Ao Smith BTH 500, BTH 300, BTH 400 User Manual
Instruction Manual
COMMERCIAL GAS WATER HEATERS
MODELS
BTH 300/400/500 (A)
SERIES 200 & 201
INSTALLATION - OPERATION - SERVICE
500 Tennessee Waltz Parkway
Ashland City, TN 37015
- MAINTENANCE - LIMITED WARRANTY
ANSI/NSF-5
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.
Low Lead Content
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 efcient water heater.
We appreciate your condence in our products.
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED 0414 327729-000
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.
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
Qualications........................................................................ 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
Gas Line Connection Size.................................................. 10
Storage Capacities .............................................................10
Recovery Capacities .......................................................... 10
Locating the Water Heater ................................................. 11
Extended Vent Terminations .............................................. 11
Optional Direct Vent Terminations ......................................12
Hard Water .........................................................................12
Circulation Pumps .............................................................. 12
Insulation Blankets ............................................................. 12
INSTALLATION REQUIREMENTS ......................................... 13
Gas Pressure Requirements ..............................................13
Supply Gas Line .................................................................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
Unconned Space ..............................................................17
Conned Space.................................................................. 17
Fresh Air Openings For Conned 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
Venting Requirements ........................................................ 22
Venting Installation Sequence ............................................ 23
Power Vent Installation.......................................................23
Direct Vent Installation ....................................................... 23
Vertical Termination Installation .......................................... 24
Sidewall Termination Installation ........................................ 26
Polypropylene Installations ................................................27
AL29-4C Vent Installations ................................................. 27
Concentric Termination Installation ....................................28
6 Inch Concentric Termination Installation ......................... 29
LOW PROFILE VENT INSTALLATION ...................................32
Venting Arrangements ........................................................ 33
Termination Clearances Sidewall Power Vent.................... 35
Termination Clearances Sidewall Direct Vent ....................36
WATER HEATER INSTALLATION ........................................... 37
Condensate Drain Installation ............................................ 37
Supply Gas Line Installation............................................... 38
Electrical Wiring .................................................................39
Enable/Disable Circuit ........................................................39
T&P Valve Discharge Pipe ................................................. 40
TEMPERATURE REGULATION ............................................. 41
High Temperature Limit Control (ECO) ..............................41
Thermostat Control ............................................................41
CONTROL SYSTEM OPERATION ......................................... 42
Overview ............................................................................ 42
Control System Navigation................................................. 42
User Settings & Control System Menus .............................45
START UP ............................................................................... 50
Prior to Start up .................................................................. 50
Initial Start Up..................................................................... 50
Checking the Firing Rate.................................................... 51
High Altitude Installations ...................................................52
Lighting & Operation Label................................................. 53
TROUBLESHOOTING ............................................................54
Installation Checklist ..........................................................54
Sequence of Operation ...................................................... 54
Sequence of Operation Flow Chart ....................................55
Operational Problems ........................................................56
Fault and Alert Conditions ..................................................57
MAINTENANCE ......................................................................60
General ..............................................................................60
Maintenance Schedule....................................................... 60
Draining and Flushing ........................................................ 60
Filling the Water Heater .....................................................61
Sediment Removal .............................................................61
Lime Scale Removal .......................................................... 61
Powered Anode Rods ........................................................ 62
Drain Valve and Access Panels ......................................... 62
Temperature-Pressure Relief Valve Test ............................ 62
Vent System .......................................................................62
DIAGRAMS .............................................................................63
CCB - Central Control Board Layout ..................................63
Wiring Diagram ..................................................................64
Circulation Pump Wiring Diagrams .................................... 65
Water Piping Diagrams ...................................................... 66
NOTES .................................................................................... 73
LIMITED WARRANTY .............................................................75
2
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
appliance 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
ANSI/NSF-5
3
Low Lead Content
GENERAL SAFETY INFORMATION
PRECAUTIONS
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN
UNDER WATER. Immediately call a qualied service agency
to inspect the appliance 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.
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.
Verify the power to the water heater is turned off before performing any service procedures.
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.
CAUTION
Improper installation, use and service may result
in property damage.
Do not operate water heater if flood damaged.
•
Inspect and 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.
Explosion Hazard
Overheated water can cause
water tank explosion.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
4
GENERAL SAFETY INFORMATION
death. Always read and understand instruction manual.
CAUTION
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
Property Damage Hazard
Fire Hazard
For continued protection against
risk of fire:
Do not install water heater on
carpeted floor.
Do not operate water heater if
flood damaged.
Fire and Explosion Hazard
Use joint compound or Teflon tape
compatible with propane gas.
Leak test before placing the
water heater in operation.
Disconnect gas piping and main
gas shutoff valve before leak
testing.
Install sediment trap in
accordance with NFPA 54.
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.
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
Electrical Shock Hazard
Turn off power to 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
•
agent 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.
Altering the water heater controls and/or wiring in any way
•
could result in altering the ignition sequence allowing gas to
flow to the main burner before the hot surface igniter is at
ignition temperature causing delayed ignition which can
cause a fire or explosion.
Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the appliance warranty.
5
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
• GAMA - Gas Appliance Manufacturer’s Association
• 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 Qualied Agency (as dened 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: “Qualied 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 qualied (as dened by ANSI above) and licensed
or certied 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 dened 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 pages 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 identied
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
54. 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 Qualied 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 Rough In Dimensions on page 10 and Locating the Water
Heater on page 11.
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 Ofce 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.
6
Y
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.
BLOWER
INTAKE AIR
(combustion air)
CONNECTION
4 INCH PVC
EXCHANGER
MAIN
BURNER
(radial design)
HEAT
BURNER
ASSEMBL
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
INTAKE AIR
(combustion air)
CONNECTION
4 INCH PVC
BLOWER
FLANGE
FLAME SENSOR
COMBUSTION
BLOWER
HELICAL
COIL
VENT (exhaust)
OUTLET
Figure 1
MAIN BURNER
(radial design)
SPARK
IGNITER
Figure 2
Spark Electrode
The control system energizes the spark ignition control with
120 VAC during the ignition period. The spark ignition control
then sends an electrical current to the spark igniter which in turn
ignites the main burner air/gas mixture.
See the Sequence of Operation on page 54.
Flame Sensor
The control system also monitors the ame sensor to conrm
a ame is present at the Main Burner. If a ame is not veried
during the ignition trial period (3-5 seconds) the control system
will immediately de-energize the 24 VAC Gas Valve. See the
Sequence of Operation Flow Chart on page 55.
7
TOP VIEW
7
8
9
4
14
5
19
2
3
15
1
Figure 3
TOP VIEW COMPONENTS
1. Water Heater's Enable/Disable (On/Off) Switch. When in the
"Disabled" (Off) 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 heater’s covered in this
manual are equipped with two powered (non sacricial)
anode rods. 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 conguration key. The CCB
regulates water temperature and controls all water heater
functions, see Control System Operation on page 42.
4. 120 VAC junction box. Incoming power supply, ground
connections, and other eld installed electrical connections
are made here. See Power Supply on page 13 and Power
Supply Connections on page 39.
5. Intake air connection - 4 inch PVC.
6. 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.
7. Water heater's 24 VAC Gas Valve.
8. Supply gas line connection. See the requirements for the
Supply Gas Line 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
12
10
6
2
13
11
18
16
17
if its contacts are open during a heating cycle. See Table 4
and the Gas Pressure Requirements on page 13.
10. 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. The control system monitors this
switch and will disable heating operation if its contacts are closed
before the Combustion Blower is energized or open any time
during a heating cycle. See Sequence Of Operation on page 54.
11. Vent connection (exhaust/condensate elbow) - 4 inch aluminum.
12. Combustion Blower.
13. 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.
14. VFD (variable frequency drive) blower motor drive.
15. Temperature-Pressure Relief Valve. See TemperaturePressure Relief Valve on page 15.
16. 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 41.
17. Water outlet connection 1 1/2” NPT.
18. 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 42.
19. Spark Ignition Control. When energized, sends the electrical
current to the spark igniter.
8
6
4
9
3
10
19
8
2
11
12
18
18
17
14
1
13
LEFT SIDE
Figure 4 Figure 5
15
SIDE VIEWS
1. Cleanout access panel, covers water heater cleanout
opening.
2. CCB enclosure - see Figure 3 on page 8 for description.
3. 120 VAC junction box. Incoming power supply, ground
connections, and other eld installed electrical connections
are made here. See Power Supply on page 13.
4. Intake air connection - 4 inch PVC.
5. Supply gas line connection. See Supply Gas Line on page 13.
6. Low Gas Pressure switch, see description under Figure 3 on
page 8. See Table 4 and the Gas Pressure Requirements on
page 13.
7. Water heater 24 VAC Gas Valve.
8. Water outlet connection - 1 1/2” NPT connection.
9. VFD (variable frequency drive) blower motor drive - - see
Figure 3 on page 8 for description.
10. 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 42.
11. Temperature-Pressure Relief Valve. See TemperaturePressure Relief Valve on page 15.
12. Temperature-Pressure Relief Valve discharge pipe - see T&P
Valve Discharge Pipe Requirements: on page 15.
13. 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.
14. Water inlet connection - 1 1/2” NPT connection.
15. Water heater drain valve.
16. Combustion Blower.
17. Vent connection (exhaust/condensate elbow) - 4 inch
aluminum.
18. Recirculation loop return connection - 3/4" NPT.
19. Spark Ignition Control, When energized, sends the electrical
current to the spark igniter.
9
ROUGH IN DIMENSIONS
INSTALLATION CONSIDERATIONS
4" PVC AIR INTAKE
CONNECTION
69.25in
63.13in
175.9cm
160.35cm
WATER
OUTLET
HEIGHT
75.75in
192.41cm
52.00in
132.08cm
T&P
CLEANOUT
3/4" NPT DRAIN
FRONT
1 1/2" NPT
WATER INLET
3/4" NPT
RECIRC RETURN
4" EXHAUST VENT
CONNECTION
12.75in
32.39cm
4.75in
12.07cm
23.00in
58.43cm
INTAKE
CLEANOUT
1 1/2" SUPPLY GAS
CONNECTION
70°
T&P
45°
20°
GAS
BACK
73.75in
1 1/2" NPT
WATER
OUTLET
TOP
FRONT
18°
DRAIN
30°
EXHAUST
42°
187.3cm
33.12in
84.12cm
O.D.
Figure 6
These designs comply with the current edition of the American National Standard for Gas Fired Water Heaters, Volume III, ANSI
Z21.10.3-CSA 4.3. BTH 300 and 400 are Automatic Circulating Tank or Automatic Storage Water Heaters. BTH 500 is Automatic
Circulating Tank or Automatic Instantaneous Water Heater
GAS LINE CONNECTION SIZE
TABLE 1
MODEL SERIES NATURAL GAS PROPANE GAS
BTH 300 200/201 1 1/2” NPT 1 1/2” NPT
BTH 400 200/201 1 1/2” NPT 1 1/2” NPT
BTH 500 200/201 1 1/2” NPT 1 1/2” NPT
This table shows connections sizes only. 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 38.
RECOVERY CAPACITIES
TABLE 3
U.S. GALLONS/HR & LITERS/HR AT TEMPERATURE RISE INDICATED
Model
BTH 300
BTH 400
BTH 500
Type of
Gas
Natural
Propane LPH 4404 3303 2643 2202 1888 1652 1468 1321 1201 1101 1016 944
Natural
Propane LPH 5810 4357 3486 2905 2490 2179 1937 1743 1585 1452 1341 1245
Natural
Propane LPH 7263 5447 4358 3631 3113 2724 2421 2179 1981 1816 1676 1556
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
Thermal
Efciency %
300,000 88 96
399,900 117 95
499,900 146 95
°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 1164 873 698 582 499 436 388 349 317 291 269 249
GPH 1535 1151 921 767 658 576 512 460 419 384 354 329
GPH 1919 1439 1151 959 822 720 640 576 523 480 443 411
STORAGE CAPACITIES
TABLE 2
Model
BTH 300-500 119 119 450.96 450.96
U.S. Gallons Liters
ASME Standard ASME Standard
10
LOCATING THE WATER HEATER
CAUTION
Carefully choose a location for the new water heater. The placement
is a very important consideration for the safety of the occupants in
the building and for the most economical use of the water heater.
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
Whether replacing an existing water heater or installing the water
heater in a new location observe the following critical points:
1. The water heater must be located indoors.
2. The water heater must not be located in an area where it will
be subject to freezing temperatures.
3. Locate the water heater so it is protected and not subject to
physical damage by a moving vehicle.
4. Locate the water heater on a level surface.
5. Locate the water heater near a oor drain. The water heater
should be located in an area where leakage of the tank or
connections will not result in damage to the area adjacent
to the water heater or to lower oors of the structure. When
such locations cannot be avoided, it is recommended that a
metal drain pan, adequately drained, be installed under the
water heater.
6. Locate the water heater close to the point of major hot water usage.
7. Locate the water heater close to a 120 VAC power supply.
See Power Supply on page 13 for requirements.
8. Locate the water heater where an adequate supply of fresh
air for combustion and ventilation can be obtained. See Air
Requirements on page 17.
9. Locate the water heater where the vent and intake air piping,
when installed, will remain within the maximum equivalent
lengths allowed. See Venting Requirements on page 22.
10. Do not locate the water heater where noise (such as
the Combustion Blower) during normal operation will be
objectionable in adjacent areas.
11. Do not locate the water heater where the subsequent
installation of the vent (exhaust) or intake air terminations
would be objectionable due to noise at the termination(s).
This includes locations close to or across from windows and
doors. See Venting Installation on page 21.
Fire or Explosion Hazard
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas
pressure.
Use only the gas shown on the water heater rating label.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended
periods of non-use.
Read instruction manual before
installing, using or servicing
water heater.
There is a risk in using fuel burning appliances such as gas water
heaters in rooms, garages or other areas where gasoline, other
ammable liquids or engine driven equipment or vehicles are
stored, operated or repaired. Flammable vapors are heavy and
travel along the oor and may be ignited by the water heater’s
igniter or Main Burner ames causing re or explosion.
Flammable items, pressurized containers or any other potential
re hazardous articles must never be placed on or adjacent to
the water heater.
CLEARANCE TO COMBUSTIBLE MATERIALS
The water heaters covered in this manual are approved for
installation on combustible ooring. The clearance to combustible
and non combustible construction materials is 0 inches on the
back and sides of the water heater. These water heaters are also
approved for installation in an alcove.
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
0
0
0
FRONT
TOP VIEW
Figure 7
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) and the condensate
drain. Leave as much room as possible above the water heater
and near the exhaust elbow for this reason. See Figure 9 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 4 inch pipe for the intake air and/or vent piping up to a
maximum of 70 equivalent feet (21.3 m). The intake air and/
or vent piping can be extended up to 120 equivalent feet (36.5
m) by installing 6 inch pipe. See the Venting Requirements on
page 22.
The water heater ships from the factory with two (2) 4 inch
terminations that are 45° PVC elbows with a debris screen
installed. When 6 inch intake air or vent pipe is installed, factory
supplied 6 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 6 inch
termination(s).
11
death. Always read and understand instruction manual.
OPTIONAL DIRECT VENT TERMINATIONS
The water heaters covered by this manual can be installed in
a Direct Vent conguration using optional concentric and low
prole terminations.
See the Venting Requirements on page 22, Concentric Termination
Installation on page 28 and Low Prole Installation on page 32.
Concentric and low prole 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.
• 6” Concentric Termination Part # 9008841005
• 4" Low Prole Termination Part # 9008934005
• 6" Low Prole Termination Part # 9008935005
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 60 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. Refer to Figure 6 for its location. See the
Water Piping Diagrams beginning on page 66 for installation
location of circulating pumps.
See Circulation Pump Wiring Diagrams on page 65 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.
All-bronze circulators are recommended for used 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
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
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 identication of
components mentioned below. Failure to follow these instructions
can restrict the air ow required for proper combustion, potentially
resulting in re, asphyxiation, serious personal injury or death.
• DO NOT apply insulation to the top of the water heater, as this will
interfere with safe operation of the blower assembly.
• DO NOT cover the control system LCD on top of the water heater.
• DO NOT cover the Temperature-Pressure Relief Valve.
• 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.
12
INSTALLATION REQUIREMENTS
GAS PRESSURE REQUIREMENTS
TABLE 4
MODEL
BTH 300
BTH 400
BTH 500
* Manifold gas pressure; reading can only be taken while gas is owing. Reading taken should be ± 0.3” W. C. of the listed value. These water heaters are certied for
use without modication for altitudes up to 10,100 feet. For elevations above 10,100 feet (3,079 meters) see High Altitude Installations on page 52.
† Minimum supply gas pressure; readings are taken while gas is not owing (static pressure) AND while gas is owing (dynamic pressure). Supply pressure must never
fall below the minimum values. Supply gas pressures should be measured with all gas red appliances connected to a common main ring at full capacity. If supply
pressure drops more than 1.5” W. C. as gas begins to ow the supply gas system (gas line/regulator) may be restricted or undersized. See Table 5 and the Supply
Gas Regulator requirements below. See Supply Gas Line Installation on page 38 and Supply Gas Regulator on page 13 for sizing and installation instructions also.
‡ Maximum supply gas pressure; readings are taken while gas is not owing (static pressure) AND while gas is owing (dynamic pressure). Supply pressure must
never exceed this maximum value.
*MANIFOLD PRESSURE †MINIMUM SUPPLY PRESSURE ‡MAXIMUM SUPPLY PRESSURE
NATURAL GAS PROPANE GAS NATURAL GAS PROPANE GAS NATURAL GAS PROPANE GAS
0” W. C. (0 kPa) 0” W. C. (0 kPa) 4.8" W .C. (1.19 kPa) 8.5” W. C. (2.12 kPa) 14” W. C. (3.49 kPa) 14” W. C. (3.49 kPa)
0” W. C. (0 kPa) 0” W. C. (0 kPa) 4.8" W .C. (1.19 kPa) 8.5” W. C. (2.12 kPa) 14” W. C. (3.49 kPa) 14” W. C. (3.49 kPa)
0” W. C. (0 kPa) 0” W. C. (0 kPa) 4.8" W .C. (1.19 kPa) 8.5” W. C. (2.12 kPa) 14” W. C. (3.49 kPa) 14” W. C. (3.49 kPa)
SUPPLY GAS LINE
The high efciency water heaters covered in this manual require
an adequate volume of fuel gas for proper operation. A lack of
fuel gas volume can lead to ignition failure, rough starting and
rough operation. Increasing the supply gas pressure DOES
NOT necessarily increase the volume of gas supplied to the
water heater and must remain below the maximum supply gas
pressures shown in Table 4.
The minimum supply gas line sizes shown in Table 5 must be
observed on all installations to help insure an adequate volume
of fuel gas is provided. DO NOT use exible gas piping.
Supply gas lines serving more than one appliance may require
larger sizes than what is shown in Table 5. See Gas Line Sizing
on page 38.
MINIMUM SUPPLY GAS LINE SIZE
TABLE 5
MODEL *NATURAL GAS PROPANE GAS
BTH 300 1 1/4” NPT 1 1/4” NPT
BTH 400 1 1/4” NPT 1 1/4” NPT
† BTH 500 1 1/2” NPT 1 1/4” NPT
† Note that BTH 500 natural gas models require a 1 1/2” minimum supply gas
line size. 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 shown in this table - see Gas Line Sizing
on page 38.
SUPPLY GAS REGULATOR
The maximum allowable gas supply pressure for this water
heater is 14.0” 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. 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.
3. 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.
4. 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.
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.
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 the costs
to install power supply lters are not covered under the limited
warranty.
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.
13
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
inrm and the physically/mentally disabled. Table 6 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
satises the demand of the application a Mixing Valve should be
installed at the water heater (see Figure 8) or at the hot water
taps to further reduce system water temperature.
Mixing valves are available at plumbing supply stores. Consult
a Qualied Installer or Service Agency. Follow mixing valve
manufacturer’s instructions for installation of the valves.
TABLE 6
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 8
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 66.
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 Temperature-Pressure Relief Valve
operation: water discharged from the valve due to excessive
pressure build up. This condition is not covered under the limited
warranty. The Temperature-Pressure 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 40 and the Water Piping
Diagrams beginning on page 66.
14
CAUTION
TEMPERATURE-PRESSURE RELIEF VALVE
Water Damage Hazard
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
certied combination Temperature-Pressure Relief Valve (T&P
valve) by the manufacturer. The valve is certied 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 certied 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.
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.
15
CONDENSATE DRAIN
death. Always read and understand instruction manual.
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/
condensate elbow located at the bottom. The eld installed
condensate drain line must not be elevated above the condensate
drain connection on the exhaust/condensate elbow, see Figure
9. 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 57.
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
THIS SIDE VIEW
OF EXHAUST
ELBOW AND
ARROW INDICATE
THE LOCATION OF
THE PRESSURE
PORT
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 appliance 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 9
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
Do not remove the factory installed exhaust/condensate elbow
for any reason, see Figure 9. The water heater’s vent pipe is
under a slight positive pressure. The water trap prevents ue
gases from escaping into the installed space. See Condensate
Drain Installation on page 37.
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
line, such as copper, to the water heater for this reason. See
Condensate Drain Installation on page 37.
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 hot surface 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 conguration 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.
16
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 insufcient 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 conned space unless an
adequate supply of air for combustion and ventilation is brought
in to that space using the methods described in the Conned
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 Unconned 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 unconned 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 unconned spaces in buildings, inltration 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 Conned Space section that follows.
CONFINED SPACE
A Conned 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 conned spaces. The required size for
the openings is dependent on the method used to provide fresh
air to the conned space AND the total Btu/hr input rating of all
appliances installed in the space.
DIRECT VENT APPLIANCES
Appliances installed in a Direct Vent conguration 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 conned 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, sufcient 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 the opening
required to provide the free area specied. 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.
17
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 conned spaces. The
illustrations shown in this section of the manual are a reference
for the openings that provide fresh air into conned 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 11. 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 (700 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 10
The conned 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 10.
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 12
The conned 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 12.
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 11
18
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 conned
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.
Figure 13
The conned 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 13.
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.
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.
AIR FROM OTHER INDOOR SPACES
Figure 14
The conned 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. See Figure 14.
Each opening shall communicate directly with an additional
room(s) of sufcient volume so that the combined volume of all
spaces meets the criteria for an Unconned Space.
Each opening shall have a minimum free area of 1 square inch
per 1,000 Btu/hr (1100 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).
19
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 satised:
INSTALLATION OF CARBON MONOXIDE DETECTORS
At the time of installation of the side wall horizontal vented
gas fueled equipment, the installing plumber or gastter 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 gastter 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 qualied 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 certied.
SIGNAGE
A metal or plastic identication 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 identies “special venting
systems,” the following requirements shall be satised 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.
20
VENTING INSTALLATION
Breathing carbon monoxide can cause brain damage or death.
Always read and understand the instruction manual.
Install vent system in accordance with codes.
Do not operate water heater if flood damaged.
Special consideration must be taken with installations
above 10,000 feet (3,048 m) refer to high altitude
section of this manual.
Breathing Hazard - Carbon Monoxide Gas
•
•
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.
•
•
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 conguration.
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 - See Page 27.
• AL29-4C Stainless Steel - See Page 27.
Approved vent and intake air pipe materials that must be used
in Canada:
• ULC S636 PVC / CPVC
• ULC S636 Polypropylene - See Page 27.
• AL29-4C Stainless Steel - See Page 27.
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 congurations 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 congurations have one vent pipe connected to the
water heater which can be terminated in a vertical or horizontal
arrangement. See Figure 36 and Figure 37 on page 33.
DIRECT VENT CONFIGURATION
Direct Vent congurations 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 congurations have two pipes connected to the water
heater, one vent pipe and one intake air pipe. Direct Vent congurations
can be terminated in one of seven different arrangements. See Figure
38 on page 33 through Figure 44 on page 34.
GENERAL VENTING INSTRUCTIONS
These instructions must be followed on all installations.
1. DO NOT install the water heater in a Power Vent conguration
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 conguration.
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 conguration 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, concentric or low prole
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.
18. Stress levels in pipe/ttings can be signicantly increased by
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. Carefully read the Venting Requirements on page 22 and then
proceed to the Venting Installation Sequence on page 23.
21
VENTING REQUIREMENTS
FIELD SUPPLIED FITTINGS
Field supplied ttings should be equivalent to the piping material
being installed. Field installed/supplied ttings will add equivalent
feet to the vent or intake air piping as indicated below. All eld
supplied/installed ttings and piping must be factored into the
equivalent feet calculations.
• 90° elbows (short or long radius) are equivalent to 5 linear
feet (152 cm) of pipe.
• 45° elbows (short or long radius) are equivalent to 2.5 linear
feet (76 cm) of pipe.
Note: Refer to Table 10 and Table 11 for equivalent linear pipe
length of AL29-4C
PRIMER AND CEMENT
Tetrahydrofuran (THF) primer should be used to prepare the
surfaces of pipe and ttings for solvent welding. If CPVC 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.
PIPE SIZE REQUIREMENTS
The water heaters covered in this manual are certied for the use
of 4 and 6 inch pipe for the vent (exhaust) and intake air piping.
If the installed equivalent length for the intake air or vent piping
will be 70 feet (21.3 m) or less, 4 inch pipe must be used. If the
installed equivalent length will be more than 70 feet (21.3 m), 6
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
70 equivalent feet or less and the vent pipe will be more than 70
equivalent feet; the intake air pipe must be installed using 4 inch
pipe and the vent must be installed using 6 inch pipe.
MAXIMUM EQUIVALENT LENGTHS
Four Inch Pipe
The water heaters covered in this manual are certied to a
maximum length of 4 inch pipe for the exhaust venting arrangement
of 70 equivalent feet (21.3 m). The certied maximum length of
4 inch pipe for intake air piping is also 70 equivalent feet (21.3
m). IE: On Direct Vent installations both pipes can be up to 70
equivalent feet (21.3 m).
Six Inch Pipe
The water heaters covered in this manual are certied to a
maximum length of 6 inch pipe for the exhaust venting arrangement
of 120 equivalent feet (36.5 m). The certied maximum length of
6 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).
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).
MINIMUM EQUIVALENT LENGTHS
Four Inch Pipe
The water heaters covered in this manual are certied to
a minimum length of 4 inch pipe for the vent (exhaust) of 15
®
45° and 90° elbows.
equivalent feet (4.6 m). There is no minimum equivalent feet
requirement for the intake air pipe.
Six Inch Pipe
The water heaters covered in this manual are certied to
a minimum length of 6 inch pipe for the vent (exhaust) of 70
equivalent feet (21.3 m). There is no minimum equivalent feet
requirement for the intake air pipe.
MAXIMUM NUMBER OF ELBOWS
The vent pipe may have a maximum of six 90° elbows installed.
The intake air pipe may have a maximum of six 90° elbows
installed. IE: in a Direct Vent conguration each pipe can have
up to six (6) 90° elbows installed. Two (2) 45° elbows equal one
(1) 90° elbow. Each 90° elbow is equivalent to 5 feet (1.5 m) of
linear pipe, 45° elbows are equivalent to 2.5 feet (0.75 m) of
linear pipe.
Note: Refer to Table 10 and Table 11 for equivalent linear pipe
length of AL29-4C
®
45° and 90° elbows.
FACTORY SUPPLIED FITTINGS
The water heater ships with two (2) factory supplied 4 inch
terminations (PVC 45° elbows with debris screen). Factory
supplied vent and intake air terminations or concentric and
low prole terminations must be used. Factory supplied
terminations and installed ttings (exhaust elbow and intake
air connection) add zero equivalent feet to the vent and intake
air piping.
NOTE: 3 inch intake air and/or vent terminations previously
installed on older BTH 300/400 model installations must be
replaced with factory supplied 4 inch or 6 inch terminations
depending on the installed length.
TABLE 7
Number of
90° Elbows
Installed
One (1) 65 feet (19.8 meters) 115 feet (35.0 meters)
Two (2) 60 feet (18.2 meters) 110 feet (33.5 meters)
Three (3) 55 feet (16.8 meters) 105 feet (32.0 meters)
Four (4) 50 feet (15.2 meters) 100 feet (30.5 meters)
Five (5) 45 feet (13.7 meters) 95 feet (29.0 meters)
Six (6) 40 feet (12.2 meters) 90 feet (27.4 meters)
4 Inch Pipe 6 Inch Pipe
Maximum Feet (Meters) Maximum Feet (Meters)
6 INCH EXTENDED VENT TERMINATIONS
When 6 inch intake air or vent pipe is installed using standard
terminations, factory supplied 6 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
6 inch termination(s). See Optional Direct Vent Terminations
on page 12.
The water heaters covered by this manual may be installed in a
Direct Vent conguration using a 6 inch concentric or 6 inch low
prole termination.
Contact your local distributor or call the parts department phone
number listed on the back cover of this manual to order.
• 6” Concentric Termination Part # 9008841005
• 6" Low Prole Termination Part # 9008935005
22
VENTING INSTALLATION SEQUENCE
1. Read the 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 conguration and which vent
system arrangement will be used for the installation. See the
various venting arrangements on pages 33 and 34.
3. Proceed to the applicable installation instructions that follow;
Power Vent Installation or Direct Vent Installation.
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 specic for Power Vent
congurations.
2. Determine which Power Vent arrangement will be used for
the installation; vertical or horizontal termination. See Figure
36 and Figure 37 on page 33.
3. Determine the vent pipe size for the installation, see Venting
Requirements on page 22.
4. Plan the layout of the vent piping backwards from the
termination point outdoors to the water heater. Layout the
vent piping to use a minimum of pipe and elbows.
5. Install the termination rst.
If the vent piping will terminate vertically, through a roof, see
Vertical Termination Installation on page 24.
If the vent piping will terminate horizontally, through a
sidewall, see Sidewall Termination Installation on page 26.
6” PIPE FIELD
SUPPLIED
6” x 4” REDUCER
FIELD SUPPLIED
4” PIPE FIELD
SUPPLIED
ALUMINUM
EXHAUST/
CONDENSATE
ELBOW VENT
CONNECTION
FACTORY
INSTALLED
VENT (EXHAUST) CONNECTION
Figure 15
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.
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 4 inch vent pipe connect the vent pipe to the
exhaust elbow on the water heater.
11. If installing 6 inch pipe transition to 4 inch pipe as shown in
Figure 15. The eld installed 4” pipe between the exhaust
elbow and the 6” x 4” reducer coupling should be 18 inches
(45 cm) or less in length.
DIRECT 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 specic for Direct Vent congurations.
2. Determine which Direct Vent arrangement will be used for
the installation. There are seven (7) Direct Vent arrangement
options, see pages 33 and 34.
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 24.
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 26.
If a concentric termination(s) will be used see Concentric
Termination Installation on page 28. If a low-prole termination
will be used see Low Prole Termination Charts on page 32.
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 16 on page 24.
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. 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).
11. If installing 4 inch vent pipe connect the vent pipe to the
exhaust elbow on the water heater.
12. If installing 6 inch vent pipe transition to 4 inch pipe at the
exhaust elbow on the water heater as shown in Figure 15.
The eld installed 4” pipe between the exhaust elbow and
the 6” x 4” reducer coupling should be 18 inches (45 cm) or
less in length.
23
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