A. O. Smith BTF-80 Installation Manual

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MODEL BTF-80
COMMERCIAL POWER VENT GAS WATER HEATER
with Hot Surface Ignition
Thank you for buying this energy efficient water heater.
We appreciate your condence in our products.
You should thoroughly read this manual before installation and/
or operation of this water heater. Please pay particular attention
to the important safety and operating instructions as well as the WARNINGS and CAUTIONS.
TABLE OF CONTENTS
PAGE
GET TO KNOW YOUR WATER HEATER 2-3
GENERAL SAFETY INFORMATION 4-5
INSTALLATION 5-14
OPERATION 14-16
MAINTENANCE AND TROUBLESHOOTING 16-19
TROUBLESHOOTING WITH THE LEDs 20
WARRANTY 24
CAUTION
INFO RMATI ON REL ATIVE TO YOUR SAFETY. PLEASE READ THOROUGHLY BEFORE INSTALLING AND USING
THIS APPLIANCE.
KEEP THIS MANUAL IN THE POCKET ON THE HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
PRINTED IN U.S.A. 0406 PART NO. 197440-000
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ROUGH-IN-DIMENSIONS
TOP VIEW
RECOVERY CAPACITIES
Recovery capacity based on 80% thermal efciency.
FOREWORD
The design of model BTF-80 complies with the current version of ANSI Z21.10.3/CSA 4.3 as automatic storage or automatic
circulating tank type water heaters.
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 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.
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 current editions of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and the National Electrical 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.
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GET TO KNOW YOUR WATER HEATER
REPLACEMENT PARTS AND DELIMING PRODUCTS
Replacement parts and recommended delimer may be ordered through authorized servicers or distributors. Refer to the Yellow Pages for where to call or contact the water heater manufacturer at, 500 Tennessee Waltz Parkway, Ashland City, TN 37015. When ordering parts, provide complete model and serial numbers (see rating plate), quantity and name of part desired (as listed in Figure
1). Standard hardware items may be purchased locally.
(A) VENT PIPE (B) ANODE (C) HOT WATER OUTLET (D) OUTLET (120 VAC) (E) FLUE BAFFLE (F) GAS SUPPLY (G) MAIN MANUAL GAS SHUT OFF VALVE (H) GROUND JOINT UNION (J) DIRT LEG (K) OUTER DOOR (L) UNION (M) INLET WATER SHUT OFF VALVE (N) COLD WATER INLET
(O) INLET DIP TUBE (P) TEMPERATURE AND PRESSURE RELIEF VALVE (Q) RATING PLATE (R) INSULATION (S) VENT TERMINAL (T) DRAIN VALVE (U) IGNITER AND MAIN BURNER (V) FLUE (W) DRAIN PAN (X) CONTROL (Y) CONTROL HARNESS* (Z) MOTOR & BLOWER (AA) CONDENSATE FITTING
*CAUTION HARNESS HAS 115 VAC. IN OPERATION
TEMPERATURE INDICATORS
VACUUM RELIEF
VALVE
*INSTALL PER
LOCAL CODES
TEMPERATURE ADJUSTMENT BUTTONS
(U) NATURAL GAS MAIN BURNER
WITH IGNITER ASSEMBLY
(U) PROPANE GAS MAIN BURNER
WITH IGNITER ASSEMBLY
(SIDE VIEW)
FIGURE 1
3
GENERAL SAFETY INFORMATION
EXTERNAL DAMAGE
Do not operate the water heater until it has been fully checked out by a qualied technician, if the water heater:
• Has been exposed to re or damage.
• Displays evidence of sooting.
• Produces steam or unusually hot water.
If the water heater has been subject to ooding it must be replaced.
CHEMICAL VAPOR CORROSION
WARNING
CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS 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. (See limited warranty for complete terms and conditions).
LP gas must be used with great caution. It is highly explosive and heavier than air. It collects rst in the low areas making its odor difcult to detect at nose level. If LP gas is present or even suspected, do not attempt to nd 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 a diminishing sense of smell with age. For these reasons, the use of a propane gas detector is recommended.
IF YOU EXPERIENCE AN OUT-OF-GAS SITUATION, DO NOT TRY 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.
EXTENDED NON-USE PERIODS
WARNING
HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER
SYSTEM SERVED BY THIS HEATER THAT HAS NOT BEEN
USED FOR A LONG PERIOD OF TIME (GENERALLY TWO WEEKS OR MORE). HYDROGEN GAS IS EXTREMELY
FLAMMABLE. To 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 ow. THERE SHOULD BE NO
SMOKING OR OPEN FLAME NEAR THE FAUCET AT THE TIME
IT IS OPEN.
IMPROPER COMBUSTION
WARNING
ATTIC AN D/O R EX HAU ST FANS OPERATIN G ON THE PREMISES WITH A WATER HEATER CAN RESULT IN CARBON
MONOXIDE POISONING AND DEATH.
OPERATION OF THESE FANS CAN PRODUCE A NEGATIVE
DRAFT IN THE AREA OF THE WATER HEATER PREVENTING
THE PRODUCTS OF COMBUSTION FROM EXHAUSTING
THROUGH THE VENT PIPE.
The venting of the water heater should be inspected by a qualied 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 OPERATION.
LIQUID PETROLEUM MODELS
WARNING
Water heaters for propane or liqueed 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.
INSULATION BLANKETS
Insulation blankets available to the general public for external use on gas water heaters are not necessary with this product. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. Your water heater meets and exceeds the Energy Policy Act 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 (See Figure 1 for identication of components mentioned below). Failure to follow these instructions can restrict the air ow required for proper combustion, potentially resulting in re, asphyxiation, serious personal injury or death.
Do not cover the gas valve or temperature & pressure relief valve.
Do not allow insulation to come within 2" (5.1 cm) of the dilution air inlet on the blower, to prevent blockage of the dilution air.
Do not allow insulation to come within 2" (5.1 cm) of the oor to prevent blockage of combustion air ow to the burner.
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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 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 ow.
sides and rear, 5.5" (14 cm) from the front and 12" (30 cm) from the top. (Standard clearance.) If clearances stated on the heater differ from standard clearances, install water heater according to clearances stated on heater.
A minimum clearance of 4" (10 cm) must be allowed for access to replaceable parts such as the thermostats, drain valve and relief valve. A top clearance of 24" (61 cm) should be allowed for blower assembly service.
INSTALLATION
REQUIRED ABILITY
INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE FIELD INVOLVED. PLUMBING, ELECTRICAL, AIR SUPPLY, VENTING AND GAS SUPPLY ARE REQUIRED.
GENERAL
MAKE SURE that the gas supply where this water heater will be installed is the same as that stated on its model and rating plate.
The installation must conform with these instructions and the local code authority having jurisdiction. In the absence of local codes, installations shall comply with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and the National Electrical 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.
GROUNDING
The water heater when installed must be grounded in accordance with the local codes, or in the absence of local codes: The National Electrical Code, NFPA 70 or the Canadian Electrical Code CSA C221.1.
HIGH ALTITUDE INSTALLATION
INSTALLATIONS ABO VE 7700 FT. (2,347 m) REQUIRE REPLACEMENT OF THE BURNER ORIFICE IN ACCORDANCE WITH NATURAL GAS AND PROPANE INSTALLATION CODE CAN/ CSA B149.1. FAILURE TO REPLACE THE ORIFICE COULD RESULT IN IMPROPER AND INEFFICIENT OPERATION OF THE APPLIANCE, PRODUCING CARBON MONOXIDE GAS IN EXCESS OF SAFE LIMITS, WHICH COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH. CONTACT YOUR GAS SUPPLIER FOR ANY SPECIFIC CHANGES WHICH MAY BE REQUIRED IN YOUR AREA.
SOME MODEL S ARE BUILT SPECI FICALLY FOR HIGH ALTITUDE SERVICE.
PLEASE CHECK THE RATING PLATE BEFORE MAKING CHANGES.
CAUTION
LOCATION OF HEATER
When installing the heater, consideration must be given to proper location. Location selected should be as close to the outside wall to be used for terminations as practicable with adequate air supply and as centralized with the water piping system as possible.
Adequate clearance for servicing this appliance should be considered before installation, such as changing the anodes, etc. Minimum clearances for proper operation are given above.
In cold climates provide protection against freeze-up.
THE HEATER SHOULD BE LOCATED IN AN AREA WHERE LEAKAGE OF THE TANK OR CONNECTIONS WILL NOT RESULT IN DAMAGE TO THE AREA ADJACENT TO THE HEATER OR TO LOWER FLOORS OF THE STRUCTURE.
When such locations cannot be avoided, a suitable drain pan should be installed under the heater, see gure 1. The pan must not restrict combustion air ow. Such pans should have a minimum length and width of at least 2" (5.1 cm) greater than the diameter of the heater and should be piped to an adequate drain. Drain pans suitable for these heaters are available from the water heater manufacturer at, 500 Tennessee Waltz Parkway, Ashland City, TN 37015.
Installation of the water heater must be accomplished in such a manner that if the tank or any of the connections should leak, the ow will not cause damage to the structure. For this reason, it is not advisable to install the water heater in an attic or upper oor. When such locations can not be avoided, a suitable drain pan should be installed under the water heater.
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 shut-off 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 shut-off 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.
DO NOT INSTALL THIS WATER HEATER DIRECTLY ON A CARPETED FLOOR. A FIRE HAZARD MAY 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 or closet, the entire oor shall be covered by the panel.
WARNING
WARNING
The heater is design certied by the Underwriters Laboratories Inc. for installation on combustible ooring in a closet having minimum clearances from combustible material of: 0" (0 cm) clearance from
AIR REQUIREMENTS
In calculating the free area of a vent opening, the blocking effect
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of screens, louvers and grills should be considered. Screens shall not be of a mesh smaller than 1/4" (6.3 mm) square. If the free area is not known, the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the Natural Gas and Propane Installation Code CAN/CSA B149.1 recommends using gures of 20-25 percent free area for wood louvers or 60-75 percent for metal grills or louvers.
WATER CONNECTIONS
Refer to gure 1 for typical installation. A suitable pipe thread sealant must be used to prevent leakage.\
WATER (POTABLE) HEATING AND SPACE HEATING
UNCONFINED SPACE
In buildings of conventional frame, brick or stone construction, unconned spaces may provide adequate air for combustion, ventilation, and dilution air for power venter.
If the unconned space is within a building of tight construction (building using the following construction: weather stripping, heavy insulation, caulking, vapor barrier, etc.), air for combustion, ventilation, and venter dilution must be obtained from outdoors. The installation instructions for conned spaces must be followed.
CONFINED SPACE
When drawing combustion and dilution air from inside a conventionally constructed building to a conned space, such a space shall be provided with two permanent openings. ONE WITHIN 12" (30 cm) OF THE ENCLOSURE TOP AND ONE WITHIN 12" (30 cm) OF THE ENCLOSURE BOTTOM. Each opening shall have a free area of one square inch (6.5 cm²) per 1000 Btuh (292.8 W) of the total input of all 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, ventilation and power venter dilution must be obtained from outdoors. When directly communicating with the outdoors or communicating 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 (6.5 cm²) per 4000 Btuh (1,171 W) 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 (6.5 cm²) per 2000 Btuh (585.6 W)
of the total input of all appliances in the enclosure.
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 spa ce heating at temperatures higher than required for domestic water purposes, a tempering valve must be installed. Please refer to Figure 2 for suggested piping arrangement.
FIGURE 2
CLOSED WATER SYSTEM
A closed system will exist if a back-ow preventer (check valve), pressure reducing valve, or other similar device is installed in the cold water line between the water heater and the street main (or well). Excessive pressure may develop due to the thermal expansion of heated water causing premature tank failure or intermittent relief valve operation. This type of failure is not covered by the limited warranty. An expansion tank may be necessary in the cold water supply to alleviate this situation, see Figure 1. Contact the local plumbing authority.
If the temperature and pressure relief valve on the appliance discharges periodically, this may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct situation. DO NOT PLUG
THE TEMPERATURE AND PRESSURE RELIEF VALVE.
GAS CONNECTIONS
The minimum gas supply pressure for input adjustment is 5.0" (12.7 cm) W.C. for natural gas (11.0" (27.9 cm) W.C. for propane).
THE HEATER IS NOT INTENDED FOR OPERATION AT HIGHER
THAN 14" (35.6 cm) WATER COLUMN SUPPLY PRESSURE.
EXPOSURE TO HIGHER GAS SUPPLY PRESSURE MAY
CAUSE DAMAGE TO THE CONTROL WHICH COULD RESULT
IN FIRE OR EXPLOSION. If overpressure has occurred such as
through improper testing of gas lines or emergency malfunction of the supply system, the control must be checked for safe operation. Make sure that the outside vents on the supply regulators and the safety vent valves are protected against blockage. These are parts of the gas supply system not the heater. Vent blockage may occur during ice storms.
IT IS IMPORTANT TO GUARD AGAINST CONTROL FOULING FROM CONTAMINANTS IN THE GAS WAYS. SUCH FOULING
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WARNING
VENT HOOD(S) MAY BE EXTREMELY HOT DURING OPERATION.
U.S. HORIZONTAL VENT CLEARANCES
CANADIAN HORIZONTAL VENT CLEARANCES
FIGURE 3
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MAY CAUSE IMPROPER OPERATION, FIRE OR EXPLOSION.
All piping must comply with local codes and ordinances or with the National Fuel Gas Code NFPA 70 or the Natural Gas and Propane Installation Code CAN/CSA B149.1, whichever applies.
REFER TO FIGURE 1 FOR CONNECTION DETAILS. BEFORE ATTACHING THE GAS LINE BE SURE THAT ALL GAS PIPE IS CLEAN ON THE INSIDE.
TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS
SUPPLY LINE, A DIRT LEG (SOMETIMES CALLED DRIP LEG) MUST BE INCORPORATED IN THE PIPING, FIGURE. 1. The
dirt leg must be readily accessible. Install in accordance with recommendations of serving gas supplier. Refer to the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the Natural Gas and Propane Installation Code CAN/CSA B149.1.
To prevent damage, care must be taken not to apply too much torque when attaching gas supply pipe to thermostat gas inlet. The thermostat inlet has a pad for use with a backup wrench.
Apply joint compounds (pipe dope) sparingly and only to the male threads of pipe joints. Do not apply compound to the rst two threads. Use compounds resistant to the action of liqueed petroleum gases. Do not use teon tape on thermostat ttings.
CONNECTION OF GAS PIPE
1. When connecting gas pipe to unit, apply wrench to ange only. Note: Do not use wrench on gas valve or gas valve bracket.
2. PERFORM THE GAS LEAK TEST ANY TIME WORK IS DONE
ON A GAS SYSTEM TO AVOID THE POSSIBILITY OF FIRE
OR EXPLOSION WITH PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE.
The Gas Leak Test is performed as follows: Paint pipe
connections upstream of gas control with a rich soap and water solution to test for leaks before operating main burner. Bubbles indicate gas leak. To stop leak, tighten pipe connections. After piping connections are checked, turn on main burner. (See Lighting and Operating Installations in this manual or on water heater.) With main burner in operation, paint pipe joints (including anges) and control inlet and outlet with rich soap and water solution. Bubbles indicate gas leak. To stop leak, tighten ange screws, joints and pipe connections. Replace part if leak can't be stopped.
DISCONNECT THE APPLIANCE AND ITS INDIVIDUAL SHUT
OFF VALVE FROM THE GAS SUPPLY PIPING SYSTEM
DURING ANY SUPPLY PRESSURE TESTING EXCEEDING 1/2 PSI (3.5 kPa). GAS SUPPLY LINE MUST BE CAPPED WHEN DISCONNECTED FROM THE HEATER. FOR TEST PRESSURES AT 1/2 PSI (3.5 kPa) OR LESS, THE APPLIANCE NEED NOT BE DISCONNECTED, BUT MUST BE ISOLATED FROM THE SUPPLY PRESSURE TEST BY CLOSING THE MAIN
MANUAL GAS VALVE.
NOT USE MATCHES CANDLES, FLAME OR OTHER SOURCES OF IGNITION TO LOCATE GAS LEAKS.
RELIEF VALVE
A NEW TEMPERATURE AND PRESSURE RELIEF VALVE
COMPLYING WITH THE STANDARD FOR RELIEF VALVES AND AUTOMATIC GAS SHUT OFF DEVICES FOR HOT WATER SUPPLY SYSTEMS, ANSI Z21.22-CSA 4.4 MUST BE INSTALLED IN THE HEATER IN THE MARKED OPENING PROVIDED. THE VALVE MUST BE OF A SIZE (INPUT RATING) THAT WILL BE ADEQUATE FOR YOUR SIZE HEATER.
Check the metal tag on the relief valve and compare it to the heater’s rating plate. The pressure rating of relief valve must not exceed the working pressure shown on the rating plate of the heater. In addition the hourly Btu rated temperature steam discharge capacity of the relief valve shall not be less than the input rating of the heater. NO VALVE
IS TO BE PLACED BETWEEN THE RELIEF VALVE AND TANK. DO
NOT PLUG THE RELIEF VALVE.
The drain line connected to this valve must not contain a reducing coupling or other restriction and must terminate near a suitable drain to prevent water damage during valve operation. The discharge line shall be installed in a manner to allow complete drainage of both the valve and line. DO NOT THREAD, PLUG
OR CAP THE END OF THE DRAIN LINE.
VENTING
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
The rst step is to determine where the vent pipe will terminate. See Figures 3, 8 and 9. The vent may terminate through the roof as shown in Figure 9 or through a sidewall as shown in Figure 8.
IMPORTANT
The vent system must terminate so that proper clearances are maintained as cited in local codes or the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the Natural Gas and Propane Installation Code CAN/CSA-B149.1.
For your convenience instructions on proper installation through a sidewall are provided in Figure 3.
The manufacturer also recommends that the vent system termination not be installed closer than 3 feet (91 cm) from an inside corner of an L shaped structure and not be less than 1 foot (30 cm) above grade. The vent shall terminate a minimum of 12" (30 cm) above expected snowfall level to prevent blockage of vent termination.
Plan the vent system layout so that proper clearances are maintained from plumbing and wiring.
BEFORE PLACING THE HEATER IN OPERATION, CHECK FOR GAS LEAKAGE. USE SOAP AND WATER SOLUTION OR OTHER MATERIAL ACCEPTABLE FOR THIS PURPOSE. DO
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 INSTALLATION OF VENT SYSTEM, and with the National Fuel
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