Bosch AQUA STAR 2400E LP User Manual

MODEL 2400E NG and 2400E LP - INDOOR MODEL

Temperature Modulated with Electronic Ignition

Suitable for heating potable water only

Not approved for space heating purposes

(Intended for variable flow applications)

2400 E NG - Natural Gas 2400 E LP - Liquefied Petroleum (LP) Gas

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 vapor 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.

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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.

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

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

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

Index

1 Warning 2

2 Appliance details 4

2.1 Features 4

2.2 2400 E Specifications (Technical data) 4

2.3 Unpacking the 2400 E heater 5

2.4 General rules to follow for safe operation 6

2.5 Dimensions and Minimum installation clearances 7

3 Installation instructions 8

3.1 Introduction 8

3.2 Proper location for installing your heater 8

3.3 Heater placement and clearances 8

3.4 Mounting installation 8

3.5 Combustion air requirements 9

3.6 Venting 11

3.6.1 Vent material and specifications 11

3.6.2 Vent connections 12

3.6.3 Condensate drain tube requirements 13

3.6.4 Room sealed installation (Twin pipe) 13

3.6.5 Vertical terminations 14

3.6.6 Horizontal terminations 15

3.6.7 Exhaust vent configuration examples 18

3.7 Gas piping & connections 19

3.8 Measuring gas pressure 21

3.9 Water connections 22

3.10 Electrical connections 23

3.11 Cascading function 23

3.12 Recirculation application 23

4 Operation instructions 24

4.1 For your safety, read before operating your water heater 24

4.2 Power 24

4.3 Temperature selection 25

4.4 Use of optional remote control accessory 27

4.5 Operation 27

4.6 Reset button 27

4.7 Program button 27

4.8 Locked condition 27

5 Maintenance and service 28

5.1 Annual maintenance 28

5.2 Winterizing for seasonal use 28

5.3 Mineral scale build-up 29

5.4 Adjusting CO2 29

5.5 Control board diagnostics 32

6 Troubleshooting 33

6.1 Introduction 33

6.2 Burners do not ignite when hot water is turned on 33

6.3 Water is too hot 33

6.4 Water is not hot enough 33

6.5 Low water flow/pressure 34

6.6 Hot water temperature fluctuates at tap 34

6.7 Noisy burner/heater during operation 34

6.8 Error code diagnostics 36

7 Electrical diagram 41

8 2400 E Functional scheme 42

9 Interior components diagram and parts list 43

9.1 Interior components 43

9.2 Components diagram 44

9.3 Parts list 45

10 Protecting the environment 46

11 Fifteen Year Limited Warranty 47

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 from lack of air, carbon monoxide poisoning or fire.

Warning: Exhaust gas must be vented to outside using proper vent material suitable for category III vent systems and temperatures up to 480°F. Vent and combustion air 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.

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.

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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.

Warning

Fig. 1

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Appliance details

2 Appliance details

2.1 Features

Parts

• Touch pad interface control

• High power pre-mix compact burner with low NOx emissions

• Modulating gas valve with constant gas to air ratio control

• Modulating water valve for improved comfort and temperature control.

Safety

• Flame sensor (ionization) rod

• Overheat sensor

• Temperature limiter

• Fan speed monitoring.

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.

• Easily removable one-piece cover.

Features

• LCD Display

• On/Off and temperature control switches

• Reset button

• Program key (selectable temperature)

• Failure codes for easy diagnostics and repair

• Diagnostic mode for troubleshooting/informational purposes

• Cascading function.

Accessories

• Optional wireless remote control accessory to remotely set temperature (Part # TSTAT2) .

• Tankless Link: Allows two 2400 E heaters to be linked together for double the hot water volume (Part # TLINK) .

• Horizontal vent termination kit (Part # 4TWHVK3S) .

BOSCH is constantly improving its products, therefore specifications are

subject to change without prior notice.

2.2 2400 E Specifications (Technical

data)

Approved in US/Canada

Capacity

Maximum flow rate: 6.35 GPM (24 l/min) at a 45°F (25°C) rise.

Maximum output

142,968 Btu/h (41.8 kW)

Maximum input

175,000 Btu/h (51.2 kW)

Efficiency in %

Recovery efficiency 86.5%

Min. Output

31,131 Btu/h (9.1 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” NPT

Inlet gas pressure under operation (with a high hot water flow rate)*

• Propane: 11” - 14” water column

• Natural Gas: 5” - 14” water column. * To measure gas pressure, see Measuring gas

pressure, chapter 3.8.

Venting

A condensate trap is integrated into the exhaust flue gas collar of the heater, the supplied condensate drain tube MUST be installed to it for proper removal of condensate from the trap. Additional condensate traps and drains may be necessary; see chapter 3.6 for Venting.

Water

• Hot water connection (inches) - ¾” NPT

• Cold water connection (inches) - ¾” NPT

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

• Minimum water flow for activation: 0.8 gallon/minute (3 l/m)

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

• Connections: – Bottom of heater

Combustion

•NOx ≤ 55 ppm

•CO ≤ 300 ppm

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Appliance details

•CO

level set from factory, see chapter 5.4.

Dimensions

• Depth (in): 8 ½” (220 mm)

• Width (in): 15 ¾” (400 mm)

• Height (in): 23 ½” (600 mm)

• Weight: 47 pounds (21 kg).

Gas types

Natural Gas. LP Gas. Converting the gas type can only be done by a certified gas technician with a calibrated CO

analyzer.

Call Bosch Water Heating for conversion information.

Voltage

120 V AC (50/60 Hz) 6 ft power supply cord

Amperage

Idle - 40 mA Operation - ≤ 2.5 A

Noise

≤ 50 db (A)

Safety devices

• Flame failure device (ionization flame rod sensor)

• Pressure relief valve (supplied with heater)

• Over heat prevention (temperature limiter).

Water resistant

IP X4 (protection against water drops)

2.3 Unpacking the 2400 E 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 sticker which is located on the right side panel of the cover.

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

• Condensate drain tube kit

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

• Plastic decal shields for covering front cover screws and control panel, installer should affix these decals to the front of the unit after installation is complete. See Fig. 3

• Installation manual (replacement manuals can be downloaded at www.boschhotwater.com

)

• Product registration card

• Energy Guide label.

Please complete and return the enclosed product registration card.

The 2400 E is not approved or designed for:

• Manufactured (mobile) homes, RV's, boats or any mobile installation.

• Heating or other recirculating/pumping applications*

• Solar/preheat backup or high temperature booster use.

* This includes domestic hot water circulator pump loop systems that may be installed in home hot water system prior to installing this unit. An approved recirculation design can be found in chapter 3.9. The use of a small electric mini-tank water heater (4-6 gallon size) must be used for this application and designed so the pump will circulate the hot water in the mini-tank only and through the building's hot water return loop (timed or thermostatic controlled operation of the pump is commonly done). The 2400 E must be plumbed in line before the mini-tank water heater and supplied with cold water only. Contact Bosch Water Heating if further instruction is needed.

To remove front cover

• Loosen the two Philips head screws located on front panel (beneath plastic decal shields if they are already attached, see Fig. 3)

• Lift front cover panel upward and remove.

Fig. 2 Rating plate sticker

A Serial number B Type of gas

The box includes:

• Pressure relief valve (150 psi / 200,000 Btu rating)

• Bracket for wall hanging the heater

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Plastic decals

Fig. 3 Remove front cover

Appliance details

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 be caused by lack of air, carbon monoxide poisoning or fire.

B 3. When the unit is installed indoors with ROOM

SEALED (twin pipe) combustion air and venting, it is permitted to be located in bathrooms, bedrooms and occupied rooms that are normally kept closed. See chapter 3.6. 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 and National Fire Codes do not allow UNSEALED gas fired water heater installations in bathrooms, bedrooms or any occupied rooms normally kept closed.

See chapter 3.2 and 3.5.

B 4. You must vent your heater. See section 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 optimum

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 Chapter 3.7 Gas piping and connections.

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.

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 11. The heater must not be installed in an unheated

area where temperatures will reach 36°F or lower. If the heater is left in an area susceptible to such temperatures, refer to Section 5.4 on Winterizing.

B 12. In areas where water supply has a high mineral

content, a water softener is strongly recommended. Damage to the water heater resulting from hard water/scale deposits will not be covered under warranty.

B 13. In areas with warm inlet water (70°F or greater),

increasing flow rate at low flowing fixtures may be required to prevent outlet temperatures from exceeding the desired temperature set point.

B 10. Failure to install heater correctly may lead to

unsafe operation and void the warranty.

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2.5 Dimensions and Minimum installation clearances

Appliance details

Fig. 4 Dimensions

1 Cover 2 On/Off switch 3 Reset button 4 LCD display 5 Program button 6 Temperature buttons

Fig. 5 Minimum clearances

Model 2400 E

TOP (A) 12”

FRONT (B) 1”

BACK 0”

SIDES 1”

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FLOOR (C) 12”

Table 1 Minimum clearances

Installation instructions

3 Installation instructions

3.1 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. Please contact Bosch Water Heating with any questions.

3.2 Proper location for installing your heater

Carefully select the location of the water heater. For your safety and for proper heater operation, you must provide combustion air to the heater and a proper exhaust vent system. Follow the guidelines below:

B 1. Locate the heater where venting, gas and

plumbing connections are feasible and convenient.

B 2. The hot water lines should be kept short to save

energy. Centrally locating the water heater is recommended to keep hot water distribution times even throughout the structure. It is always best to have hot water lines insulated.

Warning: The water in this water heater is cold and always remains cold except for the times the burners are on. In the event of power outage during freezing temperatures, it is recommended that the heater be drained. See chapter 5.5 “Winterizing” for draining instructions.

Warning: Flammable materials, gasoline, pressurized containers, or any other items or articles that are potential fire hazards must NOT be placed on or adjacent to the heater. The appliance area must be kept free of all combustible materials, gasoline and other flammable vapors and liquids.

Warning: The water heater must be installed in a conditioned space where temperatures will not fall below 36F.

3.3 Heater placement and clearances

The 2400 E is design certified for installation on a combustible wall (see 3.4 Mounting installation) provided the floor covering below the heater is noncombustible. For installations in an alcove or closet, maintain the minimum clearances to combustible and non-combustible materials listed below. See also Fig. 5.

A. Top 12 inches (306 mm) B. Front 1 inches (25 mm) C. Back 0 inches D. Sides 1 inches (25 mm) E. Bottom 12 inches (306 mm)

Clearances from any exhaust vent pipe are dependent upon the clearance requirements of the stainless steel vent pipe manufacturer. Single wall stainless steel (AL29-4C) vent pipe (vent type rated for Category III appliances) must be used when exhaust venting this appliance. See 3.6 Venting.

3.4 Mounting installation

Warning: before starting installation:

B check that there are no loose parts

inside the appliance

B check the gas type of the heater

matches the gas supply you will be connecting the heater

B ensure that gas pipe, gas valve, mixer,

fan and burner have no damage and are properly fitted.

Front cover should be removed (see instructions on page 5) in order to inspect

components visually.

B Secure the wall mounting bracket provided with the

heater to a wall surface.

Warning: Do not install this appliance on a carpeted wall. The heater must be mounted on a wall using appropriate anchoring materials.

If wall is sheathed with plasterboard, it is recommended that two support boards, either 1”x4” or 1/2" (minimum) plywood first be attached across a pair of studs. Then attach the heater’s bracket to the upper support board. The heater should be kept level on the wall surface. See Fig. 6.

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Installation instructions

pitch down towards termination ¼ inch for every foot of horizontal length.

Single pipe method:

Although it is permissible to draw combustion air from the inside, it is not the manufacturer’s recommended installation method. Always install a 3 inch elbow on the top of the combustion air inlet adaptor to prevent foreign objects from falling into the unit. If a single pipe installation is utilized, follow guidelines below for providing adequate combustion air for the water heater as well as any other appliances that may consume air in the space. Always follow local codes if they are more stringent.

Fig. 6 Mounting the heater

3.5 Combustion air requirements

Warning: In areas where outside

temperatures commonly fall below 36°F, a twin pipe venting system is required. Failure to do so may result in cold outside air being drawn across the heat exchanger causing it to freeze and burst. This failure is not covered under the manufacturer’s warranty.

Warning: When installed in an environment where corrosive chemicals or dirty air are present, the twin pipe system is required.

Twin pipe method:

The 2400 E is designed as a sealed combustion appliance. It is recommended that the combustion air be provided by a dedicated 3” or 4” pipe to the outside. The combustion air pipe may be aluminum flex, PVC or any other rigid or semi rigid sealed 3” or 4” pipe. The combustion air inlet, whether terminating vertically or horizontally, must be located in such a manner as to provide a minimum 3 foot clearance from the exhaust vent terminator. See Fig. 17 Letter I. The maximum length of the combustion air inlet is 26 feet with one elbow. Subtract 2.5 feet for additional elbows. Maximum number of elbows permitted is 3. Horizontally terminating combustion air pipes must

Fig. 7 Single pipe installation

The 2400 E water heater holds cold water in its copper heat exchanger and water valve when not in use. Because of this, any cold air that comes through the unit's vent pipe could freeze and damage these components. This Installation Manual specifies the minimum vertical vent pipe and the amount of combustion air required for this unit. When all requirements are followed, the unit will operate properly and safely. However, there may still be a risk of freezing due to negative draft if the other combustion appliances in the building are not supplied with sufficient combustion air. A wood stove or furnace can pull its combustion air from the 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. Observe the following guidelines: Installations in structures that have been tightly constructed (air infiltration rate of 0.40 ACH or less) must be provided with combustion air per the National

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Installation instructions

Fuel Gas Code. Consult a HVAC specialist if your air infiltration rate is questionable. The space must have two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. Each opening must have a minimum free area of one square inch per:

• 1000 Btu/hr if all air is taken from inside the building

• 2000 Btu/hr if all air is taken from the outside by

horizontal ducts

• 4000 Btu/hr if all air is taken from the outside by

direct openings or vertical ducts.

Or the space must be provided with one permanent opening or duct that is within 12 inches of the ceiling of the enclosure. This opening must have a minimum free area of one square inch per:

• 3000 Btu/hr if all air is taken from the outside by a

direct opening or vertical duct.

Louvers, grills and screens have a blocking effect. If the effective free area is not known, increase the sizes of your openings by 300% if your louvers are wood and by 35% if your louvers are metal. Refer to the National Fuel Gas Code for complete information.

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Installation instructions

3.6 Venting

Danger: Do not combination vent this

appliance with any other appliance.

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 space in which it is installed.

Warning: Single wall exhaust pipe MUST be chased through double wall Type-B vent when passing through an unconditioned space.

Warning: The vent system must be installed by a qualified individual 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.

permitted in the total vent length), or subtract 11/4 feet for every 45° elbow used. Horizontal sections of vent must pitch upwards from heater ¼" for every foot of horizontal length, to prevent the pooling of condensate, and be supported at 4 foot intervals with overhead hangers. See Table 2.

Exhaust Vent

Intake Vent

Diameter Minimum

3 or 4 inches

length

3 feet

1 90° elbow

Maximum

length

26 feet with

1 90°

elbow

26 feet with

1 90°

elbow

Material

Sealed single wall stainless

steel (AL29-4C)

Sealed

aluminum flex,

PVC or any

other rigid or

semi rigid pipe

Table 2 Venting specifications

Minimum exhaust vent size and length

The minimum exhaust vent length is 3 feet. The use of a 90 degree elbow is equivalent to 2 ½ ft in vent length. The use of 45 degree elbow is equivalent to 1 ¼ ft in vent length.

Fig. 8 Minimum exhaust vent length

3.6.1 Vent material and specifications

Establish vent clearances that comply with the vent manufacturer's specifications. In all cases follow local codes. Note: Listed thimbles or collars are necessary to pass 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 (check local codes).

Warning: Type-B vent must never be used as the actual exhaust vent system for the appliance, because it is not gas tight. This will create a serious health hazard and void the warranty.

Vent lengths

The appliance should be located as close to the point of termination as possible. The maximum vent length is 26 feet (8 m) with one 90 degree elbow. Subtract 2½ feet from the total vent length for each additional 90° elbow used (a maximum of three 90° elbows are

Reduce maximum length 2 ½ ft for each 90 elbow after the first one and 1 ¼ ft for each 45 elbow.

Fig. 9 Maximum vent and combustion air lengths

Vent material

The 2400 E requires 3 or 4 inch sealed single wall stainless steel vent pipe (AL29-4C). Use of any other vent material will void the manufactures warranty and

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Installation instructions

may result in a hazardous condition. For specific questions concerning vent material, specifications, usage or installation, contact the vent manufacturer directly.

Vent manufacturer Contact information

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 3 Vent manufacturer contact information

Z flex ProTech Heat Fab

3” Venting

3” Horizontal

termination

3” Vertical

termination

90°

Condensate

Drain Tee

2SVSTB03 FSTB3 9390 TEE

2SVSRCF03 FSRC3 5300CI

2SVEVWCF03

FST3 & FSDF3

93PPLSTEE

page 33. Correct the problem and then reset the heater before operating.

3.6.2 Vent connections

Exhaust vent connection

B Attach the flue gas exhaust accessory (8 705 504

137) to the top of the unit (position 1) using the 4 screws and gasket provided.

B Insert single wall stainless steel vent pipe into the

exhaust vent adapter 1.5” and tighten the clamp ( Fig. 10 position 2).

Note: 3 to 4 inch increaser required when using 4 inch pipe.

Note: Failure to fully insert vent pipe and tighten clamp may cause flue gas leakage or condensate damage that is not covered under the manufacturer's warranty.

Horizontal

Condensate

Drain

Vertical

Condensate

Drain

Condensate

Drain Tube

3” to 4”

Increaser

(Required)

4” Horizontal

termination

4” Vertical

termination

90°

Condensate

Drain Tee

Horizontal

Condensate

Drain

Vertical

Condensate

Drain

Condensate

Drain Tube

2SVEDWCF03 FSHDT3 9321

2SVSEVDP03 N/A N/A

2SVEDTK N/A 7000TUBE

4” Venting

2SVI0304 FS0304TI 9374

2SVSRTF04 FSTB4 9490TEE

2SVSRCF04 FSRC4 5400CI

2SVEVWCF04

2SVEDWCF04 FSHDT4 9421

2SVEVDP04 FSUCD4 N/A

2SVEDTK N/A 7000TUBE

FST4 & FSDF4

9416 & 9417D

Table 4 Approved vent termination and condensate

drain part numbers (subject to change)

Fig. 10 Exhaust vent connection

Combustion air inlet connection

The combustion air inlet accessory can be connected either to the top right or left of the appliance. The unused side must be sealed.

B Attach the combustion air inlet accessory (8 705

504 115) to the top of the unit (position 3) using the 3 screws and gasket provided.

B Install combustion air pipe over the air inlet acces-

sory. If using flexible piping, secure with a clamp (position 4, not included).

Vent Safety System

The 2400 E will shut down if inadequate exhaust venting is detected or a lack of combustion air is provided to the unit. See troubleshooting section on

Fig. 11 Combustion air inlet connection

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Installation instructions

3.6.3 Condensate drain tube requirements

Exhaust collar condensate drain installation (supplied with heater)

B The condensate drain tube kit must be used for all

installation types. Failure to properly install

condensate drain will void the warranty.

B When installing the condensate drain tube kit on the

exhaust collar (see diagram below), be sure to form a trap by means of a 3" (76.2 mm) loop partially filled with water. This loop must be as low as possible to allow proper drainage of condensate. The supplied tube is 3/8" ID high temperature silicone and must be attached to the condensate port on the exhaust collar with its supplied gear clamp (first remove brass screw from port).

B To increase tube length, connect vinyl tubing (not

supplied with heater) to the supplied tube. Do not reduce tubing diameter when using connector or additional tubing.

B The condensate must be disposed of according to

local regulations.

Condensate port on exhaust collar

Note: Condensate must be disposed of according to local codes. Note: Do not install condensate drain in areas where it may freeze.

1. Install condensate drain as close to heater as possible.

2. Use 3/8" ID high temperature silicone tubing to connect 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 and fill bottom of loop 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.

1. Remove brass hex head screw

2. Fit tube with gear clamp

3. Loop size and location. Coil tube into 3” loop with nylon tie (don't crimp tubing) and fill bottom of loop with water

Fig. 12 Exhaust collar condensate drain installation

Note: No part of supplied silicone tube should be installed above condensate tapping or improper drainage may occur. (see Fig. 12).

External condensate drain installation (not supplied)

An additional external condensate drain must be installed under the following conditions:

• Vertical terminating vent installations

• Horizontal terminating vent installations where the total vent length is greater than 5 feet

• Vent installation where any section of the exhaust vent pipe passes through an unconditioned space.

Fig. 13 Required condensate drain installation

(Combustion air piping not shown)

3.6.4 Room sealed installation (Twin pipe)

Warning: In areas where outdoor

B Although it is permitted to draw combustion air from

inside the structure in warm climates, the recommended method is to provide combustion air through

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Installation instructions

a 3" or 4" pipe from the outside. See Chapter 3.5 for more direction on combustion air.

B To reduce pressure differentials between the exhaust

and combustion air intake, it is recommended that both terminators exit on the same plane. See Fig. 14 for an example horizontal twin pipe termination and Fig. 15 for the vertical twin pipe termination example.

Fig. 14 Horizontal twin pipe termination

B Use of two 90° elbows (candy-cane) is an accepta-

ble termination for combustion air intake from the roof. See Fig. 15 for an example.

B Screening (no smaller than 1/4" mesh) is recom-

mended on candy cane termination.

B Exhaust should terminate above and must be a mini-

mum of 3 feet from must intake termination.

B The exhaust vent must terminate above the roof sur-

face with an approved vent cap not less than 3 feet (0.6 m) above the highest point where it passes through the roof and at least 2 feet (0.6 m) higher than any vertical wall or similar obstruction within 10 feet (3.1m). See Fig. 16 and Table 5.

Fig. 15 Vertical twin pipe termination

3.6.5 Vertical terminations

Warning: Failure to install a

condensate drain may result in damage not covered by the manufacturer's warranty. See chapter 3.6.3. An approved vent terminator must be used. See Table 5 for known approved vertical vent terminations.

Horizontal runs

Any gas vent section that is greater than 45 degrees from the vertical is considered horizontal. Horizontal sections must slope upwards from heater at least ¼ inch for every foot of its horizontal length and be properly supported to allow condensate to be collected by condensate drains.

Vent terminations

B No pipe joints other than the termination connections

should be exposed to the outdoors. See vent manufacturer instructions for details.

Fig. 16 Vertical vent terminations clearances

(Combustion air piping not shown)

GAS VENT TERMINATIONS FOR LISTED VENT

CAPS

Roof pitch H (min.)

feet

Flat to 6/12 1.0 0.30

6/12 to 7/12 1.25 0.38

Over 7/12 to 8/12 1.5 0.46

Over 8/12 to 9/12 2.0 0.61

Over 9/12 to 10/12 2.5 0.76

Over 10/12 to 11/12 3.25 0.99

Over 11/12 to 12/12 4.0 1.22

Over 12/12 to 14/12 5.0 1.52

Over 14/12 to 16/12 6.0 1.83

Over 16/12 to 18/12 7.0 2.13

Over 18/12 to 20/12 7.5 2.27

Over 20/12 to 21/12 8.0 2.44

meters

Table 5 Termination heights at various roof pitches

Interior masonry chimneys

The single wall stainless steel exhaust vent pipe must be permanently mounted inside the masonry chimney.

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Installation instructions

The masonry chimney may have to be tile or metal lined before the insertion of the gas vent pipe; check local codes for clarification. You may not vent any other fuel burning appliances into any free space remaining in the chimney. The vent terminator must extend at least 3 feet (0.9 m) above where the chimney meets the roofline and at least 2 feet (0.6 m) higher than any vertical wall or similar obstruction within 10 feet (3.1 m). The top of the chimney must be sealed to prevent rain water or other elements from entering the chimney.

Exterior masonry chimneys

Refer to the National Fuel Gas Code and consult a local venting HVAC contractor. Not recommended in cold climates.

3.6.6 Horizontal terminations

• For horizontal vent runs less than 5 linear feet, the entire vent run must pitch down to termination 1/4" per foot to eliminate the danger of rain from entering the venting system.

• The exhaust vent must terminate immediately once it penetrates the outside wall.

• An approved vent terminator must be used. See Table 4 for known approved horizontal vent terminations.

• Install an additional condensate drain (not supplied) if the total straight vent length is greater than 5 feet or if the exhaust vent pipe passes through an unconditioned space.

• Terminating the intake air piping above the exhaust termination is not recommended.

• Fig. 17 and table 6 show the required clearances for the vent termination. Follow local codes if more stringent.

3.6.6.1 Attention residents of the Commonwealth

of Massachusetts:

In the Commonwealth of Massachusetts the following regulation went into effect on 12/30/2005:

(a)For all side wall horizontally vented gas fueled equipment 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 finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETEC- TORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter 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 side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors. a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an at tic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level. b. 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, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. 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 IAS certified.

3. SIGNAGE. A metal or plastic identification 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 one half (1/2) inch in size, "GAS VENT

DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

4. 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. (b) 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. (c) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM REQUIRED. When the manufacturer of Product Approved side wall horizontally mounted gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for the installation of the equipment and the venting shall include:

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