A.O. Smith BTH-120A, BTH-150A, BTH-199A, BTH-250A, BTH-300A Installation Manual

...

Instruction Manual

COMMERCIAL GAS WATER HEATERS

MODELS

BTH-120(A)/150(A)/199(A)/250(A)

SERIES 200 & 201

500 Tennessee Waltz Parkway

Ashland City, TN 37015

www.hotwater.com

INSTALLATION - OPERATION - SERVICE

- MAINTENANCE - LIMITED WARRANTY

WARNING: 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 efcient water heater. We appreciate your condence in our products.

Read and understand this instruction manual and the safety messages herein before installing, operating or servicing this water heater.

Failure to follow these instructions and safety messages could result in death or serious injury.

This manual must remain with the water heater.

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

PRINTED 0514 327727-000

TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE.......................................... 3

APPROVALS .......................................................................................... 3

GENERAL SAFETY INFORMATION ...................................................... 4

Precautions ........................................................................................ 4

Grounding Instructions ...................................................................... 4

Hydrogen Gas Flammable ................................................................. 4

INTRODUCTION .................................................................................... 6

Abbreviations Used ........................................................................... 6

Qualications ..................................................................................... 6

iCOMM™ & BACnet Compatible ....................................................... 6

Preparing For The Installation ...........................................................6

FEATURES AND COMPONENTS ......................................................... 7

Basic Operation ................................................................................. 7

Modulation ......................................................................................... 7

Blower/Burner Assembly Detail ......................................................... 7

Top View ............................................................................................ 8

Side Views ......................................................................................... 9

INSTALLATION CONSIDERATIONS ................................................... 10

Rough In Dimensions ......................................................................10

Locating The Water Heater ...............................................................11

Extended Vent Terminations ............................................................ 12

Optional Concentric & Low Prole Terminations.............................. 12

Hard Water ......................................................................................12

Circulation Pumps ........................................................................... 12

Insulation Blankets .......................................................................... 12

INSTALLATION REQUIREMENTS ...................................................... 13

Gas Supply Systems .......................................................................13

Supply Gas Regulator ..................................................................... 13

Power Supply .................................................................................. 13

Mixing Valves ................................................................................... 14

Dishwashing Machines .................................................................... 14

Closed Water Systems .................................................................... 14

Thermal Expansion .......................................................................... 14

Temperature-Pressure Relief Valve ................................................. 15

Condensate Drain ............................................................................ 16

Combustible Material Storage .........................................................16

Contaminated Air ............................................................................. 16

Air Requirements ............................................................................. 17

Unconned Space ...........................................................................17

Conned Space ............................................................................... 17

Fresh Air Openings For Conned Spaces ....................................... 18

Outdoor Air Through Two Openings ................................................ 18

Outdoor Air Through One Opening .................................................. 18

Outdoor Air Through Two Horizontal Ducts ..................................... 18

Outdoor Air Through Two Vertical Ducts .......................................... 19

Air From Other Indoor Spaces ......................................................... 19

INSTALLATION REQUIREMENTS - COMMONWEALTH OF

MASSACHUSETTS .............................................................................. 20

VENTING INSTALLATION ................................................................... 21

General Venting Information ............................................................ 21

General Venting Instructions ...........................................................21

Intake Air Connection ......................................................................22

Venting Requirements ..................................................................... 22

Venting Installation Sequence ......................................................... 23

Power Vent Installation .................................................................... 23

Direct Vent Installation ..................................................................... 24

Vertical Termination Installation ....................................................... 25

Sidewall Termination Installation...................................................... 27

Polypropylene Installations .............................................................. 28

AL29-4C® Vent Installations ........................................................... 29

Concentric Termination Installation .................................................. 30

4 Inch Concentric Termination Installation ....................................... 31

Low Prole Vent installation ............................................................. 34

Venting Arrangements ..................................................................... 35

Termination Clearances Sidewall Power Vent ................................. 37

Termination Clearances Sidewall Direct Vent .................................. 38

WATER HEATER INSTALLATION ........................................................ 39

Condensate Drain Installation ......................................................... 39

Supply Gas Line Installation ............................................................ 40

Gas Line Leak Testing ..................................................................... 41

Purging ............................................................................................41

Electrical Wiring ............................................................................... 41

Enable / Disable Circuit (For Building Management Systems) ........ 42

Water Line Connections ..................................................................43

T&P Valve Discharge Pipe ............................................................... 43

TEMPERATURE REGULATION .......................................................... 44

High Temperature Limit Control (ECO) ............................................ 44

Thermostat Control .......................................................................... 44

CONTROL SYSTEM OPERATION ...................................................... 45

Overview .......................................................................................... 45

Control System Navigation .............................................................. 45

User Settings & Control System Menus .......................................... 48

START UP ............................................................................................ 53

Prior to Start up ............................................................................... 53

Initial Start Up .................................................................................. 53

Lighting & Operation Labels ............................................................54

Checking The Firing Rate ................................................................ 56

High Altitude Installations ................................................................56

TROUBLESHOOTING ......................................................................... 57

Installation Checklist ........................................................................ 57

Sequence Of Operation ................................................................... 57

Sequence Of Operation Flow Chart ................................................ 58

Operational Problems ...................................................................... 59

Fault And Alert Conditions ............................................................... 60

MAINTENANCE ................................................................................... 63

General ............................................................................................ 63

Maintenance Schedule .................................................................... 63

Draining And Flushing .....................................................................63

Filling The Water Heater .................................................................. 64

Sediment Removal ..........................................................................64

Lime Scale Removal ........................................................................ 64

Powered Anode Rods ...................................................................... 65

Drain Valve and Access Panels ....................................................... 65

Vent System ....................................................................................65

DIAGRAMS .......................................................................................... 66

CCB - Central Control Board Layout ...............................................66

Wiring Diagram ................................................................................ 67

Circulation Pump Wiring Diagrams .................................................. 68

Water Piping Diagrams .................................................................... 69

NOTES ................................................................................................. 76

NOTES ................................................................................................. 77

NOTES ................................................................................................. 78

SERVICE INQUIRIES: ......................................................................... 79

COMMERCIAL ..................................................................................... 79

WATER HEATER ................................................................................. 79

LIMITED WARRANTY .......................................................................... 79

SAFE INSTALLATION, USE AND SERVICE

The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.

Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use, or service this water heater.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates an imminently

DANGER

WARNING

CAUTION

hazardous situation which, if not avoided, will result in injury or death.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in injury or death.

CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

CAUTION used without the safety alert

CAUTION

All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and how to avoid the risk of injury.

The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.

This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This water heater can cause low level exposure to some of the substances listed in the Act.

symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage.

APPROVALS

NOTE: ASME construction is optional on the water

heaters covered in this manual.

GENERAL SAFETY INFORMATION

PRECAUTIONS

DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN EXPOSED TO FLOODING OR WATER DAMAGE. Immediately call a qualied service agency to inspect the water heater and to make a determination on what steps should be taken next.

If the unit is exposed to the following, do not operate heater until all corrective steps have been made by a qualified service agency.

1. External re.

2. Damage.

3. Firing without water.

GROUNDING INSTRUCTIONS

This water heater must be grounded in accordance with the National Electrical Code and/or local codes. These must be followed in all cases. Failure to ground this water heater properly may also cause erratic control system operation.

This water heater must be connected to a grounded metal, permanent wiring system; or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the water heater.

Verify the power to the water heater is turned off before performing any service procedures. The Enable /Disable switch on front panel disables the 24 volt gas valve. Electrical supply must be turned off at circuit breaker serving water heater.

HYDROGEN GAS FLAMMABLE

Explosion Hazard

Flammable hydrogen gases may be present.

Keep all ignition sources away from faucet when turning on hot water.

Hydrogen gas can be produced in a hot water system served by this water heater that has not been used for a long period of time (generally two weeks or more). Hydrogen gas is extremely ammable. To reduce the risk of injury under these conditions, it is recommended that a hot water faucet served by this water heater be opened for several minutes 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.

Read and understand this instruction manual and the safety messages herein before installing, operating or servicing this water heater.

Failure to follow these instructions and safety messages could result in death or serious injury.

This manual must remain with the water heater.

Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death.

Children, the elderly and the physically or mentally disabled are at highest risk for scald injury.

Feel water before bathing or showering.

Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at fixtures.

Explosion Hazard

Overheated water can cause water tank explosion.

Properly sized temperature and pressure relief valve must be installed in the opening provided.

CAUTION

Improper installation, use and service may result

in property damage.

Do not operate water heater if exposed to flooding or

•

water damage. Inspect anode rods regularly, replace if damaged.

•

Install in location with drainage.

•

Fill tank with water before operation.

•

Properly sized thermal expansion tanks are required on all

•

closed water systems.

Refer to this manual for installation and service.

GENERAL SAFETY INFORMATION

Fire or Explosion Hazard

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

Avoid all ignition sources if you smell gas.

Do not expose water heater controls to excessive gas pressure.

Use only the gas shown on the water heater rating label. Maintain required clearances to combustibles.

Keep ignition sources away from faucets after extended periods of non-use.

Read instruction manual before

installing, using or servicing

water heater.

Breathing Hazard - Carbon Monoxide Gas

Do not obstruct water heater air intake with insulating blanket.

Gas and carbon monoxide detectors are available.

Install water heater in accordance with the instruction manual.

Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.

CAUTION

Property Damage Hazard

All water heaters eventually leak.

•

Fire Hazard

For continued protection against risk of fire:

Do not install water heater on carpeted floor.

Do not operate water heater if exposed to flooding or water damage.

Fire and Explosion Hazard

Use joint compound or Teflon tape compatible with propane gas.

Leak test gas connections before placing water heater in operation.

Disconnect gas piping at main gas shutoff valve before leak testing heater.

Install sediment trap in accordance with NFPA 54 or CAN/CSA B149.1.

Fire and Explosion Hazard

Do not use water heater with any gas other than the gas shown on the rating label.

Excessive gas pressure to gas valve can cause serious injury or death.

Turn off gas lines during installation. Contact a qualified installer or service

agency for installation and service.

Do not install without adequate drainage.

•

Electrical Shock Hazard

Turn off power at the branch circuit

•

breaker serving the water heater before performing any service.

Label all wires prior to disconnecting

•

when performing service. Wiring errors can cause improper and dangerous operation.

Verify proper operation after servicing.

•

Failure to follow these instructions can

•

result in personal injury or death.

Jumping out control circuits or components can

result in property damage, personal injury or death.

Service should only be performed by a qualified service

•

technician using proper test equipment.

Altering the water heater controls and/or wiring in any way

•

could result in permanent damage to the controls or water heater and is not covered under the limited warranty.

Any bypass or alteration of the water

heater controls and/or wiring will result

in voiding the appliance warranty.

INTRODUCTION

Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service.

ABBREVIATIONS USED

Abbreviations found in this Instruction Manual include :

• ANSI - American National Standards Institute

• ASME - American Society of Mechanical Engineers

• AHRI - Air Conditioning, Heating and Refrigeration Institute

• NEC - National Electrical Code

• NFPA - National Fire Protection Association

• UL - Underwriters Laboratory

• CSA - Canadian Standards Association

QUALIFICATIONS

QUALIFIED INSTALLER OR SERVICE AGENCY

Installation and service of this water heater requires ability equivalent to that of a Qualied Agency (as dened by ANSI below) in the eld involved. Installation skills such as plumbing, air supply, venting, gas supply and electrical supply are required in addition to electrical testing skills when performing service.

ANSI Z223.1 2006 Sec. 3.3.83: “Qualied Agency” - “Any individual, rm, corporation or company that either in person or through a representative is engaged in and is responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair or servicing of appliances and equipment; that is experienced in such work; that is familiar with all precautions required; and that has complied with all the requirements of the authority having jurisdiction.”

If you are not qualied (as dened by ANSI above) and licensed or certied as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the procedures described in this manual. If you do not understand the instructions given in this manual do not attempt to perform any procedures outlined in this manual.

ICOMM™ & BACNET COMPATIBLE

This water heater is compatible with the iCOMM™ remote monitoring system. The iCOMM™ system hardware and monitoring service is purchased separately. It allows users to monitor critical operational, diagnostic and energy usage data from a secure web site.

The iCOMM™ system can automatically notify selected personnel via email and/or cellular phone text messages if operational problems or user dened Alert Conditions occur.

iCOMM™ system hardware is compatible with BACnet compliant supervisory controls and building management systems. For more information call 888-928-3702.

PREPARING FOR THE INSTALLATION

1. Read the entire manual before attempting to install or operate the water heater. Pay close attention to the General Safety Information on page 4 and 5. If you don’t follow the safety rules, the water heater may not operate safely. It could cause property damage, injury and/or death.

This manual contains instructions for the installation, operation, and maintenance of the water heater. It also contains warnings throughout the manual that you must read and be aware of. All warnings and all instructions are essential to the proper operation of the water heater and your safety.

Detailed installation diagrams are also found in this manual. These diagrams will serve to provide the installer with a reference. It is essential that all venting, water piping, gas piping and wiring be installed as shown.

Particular attention should be given to the installation of thermometers at the locations indicated in the piping diagrams as these are necessary for checking the operation of the water heater.

The principal components of the water heater are identied in Features And Components on page 7 in this manual. Use this reference to locate and identify various components on the water heater.

See the Installation Checklist and Troubleshooting on page

57. By using this checklist the user may be able to make minor operational adjustments and avoid unnecessary service calls. However, service and diagnostic procedures should only be performed by a Qualied Service Agency.

NOTE: Costs to correct installation errors are not covered under the limited warranty.

2. Be sure to turn off power when working on or near the electrical system of the water heater. Never touch electrical components with wet hands or when standing in water.

3. The installation must conform to all instructions contained in this manual and the local code authority having jurisdiction. These shall be carefully followed in all cases. Authorities having jurisdiction should be consulted before installation begins if there are any questions regarding compliance with local, state or national codes.

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.

4. If after reading this manual you have any questions or do not understand any portion of the instructions, call the toll free number on the back cover of this manual for technical assistance. In order to expedite your request, please have the full Model, Serial and Series number of the water heater you are working with available for the technician. This information is located on the water heater’s rating label.

5. Carefully plan the placement of the water heater. Examine the location to ensure that it complies with the requirements in Locating The Water Heater on page 11 and the Rough In Dimensions on page 10.

6. For installation in California this water heater must be braced or anchored to avoid falling or moving during an earthquake. See instructions for correct installation procedures. Instructions may be obtained from California Ofce of the State Architect, 1102 Q Street, Suite 5100, Sacramento, CA

95811.

7. Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248-CMR 2.00: State Plumbing Code and 248-CMR 5. See Commonwealth of Massachusetts on page 20.

FEATURES AND COMPONENTS

BASIC OPERATION

The water heaters covered in this manual have a helical coil shaped heat exchanger that is submerged in the storage tank. The water heater’s Main Burner is a radial design burner, it is mounted on the top and res downward through the heat exchanger. This is a forced draft burner; hot burning gases are forced through the heat exchanger under pressure and exit through the exhaust/vent connection located at the bottom of the water heater. See Figure 1 and Figure 2.

INTAKE AIR (combustion air) CONNECTION 3 INCH PVC

BLOWER BURNER ASSEMBLY

MODULATION

The water heaters covered by this manual are capable of modulating their ring rate. The CCB monitors the water temperature in the tank and regulates the ring rate to achieve the target temperature setpoint. The ring rate is dictated by the hot water draw, proximity to the tank temperature setpoint, and various other temperature limitations. Periodically, when the heater is in modulation mode, the CCB will increase the blower speed for a short period of time to clear out any condensation that has accumulated in the heat exchanger then decreases the blower speed back to the modulating ring rate required to maintain the desired tank temperature setpoint. This ramping up and down of the blower speed is considered normal operation of the water heater.

BLOWER/BURNER ASSEMBLY DETAIL

COMBUSTION BLOWER ASSEMBLY

INTAKE AIR (combustion air) CONNECTION 3 INCH PVC

MAIN BURNER (radial design)

HEAT EXCHANGER

HELICAL COIL

VENT (exhaust) OUTLET

BURNER FLANGE

SPARK IGNITER

FLAME SENSOR

Figure 2

Spark Igniter

The control system energizes the spark ignition control with 120 VAC during the ignition cycle. The spark ignition control then sends a high-voltage current to the spark igniter which in turn ignites the main burner air/gas mixture.

Flame Sensor

The control system also monitors the ame sensor to conrm a ame is present at the Main Burner. If a ame is not veried during the ignition trial period (3-5 seconds) the control system will immediately de-energize the 24 Volt Gas Valve. See the Sequence Of Operation Flow Chart on page 58.

MAIN BURNER (radial design)

Figure 1

TOP VIEW OF ALL MODELS

TOP VIEW

FRONT

Figure 3

COMPONENTS (All Models)

IMPORTANT. The Enable/Disable switch listed in this manual is

NOT an "on/off" switch and does not disconnect 120 volt power to the CCB and other heater components.

1. Water Heater’s Enable/Disable Switch. When in the "Disabled" position the switch removes electrical power from the gas valve and blower so that water heating is disabled. The display, CCB, and other electrical components will still be energized and the display will read "Water Heating Disabled".

2. Powered anode rods. The water heaters covered in this manual are equipped with powered (non sacricial) anode rods. The BTH 120 has one powered anode, all other models will have two. Protective current is fed by the control system to the titanium electrodes at the end of each anode rod. This current ows through the water to the conductive surfaces inside the storage tank which diminishes the corrosive effect (rusting) of water when it comes in contact with steel.

3. Central Control Board (CCB) enclosure. This enclosure houses the control system’s main circuit board, power supply board, power transformer, and conguration key. The CCB regulates water temperature and controls all water heater functions, see Control System Operation on page 45.

4. Combustion Blower Assembly includes, Gas Valve and Venturi gas feed system.

5. 120 VAC junction box. Incoming power supply, ground connections, and other eld installed electrical connections are made here. See Power Supply on page 13.

6. Water heater's 24 Volt Gas Valve.

7. Blocked Intake Air switch. Normally closed contacts that open on fall in pressure. This switch is used to insure intake (combustion) air to the water heater is not restricted. The control system monitors this switch and will disable heating operation if its contacts are open during a heating cycle.

8. Supply gas line connection. See the requirements for the Gas Supply Systems on page 13.

9. Low Gas Pressure switch. Normally open contacts that close on a rise in pressure. This switch is used to insure supply

gas pressure is above minimum requirements. The control system monitors this switch and will disable heating operation if its contacts are open during a heating cycle. See Gas Pressure Requirements and Table 3 on page 11.

10. Vent connection (exhaust / condensate elbow) - three inch aluminum.

11. Intake air connection - 3 inch PVC.

12. Blocked Exhaust (vent) switch. Normally closed contacts that open on a rise in pressure. This switch is used to insure the Exhaust (vent) piping connected to the water heater is not restricted. The control system monitors this switch and will disable heating operation if its contacts are open during a heating cycle.

13. Blower Prover switch. Normally open contacts that close on a rise in pressure. This switch is used to insure the Combustion Blower is operating properly at blower start-up. The control system monitors this switch and will disable heating operation if its contacts are closed before the Combustion Blower is energized. See Sequence Of Operation on page 57.

14. Temperature-Pressure Relief Valve. See TemperaturePressure Relief Valve on page 15.

15. Upper Temperature Probe, 1 of 2 temperature probes. The water heater’s control system monitors this probe to detect water temperature in the upper portion of the storage tank. The Upper Temperature Probe also houses the ECO (energy cut out) switch. This is a non adjustable high temperature limit switch. The ECO switch contacts are normally closed and will open on a temperature rise. See High Temperature Limit Control (ECO) on page 44.

16. Water outlet connection 1 1/2” NPT.

17. UIM (user interface module). The UIM includes the display circuit board, the control system’s LCD display and operational buttons. Used to adjust various user settings and view operational information. See Control System Operation on page 45.

18. Spark Ignition Control. When energized, sends the electrical current to the spark igniter.

LEFT SIDE RIGHT SIDE

Figure 4

SIDE VIEWS

1. Cleanout access panel, covers water heater cleanout opening.

2. CCB enclosure - see item 3 on page 8 for description.

3. Intake air connection - 3 inch PVC.

4. Water heater 24 Volt Gas Valve.

5. Combustion Blower.

6. Water outlet - 1 1/2” NPT connection.

7. UIM (user interface module). The UIM includes the display circuit board, the control system’s LCD display and operational buttons. Used to adjust various user settings and view operational information. See Control System Operation on page 45.

8. Temperature-Pressure Relief Valve. See TemperaturePressure Relief Valve on page 15.

9. Temperature-Pressure Relief Valve discharge pipe - see T&P Valve Discharge Pipe Requirements: on page 15.

10. Lower Temperature Probe, 1 of 2 temperature probes. The water heater’s control system monitors this probe to detect water temperature in the lower portion of the storage tank.

11. Water inlet - 1 1/2” NPT connection.

12. Water heater drain valve.

13. Supply gas line connection. See Gas Supply Systems on page 13.

14. Low Gas Pressure switch, see description under beginning on page 8. See Gas Pressure Requirements and Table 3 on page 11.

15. Vent Connection (Exhaust/Condensate Elbow) 3" Aluminum.

16. Spark Ignition Control. When energized, sends the electrical current to the spark igniter.

ROUGH IN DIMENSIONS

INSTALLATION CONSIDERATIONS

INTAKE AIR

CONNECTION

3 INCH PVC

WATER OUTLET HEIGHT

SUPPLY GAS

CONNECTION

T & P VALV E

LOWER

TEMPERATURE

PROBE

CLEANOUT

FRONT

3/4” NPT

RECIRCULATION

RETURN

1 1/2” NPT

WATER

INLET

VENT

CONNECTION

3 INCH PVC

(exhaust elbow)

3/4” NPT

DRAIN

BACK

E E

These designs comply with the current edition of the American National Standard for Gas Water Heaters, Volume III, ANSI Z21.10.3 / CSA 4.3 as an automatic circulating tank water heater, and automatic storage water heaters.

TOP VIEW

ALL MODELS

GAS

90°

AIR INTAKE

26°

MODEL

BTH 120

BTH 150

BTH 199

BTH 250

1½" NPT WATER

OUTLET

FRONT

42°

EXHAUST

SHIP

WEIGHT

STD

SHIP

WEIGHT

ASME

DRAIN

VALVE

CLEAN OUT

T&P VALVE

30°

45°

* Center line of water outlet on top of the water heaters is approximately 7 inches from the front edge of the water heater.

18°

DIMENSIONS

A B C D E F G H I J

INCHES/CM INCHES/CM INCHES/CM INCHES/CM INCHES/CM INCHES/CM INCHES/CM INCHES/CM INCHES/CM INCHES/CM LBS/KG LBS/KG

3/7.62 27.75/70.5 6.3/16 35/88.9 55.5/141 53.5/135.9 11.25/28.6 42.25/107.32 48.5/123.2 18.25/46.36 460/208 490/220

3/7.62 27.75/70.5 6.3/16 56.38/143.2 76/193.04 75.75/192.4 11.25/28.6 64/162.6 70/177.8 18.25/46.36 523/237 553/251

Figure 5

GAS LINE CONNECTION SIZE

CAUTION

TABLE 1

† MODEL SERIES NATURAL GAS PROPANE GAS BTH 120 200/201 3/4 "NPT 3/4 "NPT BTH 150 200/201 3/4 "NPT 3/4 "NPT BTH 199 200/201 3/4 "NPT 3/4 "NPT BTH 250 200/201 3/4 "NPT 3/4 "NPT

† Depending on the installed equivalent length, and/or the number of appliances connected, the

supply gas line size may have to be increased beyond the minimum required sizes - see Gas Line Sizing on page 40.

STORAGE CAPACITIES

TABLE 2

MODEL U. S. GALLONS LITERS BTH 120 60 227 BTH 150 100 379 BTH 199 100 379 BTH 250 100 379

GAS PRESSURE REQUIREMENTS

TABLE 3

MODEL

BTH 120 0" W.C. (0 kPa) 0" W.C. (0 kPa) 4.4” W. C. (1.10 kPa) 8.5” W. C. (2.12 kPa) 14” W. C. (3.49 kPa) 14” W. C. (3.49 kPa)

BTH 150 0" W.C. (0 kPa) 0" W.C. (0 kPa) 4.4” W. C. (1.10 kPa) 8.5” W. C. (2.12 kPa) 14” W. C. (3.49 kPa) 14” W. C. (3.49 kPa)

BTH 199 0” W. C. (0 kPa) 0” W. C. (0 kPa) 4.4” W. C. (1.10 kPa) 8.5” W. C. (2.12 kPa) 14” W. C. (3.49 kPa 14” W. C. (3.49 kPa)

BTH 250 0” W. C. (0 kPa) 0” W. C. (0 kPa) 4.4” W. C. (1.10 kPa) 8.5” W. C. (2.12 kPa) 14” W. C. (3.49 kPa) 14” W. C. (3.49 kPa)

NATURAL GAS PROPANE GAS NATURAL GAS PROPANE GAS NATURAL GAS PROPANE GAS

MANIFOLD PRESSURE MINIMUM SUPPLY PRESSURE MAXIMUM SUPPLY PRESSURE

RECOVERY CAPACITIES

TABLE 4

U. S. GALLONS/HR & LITERS/HR AT TEMPERATURE RISE INDICATED

Model

BTH 120

BTH 150

BTH 199

BTH 250

Type of

Gas

Natural

Propane LPH 1743 1308 1046 872 747 654 581 523 475 436 402 374

Natural

Propane LPH 2248 1686 1349 1124 963 843 749 674 613 562 519 482

Natural

Propane LPH 2965 2224 1779 1483 1271 1112 988 890 809 741 684 635

Natural

Propane LPH 3670 2753 2202 1835 1573 1376 1223 1101 1001 918 847 786

Input

Btu/hr kW °C 17°C 22°C 28°C 33°C 39°C 44°C 50°C 56°C 61°C 67°C 72°C 78°C

120,000 35 95

150,000 44 98

199,900 58 97

250,000 73 96

Thermal

Efciency%

°F 30°F 40°F 50°F 60°F 70°F 80°F 90°F 100°F 110°F 120°F 130°F 140°F

GPH 461 345 276 230 197 173 154 138 126 11 5 106 99

GPH 594 445 356 297 255 223 198 178 162 148 137 127

GPH 783 588 470 392 336 294 261 235 214 196 181 168

GPH 970 727 582 485 416 364 323 291 264 242 224 208

LOCATING THE WATER HEATER

Carefully choose a location for the new water heater. The placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the water heater.

Property Damage Hazard

All water heaters eventually leak.

•

Do not install without adequate drainage.

•

Whether replacing an existing water heater or installing the water heater in a new location observe the following critical points:

1. The water heater must be located indoors.

2. The water heater must not be located in an area where it will be subject to freezing temperatures.

3. Locate the water heater so it is protected and not subject to physical damage by a moving vehicle.

4. Locate the water heater on a level surface.

5. Locate the water heater near a oor drain. The water 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 water heater or to lower oors of the structure. When such locations cannot be avoided, it is recommended that a metal drain pan, adequately drained, be installed under the water heater.

6. Locate the water heater close to the point of major hot water usage.

7. Locate the water heater close to a 120 VAC power supply. See Power Supply on page 13 for requirements.

8. Locate the water heater where an adequate supply of fresh air for combustion and ventilation can be obtained. See Air Requirements on page 17.

9. Locate the water heater where the vent and intake air piping, when installed, will remain within the maximum equivalent lengths allowed. See Venting Requirements on page 22.

10. Do not locate the water heater where noise (such as the Combustion Blower) during normal operation will be objectionable in adjacent areas.

11. Do not locate the water heater where the subsequent installation of the vent (exhaust) or intake air terminations would be objectionable due to noise at the termination(s). This includes locations close to or across from windows and doors. See Venting Installation on page 21.

Fire or Explosion Hazard

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

Avoid all ignition sources if you smell gas.

Do not expose water heater controls to excessive gas pressure.

Use only the gas shown on the water heater rating label. Maintain required clearances to combustibles.

Keep ignition sources away from faucets after extended periods of non-use.

Read instruction manual before

installing, using or servicing

water heater.

There is a risk in using fuel burning appliances such as gas water heaters in rooms, garages or other areas where gasoline, other ammable liquids or engine driven equipment or vehicles are stored, operated or repaired. Flammable vapors are heavy and travel along the oor and may be ignited by the water heater’s igniter or Main Burner ames causing re or explosion.

Flammable items, pressurized containers or any other potential re hazardous articles must never be placed on or adjacent to the water heater.

CLEARANCE TO COMBUSTIBLE MATERIALS

The water heaters covered in this manual are approved for installation on combustible ooring. The clearance to combustible and non combustible construction materials is 0 inches on the back and sides of the water heater. These water heaters are also approved for installation in an alcove.

When the water heater is installed directly on carpeting, the water heater shall be installed on a metal or wood panel extending beyond the full width and depth of the water heater by at least 3 in (76.2 mm) in any direction or, if the water heater is installed in an alcove or closet, the entire oor shall be covered by the panel. The panel must be strong enough to carry the weight of the heater when full of water.

NOTE: Adequate clearance for servicing should be maintained on all installations. See Service Clearance below.

ALCOVE

TOP COVER

WATER

HEATER

FRONT

FRONT VIEW

CLEARANCES TO COMBUSTIBLE

AND NON COMBUSTIBLE

CONSTRUCTION MATERIALS

FRONT

TOP VIEW

Contact your local distributor or call the parts department phone number listed on the back cover of this manual to order 4 inch termination(s).

OPTIONAL CONCENTRIC & LOW PROFILE TERMINATIONS

The water heaters covered in this manual can be installed in a Direct Vent conguration using optional concentric or Low Prole terminations. See Concentric Termination Installation on page 30 and Low Prole Vent Termination Installation on page 34.

HARD WATER

Where hard water conditions exist, water softening or the threshold type of water treatment is recommended. This will protect the dishwashers, coffee urns, water heaters, water piping and other equipment. See Maintenance on page 63 for sediment and lime scale removal procedures.

CIRCULATION PUMPS

A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the water heater. The tank is provided with a 3/4" NPT recirculation loop return connection. See the Water Piping Diagrams beginning on page 69 for installation location of circulating pumps.

See Circulation Pump Wiring Diagrams on page 68 for electrical hookup information. Install in accordance with the current edition of the National Electrical Code, NFPA 70 or the Canadian Electrical Code, CSA C22.1.

Stainless steel circulating pumps are recommended for use with commercial water heaters.

Some circulating pumps are manufactured with sealed bearings and do not require further lubrication. Some circulating pumps must be periodically oiled. Refer to the pump manufacturer’s instructions for lubrication requirements.

INSULATION BLANKETS

Figure 6

SERVICE CLEARANCE

A service clearance of 24 inches (61 cm) should be maintained from serviceable parts such as the T&P valve, control system components, gas valve, clean out opening, drain valve, the vent connection (exhaust/condensate elbow). Leave as much room as possible above the water heater and near the exhaust elbow for this reason. See Figure 8 on page 16.

INTAKE AIR AND VENT PIPE CLEARANCES

The minimum clearance from combustible materials for the vent (exhaust) and intake air piping shall be 0 inches. Vent or intake air piping passing through a combustible wall or ceiling must be a continuous run (no joints).

EXTENDED VENT TERMINATIONS

The water heaters covered by this manual can be installed using 3 inch pipe for the intake air and/or vent piping up to a maximum of 50 equivalent feet (15.2 m). The intake air and/or vent piping can be extended up to 120 equivalent feet (36.5 m) by installing 4 inch pipe. See the Venting Requirements on page 22.

The water heater ships from the factory with two (2) 3 inch terminations that are 45° PVC elbows with a debris screen installed. When 4 inch intake air or vent pipe is installed, factory supplied 4 inch terminations must be used.

Breathing Hazard - Carbon Monoxide Gas

Do not obstruct water heater air intake with insulating blanket.

Gas and carbon monoxide detectors are available.

Install water heater in accordance with the instruction manual.

Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.

Insulation blankets are available to the general public for external use on gas water heaters but are not necessary with these products. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. The water heaters covered by this manual meet or exceed the Energy Policy Act standards with respect to insulation and standby heat loss requirements, making an insulation blanket unnecessary.

Should you choose to apply an insulation blanket to this heater, you should follow these instructions. See the Features and Components section of this manual 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 apply insulation to the top of the water heater, as this will interfere with safe operation of the blower assembly.

• DO NOT cover the control system LCD on top of the water heater.

• DO NOT cover the Temperature-Pressure Relief Valve.

INSTALLATION REQUIREMENTS

• 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 the manufacturer 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.

GAS SUPPLY SYSTEMS

Low pressure building gas supply systems are dened as those systems that cannot under any circumstances exceed 14” W.C. (1/2 PSI Gauge). These systems do not require pressure regulation. Measurements should be taken to insure that gas pressures are stable and fall within the requirements stated on the water heater rating plate. Readings should be taken with all gas burning equipment off (static pressure) and with all gas burning equipment running at maximum rate (dynamic pressure). The gas supply pressure must be stable within 1.5” W.C. from static to dynamic pressure to provide good performance. Pressure drops that exceed 1.5” W.C. may cause rough starting, noisy combustion or nuisance outages. Increases or spikes in static pressure during off cycles may cause failure to ignite or in severe cases damage to appliance gas valves. If your low pressure system does NOT meet these requirements, the installer is responsible for the corrections.

High Pressure building supply systems use pressures that exceed 14” W.C. (1/2 PSI Gauge). These systems must use eld supplied regulators to lower the gas pressure to less than 14” W.C. (1/2 PSI Gauge). Water heaters require gas regulators that are properly sized for the water heater input and deliver the rating plate specied pressures. Gas supply systems where pressure exceeds 5 PSI often require multiple regulators to achieve desired pressures. Systems in excess of 5 PSI building pressure should be designed by gas delivery professionals for best performance. Water heaters connected to gas supply systems that exceed 14” W.C. (1/2 PSI Gauge) at any time must be equipped with a gas supply regulator.

All models require a minimum gas supply pressure of 4.4" W.C. for natural gas and 8.5" W.C. for propane gas. The minimum supply pressure is measured while gas is owing (dynamic pressure). The supply pressure should never fall below 4.4" W.C. for natural gas and 8.5" W.C. for propane gas. The supply pressure should be measured with all gas red appliances connected to the common main ring at full capacity. If the supply pressure drops more than 1.5” W.C. as gas begins to ow to the water heater then the supply gas system including the gas line and/or the gas regulator may be restricted or undersized. See Supply Gas Regulator section and Gas Piping section of this manual. The gas valve on all models has a maximum gas supply pressure limit of 14” W.C. The maximum supply pressure is measured while gas is not owing (static pressure).

SUPPLY GAS REGULATOR

The maximum allowable gas supply pressure for this water heater is 14.0 inches W.C. (3.49 kPa) for natural and propane gas. Install a positive lock-up gas pressure regulator in the gas supply line if inlet gas pressure can exceed these pressures at any time.

If a positive lock-up regulator is required follow these instructions:

1. Positive lock-up gas pressure regulators must be rated

at or above the input Btu/hr rating of the water heater they supply.

2. Supply gas regulators shall have inlet and outlet connections

not less than the minimum supply gas line size for the water heater they supply. See Table 11, page 40.

3. Positive lock-up gas pressure regulator(s) should be installed

no closer than 3 feet (1 meter) and no farther than 8 feet (2.4 meters) from the water heater’s inlet gas connection.

4. After installing the positive lock-up gas pressure regulator(s)

an initial nominal supply pressure setting of 7.0” W.C. while the water heater is operating is recommended and will generally provide good water heater operation. Some addition adjustment maybe required later to maintain a steady gas supply pressure.

5. When installing multiple water heaters in the same gas

supply system it is recommended that individual positive lock-up gas pressure regulators be installed at each unit from the supply gas connection on the water heater.

POWER SUPPLY

The water heaters covered in this manual require a 120 VAC, 1Ø (single phase), 60Hz, 15 amp power supply and must also be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70 or the Canadian Electrical Code, CSA C22.1.

DEDICATED POWER WIRING AND BREAKERS

Dedicated power supply wires, ground wiring and dedicated circuit breakers often prevent electrical line noise and are required when installing the water heater.

POWER FLUCTUATIONS AND ELECTRICAL NOISE

The water heater’s control system requires a source of stable clean electricity for proper operation. Connecting the water heater to a branch circuit that is subject to uctuations in voltage level or electrical line noise such as EMI (electro magnetic interference) or RFI (radio frequency interference) may cause erratic control system operation and malfunction.

A high quality power supply lter/suppressor such as the Kleen Line model SELF/T-10 Series SC-L or equivalent must be installed if the above conditions exist. Call the technical support phone number listed on the back cover of this manual for more information.

NOTE: Malfunctions caused by the power supply and costs to install power supply lters are not covered under the limited warranty.

MIXING VALVES

Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death.

Children, the elderly and the physically or mentally disabled are at highest risk for scald injury.

Feel water before bathing or showering.

Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at fixtures.

Water heated to a temperature which will satisfy clothes washing, dish washing, and other sanitizing needs can scald and cause permanent injury upon contact. Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the water heater’s temperature setting by up to 20°F (11°C).

Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the inrm and the physically/mentally disabled. Table 5 shows the approximate time-to-burn relationship for normal adult skin. If anyone using hot water provided by the water heater being installed ts into one of these groups or if there is a local code or state law requiring a certain water temperature at the point of use, then special precautions must be taken.

In addition to using the lowest possible temperature setting that satises the demand of the application a Mixing Valve should be installed at the water heater (see Figure 7) or at the hot water taps to further reduce system water temperature.

Mixing valves are available at plumbing supply stores. Consult a Qualied Installer or Service Agency. Follow mixing valve manufacturer’s instructions for installation of the valves.

TABLE 5

Water Temperature

°F (°C)

110 (43) (normal shower temp.) 116 (47) (pain threshold) 116 (47) 35 minutes 45 minutes 122 (50) 1 minute 5 minutes 131 (55) 5 seconds 25 seconds 140 (60) 2 seconds 5 seconds 149 (65) 1 second 2 seconds 154 (68) instantaneous 1 second

(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)

Time for 1st Degree Burn

(Less Severe Burns)

Time for Permanent Burns

2nd & 3rd Degree

(Most Severe Burns)

DISHWASHING MACHINES

All dishwashing machines meeting the National Sanitation Foundation requirements are designed to operate with water ow pressures between 15 and 25 pounds per square inch (103 kPa and 173 kPa). Flow pressures above 25 pounds per square inch (173 kPa), or below 15 pounds per square inch (103 kPa), will result in improperly sanitized dishes. Where pressures are high, a water pressure reducing or ow regulating control valve should be used in the 180°F (82°C) line to the dishwashing machine and should be adjusted to deliver water pressure between these limits.

HOT WATER

OUTLET

12” TO 15” (30-38 cm)

TEMPERED WATER

OUTLET

COLD

WATER

INLET

CHECK

VALV E

TO TANK

INLET

CHECK

VALV E

MIXING

VALV E

Figure 7

The National Sanitation Foundation also recommends circulation of 180°F (82°C) water. Where this is done, the circulation should be very gentle so that it does not cause any unnecessary turbulence inside the water heater. The circulation should be just enough to provide 180°F (82°C) water at the point of take-off to the dishwashing machine.

Adjust ow by throttling a full port ball valve installed in the circulating line on the outlet side of the pump. Never throttle ow on the suction side of a pump. See the Water Piping Diagrams beginning on page 69.

NOTE: To comply with NSF Standard 5 installation requirements the bottom of the water heater must be sealed to the oor with a silicone based sealant or elevated 6 inches above the oor.

CLOSED WATER SYSTEMS

Water supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure reducing valves, check valves, and back ow preventers. Devices such as these cause the water system to be a closed system.

THERMAL EXPANSION

As water is heated, it expands (thermal expansion). In a closed system the volume of water will grow when it is heated. As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent TemperaturePressure Relief Valve operation: water discharged from the valve due to excessive pressure build up. This condition is not covered under the limited warranty. The TemperaturePressure Relief Valve is not intended for the constant relief of thermal expansion.

A properly sized thermal expansion tank must be installed on all closed systems to control the harmful effects of thermal expansion. Contact a local plumbing service agency to have a thermal expansion tank installed.

See Water Line Connections on page 43 and the Water Piping Diagrams beginning on page 69.

CAUTION

TEMPERATURE-PRESSURE RELIEF VALVE

Explosion Hazard

Temperature-Pressure Relief Valve must comply with ANSI Z21.22CSA 4.4 and ASME code.

Properly sized temperaturepressure relief valve must be installed in opening provided.

Can result in overheating and excessive tank pressure.

Can cause serious injury or death.

This water heater is provided with a properly rated/sized and certied combination Temperature-Pressure Relief Valve (T&P valve) by the manufacturer. The valve is certied by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA 4.4, and the code requirements of ASME.

If replaced, the new T&P valve must meet the requirements of local codes, but not less than a combination TemperaturePressure Relief Valve rated/sized and certied as indicated in the above paragraph. The new valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (150 psi = 1,035 kPa) and a discharge capacity not less than the water heater Btu/hr or kW input rate as shown on the water heater’s model rating label.

NOTE: In addition to the factory installed Temperature-Pressure Relief Valve on the water heater, each remote storage tank that may be installed and piped to a water heating appliance must also have its own properly sized, rated and approved TemperaturePressure Relief Valve installed. Call the toll free technical support phone number listed on the back cover of this manual for technical assistance in sizing a Temperature-Pressure Relief Valve for remote storage tanks.

For safe operation of the water heater, the Temperature-Pressure Relief Valve must not be removed from its designated opening nor plugged. The Temperature-Pressure Relief Valve must be installed directly into the tting of the water heater designed for the relief valve. Install discharge piping so that any discharge will exit the pipe within 6 inches (15.2 cm) above an adequate oor drain, or external to the building. In cold climates it is recommended that it be terminated at an adequate drain inside the building. Be certain that no contact is made with any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstances. Excessive length, over 30 feet (9.14 m), or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve.

No valve or other obstruction is to be placed between the Temperature-Pressure Relief Valve and the tank. Do not connect discharge piping directly to the drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge

water in adequate quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water ow may cause property damage.

Water Damage Hazard

Temperature-Pressure Relief Valve discharge

•

pipe must terminate at adequate drain.

T&P Valve Discharge Pipe Requirements:

• Shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions.

• Shall not be plugged or blocked.

• Shall not be exposed to freezing temperatures.

• Shall be of material listed for hot water distribution.

• Shall be installed so as to allow complete drainage of both the Temperature-Pressure Relief Valve and the discharge pipe.

• Must terminate a maximum of six inches above a oor drain or external to the building. In cold climates, it is recommended that the discharge pipe be terminated at an adequate drain inside the building.

• Shall not have any valve or other obstruction between the relief valve and the drain.

Burn hazard.

Hot water discharge.

Keep clear of TemperaturePressure Relief Valve discharge outlet.

The Temperature-Pressure Relief Valve must be manually operated at least twice a year. Caution should be taken to ensure that (1) no one is in front of or around the outlet of the Temperature-Pressure Relief Valve discharge line, and (2) the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot. If after manually operating the valve, it fails to completely reset and continues to release water, immediately close the cold water inlet to the water heater, follow the draining instructions in this manual, and replace the Temperature-Pressure Relief Valve with a properly rated/sized new one.

NOTE: The purpose of a Temperature-Pressure Relief Valve is to prevent excessive temperatures and pressures in the storage tank. The T&P valve is not intended for the constant relief of thermal expansion. A properly sized thermal expansion tank must be installed on all closed systems to control thermal expansion, see Closed Water Systems and Thermal Expansion on page 14.

If you do not understand these instructions or have any questions regarding the Temperature-Pressure Relief Valve call the toll free number listed on the back cover of this manual for technical assistance.

CONDENSATE DRAIN

The water heaters covered in this manual are condensing appliances and require a building drain to be located in close proximity to allow the condensate to drain safely.

Condensate drains from the water heater at the exhaust elbow located at the bottom. The eld installed condensate drain line must not be elevated above the condensate drain connection on the condensate trap, see Figure 8. If the condensate does not drain properly it will build up in the exhaust (vent) elbow. This will restrict the ow of ue gases and cause the Blocked Exhaust pressure switch to open its contacts. The control system monitors all pressure switches, if the Blocked Exhaust Switch contacts are open the control system will lock out and disable heating operation. The “Blocked Exhaust” Fault message will be displayed on the control system’s LCD, see Fault And Alert Conditions beginning on page 60.

The Condensate Cleanout Cap must be on and tight when unit is in operation.

NOTE: If the “Blocked Exhaust “ Fault message is ever displayed on the control system LCD, check the condensate drain rst and ensure it is not blocked.

EXHAUST (VENT) ELBOW

CONDENSATE DRAIN LINE CONNECTION

DRAIN LINE TO TERMINATE NO MORE THAN 6 INCHES (15.2cm)

THIS SIDE VIEW

OF EXHAUST

ELBOW AND

ARROW INDICATE

THE LOCATION OF

THE PRESSURE

PORT

ABOVE DRAIN

line, such as copper, to the water heater for this reason. See Condensate Drain Installation on page 39.

COMBUSTIBLE MATERIAL STORAGE

Fire or Explosion Hazard

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

Avoid all ignition sources if you smell gas.

Do not expose water heater controls to excessive gas pressure.

Use only the gas shown on the water heater rating label. Maintain required clearances to combustibles.

Keep ignition sources away from faucets after extended periods of non-use.

Read instruction manual before

installing, using or servicing

water heater.

Keep water heater area clear and free of combustible materials, gasoline and other ammable vapors and liquids.

CONTAMINATED AIR

CONDENSATE

CLEANOUT CAP

CONDENSATE DRAIN LINE - FIELD INSTALLED

BUILDING DRAIN

Figure 8

CONDENSATE DRAIN WATER TRAP

Breathing Hazard - Carbon Monoxide Gas

Ensure a functioning water trap is installed in the condensate drain.

Gas and carbon monoxide detectors are available.

Install water heater in accordance with the instruction manual.

Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.

DO NOT remove the factory installed exhaust/condensate elbow for any reason, see Figure 8. The water heater’s vent pipe is under a slight positive pressure while unit is in operation. The water trap inside of the exhaust/condensate elbow prevents ue gases from escaping into the installed space. See Condensate Drain Installation on page 39.

CONDENSATE PH LEVEL

The condensate drains from the water heater’s covered in this manual have PH levels between 4.3 and 5.0. Install a commercially available neutralizing kit if required by local codes.

NOTE: Lower PH levels are acidic. Do not connect a metal drain

Breathing Hazard - Carbon Monoxide Gas

Install water heater in accordance with the Instruction Manual and NFPA 54 or CAN/CSA-B149.1.

To avoid injury, combustion and ventilation air must be taken from outdoors.

Do not place chemical vapor emitting products near water heater.

Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.

Corrosion of the ue ways and vent system may occur if air for combustion contains certain chemical vapors. Such corrosion may result in failure and risk of asphyxiation.

Combustion air that is contaminated can greatly diminish the life span of the water heater and water heater components such as igniters and burners. Propellants of aerosol sprays, beauty shop supplies, water softener chemicals and chemicals used in dry cleaning processes that are present in the combustion, ventilation or ambient air can cause such damage.

Do not store products of this sort near the water heater. Air which is brought in contact with the water heater should not contain any of these chemicals. If necessary, uncontaminated air should be obtained from remote or outdoor 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).

If the water heater will be used in beauty shops, barber shops, cleaning establishments, or self-service laundries with dry cleaning equipment, it is imperative that the water heater(s) be installed in a Direct Vent conguration so that all air for combustion is derived directly from the outdoor atmosphere through a sealed intake air pipe. See Venting Installation on page 21.

AIR REQUIREMENTS

Breathing Hazard - Carbon Monoxide Gas

Install water heater in accordance with the Instruction Manual and NFPA 54 or CAN/CSA-B149.1.

To avoid injury, combustion and ventilation air must be taken from outdoors.

Do not place chemical vapor emitting products near water heater.

Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.

For safe operation an adequate supply of fresh uncontaminated air for combustion and ventilation must be provided.

An insufcient supply of air can cause recirculation of combustion products resulting in contamination that may be hazardous to life. Such a condition often will result in a yellow, luminous burner ame, causing sooting of the combustion chamber, burners and ue tubes and creates a risk of asphyxiation.

Do not install the water heater in a conned space unless an adequate supply of air for combustion and ventilation is brought in to that space using the methods described in the Conned Space section that follows.

Never obstruct the ow of ventilation air. If you have any doubts or questions at all, call your gas supplier. Failure to provide the proper amount of combustion air can result in a re or explosion and cause property damage, serious bodily injury or death.

UNCONFINED SPACE

An Unconned Space is one whose volume IS NOT LESS THAN 50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input rating of all appliances installed in the space. Rooms communicating directly with the space, in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconned space.

Makeup air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers and replaces shall also be considered in determining the adequacy of a space to provide combustion, ventilation and dilution air.

UNUSUALLY TIGHT CONSTRUCTION

In unconned spaces in buildings, inltration may be adequate to provide air for combustion, ventilation and dilution of ue gases. However, in buildings of unusually tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.) additional air must be provided using the methods described in the Conned Space section that follows.

CONFINED SPACE

A Conned Space is one whose volume IS LESS THAN 50 cubic feet per 1,000 Btu/hr (4.8 cm per kW) of the total input rating of all appliances installed in the space.

Openings must be installed to provide fresh air for combustion, ventilation and dilution in conned spaces. The required size for the openings is dependent on the method used to provide fresh air to the conned space AND the total Btu/hr input rating of all appliances installed in the space.

DIRECT VENT APPLIANCES

Appliances installed in a Direct Vent conguration that derive all air for combustion from the outdoor atmosphere through sealed intake air piping are not factored in the total appliance input Btu/ hr calculations used to determine the size of openings providing fresh air into conned spaces.

EXHAUST FANS

Where exhaust fans are installed, additional air shall be provided to replace the exhausted air. When an exhaust fan is installed in the same space with a water heater, sufcient openings to provide fresh air must be provided that accommodate the requirements for all appliances in the room and the exhaust fan. Undersized openings will cause air to be drawn into the room through the water heater’s vent system causing poor combustion. Sooting, serious damage to the water heater and the risk of re or explosion may result. It can also create a risk of asphyxiation.

LOUVERS AND GRILLES

The free areas of the fresh air openings in the instructions that follow do not take in to account the presence of louvers, grilles or screens in the openings.

The required size of openings for combustion, ventilation and dilution air shall be based on the “net free area” of each opening. Where the free area through a design of louver or grille or screen is known, it shall be used in calculating the size of opening required to provide the free area specied. Where the louver and grille design and free area are not known, it shall be assumed that wood louvers will have 25% free area and metal louvers and grilles will have 75% free area. Non motorized louvers and grilles shall be xed in the open position.

FRESH AIR OPENINGS FOR CONFINED SPACES

The following instructions shall be used to calculate the size, number and placement of openings providing fresh air for combustion, ventilation and dilution in conned spaces. The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into conned spaces only. DO NOT refer to these illustrations for the purpose of vent installation. See Venting Installation on page 21 for complete venting installation instructions.

OUTDOOR AIR THROUGH TWO OPENINGS

Alternatively a single permanent opening, commencing within 12 inches (300 mm) of the top of the enclosure, shall be provided. See Figure 10. The water heater shall have clearances of at least 1 inch (25 mm) from the sides and back and 6 inches (l50 mm) from the front of the water heater. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of the following:

1. 1 square inch per 3000 Btu/hr (733 mm2 per kW) of the total input rating of all appliances located in the enclosure, and

2. Not less than the sum of the areas of all vent connectors in the space.

OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS

Figure 9

The conned space shall be provided with two permanent openings, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The openings shall communicate directly with the outdoors. See Figure 9.

Each opening shall have a minimum free area of 1 square inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure. Each opening shall not be less than 100 square inches (645 cm2).

OUTDOOR AIR THROUGH ONE OPENING

Figure 11

The conned space shall be provided with two permanent horizontal ducts, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The horizontal ducts shall communicate directly with the outdoors. See Figure 11.

Each duct opening shall have a minimum free area of 1 square inch per 2,000 Btu/hr (1100 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure.

When ducts are used, they shall be of the same cross sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall be not less than 3 inches.

Figure 10

OUTDOOR AIR THROUGH TWO VERTICAL DUCTS

The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into conned spaces only.

DO NOT refer to these illustrations for the purpose of vent

installation. See Venting Installation on page 21 for complete venting installation instructions.

AIR FROM OTHER INDOOR SPACES

Figure 13

Figure 12

The conned space shall be provided with two permanent vertical ducts, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The vertical ducts shall communicate directly with the outdoors. See Figure 12.

Each duct opening shall have a minimum free area of 1 square inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure.

Each opening shall communicate directly with an additional room(s) of sufcient volume so that the combined volume of all spaces meets the criteria for an Unconned Space.

Each opening shall have a minimum free area of 1 square inch per 1,000 Btu/hr (2200 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure. Each opening shall not be less than 100 square inches (645 cm2).

INSTALLATION REQUIREMENTS - COMMONWEALTH OF MASSACHUSETTS

COMMONWEALTH OF MASSACHUSETTS

For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above nished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satised:

INSTALLATION OF CARBON MONOXIDE DETECTORS

At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gastter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the oor level where the gas equipment is to be installed. In addition, the installing plumber or gastter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualied licensed professionals for the installation of hard wired carbon monoxide detectors.

In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent oor level.

In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

APPROVED CARBON MONOXIDE DETECTORS

Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/ UL 2034 listed and CSA certied.

SIGNAGE

A metal or plastic identication plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than onehalf (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP

CLEAR OF ALL OBSTRUCTIONS.”

INSPECTION

The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

EXEMPTIONS

The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building, or structure used in whole or in part for residential purposes.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED

When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED

When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the ue gases, but identies “special venting systems,” the following requirements shall be satised by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

VENTING INSTALLATION

Breathing Hazard - Carbon Monoxide Gas

Install vent system in accordance with codes.

•

Do not operate water heater if exposed to flooding or

•

water damage

Special consideration must be taken with installations

•

above 10,000 feet (3,048 m) refer to high altitude section of this manual.

Do not operate if soot buildup.

•

Do not obstruct water heater air intake with insulating

•

jacket or blanket.

Do not place chemical vapor emitting products near

•

water heater.

Gas and carbon monoxide detectors are available.

•

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.

Analyze the entire vent system to make sure that

•

condensate will not become trapped in a section of vent pipe and therefore reduce the open cross sectional area of the vent.

Breathing carbon monoxide can cause brain damage or death.

Always read and understand the instruction manual.

Never operate the water heater unless it is vented to the outdoors.

The instructions in this section of the manual must be followed to avoid choked combustion or recirculation of ue gases. Such conditions cause sooting of the combustion chamber, burners and ue tubes and creates a risk of asphyxiation.

GENERAL VENTING INFORMATION

The water heaters covered in this manual are operationally equivalent to Category IV appliances and may be installed in either a Power Vent or Direct Vent conguration.

APPROVED MATERIALS

Approved vent and intake air pipe materials that may be used in the United States:

• PVC Schedule 40 (ASTM D 2241 / CSA B181.2, ASTM D 1785 / CSA B137.3

• CPVC Schedule 40 (ASTM F-411 / CSA B137.6)

• Polypropylene

• AL29-4C Stainless Steel

Approved vent and intake air pipe materials that must be used in Canada:

• ULC S636 PVC / CPVC

• ULC S636 Polypropylene

• AL29-4C Stainless Steel

CATEGORY IV APPLIANCE

Category IV appliances operate with a positive vent (exhaust) static pressure and with vent gas temperatures low enough to produce condensate in the vent piping.

POWER VENT CONFIGURATION

Power Vent congurations derive all combustion air from the room where they are installed and discharge all ue gases to the outdoor atmosphere through a sealed vent (exhaust) pipe. Power vent congurations have one vent pipe connected to the water heater which can be terminated in a vertical or horizontal arrangement. See Figure 42 and Figure 43 on page 35.

DIRECT VENT CONFIGURATION

Direct Vent congurations derive all combustion air directly from the outdoor atmosphere through a sealed intake air pipe and

discharge all ue gases to the outdoor atmosphere through a sealed vent (exhaust) pipe. Direct Vent congurations have two pipes connected to the water heater, one vent pipe and one intake air pipe. Direct Vent congurations can be terminated in one of seven different arrangements. See Figure 44 on page 35 through Figure 50 on page 36.

GENERAL VENTING INSTRUCTIONS

These instructions must be followed on all installations.

1. DO NOT install the water heater in a Power Vent conguration unless there is adequate supply of fresh air, see Air Requirements on page 17. If the installation space does not provide an adequate supply of fresh air the water heater must be installed in a Direct Vent conguration.

2. If the water heater is to be installed in a beauty shop, barber shop, cleaning establishment, a laundry with dry cleaning equipment or any space with contaminated air it is imperative that the water heater(s) be installed in a Direct Vent conguration so that all air for combustion is derived from the outdoor atmosphere.

3. The vent and intake air piping must terminate outdoors.

4. The minimum clearance from combustible materials for the vent (exhaust) and intake air piping shall be 0 inches. Vent piping passing through a combustible wall or ceiling must be a continuous run (no joints).

5. The water heater must be protected from freezing downdrafts during shutdown periods.

6. The vent (exhaust) pipe must not be combined or connected to any other appliance’s vent system or chimney.

7. The intake air pipe must not be combined or connected to any other appliance’s intake air piping.

8. Locate the water heater where the vent (exhaust) and intake air piping will remain within the maximum equivalent lengths allowed. See Venting Requirements on page 22.

9. Do not install the vent or intake air piping in a manner that will allow water to be trapped in the piping.

10. Vent pipes must be pitched a minimum of a 1/4 inch per foot back to the water heater (to allow drainage of condensate).

11. Do not anchor the vent or intake air pipe directly to framed walls, oors or ceilings unless rubber isolation pipe hangers are used to prevent vibration noise from being transmitted.

12. Use only approved vent/intake air pipe sizes and materials. See Venting Requirements on page 22.

13. Use only factory supplied vent and intake air or concentric terminations. See the Venting Requirements on page 22.

14. Do not locate the vent (exhaust) or intake air terminations where they would be objectionable due to noise at the termination(s). This includes locations close to or across from windows and doors.

15. Direct venting into dead air spaces such as alleys, atriums, and inside corners can cause recirculation of ue gases. Recirculation of ue gases will cause sooting, premature failure of the heat exchanger and icing of the combustion air intake during severe cold weather. To prevent the recirculation of ue gases, maintain as much distance as possible between the intake air and vent terminations.

16. Do not locate the vent termination over a public area where condensate or vapor can cause a nuisance or ice hazard.

17. Ensure the screens in the factory supplied terminations are securely installed to prevent blockage in the vent system.

INTAKE AIR CONNECTION PIPE

18. Stress levels in pipe/ttings can be signicantly increased by

INTAKE AIR TEE FITTING

improper installation. If rigid pipe clamps are used to hold the pipe in place, or if the pipe cannot move freely through a wall penetration, the pipe may be stressed, or high thermal stresses may be formed when the pipe heats up and expands. Install accordingly to minimize such stresses.

19. Ensure the intake air connection Tee tting is oriented properly, see page 22 for instructions.

20. Carefully read the Venting Requirements on page 22 and then proceed to the Venting Installation Sequence on page 23.

INTAKE AIR CONNECTION

The water heaters covered in this manual are factory equipped with a unique Combustion Blower and intake air connection Tee tting. The Tee is a 3" x 3" x 1/2" fitting. The intake air connection Tee tting has a hose barb installed in the 1/2 inch branch to connect the Blocked Intake Air switch sensing tube, see Figure 14.

FACTORY INSTALLED INTAKE AIR TEE FITTING

1/2 INCH

BRANCH

HOSE BARB FITTING FOR BLOCKED INTAKE AIR SWITCH SENSING TUBE

COMBUSTION BLOWER ASSEMBLY

FERNCO

COUPLING

Figure 14

COMBUSTION BLOWER

The intake air Tee tting is factory installed with the 1/2 inch branch and hose barb angled to the right at approximately 130° when viewed from the end, see Figure 15. The Tee tting's 1/2 inch branch and hose barb must not be angled any lower (towards the ground) than this factory specication. Angling higher, up to a 90° position, will not adversely affect operation and is acceptable.

INSPECT/ADJUST INTAKE AIR TEE FITTING

Inspect the angle of the Tee tting's 1/2 inch branch and hose barb while viewing from the end of the Tee, see Figure 16. If the angle of the Tee tting 1/2 inch branch and hose barb is lower than shown, adjustment will be necessary. To adjust the intake air Tee tting angle follow the steps listed below.

Adjustment Procedure:

21. Ensure the water heater is turned off at the on/off switch on the front of the water heater.

22. Disconnect the Blocked Intake Air switch sensing tube, see Figure 3 on page 8 for location.

23. Loosen the large hose clamp on the Fernco coupling that connects the intake air connection pipe to the Combustion blower, see Figure 16.

24. Adjust the angle of the Tee tting so that the 1/2 inch branch and hose barb are at the proper angle as shown in Figure 15.

25. Retighten the large hose clamp on the Combustion Blower intake air Fernco coupling,

26. Reconnect the Blocked Intake Air switch sensing tube making sure the sensing tube is securely connected at both ends and is not kinked.

LARGE HOSE CLAMP

FERNCO COUPLING

Ensure the hose barb installed in the Tee tting IS NOT facing down towards the ground (180° - 6 o'clock position) before venting installation begins. The barb tting must be angled between 90° and no more than 130° as shown in Figure 15. If the barb tting is facing down, residual condensate that occasionally forms in the intake air pipe can drain into the Blocked Intake Air switch through the attached sensing tube and damage the switch. This condition can also lead to Blocked Intake Air fault conditions and associated control system lock outs.

90° TO 130°

END VIEW

CORRECT ORIENTATION

Figure 15

INTAKE AIR

3 INCH PVC

TEE FITTING

Figure 16

VENTING REQUIREMENTS

FIELD SUPPLIED FITTINGS

Field supplied ttings should be equivalent to the piping material being installed. Field installed/supplied ttings will add equivalent feet to the vent or intake air piping as indicated below. All eld supplied/installed ttings and piping must be factored into the equivalent feet calculations.

• 90° elbows (short or long radius) are equivalent to 5 linear feet (152 cm) of pipe.

• 45° elbows (short or long radius) are equivalent to 2.5 linear feet (76 cm) of pipe.

NOTE: Refer to Tables 9 and 10 on page 29 for the equivalent linear pipe length of AL29-4C® 45° and 90° elbows.

PRIMER AND CEMENT

Tetrahydrofuran (THF) primer should be used to prepare the surfaces of pipe and ttings for solvent welding. If CPVC or ABS

pipe and ttings are used, then the proper cement must be used for all joints, including joining the pipe to the factory provided terminations (PVC material). PVC Materials should use ASTM D-2564 Grade Cement; CPVC Materials should use ASTM F-493

Grade Cement and ABS

Materials should use ASTM D-2235 Grade Cement.

PIPE SIZE REQUIREMENTS

The water heaters covered in this manual are certied for the use of 3 and 4 inch pipe for the vent (exhaust) and intake air piping. If the installed equivalent length for the intake air or vent piping will be 50 feet (15.2 m) or less, 3 inch pipe must be used. If the installed equivalent length will be more than 50 feet (15.2 m), 4 inch pipe must be used.

NOTE: Install the pipe size required for the installed equivalent length of each pipe independently. IE: If the intake air pipe will be 50 equivalent feet or less and the vent pipe will be more than 50 equivalent feet; the intake air pipe must be installed using 3 inch pipe and the vent must be installed using 4 inch pipe.

MAXIMUM EQUIVALENT LENGTHS

Three Inch Pipe

The water heaters covered in this manual are certied to a maximum length of 3 inch pipe for the exhaust venting arrangement of 50 equivalent feet (15.2 m). The certied maximum length of 3 inch pipe for intake air piping is also 50 equivalent feet (15.2 m). IE: On Direct Vent installations both pipes can be up to 50 equivalent feet (15.2 m).

Four Inch Pipe

The water heaters covered in this manual are certied to a maximum length of 4 inch pipe for the exhaust venting arrangement of 120 equivalent feet (36.5 m). The certied maximum length of 4 inch pipe for intake air piping is also 120 equivalent feet (36.5 m). IE: On Direct Vent installations both pipes can be up to 120 equivalent feet (36.5 m).

MINIMUM EQUIVALENT LENGTHS

Three Inch Pipe

The water heaters covered in this manual are certied to a minimum length of 3 inch pipe for the vent (exhaust) of 7 equivalent feet (2.1 m). There is no minimum equivalent feet requirement for the intake air pipe.

Four Inch Pipe

The water heaters covered in this manual are certied to a minimum length of 4 inch pipe for the vent (exhaust) of 50 equivalent feet (15.2 m). There is no minimum equivalent feet requirement for the intake air pipe.

MAXIMUM NUMBER OF ELBOWS

Three Inch Pipe

The vent pipe may have a maximum of four 90° elbows installed when 3 inch pipe is being used. The intake air pipe may also have a maximum of four 90° elbows installed. IE: in a Direct Vent conguration each pipe can have up to four 90° elbows installed.

NOTE: Refer to Tables 9 and 10 on page 29 for the equivalent linear pipe length of AL29-4C® 45° and 90° elbows.

Four Inch Pipe

The vent pipe may have a maximum of six 90° elbows installed when 4 inch pipe is being used. The intake air pipe may also have a maximum of six 90° elbows installed. IE: in a Direct Vent conguration each pipe can have up to six 90° elbows installed.

FACTORY SUPPLIED FITTINGS

The water heater ships with two (2) factory supplied 3 inch terminations (PVC 45° elbows with debris screen). Factory supplied vent and intake air terminations, concentric, or low prole terminations must be used. Factory supplied terminations and installed ttings (exhaust/condensate elbow and intake air connection) add zero equivalent feet to the vent and intake air piping.

TABLE 6

Number of 90° Elbows Installed

One (1) 45 feet (13.7 meters) 115 feet (35.0 meters) Two (2) 40 feet (12.2 meters) 110 feet (33.5 meters) Three (3) 35 feet (10.7 meters) 105 feet (32.0 meters) Four (4) 30 feet (9.1 meters) 100 feet (30.5 meters) Five (5) N/A 95 feet (29.0 meters) Six (6) N/A 90 feet (27.4 meters)

3 Inch Pipe 4 Inch Pipe

Maximum Feet (Meters) Maximum Feet (Meters)

4 INCH EXTENDED VENT TERMINATIONS

When 4 inch intake air or vent pipe is installed, factory supplied 4 inch terminations must be used. Contact your local distributor or call the parts department (phone number listed on the back cover of this manual) to order 4 inch termination(s).

OPTIONAL CONCENTRIC & LOW PROFILE TERMINATIONS

The water heaters covered by this manual may be installed in a Direct Vent conguration using a 4 inch concentric termination or a 3" or 4" low prole termination.

Concentric and Low Prole terminations must be ordered separately. Contact your local distributor or call the parts department phone number listed on the back cover of this manual to order.

Concentric & Low Prole Vent Termination Part Numbers:

• 4" Concentric Termination # 9006328005

• 3" Low Prole Termination # 9008933005

• 4" Low Prole Termination # 9008934005

VENTING INSTALLATION SEQUENCE

1. Read General Venting Instructions on page 21 and Venting Requirements on page 22 before proceeding. These instructions and requirements must be followed on all installations.

2. Determine whether the water heater will be installed in a Power Vent or Direct Vent conguration and which vent system arrangement will be used for the installation. See the various venting arrangements on pages 35 and 36.

3. Proceed to the applicable instructions:

• Power Vent Installation on page 23.

• Direct Vent Installation on page 24.

POWER VENT INSTALLATION

1. Read the General Venting Instructions on page 21 and Venting Requirements on page 22 before proceeding. These instructions and requirements must be followed in addition to the instructions below that are specic for Power Vent congurations.

2. Determine which Power Vent arrangement will be used for the installation; vertical or horizontal termination. See Figure 42 and Figure 43 on page 35.

3. Determine the vent pipe size for the installation, see Venting Requirements on page 22.

4. Plan the layout of the vent piping backwards from the termination point outdoors to the water heater. Layout the vent piping to use a minimum of pipe and elbows.

5. Install the termination rst.

If the vent piping will terminate vertically, through a roof, see Vertical Termination Installation on page 25.

If the vent piping will terminate horizontally, through a sidewall, see Sidewall Termination Installation on page 27.

6. When installation of the termination is complete install necessary piping and ttings to route the vent piping back to the water heater.

7. The vent pipe must be supported properly to avoid bending or failure. The water heater manufacturer recommends that the vent pipe be supported every 5 feet (152 cm) of vertical run and every 3 feet (91 cm) of horizontal run.

8. Do not install the vent piping in a manner that will allow water to be trapped in the piping.

4” PIPE FIELD SUPPLIED

4” x 3” REDUCER FIELD SUPPLIED

3” PIPE FIELD SUPPLIED

EXHAUST ELBOW VENT CONNECTION FACTORY INSTALLED

VENT (EXHAUST) CONNECTION

Figure 17

9. All vent (exhaust) pipes must be pitched a minimum of a 1/4 inch per foot back to the water heater (to allow drainage of condensate).

10. If installing 3 inch vent pipe connect the vent pipe to the exhaust elbow on the water heater.

11. If installing 4 inch pipe transition to 3 inch pipe at the exhaust elbow on the water heater as shown in Figure 17. The eld installed 3” pipe between the exhaust elbow and the 4” x 3” reducer coupling should be 18 inches (45 cm) or less in length.

DIRECT VENT INSTALLATION

2. Determine which Direct Vent arrangement will be used for the installation. There are seven (7) Direct Vent arrangement options. See Figures 44 through 50.

3. Determine vent and intake air pipe size to be used for the installation; see Venting Requirements on page 22.

4. Plan the layout of the vent and intake air piping backwards from the termination point outdoors to the water heater. Layout the vent and intake air piping to use a minimum of pipe and elbows.

5. Install the terminations rst. If standard terminations are being used and the intake air

or vent piping will terminate vertically, through a roof, see Vertical Termination Installation on page 25.

If standard terminations are being used and the intake air or vent piping will terminate horizontally, through a sidewall, see Sidewall Termination Installation on page 27.

If a concentric termination(s) will be used see Concentric Termination Installation on page 30.

If a low-prole termination will be used see Low Prole Termination Installation on page 34.

6. When installation of the termination(s) is complete Install necessary piping and ttings to route the intake air and vent piping back to the water heater.

7. The intake air and vent piping must be supported properly to avoid bending or failure. The water heater manufacturer recommends that the vent and intake air piping be supported every 5 feet (152 cm) of vertical run and every 3 feet (91 cm) of horizontal run.

8. Do not install the vent or intake air piping in a manner that will allow water to be trapped in the piping.

9. A eld supplied condensate Tee tting and drain hose should be installed in the intake air piping near the water heater in colder climates with heavy snow accumulations and in areas that regularly experience high humidity. The drain hose should be routed to an adequate oor drain separate from any other condensate drains. See Figure 20 on page 25.

NOTE: Snow being pulled into the intake air piping and then melting can lead to excessive amounts of water accumulation and damage water heater components. Warm, humid outdoor air can lead to excessive condensation inside the intake air piping and may also damage water heater components.

10. The intake air and vent (exhaust) piping must be pitched a minimum of a 1/4 inch per foot back to the water heater (to allow drainage of condensate).

11. If installing 3 inch vent pipe connect the vent pipe to the exhaust elbow on the water heater.

12. If installing 4 inch vent pipe transition to 3 inch pipe at the exhaust elbow on the water heater as shown in Figure 17 on page 24. The eld installed 3” pipe between the exhaust elbow and the 4” x 3” reducer coupling should be 18 inches (45 cm) or less in length.

13. Ensure the Intake Air Screen on the Intake Air Connection to the water heater is removed before connecting the intake air pipe to the water heater. See Figure 18.

Breathing Hazard - Carbon Monoxide Gas

Do not obstruct water heater air intake.

Gas and carbon monoxide detectors are available.

Install water heater in accordance with the instruction manual.

Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.

NOTE: Do not leave the screen inside the Intake Air Connection for Direct Vent installations. Once the intake air pipe is installed the screen will be hidden from view and may become clogged with debris over time. This will cause improper combustion and may also lead to Blocked Intake Air fault conditions and associated control system lock outs.

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