Bosch 940 ES, 830 ES Installation Manual

940 ES

INDOOR MODEL Temperature Modulated with Electronic Ignition Suitable for heating potable water only and space heating (Intended for variable flow applications)

940 ES - Natural Gas 940 ES - Liquefied Petroleum (LP) Gas

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Warning: If the information in this manual 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.

Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency or the gas supplier. In the Commonwealth of Massachusetts this product must be installed by a licensed plumber or gas fitter.

Upon completion of the installation, these instructions should be handed to the user of the appliance for future reference.

What to do if you smell gas

• Close gas valve. Open windows.

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

• Installation and service must be performed by a qualified installer, service agency or the gas supplier.

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Index

1Warning 3

2 Appliance details 4

2.1 Features 4

2.2 Specifications (Technical data) 5

2.3 Unpacking the heater 6

2.4 General rules to follow for safe operation 7

2.5 Dimensions and Minimum installation clearances 8

3 Installation instructions 9

3.1 Specialized tools 9

3.2 Introduction 9

3.3 Venting 9

3.4 Combustion air requirements 23

3.5 Proper location for installing your heater 24

3.6 Heater placement and clearances 24

3.7 Mounting installation 24

3.8 Mounting installation for manufactured (mobile) homes 26

3.9 Gas piping & connections 26

3.10 Water connections 29

3.11 Water quality 29

3.12 Domestic hot water recirculation 30

3.13 Space heating applications 31

3.14 Measuring gas pressure 33

4 Electrical connections 34

4.1 Electrical power supply 34

4.2 Position of the fuses in control unit 34

5 Operation instructions 35

5.1 Description LCD display 35

5.2 For your safety read before operating your water heater 36

5.3 Power 36

5.4 Temperature selection 36

5.5 Use of optional remote control accessory (part no. TSTAT2) 37

5.6 Operation 37

5.7 Reset button 37

5.8 Program button 37

5.9 Locked condition 38

6 Maintenance and service 38

6.1 Annual maintenance 38

6.2 Winterizing for seasonal use 39

6.3 Mineral scale build-up 39

6.4 Adjusting CO2 40

6.5 Program values 42

6.6 Diagnostic menu 43

7 Troubleshooting 44

7.1 Introduction 44

7.2 Burner do not ignite when hot water is turned ON 44

7.3 Water is too hot 44

7.4 Water is not hot enough 44

7.5 Low water flow/pressure 45

7.6 Hot water temperature fluctuates at tap 45

7.7 Noisy burner/heater during operation 45

8 Problem solving 46

8.1 Error code diagnostics 46

9 Electrical diagram 50

10 Sensor resistance charts 51

11 Functional scheme 52

12 Interior components diagram

and parts list 53

12.1 Interior components 53

12.2 Components diagram 55

13 Protecting the environment 61

14 LIFETIME LIMITED WARRANTY

FOR BOSCH TANKLESS WATER HEATERS 62

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Warning

1 Warning

For your safety

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

Warning: Carefully plan where you install the heater. Correct combustion air supply and flue pipe installation are very important. If a gas appliance is not installed correctly, fatal accidents can result, such as carbon monoxide poisoning or fire.

Warning: Exhaust gas must be vented to outside using stainless steel vent material suitable for category III vent systems and temperatures up to 480°F. Vent piping must be sealed gas-tight to prevent possibility of flue gas spillage, carbon monoxide emissions and risk of fire, resulting in severe personal injury or death. Approved vent terminators must be used when penetrating to the outside.

Warning: Place the heater in a location where water leaks will do NO DAMAGE to adjacent areas or lower floors.

Warning: Field wiring connections and electrical grounding must comply with local codes, or in the absence of local codes, with the latest edition of the National Electric Code, ANSI/NFPA 70, or in Canada, all electrical wiring must comply with the local codes and the Canadian Electrical Code, CSA C22.1 Part 1.

Warning: Shock hazard: line voltage is present. Before servicing the water heater, unplug power supply cord from outlet. Failure to do so could result in severe personal injury or death.

Warning: The heater must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures equal to or more than 0.5 psig.

Warning: The appliance should be located in an area where leakage of the heater or connections will not result in damage to the area adjacent to the appliance or to lower floors of the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow.

Warning: The maximum inlet gas pressure must not exceed the value specified by the manufacturer and the minimum value listed is for the purpose of input adjustment.

Warning: If a water heater is installed in a closed water supply system, such as one having a backflow preventer in the cold water supply line, means shall be provided to control thermal expansion. Contact the water supplier or local plumbing inspector on how to control this situation.

Warning: Keep appliance area clear and free from combustible materials, gasoline and other flammable vapors and liquids.

Warning: Do not obstruct the flow of combustion and ventilation air.

Warning: Precautions must be taken prior to manually operating the relief valve to avoid contact with hot water coming out of the relief valve and to prevent water damage.

Caution: Label all wires prior to disconnection when servicing controls. Wiring errors can result in improper and dangerous operation. Verify proper operation after servicing.

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Appliance details

FCC: This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

Fig. 1

2 Appliance details

2.1 Features

Parts

• Key Pad interface control

• High power pre-mix compact burner with low NOx

emissions

• Modulating Gas Valve with constant gas:air ratio

control

• Modulating water valve for improved comfort and

temperature control.

High quality materials for long working life

• Copper heat exchanger

• High efficiency Ceramat Burner

• Compact space saver: mounts on a wall with a

supplied bracket.

Features

• Real-time diagnostics for troubleshooting/

informational purposes

• LCD Display with backlight

• On/Off and Temperature control switches

• Reset button

• Program button (Selectable temperature default)

Warning: If a relief valve discharges periodically, this may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation. Do not plug the relief valve.

Warning: If the water heater is used in a space heating application, all piping and components connected to the water heater must be suitable for use with potable water.

Warning: Toxic chemicals, such as those used for boiler treatment, shall not be introduced into the potable water used for space heating.

Warning: A water heater which will be used to supply potable water shall not be connected to any heating system or component(s) previously used with a nonpotable water heating appliance.

Warning: Installation in mobile homes shall conform to Title 24 CFR, Part 3280 and/or CAN/CSA Z240 MH Series, Mobile Homes.

HOT

BURN

DANGER

Water temperature over 125°F can cause severe burns instantly or death from scalds.

Children, disabled and elderly are at highest risk of being scalded.

See instruction manual before setting temperature at water heater.

Feel water before bathing or showering.

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Appliance details

• Failure codes for easy diagnostics and repair

• Easily removable one-piece cover

• Built in freeze prevention. Note: The freeze prevention kit is designed to provide

protection for the water heater down to approximately 5°F for short term conditions only. It will not protect the appliance in areas where the temperature is routinely expected to be below freezing.

- The freeze prevention kit will not protect plumbing outside the appliance from freezing. Precautions should be taken.

Accessories (Bosch part #)

• Optional wireless remote control accessory to operate with the appliance (TSTAT2)

• Cascading kit (77090003962)

• Outdoor kit (BTOK)

• External water filter (8703305356)

• Gas conversion kit (8719002176)

• Vertical vent kit (ESVVT)

• Concentric vent /air intake kit (ESHCK)

• Horizontal vent kit (4TWHVK3SII)

• Stainless steel bird screen (L2594) (fits into a 3” PCV fitting - Intake vent).

• Pipe Cover (PTPCES)

• High temperature kit (7736500074)

• Recess box kit (7736500043)

• Pressure relief valve (FWL-2).

2.2 Specifications (Technical data)

Approved in US/Canada

Capacity

Maximum flow rate: 7.15 GPM (27 l/min) at a 45°F (25°C) rise.

Maximum output

160,500 Btu/h (47.0 kW)

Maximum input

199,000 Btu/h (58.3 kW)

Efficiency in %

Thermal efficiency > 82%

Min. Input

19,900 Btu/h (5.8 kW)

Temperature Control

Selection range: 100°F (38°C) - 140°F (60°C) Default temperature: 122°F (50°C) Stability: +/- 2°F (+/- 1°C)

Gas Requirement

Gas connection (inches) - ¾” Inlet gas pressure under operation (with a high hot

water flow rate)*

• Propane: 8” - 13” water column.

• Natural Gas: 3.5” - 10.5” water column. * To measure gas pressure, see Measuring Gas

Pressure, chapter 3.14, page 33.

Water

• Hot water connection (inches) - ¾”

• Cold water connection (inches) - ¾”

• Water valve material: Polymer (PPS) (Polypropylene Sulfid)

• Minimum water flow: 0.5 gallon/minute (1,9 l/m). Note: Activation varies with inlet water temperatures from 0.5 - 1.6 gallon/minute (1,9 - 6.1 l/m).

• Minimum recommended water pressure: 30 PSI (2.07 bar).

• Minimum well pressure 40 psi, see page 29.

• Connections: – Bottom of heater

Combustion

• Design is NOx compliant with SCAQMD requirements - rule 1146,2 approved type 1 appliances

•CO  250 ppm (measured)

•CO

level set from factory, see chapter 6.4, page 40.

1) 4TWHVK3S vent kit is compatible with this appliance but requires the purchase of an additional 12" piece of straight pipe to meet minimum vent length requirements. The aluminum flex piping included with this kit is not permissible for use with this appliance.

BOSCH is constantly improving its products, therefore specifications are subject to change without prior notice.

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Appliance details

Dimensions

• Depth (in): 11¼” (286 mm)

• Width (in): 17

” (452 mm)

• Height (in): 30½” (775 mm)

• Weight: 67 pounds (30.5 kg).

Gas types

Natural Gas. LP Gas.

Voltage

120 V AC (60 Hz) nominal

Amperage

Idle - 40 mA Operation -  2.5 A

Noise

45 - 65 db (A)

Safety devices

• Flame failure device (ionization flame rod sensor)

• Over heat prevention (temperature limiter)

• Inlet temperature sensor

• Outlet temperature sensor

• Back flow temperature sensor.

Water protection

IP X4 (protection against water drops)

2.3 Unpacking the heater

Before installing the unit, be certain you have the correct heater for your type of Gas: Propane or Natural Gas. Identification labels are found on the

shipping box, and on the rating plate which is located on the right side panel of the cover.

Fig. 2 Rating plate

A Serial number B Type of gas

The box includes:

•940 ES

• Bracket for wall hanging the heater

• Exhaust vent adaptor (with 4 screws and gasket provided)

• Combustion air inlet adaptor (with 3 screws and gasket provided)

• Installation manual (manual can be downloaded at www.bosch-climate.us)

• Product registration card.

Please complete and return the enclosed product registration card.

The 940 ES is not approved or designed for:

• Recreational vehicle (RV) or boat installations.

• Use above 8000 ft A.S.L. altitude (see page 20).

• Outdoor installation without installation of Outdoor kit (BTOK).

• Applications where inlet water temperature is higher than 140ºF (60°C). A 3-way valve or mixing valve must be installed before the appliance if inlet water temperature exceeds this limit.

To remove front cover

B Loosen the two Philips head screws located on

bottom rear of cover (see Fig. 3).

Fig. 3 Loosen the two screws

If appliance is installed at elevations above 2000ft, refer to Section 3.3.8 Fan speed adjustment.

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Appliance details

B Lift front cover panel upward and remove.

Fig. 4 Remove the front cover

To remove combustion cover (service only)

B Open the four clips and remove the combustion

cover see Fig. 5.

Fig. 5 Remove the combustion cover

2.4 General rules to follow for safe operation

B 1. You must follow these instructions when you install

your heater. In the United States: The installation must conform with local codes or, in the absence of local codes, the National Fuel Gas Code ANSI Z223.1/ NFPA 54. In Canada: The Installation must conform with CGA B149.(1,2) INSTALLATION CODES and /or local installation codes.

B 2. Carefully plan where you install the heater. Correct

combustion air supply and vent pipe installation are very important. If not installed correctly, fatal accidents can occur, such as carbon monoxide poisoning or fire.

B 3. When the unit is installed indoors and ROOM

SEALED (twin pipe) it is permitted to be located in

bathrooms, bedrooms and occupied rooms that are normally kept closed. See chapter

3.3 (page 9). If the

unit will be installed indoors and use indoor combustion air, the place where you install the heater must have enough ventilation. The National Fuel

Gas Code does not allow UNSEALED gas fired water heater installations in bathrooms, bedrooms or any occupied rooms normally kept closed. See chapter

3.5, page 24 and 3.4,

page 23.

B 4. You must vent your heater. See chapter 3.3, page

on VENTING.

B 5. The appliance and its gas connection must be leak

tested before placing the appliance in operation. The appliance must be isolated from the gas supply piping system by closing its individual manual gas shutoff valve (not supplied with heater) during any pressure testing at pressures in excess of ½ Psig (3.5 kPa).

B 6. Keep water heater area clear and free from

combustibles and flammable liquids. Do not locate the heater over any material which might burn.

B 7. Correct gas pressure is critical for the proper

operation of this heater. Gas piping must be sized to provide the required pressure at the maximum output of the heater, while all the other gas appliances are in operation. Check with your local gas supplier, and see the section on connecting the gas supply, see

chapter 3.9.

B 8. Should overheating occur or the gas supply fail to

shut off, turn off the gas supply at the manual gas shut off valve, on the gas line. Note: manual gas shutoff valve is not supplied with the heater but must be field installed.

B 9. Do not use this appliance if any part has been

underwater. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been underwater.

B 10. Failure to install heater correctly may lead to

unsafe operation and void the warranty.

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Appliance details

2.5 Dimensions and Minimum installation clearances

Fig. 6 Dimensions

1 On/Off button 2 Reset button 3 Program key 4 Power ON or stand-by LED 5 LCD display 6 Up button 7 Down button

Fig. 7 Minimum clearances

Note: For servicing access, a 2ft clearance to front cover is recommended.

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reset

5¼"

30 ½"

17 "

5¼"

11 ¼"

2 ¾"

6 ½"

2 "

5¼"

2 "

4 "

6 "

Model 940 ES

TOP (A) 12”

FRONT (B) 1”

BACK 0”

SIDES 1”

FLOOR (C) 12”

Table 1 Minimum clearances

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Installation instructions

3 Installation instructions

3.1 Specialized tools

The following specialized tools may be required for installation:

• Manometer

• Multi-meter

• Combustion Gas Analyzer.

3.2 Introduction

Please follow these instructions. Failure to follow instructions may result in:

B Damage or injury. B Improper operation. B Loss of warranty.

If you are unable to perform the tasks required to install this heater properly, please contact a locally licensed plumber or gas technician.

3.3 Venting

3.3.1 Vent material

Establish vent clearances that comply with the vent manufacturer's specifications. In all cases, follow local codes. See Table 2.

Horizontal venting systems only:

An optional stainless concentric vent/air intake termination can be used to provide only one penetration point through the exterior wall (see Fig. 8, 9 & 10). The concentric vent/air intake kit can be ordered from your local wholesaler. (Part# ESHCK). Note: Only tee

terminals are approved for use with the concentric vent/air intake kit (see Table 3). Vent piping and tee terminal used with kit must be from the same vent pipe manufacturer. The appliance can also be installed with separate air intake and exhaust piping (see Fig. 16 ).

Common installation practice is to determine the venting/intake system layout and penetration and then work back to the heater.

Warning: Do not reduce the vent (exhaust and combustion) pipe sizes and do not common vent with any other vented appliance or stove.

Warning: Failure to vent the exhaust gases to the outside with sealed stainless steel vent pipe (AL29-4C) may result in dangerous flue gases filling the structure in which it is installed.

Warning: Do not mix vent pipe or joining methods from different manufacturers.

Warning: Approved terminators must be used for inlet and exhaust vent systems to prevent rain from entering the appliance. Failure to do so may result in damage to the appliance. This failure is not covered under the manufacturer’s warranty.

Caution: The vent system must be installed by a qualified installer in accordance with these instructions. If improperly installed, a hazardous condition such as explosion or carbon monoxide poisoning could result. Bosch Water Heating will not be responsible for improperly installed appliances.

Warning: In areas where outside temperatures routinely come close to freezing, sealed combustion operation is required. Use separate terminations for combustion and vent, which must be installed on the same wall or roof surface, however never facing the direction of prevailing winds. Failure to do so may result in heat exchanger freezing up and bursting. This failure is not covered under the manufacturer's warranty.

Diam. Material

Exhaust Vent

3 or 4 inches Sealed single wall stainless steel

(AL29-4C)

Intake Vent

3 or 4 inches Sealed PVC or any other rigid pipe

Table 2 Venting Specifications

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Installation instructions

Fig. 8 Concentric kit part # ESHCK

Fig. 9 Concentric kit vent assembly

Fig. 10 Concentric kit installation

3.3.2 Venting Specifications

Install appliance as close to point of vent termination as possible. The exhaust piping must vent directly to the outside of the structure. Horizontal sections of vent must pitch upward towards termination ¼" for every foot of horizontal length, to prevent the pooling of condensate, and be supported at 4 foot intervals with overhead hangers. Exception: horizontal run between last elbow and termination must pitch down to termination 1/4" per foot. Note: For horizontal terminations, venting must terminate once it penetrates to the outside of the

structure. There must be no sections of vent pipe exposed to the outdoors other than the termination. Note: Listed thimbles or collars are necessary where venting passes through wall and ceiling partitions. If the vent system passes through combustible areas where the vent clearance requirements cannot be maintained, it is permissible to chase straight sections of sealed 3 inch single wall vent through 4 inch (or greater) Type-B vent. The distance to combustibles using this chase technique is 1 inch. Note: Type-B vent must never be used as the actual exhaust vent system for the appliance, as it is not gas tight and illegal for use with this appliance. This will create a serious health hazard and void the warranty.

For specific questions concerning vent material, specifications, usage or installation, please contact the vent manufacturer directly.

6720608782-09.1Av

6720608782-10.1Av

12"

6720608782-11.1Av

3” stainless steel pipe

3”

VENTING

Z flex Protech Heat Fab

90° elbow

2SVEEWCF0390 FSELB9003 9314

3" Tee

Terminal

2SVSTTF03 FSTT3 9390TEE

3”

Horizontal

Terminal

2SVSTB03 FSTB3 N/A

3" horiz. terminal

with damper

2SVSHTD03 N/A N/A

3” Vertical

Terminal

2SVSRCF03 FSRC3 5300CI

Table 3 3" Terminator Part Numbers

4”

VENTING

Z flex Protech Heat Fab

90° elbow

2SVEEWCF0490 FSELB9004 9414

4" Tee

Terminal

2SVSTTF04 FSTT4 9490TEE

4”

Horizontal

Terminal

2SVSTB04 FSTB4 N/A

4" horiz. terminal

with damper

2SVSHTD04 FSRC4 5400CI

vertical

terminal

2SVSRCF04 N/A N/A

Table 4 4" Terminator Part Numbers

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Installation instructions

Condensate drain requirements

An external condensate drain (not supplied with the heater) must be installed under the following conditions:

• All vertical terminating vent installations.

• Horizontal terminating vent installations where the

total linear vent length is greater than 10 feet (3.1 m) for 3" and 5 feet (1.5 m) for 4".

• Vent installations where any section of the exhaust

vent pipe passes through an unconditioned space.

Twin pipe termination clearances

The minimum clearance between exhaust vent and combustion air inlet terminations for twin pipe penetration is 3 feet.

Minimum combustion air and exhaust pipe length

The minimum exhaust pipe length is 1 foot (0.3m) of straight vent pipe. The minimum combustion air pipe length is one 90° elbow.

Maximum combustion air and exhaust pipe length

The following tables display the maximum allowable straight pipe lengths for combustion air and exhaust piping with consideration to the number of elbows used. Reduce the equivalent length for each elbow used from the maximum allowable length.

Use of elbows

It is recommended to limit the amount of elbows used in the exhaust and combustion air piping to reduce friction in the air flow. The following lists the maximum amount of 90° elbows allowed in either the exhaust or combustion air piping:

Company Contact info

Z-flex www.z-flex.com

800-654-5600

ProTech Industries www.protechinfo.com

800-766-3473

Heat-Fab www.heatfab.com

800-772-0739

Table 5 Vent manufacturers

Venting Maximum

allowable

Exhaust

pipe length

Maximum allowable

Combustio

n air pipe

length

Elbow

Equivalency

90° 45°

28.5 ft 28.5 ft 2.5 ft 1.25 ft

61.25 ft 61.25 ft 1.25 ft .75 ft

Table 6 Maximum Allowable Exhaust and Combustion

Air Lengths

90° elbows

Venting

Max number of elbows 5 7

Table 7

Two 45° elbows are equal to one 90° elbow. Any combination of 45° and 90° elbows may be used in the vent system as long as the combination does not exceed the maximum listed in table 7 above.

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Installation instructions

Calculation example for 3" venting: Exhaust

Combustion air

Calculation example for 4" venting: Exhaust

Combustion air

System used Concentric

Number of 90° elbows needed: 1

Number of 45° elbows needed: 2

Table 8

Calculation of example

Max. length 28.5’

90° elbow reduction - 2.5’

sub-total = 26’

45° elbow reduction - 2.5’

Total = 23.5’

Table 9

For this example, the maximum allowable exhaust pipe length is 23.5 feet.

System used Concentric

Number of 90° elbows needed: 2

Number of 45° elbows needed: 1

Table 10

Calculation of example

Max. length 28.5’

90° elbow reduction - 5’

sub-total = 23.5’

45° elbow reduction - 1.25’

Total = 22.25’

Table 11

For this example, the maximum allowable combustion air pipe length is 22.25 feet.

System used Twin pipe

Number of 90° elbows needed: 2

Number of 45° elbows needed: 2

Table 12

Calculation of example

Max. length 61.25’

90° elbow reduction - 2.5’

sub-total = 58.75’

45° elbow reduction - 1.5’

Total = 57.25’

Table 13

For this example, the maximum allowable exhaust pipe length is 57.25 feet.

System used Twin pipe

Number of 90° elbows needed: 1

Number of 45° elbows needed: 2

Table 14

Calculation of example

Max. length 61.25’

90° elbow reduction - 1.25’

sub-total = 60’

45° elbow reduction - 1.5’

Total = 58.5’

Table 15

For this example, the maximum allowable combustion air pipe length is 58.5 feet.

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Installation instructions

Required direct vent terminal clearances (twin pipe / concentric penetration)

Fig. 11

* For clearances not specified in ANSI Z223.1 / NFPA 54 or CSA-B149.1, one of the following shall be indicated:

a) A minimum clearance value determined by testing in accordance with section 2.20, or; b) A reference to the following footnote: “Clearance in accordance with local installation codes and the requirements of the gas supplier.”

6720608836-23.1Av

Canadian installations

U.S. installations

A Clearance above grade, veranda, porch, deck or balcony 12 in. 12 in.

B Clearance to window or door that may be opened 36 in. 12 in.

C Clearance to permanently closed window * *

D Vertical clearance to ventilated soffit located above the vent

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

E Clearance to unventilated soffit * *

F Clearance to outside corner * *

G Clearance to inside corner * *

H Clearance to each side of center line extended above meter/

regulator assembly

36 in. within a height 15 feet above

meter/ regulator assembly

I Clearance to service regulator vent outlet 36 in. *

J Clearance to non-mechanical air supply inlet to building or the

combustion air inlet to any other application

36 in. 12 in.

K Clearance to mechanical air supply inlet 72 in. 36 in. above if within 10 feet

horizontally

L Clearance above paved sidewalk or paved driveway located on

public property

84 in.

M Clearance under veranda, porch deck or balcony 12 in.

Table 16

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

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

3) A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

4) Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.

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Installation instructions

Required other than direct vent terminal clearances (single pipe penetration)

Fig. 12

* For clearances not specified in ANSI Z223.1 / NFPA 54 or CSA-B149.1, one of the following shall be indicated:

6720608836-23.1Av

Canadian installations

U.S. installations

A Clearance above grade, veranda, porch, deck or balcony 12 in. 12 in.

B Clearance to window or door that may be opened 36 in. 4 feet below or to side of opening;

1 foot above opening

C Clearance to permanently closed window * *

D Vertical clearance to ventilated soffit located above the vent

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

E Clearance to unventilated soffit * *

F Clearance to outside corner * *

G Clearance to inside corner * *

H Clearance to each side of center line extended above meter/

regulator assembly

36 in. within a height 15 feet above

meter/ regulator assembly

I Clearance to service regulator vent outlet 36 in. *

J Clearance to non-mechanical air supply inlet to building or the

combustion air inlet to any other application

36 in. 4 feet below or to side of opening;

1 foot above opening

K Clearance to mechanical air supply inlet 72 in. 36 in. above if within 10 feet

horizontally

L Clearance above paved sidewalk or paved driveway located on

public property

84 in.

M Clearance under veranda, porch deck or balcony 12 in.

Table 17

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

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

3) A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

4) Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.

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Installation instructions

3.3.3 Venting configuration examples

Below are approved examples of horizontal venting installations.

Fig. 13 Horizontal side wall venting installation (single

pipe penetration)

Fig. 14 Horizontal venting installation (combustion air

piping not shown)

Warning: Single pipe penetration should be used in non-freezing climates only!

Important:

Note: Pitch horizontal runs down toward the heater, except horizontal run between last elbow and termination which must slope down to termination 1/4" per foot.

Note: For horizontal terminations, venting must terminate once it penetrates to the outside of the structure. There must be no sections of vent pipe exposed to the outdoors.

Fig. 15 Horizontal venting installation (concentric

penetration)

Fig. 16 Horizontal twin pipe penetration

Below are approved examples of vertical venting installations.

Important:

Note: Pitch horizontal runs down toward the heater, 1/4" per foot.

6720608542-02.2AL

HORIZONTALRUN

1/4" PER FOOT

DOWN TO

TERMINATOR.

CONDENSATE

DRAIN

HORIZONTAL RUN

DOWN TO

TERMINATOR.

SIDE

WATER

HEATER

NOTE: MINIMUM 1FT OF STRAIGHT VENT PIPE REQUIRED

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12"

6720608782-11.2V

6720608542-05.3V

26ft with 3" venting

60ft with 4" venting

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Installation instructions

Fig. 17 Vertical venting installation (single pipe pene-

tration)

Warning: Single pipe penetration should be used in non-freezing climates only!

Fig. 18 Vertical venting installation (twin pipe penetra-

tion)

Fig. 19 Vertical venting installation - Masonry Chim-

ney (combustion air piping not shown)

3.3.4 Vent connections

B Attach the flue gas exhaust accessory (8 705 504

151) to the top of the unit (position 1) using the 4 screws and gasket provided. Fully insert stainless steel vent pipe 1.5” minimum into the accessory and tighten the clamp (position 2).

FIRESTOP SUPPORT

ELBOW

APPLIANCE

HOSE CLAMP

RAIN CAP

STORM COLLAR

FLASHING

FIRESTOP SUPPORT

4" MIN.

AIR SPACE

6720608158-91.2Av

CONDENSATE

DRAIN

2' MIN.

10' MIN.

3' MIN.

If using the 4” vent, a 3” to 4” increaser is required immediately off the top of the heater.

NOTE: Vent pipe must be completely vertical when inserting or gasket inside exhaust accessory can become displaced. Exhaust accessory can be removed with vent pipe attached to check gasket position.

CHIMNEY

MORTAR

HANGER STRAP

HORIZONTAL RUN 1/4" RISE/FT

ELBOW

APPLIANCE

MAY BE INSULATED IF NECESSARY

6720608158-14.2AL

HOSE CLAMP

ELBOW

RAIN CAP

STORM COLLAR

SILICONE SEAL

FLASHING

CONDENSATE

DRAIN

2' MIN.

10' MIN.

3' MIN.

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Installation instructions

Fig. 20

B Attach the combustion air inlet accessory (8 705

504 154) to the top of the unit (position 3) using the 3 screws and gasket provided, and install air intake pipe over the accessory. NOTE: The appliance has the option to mount the combustion air inlet accessory on the top right or on the top left side of the heater. The combustion air inlet that is not used must be kept sealed.

Fig. 21

B Ensure that exhaust vent pipe is fully inserted in collar

to enable proper connection.

3.3.5 Condensate drain installation

Note: Do not install condensate drain in areas where it

may freeze.

1. Install condensate drain as close to heater as possi-

ble.

2. Use 3/8" ID high temperature silicone tube to con-

nect to condensate drain port. Do not use copper piping for any portion of the condensate drain.

3. Form a condensate trap by means of a 3" loop par-

tially filled with water.

4. To increase the tube length, connect to end of the

high temperature silicone tubing with vinyl tubing, PVC or CPVC pipe. Do not reduce the internal diameter at

any point.

5. Dispose of condensate according to local codes.

Fig. 22 Condensate drain installation (combustion air

piping not shown)

3.3.6 Freeze prevention

In cold climates, components of a tankless water heater can freeze and burst from negative draft. A leading cause of negative draft is combustion appliances in the building not being supplied with sufficient combustion air. A wood stove or furnace can pull its combustion air from the water heater‘s vent pipe, allowing the cold incoming air to freeze the cold water in the heat exchanger. Supplying more combustion air for all combustion appliances is the solution. A HVAC specialist should be consulted to design solutions for providing more combustion air.

Listed below are additional measures designed to further limit backdraft in extreme conditions assuming all other possible causes have been addressed.

Exhaust venting must be 3" or 4" sealed single wall stainless steel (AL29-4C) vent pipe.

3" Venting Z-flex ProTech Heat Fab

90° Condensate Drain Tee

2SVEVWCF03 FST3 &

FSDF3

93PPLSTEE

Horizontal Condensate Drain

2SVEDWCF03 FSHDT3 9321

Condensate Drain Tube

2SVEDTK24 N/A 7000TUBE

Table 18 Approved Condensate Drain Part Numbers

RAIN CAP

STORM COLLAR

FLASHING

4" MIN.

AIR SPACE

CONDENSATE

APPLIANCE

6720608782-04.2Av

ELBOW

FIRESTOP SUPPORT

DRAIN TRAP TO DRAIN - DISPOSE

OF CONDENSATE ACCORDING TO LOCAL CODES

DRAIN TEE

2' MIN.

10' MIN.

3' MIN.

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Installation instructions

Solution One

The Z-flex vent termination hood is the preferred option for limiting backdraft under the following conditions (see Fig. 23):

• The vent hood is only to be used in the exhaust vent piping.

• The vent hood can only be used for horizontal terminations.

• The vent hood is able to meet the required clearances outlined in the venting section of the water heater‘s installation manual.

Fig. 23 Part nr. 2SVSHTD03 for 3" venting

Part nr. 2SVSHTD04 for 4" venting

Solution Two

If the required clearances of the Zflex termination hood cannot be met, the Zflex damper is the preferred alternative (see Fig. 24).

Fig. 24 Part nr. 2ZVBP03 for 3" venting

Part nr. 2ZVBP04 for 4" venting

Installation

For these solutions to be effective, the internal flapper must be 100% closed when the water heater is not running. Refer to Fig. 25 and 26 for preferred installation positions in the vent system.

If using the Zflex damper:

• Ensure directional arrow on damper label faces in the same direction as exhaust flow.

• If installed horizontally, the axis must be horizontal or slightly pitched up towards termination to ensure damper closes 100% when heater is not running.

• To allow accessibility, damper must not be installed in an enclosed section of vent pipe.

• Do not install damper in unconditioned spaces (e.g. attics) Condensation can build up while the heater is running which can later freeze and potentially block the flapper.

Fig. 25 Combustion air piping not shown for clarity

purposes

Good - Vertical directly on top of the heater. Better - Closer to the termination horizontally installed in a condi-

tioned space.

Best - Closer to the termination vertically installed in a conditioned

space.

6720608542-07.1V

6720608542-08.1V

6720608542-06.1V

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Installation instructions

Fig. 26 Combustion air piping not shown for clarity

purposes

Good - Vertical directly on top of the heater. Better - Closer to the termination horizontally installed in a condi-

tioned space.

Best - Closer to the termination vertically installed in a conditioned

space.

3.3.7 Venting for manufactured (mobile) homes

When this appliance is installed in a mobile home, it is required that the venting be installed such that all combustion air is provided from outside the structure. As such, single pipe venting installations are forbidden in mobile home installations. Appropriate flue gas venting parts are listed in the table 19:

Warning: In a manufactured (mobile) home installation, combustion air shall not be supplied from occupied spaces.

Preferred damper position for vertical terminations

Unconditioned space. Do not install damper.

Enclosed vent pipe. Do not install damper.

6720608542-09.1V

3" Venting Z-flex Venting

24" Drain Tube Kit 2SVEDTK24

3" x 45° Elbow 2SVEEWCF0345

3" x 90° Elbow 2SVEEWCF0390

3" x 6" Pipe 2SVEPWCF03.5

3" x 12" Pipe 2SVEPWCF0301

3" x 18" Pipe 2SVEPWCF0301.5

3" x 2' Pipe 2SVEPWCF0302

3" x 3' Pipe 2SVEPWCF0303

3" x 4' Pipe 2SVEPWCF0304

Inline Vertical Tee 2SVEVDP03

3" Roof Flashing 0/12-6/12 2SVSADJF03

3" Roof Flashing 7/12-12/12 2SVSADJSF03

3" Rain Cap 2SVSRCF03

3" Custom Wall Thimble 2SVSWTCEC03

3" Exhaust/Intake Vent Hood w/10" Sleeve (Qty 2)

2SVSTB03

3" Adjustable Adapter 4ZVAL03

3" Gear Clamps (Qty 2) 7HS44XX

3" Storm Collar 2SVSLSF03

Extreme Weather Termination*

2SVSHRC03

Horizontal Drain Tee 2SVEDWCF03

Table 19 Z-Flex Venting list

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Installation instructions

3.3.8 Fan speed adjustment

IMPORTANT! Installation adjustment:

After installing the water heater, the fan speed values for minimum power (P2) and maximum power (P1) may need adjustment due to variations in altitude and vent pipe length. Failure to make necessary adjustments to fan speed values may result in improper operation of the appliance.

First calculate the total equivalent vent length. This is the straight pipe length of both exhaust and combustion air plus the number of elbows used. To determine the length equivalency of each elbow refer to table 6. Use the equivalent vent length value to determine the appropriate fan speed values found in Table 20 and 21. Refer to page 21 on how to adjust the fan speeds if an adjustment is necessary. After changing fan speed values, proceed to section 6.4 to confirm CO2 values are within specified ranges.

Fan speed adjustment

Natural Gas Liquid propane

Altitude

(above sea

level)

Total

equivalent

vent length

1) Full equivalent length (inlet + outlet piping + fittings)

Minimum

power fan

speed (P2)

Maximum

power fan speed

(P1)

Maximum

power fan speed

(P1)

0 - 2000 ft

(0 - 610 m)

3.5 - 32 ft

modification required

For operation at elevations

above 2,000 ft (610 m) the

equipment ratings shall be

reduced at the rate of 4% for

each 1,000 ft (305 m) above sea

level

33 - 57 ft

2000 - 4500 ft

(610 - 1372 m)

3.5 - 32 ft 8* 54* 47*

33 - 57 ft 8* 55* 48*

4500 - 8000 ft

(1372 - 2439 m)

3.5 - 32 ft 9* 55*

48*

33 - 57 ft 9* 55* 49*

* Above 2000 ft, CO2 levels must be checked with a combustion gas analyzer, see section 6.4 for instructions.

Table 20 Fan speed adjustment for 3" piping

Natural Gas Liquid propane

Altitude

(above sea

level)

Total

equivalent

vent length

1) Full equivalent length (inlet + outlet piping + fittings)

Minimum

power fan

speed (P2)

Maximum

power fan speed

(P1)

Maximum

power fan speed

(P1)

0 - 2000 ft

(0 - 610 m)

2.25 - 59 ft

modification required

For operation at elevations

above 2,000 ft (610 m) the

equipment ratings shall be

reduced at the rate of 4% for

each 1,000 ft (305 m) above sea

level

60 - 122.5 ft

2000 - 4500 ft

(610 - 1372 m)

2.25 - 59 ft 8* 54* 47*

60 - 122.5 ft 8* 55* 48*

4500 - 8000 ft

(1372 - 2439 m)

2.25 - 59 ft 9* 55*

48*

60 - 122.5 ft 9* 55* 49*

* Above 2000 ft, CO2 levels must be checked with a combustion gas analyzer, see section 6.4 for instructions.

Table 21 Fan speed adjustment for 4" piping

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