Bradford-White EFR-1-60T1206EN, EFR160T120 User Manual

y

ULTRA HIGH EFFICIENCY GAS WATER HEATER

(EFR160T120 Series Models)

Ambler, PA 19002

Tech. Service [phone]

Service Parts [phone]

Warrant

Service [phone]

WARNING: If the information in

these instructions is not followed
exactly, a fire or explosion may
result causing property damage,
personal injury or death

- Do not store or use gasoline or other

flammable vapors and liquids in the
vicinity of this or any other appliance

- WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do

not use any phone in your building.

• Immediately call your gas supplier

from a neighbor’s phone. Follow the
gas supplier’s instructions.

• If you cannot reach your gas supplier,

call the fire department.

- For your family’s comfort, safety and

convenience, it is recommended this water
heater be installed and serviced by a
plumbing professional.

INSTALLATION/OPERATING MANUAL

WITH TROUBLESHOOTING GUIDE

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

238-48144-00A 08/09

SECTION I: IMPORTANT INFORMATION

This gas-fired water heater is design certified by CSA International under the American National
Standard, Z21.10.3 (as indicated on the rating plate) and CAN/CGA 4.3-M (as indicated on the rating

plate). These standards are available from CSA Standards Association, 5060 Spectrum Way

Mississauga, Ontario L4W 5N6 CANADA.

This water heater must be installed in accordance with local codes. In the absence of local codes, it
must be installed in compliance with the National Fuel Gas Code (ANSI Z223.1-Latest Edition), or in
Canada CAN/CGA B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.2
Propane Installation Code (Latest Edition).

READ CAREFULLY

The following terms are used throughout this manual to bring attention to the presence of hazards at
various risk levels, or to important information concerning product life.

DANGER

Indicates an imminently hazardous
situation, which, if not avoided, will
result in death, serious injury or
substantial property damage.

WARNING

Indicates a potentially hazardous
situation, which, if not avoided, could
result in death, serious injury or
substantial property damage.

This water heater has a limited warranty. The warranty for this water heater is valid only if the
water heater has been installed, maintained and operated in accordance with these instructions.

NOTICE

CAUTION

Indicates potentially hazardous
situation, which, if not avoided, may
result in moderate or minor injury or
property damage.

Indicates special instructions on
installation, operation or maintenance,
which are important but not related to
personal injury hazards.

NOTICE

TABLE OF CONTENTS

I IMPORTANT INFORMATION .............. 2 VII GAS CONNECTIONS .................................................... 35

II SPECIFICATIONS................................... 5 VIII ELECTRICAL CONNECTIONS.................................... 37

III GENERAL INFORMATION...................6 IX OPERATING INSTRUCTIONS..................................... 38

IV INSTALLATION INSTRUCTIONS........ 9 X MAINTENANCE............................................................ 46

V WATER CONNECTIONS ....................... 16 XI DIAGNOSTIC AND TROUBLESHOOTING GUIDE .. 51

VI VENTING................................................. 18 XII PARTS LIST ................................................................... 70

2

DANGER

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

DO NOT install any damaged venting system components. If damage is evident then please contact the supplier where the water
heater was purchased or the manufacturer listed on the rating plate for replacement parts.

Use only vent terminals provided or factory authorized terminals for venting this water heater.

This water heater is equipped with an adjustable thermostat to control water temperature. Hot water temperatures required for
automatic dishwasher and laundry use can cause scald burns resulting in serious personal injury and/or death. The temperature at
which injury occurs varies with the person’s age and the time of exposure. The slower response time of disabled persons
increases the hazards to them. NEVER
leave a child or disabled person unattended in a bathtub or shower.

Failure to properly install the vent and air intake (if applicable) system could result in property damage, personal injury, or death.

allow small children to use a hot water tap, or to draw their own bath water. NEVER

WARNING

Improper installation, adjustments, alteration, service or maintenance can cause property damage, personal injury or loss of life.
Failure to follow all instructions in the proper order can cause personal injury or death. Read and understand all instructions,
including all those provided with the appliance before installing, starting-up, operating, maintaining or servicing this appliance.

Keep this manual and literature in legible condition with this water heater for reference by owner and service technician.
This water heater requires regular maintenance and service to operate safely. Follow the instructions contained in this manual.

Installation, maintenance, and service must be performed only by a qualified, skilled and knowledgeable installer or service

provider.

Installation is not complete unless a temperature and pressure relief valve is installed into the proper location at the top of this

water heater.

It is the responsibility of the installing contractor to see that all controls are correctly installed and are properly operating when

the installation is complete.
This water heater is suitable for installation on combustible flooring. Do not install water heater directly on carpeting.

DO NOT operate this water heater without first being certain it is filled with water.

DO NOT tamper with or alter the water heater and/or controls.

DO NOT operate water heater with jumpered or absent controls or safety devices.

DO NOT operate water heater if any external part has been under water. Immediately call a qualified service agency to inspect
the appliance and to replace any part of the control system including gas controls, which has been under water.

DO NOT attempt to use this water heater with any gas other than the type listed on the rating plate. Do not attempt to convert
this water heater for use with a gas other than the type for which it is equipped. Failure to use the proper gas can create an unsafe
condition resulting in property damage, bodily injury, or death. Consult your local gas supplier or gas company if there are any
questions.

DO NOT operate this water heater if the input rate exceeds the rate shown on the water heater rating plate.

This water heater contains very hot water under high pressure. Do not unscrew any pipe fittings nor attempt to disconnect any
components of this water heater without positively assuring the water is cool and is not under pressure. Always wear protective
clothing and equipment when installing, starting up or servicing this water heater to prevent scald injuries. Do not rely on the
temperature gauges to determine the temperature. Do not touch any components unless they are cool.

This water heater must be properly vented and connected to an approved vent system in good condition. DO NOT operate water
heater with the absence of an approved vent system. A clean and unobstructed vent system is necessary to allow noxious fumes

that could cause injury or loss of life to vent safely and will contribute toward maintaining the water heater’s efficiency.

3

WARNING

This water heater needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air. Insufficient air supply will cause a recirculation of combustion products resulting in
contamination that may be hazardous to life. This will result in carboning or sooting of the combustion chamber,

burners, and flue tubes and creates a risk of asphyxiation.

This water heater requires its own separate venting system. DO NOT connect the exhaust vent into an existing vent

pipe or chimney.

Water heater materials of construction, products of combustion and the fuel contain carbon monoxide, nitrogen
oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are
known to the state of California to cause cancer, birth defects and other reproductive harm. Always use proper

safety clothing, respirators and equipment when servicing or working nearby this water heater.

Flammable items, pressurized containers or any other potential fire hazardous articles must never be placed on or
adjacent to the water heater. Open containers of flammable material should not be stored or used in the same room

with this water heater.

Insulation blankets are not required for this water heater. This water heater meets or exceeds the ASHRAE/IES

90.1b (latest edition) standards with respect to insulation and standby loss requirements.

Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long
period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the possibility of
injury under these conditions, we recommend the hot water faucet to be open for several minutes at the kitchen sink
before you use any electrical appliance, which is connect to the hot water system. If hydrogen is present, there will
be unusual sounds such as air escaping through the pipes as hot water begins to flow. Do not smoke or have open

flame near the faucet at the time it is open.

WARNING

Liquefied petroleum gases/propane gas is heavier than air and will remain at floor level if there is a leak.
Basements, crawl spaces, closets and areas below ground level will serve as pockets for accumulation of leaking
gas. Before lighting, smell all around the appliance area for gas. Be sure to smell next to the floor.

IF YOU SMELL GAS:

• DO NOT try to light any appliance.

• DO NOT touch any electric switch; do not use any telephone in your building.

• Immediately call your gas supplier from a telephone in another building. Follow the gas supplier’s

instructions.

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

DO NOT OPERATE THE APPLIANCE UNTIL THE LEAKAGE IS CORRECTED!

To comply with NSF requirements this water heater must be sealed to the floor with sealant, in a smooth and easily cleanable way.

4

SECTION II: SPECIFICATIONS

Figure 1. Dimensional Layout

1st Hr.

Del.
Gal.

Input

Rate

Model No.

EFR-1-60T120 120,000 180 345 138 99 60 95.0 57 28 ¼ 5 13 40 42 ½ 52 ½ 53 ½ 1 1 ¾ ¾ 570

BTU/h

100°F

Rise

Recovery GPH
At Degree Rise

At

40°F 100°F 140°F

Stg.

Cap.

U.S.
Gal.

Therm.

Eff.

%

A

Ht. B Dia.

C

Flr to

Vent

Outlet

Flr to

Inlet
Wtr.

Conn

DIMENSIONS ( INCHES )

D

E

F

Flr to

Fl. to

T&P

Outlet

Valve

Wtr.

Conn

Fl. to Air

Conn

G

Intake

H

Fl. to

Gas

Conn.

Front

Wtr.

Conn.

Dia.

Space

Heating

Conn.

Dia.

Gas

Conn.

Dia.

Relief
Valve
Open.

Shpg.

Wt.

(LBS)

Rate

KW

1st Hr.

Del. LPH

at 56°C

Rise

Input

Model No.

EFR-1-60T120 35.2 681 1306 522 375 227 95.0 1448 718 127 330 1016 1080 1334 1359 25 25 19 19 259

Recovery LPH
At Degree Rise

22°C 56°C 78°C

Stg.
Cap.
Liter

Therm.

Eff.

%

A

Ht.B Dia.

C

Flr to

Vent

Outlet

DIMENSIONS ( MILLIMETERS)

D

E

Flr to

T&P

Conn

F

Fl. to

Outlet

Wtr.

Conn

G

Fl. to Air

Intake

Flr to

Inlet
Wtr.

Conn

Valve

H

Fl. to

Gas

Conn.

Front

Wtr.

Conn.

Dia.

Space

Heating

Conn.

Dia.

Gas

Conn.

Dia.

Relief
Valve
Open.

Shpg.

Wt.

(KG)

Table 1. Specifications

5

SECTION III: GENERAL INFORMATION

FEATURES

This water heater contains the following features:

MAIN POWER ON/OFF SWITCH – The front panel of this water heater has a lighted ON/OFF switch, which is illuminated

when the main power is turned on to indicate power to the water heater.

COMBUSTION SYSTEM – This water heater is equipped with a self-compensating negative pressure pre-mix combustion

system. As the blower operates, air is drawn in through the air intake and into a venturi, which pulls gas from the gas valve. The
gas and air is then mixed in the combustion blower and sent through the transition tube into the burner. The Direct Spark Ignition
System (DSI) then ignites the gas/air fuel mixture to produce flue products (combustion). The flame sensor signals the ignition
control board (described below), that a flame is present.

HONEYWELL INTEGRATED CONTROL – Consists of a control board and a water heater display. An attractive digital water

heater display is on the top front of the water heater for precisely setting and displaying the temperature setpoint and monitoring the
status of the water heater. Pressing the temperature UP and DOWN buttons changes the temperature setpoint. The temperature

format may be displayed in degrees F or degrees C. The water heater display will show diagnostic codes in the event the water

heater needs servicing. The temperature readings of the tank sensor can be monitored in Service Mode. Also in Service Mode, the
display can show up to 10 previous error codes to further aid in servicing the water heater.
The single control board has plug in wiring harnesses to reduce the chance of miswiring. The control board controls all ignition,
temperature, and combustion blower functions. The control board controls the combustion blower, ignition timings, and gas valve
to control the combustion system in order to maintain the desired tank temperature. The sequence of operation is described in detail
in the Diagnostic Section at the back of this Installation and Operating Instruction Manual.

ADJUSTABLE THERMOSTAT – This water heater is equipped with an adjustable thermostat to control water temperature. Hot

water temperatures required for automatic dishwasher and laundry use can cause scald burns resulting in serious personal injury
and/or death.

The temperature may be adjusted from about 70°F (21°C) to about 180°F (82°C). The thermostat was adjusted to 70°F (21°C)

before the water heater was shipped from the factory. It is recommended that lower temperatures be used to avoid the risk of
scalding. Refer to the “Warnings” and the section on SCALDING in “Section V: Water Connections.” It is further recommended,
in all cases, that the water temperature be set for the lowest temperature, which satisfies your hot water requirements for the
installation. This will also provide the most energy efficient operation of the water heater and minimizes scale formation.

Setting the water heater temperature at 120°F (49°C) will reduce the risk of scalds. Some states require setting lower temperatures

for specific installations.

The top immersion well of the single sensor control also contains a redundant sensor for the high limit (energy cutoff). The high

limit circuit interrupts the main burner gas flow should the water temperature exceed approximately 200°F (93°C). Error code “65”

will be shown on the water heater control display if the high limit temperature has been exceeded.

Should the high limit switch activate, it must be manually reset. This should only be done by a service technician after the cause of
overheating has been corrected. Refer to the section on “Accessing Service Mode on the Display” in the Diagnostic section of this
Installation and Instruction Manual.

Contact your qualified installing contractor, service provider or manufacturer listed on the rating plate if continued high limit
operation occurs.

SERVICE PANEL – The service panel is located behind the service panel access cover, which is located by the exhaust elbow near

the bottom of the water heater. This panel contains a pressure switch that monitors the pressure in the exhaust pipe in case the vent
terminal becomes blocked. A collector high limit switch is used to monitor the ambient temperature between the first pass collector
and the exhaust collector. This is a manually re-settable switch. If this switch continues to trip, please contact an authori
agency.

zed service

6

LATCHES – The latches allow easy access for servicing the water heater from the top. Simply remove the two latches for

servicing and re-latch upon completion. No tools are required to obtain access to the top of the water heater.

MIXING VALVE – This water heater is supplied with an ASSE approved mixing valve to reduce the potential for scald injury
when thermostat settings over 120˚F (49ºC) are used for dishwashers or other appliances. The mixing valve reduces the discharge

temperature by mixing cold and hot water in the branch supply lines. Refer to the instructions supplied with the mixing valve for
installation procedures and device specifications. The mixing valve is located inside the control compartment.

SCALDING WARNING

ASSE APPROVED MIXING DEVICE MUST BE INSTALLED

TO PROVIDE PROTECTION FROM SCALDING

This water heater can deliver scalding temperature water at any faucet in the system if installed without installing the
supplied ASSE mixing device. By setting the thermostat on this water heater to obtain an increased water temperature
without properly installing the supplied mixing device, you may create the potential for scald injury. To protect against
injury, the supplied ASSE approved mixing device (a device to limit the temperature of water to protect against scald injury
via mixing hot and cold water supply) must be properly installed in the water system. This valve will reduce point of
discharge temperature in branch supply lines.

TEMPERATURE AND PRESSURE RELIEF VALVE –

WARNING

Keep clear of the combination temperature and pressure relief valve discharge line outlet. The discharge

may be hot enough to cause scald injury. The water is under pressure and may splash.

For protection against excessive temperatures and pressure, install temperature and pressure protective equipment
required by local codes, but not less than a combination temperature and pressure relief valve certified by a
nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or

materials as meeting the requirements of the Standard for Relief Valves and Automatic Gas Shutoff Devices for

Hot Water Supply Systems, ANSI Z21.22 and the Standard CAN1-4.4 Temperature, Pressure, Temperature and
Pressure Relief Valves and Vacuum Relief Valves. The combination temperature and pressure relief valve must be

marked with a maximum set pressure not to exceed the maximum working pressure of the water heater. The
combination temperature and pressure relief valve rating must not be less than the hourly rating of the water
heater

Install the combination temperature and pressure relief valve into the opening provided and marked for this
purpose on the water heater.

Note: Some models may already be equipped or supplied with an installed combination temperature and pressure
relief valve. Verify that the combination temperature and pressure relief valve complies with local codes. If the
combination temperature and pressure relief valve does not comply with local codes, replace it with one that does.
Follow the installation instructions above on this page

Install a discharge line so that water discharged from the combination temperature and pressure relief valve will

exit within 6 inches (15.2 cm) above, or any distance below the structural floor and cannot contact any live

electrical part. The discharge line is to be installed to allow for complete drainage of both the combination
temperature and pressure relief valve and the discharge line. The discharge opening must not be subjected to

blockage or freezing. DO NOT thread, plug or cap the discharge line. It is recommended that a minimum
clearance of 4 inches (10.2 cm) be provided on the side of the water heater for servicing and maintenance of the

combination temperature and pressure relief valve.

Do not place a valve between the combination temperature and pressure relief valve and the tank!

7

CONDENSATE DRAIN – The water heater should either be raised several inches above the floor on a concrete slab or use a low

profile condensate pump to allow free drainage of condensate from the elbow drain fitting. This water heater is a condensing type
unit and requires a drain to be located in close proximity to allow the condensate to drain safely. The condensate drains from the

unit at the exhaust elbow located near the bottom of the unit. The preferred connection to the drain fitting is to use a ¾ inch (1.9
cm) PVC elbow sealed with silicone over the outside of the drain outlet and use ¾ inch (1.9 cm) PVC for the drain trap and

condensate line to a drain. Use a thick bead of silicone caulk over the outside of the drain outlet connection before assembling the
elbow. This is preferred over using the threaded tap because the larger drain line will drain more freely and if too much force is
applied to the plastic threads, the fitting may crack and cause a leak. Make sure the condensate drain line slopes down, away from

the water heater at least ⅛ inch (.3 cm) per foot (.3 m) toward the drain. The condensate drain pipe must not be routed through an

area subject to below freezing temperatures. The condensate build-up will block the exhaust outlet, which will cause improper

operation. Refer to Figure 2 for the proper connection of a PVC elbow to the drain outlet and a condensate trap.

Figure 2. Condensate Elbow With Trap

CLEANOUT – All models are equipped with a cleanout opening to aid in removal of hard water deposits from the tank bottom. If

this water heater operates under hard water conditions, the following should be performed at least every 3 months: Turn off water
supply and drain the water heater. Remove the cleanout jacket cover and tank cover. When cleaning the tank, care must be taken to
avoid trying to break deposits loose as this could damage the glass lining and shorten the life of the water heater. After cleaning, re­install the cleanout tank cover and jacket cover, and refill with water. Refer to the section, “Section X: Maintenance” in this
Installation and Operating Instruction manual for the procedures for filling and draining the water heater.

SACRIFICIAL ANODES – Four sacrificial anode rods have been installed in the tank head to extend tank life. The anode rods

should be inspected periodically for corrosion and replaced when necessary to prolong tank life. Water conditions in your area will
influence the time interval for inspection and replacement of the anode rods. The use of a water softener may increase the speed of
anode consumption. More frequent inspection of the anodes is needed when using softened (or phosphate treated) water. Contact
the installing contractor, or service provider that installed the water heater or the manufacturer listed on the rating plate for anode
replacement information.

8

SECTION IV: INSTALLATION INSTRUCTIONS

INSTALLATION OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT
TO THAT OF A LICENSED TRADESMAN IN THE FIELD. PLUMBING, AIR
SUPPLY, VENTING, GAS SUPPLY AND ELECTRICAL WORK ARE REQUIRED.

DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT
CERTAIN OF THE FOLLOWING:

• Liquefied petroleum gases/propane gas and natural gas have an odorant added by the

gas supplier that aids in detection of the gas.

• Most people recognize this odor as a “sulfur” or “rotten egg” smell.

• Other conditions, such as “odorant fade” can cause the odorant to diminish in

intensity, or “fade”, and not be as readily detectable.

• If you have a diminished sense of smell, or are in any way unsure of the presence of

gas, immediately contact your gas supplier from a telephone in another building.

• Gas detectors are available. Contact your gas supplier or plumbing professional for

more information.
Liquefied petroleum gases/propane gas is heavier than air and will remain at floor level if
there is a leak. Basements, crawl spaces, closets and areas below ground level will serve as
pockets for accumulation of leaking gas. Before lighting, smell all around the appliance area
for gas. Be sure to smell next to the floor.
IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any telephone in your building.

• Immediately call your gas supplier from a telephone in another building. Follow the

gas supplier’s instructions.

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

DO NOT OPERATE THE APPLIANCE UNTIL THE LEAKAGE IS CORRECTED!

This water heater must be located in an area where leakage of the tank, water line connections,
or the combination temperature and pressure relief valve will not result in damage to the area
adjacent to the water heater or to lower floors of the structure. When such locations cannot be
avoided, a suitable drain pan must be installed under the water heater. The drain pan depth
must be suitable for draining and collecting water, and have a minimum length and width of at

least 4 inches (10.2 cm) measured from the jacket of the water heater. The drain pan, as

described above, can be purchased from your plumbing professional. The drain pan must be

piped to an adequate drain. The piping must be at least ¾ inch (1.9 cm) in diameter and

pitched for proper drainage.

WARNING

WARNING

9

Sacrificial anode rods have been installed in the tank head of the water heater to extend tank life. The removal of these anodes for

any reason will nullify the warranty. In areas where water is unusually active, an odor may occur at the hot water faucet due to a
reaction between the sacrificial anode and the impurities in the water. If this should happen, alternative anodes may be purchased
from the supplier that installed this water heater. This will minimize the odor while protecting the tank. Additionally, the water
heater should be flushed with appropriate dissolvers to eliminate any bacteria.

This water heater MUST be installed indoors out of the wind and weather.

This water heater MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present,
unless the installation is such to eliminate the probable ignition of gasoline or flammable vapors.

Water heaters in residential garages must be installed so that all burner(s) and ignition device(s) are located not less than 18
inches (45.7 cm) above the floor and be located, or protected , to avoid physical damage. For other installations, refer to
local codes. In the absence of local codes, the water heater must be installed in compliance with the National Fuel Gas Code,
(ANSI Z223.1-Latest Edition) or CAN/CGA B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.2
Propane Installation Code (Latest Edition).

UNPACKING

INSPECT SHIPMENT carefully for any signs of damage.

1. All equipment is carefully manufactured, inspected and packed.

2. Any claims for damage or shortage in shipment must be filed immediately with Bradford White Corporation and noted on

the Bill of Lading.

3. Remove all venting components and mixing valve from the combustion assembly compartment by removing the latches.

NOTICE

The mixing valve, vent terminals and the condensate elbow that are supplied with this water heater are
stored at the top in the Combustion Assembly Compartment. To access these parts, unlatch the top lid.
Be sure to replace the top and relatch.

LOCATE WATER HEATER in front of final position before removing crate.

1. LOCATE so that venting connections will be short and direct.

2. THIS WATER HEATER IS SUITABLE FOR INSTALLATION ON A COMBUSTIBLE FLOOR. Do not install this

water heater directly on carpeting. If the water heater is to be installed on carpeting, it must be installed on top of a metal
or wood panel extending beyond the full width and depth of the appliance by at least three (3) inches (7.6 cm) in any
direction or, if the appliance is to be installed in an alcove or closet, the entire floor must be covered by the panel.

3. FOR BASEMENT INSTALLATION, provide a solid level elevated base such as concrete or other suitable pad to raise

the water heater at least 3 inches (7.6 cm) to provide a slope of ⅛ inch (.3 cm)

condensate line to a suitable drain.

4. Minimum clearance to combustible material is 0 inches for the Top, Sides, and Rear of this water heater. However, it is

recommended that at least 18 inches (45.7 cm) from the Top, 24 inches (61 cm) from the Front, 4 inches (10.2 cm)

for the Left Side and Rear, and 12 inches (30.5 cm) from the Right Side Exhaust Elbow of the water heater be
provided for servicing. Clearance for servicing may be reduced down to minimum clearance to combustible material,

but service time and effort may be greatly increased.

to ¼ inch (.6 cm) per foot (.3 m) for the

10

M

r

ain Powe

Figure 3a. Minimum Clearance To Combustible Material

Figure 3b. Recommended Minimum Clearances For Service Access

11

REMOVE CRATE

1. Remove all banding and pry off crate sides carefully so as not to damage the water heater.

2. Carefully roll/lift the water heater from the crate base.

CAUTION

Do not drop water heater. Do not bump water heater jacket against floor.

Do not bump exhaust vent pipe against crate or other objects. This will damage the water heater and
cause it to be inoperable or create nuisance problems.

MOVE WATER HEATER TO PERMANENT POSITION by sliding or walking. Place drain pan underneath water heater

INSTALL TEMPERATURE AND PRESSURE RELIEF VALVE (if not already installed).

WARNING

Temperature and pressure relief valve discharge piping must be piped near floor to eliminate potential
of severe burns. Do not pipe in any area where freezing could occur. Do not install any shut-off
valves, plugs or caps to the temperature and pressure relief valve or piping.

SCALDING WARNING

ASSE APPROVED MIXING DEVICE MUST BE INSTALLED

TO PROVIDE PROTECTION FROM SCALDING

This water heater can deliver scalding temperature water at any faucet in the system if installed without installing the
supplied ASSE mixing device. By setting the thermostat on this water heater to obtain an increased water temperature
without properly installing the supplied mixing device, you may create the potential for scald injury. To protect against
injury, the supplied ASSE approved mixing device (a device to limit the temperature of water to protect against scald injury
via mixing hot and cold water supply) must be properly installed in the water system. This valve will reduce point of
discharge temperature in branch supply lines.

CAUTION

If the building cold water supply has a back-flow preventer, check valve or water meter with check
valve, provisions for thermal expansion of water in the hot water system must be provided.

LOCATION

KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE MATERIALS, GASOLINE AND OTHER
FLAMMABLE VAPORS AND LIQUIDS.

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

AIR REQUIREMENTS

1. Do not obstruct the flow of combustion and ventilating air.

2. For safe operation, adequate air is needed for combustion and ventilation. Sooting may result in serious damage to the

water heater and risk of fire or explosion. It can also create a risk of asphyxiation. Such a condition often will result in a
yellow, luminous burner flame, causing carboning or sooting of the combustion chamber, burner and flue tubes.

12

MECHANICAL EXHAUSTING OF ROOM AIR

1. Where an exhaust fan is installed in the same room with this water heater and combustion air is drawn from inside the

room, sufficient openings for air must be provided in the walls. UNDERSIZED OPENINGS WILL CAUSE AIR TO BE
DRAWN INTO THE ROOM THROUGH THE WATER HEATER’S VENTING SYSTEM, CAUSING POOR
COMBUSTION THAT MAY BE HAZARDOUS TO LIFE. SOOTING MAY RESULT IN SERIOUS DAMAGE TO
THE WATER HEATER AND RISK OF FIRE OR EXPLOSION, WHICH CAN ALSO CREATE A RISK OF

UNCONFINED SPACE

CONFINED SPACE

CHEMICAL VAPOR CORROSION

TYPICAL INSTALLATION ILLUSTRATION

ASPHYXIATION. Refer to local codes and /or National Fuel Gas Code for proper air opening sizing.

1. In buildings of conventional frame, brick or stone construction, unconfined spaces may provide adequate air for

combustion and ventilation.

2. If the unconfined space is within a building of tight construction (buildings using the following construction: weather

stripping, heavy insulation, caulking, vapor barrier, etc.), air for combustion and ventilation must be obtained from
outdoors. This may be accomplished by piping air directly to the water heater from outside or providing opening or
ducts in the wall. The installation instructions for confined spaces in tightly constructed buildings must be followed to
ensure adequate air supply.

1. When drawing combustion air from inside a conventionally constructed building to a confined space, such a space shall

be provided with two permanent openings.

• The top opening is to be located within 12 inches (30.5 cm) of the enclosure top and the bottom opening within 12

inches (30.5 cm) of the enclosure bottom.

• Each opening shall have a free area of at least 1 inch² (6.5 cm²) per 1000 Btu/h (.3 kw) of the total input of all

appliances in the enclosure, but not less than 100 inches² (645.2 cm²).

2. If the confined space is within a building of tight construction, air for combustion and ventilation must be obtained from

outdoors. This may be accomplished by piping air directly to the water heater from outside or providing opening or ducts
in the wall. When directly communicating with the outdoors through vertical ducts, two permanent openings, located in
the above manner, shall be provided.

• Each opening shall have a free area of not less than 1 inch² (6.5 cm²) per 4000 Btu/h (1.2 kw) of the total input of

all appliances in the enclosure.

• If horizontal ducts are used, each opening shall have a free area of not less than 1 inch² (6.5 cm²) per 2000 Btu/h

(.6 kw) of the total input of all appliances in the enclosure.

3. If the water heater is installed as a direct vent (outside air piped directly to the water heater), then additional opening,

other than the opening for the air intake, are not required. However, adequate ventilation air must be provided in all
cases to prevent increased room temperature.

Corrosion of the flue ways and vent system will occur if air for combustion contains certain chemical vapors. Such corrosion
may result in poor combustion and create a risk of asphyxiation, as well as reducing the life of the water heater. Spray can
propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium
chloride, waxes and process chemicals are corrosive. Products of this sort should not be stored near the water heater or outside
by the air intake (if applicable).

CAUTION

If the building cold water supply has a back-flow preventer, check valve, or water meter with check valve,
provisions for thermal expansion of water in the hot water system must be provided.

13

Figure 4. Typical Front Inlet Connection

Figure 5. Typical Front Inlet Connect with Storage Heater

14

Figure 6. Typical Two Water Heater Connection

Figure 7. Typical Three Water Heater Connection

Figure 8. Typical Four Water Heater Connection

15

SECTION V: WATER CONNECTIONS

WARNING

Failure to install and maintain a new, listed temperature and pressure relief valve will release the manufacturer from any claim,
which might result from excessive temperature and pressures.

Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time
(generally two weeks or more). HYDROGEN GAS IS EXTREMELY FLAMMABLE. To prevent the possibility of injury
under these conditions, we recommend the hot water faucet to be open for several minutes at the kitchen sink before you use any
electrical appliance, which is connected to the hot water system. If hydrogen is present, there will be an unusual sound such as
air escaping through the pipes as hot water begins to flow. Do not smoke or have open flame near the faucet at the time it is
open.

Keep clear of the combination temperature and pressure relief valve discharge line outlet. The discharge may be hot enough to
cause scald injury. The water is under pressure and may splash.

Setting the water temperature to the maximum set point can result in scalding hot water delivered to the faucets. It is highly
recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the installation. See
following section to change the maximum setpoint limit (max setpoint). Make sure the water heater control display is not in a
public area that can result in the temperature settings being improperly adjusted. See previous warning on scalds and an ASSE
approved mixing valve.

CAUTION

If sweat fittings are to be used, DO NOT apply heat to the nipples in front or side of the water heater. Sweat the tubing to the
adapter before fitting the adapter to the water connections. It is imperative that heat is not applied to the nipples containing a
plastic liner.

This water heater must not be operated without installing the mixing valve included in the box shipped with the water heater
located in the control compartment. Refer to the instructions supplied with the mixing valve for proper installation and settings.

INSTRUCTIONS FOR CONNECTIONS

1. BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN WATER SUPPLY VALVE. After

shutting off the main water supply, open a faucet to relieve the water line pressure to prevent any water from leaking out of
the pipes while making the water connections to the water heater. The COLD water inlet and HOT water outlet are
identified on the water heater. Make the proper plumbing connections between the water heater and the plumbing system

SCALDING

This water heater can deliver scalding temperature water at any faucet in the system. Be
careful whenever using hot water to avoid scalding injury. Certain appliances such as
dishwashers and automatic clothes washers may require increased temperature water. By
setting the thermostat on this water heater to obtain the increased temperature water

to the house. Install a shut-off valve in the cold water supply line.

2. If this water heater is installed in a closed water supply system, such as the one

having a back-flow preventer in the cold water supply, provisions must be made to

control thermal expansion. DO NOT operate this water heater in a closed system

without provisions for controlling thermal expansion. Warranties do not cover
damages from thermal expansion such as pressure bulges and/or deformities.
Your water supplier or local plumbing inspector should be contacted on how to
control this situation.

3. After installation of the water lines, open the main water supply valve and fill the

water heater. While the water heater is filling, open several hot water faucets to
allow air to escape from the water system. When a steady stream of water flows
through the faucets, close them and check all water connections for possible leaks.

4. Never operate the water heater without first being certain it is filled with water.

16

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

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

Review this instruction manual
before setting temperature
at water heater.

Feel water before bathing or
showering.

Temperature limiting valves are
available.

Figure 9. Scald Warning

M

r

y

required by these appliances, you might create the potential for scald injury. To protect against injury, you must install the ASSE
approved mixing valve supplied with the water heater in the water system. This valve will reduce point of discharge temperature by
mixing cold and hot water in branch supply lines. Follow the instructions supplied with the mixing valve for proper installation and
adjustment. The following chart details the relationship of water temperature and time with regard to scald injury and may be used
as a guide in determining the safest water temperature for your applications.

Approximate Time/Temperature Scald Chart

APPROXIMATE TIME/TEMPERATURE

RELATIONSHIPS IN SCALDS

120°F (49°C) More than 5 minutes
125°F (52°C) 1½ to 2 minutes
130°F (54°C) About 30 seconds
135°F (57°C) About 10 seconds
140°F (60°C) Less than 5 seconds
145°F (63°C) Less than 3 seconds
150°F (66°C) About 1½ seconds
155°F (68°C) About 1 second

Table 2.

ALTERNATE SPACE HEATING WATER CONNECTIONS

DANGER

Toxic chemicals, such as those used for boiler treatment, must not be introduced into potable water used for space heating.
This water heater must not be connected to an existing heating system or component(s) previously used with a non-potable

water heating appliance.

All piping components connected to this water heater for space heating applications must be suitable for use with potable
water.

WARNING

When the system requires water for space heating at temperatures higher than required for other means, the supplied ASSE
approved mixing valve must be installed to temper the water for those uses in order to reduce the scald hazard potential.

Failure to properly pipe this water heater may result in improper operation and damage to the water heater or structure.

Oxygen contamination of this water heater will cause corrosion of iron and steel components, and can lead to water heater
failure.

Connect the system supply and return piping to the water heater.

Refer to Figure 10 and Figure 11 for installation examples. Maintain

a minimum ½ inch (1.3 cm) clearance from hot water piping to

combustible materials.

ain Powe

Ultra High Efficienc

Figure 10. Alternate Space Heating Connections

17

Figure 11. Typical Plumbing Schematic for Zoned Heating

SECTION VI: VENTING

WARNING

The vent system must be properly installed. Failure to properly install the vent system could result in property damage,
personal injury, or death.

DO NOT install damaged venting system components. If damage is evident then please contact the supplier where the water

heater was purchased or the manufacturer listed on the rating plate for replacement parts.

Use only the vent terminals provided or factory authorized terminals for venting this water heater.

The water heater requires its own separate venting system. Do not connect the exhaust vent into an existing vent pipe or
chimney.

All of the exhaust venting connections must be leak checked with a soap solution upon initial start up of the water heater. Any
leaks must be repaired before continuing operation of the water heater.

Do not terminate the venting where noise from the exhaust or intake will be objectionable. This includes locations close to or
across from windows and doors. Avoid anchoring the vent and intake pipes directly to framed walls, floors, or ceilings unless
rubber isolation pipe hangers are used. This prevents any vibrations from being transmitted into the living spaces.

Do not exceed the venting distances or the number of elbows listed in this manual. Exceeding the maximum venting distances
may cause the water heater to malfunction or cause an unsafe condition.

DO NOT operate this water heater until the venting installation is complete and the piping completed. Failure to complete
installation before operation can result in property damage, personal injury, or death.

NOTICE

For installations in Canada, field supplied plastic vent piping must comply with CAN/CGA B149.1 (latest edition) and be
certified to the Standard For Type BH Gas Venting Systems, ULC S636. Components of this listed system shall not be
interchanged with other vent systems or unlisted pipe/fittings. All plastic components and specified primers and glues of the
certified vent system must be from a single system manufacturer and not intermixed with other system manufacturer’s vent
system parts.
The supplied vent connector and vent termination are certified as part of the water heater.

18

CAUTION

Check to make sure flue gases do not recirculate into the air intake terminal when using direct venting. If the water

heater is having service issues, flue recirculation may be a contributing factor. Even when the minimum vent terminal
separation distances are followed, recirculation may still occur depending upon the location outside the building, the
distance from other buildings, proximity to corners, weather conditions, wind patterns, and snow depth. Periodically
check to make sure that flue recirculation is not occurring. Signs of flue gas recirculation include frosted or frozen
intake terminals, condensate in the intake terminal and venting system, oxidation or white chalk material on the flame
sensor or igniter shield. Correction to flue recirculation may involve angling the intake away from the exhaust
terminal, increasing the distance between them, relocating the air intake to another side of the building, or using inside
air for combustion. Check to be sure the intake and exhaust terminals are not obstructed, especially during periods of
below freezing weather.

All intake and exhaust venting components must have the same diameter size. Do not use a different size on the
intake and exhaust venting. For 3 inch (7.6 cm) and 4 inch (10.2 cm) venting, use the supplied 2 inch (5.1 cm) vent

terminals.

Be sure the condensate runs freely to a drain and does not accumulate inside the water heater. In cold climates,
precautions may need to be taken to insure that the condensate drain does not freeze. Make sure the condensate trap
or drain loop is installed to prevent flue gases from being discharged into the room. Refer to the Venting section of
the Installation and Operating Instructions Manual for complete instructions on venting and condensate drainage.

High levels of dust and debris such as road and construction dust, insects, and tree pollen may clog the burner
resulting in poor performance and damage to the water heater. Avoid air intake locations where debris can be created
such as exhaust ventilation hoods, gravel parking lots, and near outdoor spotlights that attract bugs. For these
installations, an air intake filter kit, part number 239-47330-00A, is available as an accessory service part from the
installer of this water heater. The air intake filter kit is not
that may damage the water heater.

designed to filter out airborne contaminants or chemicals

CAUTION

The vent shall terminate a minimum of 12 inches (30.5 cm) above expected snowfall level to prevent blockage of vent

termination.

The horizontal centerline of the exhaust vent terminal (if applicable) must not be located lower than the horizontal

centerline of the air intake terminal if vented through the same wall.

A service drain loop must be installed in the drain tubing to serve as a condensate trap to prevent flue gases from
escaping into the room.

DO NOT position the air intake above the exhaust terminal.
NEVER locate the air intake where exhaust gases can be introduced.

NOTICE

Before beginning installation of any vent pipe, read the vent pipe manufacturer’s installation instructions.

Do not install the water heater in any location where the ambient temperature may fall below freezing. Water heater

must be protected from freezing downdrafts during shutdown periods.

Provide protection of the building materials from degradation by flue gases from the exhaust vent terminal.

19

VENTING

The venting instructions must be followed to avoid restricted combustion or recirculation of flue gases. Such conditions
cause sooting or risks of fire and asphyxiation.

This water heater can be installed as either a direct vent system or power vent (air from inside) system. If it is installed as a
direct vent system, then the air intake and the exhaust vent are piped to the outside. If a power vented system is used, then air
is drawn from inside and only the exhaust is piped to the outside. Determine which system is best for your application and
install as described in the following sections.

DIRECT VENT INSTALLATION
Venting may be run horizontally through an outside wall or vertically through a roof through using either 2 inch (5.1 cm), 3
inch (7 .6 cm), or 4 inch (10.2 cm) diameter PVC, ABS or CPVC pipe. This water heater is supplied with a screened intake

and exhaust elbow referred to as the air intake terminal and the exhaust vent terminal.

NOTICE

If 4 inch (10.2 cm) PVC, ABS, or CPVC pipe is used, then a use a 4 inch (10.2 cm) to 2 inch (7.6 cm) reducer

fitting before exiting the wall or roof to use the supplied screened intake and exhaust terminals.

If 3 inch (5.1 cm) PVC, ABS, or CPVC pipe is used, then use a 3 inch (5.1 cm) to 2 inch (7.6 cm) reducer fitting

before exiting the wall or roof to use the supplied screened intake and exhaust terminals.

Direct Vent Terminal Location
Plan the vent system layout so that proper clearances are maintained from plumbing and wiring. Before the vent is installed,
determine the vent pipe termination location as shown in Figure 12.

NOTICE

The air intake and exhaust terminals may be located on separate outside walls or one terminal may exit the roof
while the other is through the wall. The total combined equivalent vent length must be within the limits specified

in the venting tables and the intake length cannot exceed the exhaust by more than 30 feet (9 m). The minimum
recommended vent separation distance between the intake and exhaust terminals is 36 inches (91.4 cm). Local

conditions may require a need for greater vent separation distances.

20

Canadian

A= Clearance above

B= Clearance to widow or

C= Clearance to

D= Vertical clearance to

E= Clearance to

F= Clearance to outside

G= Clearance to inside

1

In accordance with the current CAN/CGA-B149 Installation Codes.

2

In accordance with the current ANSI Z223.1-(Latest Edition)/NFPA 54 National Fuel Gas Code.

Figure 12a. Vent Terminal Clearances (Other than Direct Vent or “Power Vented” Installations)

grade, veranda, porch,
deck or balcony

door that may be
opened

permanently closed
window

ventilated soffit
located above the
terminal within a
horizontal distance of
2 feet (.61 m) from the
center line of the
terminal

unventilated soffit

corner

corner

1

Installations

12 inches
(30.5 cm)

36 inches
(91.4 cm)

36 inches

(91.4 cm)*a

*b *b J= Clearance to non -

*b *b K= Clearance to a

*b *b L= Clearance above paved

*b *b M= Clearance under a

US

Installations2

12 inches

(30.5 cm)

4 feet (1.2 m)

below or to the

side of opening;

12 inches
(30.5 cm)

above opening

36 inches

(91.4 cm)*a

Canadian

H= Clearance to each side

of center line extended
above meter/regulator
assembly

I= Clearance to service

regulator vent outlet or
oil tank vent

mechanical air supply
inlet to building or the
combustion air inlet to
any other appliance

mechanical air supply
inlet

sidewalk or paved
driveway located on
public property

veranda, porch, deck, or
balcony

Installations1

3 feet (.9 m) within a
height 15 feet (4.6 m)

above the

meter/regulator

assembly

36 inches

(91.4 cm)

36 inches

(91.4 cm)

6 feet

(1.8 m)

7 feet

(2.1 m)†

12 inches (30.5 cm)‡ *b

US Installations

*b

*b

4 feet (1.2 m)

below or to side

of opening; 12

inches (30.5 cm)

above opening.

3 feet (.9 m)

above if within

10 feet (3 m)

horizontally

7 feet

(2.1 m)†

† A vent shall not terminate directly above a sidewalk or paved dr iveway that is located bet ween two single-family dwellings and
serves both dwellings.
‡ Permitted only if a veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.
*a) A minimum clearance value determined by testing in accordance with section 2.20.
*b) “Clearance in accordance with local installation codes and the requirements of the gas supplier”.

2

21

Figure 12b. Direct Vent Terminal Clearances

Canadian

A= Clearance above grade,

veranda, porch, deck or
balcony

B= Clearance to widow or

door that may be
opened

C= Clearance to

permanently closed
window

D= Vertical clearance to

ventilated soffit located
above the terminal within
a horizontal distance of 2
feet (.61 m) from the
center line of the
terminal

E= Clearance to

unventilated soffit

F= Clearance to outside

corner

G= Clearance to inside

corner

1

In accordance with the current CAN/CGA-B149 Installation Codes.

2

In accordance with the current ANSI Z223.1-(Latest Edition)/NFPA 54 National Fuel Gas Code.

Installations

12 inches

(30.5 cm)

36 inches
(91.4 cm)

12 inches

(30.5 cm)*a

12 inches

(30.5 cm)*a

36 inches

(91.4 cm)*a

1

*b *b J= Clearance to non -

*b *b M= Clearance under a

US

Installations2

12 inches

(30.5 cm)

12 inches
(30.5 cm)

12 inches

(30.5 cm)*a

12 inches

(30.5 cm)*a

36 inches

(91.4 cm)*a

Canadian

H= Clearance to each side

of center line extended
above meter/regulator
assembly

I= Clearance to service

regulator vent outlet or
oil tank vent

mechanical air supply
inlet to building or the
combustion air inlet to
any other appliance

K= Clearance to a

mechanical air supply
inlet

L= Clearance above paved

sidewalk or paved
driveway located on
public property

veranda, porch, deck, or
balcony

Installations1

3 feet (.9 m) within a
height 15 feet (4.6 m)

above the

meter/regulator

assembly

36 inches

(91 cm)

36 inches

(91.4 cm)

6 feet

(1.8 m)

7 feet

(2.1 m)†

12 inches (30.5 cm)‡ *b

US Installations

above if within

*b

*b

12 inches

(30.5 cm)

3 feet (.9 m)

10 feet (3 m)

horizontally

*b

† A vent shall not terminate directly above a sidewalk or paved dr iveway that is located bet ween two single-family d wellings and
serves both dwellings.
‡ Permitted only if a veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.
*a) A minimum clearance value determined by testing in accordance with section 2.20.
*b) “Clearance in accordance with local installation codes and the requirements of the gas supplier”.

2

22