Enviro 6G75100, 6G50100, NPDVH02, NPDVH05, PPDVH02 Instruction Manual

...

Instruction Manual

RESIDENTIAL GAS WATER HEATERS

POWER VENT/POWER DIRECT VENT GAS MODELS

WITH DIRECT SPARK IGNITION

MODELS 6G50100 (N,P)PDVH (02,05) &

6G75100 (N,P)PDVH (02,05)

SERIES 130/131

CANADIAN MANUAL

Thank you for buying this energy efcient water heater. We appreciate your condence in our products.

ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, CALL THE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING.

KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE

WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

PRINTED 0114 326464-000

• For Your Safety •

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE.................................3

APPROVALS .................................................................................3

GENERAL SAFETY INFORMATION .............................................4

Precautions ..............................................................................4

Grounding Instructions .............................................................4

Hydrogen Gas Flammable .......................................................4

INTRODUCTION ...........................................................................7

Abbreviations Used ..................................................................7

Qualications ............................................................................7

Preparing For The Installation ..................................................7

DIMENSIONS AND CAPACITY DATA ...........................................8

Rough In Dimensions: 50 Gallon Unit ......................................8

Rough In Dimensions: 75 Gallon Unit ......................................8

FEATURES AND COMPONENTS ..............................................10

Controls And Switches ...........................................................13

INSTALLATION CONSIDERATIONS ..........................................14

Locating The Water Heater ....................................................14

Insulation Blankets .................................................................15

Combustion Air And Ventilation ..............................................15

Unconned Space ..................................................................16

Conned Space ......................................................................16

Fresh Air Openings For Conned Spaces ..............................16

Outdoor Air Through Two Openings .......................................16

Outdoor Air Through One Opening.........................................16

Outdoor Air Through Two Horizontal Ducts ............................17

Air From Other Indoor Spaces ...............................................17

INSTALLATION REQUIREMENTS .............................................18

Chemical Vapor Corrosion......................................................18

Water Piping ...........................................................................18

Power Supply .........................................................................18

Mixing Valves..........................................................................19

Gas piping ..............................................................................19

Gas Supply Systems ..............................................................20

Gas Pressure Requirements ..................................................20

Supply Gas Regulator ............................................................20

Space Heating And Potable Water System ............................21

Closed Water Systems ...........................................................21

Thermal Expansion ................................................................21

Temperature-Pressure Relief Valve ........................................22

Condensate Piping .................................................................23

High Altitude Installations .......................................................23

Filling The Water Heater .........................................................23

VENTING INSTALLATION ..........................................................24

Vent Installation Considerations .............................................24

Polypropylene Installations .....................................................25

Vent Pipe Termination.............................................................26

Planning The Vent System .....................................................26

Installation Of Horizontal Through The Wall Vent System ......26

Direct Vent Terminal Installation .............................................27

Installation Sequence .............................................................27

Termination Clearances Sidewall Power Vent ........................28

Termination Clearances Sidewall Direct Vent .........................29

Vertical Vent Terminal Installation ...........................................30

Direct Vent Diagram ...............................................................31

Concentric Vent Installation ....................................................32

Low Prole Termination Installation ........................................35

LIGHTING AND OPERATION LABELS .......................................36

TEMPERATURE REGULATION .................................................37

CONTROL SYSTEM OPERATION .............................................38

Overview ................................................................................38

Control System Navigation .....................................................38

User Settings & Control System Menus .................................41

FOR YOUR INFORMATION ........................................................46

Start Up Conditions ................................................................46

Operational Conditions ...........................................................46

PERIODIC MAINTENANCE ........................................................47

Venting System Inspection .....................................................47

Anode Rod INSPECTION ......................................................47

Powered Anode Rod (optional models) ..................................48

Temperature-Pressure Relief Valve Test ................................48

Draining and ushing ..............................................................48

Service ...................................................................................49

LEAKAGE CHECKPOINTS .........................................................50

TROUBLESHOOTING ................................................................51

Installation Checklist ...............................................................51

Sequence Of Operation ..........................................................51

Sequence Of Operation Flow Chart .......................................52

Operational Problems .............................................................53

Fault And Alert Conditions ......................................................54

WIRING DIAGRAM .....................................................................57

NOTES ........................................................................................58

SAFE INSTALLATION, USE AND SERVICE

The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.

Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use, or service this water heater.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates an imminently

DANGER

WARNING

CAUTION

hazardous situation which, if not avoided, will result in injury or death.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in injury or death.

CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

CAUTION used without the safety alert

CAUTION

All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and how to avoid the risk of injury.

symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage.

APPROVALS

CAUTION

GENERAL SAFETY INFORMATION

PRECAUTIONS

DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN

UNDER WATER. Immediately call a qualied service agency to inspect the water heater and to make a determination on what steps should be taken next.

If the unit is exposed to the following, do not operate heater until all corrective steps have been made by a qualied service agency.

1. External re.

2. Damage.

3. Firing without water.

GROUNDING INSTRUCTIONS

This water heater must be grounded in accordance with the National Electrical Code and/or local codes. These must be followed in all cases. Failure to ground this water heater properly may also cause erratic control system operation.

This water heater must be connected to a grounded permanent wiring system; or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the water heater.

HYDROGEN GAS FLAMMABLE

Explosion Hazard

Flammable hydrogen gases may be present.

Keep all ignition sources away from faucet when turning on hot water.

Hydrogen gas can be produced in a hot water system served by this water heater that has not been used for a long period of time (generally two weeks or more). Hydrogen gas is extremely ammable. To reduce the risk of injury under these conditions, it is recommended that a hot water faucet served by this water heater be opened for several minutes before using any electrical appliance connected to the hot water system. If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to ow. THERE SHOULD BE NO SMOKING

OR OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.

Verify the power to the water heater is turned off before performing any service procedures.

Read and understand this instruction manual and the safety messages herein before installing, operating or servicing this water heater.

Failure to follow these instructions and safety messages could result in death or serious injury.

This manual must remain with the water heater.

Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death.

Children, the elderly and the physically or mentally disabled are at highest risk for scald injury.

Feel water before bathing or showering.

Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at fixtures.

Improper installation, use and service may result

in property damage.

Do not operate water heater if flood damaged.

•

Inspect anode rods regularly, replace if damaged.

•

Install in location with drainage.

•

Fill tank with water before operation.

•

Properly sized thermal expansion tanks are required on all

•

closed water systems.

Refer to this manual for installation and service.

Explosion Hazard

Overheated water can cause water tank explosion.

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

GENERAL SAFETY INFORMATION

Fire or Explosion Hazard

Read instruction manual before

installing, using or servicing

water heater.

Avoid all ignition sources if you smell gas.

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

Use only the gas shown on the water heater rating plate.

Keep ignition sources away from faucets after extended periods of non-use.

Maintain required clearances to combustibles.

Do not expose water heater controls to excessive gas pressure.

Do not obstruct water heater air intake with insulating blanket.

Gas and carbon monoxide detectors are available.

Install water heater in accordance with the instruction manual.

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

Breathing Hazard - Carbon Monoxide Gas

Property Damage Hazard

All water heaters eventually leak.

•

Do not install without adequate drainage.

•

CAUTION

GENERAL SAFETY INFORMATION

Fire Hazard

For continued protection against risk of fire:

Do not install water heater on carpeted floor.

Do not operate water heater if flood damaged.

Electrical Shock Hazard

Turn off power to the water heater

•

before performing any service. Label all wires prior to disconnecting

•

when performing service. Wiring errors can cause improper and dangerous operation.

Verify proper operation after servicing.

•

Failure to follow these instructions can

•

result in personal injury or death.

Fire and Explosion Hazard

Do not use water heater with any gas other than the gas shown on the rating plate.

Excessive gas pressure to gas valve can cause serious injury or death.

Turn off gas lines during installation. Contact a qualified installer or service

agency for installation and service.

INTRODUCTION

Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service.

ABBREVIATIONS USED

Abbreviations found in this Instruction Manual include :

• ANSI - American National Standards Institute

• ASME - American Society of Mechanical Engineers

• AHRI - Air-Conditioning, Heating and Refrigeration Institute

• NEC - National Electrical Code

• CSA - Canadian Standards Association

QUALIFICATIONS

QUALIFIED INSTALLER OR SERVICE AGENCY

Installation and service of this water heater requires ability equivalent to that of a Qualied Agency (as dened by ANSI below) in the eld involved. Installation skills such as plumbing, air supply, venting, gas supply and electrical supply are required in addition to electrical testing skills when performing service.

ANSI Z223.1 2006 Sec. 3.3.83: “Qualied Agency” - “Any individual, rm, corporation or company that either in person or through a representative is engaged in and is responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair or servicing of appliances and equipment; that is experienced in such work; that is familiar with all precautions required; and that has complied with all the requirements of the authority having jurisdiction.”

If you are not qualied (as dened by ANSI above) and licensed or certied as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the procedures described in this manual. If you do not understand the instructions given in this manual do not attempt to perform any procedures outlined in this manual.

PREPARING FOR THE INSTALLATION

See the Installation Checklist and Troubleshooting on Page 50. By using this checklist the user may be able to make minor operational adjustments and avoid unnecessary service calls. However, service and diagnostic procedures should only be performed by a Qualied Service Agency.

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

2. Be sure to turn off power when working on or near the electrical system of the water heater. Never touch electrical components with wet hands or when standing in water.

3. The installation must conform to all instructions contained in this manual and the local code authority having jurisdiction. These shall be carefully followed in all cases. Authorities having jurisdiction should be consulted before installation begins if there are any questions regarding compliance with local, state or national codes.

In the absence of local codes, the installation must comply with the current editions of the CAN/CSA-B149.1, the Natural Gas and Propane Installation Code and CSA C22.1, the Canadian Electrical Code. All documents are available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131.

4. If after reading this manual you have any questions or do not understand any portion of the instructions, call the toll free number on the back cover of this manual for technical assistance. In order to expedite your request, please have the full Model, Serial and Series number of the water heater you are working with available for the technician. This information is located on the water heater’s rating plate.

5. Carefully plan the placement of the water heater. Examine the location to ensure that it complies with the requirements in Locating The Water Heater on Page 14 and the Rough In Dimensions on Page 8..

1. Read the entire manual before attempting to install or operate the water heater. Pay close attention to the General Safety Information on Page 4 thru Page 6. If you don’t follow the safety rules, the water heater may not operate safely. It could cause property damage, injury and/or death.

This manual contains instructions for the installation, operation, and maintenance of the water heater. It also contains warnings throughout the manual that you must read and be aware of. All warnings and all instructions are essential to the proper operation of the water heater and your safety. Detailed installation diagrams are also found in this manual. These diagrams will serve to provide the installer with a reference. It is essential that all venting, water piping, gas piping and wiring be installed as shown.

Particular attention should be given to the installation of thermometers at the locations indicated in the piping diagrams as these are necessary for checking the operation of the water

heater.

The principal components of the water heater are identied in Features And Components on Page10 & Page 11 in this manual. Use this reference to locate and identify various components on the water heater.

DIMENSIONS AND CAPACITY DATA

ROUGH IN DIMENSIONS: 50 GALLON UNIT

Figure 1: DIMENSIONS FOR 50 GALLON UNIT

ROUGH IN DIMENSIONS: 75 GALLON UNIT

Figure 1A: DIMENSIONS FOR 75 GALLON UNIT

Table 1 – ROUGH-IN-DIMENSIONS

Units A B C D E F G H I

50G

75G

Top Inlet and Outlet: 50G - 3/4” NPT; 75G - 1” NPT Side Inlet and Outlet: 3/4” NPT Gas Inlet: 1/2” NPT

Inches 66.75 49.25 22.00 15.75 3.00 8.00 8.00 62.00 65.00

cm 169.5 125.09 55.88 40.00 7.62 20.32 20.32 157.48 165.1

Inches 64.71 45.64 27.75 16.00 3.71 8.00 7.93 57.36 58.98

cm 164.4 115.9 70.5 40.6 9.4 20.3 20.1 145.7 149.8

DIMENSIONS AND CAPACITY DATA

Table 2 – CAPACITY, GAS AND ELECTRICAL CHARACTERISTICS

Approximate Capacity Manifold Pressure Electrical Characteristics

U.S. Gals. Liters Gas Type “WC kPA Volts/Hz Amperes

50 189 Nat./LP 0 0 120/60 <5

75 284 Nat/LP 0 0 120/60 <5

All models - Maximum Supply Pressure: 14 inches W.C. (3.48kPa) Minimum Supply Pressure for Natural Gas: 3.50” (.87kPa) Minimum Supply Pressure for Propane Gas: 8.00” (1.99kPa) Minimum pressure must be maintained under both load and no load (dynamic and static) conditions.

Table 3 – RECOVERY CAPACITIES

Input Recovery Capacities

Rating

(Btu/hr)

100,000 29.3

Recovery capacity based on 96% thermal efciency.

Rating

(kW)

Temp.

Rise

F 30 40 50 60 70 80 90 100 110 120 130 140

C 17 22 28 33 39 44 50 56 61 67 72 78

GPH 387 291 233 194 166 145 129 116 106 97 90 83

LPH 1465 1102 882 734 628 549 488 439 401 367 341 314

**29

FEATURES AND COMPONENTS

50 GALLON UNIT

**14

**15

ACCESS PANEL

26, 27

Caution:

This access panel covers a 2” NPT plug that was required during the manufacturing of this water heater. This 2” NPT ange is not a cleanout tting, removing the 2” NPT plug and using this tting as a cleanout could void your warranty.

34 (SEE ACCESS

PANEL CAUTION)

VACUUM RELIEF

VALV E

* CAUTION HARNESS HAS 120 VAC. IN OPERATION. ** See Planning the Vent System, Installation of Vent System and Condensate Piping for more information.

*INSTALL PER

LOCAL CODES

Figure 1B: 50 GALLON UNIT

**29

FEATURES AND COMPONENTS (CONT.)

75 GALLON UNIT

**14

**15

26, 27

* CAUTION HARNESS HAS 120 VAC. IN OPERATION. ** See Planning the Vent System, Installation of Vent System and Condensate Piping for more information.

VACUUM RELIEF

VALV E

*INSTALL PER

LOCAL CODES

Figure 1C: 75 GALLON UNIT

FEATURES AND COMPONENTS (CONT.)

1: Control Assembly 2: Blocked Intake Switch 3: Blocked Outlet Switch 4: Blower Prover Switch 5: Blower Assembly 6: Burner Assembly 7: Flame Sensor 8: Igniter Assembly 9: Junction Box 10: Gas Control Valve Assembly 11: Display Board 12: Top Plastic Enclosure 13: Display Enclosure ** 14: Exhaust Elbow Assembly ** 15: Condensate Tubing 16: Off/On Switch 17: Display Label 18: Hot Water Outlet 19: Gas Supply 20: Main Manual Gas Shutoff Valve 21: Union 22: Inlet Water Shutoff Valve 23: Cold Water Inlet

24: Inlet Dip Tube

25: T/P Relief Valve

26: Rating Plate

27: Labels

28: Drain Valve

** 29: Vent Terminal

30: Drain Pan

31: Anode Rod

32: Insulation

33: Temperature Probe

34: Access Door

35: Spark Module

CONTROLS AND SWITCHES

This model is provided with three pressure switches. These switches are essential to the safe and proper operation of the unit. All switches are wired in series. The controller is set up to shut the unit down whenever there is a failure of any of the switches. It is important to understand the purpose of each switch.

BLOCKED EXHAUST SWITCH

The Blocked Exhaust Switch is set up to shut the unit off when a buildup of positive pressure in the exhaust vent pipe occurs. This switch is a positive pressure switch that requires an increase in pressure to

change the electrical contacts from normally closed to open. When this switch prevents the unit from igniting, most likely the exhaust is blocked by some means. Check to see if the condensate is allowed to ow freely from the exhaust elbow and for obstructions in the exhaust venting and exhaust vent terminal. Also verify that the vent length does not exceed the maximum allowed as shown in the Vent Section of this manual.

Blocked Exhaust Switch

Blocked

Intake

Switch

Blower

Prover

Switch

50 GALLON UNIT

Blocked

Intake

Switch

Blower

Prover

Switch

BLOCKED INTAKE SWITCH

The Blocked Intake Switch is set up to shut the unit off when a build-up of negative pressure in the intake air pipe occurs. This switch is a negative pressure switch that requires an increase in negative pressure to change the electrical contacts from normally closed to open. The switch is connected to the pressure tap on the PVC pipe connected to the inlet of the blower. When this switch prevents the unit from igniting, most likely the intake is blocked. Verify that the screen on the intake air connection (conventional vent), the intake air pipe and termination (direct vent installations) are free of obstructions that may prevent air from entering the unit. Insure the screen on intake air connection has been removed on direct vent installations, see “Figure 13: AIR INTAKE SCREEN”. Also verify the intake air pipe length does not exceed the maximum allowed as shown in the Vent Section of this manual.

WATER HEATING ENABLE/DISABLE (ON/OFF) SWITCH

The Water Heating Enable/Disable (On/Off) Switch is a single-pole, single-throw rocker switch. This switch provides 24V power to the gas control valve.

SPARK IGNITER

The Spark Igniter is a device that ignites the main burner by spark. When high voltage is applied to the igniter, spark is generated to ignite the main burner.

75 GALLON UNIT

Figure: 2

BLOWER PROVER SWITCH

The Blower Prover Switch is provided on the heater to verify that the fan is operating. It is a positive pressure switch whose electrical contacts are normally open. When the fan increases the pressure in the burner, the pressure switch will allow the electrical contacts to close. The pressure switch is connected to the blower pressure tap by a piece of tygon tubing. This tubing must be connected in order for the switch to change the electrical contacts. The controller requires that the electrical contacts on this air ow switch be open before it will allow the blower to come on.

CAUTION

INSTALLATION CONSIDERATIONS

LOCATING THE WATER HEATER

Carefully choose a location for the new water heater. The placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the water heater.

Property Damage Hazard

All water heaters eventually leak.

•

Do not install without adequate drainage.

•

Whether replacing an existing water heater or installing the water heater in a new location observe the following critical points:

1. The water heater must be located indoors.

2. The water heater must not be located in an area where it will be subject to freezing temperatures.

3. Locate the water heater so it is protected and not subject to physical damage by a moving vehicle.

4. Locate the water heater on a level surface.

5. Locate the water heater near a floor drain. The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure. When such locations cannot be avoided, it is recommended that a metal drain pan, piped to adequate drain, be installed under the water heater. Drain pan should be fabricated with sides at least 2” deep with diameter at least 2” greater than diameter of heater. Pan must not restrict combustion air flow.

6. Locate the water heater close to the point of major hot water usage.

7. Locate the water heater close to a 120 VAC power supply. See Power Supply on Page 18 for requirements.

8. Locate the water heater where an adequate supply of fresh air for combustion and ventilation can be obtained. See Combustion Air and Ventilation on Page 15.

9. Locate the water heater where the vent and intake air piping, when installed, will remain within the maximum equivalent lengths allowed. See Venting on Page 24.

10. Do not locate the water heater where noise (such as the Combustion Blower) during normal operation will be objectionable in adjacent areas.

11. Do not locate the water heater where the subsequent installation of the vent (exhaust) or intake air terminations would be objectionable due to noise at the termination(s). This includes locations close to or across from windows and doors. See Venting starting on Page 24.

Do not locate water heater areas where flammable liquids (vapors) are likely to be present or stored (garages, storage and utility areas, etc.): Flammable liquids (such as gasoline, solvents, propane (LP or butane, etc.) and other substances (such as adhesives, etc.) emit flammable vapors which can be ignited by a gas water heater’s ignition device or main burner. The resulting flashback and fire can cause death or serious

burns to anyone in the area.

Also, the water heater must be located and/or protected so it is not subject to physical damage by a moving vehicle.

This water heater must not be installed directly on carpeting. Carpeting must be protected by metal or wood panel beneath the water heater extending beyond the full width and depth of the water heater by at least 3” (7.6 cm) in any direction, or if the water heater is installed in an alcove or closet, the entire oor must be covered by the panel. Failure to heed this warning may result in a re hazard.

Minimum clearances between the water heater and combustible construction are 0 inch at the sides and rear, 5.5” (14.0 cm) from the front and 18” (45.7 cm) from the top. (Standard clearance.) If clearances stated on the heater differ from standard clearances, install water heater according to clearances stated on the heater.

Adequate clearance 30” (76 cm) for servicing this water heater should be considered before installation, such as changing the anode rods, control system components and gas control valve.

A minimum clearance of 5.5” (14.0 cm) must be allowed for access to replaceable and/or serviceable parts such as the thermostats, drain valve, condensate drain, temperature-pressure relief valve, clean out opening, and the vent connection (exhaust elbow).

When installing the heater, consideration must be given to proper location. Location selected should be as close to the wall as practicable and as centralized with the water piping system as possible.

• Do not apply insulation to the top of the water heater, as this will interfere with safe operation of the blower assembly.

• Do not cover the control system LCD on top of the water heater.

• Do not cover the outer door, thermostat or temperature & pressure relief valve.

• Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.

• Do obtain new warning and instruction labels from the manufacturer for placement on the blanket directly over the existing labels.

• Do inspect the insulation blanket frequently to make certain it does not sag, thereby obstructing combustion air ow.

COMBUSTION AIR AND VENTILATION

A gas water heater cannot operate properly without the correct amount of air for combustion. Do not install in a conned area such as a closet, unless you provide air as shown in the Facts to Consider About Location section. Never obstruct the ow of ventilation air. If you have any doubts or questions at all, call your gas supplier. Failure to provide the proper amount of combustion air can result in a re or explosion and cause death, serious bodily injury, or property damage.

Figure 3: CLEARANCES

INSULATION BLANKETS

Insulation blankets are available to the general public for external use on gas water heaters but are not necessary with these products. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. Your water heater meets or exceeds the Energy Policy Act standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary.

Should you choose to apply an insulation blanket to this heater, you should follow these instructions (For identication of components mentioned below, see “Figure 1B: 50 GALLON UNIT” & “Figure 1C: 75 GALLON UNIT”. Failure to follow these instructions can restrict the air ow required for proper combustion, potentially resulting in re, asphyxiation, serious personal injury or death.

Figure 4: COMBUSTION AIR AND VENTILATION

If this water heater will be used in beauty shops, barber shops, cleaning establishments, or self-service laundries with dry cleaning equipment, it is imperative that the water heater(s) be installed direct vent so that all air for combustion and ventilation is taken from outdoors.

Propellants of aerosol sprays and volatile compounds, (cleaners, chlorine based chemicals, refrigerants, etc.) in addition to being highly ammable in many cases, will also react to form corrosive hydrochloric acid when exposed to the combustion products of the water heater. The results can be hazardous, and also cause product failure.

UNCONFINED SPACE

An Unconned Space is one whose volume IS NOT LESS THAN 50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input rating of all appliances installed in the space. Rooms communicating directly with the space, in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconned space.

FRESH AIR OPENINGS FOR CONFINED SPACES

The following instructions shall be used to calculate the size, number and placement of openings providing fresh air for combustion, ventilation and dilution in conned spaces. The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into conned spaces only. DO NOT refer to these illustrations for the purpose of vent installation. See Venting Installation on Page 24 for complete venting installation instructions.

Makeup air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers and replaces shall also be considered in determining the adequacy of a space to provide combustion, ventilation and dilution air.

UNUSUALLY TIGHT CONSTRUCTION

In unconned spaces in buildings, inltration may be adequate to provide air for combustion, ventilation and dilution of ue gases. However, in buildings of unusually tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.) additional air must be provided using the methods described in the Conned Space section that follows.

CONFINED SPACE

A Conned Space is one whose volume IS LESS THAN 50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input rating of all appliances installed in the space.

Openings must be installed to provide fresh air for combustion, ventilation and dilution in conned spaces. The required size for the openings is dependent on the method used to provide fresh air to the conned space AND the total Btu/hr input rating of all appliances installed in the space.

DIRECT VENT APPLIANCES

Appliances installed in a Direct Vent conguration that derive all air for combustion from the outdoor atmosphere through sealed intake air piping are not factored in the total appliance input Btu/hr calculations used to determine the size of openings providing fresh air into conned spaces.

EXHAUST FANS

OUTDOOR AIR THROUGH TWO OPENINGS

Figure: 5

The conned space shall be provided with two permanent openings, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The openings shall communicate directly with the outdoors. See Figure 5.

Each opening shall have a minimum free area of 1 square inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure. Each opening shall not be less than 100 square inches (645 cm2).

Where exhaust fans are installed, additional air shall be provided to replace the exhausted air. When an exhaust fan is installed in the same space with a water heater, sufcient openings to provide fresh air must be provided that accommodate the requirements for all appliances in the room and the exhaust fan. Undersized openings will cause air to be drawn into the room through the water heater’s vent system causing poor combustion. Sooting, serious damage to the water heater and the risk of re or explosion may result. It can also create a risk of asphyxiation.

LOUVERS AND GRILLES

The free areas of the fresh air openings in the instructions that follow do not take in to account the presence of louvers, grilles or screens in the openings. The required size of openings for combustion, ventilation and dilution air shall be based on the net free area of each opening. Where the free area through a design of louver or grille or screen is known, it shall be used in calculating the size of opening required to provide the free area specied. Where the louver and grille design and free area are not known, it shall be assumed that wood louvers will have 25% free area and metal louvers and grilles will have 75% free area. Non motorized louvers and grilles shall be xed in the

open position.

OUTDOOR AIR THROUGH ONE OPENING

Figure: 6

Alternatively a single permanent opening, commencing within 12 inches (300 mm) of the top of the enclosure, shall be provided. See Figure 6. The water heater shall have clearances of at least 1 inch (25 mm) from the sides and back and 6 inches (150 mm) from the front of the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of the following:

1. 1 square inch per 3000 Btu/hr (733 mm2 per kW) of the total input rating of all appliances located in the enclosure, and

2. Not less than the sum of the areas of all vent connectors in the space.

OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS

AIR FROM OTHER INDOOR SPACES

Figure: 8

Figure: 7

The conned space shall be provided with two permanent horizontal ducts, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The horizontal ducts shall communicate directly with the outdoors. See Figure 7.

Each duct opening shall have a minimum free area of 1 square inch per 2,000 Btu/hr (1100 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure.

When ducts are used, they shall be of the same cross sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall be not less than 3 inches.

Each opening shall communicate directly with an additional room(s) of sufcient volume so that the combined volume of all spaces meets the criteria for an Unconned Space.

Each opening shall have a minimum free area of 1 square inch per 1,000 Btu/hr (2200 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure. Each opening shall not be less than 100 square inches (645 cm2).

INSTALLATION REQUIREMENTS

CHEMICAL VAPOR CORROSION

Corrosion of the ueways and vent system may occur if air for combustion contains certain chemical vapors. Such corrosion may result in failure and risk of asphyxiation.

Spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride (water softener salt), waxes, and process chemicals are typical compounds which are potentially corrosive.

Do not store products of this sort near the heater. Also, air which is brought in contact with the heater should not contain any of these chemicals. If necessary, uncontaminated air should be obtained from remote or outside sources. The limited warranty is voided when failure of water heater is due to a corrosive atmosphere. (See limited warranty for complete terms and conditions).

WATER PIPING

HOTTER WATER CAN SCALD: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, cleaning and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the physically or developmentally disabled. If anyone using hot water ts into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satises your hot water needs, a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater. Valves for reducing point of use temperature by mixing cold and hot water are also available:

This water heater shall not be connected to any heating systems or component(s) used with a non-potable water heating appliance.

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

Toxic chemicals, such as those used for boiler treatment shall not be introduced into this system.

When the system requires water for space heating at temperatures higher than required for domestic water purposes, a mixing valve must be installed.

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

POWER SUPPLY

The water heaters covered in this manual require a 120 VAC, 1Ø (single phase), 60Hz, 15 amp power supply and must also be electrically grounded in accordance with local codes or, in the absence of local codes, with the CSA C22.1, the Canadian Electrical Code.

POWER FLUCTUATIONS AND ELECTRICAL NOISE

The water heater’s control system requires a source of stable clean electricity for proper operation. Connecting the water heater to a branch circuit that is subject to fluctuations in voltage level or electrical line noise such as EMI (electro magnetic interference) or RFI (radio frequency interference) may cause erratic control system operation and malfunction.

A high quality power supply filter/suppressor must be installed if the above conditions exist. Call the technical support phone number listed on the back cover of this manual for more information.

NOTE: Malfunctions caused by the power supply and the costs to install power supply filters are not covered under the limited warranty.

DEDICATED POWER WIRING AND BREAKERS

Dedicated power supply wires, ground wiring and dedicated circuit breakers often prevent electrical line noise and should be considered when installing the water heater.

Consult a Qualied Installer or Service Agency. Follow manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the Temperature Regulation section in this manual.

MIXING VALVES

Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death.

Children, the elderly and the physically or mentally disabled are at highest risk for scald injury.

Feel water before bathing or showering.

Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at fixtures.

Water heated to a temperature which will satisfy clothes washing, dish washing, and other sanitizing needs can scald and cause permanent injury upon contact. Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the water heater’s temperature setting by up to 20°F (11°C).

Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the inrm and the physically/mentally disabled. Table 4 shows the approximate timeto-burn relationship for normal adult skin. If anyone using hot water provided by the water heater being installed ts into one of these groups or if there is a local code or state law requiring a certain water temperature at the point of use, then special precautions must be taken.

In addition to using the lowest possible temperature setting that satises the demand of the application a Mixing Valve should be installed at the water heater or at the hot water taps to further reduce system water temperature.

Mixing valves are available at plumbing supply stores. Consult a Qualied Installer or Service Agency. Follow mixing valve manufacturer’s instructions for installation of the valves.

In all cases, the following burn table must be used.

GAS PIPING

Make sure gas supplied is same type listed on model rating plate. The inlet gas pressure must not exceed 14 inch water column (3.5 kPa) for natural and propane gas (L.P.). The minimum inlet gas pressure shown on rating plate is that which will permit ring at rated input.

SEDIMENT TRAPS

A sediment trap shall be installed as close to the gas inlet of the water heater as practical at the time of water heater installation. The sediment trap shall be either a tee tting with a capped nipple in the bottom outlet or other device recognized as an effective sediment

trap.

Contaminants in the gas lines may cause improper operation of the gas control valve that may result in re or explosion. Before attaching the gas line be sure that all gas pipe is clean on the inside. To trap any dirt or foreign material in the gas supply line, a sediment trap must be incorporated in the piping. The sediment trap must be readily accessible. Install in accordance with the Gas Piping section. Refer to the current edition of the CAN/CSA-B149.1, the Natural Gas and Propane Installation Code.

Table 4

Water Temperature

°F (°C)

110 (43.3) (normal shower temp.)

116 (46.7) (pain threshold)

116 (46.7) 35 minutes 45 minutes

122 (50) 1 minute 5 minutes

131 (55) 5 seconds 25 seconds

140 (60) 2 seconds 5 seconds

149 (65) 1 second 2 seconds

154 (67.8) instantaneous 1 second

(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)

Time for 1st Degree Burn

(Less Severe Burns)

Time for Permanent

Burns

2nd & 3rd Degree

(Most Severe Burns)

Use pipe joint compound or teon tape marked as being resistant to the action of petroleum [Propane (L.P.)] gases.

The water heater and its gas connection must be leak tested before placing the water heater in operation.

The water heater and its individual Shut-off valve shall be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 pound per square inch (3.5 kPa). It shall be isolated from the gas supply piping system by closing its individual manual Shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 pound per square inch (3.5 kPa).

GAS SUPPLY SYSTEMS

Low pressure building gas supply systems are dened as those systems that cannot under any circumstances exceed 14” W.C. (1/2 PSI Gauge). These systems do not require pressure regulation. Measurements should be taken to insure that gas pressures are stable and fall within the requirements stated on the water heater rating plate. Readings should be taken with all gas burning equipment off (static pressure) and with all gas burning equipment running at maximum rate (dynamic pressure). The gas supply pressure must be stable within 1.5” W.C. from static to dynamic pressure to provide good performance. Pressure drops that exceed 1.5” W.C. may cause rough starting, noisy combustion or nuisance outages. Increases or spikes in static pressure during off cycles may cause failure to ignite or in severe cases damage to water heater gas control valves. If your low pressure system does NOT meet these requirements, the installer is responsible for the corrections.

High Pressure building supply systems use pressures that exceed 14” W.C. (1/2 PSI Gauge). These systems must use eld supplied regulators to lower the gas pressure to less than 14” W.C. (1/2 PSI Gauge). Appliances require gas regulators that are properly sized for the water heater input and deliver the rating plate specied pressures. Gas supply systems where pressure exceeds 5 PSI often require multiple regulators to achieve desired pressures. Systems in excess of 5 PSI building pressure should be designed by gas delivery professionals for best performance. Water heaters connected to gas supply systems that exceed 14” W.C. (1/2 PSI Gauge) at any time must be equipped with a gas supply regulator.

GAS PRESSURE REQUIREMENTS

All models require a minimum gas supply pressure of 3.5” W.C.(0.87 kPa) for natural gas and 8.0” W.C. (1.99 kPa) for propane. The minimum supply pressure is measured while gas is not owing (static pressure) AND while gas is owing (dynamic pressure). The supply pressure (static and dynamic) should never fall below 3.5” W.C.(0.87 kPa) for natural gas or 8.0” W.C. (1.99 kPa) for propane. The supply pressure should be measured with all gas red water heaters connected to the common main ring at full capacity. If the supply pressure drops more than 1.5” W.C. (0.37 kPa) as gas begins to ow to the water heater then the supply gas system including the gas line and/or the gas regulator may be restricted or undersized. See Supply Gas Regulator section and Gas Piping section of this manual. The gas control valve on all models has a maximum gas supply pressure limit of 14” W.C.(3.48 kPa) The maximum supply pressure is measured while gas is not owing (static pressure) AND while gas is owing (dynamic pressure).

SUPPLY GAS REGULATOR

The maximum allowable gas supply pressure for this water heater is 14 inches W.C. (3.5 kPa). Install a positive lock-up gas pressure regulator in the gas supply line if inlet gas pressure can exceed 14 inches W.C. (3.5 kPa) at any time. Regulators must be sized/used according to manufacturer’s specications.

If a positive lock-up regulator is required follow these instructions:

1. Positive lock-up gas pressure regulators must be rated at or above the input Btu/hr rating of the water heater they supply.

2. Positive lock-up gas pressure regulator(s) should be installed no closer than 3 feet (1 meter) and no farther than 8 feet (2.4 meters) from the water heater’s inlet gas connection.

3. After installing the positive lock-up gas pressure regulator(s) an initial nominal supply pressure setting of 7.0” W.C.(1.74 kPa) for Natural Gas and 11.0” W.C. (2.74 kPa) for Propane (LP) while the water heater is operating is recommended and will generally provide good water heater operation. Some additional adjustment may be required later to maintain a steady gas supply pressure.

4. When installing multiple water heaters in the same gas supply system it is recommended that individual positive lock-up gas pressure regulators be installed at each unit.

All gas piping must comply with local codes and ordinances or with the current edition of CAN/CSA-B149.1, the Natural Gas and Propane Installation Code. Copper or brass tubing and ttings (except tin lined copper tubing) shall not be used.

If the gas control valve is subjected to pressures exceeding 1/2 psi (3.5 kPa), the damage to the gas control valve could result in a re or explosion from leaking gas.

If the main gas line Shut-off serving all gas water heaters is used, also turn off the gas at each water heater. Leave all gas appliances shut off until the water heater installation is complete.

A gas line of sufcient size must be run to the water heater. Consult the current edition of CAN/CSA-B149.1, the Natural Gas and Propane Installation Code and your gas supplier concerning pipe size.

There must be:

• A readily accessible manual shut off valve in the gas supply line serving the water heater, and

• A sediment trap ahead of the gas control valve to help prevent dirt and foreign materials from entering the gas control valve.

• A ground joint union of proper size between the manual shut off valve and control valve to permit servicing of the unit.

Be sure to check all the gas piping for leaks before lighting the water heater. Use a soapy water solution, not a match or open ame. Rinse off soapy solution and wipe dry.

SPACE HEATING AND POTABLE WATER SYSTEM

Your water heater is equipped with inlet/outlet connections for use in space heating applications (see Figure 9). If this water heater is to be used to supply both space heating and potable (drinking) water, the instructions listed below must be followed:

• Be sure to follow the manual(s) shipped with the air handler or other type heating system.

• This water heater cannot be used in space heating applications only.

• This water heater is not to be used as a replacement for an existing boiler installation.

• Do not use with piping that has been treated with chromates, boiler seal or other chemicals and do not add any chemicals to the water heater piping

• If the space heating system requires water temperatures in excess of 120°F, a mixing valve must be installed per the manufacturer’s instructions in the potable hot water supply to limit the risk of scald injury.

• Pumps, valves, piping and ttings must be compatible with potable water.

• A properly installed ow control valve is required to prevent thermosiphoning. Thermosiphoning is the result of a continuous ow of water through the air handler circuit during the off cycle. Weeping (blow off) of the temperature and pressure relief valve (T & P relief valve) or higher than normal water temperatures are the rst signs of thermosiphoning.

• The hot water line from the water heater should be vertical past any mixing valve or supply line to the heating system to remove air bubbles from the system Do not connect the water heater to any system or components previously used with non-potable water heating appliances when used to supply potable water.

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

THERMAL EXPANSION

As water is heated, it expands (thermal expansion). In a closed system the volume of water will grow when it is heated. As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent temperature-pressure relief valve operation: water discharged from the valve due to excessive pressure build up. This condition is not covered under the limited warranty. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion. Contact a local plumbing service agency to have a thermal expansion tank installed.

NOTE: To protect against untimely corrosion of hot and cold water t t ing s, it is str o ngl y recomm end ed that di - elec t ric uni ons or couplings be installed on this water heater when connected to copper pipe, see Figure 10 also.

Figure: 9

CLOSED WATER SYSTEMS

Water supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure reducing valves, check valves, and back ow preventers. Devices such as these cause the water system to be a closed system.

Figure: 10

Figure 9 and Figure 10 show the typical attachment of the water piping to the water heater. The water heater is equipped with 3/4 inch NPT water connections for 50 gallon unit and 1 inch NPT water connections for 75 gallon unit.. NOTE: If using copp e r tu bing, sol d e r tubing to an ada p ter befo r e attaching the adapter to the water heater connections. Do not solder the water lines directly to the water heater connections. It will harm the dip tube and damage the tank, T & P Valve and Pipe Insulation (if supplied) Fit pipe insulation over the incoming cold water line and the hot water line. Make sure that the insulation is against the top cover of the heater.Fit T & P valve insulation over valve. Make sure that the insulation does not interfere with the lever of the T & P valve. Secure all insulation using tape.

CAUTION

TEMPERATURE-PRESSURE RELIEF VALVE

This water heater is provided with a properly rated/sized and certied combination Temperature-Pressure Relief Valve (T&P relief valve) by the manufacturer. The valve is certied by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA 4.4, and the code requirements of ASME. If replaced, the new T&P valve must meet the requirements of local codes, but not less than a combination TemperaturePressure Relief Valve rated/sized and certied as indicated in the above paragraph. The new valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (150 psi = 1,035 kPa) and a discharge capacity not less than the water heater Btu/hr or kW input rate as shown on the water heater’s model rating plate.

NOTE: In addition to the factory installed Temperature-Pressure Relief Valve on the water heater, each remote storage tank that may be installed and piped to a water heating appliance must also have its own properly sized, rated and approved Temperature-Pressure Relief Valve installed. Call the toll free technical support phone number listed on the back cover of this manual for technical assistance in sizing a TemperaturePressure Relief Valve for remote storage tanks.

Water Damage Hazard

Temperature-Pressure Relief Valve discharge

•

pipe must terminate at adequate drain.

T&P VALVE DISCHARGE PIPE REQUIREMENTS:

• Shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions.

• Shall not be plugged or blocked.

• Shall not be exposed to freezing temperatures.

• Shall be of material listed for hot water distribution.

• Shall be installed so as to allow complete drainage of both the Temperature-Pressure Relief Valve and the discharge pipe.

• Must terminate a maximum of six inches (15.2 cm) above a oor drain or external to the building. In cold climates, it is recommended that the discharge pipe be terminated at an adequate drain inside the building.

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

Burn hazard.

Hot water discharge.

Explosion Hazard

Temperature-Pressure Relief Valve must comply with ANSI Z21.22CSA 4.4 and ASME code.

Properly sized temperaturepressure relief valve must be installed in opening provided.

Can result in overheating and excessive tank pressure.

Can cause serious injury or death.

For safe operation of the water heater, the TemperaturePressure Relief Valve must not be removed from its designated opening nor plugged. The Temperature-Pressure Relief Valve must be installed directly into the tting of the water heater designed for the relief valve. Install discharge piping so that any discharge will exit the pipe within 6 inches (15.2 cm) above an adequate oor drain, or external to the building. In cold climates it is recommended that it be terminated at an adequate drain inside the building. Be certain that no contact is made with any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstances. Excessive length, over 30 feet (9.14 m), or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve. No valve or other obstruction is to be placed between the Temperature-Pressure Relief Valve and the tank. Do not connect discharge piping directly to the drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the temperature-pressure relief valve must be allowed to discharge water in adequate quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water ow may cause property damage.

Keep clear of TemperaturePressure Relief Valve discharge outlet.

The Temperature-Pressure Relief Valve must be manually operated at least twice a year. Caution should be taken to ensure that (1) no one is in front of or around the outlet of the Temperature-Pressure Relief Valve discharge line, and (2) the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot. If after manually operating the valve, it fails to completely reset and continues to release water, immediately close the cold water inlet to the water heater, follow the draining instructions in this manual, and replace the Temperature-Pressure Relief Valve with a properly rated/sized new one.

NOTE: The purpose of a Temperature-Pressure Relief Valve is to prevent excessive temperatures and pressures in the storage tank. The T&P valve is not intended for the constant relief of thermal expansion. A properly sized thermal expansion tank must be installed on all closed systems to control thermal expansion, see Closed Water Systems and Thermal Expansion on Page 21.

If you do not understand these instructions or have any questions regarding the Temperature-Pressure Relief Valve call the toll free number listed on the back cover of this manual for technical assistance.

CONDENSATE PIPING

This water heater is a condensing 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 tee located at the bottom of the unit (see Figure 11). Condensate from this water heater is mildly acidic. Please note that some local codes require that condensate is treated by using a pH neutralizing lter prior to disposal.

Caution must be used to ensure that the drain is free and clear of debris and will not allow backow through the condensate hose. Consideration must be given to avoid freezing of the condensate lines which could result in excessive build up of condensate inside the water heater. freezing of the condensate condensate drain does not create a slippery condition which could lead to personal injury.

Condensation warning: this water heater is a condensing unit and re q u ires a dr a i n to be lo c a ted in clo s e pr oxim i t y to allo w co n densat e to dr ain sa f e ly. The con d e nsate dr ains fr o m unit at the ex h aust el bow located at bottom of unit. Note: it is important that the condensate hose not be elevated above the exhaust elbow, see Figure 11. Condensate build-up will block the exhaust outlet, which will cause improper operation.

Waterproof heat tape may be required to prevent

lines. Please ensure that the outlet of the

• Slope the condensate drain toward the inside oor drain or condensate pump.

• The condensate drain line and connection to the drain piping must comply with all local codes.

HIGH ALTITUDE INSTALLATIONS

This high efciency water heater is certied for use without modication for an altitude of 10,100 feet (3,078 m). Consult the factory for installation at altitudes over 10,100 feet (3,078 m).

Some gas utility companies derate their gas for altitude, making it unnecessary to install high altitude orices. Call the local gas or utility company to verify BTU content.

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

FILLING THE WATER HEATER

Exhaust

Elbow

Figure: 11

The condensate drain line must be routed to a suitable drain. If no oor drain is available or the drain is above the level of the condensate line, install a condensate pump that is resistant to the acidic condensate. These pumps are available from local distributors. If the pump is not resistant to acidic water, a condensate neutralizer must be used ahead of the pump. When installing the drain line, note the following:

• Plastic pipe or tubing must be used to connect the condensate drain to a suitable drain or condensate pump. Do not use copper tubing, iron, or steel pipe for the condensate drain line.

• Condensate drain lines should be installed in conditioned areas only. Drain lines installed in areas that are subject to freezing temperatures should be wrapped with a nationally recognized/ listed heat tape and/or approved insulation for freeze protection. Install per manufacturer’s instructions.

• Do not common drain with the temperature and pressure relief valve or the condensate line from an air conditioner evaporator coil.

Never use this water heater unless it is completely full of water. To prevent damage to the tank, the tank must be lled with water. Water must ow from the hot water faucet before turning ON gas to the water heater.

To ll the water heater with water:

1. Close the water heater drain valve by turning the handle to the right (clockwise). The drain valve is on the lower front of the water heater.

2. Open the cold water supply valve to the water heater. NOTE: The cold water supply valve must be left open when the water heater is in use.

3. To insure complete lling of the tank, allow air to exit by opening the nearest hot water faucet. Allow water to run until a constant ow is obtained. This will let air out of the water heater and the

piping.

4. Check all water piping and connections for leaks. Repair as needed.

VENTING INSTALLATION

VENT INSTALLATION CONSIDERATIONS

This water heater can be vented using room air for intake combustion air, or direct vented so that all intake air for combustion comes from the outside through a sealed pipe.

This water heater may be installed in 4 separate orientations depending on the requirements of the building and the water heater. The installer must decide which method is most appropriate for each installation. These orientations are:

1. Vertical Termination - vertical vent termination through unenclosed or enclosed areas with roof penetration, refer to Vertical Vent Terminal Installation on Page 30.

2. Through-the-Wall Termination - horizontal vent termination directly through an outside wall, see “Figure 12: VENT TERMINATION” on Page 26.

3. Horizontal Direct Vent - using Through-the-Wall Termination to exhaust ue products and piping to bring combustion air to the water heater from the outside. See “Figure: 14” on Page 27.

4. Vertical Direct Vent - using a vertical vent termination to exhaust ue products and piping to bring combustion air to the water heater from outside, see “Figure: 20” & “Figure: 21”

on Page 31.

Installation of this water heater must comply with the current edition CAN/CSA B149.1 - Natural Gas and Propane Installation Code which requires the vent system components be certied to ULC

S636.

This water heater has been design certied to be vented with PVC/CPVC pipe and Polypropylene pipe certied and marked as complying with ULC S636.

If the water heater is being installed as a replacement for an existing power vented heater in pre-existing venting, a thorough inspection of existing venting system must be performed prior to any installation work. Verify that correct material as detailed above has been used, and that the minimum or maximum vent lengths and terminal location as detailed in this manual have been met. Carefully inspect the entire venting system for any signs of cracks or fractures, particularly at joints between elbows and other ttings and straight runs of vent pipe. Check system for signs of sagging or other stresses in joints as a result of misalignment of any components in the system. If any of these conditions are found, they must be corrected in accordance with the venting instructions in this manual before completing installation and putting the water heater into service.

NOTE: For water heaters in locations with high ambient temperatures above 100°F (38°C) it is recommended that CPVC or Polypropylene pipe and ttings be used. All vent (exhaust) pipes must be pitched a minimum of a 1/4” per foot back to the water heater to allow drainage of condensation.

Never operate the water heater unless it is vented to the outdoors.

The instructions in this section of the manual must be followed to avoid choked combustion or recirculation of ue gases. Such conditions cause sooting of the combustion chamber, burners and ue tubes and creates a risk of asphyxiation.

For direct vent application where combustion air might be supplied from extremely cold ambient through fresh air intake piping system, it is recommended that a backow preventer be installed at the intake vent terminal close to the blower before proceeding with installation of the rest of the fresh air intake piping. Call the technical support phone number listed on the back cover of this manual for more information.

In cold climates any water vapor remaining in the ue gases will condense into a cloud of vapor at the point where the vent system exits the building. Special consideration is recommended, before locating the vent termination near walkways, windows and building entrances.

Direct venting into dead spaces such as alleys, atriums, and inside corners can cause recirculation of ue gases. Recirculation of ue gases will cause sooting, and icing of the combustion air intake during severe cold weather. To prevent the recirculation of ue gases, maintain as much distance as possible between the combustion air intake and the exhaust vent terminal refer to “Figure: 15” and “Figure: 16” on Page 28 & Page 29 respectively.

POLYPROPYLENE INSTALLATIONS

The water heater has been approved to be installed with Polypropylene vent material as shown in Table 5 and Table 6. The approved application of single wall, non-exible, non-concentric Polypropylene vent material is offered by two specic manufacturers (Centrotherm ECO Systems and DuraVent Polypropylene. These listed products must be installed by following the vent manufacturer’s instructions. Refer to “Table 7” on Page 26 to determine the maximum pipe length and number of elbows that can be used.

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

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

Table 5

M & G Duravent PolyPro

Nominal Pipe

Diameter

2” 2PPS-AD PPS-PAC 2PPS-LB 2PPS-E90 2PPS

Flue Outlet Adapter

Adapter

Connector

Ring

Connector

90 Degree

Elbow

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

In order to be in full compliance with ULC-S636 and to meet the requirements of the water heater manufacturer, you must use the metal joint connector rings, available from the Polypropylene vent manufacturer, to stiffen the joints of 2”, and 3” diameter pipes.

Vent Material Terminal(s)

2PPS & 2PPS-BG for Exhaust;

2PPS-E90 & 2PPS-BG for Intake (Direct Vent

only)

3” 3PPS-AD PPS-PAC 3PPS-LB 3PPS-E90 3PPS

Table 6

Centrotherm InnoFlue SW

Nominal Pipe

Diameter

2”

3”

Flue Outlet Adapter

ISAGL

0202

ISAGL

0303

Adapter

Connector

IAFC02 IANS02 ISELL0287 ISVL02

IAFC03 IANS03 ISELL0387 ISVL03

Ring

Connector

90 Degree

Elbow

3PPS & 3PPS-BG for Exhaust;

3PPS-E90 & 3PPS-BG for Intake (Direct Vent

only)

Vent Material Terminal(s)

ISVL02 & IASPP02 for Exhaust;

ISELL0287 & IASPP02 for Intake (Direct Vent

only)

ISVL03 & IASPP03 for Exhaust;

ISELL0387 & IASPP03 for Intake (Direct Vent

only)

VENT PIPE TERMINATION

The rst step is to determine where the vent pipe will terminate. See Figures 12, “Figure: 13A”, and “Figure: 14”. The vent may terminate thr o u gh a side w all as sh own in Fi gure 12 and “Figu r e: 14” or th r ough the roof as shown in “Figure: 15” and “Figure: 16”.

The vent system must terminate so that proper clearances are maintained as cited in local codes or the current edition of the Natural Gas and Propane Installation Code (CAN/CSA-B149.1). See “Figure: 15” and “Figure: 16”.

Instructions on proper installation through a sidewall are provided in Figures 12, “Figure: 13A”, and “Figure: 14”.

Plan the vent system layout so that proper clearances are maintained from plumbing and wiring.

Vent pipes serving power vented water heaters are classied by building codes as vent connectors. Required clearances from combustible materials must be provided in accordance with information in this manual under FACTS TO CONSIDER ABOUT LOCATION and INSTALLING THE WATER HEATER, and with the National Fuel Gas Code and local codes.

PLANNING THE VENT SYSTEM

Plan the route of the vent system from the exhaust elbow to the planned location of the vent terminal.

1. Layout total vent system to use a minimum of vent pipe and

elbows.

2. This water heater is capable of venting ue gases in equivalent

feet of pipe as listed in Table 7.

Table 7

Number of

90° Elbows

1 40 (12.19) 120 (36.57) 2 35 (10.66) 115 (35.05) 3 30 (9.14) 110 (33.52) 4 25 (7.62) 105 (32)

5 20 (6.09) 100 (30.48) 6 15 (4.57) 95 (28.95)

The minimum vent length for each of the pipe size is one 90° elbow plus 2’ and 7’ (0.61 m and 2.1 m) of straight pipe for air intake and exhaust vent respectively and the appropriate termination.

NOTE: Th e equiva l e nt fe e t (m) of pip e li sted ab ove ar e excl u s ive

of the termination. That is, the termination, with an installed screen, is assumed to be in the system and the remainder of the system must not exceed the lengths and number of elbows shown in Table 7.

If using 2” inch vent pipe: A 2” diameter vent pipe must be

inserted and glued to the exhaust elbow assembly.

If using 3” inch vent pipe: Two inches (5.1cm) of 2” diameter pipe

must be inserted and glued to the exhaust elbow assembly before adding a 2’ x 3” reducer to acquire the desired pipe diameter. A 3” coupling (supplied locally-a schedule 40 DWV) vent terminal must be obtained. A 3” diameter screen is supplied in the vent

kit.

2” Maximum

Pipe - ft. (m)

3” Maximum

Pipe - ft. (m)

INSTALLATION OF HORIZONTAL THROUGH THE WALL VENT SYSTEM

If yo u are inst a l ling yo u r syst e m so that it vent s th r ough ro o f, plea s e re f e r to se c t i on titl e d VERTIC A L VE NT TERMI N A L IN S TA L L AT I O N .

VENT TERMINAL INSTALLATION, SIDEWALL

1. I n stall th e vent te r m i nal by us ing the co ver pla t e as a tem p l ate to mark the hole for the vent pipe to pass through the wall. BEWARE

OF CONCEALED WIRING AND PIPING INSIDE THE WALL.

2. If the Vent Terminal is being installed on the outside of a nished wall, it may be easier to mark both the inside and outside wall. Align the holes by drilling a hole through the center of the template from the inside through to the outside. The template can now be positioned on the outside wall using the drilled hole as a centering point for the template.

3. A) MASONRY SIDE WALLS

Chisel an opening approximately one half inch (1.3 cm) larger

than the marked circle.

B) WOODEN SIDE WALLS

Drill a pi lot ho l e approx i mate l y one quar te r inch (0. 6 4 cm) ou t side

of the marked circle. This pilot hole is used as a starting point for a saws-all or sabre saw blade. Cut around the marked circle staying approximately one quarter inch (0.64 cm) outside of the line. (This will allow the vent to easily slide through the opening. The resulting gap will be covered up by the Vent Terminal cover plate.) Repeat this step on inside wall if necessary.

Cut a length of pipe about 3.5 inches (8.9 cm) longer than the wall thi c k n ess at th e open i n g. Glue th e ven t termi n a l to th i s sectio n of pipe . Slide the wall plate over the pipe to stop against the vent terminal. Place a bead of caulking (not supplied) around the gap between the pipe and cover plate. Apply enough to ll some of the gap between the pipe and wall. Place some of the caulking on the back of the plate to hold it against the wall after installation. If the vent pipe is installed up to the wall, with a coupling on the end against the wall opening, the pipe with the vent terminal can be prepared for gluing before inserting through the wall. Slide the pipe through the wall and insert into the coupling on the other side of the wall, making sure that the vent terminal ends up pointed in the correct position, see Figure 12.

Figure 12: VENT TERMINATION

DIRECT VENT TERMINAL INSTALLATION

The air intake provided on the unit contains an air intake screen to prevent large particles from entering the unit.

Blower Air Inlet Assembly

Air Intake Screen

Figure 13: AIR INTAKE SCREEN

When the unit is to be setup as a direct vent, the air intake screen must be removed. The air intake pipe may then be glued to the air intake (see Figure 13) provided on the unit.

This unit consists of two terminals - an air intake terminal and an exhaust vent terminal. The air intake terminal is a 2” 90° pvc elbow with an air intake screen and the exhaust vent terminal is a 2” straight pvc coupling with a mesh wire screen.

B.) WOODEN SIDE WALLS Drill a pilot hole approximately one quarter inch outside of the marked circle. This pilot hole is used as a starting point for a saws-all or sabre saw blade. Cut around the marked circle staying approximately one quarter inch outside of the line. (This will allow the vent pipe to easily slide through the opening. The resulting gap will be covered by the vent terminal cover plates.) Repeat this step on the inside wall if necessary.

2. Cut a length of pipe about 3.5” (8.9 cm) longer than the wall thickness at the opening.

3. Glue the air intake terminal to the section of the pipe.

4. Slide the wall plate over pipe to stop against air intake terminal.

5. Place a bead of caulking (not supplied) around the gap between the pipe and the wall. Place some of the caulking on the back of the plate to hold it against the wall after installation.

6. If the air intake pipe is installed up to the wall, with a coupling on the end against the wall opening, the pipe with the air intake terminal can be prepared for gluing before inserting through the wall. Slide the pipe through the wall and insert into coupling on the other side of the wall, making sure that the air intake terminal ends up pointed in the correct position (Figure 13A and Figure 14).

Note: to prevent exhausting products from circulating to the air intake in windy/cold areas, the maximum practical distance between these two terminals is recommended.

Figure: 13A

INSTALLATION SEQUENCE

1. After the points of termination have been determined, use the cover plates as templates to mark the holes for the vent pipes to be inserted through the wall. BEWARE OF

CONCEALED WIRING AND PIPING INSIDE OF WALL. If the

vent terminals are being installed on the outside of a nished wall, it may be easier to mark both the inside and outside wall. Align the holesby drilling a hole through the center of the template from the inside through to the outside. The template can now be positioned on the outside wall using the drilled holes as a centering point for the template.

A.) MASONRY SIDE WALLS Chisel an opening approximately

1/2” (1.3 cm) larger than the marked circle.

Figure: 14

TERMINATION CLEARANCES SIDEWALL POWER VENT

POWER VENT

EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION

(using room air for combustion)

FIX ED

CLOSED

OPERABLE

FIX ED

CLOSED

VENT TERMINAL AIR SUPPLY INLETAREA WHERE TERMINAL IS NOT PERMITTED

V X

Figure: 15

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

Clearance above grade, veranda, porch, deck or

balcony

Clearance to window or door that may be

opened

CANADIAN INSTALLATIONS

12 inches (30 cm)

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

Clearance to each side of center line extended

above meter/regulator assembly

Clearance to service regulator vent outlet

CANADIAN INSTALLATIONS

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

3 feet (91 cm)

Clearance to permanently closed

window

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

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

Clearance to

unventilated soft

Clearance to outside

corner

Clearance to inside

corner

12 inches (30 cm)*

2 feet (60 cm)*

18 inches (45 cm)*

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

† A vent shall not terminate where it may cause hazardous frost or ice accumulations on adjacent property surfaces.

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

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

Clearance to a non mechanical air supply inlet into building or

combustion air inlet to any other appliance

Clearance to a mechanical air supply

inlet

Clearance above paved sidewalk or paved

driveway located on public property

Clearance under veranda, porch, deck, or

balcony

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

6 feet (1.83 m)

7 feet (2.13 m)†

12 inches (30 cm) ‡

TERMINATION CLEARANCES SIDEWALL DIRECT VENT

(using outdoor air for combustion)

FIX ED

CLOSED

OPERABLE

FIX ED

CLOSED

VENT TERMINAL AIR SUPPLY INLETAREA WHERE TERMINAL IS NOT PERMITTED

V X

EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION

Figure: 16

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

DIRECT VENT

CANADIAN INSTALLATIONS

Clearance above grade, veranda, porch, deck or

balcony

Clearance to window or

door that may be opened

Clearance to permanently closed

window

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

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

Clearance to unventilated

soft

Clearance to outside

corner

Clearance to inside

corner

12 inches (30 cm)

6 inches (15 cm)*

12 inches (30 cm)*

2 feet (60 cm)*

18 inches (45 cm)*

Clearance to each side of center line extended

above meter/regulator assembly

Clearance to service

regulator vent outlet

Clearance to a non mechanical air supply inlet into building or

combustion air inlet to any other appliance

Clearance to a mechanical air supply

inlet

Clearance above paved sidewalk or

paved driveway located on public property

Clearance under veranda, porch, deck,

or balcony

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

3 feet (91 cm)

6 feet (1.83 m)

7 feet (2.13 m)†

12 inches (30 cm) ‡

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

† A vent shall not terminate where it may cause hazardous frost or ice accumulations on adjacent property surfaces.

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

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

VERTICAL VENT TERMINAL INSTALLATION

WHEN TERMINATING THROUGH A ROOF, THE FOLLOWING SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE FOLLOWED.

1. Proper support must be provided for all pipe protruding through

the roof.

2. The vertical roof terminations should be sealed with a plumbing roof boot or equivalent ashing.

3. The air intake termination and the exhaust vent termination must penetrate the same side of roof.

4. The center line of the air intake termination and the center line of the exhaust vent termination must be no closer than 24” (61cm). See Figure 17 and Figure 18.

FLAT ROOF INSTALLATION

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

See Figure 19.

Figure: 19

Figure: 17

Figure: 18

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Enviro 6G75100, 6G50100, NPDVH02, NPDVH05, PPDVH02 Instruction Manual

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Frequently Asked Questions

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