secure the brackets to the jacket top with the screws furnished, see Figure 3.
SYSTEM CONNECTIONS
The system installation must conform to these instructions and to the local code authority having jurisdiction. Good practice requires that all heavy piping be supported.
VENTING
WARNING
THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST BE FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULA TION OF FLUE GASES. SUCH CONDITIONS CAUSE SOOTING OR RISKS OF FIRE AND ASPHYXIA TION.
FIGURE 3.
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