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

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Page 1

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

Page 2

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

Page 3

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.

Page 4

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.

Page 5

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.

Page 6

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.

Page 7

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

Page 8

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.

Page 9

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.

Page 10

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

Page 11

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.

Page 12

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

Page 13

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.

Page 14

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.

Page 15

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.

Page 16

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.

Page 17

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.

Page 18

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

Page 19

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).

Page 20

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.

Page 21

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.

Page 22

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.

Page 23

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.

Page 24

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.

Page 25

INTAKE AIR

INTAKE AIR CONNECTION

SCREEN

3 INCH INTAKE AIR CONNECTIONS

FACTORY INSTALLED

INTAKE AIR SCREEN

(remove for Direct Vent)

Figure 18

14. If installing 3 inch intake air pipe connect the intake air pipe to the intake air connection on the water heater.

15. If installing 4 inch intake air pipe transition to 3 inch pipe at the intake air connection on the water heater as shown in Figure 19. The eld installed 3” pipe between the intake air connection and the 4” x 3” reducer coupling should be 18 inches (45 cm) or less in length.

FACTORY INSTALLED INTAKE AIR TEE FITTING

INTAKE AIR

HOSE BARB FITTING FOR BLOCKED INTAKE AIR SWITCH SENSING TUBE

INSTALL TEE FITTING AS CLOSE TO WATER HEAT ER INTAKE AIR CONNECTION AS POSSIBLE

1/2 INCH BRANCH

INTAKE AIR CONDENSATE TEE INSTALLATION

3” PIPE FACTORY INSTALLED

FERNCO

COUPLING

Figure 19

FACTORY INTAKE AIR CONNECTION

Figure 20

COMBUSTION

BLOWER

INTAKE

AIR

PIPING

FIELD SUPPLIED 3” x 3” x 1/2” TEE WITH HOSE BARB FITTING INSTALLED

CONNECT FIELD SUPPLIED FLEXIBLE DRAIN HOSE TO BARB FITTING AND FORM A LOOP WATER TRAP IN DRAIN HOSE

RUN DRAIN HOSE TO SUITABLE FLOOR DRAIN SEPARATELY FROM OTHER CONDENSATE DRAINS

VERTICAL TERMINATION INSTALLATION

1. Determine the location for the termination(s).

2. If installing only the vent (exhaust) piping in a Power Vent conguration vertically through the roof; ensure that all exterior vertical clearance requirements shown in Figure 22 and Figure 23 on page 26 are being maintained. These clearances and those cited by local and national codes must be maintained.

NOTE: On at roof installations the vent termination must be a minimum of 24 inches (60 cm) above any parapet, vertical wall or structure within 10 feet (3 m) horizontally. See Figure 23 on page 26.

3. If installing both intake air and vent piping in a Direct Vent conguration vertically through the roof; ensure that all exterior vertical clearance requirements shown in Figure 22 and Figure 23 on page 26 are being maintained. These clearances and those cited by local and national codes must be maintained.

NOTE: On at roof installations the intake air and the vent terminations must be a minimum of 24 inches (60 cm) above any parapet, vertical wall or structure within 10 feet (3 m) horizontally. See Figure 23 on page 26.

4. If installing only vent piping in a Power Vent conguration vertically through the roof the following instructions must be followed:

The vent termination must be oriented facing downward as shown in Figure 22 and Figure 23 on page 26.

The bottom edge of the vent termination must be a minimum of 12 inches (30 cm), 18 inches (45 cm) in Canada, above the average or expected snow level as shown in Figure 22 on page 26.

5. If installing both intake air and vent piping in a Direct Vent conguration vertically through the roof the following instructions must be followed:

The intake air and vent pipes must penetrate the same side of the roof as shown in Figure 24 on page 26.

The intake air and vent terminations must be oriented facing downward and in the same direction as shown in Figure 24 on page 26.

The intake air and vent terminations must have a minimum separation of 24” (61 cm) measured on center line as shown in Figure 24 on page 26. In colder climates this separation should be increased to at least 48 inches (122 cm).

The bottom edge of the intake air and vent terminations must be a minimum of 12 inches (30 cm), 18 inches (45 cm) in Canada, above the average or expected snow level as shown in Figure 22 and Figure 24 on page 26.

6. When the intake air and/or vent piping from multiple water heaters will terminate in the same location the vent terminations can be grouped together in close proximity 0 inches/touching. Intake air terminations can also be grouped together in close proximity 0 inches/touching.

The distance between the closest vent and intake air terminations must be a minimum of 24 inches (61 cm) as shown in Figure 24 on page 26. In colder climates this separation should be increased to at least

7. Cut a 4 inch (10 cm) diameter hole for 3 inch pipe or 5 inch (13 cm) diameter hole for 4 inch pipe where the pipe(s) will pass through the roof.

NOTE: Beware of concealed wiring and piping when cutting through the roof.

48 inches (122 cm).

Page 26

8. Suspend the pipe(s) through center of hole using eld supplied metal strapping or equivalent support materials as shown in Figure 22 on page 26.

9. Slide a roof boot or equivalent ashing over the pipe and secure roof boot or equivalent ashing to roof and seal around the ashing as shown in Figure 22, Figure 23 and Figure 24 on page 26.

10. Install the factory supplied intake air and/or vent termination(s) using eld supplied pipe and one eld supplied 90° elbow as shown in Figure 22 on page 26. The short section of pipe that connects between the eld supplied 90° elbow and the factory supplied termination must not be excessive in length. The exposed portion of this pipe shall be no more than 2 inches (5 cm), see Figure 22 on page 26.

11. Return to Power Vent Installation on page 23 or Direct Vent Installation on page 24 to complete the installation of the intake air and/or vent piping between the termination(s) and the water heater.

INTAKE AIR AND VENT (EXHAUST) TERMINATIONS 45° ELBOW WITH RECESSED DEBRIS SCREEN

IF LESS THAN

10 FEET (3 m)

24 INCHES (60 cm)

MINIMUM HEIGHT ABOVE

INTAKE AIR AND/OR VENT TERMINATION(S) MUST BE A MINIMUM OF 24 INCES (60 cm) ABOVE ANY PARAPET, VERTICAL WALL OR STRUCTURE WITHIN 10 FEET (3 m) HORIZONTALLY.

VERTICAL TERMINATION(S) FLAT ROOF CLEARANCE

INTAKE AIR AND/OR VENT (EXHAUST)

STANDARD FACTORY SUPPLIED TERMINATIONS

Figure 21

2” (5 cm)

MAXIMUM

FIELD

SUPPLIED

90° ELBOW

FIELD SUPPLIED PLUMBING ROOF BOOT OR FLASHING

FACTORY SUPPLIED

STANDARD TERMINATION

POINTED DOWN TOWARDS

THE GROUND

MAINTAIN 12” (30 cm) 18” (45 cm) FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL.

Figure 23

24 INCHES (61 cm) MINIMUM

48 INCHES (122 cm) IN COLDER CLIMATES

FIELD

SUPPLIED

90° ELBOW

VENT (EXHAUST)

TERMINATION

FACTORY SUPPLIED STANDARD TERMINATIONS POINTED DOWNWARD

FIELD SUPPLIED PLUMBING ROOF BOOTS OR FLASHINGS

VERTICAL TERMINATION - DIRECT VENT

STANDARD TERMINATIONS

Figure 24

INTAKE AIR

TERMINATION

MAINTAIN 12” (30 cm) 18” (45 cm) FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL.

FIELD SUPPLIED STRAP/SUPPORT

VERTICAL TERMINATION(S) INSTALLATION

INTAKE AIR AND/OR VENT (EXHAUST)

Figure 22

Page 27

SIDEWALL TERMINATION INSTALLATION

12. Determine the location for the termination(s).

13. If installing only vent (exhaust) piping in a Power Vent conguration through a sidewall; ensure that all exterior sidewall clearance requirements for the termination, shown in Figure 51 on page 37, are being maintained. These clearances and those cited by local and national codes must be maintained.

14. If installing both the intake air and the vent piping in a Direct Vent conguration through a sidewall; ensure that all exterior sidewall clearance requirements for the terminations, shown in Figure 52 on page 38, for the vent and the intake air termination are being maintained. These clearances and those cited by local and national codes must be maintained.

15. If installing both an intake air and vent termination in a Direct Vent conguration through a sidewall there must be a minimum of 24 inches (61 cm) separation, measured on vertical center line, between the intake air and vent terminations, see Figure 25.

NOTE: In colder climates this separation should be increased to at least 48 inches (122 cm) between the intake air and vent termination or any other appliance vent that discharges moisture-laden air such as clothes dryers. This will reduce possibility of frost over from side winds blowing exhaust vapors to the intake air termination and is recommended for Canadian installations.

16. If installing both intake air and vent terminations in a Direct Vent conguration through a sidewall the intake air and vent terminations must be installed at the same elevation measured on horizontal center line - see Figure 25.

VENT (EXHAUST)

TERMINATION

ELEVATION

INSTALL ON

CENTERLINE

INTAKE AIR

TERMINATION

18. Cut a 4 inch (10 cm) diameter hole for 3 inch pipe or 5 inch (13 cm) diameter hole for 4 inch pipe where the pipe(s) will pass through the wall.

NOTE: Beware of concealed wiring and piping when cutting through the wall.

19. Cut a length(s) of pipe being installed 3.5 inches (8.9 cm) to 9.5 inches (24.1 cm) longer than the wall thickness at the opening. See Figure 26.

NOTE: Vent Termination – exhaust gases of this water heater are less than 140°F. In cold climates water vapor in the exhaust gases will condense into a cloud of vapor where the vent exits the building. This vapor can gradually discolor exterior building surfaces. The vent termination should be located where this vapor cloud and potential discoloration are not a concern. Extending the exposed vent piping up to a maximum of 6 inches (15.2 cm) from the wall helps vapor from being trapped along a building’s face. To avoid this problem, the vent can also be terminated vertically through the roof, see Vertical Termination Installation on page 25.

20. Cement the intake air and/or vent termination to the section(s) of pipe cut to length in the above Step.

21. Slide the included metal wall plate(s) over the pipe(s) to stop against the intake air and/or vent termination. Place some silicone caulking (eld supplied) on the back of the wall plate(s) to secure it to the wall.

22. Working from outside, slide the pipe and termination(s) assembled in the above steps through the wall. Ensure the termination(s) is pointed down towards the ground. See Figure 26.

METAL PLATES INSTALL INSIDE AND/OR OUTSIDE

FROM WATER HEATER

COUPLING

INTERIOR WALL EXTERIOR WALL

INCREASE EXPOSED VENT PIPING UP TO A MAXIMUM OF 6 INCHES (15.2 cm) FROM WALL TO HELP PREVENT VAPOR FROM DISCOLORING THE WALL SURFACE IN COLDER CLIMATES

FACTORY SUPPLIED STANDARD TERMINATION POINTED DOWN TOWARDS THE GROUND

KEEP INTAKE AND VENT

TERMINATION SCREENS

CLEAR OF DEBRIS

24 INCHES (61 cm) MINIMUM

48 INCHES (122 cm) IN COLDER CLIMATES

SIDEWALL TERMINATION - DIRECT VENT

STANDARD TERMINATIONS

Figure 25

17. When the intake air and/or vent piping from multiple water heaters will terminate at the same location through a sidewall, the vent terminations can be grouped together in close proximity - 0 inches/touching. The intake air terminations can also be grouped together in close proximity

- 0 inches/touching.

However, the distance between the closest vent and intake air terminations must be a minimum of 24 inches (61 cm). In colder climates this separation should be increased to at least 48 inches (122 cm). See Figure 25.

SIDEWALL TERMINATION INSTALLATION

INTAKE AIR AND/OR VENT (EXHAUST)

Figure 26

23. Place a bead of silicone caulking (eld supplied) around the gap between the installed pipe(s) and the wall. Apply enough to ll the gap between the pipe(s) and wall.

24. Press the wall plate ush against the outside wall.

25. Working from the inside apply enough silicone caulking on the back of the interior wall plate(s) to hold it in place and slide the wall plate over the installed pipe(s).

26. Install a coupling to the end of the pipe(s) inside the building. Before the silicone caulking has time to completely set go outside the building and ensure the termination(s) is still pointing down towards the ground. See Figure 26.

27. Return to Power Vent Installation on page 23 or Direct Vent Installation on page 24 to complete the installation of the intake air and/or vent piping between the termination(s) and the water heater.

Page 28

POLYPROPYLENE INSTALLATIONS

The water heater has been approved to be installed with Polypropylene vent material as shown in Tables 7 and 8. The approved application of single wall, non-flexible, nonconcentric Polypropylene vent material is offered by two specific manufacturers (Centrotherm ECO Systems and DuraVent Polypropylene. These listed products must be installed by following the vent manufacturer’s instructions. Refer to Table 6 on Page 23 to determine the maximum pipe length and number of elbows that can be used.

Insulation should not be used on Polypropylene venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.

Use only the adapters and vent system listed in Tables below. DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.

Installations must comply with applicable national, state, and local codes. For Canadian installation, Polypropylene vent must be listed as a ULC-S636 approved system. If Polypropylene vent is not required by your local code, you may use either PVC or CPVC pipes for your water heater that allows non-metallic venting material installations.

Polypropylene vent systems do not use cement to connect the pipe and elbow sections but use a push together gasket seal method. Do not attempt to connect Polypropylene with sealant cement. All vent connections MUST be secured by the vent manufacturer’s joint connector. The installer must use a specific vent starter adapter at the flue connection. The adapter is supplied by the vent manufacturer to adapt to its vent system.

In order to be in full compliance with UL 1738 or ULC-S636 and to meet the requirements of the water heater manufacturer, you must use the metal joint connector rings, available from the Polypropylene vent manufacturer, to stiffen the joints of 3” and 4” diameter pipes.

TABLE 7

M & G Duravent PolyPro

Nominal Pipe

Diameter

3" 3PPS-AD PPS-PAC 3PPS-LB 3PPS-E90B 3PPS

4" 4PPS-AD PPS-PAC 4PPS-LB 4PPS-E90B 4PPS

Flue Outlet Adapter

Adapter

Connector

Ring

Connector

90 Degree

Elbow

TABLE 8

Centrotherm InnoFlue SW

Nominal Pipe

Diameter

Flue Outlet Adapter

ISAGL

0303

ISAGL

0404

Adapter

Connector

IAFC03 IANS03 ISELL0387 ISVL03

IAFC04 IANS04 ISELL0487 ISVL04

Ring

Connector

90 Degree

Elbow

Vent Material Terminal(s)

3PPS-E45B for Exhaust;

3PPS-E45B for Intake (Direct Vent only)

4PPS-E45B for Exhaust;

4PPS-E45B for Intake (Direct Vent only)

Vent Material Terminal(s)

ISELL0345UV for Exhaust; ISELL0345UV

for Intake (Direct Vent only)

ISELL0445UV for Exhaust; ISELL0445UV

for Intake (Direct Vent only)

Page 29

AL29-4C® VENT INSTALLATIONS

(AL29-4C® is a registered trademark of Allegheny Technologies, Inc.)

The water heaters covered by this manual are approved to be installed with AL29-4C® stainless steel vent material using parts from the manufacturers listed in Tables 9 and 10 below. These listed systems must be installed using the vent manufacturer’s instructions including their listed clearances to combustible and noncombustible materials. Refer to Table 6 on page 23 for the maximum and minimum equivalent linear vent lengths and number of elbows that may be used. However, use Tables 9 and 10 below to find the appropriate equivalent linear vent lengths for the AL29-4C® elbows.

NOTE: The equivalent lengths of the AL29-4C® elbows are different than those from smooth walled plastic vents. Consult Tables 9 and 10 for the correct equivalent linear vent lengths.

Listed vent systems composed of AL29-4C® must not mix parts from the different manufacturers. The joints of these products are sealed by internal gaskets. Do not use any other type of sealant. When assembling these vent systems, follow the vent manufacturer’s instructions for cleaning and lubricating the joints, if required. Each section must be locked together using the method supplied by the vent manufacturer.

The water heaters covered by this manual are approved to be installed using the approved vent terminations shown in this manual. This means that, the installer must use the adapter listed in Tables 9 and 10 and a short piece of PVC pipe to complete the end of the vent system with an approved termination. In Canada, the PVC pipe length must be listed to ULC636.

TABLE 9

HeatFab Saf-T Vent AL29-4C® Vent System Parts

Diameter

3 inches 9301 PVC 9307 9311 5 feet 9314 10 feet 9353CPVC

4 inches 9401 PVC 9407 9411 5 feet 9414 10 feet 9454CPVC

*Consult vent manufacturer’s catalog for other available lengths.

Flue Outlet

Adapter

*Straight Pipe

(3’ Section)

45° Elbow

Equivalent

Linear Length,

45° Elbow

90° Elbow

Equivalent

Linear length,

90° Elbow

TABLE 10

Duravent FasNSeal AL29-4C® Vent System Parts

Diameter Flue Outlet Adapter

3” 810005378 FSVL3603 FSELB4503 5 feet FSELB9003 10 feet 810009530

4” 810005545 FSVL3604 FSELB4504 5 feet FSELB9004 10 feet 810009529

*Consult vent manufacturer’s catalog for other available lengths.

“Straight Pipe

(3’ Section)

45” Elbow

Equivalent

Linear Length,

45” Elbow

90° elbow

Equivalent

Linear Length,

90- Elbow

Adapter to

PVC

Adapter to

PVC

Page 30

CONCENTRIC TERMINATION INSTALLATION

1. Concentric terminations must be ordered separately. BTH 120 - 250 models must use the 4 inch concentric termination; Part Number: 9006328005. Contact your local distributor or call the parts department phone number on the back cover of this manual to order concentric terminations.

2. Determine the location for the termination.

NOTE: Roof termination is preferred since it is less susceptible to damage, has reduced chances to intake contaminants and vent vapors are less visible.

3. When installing a concentric termination vertically through the roof; ensure that all exterior vertical clearance requirements for the concentric termination, shown in Figure 29 on page 31 are being maintained. These clearances and those cited by local and national codes must be maintained.

4. When installing a concentric termination vertically through a at roof, the termination's vent cap must be a minimum of 10 feet (3 m) away from any parapet, vertical wall or structure as shown in Figure 27.

CONCENTRIC TERMINATION(S) MUST BE A MINIMUM OF 10 FEET (3 m) AWAY FROM ANY PARAPET, VERTICAL WALL OR STRUCTURE.

CONCENTRIC TERMINATION

FLAT ROOF CLEARANCE

NOTE: If this required 10 foot (3 m) distance to a parapet, vertical wall or structure cannot be maintained, standard terminations must be used. See Vertical Termination Installation on page 25.

5. When installing a concentric termination through a sidewall; ensure that all exterior sidewall clearance requirements for the termination, shown in Figure 52 on page 38, are being maintained. These clearances and those cited by local and national codes must be maintained.

6. When installing multiple concentric terminations vertically through a roof or horizontally through a sidewall ensure the required clearances between terminations and groupings of multiple terminations are maintained. See pages 32 and 33 for more information.

7. Cut a 5 inch (13 cm) diameter hole for the 4 inch concentric termination where the termination will pass through the wall or roof.

NOTE: Beware of concealed wiring and piping when cutting through the wall or roof.

8. When installing multiple concentric terminations vertically through the roof in the same location the termination caps for all concentric terminations must be at the same height measured from ground. See Multiple Concentric Termination Arrangements on page 33.

9. Determine if the concentric termination will need to be shortened to accommodate required clearances or to ensure all vent caps are at the same height when installing multiple terminations vertically through the roof in the same location.

See Figure 28 on page 31 for the minimum lengths allowed for the 4 inch concentric termination.

Use only SDR-26 pipe to extend the 4 inch concentric termination.

NOTE: When shortening the length of the termination carefully measure and cut the larger (intake air) pipe rst. Cut the same amount of pipe off of the smaller (vent) pipe.

NOTE: Lengthening of the Concentric Vent Termination is not permitted.

10. Proceed to 4 Inch Concentric Termination Installation on page 31.

Figure 27

Page 31

4 INCH CONCENTRIC TERMINATION INSTALLATION

INTAKE AIR CONNECTION 3 INCH PVC

3” x 3” x 4” Y FITTING

INTAKE AIR PIPE

VENT PIPE

When installing 4 inch intake air and vent pipe - connect the piping to the concentric termination using eld supplied 4" x 3" reducer couplings and short sections of 3 inch pipe (18 inches or less) pipe. Cement all ttings and pipe in place.

9. Return to Direct Vent Installation on page 24 to complete the installation of the intake air and vent piping between the concentric termination and the water heater.

VENT CONNECTION - 3 INCH PVC

VENT PIPE IS 2 1/2 INCH SDR-26 PIPE SUPPLIED LENGTH 37 INCHES (94 cm) MINIMUM ALLOWABLE LENGTH 25 INCHES (64 cm)

INTAKE AIR PIPE IS 4 INCH SDR-26 PIPE SUPPLIED LENGTH 24 INCHES (60 cm) MINIMUM ALLOWABLE LENGTH 12 INCHES (30 cm)

INTAKE AIR PIPE

Y FITTING ASSEMBLY

VENT CAP

VENT PIPE ASSEMBLY

VENT CAP

4 INCH CONCENTRIC TERMINATION KIT

FOUR PIECE KIT - FIELD ASSEMBLY REQUIRED

Figure 28

Assemble and install the 4 inch concentric termination. Refer to Figure 28, Figure 29 and Figure 30 for these instructions:

1. Cement the Y tting to the larger diameter intake air pipe.

2. Slide the intake air pipe and Y tting assembly from inside the building through the hole cut for the termination in the roof or sidewall. Ensure no foreign materials such as insulation accumulate inside the assembly.

3. Secure the intake air Y tting assembly using eld supplied metal strapping or equivalent support materials.

4. On installations installed through the roof slide a eld supplied plumbing boot or roof ashing over the intake air Y tting assembly and secure it to the roof.

5. Seal around the plumbing boot or roof ashing.

6. Cement the vent cap onto the vent pipe. Alternately a eldsupplied stainless steel screw may be used to secure the 2 components together when eld disassembly is desired for cleaning. A pilot hole must be drilled for the screw to prevent damage/cracking of the vent cap and/or vent pipe.

7. Install the vent cap/vent pipe assembly into the intake air Y tting assembly, Ensure small diameter vent pipe is cemented and bottomed in the Y tting.

8. When installing 3 inch intake air and vent piping connect and cement the pipe directly to the concentric termination.

VENT

COMBUSTION

AIR

ROOF FLASHING (field supplied)

VENT

PIPE

4 INCH CONCENTRIC TERMINATION

VERTICAL INSTALLATION

Figure 29

NOTE: SECURING STRAP MUST BE FIELD INSTALLED TO PREVENT MOVEMENT OF TERMINATION KIT IN SIDEWALL.

VENT

PIPE

INTAKE

AIR PIPE

STRAP

(field supplied)

4 INCH CONCENTRIC TERMINATION

SIDEWALL INSTALLATION

Figure 30

MAINTAIN 12” (30 cm) 18” (45 cm) FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24” (60 cm) ABOVE ROOF.

STRAP

(field supplied)

NOTE: SECURING STRAP MUST BE FIELD INSTALLED TO PREVENT MOVEMENT OF TERMINATION KIT

INTAKE

AIR PIPE

COMBUSTION

AIR

VENT

1 INCH MAXIMUM

Page 32

MULTIPLE CONCENTRIC TERMINATION CLEARANCES

When installing multiple concentric terminations vertically through a roof or horizontally through a sidewall ensure the required clearances (separation) between terminations are maintained. Ensure multiple terminations are arranged or grouped as required.

NOTE: These clearances must be maintained to prevent the recirculation of vent (exhaust) gases to the intake air. Clearances are measured between the edges of the concentric termination caps.

When installing multiple concentric terminations through a roof or through a sidewall the clearances shown in Figure 31 must be maintained.

See Multiple Concentric Termination Arrangements on page 33.

Close Proximity & Standard Clearance

1. The clearance between multiple termination caps must be 0 inches (touching) to a maximum of 2 inches (5 cm), dimension A - Figure 31, when installing concentric terminations in close proximity. See Figure 36 on page 33.

2. The clearance between multiple termination caps must be increased to a minimum of 24 inches (61 cm), dimension B Figure 31, when installation in close proximity (above) is not possible. This is the standard clearance.

CONCENTRIC

TERMINATION CAPS

END VIEW

Four Concentric Terminations

1. When installing four concentric terminations through a roof or through a sidewall in close proximity they may be arranged into stacked rows of two as shown in Figure 33 or lateral rows of two as shown in Figure 34.

2. Four is the maximum number of concentric terminations that may be installed in a group where all terminations are in close proximity as shown in Figure 33.

CONCENTRIC

A = 0 - 2 INCHES (0 - 5 cm)

CLOSE PROXIMITY

TERMINATION

CAPS END VIEW

FOUR CONCENTRIC TERMINATIONS

(THROUGH A ROOF OR SIDEWALL)

Figure 33

A B

CLOSE PROXIMITY STANDARD CLEARANCE

A = 0 - 2 INCHES (0 - 5 cm)

TWO CONCENTRIC TERMINATIONS

(THROUGH A ROOF OR SIDEWALL)

Figure 31

Three Concentric Terminations

1. When installing three concentric terminations through a roof or through a sidewall the third termination may be installed in close proximity as indicated by dimension A in Figure 32.

2. If close proximity installation of the third termination is not possible the third termination may be installed as indicated by dimension B in Figure 32.

CONCENTRIC TERMINATION

CAPS END VIEW

A B

TERMINATION

A = 0 - 2 INCHES (0 - 5 cm)

THREE CONCENTRIC TERMINATIONS

CLOSE PROXIMITY

(THROUGH A ROOF OR SIDEWALL)

B = 24 INCHES (61 cm)

OR GREATER

THIRD

B = 24 INCHES (61 cm)

OR GREATER

CONCENTRIC

TERMINATION

CAPS END VIEW

A = 0 - 2 INCHES (0 - 5 cm)

CLOSE PROXIMITY

B = 24 INCHES (61 cm)

OR GREATER

FOUR CONCENTRIC TERMINATIONS

(THROUGH A ROOF OR SIDEWALL)

Figure 34

Groups Of Terminations

1. When installing multiple groups of concentric terminations through a roof or through a sidewall in close proximity they can be installed into stacked groups of four as shown in Figure 35. Lateral groups of four as shown in Figure 34 may be a more convenient installation arrangement for multiple groups depending on available space.

CONCENTRIC TERMINATION

A B

CAPS END VIEW

A = 0 - 2 INCHES (0 - 5 cm)

CLOSE PROXIMITY

EIGHT CONCENTRIC TERMINATIONS

(THROUGH A ROOF OR SIDEWALL)

B = 24 INCHES (61 cm)

OR GREATER BETWEEN

GROUPS OF FOUR

Figure 32

Figure 35

Page 33

MULTIPLE CONCENTRIC TERMINATION ARRANGEMENTS

The illustrations on this page show some of the installation arrangements for multiple concentric terminations that are allowed.

See Multiple Concentric Termination Clearances on page 32 for detailed information on clearances and additional arrangement options.

NOTE: When multiple concentric terminations are installed through a roof in the same location all termination caps must be at the same height measured from the ground.

Two Concentric Terminations

Two concentric terminations may be installed in close proximity as shown in Figure 36 or with standard clearances when this arrangement is not possible. See Figure 31 on page 32 for detailed information on clearances. See Figure 32 on page 32 when installing three concentric terminations.

SIDEWALL

ROOF

SIDEWALL

ROOF

Figure 37

Eight Concentric Terminations

Eight concentric terminations may be installed in two stacked groups of four, in close proximity, as shown in Figure 38. See Figure 35 on page 32 for detailed information on clearances.

Lateral groups of four as shown in Figure 34 on page 32 may be a more convenient installation arrangement for multiple groups depending on available space.

SIDEWALL

Figure 36

Four Concentric Terminations

Four concentric terminations may be installed in close proximity as shown in Figure 37. See Figure 33 and Figure 34 on page 32 for detailed information on clearances and additional arrangement options.

ROOF

Figure 38

Page 34

To Heater Intake

Snow Line

LOW PROFILE VENT INSTALLATION

This water heater is certied for sidewall direct venting with IPEX System 636 Low Prole Vent Kit. Follow instructions below for proper installations.

All termination kits must be located and installed in accordance with locl building code and CSA B149.1 Natural Gas and Propane Installation Code.

1. Once the proper location has been determined, cut 2 holes in the wall large enough to accomodate the pipe. See the Chart at bottom of this page for pipe diameters and distance between hole centers.

2. Slide both the intake and exhaust pipes through the holes. Solvent cement both pipes to the base of the vent termination kit, follow the solvent cementing procedures outlined in the IPEX System 636 Installation Guide, which is available on the web www.ipexinc.com.

3. To fasten the Base to the wall, use the supplied screws and anchors. A 3/16” (5mm) hole, 1-3/16” (30mm) deep, will need to be drilled for the anchors. Locate the anchor hole using the base as a template.

4. Screw the Cap to the Base using the supplied screws.

5. Once the vent termination and pipes are secured, the wall penetrations will need to be sealed from the interior using a PVC-compatible sealant material.

6. All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death, or substantial property damage.

7. Operate heater through 1 heat cycle to ensure combustion-air and vent pipes are properly connected to concentric vent termination.

From Heater Vent Pipe Connection

Possible Orientations

Vent (Exhaust)

Air Connection

12” Min to OverHang

Vent/Air Termination

12” Min

Grade or

Figure 40

12” Min between Edge of Air Inlet and Adjacent Vent (Exhaust) Outlet

Air Inlet

Vent (Exhaust)

Piping

Air Inlet Piping

Vent Base

Vent Cap

Vent/Air Termination

Figure 41

Figure 39

Low Prole Termination Kits - Dimensions and Contents Chart

Low Prole Termination Kits - Dimensions

Kit Number IPEX Part Number Description

9008933005 196985 3″ Flush Mount Vent Kit 3.5″ 5.63″

9008934005 196986 4″ Flush Mount Vent Kit 4.5″ 5.63″

Pipe Outside

Diameter

Hole Spacing

(ctr to ctr)

Each Kit Contains

Qty Item Description

1 Base (two holes)

1 Cap (one hole)

8 Stainless Steel Screws

Plastic Anchors

Page 35

VENTING ARRANGEMENTS

Power Vent Vertical

Figure 42

Power Vent Horizontal

Figure 43

Direct Vent Vertical

Figure 44

Direct Vent Horizontal

Figure 45

Direct Vent Vertical Vent

Horizontal Intake

Figure 46

Direct Vent Horizontal Vent

Vertical Intake

Figure 47

Page 36

VENTING ARRANGEMENTS

Direct Vent Vertical Concentric

Figure 48

Direct Vent Horizontal Concentric

Figure 49

Direct Vent Horizontal Low Prole

Figure 50

Page 37

TERMINATION CLEARANCES SIDEWALL POWER VENT

POWER VENT

EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION

(using room air for combustion)

FIX ED

CLOSED

OPERABLE

FIX ED

CLOSED

VENT TERMINAL AIR SUPPLY INLETAREA WHERE TERMINAL IS NOT PERMITTED

V X

Figure 51

Vent terminal clearances for “Power Vent” installations. Power Vent congurations use room air for combustion.

Clearance to each side of center line extended

above meter/regulator assembly

Clearance to service

regulator vent outlet

CANADIAN INSTALLATIONS 1US INSTALLATIONS

3 feet (91 cm) within a height 15 feet (4.5 m) above the meter/ regulator assembly

3 feet (91 cm) 3 feet (91 cm)*

3 feet (91 cm) within a height 15 feet (4.5 m) above the meter/regulator assembly*

Clearance above grade, veranda, porch, deck or

balcony

Clearance to window or door that may be

opened

CANADIAN INSTALLATIONS 1US INSTALLATIONS

12 inches (30 cm) 12 inches (30 cm)

6 inches (15 cm) for appliances up to 10,000 Btu/hr (3 kW), 12 inches (30 cm) for appliances between 10,000 Btu/hr (3 kW) and 100,000 Btu/hr (30 kW), 36 inches (91 cm) for appliances above 100,000 Btu/hr (30 kW)

4 feet (1.2 m) below or to side of opening; 1 foot (30 cm) above

opening

6 inches (15 cm) for appliances up to 10,000 Btu/hr (3 kW), 12 inches (30 cm) for appliances between 10,000 Btu/hr (3 kW) and 100,000 Btu/hr (30kW), 36 inches (91cm) for appliances above 100,000 Btu/ hr (30 kW)

6 feet (1.83 m)

7 feet (2.13 m)†

12 inches (30 cm) ‡ 12 inches (30 cm) ‡

4 feet (1.2 m) below or to side of opening; 1 foot (30 cm) above opening.

3 feet (91 cm) above if within 10 feet (3 m) horizontally

7 feet (2.13 m)

Clearance to permanently closed

window

Vertical clearance to ventilated soft located above the terminal within a horizontal

distance of 2 feet (61 cm) from the center line of the terminal

Clearance to

unventilated soft

Clearance to outside

corner

Clearance to inside

corner

12 inches (30 cm)* 12 inches (30 cm)*

2 feet (60 cm)* 2 feet (60 cm)*

18 inches (45 cm)* 18 inches (45 cm)*

Clearance to a non mechanical air supply inlet into building or

combustion air inlet to any other appliance

Clearance to a mechanical air supply

inlet

Clearance above paved sidewalk or paved

driveway located on public property

Clearance under veranda, porch, deck, or

balcony

1 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code.

2 In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. Where it may cause hazardous frost or ice accumulations on adjacent property surfaces.

‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the oor.

* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.

Page 38

TERMINATION CLEARANCES SIDEWALL DIRECT VENT

(using outdoor air for combustion)

FIX ED

CLOSED

OPERABLE

FIX ED

CLOSED

VENT TERMINAL AIR SUPPLY INLETAREA WHERE TERMINAL IS NOT PERMITTED

V X

EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION

Figure 52

Vent terminal clearances for “Direct Vent” installations. Direct Vent congurations use outdoor air for combustion.

DIRECT VENT

Clearance above grade, veranda, porch, deck or

balcony

CANADIAN INSTALLATIONS 1US INSTALLATIONS

12 inches (30 cm) 12 inches (30 cm)

Clearance to each side of center line extended

above meter/regulator assembly

CANADIAN INSTALLATIONS

3 feet (91 cm) within a height 15 feet (4.5 m) above the meter/ regulator assembly

US INSTALLATIONS

3 feet (91 cm) within a height 15 feet (4.5 m) above the meter/regulator assembly*

6 inches (15 cm) for appliances up to 10,000 Btu/hr (3 kW), 9 inches (23 cm) for appliances between 10,000 Btu/hr (3 kW) and 50,000 Btu/hr (15 kW), 12 inches (30 cm) for appliances above 50,000 Btu/hr (15 kW)

Clearance to service

regulator vent outlet

Clearance to a non mechanical air supply inlet into building or

combustion air inlet to any other appliance

Clearance to a mechanical air supply

inlet

Clearance above paved sidewalk or

paved driveway located on public property

Clearance under veranda, porch, deck,

or balcony

3 feet (91 cm) 3 feet (91 cm)*

6 feet (1.83 m)

7 feet (2.13 m)† 7 feet (2.13 m)†*

12 inches (30 cm) ‡ 12 inches (30 cm) ‡*

3 feet (91 cm) above if within 10 feet (3 m) horizontally

Clearance to window or

door that may be opened

Clearance to permanently closed

window

Vertical clearance to ventilated soft located above the terminal within

a horizontal distance of 2 feet (61 cm) from the center line of the terminal

Clearance to unventilated

soft

Clearance to outside

corner

Clearance to inside

corner

6 inches (15 cm)* 6 inches (15 cm)*

12 inches (30 cm)* 12 inches (30 cm)*

2 feet (60 cm)* 2 feet (60 cm)*

18 inches (45 cm)* 18 inches (45 cm)*

1 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code.

2 In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.

‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the oor.

* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.

Page 39

WATER HEATER INSTALLATION

CONDENSATE DRAIN INSTALLATION

Installation must conform with these instructions and local building codes.

Field supplied materials required for installation include:

• Approved PVC cement and PVC primer.

• 1/2 inch PVC pipe - minimum length to equal the distance between the water heater and a suitable building drain.

• 1/2 inch PVC ttings (elbows, couplings, and adapters) necessary to install a condensate drain line between the Exhaust/Condensate Elbow Assembly and a suitable building drain.

• Floor mounted standoffs to brace the drain line.

INSTALLATION NOTES

1. The condensate drains from the water heater’s covered by this instruction have PH levels between 4.3 and 5.0. Install a commercially available neutralizing kit if required by local codes. Lower PH levels are acidic. Do not connect a metal condensate drain line, such as copper pipe, to the water heater for this reason.

2. The eld installed condensate drain line must not be less than 1/2 inch PVC in size.

3. DO NOT remove, modify or alter the factory condensate trap.

INSTALLATION INSTRUCTIONS

1. Ensure the water heater’s on/off switch is in the “off” position.

2. Install a 1/2 inch PVC condensate drain line between condensate drain connection on the Exhaust/Condensate Elbow and a suitable building drain, see Figure 53.

3. Terminate the condensate drain piping with an elbow above the drain. Ensure that any discharge will exit the condensate drain line no more than 6 inches (15.2 cm) above a suitable building drain, or external to the building, see Figure 53.

NOTE: In cold climates it is recommended the condensate drain be terminated at a suitable drain inside the building.

4. Ensure the condensate drain line is not elevated above the condensate drain connection on the Exhaust/Condensate Elbow, see Figure 53.

5. Brace the condensate drain line with oor mounted standoffs every three feet.

6. Ensure the condensate drains freely during start up, see Start Up on page 53.

EXHAUST/CONDENSATE

(VENT) ELBOW

PRESSURE PORT

1/2” NPT CONDENSATE DRAIN CONNECTION

CONDENSATE

CLEANOUT

Figure 53

CONDENSATE DRAIN LINE - FIELD INSTALLED

BUILDING DRAIN

DRAIN LINE TO

TERMINATE NO

MORE THAN 6

INCHES (15.2 cm)

ABOVE DRAIN

Page 40

SUPPLY GAS LINE INSTALLATION

Contact your local gas utility company to ensure that adequate gas service is available and to review applicable installation codes for your area.

Be sure that the gas meter has sufcient capacity to supply the rated gas input of the water heater as well as the requirements of all other gas red equipment supplied by the meter. If the gas meter is undersized, the gas company will have to install a properly sized gas meter.

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.

Make sure gas supplied is same type listed on the water heater’s rating label.

The water heaters covered in this manual are not intended for operation at higher than 14.0" W. C. (2.62 kPa) for natural gas and

14.0" W. C. (3.49 kPa) for propane gas supply pressure, see Table 3 on page 11. The water heaters covered in this manual require supply gas regulators to maintain required supply gas pressure. Exposure to higher gas supply pressure may cause damage to the gas controls which could result in re or explosion. If overpressure has occurred such as through improper testing of gas lines or malfunction of the supply system the water heater’s gas valve must be checked for safe operation by a Qualied Service Agency.

Ensure supply regulator vent lines and the safety vent valves are protected against blockage. These are components of the gas supply system, not the water heater. Vent blockage may occur during ice storms.

It is important to guard against gas valve fouling from contaminants in the gas ways. Such fouling may cause improper operation, re or explosion. If copper supply lines are used they must be internally tinned and certied for gas service.

REGULATED GAS SUPPLY LINE

MAIN GAS SHUTOFF VALV E

TEE FITTING

SEDIMENT TRAP

PIPE CAP

Figure 54

Ensure all gas pipe is clean on the inside before installation. To trap any dirt or foreign material in the gas supply line a sediment trap must be installed as shown in Figure 54. The sediment trap must be readily accessible and not subject to freezing conditions. Install in accordance with the recommendations of the local gas utility company.

GAS LINE SIZING

Depending on the developed equivalent length and/or the number of appliances connected to a common main, the size of supply gas lines may have to be increased.

Size the supply/main gas line(s) in accordance with Table 11 or Table 12. The values given in Table 11 and Table 12 are for straight lengths of iron pipe at 0.5" W. C. (125 Pa) pressure drop, which is considered normal for low pressure systems. Note that ttings such as elbows and tees will add to the pipe pressure drop.

Schedule 40 Steel or Wrought Iron Pipe is the preferred material for the gas line of this water heater. It is imperative to follow the sizing recommendations in the latest version of the National Fuel Gas Code if Corrugated Stainless Steel Tubing (CSST) is used as the gas line for this water heater.

SUPPLY GAS LINE SIZING U. S. UNITS TABLE 11

LENGTH

FEET

NORMAL IRON PIPE SIZES (INCHES)

INPUT IN THOUSANDS BTU/HR

1/2” 3/4” 1” 1 1/4” 1 1/2” 2”

10 175 360 680 1400 2100 3960

20 120 250 485 950 1460 2750

30 97 200 375 770 1180 2200

40 82 170 320 660 990 1900

50 73 151 285 580 900 1680

60 66 138 260 530 810 1520

70 61 125 240 490 750 1400

80 57 118 220 460 690 1300

90 53 110 205 430 650 1220

100 50 103 195 400 620 1150

125 44 93 175 360 550 1020

150 40 84 160 325 500 950

175 37 77 145 300 460 850

200 35 72 135 280 430 800

SUPPLY GAS LINE SIZING METRIC UNITS TABLE 12

LENGTH

METERS

NORMAL IRON PIPE SIZES (INCHES)

INPUT IN kW

1/2” 3/4” 1” 1 1/4” 1 1/2” 2”

3.0 51 105 199 410 615 1160

6.1 35 73 142 278 428 805

9.1 28 59 110 225 346 644

12.2 24 50 94 193 290 556

15.2 21 44 83 170 264 492

18.3 19 40 76 155 237 445

21.3 18 37 70 143 220 410

24.4 17 35 64 135 202 381

27.4 16 32 60 126 190 357

30.5 15 30 57 117 182 337

38.1 13 27 51 105 161 299

45.7 12 25 47 95 146 278

53.3 11 23 42 88 135 249

61.0 10 21 40 82 126 234

Page 41

GAS LINE CONNECTION

1. The water heaters covered by this manual are shipped from the factory with 3/4 inch supply gas connections. The supply gas line must not be smaller than 3/4 inch. Connect the supply gas line to the water heater's 24 Volt Gas Valve in accordance with all applicable local and national code requirements.

2. Depending on the developed equivalent length and/or the number of appliances connected to a common main, the size of the supply gas line may have to be increased, see Gas Line Sizing on page 40. If the supply gas line must be re-sized larger to accommodate increased supply gas line lengths or multiple appliances use reducer couplings and short pipe nipples to increase the supply gas line.

NOTE: Make the transition to the larger supply gas line as close to the supply gas connection as possible.

3. Apply thread sealing compounds (pipe dope/Teon tape) sparingly and only to the male threads of the pipe joints. Do not apply sealing compound to the rst two threads. Use pipe dope or Teon tape marked as being resistant to the action of liquid petroleum (LP/propane) gases.

SUPPLY GAS CONNECTION FACTORY INSTALLED

LOW GAS PRESSURE SWITCH

COMBUSTION BLOWER

TEE FITTING

SUPPLY GAS LINE CONNECTION

Figure 55

4. Use only a smooth jaw adjustable wrench as a back up on the body of the 24 Volt Gas Valve when tightening the rst pipe nipple into the body of the valve. DO NOT use a standard pipe wrench (Stillson wrench) with metal tooth jaws as this may permanently damage the valve.

5. Use a standard pipe wrench (Stillson wrench) as a back up on the rst pipe nipple installed above when connecting other ttings and pipe in the supply gas line to prevent the 24 Volt Gas Valve on the water heater from twisting during installation.

6. To prevent damage, care must be taken not to apply too much torque when connecting the supply gas line to the water heater.

7. Install a sediment trap as shown in Figure 54 on page 40.

8. Install a Main Gas Shutoff valve in the supply gas line as shown in Figure 54 on page 40.

NOTE: Should overheating occur or the gas supply fail to shut off, turn off the Main Gas Shutoff valve to the water heater.

GAS LINE LEAK TESTING

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.

Any time work is done on the gas supply system perform a leak test to avoid the possibility of re or explosion.

1. For test pressures exceeding 1/2 psi (3.45 kPa) disconnect the water heater and its Main Gas Shutoff Valve from the gas supply piping system during testing, see Figure 54 on page 40. The gas supply line must be capped when disconnected from the water heater.

2. For test pressures of 1/2 psi (3.45 kpa) or less, the water heater need not be disconnected, but must be isolated from the supply gas line by closing the Main Gas Shutoff Valve during testing.

3. Paint all supply gas line joints and connections upstream of the water heater with a rich soap and water solution to test for leaks. Bubbles indicate a gas leak. Do not use matches, candles, ame or other sources of ignition for this purpose.

4. Repair any leaks before placing the water heater in operation.

PURGING

Gas line purging is required with new piping or systems.

Purging should be performed per the current edition of NFPA 54 the National Fuel Gas Code or CAN/CSA B149.1 Natural Gas and Propane Installation Code.

ELECTRICAL WIRING

All electrical work must be installed in accordance with the National Electrical Code, ANSI/NFPA 70 or the Canadian Electrical Code, CSA C22.1 and local requirements.

When installed, the water heater must 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.

If any of the original wire as supplied with the water heater must be replaced, it must be replaced with 105°C rated wiring or its equivalent, except in the burner housing. In this case 200°C rated wire must be used.

Page 42

POWER SUPPLY CONNECTIONS

Read the requirements for the Power Supply on page 13 before connecting power.

The 120 VAC hot wire from the power supply must connect to the black jumper wire or the "L1" terminal block location in the junction box and the 120 VAC neutral wire must connect to the white jumper wire or the "Neutral" terminal block location in the junction box for correct polarity. See Figure 56.

Power supply connections must be made as follows:

1. Ensure the power supply is turned off at the breaker or disconnect switch.

2. Remove the junction box cover. See Figure 3 on page 8 for junction box location.

3. Connect the 120VAC hot wire from the power supply to the black jumper wire or the terminal block location marked "L1" inside of the junction box located on top of the water heater. If the black jumper wire is used make the connection inside of the junction box with a properly sized wire nut and wrap electrical tape around the wire nut and wire end. See junction box Figure 56 and wiring diagram Figure 67 on page 67.

NOTE: If electrical connection is made directly to terminal

block remove black jumper wire before making connection.

4. Connect the 120VAC neutral wire from the power supply to the white jumper wire or the terminal block location marked "Neutral" inside of the junction box located on top of the water heater. If the white jumper wire is used, make the connection inside of the junction box with a properly sized wire nut and wrap electrical tape around the wire nut and wire end. See junction box Figure 56 and wiring diagram Figure 67 on page 67.

NOTE: If electrical connection is made directly to terminal

block remove white jumper wire before making connection.

5. Connect the ground wire from the power supply to the grounding lug inside the junction box. See junction box Figure 56 and Wiring Diagram Figure 67 on page 67.

6. Replace junction box cover when connections are complete.

NOTE: Do not apply power to the water heater before installation is complete and the water heater is lled with water.

Heater Wiring

(Factory Installed)

MOV

Ground

Ground Terminal

Jumper Wire

Neutral

Figure 56

ENABLE / DISABLE CIRCUIT (For Building Management Systems)

The water heaters covered in this manual are equipped with an enable/disable circuit for use with eld supplied external supervisory controls such as time clocks or Building Management Systems. The enable/disable circuit may be used to disable

heating operation during periods when the building is unoccupied or there is no demand for hotwater.

To use the enable/disable circuit it must rst be activated by selecting the “Use External Enable” from the UIM. Field supplied wiring is then installed between the water heater’s CCB and a set of “dry contacts” (no voltage or load) on the eld supplied external control.

NOTE: The water heater’s enable/disable circuit is a switching circuit only: Do not apply external voltage or connect any load (IE: relay coil) to this circuit. This will damage the CCB circuit board and is not covered under the limited warranty.

CONNECTING AN EXTERNAL SUPERVISORY CONTROL

The enable/disable circuit is accessed from the CCB’s J17 plug inside the CCB enclosure; see Figure 3 on page 8 to locate the CCB enclosure. Install eld wiring to the enable/disable circuit:

1. Turn off power at the water heater’s enable/disable switch and the breaker that supplies power to the water heater.

2. Locate the CCB enclosure.

3. Carefully remove the Temperature Probe connectors and CCB enclosure cover.

4. Locate pins 1 and 2 on the CCB J17 plug. See Figure 66 on page 66.

5. Connect the two eld supplied control wires to pins 1 and 2 on the CCB J17 plug.

6. Thread the control wires out of the CCB enclosure with the other wiring and carefully replace the CCB enclosure cover. Ensure all wiring is routed through the intended area provided for strain relief. Ensure no wiring is being pinched.

7. Reinstall the CCB enclosure cover.

8. Route the control wires inside the junction box on the top of the water heater; see Figure 3 on page 8 to locate the junction box. Use an available knock-out to route the wires inside the junction box.

9. Install eld supplied control wiring and conduit as required by national and local codes between the water heater’s junction box and the external supervisory control. Connect the wiring from the external control to the control wires inside the junction box using wire nuts and electrical tape.

10. Connect the control wiring to a set of dry contacts on the external control. Follow the control manufacturer’s instructions for making connections.

11. Restore power to the water heater.

12. From the water heaters UIM “Heater Information Screen” select “Use External Enable” and change to “Yes”. See Figure 3 on page 8 to locate the UIM.

NOTE: Whenever the external control opens the set of dry contacts used, water heating operation will be disabled. Whenever the external control closes the set of dry contacts used, water heating operation will be enabled. A diagonal line and circle appears over the thermometer icon on the UIM when water heating operation is disabled. See the Status Icons descriptions in Table 14 on page 46.

NOTE: Ensure the water heater is protected from freezing temperatures when water heating operation is disabled. Damage to the water heater caused by freezing temperatures is not covered under the limited warranty.

Page 43

WATER LINE CONNECTIONS

The water piping installation must conform to these instructions and to all local and national code authority having jurisdiction. Good practice requires that all heavy piping be supported.

Read and observe all requirements in the following sections before installation of the water piping begins:

1. Mixing Valves on page 14.

2. Dishwashing Machines on page 14.

3. Temperature-Pressure Relief Valve on page 15.

4. Closed Systems and Thermal Expansion on page 14.

5. For multiple water heater installations see Water Piping Diagrams beginning on page 69.

WATER PIPING DIAGRAMS

This manual provides detailed water piping diagrams for typical methods of application for the water heaters, see Water Piping Diagrams beginning 69.

The water heater may be installed by itself, or with a separate storage tank. When used with a separate storage tank, the circulation may be either by gravity or by means of a circulating pump. When a circulating pump is used, it is important to note that the ow rate should be slow so that there will be a minimum of turbulence inside the water heater storage tank.

NOTE: In addition to the factory installed Temperature-Pressure Relief Valve (T&P 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 Temperature-Pressure Relief Valve installed.

Call the toll free technical support phone number listed on the back cover of this manual for further assistance in sizing a T&P valve for remote storage tanks.

THERMOMETERS (NOT SUPPLIED)

Thermometers are installed in the water piping system as a means of detecting the temperature of the hot water supply at critical points in the system. Field supplied thermometers should be obtained and installed. See Water Piping Diagrams on page 69.

WATER (POTABLE) HEATING AND SPACE HEATING

1. All water piping components connected to the water heater that are for space heating applications shall be suitable for use with potable water.

2. Toxic chemicals, such as those used for boiler treatment, must NEVER be introduced into this system.

3. The water heaters covered in this manual may never be connected to any existing heating system or component(s) previously used with non-potable water heating appliance.

4. When the system requires water for space heating that exceed safe temperatures at domestic water xtures a mixing valve must be installed, see Mixing Valves on page 14.

5. These water heaters cannot be used in space heating applications only.

T&P VALVE DISCHARGE PIPE

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 (T&P) relief valve by the manufacturer. See Temperature-Pressure Relief Valve on page 15 for information on replacement and other requirements.

CAUTION

Water Damage Hazard

Temperature-Pressure Relief Valve discharge

•

pipe must terminate at adequate drain.

Install a discharge pipe between the T&P valve discharge opening and a suitable oor drain. 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.

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.

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

Page 44

TEMPERATURE REGULATION

HIGH TEMPERATURE LIMIT CONTROL (ECO)

This water heater is equipped with an ECO (energy cut out) non adjustable high temperature limit switch. The ECO is a normally closed switch that opens (activates) on a rise in temperature.

The ECO is located inside the Upper Temperature Probe (two red wires), see pages 8 and 9 for location. The ECO switch contacts will open when the water temperature reaches approximately 202°F (94°C) and close at approximately 140°F (49°C).

If the ECO activates (contacts open) due to abnormally high water temperatures in the storage tank the control system will immediately de-energize the 24 Volt Gas Valve and end the current heating cycle. The control system will "lock out" disabling further heating operation. The control system will display the "Energy Cut Out (ECO)" Fault message on the LCD screen. It is important that a Qualied Service Agent be contacted to determine the reason for the ECO activation before resetting the ECO. Once the reason has been determined and corrected the ECO can be reset as follows:

Should the ECO activate, the water temperature must drop below 140°F (49°C) before the control system can be reset. Once the water temperature has cooled below this point the power supply to the water heater must be turned off and on again to reset the control system.

THERMOSTAT CONTROL

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.

Hot water temperatures required for automatic dishwasher and laundry use can cause scald burns resulting in serious personal injury and/or death. Table 13 shows the approximate time-toburn relationship for normal adult skin.

The temperature at which injury occurs varies with the person’s age and duration of exposure. The slower response time of children, the elderly or disabled persons increases the hazards to them. 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 can be installed at the water heater (see Figure 7 on page 14) or at the hot water taps to further reduce system water temperature.

Never allow small children to use a hot water tap or draw their own bath water. Never leave a child or disabled person unattended in a bathtub or shower.

The water heater should be located in an area where the general public does not have access to set temperatures.

Setting the Operating Set Point at 120°F (49°C) will reduce the risk of scalds. Some States require settings at specic lower temperatures.

TABLE 13

Water Temperature

°F (°C)

(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)

The water heaters covered in this manual are equipped with an electronic control system to regulate water temperature inside the storage tank. The control system senses temperature from two factory installed temperature probes, one installed in the top of the storage tank and one installed near the bottom, See Top Views on page 8 and Figure 4 on page 9 for location.

The “Operating Set Point”

is adjusted to

regulate water temperature inside the storage tank. This is an adjustable user setting in the control system’s “Temperatures Menu.” This and all control system menus are accessed through the UIM module)

located on the front of the water heater, see Figure 57.

(user interface

The Operating Set Point is adjustable from 90°F (42°C) to 180°F (82°C). The factory setting is 120°F (49°C). See Operating Set Point And Differential Adjustment on page 48 for instructions on how to adjust the Operating Set Point and other user settings.

Set the Operating Set Point at the lowest setting which produces an acceptable hot water supply. This will always provide the most energy efcient operation.

MODULATION

HIGH TEMPERATURE APPLICATIONS

Higher operating temperatures cause more wear on all water heaters and will decrease the life span of the water heater. Consider installing a small booster water heater for high temperature applications, such as commercial dishwashers, to raise the outlet temperature from the larger primary water heater to the desired point of use temperature.

Contact your local distributor or call the technical support phone number listed on the back cover of this manual for further technical assistance.

MANUFACTURER / MODEL INFORMATION

Tank Te mperature 103°F Operating Set Point 120°F

Status: Heating

OFF

GAS

MENU HELP

Figure 57

Page 45

CONTROL SYSTEM OPERATION

OVERVIEW

The water heaters covered in this manual are equipped with an electronic control system that regulates water temperature inside the storage tank. Heating cycles and ignition are managed by the control system. The ECO (energy cut out), ame sensor, pressure switches and temperature probes are monitored by the control system. The Combustion Blower, Spark Ignition Control, 24 Volt Gas Valve and anode rods are all powered by the control system.

The main components of the control system are a UIM (user interface module) and a CCB (central control board). The UIM is located on the top front side of the water heater. The CCB is mounted on top of the water heater inside a protective enclosure. See Features And Components on page 7 for location of these and all water heater components.

CONFIGURATION KEY

POWER

SUPPLY

BOARD

CCB

BOARD

TRANSFORMER

Figure 58

CONTROL SYSTEM NAVIGATION

All operational information and user settings are displayed and accessed from the UIM. The UIM houses the control system's LCD (liquid crystal display) and ve snap acting (momentary)

user input buttons; an up, down and three (3) multi functional operational buttons below the LCD, see Figure 59.

User Input Buttons

• The up and down buttons are used to navigate menus and adjust user settings.

• The operational buttons are used to enter/exit menus, select menu items, activate adjustment modes and conrm or cancel new user settings. The operational buttons are multifunctional, their current function is dened by the text that appears directly above each button on the LCD screen.

THE DESKTOP SCREEN

During normal operation the control system will display the "Desktop" screen on the LCD which is the default screen. The control system will return to the Desktop screen when there are no active Fault or Alert conditions or when there has been no user input for several minutes.

• Manufacturer and water heater model information is displayed in Title Bar at the top of the Desktop screen. Menu titles are displayed in the Title Bar when navigating the control system menus.

• The rst temperature shown on the Desktop screen, Tank Temperature, is the temperature of the water inside the water heater's storage tank.

• The second temperature shown on the Desktop screen is the Operating Set Point. The Operating Set Point is the temperature at which the control system will maintain the water inside the storage tank.

• Beneath the Operating Set Point is the "Status" line. The Status line shows the current operational state of the control system in real time, see Table 15 on page 47 for a description of the various operational states.

• The Desktop screen also displays animated "Status Icons" to convey operational information, see Table 14 on page 46 for descriptions of the Status Icons.

UIM (user interface module)

Desktop Screen Shown

LCD Screen Information Display

Status Icons

Operational buttons are multi functional. Their current function is defined by the text that appears directly above each button on the LCD screen.

MANUFACTURER / MODEL INFORMATION

Tank Temperature 103°F Operating Set Point 120°F

Status: Heating

OFF

GAS

MENU HELP

Figure 59

Title Bar

Up & Down buttons: navigate menus, adjust user settings

3 Operational buttons: enter/exit menus, select menu items, activate adjustment modes, confirm/cancel changes.

Page 46

STATUS ICONS

OFF

The Status Icons are displayed on the Desktop screen and convey operational and diagnostic information. The icons are described in the table below. See Figure 59 on page 45 and the Sequence Of Operation on page 57.

TABLE 14

Icon Description

Water temperature in the tank has fallen. Shaded area of the animated thermometer icon will rise and fall in response to water temperature in the storage tank as sensed from the Upper and Lower Temperature Probes. See beginning on page 8 and Figure 4 on page 9 for location of Temperature Probes.

Water temperature in the tank has reached the Operating Set Point. The control system enters the Standby mode.

The control is unable to initiate a heating cycle. This will happen whenever a Fault condition is detected by the control system or when the Enable/Disable switch on front panel or Building Management system Enable/Disable circuit is an open circuit. Display will read "Status: Water Heating Disabled". For more information see Enable/Disable Circuit on page 42.

The Combustion Blower is being energized.

The Blower Prover pressure switch contacts have closed. The check mark icon is visual conrmation of contact closure. See beginning on page 8 for Blower Prover Switch location.

The Spark Igniter is being energized. See Figure 2 on page 7 for Spark Igniter location.

GAS

The 24 Volt Gas Valve is being energized.

O N

The control system has sensed ame at the Main Burner from the ame sensor. See the Sequence Of Operation Flow Chart on page 58 and Figure 2 on page 7.

The control system has declared a Fault condition and must be inspected/serviced by a Qualied Service Agent. Fault message details can be viewed in the Current Fault menu. Heating operation is disabled (lock out) until the condition that caused the Fault is corrected. Power to the water heater must be cycled off and on at the breaker to reset the control system.

NOTE: Cycling power will not reset the control system if the condition that caused the Fault has not been corrected.

The control system has declared an Alert condition and must be inspected/serviced by a Qualied Service Agent. The water heater will continue to operate during an Alert condition.

Page 47

OPERATING STATES

The current operational state of the water heater is displayed on the Desktop screen as the "Status." The common operational states are described in the table below. See Figure 59 on page 45 and the Sequence Of Operation on page 57.

TABLE 15

State Description

Standby The water heater is not in an active heating cycle. IE: the Tank Temperature is at or above the Operating Set Point.

Input Verication The control system is conducting a diagnostic check at the beginning of a heating cycle.

Water Heating

Disabled

Pre-Purge The Combustion Blower is energized to ush residual ue gases from the combustion chamber prior to ignition.

Spark Igniter Energized

Ignition Activation The 24 Volt Gas Valve is energized and opens to allow fuel gas to ow to the Main Burner.

Ignition Verication The control system is monitoring the ame sensor for the required minimum ame sensing current.

Inter-Purge The Combustion Blower is energized to ush residual fuel gas from the combustion chamber after a failed ignition attempt.

Heating Ignition was successful, ame sensing current has been established. The water in the storage tank is being heated.

Post-Purge The Combustion Blower is energized to ush residual ue gases from the combustion chamber at the end of a heating cycle.

Fault The control system has detected a Fault condition. Heating operation is disabled until the Fault condition is corrected. Power

A Fault condition is detected by the control or when the Enable/Disable switch on front panel or the Building Management system Enable/Disable is an open circuit.

The Spark Igniter is energized.

See the Sequence Of Operation on page 57 for minimum ame sensing current (DC micro amps) information.

to the water heater must be cycled off and on at the breaker to reset the control system.

NOTE: Cycling power will not reset the control system if the condition that caused the Fault has not been corrected.

CONTROL SYSTEM MENUS

From the Desktop screen pressing the Operational directly below "Menu" on the LCD will display the "Main Menu" this is where all control system menus are located. The table below describes the control system menus.

TABLE 16

Menu Description

Temperatures Most commonly accessed menu. Contains the Operating Set Point and Differential user settings.

Heater Status This menus displays the current state of all pressure switches and the ECO (open/closed). The on/off status of the

Display Settings Temperature units (°F or °C), the LCD appearance (brightness/contrast) and backlight delay user adjustable settings

Heater Information Elapsed time of operation, total heating cycle time, heating cycle count, heating on time along with UIM and CCB

Current Fault Displays any current Alert or Fault messages.

Fault History This control system menu retains a list of the last nine (9) Fault and Alert messages with a time stamp. The newest

Fault Occurrence This control system menu retains a running total of how many times each Fault condition has occurred since the water

Restore Factory Defaults This control system feature allows the user to restore control system user settings to their factory default settings.

Help Screens Text based operational and user information explaining how to change user settings, navigate the control system menus

Combustion Blower, gas valve, Spark Igniter, ame sensor and other monitored water heater components are displayed in this menu.

are located in this menu.

software revisions can be viewed in this menu.

event will replace the oldest. Faults will clear after 30 days.

heater was rst installed. The data does not clear and cannot be reset.

Display Settings preferences ARE NOT changed when factory defaults are restored.

and icon descriptions.

Page 48

USER SETTINGS & CONTROL SYSTEM MENUS

TEMPERATURES MENU

Operating Set Point And Differential Adjustment

The Operating Set Point is adjustable from 90°F (42°C) to 180°F (82°C). The factory setting is 120°F (49°C). The Differential is adjustable from 2° to 20°. The factory setting is 8°. These user settings are accessed from the Temperatures menu. The following instructions will explain how to adjust these settings and navigate the control system menus.

When the water temperature sensed by the control system from the two (upper and lower) Temperature Probes reaches the Operating Set Point the control system will end the heating cycle. A heating cycle will be activated again when the sensed water temperature drops below the Operating Set Point minus the Differential setting.

NOTE: Lower Differential settings may cause excessive heating cycles (short-cycling) which can cause premature failure of heater components. Set the Differential at the highest setting which produces an acceptable hot water supply. Set the Operating Set Point to the lowest setting which produces an acceptable hot water supply for most efcient use.

DESCRIPTION/ACTION DISPLAY

From the Desktop screen, press the Operational Button under MENU. The "Main Menu" screen will be displayed.

MANUFACTURER / MODEL INFORMATION

Tank Temperature 120°F Operating Set Point 120°F

Status: Standby

The Main Menu is where all control system menus are listed, see Table 16 on page 47 for a complete list and description of control system menus. Use the Up and Down Buttons to view all control system menus from the Main Menu.

With Temperatures menu selected (highlighted in black) in the Main Menu screen, press the Operational Button under “SELECT” to enter the Temperatures menu.

If the Temperatures menu is not selected use the Up and Down Buttons to select this menu item.

With the Operating Set Point selected in the Temperatures menu, press the Operational Button underneath “CHANGE” to activate the adjustment mode for this menu item.

If Operating Set Point is not selected use the Up and Down Buttons to select this menu item.

NOTE: Higher Temperature settings increase wear and operating costs. Set the Operating Set Point to the lowest setting which produces an acceptable hot water supply. This will always provide the most energy efcient operation and longer life.

With the adjustment mode for the Operating Set Point activated the selection bar will change from a black ll to a black outline.

Use the Up and Down Buttons to change the current setting.

Press the Operational Button under "UPDATE" to save the new setting. Press the Operational Button under "CANCEL" to discard changes and return to the previously saved setting.

NOTE: Use this same procedure to change the Differential setting and other adjustable user settings in the control system menus.

MEN

ELP

Main Menu

Temperatures

Heater Status Display Settings Heater Information Current Fault

SELECT BACK HELP

Temperatures

Operating Set Point 120°F

Differential 8°F Tank Te mperature 120°F Upper Temperature 122°F Lower Temperature 118°F Tank Probe Offset 0°F

CHANGE BACK HELP

Temperatures

Operating Set Point 140°F Differential 8°F Tank Te mperature 120°F Upper Temperature 122°F Lower Temperature 118°F Tank Probe Offset 0°F

UPDATE CANCEL

Page 49

TEMPERATURES MENU (CONT)

DESCRIPTION/ACTION DISPLAY

• Differential - Adjustable user setting that changes the tank temperature differential with a range of 2° to 20°F. The factory setting is 8°F.

• Tank Temperature - non adjustable - control system sensed temperature (averaged from upper and lower temperature probes).

• Upper Temperature - non adjustable - control system sensed temperature from the Upper Temperature Probe.

• Lower Temperature - non adjustable - control system sensed temperature from the Lower Temperature Probe.

• Tank Probe Offset - adjustable user setting, range -5° to +5° (factory setting 0°).

NOTE: These settings should only be used if the hot water supply temperature varies greatly from the Operating Set Point setting.

The Tank Probe Offset is used to calibrate control system temperature sensing. This can improve the precision of temperature control in the storage tank and at points of use. This feature can also be used to compensate for building recirculation loops (hot water returning to the storage tank) that may cause the heating cycles to terminate prematurely.

Example: If the current sensed temperature from a temperature probe is 120°F (49°C) and the Offset setting is adjusted to a value other than 0°, the control system would calibrate or “offset” the sensed temperature from the probe and the averaged tank temperature. Heating cycles would be activated and deactivated based on the calibrated (offset) temperature. A -5° setting results in +5° hotter water.

These settings are adjusted in the same way described for Operating Set Point And Differential Adjustment on page 48.

Temperatures

Operating Set Point 140°F

Differential 8°F Tank Te mperature 120°F Upper Temperature 122°F Lower Temperature 118°F Tank Probe Offset 0°F

CHANGE BACK HELP

HEATER STATUS MENU

DESCRIPTION/ACTION DISPLAY

Select Heater Status from the Main Menu and press the Operational Button under "SELECT" to enter this menu. This menu contains non adjustable operational information. Use the Up & Down Buttons to navigate the menu.

• Status - displays the current Operating State, see Table 15 on page 47.

• ECO Contact, Low Gas PS, Blocked Inlet PS, Blocked Outlet PS, Blower Prover PS - displays the current state of the switch contacts; open or closed.

• Igniter On, Gas Valve On - displays whether or not the control system is currently energizing these water heater components; yes = energized, no = de-energized.

• Flame Detected - displays whether or not the control system has detected Main Burner ame during ignition from the ame sensor.

Top of Menu

Heater Status

Status Standby ECO Contact Closed Low Gas PS Closed Blocked Inlet PS Closed Blocked Outlet PS Closed Blower Prover PS Open Igniter On No

BACK HELP

Bottom of Menu

Heater Status

Gas Valve On No Flame Detected No

BACK HELP

Page 50

DISPLAY SETTINGS

DESCRIPTION/ACTION DISPLAY

Select Display Settings from the Main Menu and press the Operational Button under "SELECT" to enter this menu. This menu contains adjustable display options for viewing information on the UIM’s LCD screen. Use the Up & Down Buttons to navigate the menu.

• Temperature Units - Adjustable user setting that changes temperature units display to Celsius °C or Fahrenheit °F.

• Backlight Delay - Adjustable user setting that determines how long the UIM’s LCD backlight remains illuminated after a key has been pressed. Available settings are; Always Off, 10, 30 or 60 seconds and Always On.

• Contrast - Adjustable user setting to adjust the UIM’s LCD screen contrast between text and background.

NOTE: These settings are adjusted in the same way described for the Operating Set Point And Differential Adjustment on page 48.

HEATER INFORMATION

DESCRIPTION/ACTION DISPLAY

Select Heater Information from the Main Menu and press the Operational Button under "SELECT" to enter this menu. This menu contains non adjustable operational information.

• Elapsed Time - Total accumulated time the control system (water heater) has been energized.

• Burner On Time - Total accumulated time the control system has been in the heating operating state; burner run time.

• Total Cycle Count - Total accumulated count of heating cycles.

• CCB Version - Software version for central control board.

• Cong CRC - Veries the conguration key matches the CCB programming.

• UIM Version - Software version for user interface module.

• Use External Enable - Enables/Disables the external enable circuit.

• External Enable Status - Displays whether or not the external enable circuit has been activated.

• Ignition Trials - Displays the number of ignition trials allowed.

NOTE: Historical data is stored in the conguration key. If this "key" is replaced during servicing the historical data will be lost. The data stored in the new conguration key will no longer reect the entire history of the water heater.

The Elapsed Time, Burner On Time and Cycle Count indicate age, usage and wear.

If the Cycle Count per day is high (divide cycle count by days to determine cycles per day) or the cycle duration is short (determine burner on time total minutes, divide burner on time total minutes by cycle count) consider rasing the Differential setting to avoid short cycling and excessive component wear, see Operating Set Point And Differential Adjustment on page 48.

This historical data can also be used to assist facilities managers in forecasting planned replacement of equipment to help avoid lengthy and costly hot water supply interruptions.

Display Settings

Temperature Units °F Backlight Delay 30s Contrast 60%

CHANGE BACK HELP

Heater Information

Elapsed Time 10 day 0 hrs 0 mins Burner On Time 5 hrs 22 mins Total Cycle Count 00000035 CCB Version X.XX Config CRC 0 x 605D

CHANGE BACK HELP

Bottom of Menu

Heater Information

UIM Version X.XX Use External Enable No External Enable Status No Ignition Trials 3

BACK HELP

Page 51

CURRENT FAULT

DESCRIPTION/ACTION DISPLAY

Select Current Fault from the Main Menu and press the Operational Button under "SELECT" to enter this menu. This menu contains non adjustable operational information. Use the Up & Down Buttons to navigate the menu.

This menu contains the current Fault or Alert error message. The time the Fault or Alert message occurred appears directly below. A brief description of what causes the particular Fault or Alert condition appears below that. Pressing the Operational Button under "ADVANCED" will give more detailed service information and a list of possible causes for the Fault or Alert condition. See Fault And Alert Messages on page 61 for more detailed information and diagnostic procedures.

If there is no Fault or Alert condition active this menu will not contain any information, "(none)" will be shown next to Current Fault in the Main menu.

FAULT HISTORY

DESCRIPTION/ACTION DISPLAY

Select Fault History from the Main Menu and press the Operational Button under "SELECT" to enter this menu. This menu contains non adjustable operational information. Use the Up & Down Buttons to navigate the menu.

This menu contains a list of the last nine (9) Fault and Alert messages with a time stamp. The newest event will replace the oldest.

Press the Operational Button under "VIEW" to view details for each Fault or Alert message stored.

Blocked Exhaust

Fault occurred 2 mins ago

Restriction in exhaust pipe. Check exhaust pipe and termination for blockage.

Call a service professional: Your Company Name Here

(press [DOWN] for more....)

CHANGE BACK

Fault History

1: Blocked Air Intake (A7) 51 mins ago 2: Blocked Exhaust (A8) 54 mins ago 3: Low Gas Pressure (A6) 57 mins ago 4: Blower Prover Failure (AC)

ADVANCED

FAULT OCCURRENCE

DESCRIPTION/ACTION DISPLAY

Select Fault Occurrence from the Main Menu and press the Operational Button under "SELECT" to enter this menu. This menu contains non adjustable operational information. Use the Up & Down Buttons to navigate the menu.

This menu contains a running total of how many times each Fault condition has occurred since the water heater was rst installed.

RESTORE FACTORY DEFAULTS

DESCRIPTION/ACTION DISPLAY

Select Restore Factory Defaults from the Main Menu and press the Operational Button under "SELECT" to enter this menu.

To restore the adjustable user settings to their factory default settings press the Operational Button underneath “YES.” The display will show text conrming the factory default settings have been restored.

Press the Operational Button underneath “BACK” to exit the Restore Factory Defaults menu.

VIEW BACK HELP

Fault Occurrence

Ignition Failure 10 ECO 0 Low Gas Pressure 10 Blocked Intake Air 0 Blocked Exhaust 0 Blower Prover 0 Flame Detect Error 3

BACK HELP

Restore Factory Defaults

Are you sure you want to restore the system to factory defaults?

YES NO

Page 52

SERVICE CONTACT INFORMATION

The control system has a discrete menu that Installing contractors and/or service agents can access to enter contact information for their customers. This contact information will be displayed with all Fault and Alert messages.

DESCRIPTION/ACTION DISPLAY

From the Desktop Screen (see Figure 59 on page 45) press and hold down the middle (unmarked) Operational Button for 30 seconds and then release it.

This will launch a discrete menu where personalized contact information can be entered.

Using the UP and DOWN buttons select (highlighted in black) the "Show Contact Information" menu item.

Show Contact Information No

Change Contact Name Change Contact Phone Current Contact Info:

Service Contact Information

(000) 000-0000

Press the Operational Button under "CHANGE" to activate the adjustment mode for this parameter.

Access Code

CHANGE BACK HELP

With the adjustment mode for "Show Contact Information" activated the selection bar will change from a black ll to a black outline.

Use the Up and Down Buttons to change the setting from "No" to "Yes" and press the Operational Button underneath "UPDATE" to save the new setting.

NOTE: The Access Code at the bottom of the Service Contact Information screen is for manufacturing engineering purposes only. There are no user settings or information accessed through this menu item.

Using the UP and DOWN buttons select (highlighted in black) the "Change Contact Name" menu item.

Press the Operational Button under "SELECT" to open the Change Contact Name menu.

Follow the on screen instructions to enter your name or the name of your company. There is a maximum of 20 character spaces for this purpose.

When nished press the Operational Button "UPDATE" to save the new Contact Name. The control system will return to the discrete menu.

Service Contact Information

Show Contact Information Yes Change Contact Name Change Contact Phone Current Contact Info:

(000) 000-0000 Access Code

UPDATE CANCEL

Service Contact Information

Show Contact Information Yes

Change Contact Name

Change Contact Phone Current Contact Info:

(000) 000-0000 Access Code

SELECT BACK HELP

Enter the service contact below:

Use the > and < keys to move between characters. Use the UP and DOWN keys to change the character.

NAME: _

Using the UP and DOWN buttons select (highlighted in black) the "Change Contact Phone" menu item and press the Operational Button under "SELECT".

Follow the on screen instructions to enter a new Contact Phone number and press the Operational Button under "UPDATE" to save the new phone number.

When the new Contact Name and Contact Phone number have both been updated, press the Operational Button under "BACK" to return to the Desktop screen.

< > UPDATE

Service Contact Information

Show Contact Information Yes Change Contact Name Change Contact Phone

Current Contact Info:

YOUR COMPANY NAME HERE (123) 456-7890 Access Code

BACK HELP

Page 53

START UP

PRIOR TO START UP

Installation and start up of this water heater requires abilities and skills equivalent to that of a licensed tradesman in the eld involved, see Qualications on page 6.

Do not place the water heater in operation if any part has been exposed to ooding or water damage. Immediately call a qualied service technician to inspect the water heater and to replace any part of the control system and any gas control which has been under water.

Light the water heater in accordance with the Lighting and Operation Instruction label on the water heater and in this manual beginning on page 54.

The water heaters covered by this manual are equipped with an electronic control system (see page 45) which automatically sequences the Combustion Blower, pre and post purging of the combustion chamber, the spark generator, the 24 Volt Gas Valve, Main Burner ignition, and ame sensing. The control system will lock out after three unsuccessful ignition attempts.

Before attempting start up, thoroughly study and familiarize yourself with the exact Sequence Of Operation, see the written Sequence Of Operation on page 57 and the Sequence Of Operation Flow Chart on page 58.

Be certain that the water heater is full of water, that air is purged from the gas and water lines and that there are no leaks in the gas and water lines. Ensure all inlet water valves are open.

FILLING THE WATER HEATER

Follow these steps to ll the water heater prior to start up.

1. Close the heater drain valve.

2. Open a nearby hot water faucet to permit air in system to escape.

3. Fully open the cold water inlet valve allowing the piping and water heater to ll with water.

4. Close the hot water faucet opened in Step 2 as water starts to ow.

INITIAL START UP

REQUIRED TEST EQUIPMENT

• Two U-tube manometers, recommended ranges; 0-14” W.C. (0-3.5 kPa) and 0-35” W.C. (0-8.7 kPa) or pressure gauges.

• Two digital manometers can be used in place of U-tube manometers or pressure gauges. Recommended ranges;

-14.00 to +14.00” W.C. (0-3.5 kPa) resolution 0.01” W.C. and 0-35” W.C. (0-8.7 kPa) resolution 0.10” W.C.

NOTE: All test equipment must be acclimated to ambient temperature before calibration and use.

port one full turn only; turn the needle valve screw counterclockwise to open the valve. Slide the manometer sensing tube over the top of the test port, see Figure 60 and Figure

61.

6. Connect one manometer (lower range) to an available test port for manifold gas pressure to the Main Burner:

Using a small flat tip pocket screw driver - open the needle valve inside the manifold gas pressure test port one full turn only; turn the needle valve screw counterclockwise to open the valve. Slide the manometer sensing tube over the top of the test port, see Figure 60 and Figure 61.

7. Open the Main Gas Shutoff Valve.

8. Measure and record the supply gas pressure, this is a “static” supply gas pressure reading; while the water heater is not ring. Adjust supply gas pressure as necessary, see Supply

Gas Pressure Adjustment on page 55.

MANIFOLD GAS PRESSURE TEST PORT

COMBUSTION BLOWER CONNECTION

SUPPLY GAS PRESSURE TEST PORT

GAS VALV E

COMBUSTION AIR INLET

VENTURI

GAS VALVE / VENTURI ASSEMBLY TOP VIEW

Figure 60

MANIFOLD GAS PRESSURE TEST PORT

SUPPLY GAS

PRESSURE TEST PORT

GAS VALVE TOP DETAIL VIEW

PREPARATION

1. Using the control system menus, change the Operating Set Point to the lowest temperature setting, see Operating Set Point And Differential Adjustment on page 48.

2. Turn the water heater’s enable/disable switch to the "disabled" position.

3. Close the Main Gas Shut Off Valve, see Figure 54 on page 40.

4. Wait ve (5) minutes for any residual gas to clear.

5. Connect one manometer (higher range) to an available test port for the supply gas pressure to the water heater:

On the water heaters covered by this manual there are test ports for supply and manifold gas pressure readings on the gas valve. Using a small at tip pocket screw driver open the needle valve inside the supply gas pressure test

Figure 61

GAS VALV E

COMBUSTION AIR INLET

VENTURI

GAS VALVE / VENTURI ASSEMBLY SIDE VIEW

SUPPLY GAS CONNECTION

LOW GAS PRESSURE SWITCH

Figure 62

Page 54

LIGHTING THE WATER HEATER

LIGHTING & OPERATION LABELS

The instruction label below is afxed to the water heater's covered by this manual at the factory and must be followed when lighting and operating the water heater.

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING:

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

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SAG LLEMS UOY FI OD OT TAHW

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.gnidliub ruoy ni enohp yna esu ton od

ENABLE/DISABLE

!POTS

SWITCH

.lebal siht no

Set the Enable/Disable switch on the control panel

2 to

the Enable position.

Set the Enable/Disable switch on the control panel

the Disable position.

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ELBAMMALF

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SNOITCURTSNI GNITAREPO

ot setunim )5( evif tiaW

,sag llems neht uoy fI

Set the Enable/Disable switch on the control panel

the Enable position.

10. lf the appliance will not operate, follow the

evoba noitamrofni ytefas eht daeR

instructions “

TO TURN OFF GAS TO APPLIANCE

and call your technician or gas supplier.

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.renrub eht sthgil yllacitamotua hcihw

.DNAH YB RENRUB EHT THGIL OT YRT TON OD

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”

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.GNICIVRES EROFEB REWOP

ECNAILPPA OT SAG FFO NRUT OT

gnittes tsewol eht ot tatsomreht eht teS

Set the Enable/Disable switch on the control panel

the

Disable

position.

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.demrofrep eb ot si ecivres

Page 55

SUPPLY GAS PRESSURE ADJUSTMENT

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.

Supply gas pressure shall be measured while the water heater is not ring (static pressure) AND while the water heater is ring at full capacity (dynamic pressure).

If the supply gas pressure to the water heater is not between the required minimum and maximum values given in Table 3 on page 11 adjust the supply gas regulator as necessary. Adjust the supply gas regulator(s) per the regulator manufacturer’s instructions to achieve the required “static” and “dynamic” supply gas pressure.

Multiple Water Heater Installations:

In multiple water heater installations or in installations where the installed water heater(s) share a common gas supply main

with other gas red appliances; the supply gas pressures shall be measured at each water heater with all gas red appliances connected to a common main ring at full capacity.

On multiple water heater installations the supply gas line regulators shall be adjusted to provide gas pressure to each water heater within the minimum and maximum supply pressure requirements listed in Table 3 on page 11 with all gas red appliances connected to a common gas main ring at full capacity.

NOTE: A pressure drop of more than 1.5” W. C. (0.37 kPa) when the Main Burner ignites is an indication of an inadequate supply of gas and can lead to ignition failure, rough starts and/or rough operation. If a drop of more than 1.5” W. C. (0.37 kPa) in supply gas pressure occurs when the Main Burner ignites, ensure the supply gas lines and regulator(s) are properly sized and installed. See the requirements for Supply Gas Regulator and Gas Supply Systems on page 13. See Supply Gas Line Installation on page 40 and Supply Gas Regulator on page 13. Ensure all requirements and installation instructions are maintained.

MANIFOLD GAS PRESSURE

The manifold pressure is non adjustable. The manifold gas pressure is factory set and cannot be eld adjusted. If the manifold gas pressure readings taken on these models is off by more than ± 0.3" W. C. from the listed values in Table 3 on page 11 call the technical support phone number listed on the back cover of this manual for further assistance.

Page 56

CHECKING THE FIRING RATE

If ring rate adjustment is required follow these instructions to determine the actual ring rate of the water heater:

NOTE: The heaters covered by this manual are capable of modulating their ring rate. The ring rate should be checked with the heater operating at it's full ring rate.

1. Ensure there are no other gas red appliances connected to the gas meter ring during this test.

2. Contact the gas supplier to determine the heating value, in Btu per cubic foot, of the gas supply.

3. Connect a manometer to the supply gas pressure tap. Follow the instructions for Initial Start Up on page 53.

4. Start the water heater and ensure it is ring.

5. Check the supply gas pressure, refer to Table 3 on page 11 for correct pressure.

6. Locate the gas meter serving the water heater.

7. Time how long (in seconds) it takes for one cubic foot of gas to be used while the water heater is ring with a stop watch.

8. Use the formula below to “clock” the gas meter and determine the actual ring rate of the water heater based on the heating value (Btu per cubic foot) of the gas supply:

3600

x H = Btu/hr

Example:

3600

x 1050 = 300,000 Btu/hr (87.9 kW)

12.6

• 3600 = seconds in one hour.

• T = time, in seconds, to burn one cubic foot of gas.

• H = heating value of gas in Btu per cubic foot.

• Btu/hr = actual ring rate of the water heater. NOTE: 1050 Btu per cubic foot is a standard value for

natural gas. Standard propane gas Btu content is 2500 Btu per cubic foot. Btu values may change in certain areas and at high elevations. Check with the local gas utility company.

TO TURN OFF GAS

1. Change the Operating Set Point to the lowest temperature setting, see Operating Set Point And Differential Adjustment on page 48.

2. When the water heater has completed its shut down sequence and enters the standby mode, turn the water heater’s on/off switch to the “off” position.

3. Close Main Gas Shutoff Valve, see Figure 54 on page 40.

HIGH ALTITUDE INSTALLATIONS

Fire and Explosion Hazard

Under no circumstances should the input exceed the rate shown on the water heater’s rating label.

Overfiring could result in fire or explosion.

Gas and carbon monoxide detectors are available.

Breathing Hazard - Carbon Monoxide Gas

Under no circumstances should the input exceed the rate shown on the water heater’s rating label.

Overfiring could result in damage to the water heater and sooting.

Gas and carbon monoxide detectors are available.

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

The heater models covered by this manual are certied for use without modication for altitudes up to 10,100 feet (3,078 m).

Most gas utility companies de-rate their gas for high altitudes, making it unnecessary to install high altitude orices.

For installations above the certied elevations listed above call the technical support phone number listed on the back cover of this manual for further technical assistance. Call the local gas or utility company to verify Btu per cubic foot content before calling for technical assistance and have that information available.

NOTE: The actual ring rate of the water heater must not exceed the input rating on the water heater's rating label under any circumstances.

NOTE: Due to the input rating reduction at high altitudes, the output rating of the water heater is also reduced and should be compensated for in the sizing of the equipment.

Page 57

TROUBLESHOOTING

INSTALLATION CHECKLIST

The list below represents some of the most critical installation requirements that, when overlooked, often result in operational problems, down time and needless parts replacement. This is not a complete list. Before performing any troubleshooting procedures use the list below to check for installation errors. Costs to correct installation errors are not covered under the limited warranty. Ensure all installation requirements and instructions in this manual have been maintained and followed.

WATER HEATER LOCATION

1. Ensure proper clearances to combustibles are maintained and there is sufcient room to service the water heater. See Clearance To Combustible Materials on page 12.

2. Ensure the area is free of corrosive elements and ammable materials. See the instructions on page16.

VENTING

1. Ensure the intake air and/or vent (exhaust) piping is

the correct size for the installed length. See Venting Requirements on page 22.

2. Ensure the maximum equivalent feet of pipe has not been

exceeded for the intake air and/or vent pipe. See Table 6 on page 23.

3. Ensure the maximum number of elbows has not been

exceeded in the intake air and/or vent pipe. See Venting Requirements on page 22.

4. Ensure the intake air screen has been removed from the

intake air connection on the water heater when installing the water heater in a Direct Vent conguration. See Figure 18 on page 25.

5. Ensure all exterior clearances for the intake air, vent,

concentric, and low prole terminations are maintained. See Vertical Termination Installation on page 25, Sidewall Termination Installation on page 27, Concentric Termination Installation on page 30 and Low Prole Termination Installation on page 34. These clearances and those cited by local and national codes must be maintained.

GAS SUPPLY AND PIPING

1. Ensure a supply gas regulator has been installed for each

water heater. See the requirements for a Supply Gas Regulator on page 13.

2. Ensure the supply gas line to each water heater meets

the minimum supply gas line size requirements. See the requirements for the Gas Supply Systems on page 13 and the installation instructions on page 40 and 41.

CONDENSATE DRAIN

Ensure the condensate drain is properly connected to the exhaust elbow on the water heater and draining freely to a suitable oor drain. See Figure 8 on page 16 and Condensate Drain Installation on page 39.

ELECTRICAL CONNECTIONS

1. Ensure the power supply connections to the water heater

are polarity correct. See the requirements for the Power Supply on page 13 and Electrical Wiring on page 41.

2. Ensure the water heater is properly grounded. Flame

sensing requires an adequate earth ground. If the water heater is not properly grounded it will cause Ignition Failure.

SEQUENCE OF OPERATION

Read the Sequence of Operation below before attempting to correct any operational problems. Refer to the Features And Components section beginning on page 7 for the location of various water heater components described below. See the Sequence Of Operation Flow Chart on page 58 also.

1. When the control system is rst powered, during boot up, it will display water heater model information during initialization. After a few moments the control system LCD which is part of the UIM (user interface module) will display the default screen known as the "Desktop" screen.

2. If the control system determines that the actual water temperature inside the tank is below the programmed Operating Set Point minus the Differential setting, a heating cycle is activated.

3. The control system then performs selected diagnostic system checks. This includes conrming the low gas pressure, blocked exhaust, blocked intake and ECO (energy cut out) switch contacts are closed. The Blower Prover Switch contacts are conrmed open.

4. If all diagnostic checks are successfully passed, the control system energizes the Combustion Blower for pre-purge.

5. The control system must conrm the Blower Prover Switch contacts close after the Combustion Blower is energized.

6. If the Blower Prover Switch contacts are conrmed closed the control system energizes the Spark Ignition Control.

7. The control system energizes the 24 Volt Gas Valve allowing gas to ow to the Main Burner.

8. The control system 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 the control system will try for ignition up to two more times. If ame can not be veried after three trials for ignition, the control system will lock out and display the “Ignition Failure” Fault message.

9. If a ame is veried, the control system will enter the heating mode where it will continue heating the water until the Operating Set Point is reached. At this point, the control system will de-energize the 24 Volt Gas Valve and enter the post-purge cycle (approximately 30 seconds).

10. The control system de-energizes the Spark Ignition Control.

11. The water heaters covered by this manual are capable of modulating their ring rate. The ring rate is dictated by the hot water draw and various other temperature limitations.

12. The Combustion Blower will run for the duration of the postpurge cycle to purge the water heater of all combustion gases. When the post-purge cycle is complete, the blower is de-energized and will coast to a stop.

13. The control system now enters the standby mode while continuing to monitor the internal storage tank water temperature and the state of other system devices. If the tank temperature drops below the Operating Set Point minus the Differential setting, the control will automatically return to Step 2 and repeat the operating cycle.

Page 58

SEQUENCE OF OPERATION FLOW CHART

Sequence is shown with Enable/Disable Switch in the Enable position

If tank temperature drops below Operating Set Point minus

Differential setting a heating cycle is activated

Control System performs diagnostic checks

Normal State of all pressure switches and ECO are checked

Blower Prover pressure switch verified open

All other pressure switches and ECO are verified closed

Combustion Blower is energized

Pre-Purge cycle

Control System Locks Out

Displays Fault Msg

Blower Prover switch contacts confirmed

Is flame sensed at the Main Burner ?

(control system monitors the flame sensor)

Water is heated to

set point

24 Volt Gas Valve

de-energized

closed by control system

Spark Ignition Control is energized

24 Volt Gas Valve is energized

gas flows to Main Burner

YES NO

24 Volt Gas Valve

de-energized

Inter-Purge cycle

Control System Locks Out

“Blower Prover Open”

Fault Msg is displayed

Post-Purge cycle

Water heater goes into standby mode

Retries up to

two more times

Control System

Locks Out

“Ignition Failure”

Fault Msg is

displayed

Figure 63

Page 59

CAUTION

OPERATIONAL PROBLEMS

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.

This section of the manual is intended to be an aid in correcting common operational problems, it is not all inclusive. The installer may be able to observe and correct certain problems which might arise when the water heater is rst put into operation or when it is re-red after a prolonged shutdown. However, only qualied service agents, as dened in Qualications on page 6, using appropriate test equipment, should perform any service procedures on the water heater.

NOTE: Call the technical support phone number listed on the back cover of this manual for further technical assistance or to locate a qualied service agent in your area.

INSTALLATION ERRORS

Operational problems on new installations are often the result of installation requirements that have been overlooked rather than failed components. IE: A "Low Gas Pressure" Fault condition is most often caused by low supply gas pressure rather than a defective Low Gas Pressure switch. Rough starting and rough operation are often caused by undersized supply gas lines and/ or the absence of a supply gas regulator at the water heater.

Prior to performing any operational checks inspect the water heater installation to ensure all installation requirements and instructions have been maintained and followed. See the Installation Checklist on page 57

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

ROUGH STARTING, ROUGH OPERATION

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.

• Undersized supply gas line (low volume of supply gas) - see Gas Supply Systems on page 13.

• Supply gas regulator is not installed per installation

• Excessive supply gas pressure - see Table 3 on page 11

requirements (erratic gas supply volume/pressures) - see Supply Gas Regulator on page 13.

and Supply Gas Pressure Adjustment on page 55.

• Vent (exhaust) gas recirculation at the vent and intake air pipe terminations on Direct Vent installations - see Direct Vent Installation on page 24.

• Excessive equivalent lengths of intake air and/or vent (exhaust) piping installed - see Venting Requirements on page 22.

• Debris clogging/blocking the intake air screen(s) - see Figure 18 on page 25 and Figure 25 on page 27.

• Debris clogging/blocking the Main Burner - see Figure 2 on page 7.

MOMENTARY IGNITION

Burn Hazard

The combustion chamber and burner sleeve

•

and housing become very hot during operation.

Do not reach into the burner housing or

•

combustion chamber if the water heater is still hot.

Allow the water heater to cool and always use

•

gloves when handling the main burner.

If the Main Burner ignites momentarily but does not sustain ignition allow the water heater to try to ignite up to two more times until control system locks out and the Ignition Failure Fault message is displayed on the control system's LCD. If the water heater is experiencing rough starts - see Rough Starting, Rough Operation on this page. For momentary ignition problems without rough starting check the following:

• Undersized supply gas line (low volume of supply gas) - see Gas Supply Systems on page 13.

• Supply gas regulator is not installed per installation requirements (erratic gas supply volume/pressures) - see Supply Gas Regulator on page 13.

• See the list of possible causes and things to check and repair for the Ignition Failure Fault message on page 61.

• Debris clogging/blocking the intake air screen(s) - see Figure 18 on page 25 and Figure 25 on page 27.

• Debris clogging/blocking the Main Burner - see Figure 2 on page 7.

NOT ENOUGH OR NO HOT WATER

• No power to the water heater, check breaker, fuses and the water heater on/off switch.

• Enable/Disable switch in "disabled" position. Set to enable to allow unit to operate.

• Hot water supply valve(s) to xtures closed.

• Operating Set Point is set too low, Differential setting is set too high. See Control System Operation on page 45.

• Upper and/or Lower Probe Offset settings are causing the heating cycles to terminate prematurely - see Temperatures Menu (cont) on page 49.

• Ensure there is not any external supervisory control (using the enable/disable circuit) disabling heating operation.

• The heating capacity of the water heater has been exceeded, the water heater is unable to meet demand.

• Colder incoming water temperature lengthening the time required to heat water to desired temperature.

• Hot water piping leaks, open faucets, water heater drain valve leaking or open.

Page 60

• Sediment or lime scale accumulation may be affecting water heater operation. See Maintenance on page 63 for sediment and lime scale removal procedures.

• Water heater not ring at full input rating. Check actual ring rate of the water heater, see instructions on page 56. Note that the water heaters covered by this manual are capable of modulating their ring rate. The ring rate is dictated by the hot water draw and various other temperature limitations.

WATER IS TOO HOT

• Operating Set Point is set too high. See Operating Set Point And Differential Adjustment on page 48.

• If installed check Thermostatic Mixing Valve settings

• Upper and/or Lower Probe Offset settings improperly set - see Temperatures Menu (cont) on page 49.

• Lime build-up on temperature probes. Inspect and Clean.

• Improper water piping - see diagrams beginning on page 69.

NOISY OPERATION

• Sediment or lime scale accumulations can cause rumbling and pounding noises during heating cycles. See the Maintenance section of this manual beginning on page 63 for sediment and lime scale removal procedures.

• Normal operating noise of electrical components; Combustion Blower, transformer hum, relay contact closure.

WATER LEAKAGE IS SUSPECTED

• Ensure the water heater drain valve is tightly closed.

• Check cleanout opening for leaks - see Figure 4 on page 9.

• Check inlet/outlet water connections and system piping.

• Check the Temperature-Pressure Relief Valve.

• Excessive water temperature.

• Excessive water pressure.

• Defective Temperature-Pressure Relief Valve.

NOTE: Excessive water pressure is the most common cause of Temperature-Pressure Relief Valve leakage. Excessive water system pressure is most often caused by "thermal expansion" in a "closed system." See Thermal Expansion and Closed Water Systems on page 14. The Temperature-Pressure Relief Valve is not intended for the constant relief of thermal expansion.

Temperature-Pressure Relief Valve leakage due to pressure build up in a closed system that does not have a thermal expansion tank installed is not covered under the limited warranty. Thermal expansion tanks must be installed on all closed water systems.

REPLACEMENT PARTS

Replacement parts may be ordered from the manufacturer, authorized service agencies or distributors. When ordering parts be sure to have the complete water heater Model Number, Serial Number and Series Number available. This information can be found on the rating label afxed to the water heater.

Refer to the parts list included with the water heater from the factory for more information or call the parts department or technical support phone number listed on the back cover of this manual for further assistance.

FAULT AND ALERT CONDITIONS

FAULT CONDITIONS

When the control system declares a Fault condition it will display a Fault message on the control system's LCD with an exclamation "!" mark. The control system will lock out and disable heating operation until the condition is corrected. The water heater must be serviced by a qualied service agent before operation can be restored.

mark. The water heater will continue to operate during an Alert condition but the water heater must be serviced by a qualied service agent as soon as possible.

RESETTING CONTROL SYSTEM LOCK OUTS

To reset the control system from a lock out condition; turn the power supply off at the breaker for approximately 20 seconds and then back on. Keep in mind; if the condition that caused the Fault has not been corrected, the control system will continue to lock out.

DIAGNOSTIC CHECKS

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.

The following section, Fault And Alert Messages on page 61, lists some of the messages the control system will display on the LCD when there are operational problems. This is not a complete list. Along with each of the Fault and Alert messa ges descr ibed there will be a list of possible caus es and things to check and repair.

Only qualied service agents, as dened in Qualications on page 6, using appropriate test equipment, should perform any service procedures on the water heater.

NOTE: If you are not qualied 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 diagnostic or service procedures described in the following section.

If you do not understand the instructions in the following section do not attempt to perform any procedures.

Call the technical support phone number listed on the back cover of this manual for further technical assistance or to locate a qualied service agent in your area.

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.

ALERT CONDITIONS

When the control system declares an Alert condition it will display an Alert message on the control system's LCD with a question "?"

Page 61

FAULT AND ALERT MESSAGES

Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualied service agent in your area.

POSSIBLE CAUSES - CHECK/REPAIR DISPLAYED FAULT/ALERT MESSAGE

• Using a manometer, ensure that gas supply pressure is above minimum requirement listed on heater’s data plate and does not drop more than 1.5” W.C. when unit res.

• Ensure wire connections to gas valve are clean and tight.

• Ensure wire connections to ame sensor are clean and tight.

• Ensure wire connections to spark igniter are clean and tight.

• Inspect ame sensor, clean/replace as needed.

• Inspect spark igniter, realign igniter gap as needed

• Ensure adequate electrical ground to heater.

CHANGE BACK

Ignition Failure

Fault occurred 2 mins ago

Flame not detected. Clean flame rod. Check gas supply.

Call a service professional: Your Company Name Here

(press [DOWN] for more....)

ADVANCED

• Conrm supply gas is turned on.

• Using a manometer, ensure the supply gas pressure is above minimum pressure requirement listed on heater’s data plate before and during operation.

• Ensure wire connections to gas pressure switch are clean and tight.

• If all above conditions are met, replace gas pressure switch.

• If Blocked Exhaust error occurs when blower is running, check for restrictions in exhaust pipe, including exhaust elbow, condensate drain, and outside termination. Also check exhaust pipe installation (size/length) per manual.

• If Blocked Exhaust error occurs before blower runs, make sure pressure switch connections are clean and tight. Check pressure switch continuity/resistance. Switch should be closed (continuity/0 ohms). Replace switch if open (no continuity).

• Other possible causes: high wind conditions and excessive negative air pressure in building.

Low Gas Pressure

Fault occurred 2 mins ago

Gas pressure is below minimum required to operate this unit. Check gas pressure and switch.

Call a service professional: Your Company Name Here

(press [DOWN] for more....)

CHANGE BACK

Blocked Exhaust

Fault occurred 2 mins ago

Restriction in exhaust pipe. Check exhaust pipe and termination for blockage.

Call a service professional: Your Company Name Here

(press [DOWN] for more....)

CHANGE BACK

ADVANCED

Page 62

FAULT AND ALERT MESSAGES (CONT)

Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualied service agent in your area.

POSSIBLE CAUSES - CHECK/REPAIR DISPLAYED FAULT/ALERT MESSAGE

• Ensure excessive wind is not pressurizing the intake air or exhaust pipe.

• Conrm wire connections of the blower prover switch are clean, tight, and not jumped/shorted.

• Use multi-meter to check continuity/resistance of blower prover pressure switch. Switch should be open (no continuity) when blower is not operating. Replace switch if contacts are closed when blower is off.

CHANGE BACK

Blower Operation Error

Fault occurred 2 mins ago

Blower Prover Pressure Switch may have failed closed. Check/replace pressure switch.

Call a service professional: Your Company Name Here

(press [DOWN] for more....)

ADVANCED

• Conrm that blower runs during a call for heat.

• If blower runs, conrm sensing tube is connected and clear of obstructions, blower port for sensing tube is clear of obstructions, and wire connections for blower prover switch are clean and tight.

• If all above conditions are met, replace pressure switch.

• If Blocked Intake error occurs before blower runs, make sure pressure switch connections are clean and tight. Check pressure switch continuity/resistance. Switch should be closed (continuity/0 ohms). Replace switch if open (no continuity).

• If Blocked Intake error occurs when blower is running, check for restrictions in intake pipe, including intake air connection, outside termination, and inlet condensate drains (if installed).

• Other possible causes: High wind conditions, excessive negative air pressure in building.

• Ensure wire connections to upper temperature probe are clean and tight.

• Using a thermometer, check the water temperature of the heater.

• Use a multi-meter and check for continuity between the two red wires of the upper temperature probe.

• If the two red wires are open (no continuity) and water temperature is below 160°F, replace upper temperature probe.

• If the water temperature exceeds 195°F, turn off electric power and gas supply and call Tech Support for further instructions.

Blower Prover Open

Fault occurred 2 mins ago

The blower prover switch remains open after the blower has been energized.

Call a service professional: Your Company Name Here

(press [DOWN] for more....)

CHANGE BACK

Blocked Air Intake

Fault occurred 2 mins ago

Restriction in air intake. Check intake pipe and termination for blockage.

Call a service professional: Your Company Name Here

(press [DOWN] for more....)

CHANGE BACK

Energy Cut Out (ECO)

Fault occurred 2 mins ago

Tank temperature is excessive. The water heater has been disabled.

Call a service professional: Your Company Name Here

(press [DOWN] for more....)

CHANGE BACK

ADVANCED

• Conrm the water heater is full of water.

• Conrm the powered anode wire connections are tight and free of debris or moisture (i.e. rust, solder, metal pipe shavings).

• Conrm proper electrical ground to the water heater.

Alert:

No Water

Alert occurred 2 mins ago

No water detected by Powered Anode.

Call a service professional: Your Company Name Here

(press [DOWN] for more....)

CHANGE BACK

ADVANCED

Page 63

MAINTENANCE

CAUTION

GENERAL

Do not have any combustible materials (such as gasoline, ammable liquids or ammable vapors) within the water heater area. See Locating The Water Heater on page 11.

Water heater maintenance includes periodic tank ushing and cleaning, and removal of lime scale. The water heater should be inspected and adjusted to maintain proper combustion. See Initial Start Up on page 53. A periodic inspection of the venting system should be made. Where used, water circulating pump(s) should be oiled according to the pump manufacturers recommendations.

PRECAUTIONS

Do not operate the water heater if it has

been exposed to or exhibits the following:

Exposed to flooding or water damage

•

External damage.

•

Firing without water.

•

Sooting.

•

Do not operate the water heater until all corrective steps have been made by a qualified service technician.

Never operate the water heater without rst being certain it is lled with water and a properly sized and rated TemperaturePressure Relief Valve is installed in the relief valve opening on the water heater. See Temperature-Pressure Relief Valve on page 15.

Explosion Hazard

Overheated water can cause water tank explosion.

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

Should overheating occur or the gas supply fail to shut off, turn off the Main Gas Shutoff valve. See Figure 54 on page 40.

Water heater maintenance includes periodic tank ushing and cleaning, and removal of lime scale. The water heater should be inspected and adjusted to maintain proper combustion. Refer to the following table. A periodic inspection of the venting system should be made. Where used, the water circulating pump should be oiled according to the pump manufacturer's recommendations.

MAINTENANCE SCHEDULE

TABLE 17

COMPONENT OPERATION INTERVAL REQUIRED

Tank

Anode Rods

T&P Valve Test Operation Semi Annually Test

Vent System Inspection Annually

Sediment

Removal

Lime Scale

Removal

Inspection

Cleaning

Semi Annually Flushing

Semi Annually UN-LIME®

Annually

Clean Scale

Deposits

Termination

Screens Clean

Reseal/Repair

DRAINING AND FLUSHING

It is recommended that the water heater storage tank be drained and ushed every 6 months to reduce sediment buildup. The water heater should be drained if being shut down during freezing temperatures. See Features And Components on page 7 for the location of the water heater components described below.

Burn hazard.

Hot water discharge.

Keep hands clear of drain valve discharge.

To drain the water heater storage tank:

1. Turn off the electrical supply to the water heater.

2. Turn off the gas supply at the Main Gas Shutoff Valve if the water heater is going to be shut down for an extended period.

3. Ensure the cold water inlet valve is open.

4. Open a nearby hot water faucet and let the water run until the water is no longer hot.

5. Connect a hose to the water heater drain valve and terminate it to an adequate drain.

6. Close the cold water inlet valve.

7. Open the water heater drain valve and allow all the water to drain from the storage tank.

8. Close the water heater drain valve when all water in the storage tank has drained.

9. Close the hot water faucet opened in Step 4.

10. If the water heater is going to be shut down for an extended period, the drain valve should be left open.

To Flush the tank perform the following steps:

1. Turn off the electrical supply to the water heater.

2. Ensure the cold water inlet valve is open.

3. Open a nearby hot water faucet and let the water run until the water is no longer hot. Then close the hot water faucet.

4. Connect a hose to the drain valve and terminate it to an adequate drain.

Page 64

5. Ensure the drain hose is secured before and during the entire ushing procedure. Flushing is performed with system water pressure applied to the water heater.

6. Open the water heater drain valve to ush the storage tank.

7. Flush the water heater storage tank to remove sediment and allow the water to ow until it runs clean.

8. Close the water heater drain valve when ushing is completed.

9. Remove the drain hose.

10. Fill the water heater - see Filling The Water Heater on page 53.

11. Turn on the electrical supply to place the water heater back in operation.

12. Allow the water heater to complete several heating cycles to ensure it is operating properly.

FILLING THE WATER HEATER

See Filling The Water Heater on page 53.

SEDIMENT REMOVAL

Waterborne impurities consist of the particles of soil and sand which settle out and form a layer of sediment on the bottom of the tank.

For convenience, sediment removal and lime scale removal should be performed at the same time.

LIME SCALE REMOVAL

When water is heated dissolved minerals in the water such as calcium and magnesium carbonate (lime scale) become less soluble. As the water temperature rises these minerals will precipitate or “fall out” of solution.

The amount of lime scale released from water is in direct proportion to water temperature and usage. The higher the water temperature or water usage, the more lime deposits are dropped out of the water.

Water hardness also affects lime scale accumulation. With the temperature and usage being the same, hard water will release more lime scale than softer water.

Lime scale reduces heating efciency as it accumulates inside a water heater. Heating transfer surfaces become coated with lime scale deposits which increases fuel costs to operate the water heater. Lime scale deposits can also cause rumbling and pounding noises as air molecules trapped in the lime scale escape when heated. Lime scale accumulation also reduces the life span of water heaters. For these reasons a regular schedule for deliming should be set up.

The depth of lime accumulation in the bottom of the water heater should be measured periodically. Inspect by removing the cleanout cover once every 6 months at rst. Deliming maintenance should then be performed based on the time it takes for 1 inch (2.5 cm) of lime to accumulate in the bottom of the water heater.

Sediment and lime scale removal may be accomplished manually through the cleanout opening furnished on the water heater, see Figure 64.

CLEANOUT

TANK

CLEANOUT

OPENING

CLEANOUT

COVER

MANUAL LIME SCALE REMOVAL

NOTE: Contact your local distributor or call the parts department

phone number on the back cover of this manual to order a new cleanout gasket. Have the new gasket available before removing the cleanout cover.

The cleanout opening is shown in Figure 64. To remove lime scale manually through the cleanout opening proceed as follows:

1. Turn off the electrical supply to the water heater.

2. The water heater must be drained, see Draining And Flushing on page 63, follow the instructions on how to drain the water heater.

3. Remove outer cleanout access plate from lower side of the water heater jacket.

4. Remove the cleanout cover from cleanout opening.

5. Remove lime, scale and/or sediment using care not to damage the glass-lining.

6. Install a new cleanout gasket if required.

7. Reinstall the cleanout cover. Be sure to draw plate up tight by tightening screws securely.

8. Close the water heater drain valve.

9. Fill the water heater - see Filling The Water Heater on page 53.

10. Turn on the electrical supply to place the water heater back in operation. See Initial Start Up on page 53.

11. Allow the water heater to complete several heating cycles to ensure it is operating properly.

12. Check for water leakage.

13. Reinstall the cleanout access plate.

CHEMICAL LIME SCALE REMOVAL

To dissolve and remove more stubborn lime scale deposits, UNLIME® Professional Delimer should be used.

UN-LIME® Professional Delimer is an easy to handle patented food grade acid formulated specically for lime scale removal from all types of water using equipment. Hydrochloric base acids must not be used to delime the water heaters covered in this manual.

Follow the instructions on the UN-LIME® to delime the water heater.

NOTE: Call the parts department phone number on the back cover of this manual to order UN-LIME® Professional Delimer. See Table 18 on page 65 for part numbers.

ACCESS PANEL

CLEANOUT

GASKET

Figure 64

Page 65

TABLE 18

UN-LIME® PROFESSIONAL DELIMER

Part Number Description

9005416105 4 - 1 gallon (case)

9005417105 1 - 5 gallon

POWERED ANODE RODS

To insure a long, trouble-free operating life, the water heaters covered in this manual are factory equipped with a powered anode system. The anode rod(s) are of a permanent design and do not need replacing unless damaged. Inspection and cleaning should be performed once a year.

NOTE: Follow the instructions to drain the water heater storage tank on page 63 rst. Remove the powered anodes from the water heater by loosening the 3/4" NPT bushing that forms the top of the anodes. Do not disassemble the retaining nut and wire terminal from the top while installed in the water heater, the anode's electrode may fall inside the tank. Remove the entire anode rod from the water heater prior to inspection. Clean the anode rods with a soft cloth and reinstall. Follow the instructions for lling the water heater on page 53 when nished.

DRAIN VALVE AND ACCESS PANELS

The water heaters covered in this manual are equipped with a drain valve, see Features And Components on page 7 for location. The water heaters covered in this manual are also equipped with a cleanout opening for sediment and lime scale removal. See Figure 64 on page 64.

TEMPERATURE-PRESSURE

RELIEF VALV E

DISCHARGE PIPE

Figure 65

If the Temperature-Pressure Relief Valve on the water heater weeps or discharges periodically, this may be due to thermal expansion.

DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF VALVE OPENING. THIS CAN CAUSE PROPERTY DAMAGE, SERIOUS INJURY OR DEATH.

TEMPERATURE-PRESSURE RELIEF VALVE TEST

Burn hazard.

Hot water discharge.

Keep clear of TemperaturePressure Relief Valve discharge outlet.

It is recommended that the Temperature-Pressure Relief Valve should be checked to ensure that it is in operating condition every 6 months.

When checking the Temperature-Pressure Relief Valve operation, make sure that (1) no one is in front of or around the outlet of the Temperature-Pressure Relief Valve discharge line, and (2) that the water discharge will not cause any property damage, as the water may be extremely hot. Use care when operating valve as the valve may be hot.

To check the relief valve, lift the lever at the end of the valve several times, see Figure 65. The valve should seat properly and operate freely.

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 and drain the water heater, see Draining And Flushing on page 63. Replace the TemperaturePressure Relief Valve with a properly rated/sized new one, see Temperature-Pressure Relief Valve on page 15 for instructions on replacement.

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.

VENT SYSTEM

Examine the vent system once a year. Points of inspection are as follows:

1. Check for obstructions and/or deterioration of the intake air and/or vent piping and the intake air and vent terminations. Replace immediately where needed.

2. The debris screens in the intake air and vent terminations should be should be cleaned of foreign material and soot. See Figure 25 on page 27.

NOTE: Do not reach inside the vent termination when the heater is in operation.

3. Check all vent system connections for leakage and repair or reseal as necessary.

Page 66

CCB - CENTRAL CONTROL BOARD LAYOUT

DIAGRAMS

10 11

7 8

1 2

3 4

5 6

J14

J15

J16

J13

J10

4 3

J17 6 5

4 3 2 1

Figure 66

J12

3 2 1

Page 67

WIRING DIAGRAM

Blower

24Vureg

Dgnd

1 White / Brown 2 White / Orange

4 White / Blue

Speed

Blower

5 White / Green

1 Black 2 White 3 Green

120V OUT to blower

Junction Box

Speed f-back

PWM Signal

Neutral

Protective

Earth

Green

Neutral

L1 Auxiliary Auxiliary

AUX Common

AUX NO AUX NC

Spark

Blue

Brown

Anode

Rod

Yellow

Blue

Module

Neutral

120V

Spark

Rod

Outlet Pressure

Switch

Inlet Pressure

Switch

Blower Prover

Pressure

Switch

Anode

Rod

Flame

Rod

Gas Pressure

Switch

Blower Logic

No factory

connections

Low Voltage In

24Vureg

PWM Signal

CCB J5

Speed f-back

Dgnd

Low Voltage Field

CCB J17

Central Control Board

Dgnd

CCB J16

5VDC

12VDC

24VAC 24VAC

Neutral

120 to Spark

CCB J6

120V Out

(CCB)

ECO Thermistor Thermistor

CCB J9

ECO

Upper Probe

Thermistor Thermistor

CCB J10

Lower Probe

Inlet return / Prover power Outlet return / Inlet power

Prover return

Outlet power

CCB J15

Pressure

1 Red

2 Black

1 Red 2 Black 3 Black

4 Red

1 Black 2 Black

1 Black

2 Red 3 White 4 Green

Switches

Neutral

Hot

Upper Temperature

Probe / ECO

Red Black Black Red

Lower

Temperature

Probe

Black Black

Splice

2 White 3 Black

Black

White

Primary

Supply J1

Power

Transformer

Power Supply

Secondary

Power

Transformer

Supply J2

4 White/Green

3 Orange

1 Blue

White / Blue

White / Red

Ferrite Bead

Enable/Disable

Switch

1 White/Brown

2 White/Blue

4 White/Orange

5 White/Green

6 White/Green

5 Orange

4 Blue

2 White/Blue 1 White/Red

Blue

1 Blue

2 Green

3 Yellow

4 Black

6 Black

7 Red

8 Black

9 Red

10 Black

11 Red

12 Black

Splice

Green

Connects to burner

bolt

8 White 7 Black

6 Red

5 Green

4 White 3 Black

Field Box

HIGH Voltage

2 Red Green

Green

Ground Bar

9 White

8 Black

7 Red

6 Green

4 White

3 Black

2 Red

HIGH Voltage In

CCB J1

Pump Common

Pump NO

AUX Common

AUX NO AUX NC

Neutral

Anode

Dgnd

Flame Rod

Condensate

Gas PS

Gas V Switch

Gas V 24V

24V Rtn

CCB J14

Limit String

Display

Display / AIN

= 18AWG AWM wire 105°C 600V UL style 1015. Flame rod wire = 200°C 300V UL 1180.

= multi-conductor power limited cable, 18AWG 80°C 300V UL category QPTZ

= Spark ignition wire, 220°C 25kVDC 8mm EMI suppression

Figure 67

Gas Valve

Display / AIN

CCB J13

+5V

P1-6

CCB J12

P1-5 P1-4

P1-3 P1-2 P1-1

Configuration Key

W5-White/Orange

W4-White/Blue

W3-White/Brown

W2-Green

W1-Red

Configuration

Key

Dgnd

Write protect

SCL (data) SDA (data)

Page 68

CIRCULATION PUMP WIRING DIAGRAMS

CIRCULATING PUMP WIRING DIAGRAM

STORAGE TANK OR BUILDING RECIRCULATION

NOTE: USE SEPARATE 120 VAC POWER SUPPLY FOR PUMP CIRCUIT. DO NOT SHARE POWER WITH WATER HEATER AS THIS MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION.

L1 HOT

FIELD SUPPLIED TEMPERATURE CONTROL INSTALLED IN THE STORAGE TANK OR CIRCULATING LOOP RETURN LINE

120 VAC

POWER

L2 NEUTRAL

CIRCULATING PUMP WIRING DIAGRAM

DISHWASHER LOOP WITH TOGGLE SWITCH

DISHWASHER TOGGLE SWITCH

NOTE: USE SEPARATE 120 VAC POWER SUPPLY FOR PUMP CIRCUIT. DO NOT SHARE POWER WITH WATER HEATER AS THIS MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION.

L1 HOT

CIRC

PUMP

MOTOR

Figure 68

FIELD SUPPLIED TEMPERATURE CONTROL INSTALLED IN THE CIRCULATING LOOP RETURN LINE

L2 NEUTRAL

120 VAC POWER

CIRC

PUMP

MOTOR

Figure 69

Page 69

LEGEND

recirculation loop wire according to Figure 68 on page 68.

commercial dishwasher wire according to Figure 68 or Figure 69 on page 68.

4. See Closed Systems and Thermal Expansion on page 14.

5. See Water Line Connections on page 43.

6. If a pump is being installed between a water heater and storage tank or on a building

7. If a pump is being installed in a recirculation loop between the water heater and a

CHECK VALV E

TEMPERATURE CONTROL

PROBE

TEMPERATURE &

PRESSURE RELIEF VALV E

TEMPERATURE GAGE

WATER FLOW SWITCH

FULL PORT BALL VALVE

DRAIN

PRESSURE RELIEF VALV E

CIRCULATING PUMP

HOT WATER

RETURN

COLD WATER

SUPPLY

EXPANSION

TANK

TO FIXTURES

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

FOR ADDITIONAL REQUIREMENTS.

ANY MATERIAL, COMPONENT OR VENDOR CHANGE

ONE WATER HEATER, SINGLE TEMPERATURE

WITH BUILDING RECIRCULATION

ONE WATER HEATER, SINGLE TEMPERATURE

WITH BUILDING RECIRCULATION

WATER PIPING DIAGRAMS

Before installation of water piping review the following:

1. See Mixing Valves on page 14.

2. See Dishwashing Machines on page 14.

3. See Temperature-Pressure Relief Valve on page 15.

PRODUCT ENGINEERING DEPARTMENT.

MUST HAVE PRIOR APPROVAL BY THE APPLICABLE

PIPE T&P TO

OPEN DRAIN

FINISHED FLOOR

NOTES:

1. Preferred piping method.

2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.

3. Service valves are shown for servicing unit. However, local codes shall govern their usage.

Page 70

CHECK VALV E

TEMPERATURE GAGE

WATER FLOW SWITCH

LEGEND

TEMPERATURE CONTROL

recirculation loop wire according to Figure 68 on page 68.

commercial dishwasher wire according to Figure 68 or Figure 69 on page 68.

4. See Closed Systems and Thermal Expansion on page 14.

5. See Water Line Connections on page 43.

6. If a pump is being installed between a water heater and storage tank or on a building

7. If a pump is being installed in a recirculation loop between the water heater and a

PROBE

TEMPERATURE &

PRESSURE RELIEF VALV E

DRAIN

FULL PORT BALL VALVE

PRESSURE RELIEF VALV E

MIXING VALV E

CIRCULATING PUMP

OUTLET

WATER

OUTLET

TEMPERED

RETURN

PIPE T&P TO

OPEN DRAIN

HOT

HOT WATER

RETURN

COLD

EXPANSION

TANK

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

ONE WATER HEATER, TWO TEMPERATURE

WITH HIGH TEMPERAURE LOOP RECIRCULATION

WITH BUILDING RECIRCULATION

WATER PIPING DIAGRAMS

Before installation of water piping review the following:

1. See Mixing Valves on page 14.

2. See Dishwashing Machines on page 14.

3. See Temperature-Pressure Relief Valve on page 15.

FOR ADDITIONAL REQUIREMENTS.

TEMPERED WATER

PRODUCT ENGINEERING DEPARTMENT.

ANY MATERIAL, COMPONENT OR VENDOR CHANGE

MUST HAVE PRIOR APPROVAL BY THE APPLICABLE

COLD WATER

SUPPLY

FINISHED FLOOR

NOTES:

1. Preferred piping method.

2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.

3. Service valves are shown for servicing unit. However, local codes shall govern their usage.

Page 71

CHECK VALV E

TEMPERATURE GAGE

WATER FLOW SWITCH

HOT WATER

RETURN

COLD WATER

SUPPLY

EXPANSION

TANK

LEGEND

recirculation loop wire according to Figure 68 on page 68.

commercial dishwasher wire according to Figure 68 or Figure 69 on page 68.

4. See Closed Systems and Thermal Expansion on page 14.

5. See Water Line Connections on page 43.

6. If a pump is being installed between a water heater and storage tank or on a building

7. If a pump is being installed in a recirculation loop between the water heater and a

TEMPERATURE CONTROL

PROBE

TEMPERATURE &

PRESSURE RELIEF VALV E

DRAIN

PRESSURE RELIEF VALV E

FULL PORT BALL VALVE

CIRCULATING PUMP

HOT WATER

ALT. COLD WATER

CONNECTION

TO FIXTURES

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

ONE WATER HEATER, SINGLE TEMPERATURE

WITH VERTICAL STORAGE TANK FORCED RECIRCULATION

WITH BUILDING RECIRCULATION

WATER PIPING DIAGRAMS

Before installation of water piping review the following:

1. See Mixing Valves on page 14.

2. See Dishwashing Machines on page 14.

3. See Temperature-Pressure Relief Valve on page 15.

FOR ADDITIONAL REQUIREMENTS.

PRODUCT ENGINEERING DEPARTMENT.

ANY MATERIAL, COMPONENT OR VENDOR CHANGE

MUST HAVE PRIOR APPROVAL BY THE APPLICABLE

PIPE T&P TO

OPEN DRAIN

FINISHED

FLOOR

NOTES:

1. Preferred piping method.

2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.

3. Service valves are shown for servicing unit. However, local codes shall govern their usage.

4. The tank temperature control should be wired to and control the pump between the water heater(s) and the storage tank(s).

5. The water heater’s operating thermostat should be set 5 degrees F higher than the tank temperature control.

Page 72

CHECK VALV E

HOT

WATER

TEMPERATURE GAGE

WATER FLOW SWITCH

HOT WATER

RETURN

CIRCULATING

PUMP

COLD WATER

SUPPLY

EXPANSION

TANK

LEGEND

TEMPERATURE CONTROL

PROBE

TEMPERATURE &

PRESSURE RELIEF VALV E

recirculation loop wire according to Figure 68 on page 68.

commercial dishwasher wire according to Figure 68 or Figure 69 on page 68.

4. See Closed Systems and Thermal Expansion on page 14.

5. See Water Line Connections on page 43.

6. If a pump is being installed between a water heater and storage tank or on a building

7. If a pump is being installed in a recirculation loop between the water heater and a

DRAIN

PRESSURE RELIEF VALV E

FULL PORT BALL VALVE

CIRCULATING PUMP

ALTERNATE

LOCATION

TO FIXTURES

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

ONE WATER HEATER, SINGLE TEMPERATURE

WITH HORIZONTAL STORAGE TANK FORCED RECIRCULATION

WITH BUILDING RECIRCULATION

WATER PIPING DIAGRAMS

Before installation of water piping review the following:

1. See Mixing Valves on page 14.

2. See Dishwashing Machines on page 14.

3. See Temperature-Pressure Relief Valve on page 15.

FOR ADDITIONAL REQUIREMENTS.

PRODUCT ENGINEERING DEPARTMENT.

ANY MATERIAL, COMPONENT OR VENDOR CHANGE

MUST HAVE PRIOR APPROVAL BY THE APPLICABLE

PIPE T&P TO

OPEN DRAIN

FINISHED

FLOOR

NOTES:

1. Preferred piping method.

2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.

3. Service valves are shown for servicing unit. However, local codes shall govern their usage.

4. The tank temperature control should be wired to and control the pump between the water heater(s) and the storage tank(s).

5. The water heater’s operating thermostat should be set 5 degrees F higher than the tank temperature control.

Page 73

LEGEND

recirculation loop wire according to Figure 68 on page 68.

commercial dishwasher wire according to Figure 68 or Figure 69 on page 68.

4. See Closed Systems and Thermal Expansion on page 14.

5. See Water Line Connections on page 43.

6. If a pump is being installed between a water heater and storage tank or on a building

7. If a pump is being installed in a recirculation loop between the water heater and a

CHECK VALV E

TEMPERATURE CONTROL

PROBE

TEMPERATURE &

PRESSURE RELIEF VALV E

TEMPERATURE GAGE

WATER FLOW SWITCH

FULL PORT BALL VALVE

DRAIN

PRESSURE RELIEF VALV E

CIRCULATING PUMP

HOT WATER

RETURN

COLD WATER

SUPPLY

EXPANSION

TANK

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

FOR ADDITIONAL REQUIREMENTS.

TWO WATER HEATERS, SINGLE TEMPERATURE

WITH BUILDING RECIRCULATION

WATER PIPING DIAGRAMS

Before installation of water piping review the following:

1. See Mixing Valves on page 14.

2. See Dishwashing Machines on page 14.

3. See Temperature-Pressure Relief Valve on page 15.

ANY MATERIAL, COMPONENT OR VENDOR CHANGE

HOT WATER

PRODUCT ENGINEERING DEPARTMENT.

MUST HAVE PRIOR APPROVAL BY THE APPLICABLE

TO FIXTURES

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

FINISHED

FLOOR

NOTES:

1. Preferred piping method.

2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.

3. Service valves are shown for servicing unit. However, local codes shall govern their usage.

Page 74

CHECK VALV E

TEMPERATURE GAGE

WATER FLOW SWITCH

HOT WATER

RETURN

COLD WATER

SUPPLY

EXPANSION

TANK

LEGEND

recirculation loop wire according to Figure 68 on page 68.

commercial dishwasher wire according to Figure 68 or Figure 69 on page 68.

4. See Closed Systems and Thermal Expansion on page 14.

5. See Water Line Connections on page 43.

6. If a pump is being installed between a water heater and storage tank or on a building

7. If a pump is being installed in a recirculation loop between the water heater and a

TEMPERATURE CONTROL

PROBE

TEMPERATURE &

PRESSURE RELIEF VALV E

DRAIN

PRESSURE RELIEF VALV E

FULL PORT BALL VALVE

CIRCULATING PUMP

PIPE T&P TO

OPEN DRAIN

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

THREE WATER HEATERS, SINGLE TEMPERATURE

WITH BUILDING RECIRCULATION

WATER PIPING DIAGRAMS

Before installation of water piping review the following:

1. See Mixing Valves on page 14.

2. See Dishwashing Machines on page 14.

3. See Temperature-Pressure Relief Valve on page 15.

FOR ADDITIONAL REQUIREMENTS.

HOT WATER

PRODUCT ENGINEERING DEPARTMENT.

ANY MATERIAL, COMPONENT OR VENDOR CHANGE

MUST HAVE PRIOR APPROVAL BY THE APPLICABLE

PIPE T&P TO

OPEN DRAIN

TO FIXTURES

PIPE T&P TO

OPEN DRAIN

FINISHED

FLOOR

NOTES:

1. Preferred piping method.

2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.

3. Service valves are shown for servicing unit. However, local codes shall govern their usage.

Page 75

CHECK VALV E

TEMPERATURE GAGE

WATER FLOW SWITCH

HOT WATER

RETURN

COLD WATER

TANK TEMPERAT URE

CONTROL

SUPPLY

EXPANSION

TANK

LEGEND

recirculation loop wire according to Figure 68 on page 68.

commercial dishwasher wire according to Figure 68 or Figure 69 on page 68.

4. See Closed Systems and Thermal Expansion on page 14.

5. See Water Line Connections on page 43.

6. If a pump is being installed between a water heater and storage tank or on a building

7. If a pump is being installed in a recirculation loop between the water heater and a

TEMPERATURE CONTROL

PROBE

TEMPERATURE &

PRESSURE RELIEF VALV E

DRAIN

PRESSURE RELIEF VALV E

FULL PORT BALL VALVE

CIRCULATING PUMP

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

FOUR WATER HEATERS, SINGLE TEMPERATURE

WITH BUILDING RECIRCULATION

WATER PIPING DIAGRAMS

Before installation of water piping review the following:

1. See Mixing Valves on page 14.

2. See Dishwashing Machines on page 14.

3. See Temperature-Pressure Relief Valve on page 15.

FOR ADDITIONAL REQUIREMENTS.

HOT WATER

TO FIXTURES

PRODUCT ENGINEERING DEPARTMENT.

ANY MATERIAL, COMPONENT OR VENDOR CHANGE

MUST HAVE PRIOR APPROVAL BY THE APPLICABLE

PIPE T&P TO

OPEN DRAIN

PIPE T&P TO

OPEN DRAIN

FINISHED

FLOOR

NOTES:

1. Preferred piping method.

2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.

3. Service valves are shown for servicing unit. However, local codes shall govern their usage.

Page 76

NOTES

Page 77

NOTES

Page 78

NOTES

Page 79

COMMERCIAL

WATER HEATER

LIMITED WARRANTY

EFFECTIVE

For 3 Years, in the event of a tank leak, we will repair or, at our

discretion, replace the defective water heater.

For 1 Year, in the event of part failure, we will repair or, at our

discretion, replace the defective part.

We warrant this product against defects in materials or workmanship as described in this document if installed within the United States or Canada and provided the product remains at its original place of installation.

Warranty coverage begins the date of installation OR the date of manufacture if installation cannot be veried.

WHAT'S COVERED

Subject to these terms, in the event of defect in materials and/ or workmanship resulting in a tank leak during the rst three years, we will:

• Replace the water heater should the tank leak.

Subject to these terms, in the event of a defect in materials and/or workmanship appearing during the rst year, we will:

• Repair or, at our discretion, replace any part of the water heater covered under this limited warranty excluding parts subject to normal maintenance (Example: non-electronic anode rod, lter, etc)

Service/labor, shipping, delivery, installation, handling or any other costs are not covered at any time under this warranty.

Any replacement part or product will be warranted only for the unexpired portion of the original water heater’s limited warranty period.

If an identical model is no longer available due to a change in law, regulation, or standard, we will replace the product with one having comparable capacity and input. In these instances, the owner will have the option of paying the difference between what was paid for the original model and the new model with the additional features, or receiving a refund of the portion of the purchase price, on a pro-rata basis allocable to the unexpired portion of the warranty.

WHAT'S NOT COVERED

• Problems caused by improper: gas supply line sizing, gas type, venting, connections, combustion air, voltage, wiring, or fusing

• Failure to follow applicable codes

• Failure to follow printed instructions

• Abuse, misuse, accident, re, ood, Acts of God

• Improper installation, sizing, delivery, or maintenance

• Claims related to rust, noise, smell, or taste of water

• Failure to conduct authorized factory start up if required

• Alterations to the water heater

• Non-outdoor heaters installed outdoors

• Damages due to a failure to allow for thermal expansion

• Heat exchanger failure due to lack of adequate / proper supply of water

• Heaters moved from their original location

• Service trips to explain proper installation, use, or maintenance of the product/unit or to describe compliance requirements under applicable codes and regulations

• Charges related to accessing your heater including but not limited to door/wall removal, equipment rental, etc.

• Replacement parts after expiration of this warranty

LIMITATIONS

NOTWITHSTANDING ANYTHING ELSE TO THE CONTRARY, THIS IS YOUR SOLE AND EXCLUSIVE WARRANTY. ALL OTHER WARRANTIES INCLUDING A WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. SELLER SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, SPECIAL, PUNITIVE OR OTHER INDIRECT DAMAGES. TOTAL LIABILITY ARISING AT ANY TIME SHALL NOT EXCEED THE PURCHASE PRICE PAID WHETHER BASED ON CONTRACT, TORT, STRICT LIABILITY OR ANY OTHER LEGAL THEORY.

SERVICE INQUIRIES:

For service inquiries call the telephone number listed below. Be prepared to provide the following information:

name, address, and telephone number; the model and serial number of the water heater; proof of installation; and a clear description of the problem.

For your records, fill in the product:

Serial: ___________________ Model: ___________________ U.S. Customers: Canadian Customers:

A. O. Smith Corporation P. O. Box 310 – 768 Erie Street

500 Tennessee Waltz Parkway Stratford (Ontario) N5A 6T3 Ashland City, Tennessee 37015 800-265-8520

800-527-1953 www.hotwater.com

Page 80

500 Tennessee Waltz Parkway, Ashland City, TN 37015

Technical Support: 800-527-1953 • Parts: 800-433-2545

www.hotwater.com

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

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFE INSTALLATION, USE AND SERVICE

APPROVALS

GENERAL SAFETY INFORMATION

PRECAUTIONS

GROUNDING INSTRUCTIONS

HYDROGEN GAS FLAMMABLE

INTRODUCTION

ABBREVIATIONS USED

QUALIFICATIONS

ICOMM™ & BACNET COMPATIBLE

PREPARING FOR THE INSTALLATION

FEATURES AND COMPONENTS

BASIC OPERATION

MODULATION

BLOWER/BURNER ASSEMBLY DETAIL

TOP VIEW

SIDE VIEWS

ROUGH IN DIMENSIONS

INSTALLATION CONSIDERATIONS

LOCATING THE WATER HEATER

OPTIONAL CONCENTRIC & LOW PROFILE TERMINATIONS

HARD WATER

CIRCULATION PUMPS

INSULATION BLANKETS

EXTENDED VENT TERMINATIONS

INSTALLATION REQUIREMENTS

GAS SUPPLY SYSTEMS

SUPPLY GAS REGULATOR

POWER SUPPLY

MIXING VALVES

DISHWASHING MACHINES

CLOSED WATER SYSTEMS

THERMAL EXPANSION

TEMPERATURE-PRESSURE RELIEF VALVE

CONDENSATE DRAIN

COMBUSTIBLE MATERIAL STORAGE

CONTAMINATED AIR

AIR REQUIREMENTS

UNCONFINED SPACE

CONFINED SPACE

FRESH AIR OPENINGS FOR CONFINED SPACES

OUTDOOR AIR THROUGH TWO OPENINGS

OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS

OUTDOOR AIR THROUGH ONE OPENING

OUTDOOR AIR THROUGH TWO VERTICAL DUCTS

AIR FROM OTHER INDOOR SPACES

INSTALLATION REQUIREMENTS - COMMONWEALTH OF MASSACHUSETTS

VENTING INSTALLATION

GENERAL VENTING INFORMATION

GENERAL VENTING INSTRUCTIONS

INTAKE AIR CONNECTION

VENTING REQUIREMENTS

VENTING INSTALLATION SEQUENCE

POWER VENT INSTALLATION

DIRECT VENT INSTALLATION

VERTICAL TERMINATION INSTALLATION

SIDEWALL TERMINATION INSTALLATION

POLYPROPYLENE INSTALLATIONS

AL29-4C® VENT INSTALLATIONS

CONCENTRIC TERMINATION INSTALLATION

4 INCH CONCENTRIC TERMINATION INSTALLATION

LOW PROFILE VENT INSTALLATION

VENTING ARRANGEMENTS

TERMINATION CLEARANCES SIDEWALL POWER VENT

TERMINATION CLEARANCES SIDEWALL DIRECT VENT

WATER HEATER INSTALLATION

CONDENSATE DRAIN INSTALLATION

SUPPLY GAS LINE INSTALLATION

GAS LINE LEAK TESTING

PURGING

ELECTRICAL WIRING

ENABLE / DISABLE CIRCUIT (For Building Management Systems)

WATER LINE CONNECTIONS

T&P VALVE DISCHARGE PIPE

TEMPERATURE REGULATION

HIGH TEMPERATURE LIMIT CONTROL (ECO)