Raypak NH-188XL Installation Manual

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Page 1

CERTIFIED

INSTALLATION & OPERATING

INSTRUCTIONS

Commercial

Tankless

Water Heater

NH-188DVL & XL NH-208DVL & XL

WARNING: If the information in these instructions is not followed exactly, a re or explosion may result, causing death, personal injury, or property damage.

Do not store or use gasoline or other ammable vapors and liquids in the vicinity of this or any other appliance. To do so may result in an explosion or re.

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.

• Do not return to your home until authorized by the gas supplier or fire department.

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

This manual should be maintained in legible condition and kept adjacent to the water heater or in a safe place for future reference.

Catalog No. 3000.57

Effective: 08-01-12

AP16565 (07/12)

Page 2

CONTENTS

Important Safety Information

Safety Precautions .................................................. 2–8

Product Information

Product Information .................................................... 8

Specifications ........................................................ 9, 10

Safety

General Descriptions ............................................11, 12

Using Your Water Heater

Setting the Water Temperature ............................ 13, 14

Caring for Your Water Heater

Water Heater Inspections .................................... 15, 16

Care and Cleaning ................................................17, 18

Preventive Maintenance ............................................ 19

Draining the Water Heater .....................................20–22

Freeze Protection ...................................................... 22

Vacation and Extended Shutdown ........................... 23

Troubleshooting Chart ......................................... 23, 24

Service Error Code Chart .................................... 25, 26

If You Need Service

Call for Assistance .................................................... 26

Installation Instructions

Standards Compliance ...............................................28

Choosing a Location ............................................ 28, 29

Product Inspection .................................................... 30

Water Heater Installation ...................................... 30–33

Venting ..................................................................34–45

Water Supply ........................................................ 46–50

Gas Supply ........................................................... 50–54

Electrical Wiring .................................................... 54–58

Remote Control Installation .................................. 57, 58

Insulation Blankets .....................................................59

Installation Precautions .............................................. 59

Installation Checklist ..................................................60

Piping for Space Heaters ........................................... 61

Lighting the Water Heater ....................................62, 63

Setting the Water Temperature .............................64–66

High-Altitude Dip Switch Adjustments.................66, 67

Parts Replacement

Warranty Information.............................................70-71

IMPORTANT SAFETY INFORMATION

...........................................68, 69

READ THE SAFETY INFORMATION

Your safety and the safety of others are very important. There are many important safety messages in this manual and on your appliance. Always read and obey all safety messages.

This is the safety alert symbol. Recognize this symbol as an indication of Important Safety Information! This symbol alerts you to potential hazards

that can kill or hurt you and others.

All safety messages will follow the safety alert symbol and either the word “DANGER,” “WARNING,” “CAUTION,” or “NOTICE.”

These words mean:

DANGER: An imminently hazardous

situation that will result in death or serious injury.

WARNING: A potentially hazardous

situation that can result in death or serious injury and/or damage to property.

CAUTION: A potentially hazardous

situation that may result in minor or moderate injury.

NOTICE: Attention is called to observe a

specified procedure or maintain a specific condition.

WARNINGS:

• This water heater is not suitable for use in manufactured (mobile) homes!

• Improper installation, adjustment, alteration, service, or maintenance can cause death, personal injury, or property damage. Follow the instructions in this manual.

READ ALL INSTRUCTIONS BEFORE USING.

Be sure to read and understand the entire Use and Care Manual before attempting to install or operate this water heater. It may save you time and money. Pay particular attention to the Safety Instructions. Failure to follow these warnings could result in death or serious bodily injury. Should you have problems understanding the instructions in this manual, or have any questions, STOP and get help from a qualified service technician or the local gas utility.

WARNING:

California Proposition 65

This product contains chemicals known to the state of California to cause cancer, birth defects, or other reproductive harm.

Page 3

IMPORTANT SAFETY INFORMATION

Water Heater Venting Safety

DANGER: Failure to install and properly

vent the water heater to the outdoors as outlined in the “Venting” section of the Installation Instructions in this manual will result in death from fire, explosion, or asphyxiation from carbon monoxide. NEVER operate this water heater unless it is properly vented and has an adequate air supply for proper operation.

Be sure to inspect the vent terminal, the air intake, and the coaxial vent system on the water heater for proper installation at initial start-up and at least annually thereafter. Refer to the “Care and Cleaning” section of this manual for more information regarding coaxial vent system inspection.

WARNINGS:

• Gasoline and other flammable liquids, materials, and vapors (including paint thinners, solvents, and adhesives) are extremely dangerous. DO NOT handle, use, or store gasoline or other flammable or combustible materials anywhere in the vicinity of a water heater or any other appliance. Be sure to read and follow the labels on the water heater, as well as the warnings printed in this manual. Failure to do so can result in death, bodily injury, or property damage.

• Combustible construction refers to adjacent walls and ceilings and should not be confused with combustible or flammable products and materials. Combustible materials, such as clothing, cleaning materials, or flammable liquids, should never be stored in the vicinity of this or any gas appliance. Fire or explosion can occur causing death, personal injury, and/or product damage. See page 29 for clearances to combustible materials.

• Follow vent manufacturer’s instructions for venting installation, including additional clearances from combustibles, to avoid conditions that can lead to death, personal injury, and/or property damage.

• Use tankless water heater manufacturer-approved Category III Stainless Steel vent material only. No other vent material is permitted.

• Moisture in the flue gas will condense as it leaves the vent terminal. In cold weather this condensate can freeze on the exterior wall, under the eaves, and on surrounding objects. Some discoloration to the exterior of the building is to be expected. However, improper location or installation can result in severe damage to the structure or exterior finish of the building.

DANGER

FLAMMABLES

Vapors from flammable liquids will explode and catch fire causing death or severe burns.

Do not use or store flammable products such as gasoline, solvents or adhesives in the same room or area near the water heater.

Keep flammable products:

1. far away from heater,

2. in approved containers,

3. tightly closed and

4. out of children's reach.

Installation: Do not install water heater where flammable products will be stored or used unless the main burner flame is at least

Read and follow water heater warnings and instructions. If owners manual is missing, contact the retailer or manufacturer.

• For multiple-unit installation, a minimum distance between vent terminations must be maintained to prevent recirculation of vent gases. Maintain a center-to-center distance between vent terminations of 19 in. (48 cm) for two-unit installation. Maintain a center-to-center distance between vent terminations of 21 in. (53 cm) for installation of three or more units.

Flammable Vapors

Water heater has a main burner flame. The main burner flame:

1. which can come on at any time and

2. will ignite flammable vapors.

Vapors:

1. cannot be seen,

2. are heavier than air,

3. go a long way on the floor and

4. can be carried from other rooms to the main burner flame by air currents.

18" above the floor. This will reduce, but not eliminate, the risk of vapors being ignited by the main burner flame.

CAUTIONS:

• Ensure that the appliance vent is securely attached to the water heater collar.

• Condensate must drain away from the water heater and should not be allowed to drain back into any part of the vent system.

• Do not operate without the condensate trap connected to the vent and routed to the proper drain.

• Follow the vent manufacturer’s installation instructions because the design might vary from manufacturer to manufacturer.

Safety

Page 4

IMPORTANT SAFETY INFORMATION

Water Supply Safety

DANGERS:

• WATER TEMPERATURE

Safety

SETTINGS – Safety and energy

conservation are factors to be considered when selecting the water temperature setting of a water heater’s remote control. Water temperatures above 125°F (52°C) can cause death or severe burns from scalding. Be sure to read and follow the warnings outlined on the pictured label.

• There is a hot water scald potential if the water temperature is set too high. Households with small children, the disabled, or elderly persons may require a 120°F (49°C) or lower temperature setting to prevent contact with “HOT” water.

• Before manually operating the relief valve, make certain no one will be exposed to the danger of the hot water released by the valve. The water may be hot enough to create a scald hazard. The water should be released into a suitable drain to prevent injury or property damage.

• Failure to perform the recom-

mended Routine Preventive Maintenance can harm

•

the proper operation of this water heater, which can cause carbon monoxide dangers, excessive hot water temperatures, and other potentially hazardous conditions.

WARNINGS:

• IMPORTANT: Do not apply heat to the HOT or COLD water connections. If sweat connections are used, sweat tubing to adapter before fitting adapter to the water connections on heater. Any heat applied to the water supply fittings will permanently damage the internal components of the water heater.

• In case the pipe insulation is not rated for the appropriate weather conditions, install electric heat tracing or equivalent to prevent freezing of the pipes. Do not insulate or block the drain valve on the hot outlet fitting. If the pipes are allowed to freeze, the water heater and the pipes may malfunction or leak due to freezing water.

• Failure to drain the water heater as described on page 20 can cause serious personal injuries from scalding and/or damage the water heater.

DANGER

HOT

BURN

Water temperature over 125°F (52°C) can cause severe burns instantly or death from scalds.

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

See instruction manual before setting temperature at water heater.

Feel water before bathing or showering.

Temperature limiting valves are available, see manual.

Time/Temperature Relationship in Scalds

Water Time to Produce Temperature a Serious Burn

120°F (49°C) More than 5 minutes 125°F (52°C) 1 1/2 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 1 1/2 seconds 155°F (68°C) About 1 second

Table courtesy of Shriners Burn Institute

Temperature Conversion Chart °F/°C

85 100 102 104 106 108 110 112 °F

29 38 39 40 41 42 43 44 °C

114 116 118 120 125 130 140 °F

46 47 48 49 52 54 60 °C

CAUTIONS:

• This water heater must only be used with the following water supply system conditions:

– With clean, potable water free of

corrosive chemicals, sand, dirt, or other contaminants.

– With inlet water temperatures

above 32°F (0°C), but not exceeding 120°F (49°C).

– DO NOT reverse the hot and

cold water connections. The water heater will not operate.

• Even when drained properly, a small amount of water will remain in the water heater. In cold weather conditions, this water can freeze. If this happens, allow the defrost protection on the heater at least 30 minutes to melt the frozen water or the water heater may not work properly.

Page 5

IMPORTANT SAFETY INFORMATION

Natural Gas and Liqueed Petroleum Safety

DANGERS:

• Never attempt to convert the water heater from natural gas to LP. The water heater should only use the fuel type in accordance with listing on data plate—natural gas for natural gas units and LP for LP units. Any other fuel usage will result in death or serious personal injury from fire and/or explosion. This water heater is not certified for any other fuel type.

• Both natural gas and propane (LP) have an odorant added to aid in detecting a gas leak. Some people may not physically be able to smell or recognize this odorant. If you are unsure or unfamiliar with the smell of natural gas or LP, ask the gas supplier. Other conditions, such as “odorant fade,” which causes the odorant to diminish in intensity, can also hide or camouflage a gas leak.

• Water heaters using LP gas are different from natural gas models. A natural gas water heater will not function safely on LP and vice versa.

• LP water heaters should not be installed below grade (for example, in a basement) if such installation is prohibited by federal, state, and/or local laws, rules, regulations, or customs.

• LP must be used with great caution. It is heavier than air and will collect first in lower areas, making it hard to detect at nose level.

• Before attempting to light the water heater, make sure to look and smell for gas leaks. Use a soapy solution to check all gas fittings and connections. Bubbling at a connection indicates a leak that must be corrected. When smelling to detect a gas leak, be sure to also sniff near the floor.

• Gas detectors are recommended in LP and natural gas applications and their installation should be in accordance with the detector manufacturer’s recommendations and/or local laws, rules, regulations, or customs.

• Combustible materials, such as clothing, cleaning materials, or flammable liquids, must not be placed in the vicinity of the water heater.

• If a gas leak is present or suspected:

– Do not attempt to find the cause yourself. – Never use an open flame to test for gas leaks. The

gas can ignite resulting in death, personal injury, or property damage.

– Follow the steps listed under “What to Do If

You Smell Gas” found on the front cover of this manual.

WARNINGS:

• The installation of gas piping must conform to local

utility company requirements and/or in the absence of local codes, use the latest edition of National Fuel Gas Code (NFGC), ANSI Z223.1/NFPA 54, or CAN/ CSA B149.1, Natural Gas and Propane Installation Code.

• Install a gas pressure regulator in the gas supply line. The regulator should not exceed the maximum supply pressure. DO NOT use an industrial-type gas regulator.

• Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the water heater.

CAUTIONS:

• Do not attempt repair of electrical wiring, gas piping, remote control, burners, vent connectors, or other safety devices. Refer repairs to qualified service personnel.

• Turn off the manual gas shut-off valve if the water heater has been subjected to overheating, fire, flood, physical damage, or if the gas supply fails to shut off.

• Do not turn on the water heater unless the water and gas supplies are completely opened.

NOTICE:

• The factory setting allows operating temperatures between 100°F (38°C) and 120°F (49°C). Temperatures of 85°F (29°C) and up to 185°F (85°C) can be achieved with the MAIN (UMC-117) remote control. Temperatures of 85°F (29°C) can be achieved with the Bath (USC-117 or USC2-117) remote control. Only qualified service personnel should perform this adjustment. Only factoryauthorized remote control(s) should be used.

Safety

Page 6

IMPORTANT SAFETY INFORMATION

Before operating this water heater, be sure to read and follow the instructions on the label pictured below and all other labels on the water heater, as well as the warnings printed in this manual. Failure to do so can result in unsafe operation of the water heater, resulting in death, personal injury, or property

Safety

damage. Should you have any problems reading or following the instructions in this manual, STOP and get help from a qualified service technician.

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING

causing property damage, personal injury or loss of life.

: If you do not follow these instructions exactly, a fire or explosion may result

OPERATING INSTRUCTIONS

1.STOP! Read the safety information above on this label.

2.Turn off all electric power to the appliance.

3.Do not attempt to light the burner by hand.

4.Turn the Gas Shutoff Valve located on the outside of the unit clockwise to the "OFF" position.

5.Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow "B" in the safety information above on this label. If you don't smell gas, go to the next step.

6.Turn the Gas Shutoff Valve located on the outside of the unit counterclockwise to the "ON" position.

7.Turn on all electric power to the appliance.

8.If the appliance will not operate, follow the instructions "To Turn Off Gas To Appliance" and call your service technician or gas supplier.

GAS SHUTOFF

VALVE

OPEN CLOSE

TO TURN OFF GAS TO APPLIANCE

1.Turn off all electric power to the appliance if service is to be performed.

2.Turn the Gas Shutoff Valve located on the outside of the unit clockwise to the "OFF" position.

Page 7

Electrical Safety

IMPORTANT SAFETY INFORMATION

DANGER: Shock Hazard – Make sure

the electrical power to the water heater is off to avoid electric shock that will result in death or serious personal injury.

WARNINGS:

• For your safety, the information in this manual must be followed to minimize the risk of fire, explosion, or electric shock that can result in death, personal injury, and/or property damage.

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

CAUTIONS:

• Label all wires prior to disconnecting for service. Wiring errors can cause dangerous and improper operation. Verify correct operation after servicing.

• For your safety, burner inspection and cleaning should be performed only by qualified service personnel.

• Make certain the power to the water heater is OFF before removing the unit cover panel. Exposed electrical components and moving parts can cause personal injuries.

• For your safety, DO NOT attempt repair of electrical wiring, gas piping, remote control, burners, vent connectors, or other safety devices. Refer repairs to qualified service personnel.

FOR INSTALLATIONS IN THE STATE OF CALIFORNIA

California law requires that water heaters must be braced, anchored, or strapped to resist falling or horizontal displacement due to earthquake motions. For water heaters up to 52-gallon capacity, a brochure with generic earthquake bracing instructions can be obtained from: Office of the State Architect, 1102 Q Street, Suite 5100, Sacramento, CA 95814, or you may call 916-445-8100 or ask a water heater dealer.

However, applicable local codes shall govern installation. For residential water heaters of a capacity greater than 52 gallons or tankless-style, consult the local building jurisdiction code for acceptable bracing procedures.

Safety

Page 8

IMPORTANT SAFETY INFORMATION

General Installation and Maintenance Safety

WARNINGS:

• This water heater must be installed in accordance

SafetyProduct Information

with these instructions, local codes, utility company requirements and/or in the absence of local codes, use the latest edition of the American National Standard/National Fuel Gas Code (NFGC), ANSI Z223.1 and National Fire Protection Association, NFPA 54, or in Canada, CAN/CSA B149.1, Natural Gas and Propane Installation Code, and the latest edition of the National Electrical Code, ANSI/NFPA 70, or in Canada, Canadian Electrical Code, CAN/CSA C22.1, Part 1.

• If local codes require the application of external insulation blanket kits, carefully follow the manufacturer’s installation instructions included with the kit. Only use blanket kits that are approved for use with your water heater.

• For your safety, DO NOT attempt to disassemble this water heater for any reason. Improper adjustments, alterations, service, or maintenance can cause death, personal injury, or property damage.

SAFETY PRECAUTIONS:

• Read this manual entirely before installing and/or operating the water heater.

• Use this water heater only for its intended purpose as described in this Use and Care Manual.

• Have the installer show you the location of the gas shut-off valve and how to shut it off if necessary. Turn off the manual shut-off valve if the water heater has been subjected to overheating, fire, flood, physical damage, or if the gas supply fails to shut off.

• Be sure your water heater is properly installed in accordance with local codes and the provided installation instructions.

• Do not attempt to repair or replace any part of your water heater unless it is specifically recommended in this manual. All other servicing should be referred to a qualified service technician.

SAVE THESE

INSTRUCTIONS

PRODUCT INFORMATION

For Your Records

Write down and save the following product information along with the original sales slip and/or cancelled check. The model and serial numbers can be found on the top label on the right side of the water heater.

MODEL NUMBER:

SERIAL NUMBER:

DATE OF INSTALLATION:

INSTALLING COMPANY/PHONE NUMBER:

PLUMBING CONTRACTOR/PHONE NUMBER:

Read This Manual

Inside you will find many helpful hints on how to use and maintain your water heater properly. A little preventive care on your part can save you time and money over the life of your water heater.

You’ll find many answers to common problems in the Troubleshooting Chart on pages 23 and 24. Always refer to this chart before calling for service. Referring to this chart before calling may answer your question(s) and eliminate the need for service.

Preoperating Checklist

Is the main gas valve to the water heater turned on?

Is the fuse in place or is the breaker turned on?

Does the water heater’s electronic ignition light?

Is the water temperature set to a safe temperature?

Is the water heater connected to a floor drain?

Is the water heater properly vented to the outside?

Is the water heater installed in a safe location away from flammable materials and/or freezing conditions?

See page 26 for additional service information.

Page 9

1315/16"

(354 mm)

19/16"

(40 mm)

/4"

(45 mm)

/16"

(131 mm)

/8"

(143 mm)

55/8"

(143 mm)

/2"

(140 mm)

/16"

(106 mm)

/8"

(86 mm)

35/8"

(92 mm)

/2"

(343 mm)

/4"

(172 mm)

/2"

(241 mm)

Specications – Direct-Vent Models

1315/16"

(354 mm)

81/2"

(216 mm)

/16"

(40 mm)

/4"

(45 mm)

/8"

(143 mm)

55/8"

(143 mm)

/16"

(106 mm)

/8"

(73 mm)

/16"

(53 mm)

/4"

(58 mm)

/2"

(343 mm)

2913/16"

(757 mm)

/8"

(651 mm)

PRODUCT INFORMATION

/2"

(140 mm)

(131 mm)

19/16"

(40 mm)

(343 mm)

/16"

1315/16"

(354 mm)

/4"

(172 mm)

/4"

(45 mm)

/2"

(241 mm)

Product Information

Specications – Outdoor Models

2613/16"

(663 mm)

/8"

(86 mm)

/16"

(106 mm)

/4"

(603 mm)

/16"

(106 mm)

/16"

(40 mm)

(143 mm)

/8"

/2"

(343 mm)

1315/16"

(354 mm)

55/8"

(143 mm)

35/8"

(92 mm)

/4"

(45 mm)

81/2"

(216 mm)

(53 mm)

/8"

(73 mm)

/16"

(143 mm)

/8"

55/8"

(143 mm)

/4"

(58 mm)

Page 10

PRODUCT INFORMATION

Specications

The following product information can be found from the rating label on this water heater.

A. Model Number B. Serial Number C. Data Bar Code D. Heater Type E. Installation Type F. Type of Gas G. Max. Inlet Gas Pressure H. Min. Inlet Gas Pressure J. Recovery Rating K. Max. BTU Input Rating L. Min. BTU Input Rating M. Manifold Gas Pressure

Product Information

N. Certification Stamp P. Alternate Approval Stamp Q. Clearances

English Rating Label

English/French Rating Label

Page 11

General Descriptions

PRODUCT INFORMATION

Typical Direct-Vent Water Heater

(Venting Required)

Condensate

Collector

Remote Control

With Power Switch

Product Information

To Hot Water

Faucet(s)

Drain Valve

Power

Supply

Cord

Union

Relief

Valve

Service

Valve

Water

Filter

Cold Water Supply

Shut-Off Valve

To Drain: Dispose of condensate in accordance with local codes.

Manual Gas

Shut-Off Valve

Union

Sediment Trap (in accordance with the local gas authority)

Cap

Manual Gas Supply Line

Shut-Off Valve

Discharge Line

(To Suitable Drain)

(150 mm)

Air Gap

Page 12

PRODUCT INFORMATION

Typical Outdoor Water Heater

(No Venting Required)

This water heater is for OUTDOOR installation only.

DANGER: DO NOT install this water heater indoors or in a confined area. It is designed for

outdoor installation only. Any other type of installation will result in death or serious personal injury.

Product Information

Flue

Terminal

Remote Control

With Power Switch

To Hot Water

Faucet(s)

Drain Valve

Hard-Wire

Power Supply

(not supplied)

Cord

Union

Relief

Valve

Relief

Valve

Service

Valve

Air Inlet

Cold Water Supply

Water Filter

Shut-Off Valve

Manual Gas

Shut-Off Valve

Union

Sediment Trap (in accordance with the local gas authority)

Cap

Manual Gas Supply Line

Shut-Off Valve

Discharge Line

(To Suitable Drain)

(150 mm)

Air Gap

Page 13

Safety Precautions

USING YOUR WATER HEATER

WARNING: Flammable vapors can

be drawn by air currents from surrounding areas to the water heater. Vapors can ignite causing death, personal injury, or product damage.

• DO NOT store or use flammable or combustible materials (gasoline, paint thinner, adhesives, newspapers, rags, mops, etc.) in the vicinity of the water heater or any other gas appliance. If they must be used, open doors and windows for ventilation, and shut off all gas-burning appliances, including their pilot lights.

• DO turn off manual gas shut-off valve if water heater has been subjected to overheating, fire, flood, physical damage, or if the gas supply fails to shut off.

• DO NOT turn on water heater unless water and gas supplies are completely opened.

• If there is any difficulty in understanding or following the operating and care instructions in this manual, it is recommended that you contact a qualified service technician to perform the work.

Setting the Water Temperature

DANGER: Water temperatures above 125°F (52°C)

will result in death and/or severe burns from scalding. Safety and energy conservation are factors to be considered

when selecting the water temperature setting. The temperature of the water in the water heater can be regulated by setting the temperature on the front of the remote control. Be sure to read and follow the warnings outlined on the pictured label.

The remote control has been preset and shipped at the recommended temperature setting.

Safety factors should be considered whenever altering the water temperature setting. The chart below may be used as a guide in determining the proper water temperature for your home.

DANGER

HOT

Use Instructions

BURN

Time/Temperature Relationship in Scalds

Water Time to Produce

Temperature a Serious Burn

Table courtesy of Shriners Burn Institute

Water temperature over 125°F (52°C) can cause severe burns instantly or death from scalds.

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

See instruction manual before setting temperature at water heater.

Feel water before bathing or showering.

Temperature limiting valves are available, see manual.

Page 14

USING YOUR WATER HEATER

Setting the Water Temperature (cont.)

Maximum water temperature occurs while the water heater burner is on. To determine the water temperature:

Turn on the hot water faucet and place a thermometer in the water stream.

NOTICE: Water temperature at the faucet

may vary depending on the season and the length of pipe from the water heater.

The remote control temperature range is between 100°F (38°C) and 120°F (49°C). To adjust the temperature to a desired setting, press the UP or DOWN adjustment button on the face of the remote control. The new temperature set point will show on the LED display.

Use Instructions

In-Use Indicator

(Lit during operation)

Priority

Indicator

Temperature

Adjustment

Buttons

NOTICES:

• The temperature set point on the standard remote control cannot be increased above 112°F (44°C) when a hot water faucet is in the open position. To achieve temperatures above 120°F (49°C) or 85°F (29°C), contact a qualified service technician. Only factory-authorized remote control(s) should be used.

• The water heater may not operate with a small water flow. Increase the water flow and recheck. If it still does not operate with the hot water faucet completely open, increase the temperature setting on the remote control.

Water Heater Facts

DANGER: Water temperatures above

125°F (52°C) will result in death and/or severe burns from scalding.

• The hottest-temperature water will be at the faucet closest to the water heater.

• Always remember to test the water temperature with your hand before use.

• Always supervise young children or others who are incapacitated.

• The water heater is equipped with a device that will shut off the gas supply to the burner if the water heater exceeds normal operating temperatures.

• Any water heater that has been subjected to fire, flood, physical damage, or been under water should be turned off at the manual gas shut-off valve and not used until it has been checked by qualified service personnel.

LED Temperature

and Error Code

Display

Power On/Off

Button and

Indicator

Page 15

Water Heater Inspections

CARING FOR YOUR WATER HEATER

Venting System

The venting system should be inspected annually by a qualified service technician to ensure all of the vent sections are secure and airtight.

(Direct Vent Only)

WARNING: Do not operate the

water heater if the vent system shows signs of leaking exhaust. Leaking exhaust could lead to death, personal injury, and/or product failure.

Outdoor models

Check the air intake and vent outlet for blockage and/or debris.

Condensate Trap (Direct Vent Only)

CAUTION: Do not operate without

the condensate trap connected to the vent and routed to the proper drain. It could cause the system to malfunction or fail.

On a regular basis, inspect the condensate trap to ensure there is enough water in the trap and the condensate is draining properly.

Ensure that condensate is disposed of per local codes and regulations.

Use Instructions

Page 16

Burner

Sight

Glass

CARING FOR YOUR WATER HEATER

Water Heater Inspections (cont.)

Burner

It is recommended that the burner be inspected annually by a qualified service technician.

DANGER: Shock Hazard –

Removing the front cover panel exposes you to live electricity. Electric shock will cause death or serious personal injury.

Remove 4 screws and the unit cover panel.

While the water heater is operating, inspect the main burner flames through the burner sight glass. The flames should be blue when the main burner is firing.

NOTICE: If the flames are not blue

or you observe unusual burner operation, shut off the water heater and contact a qualified service technician.

Turn on a hot water faucet.

Care Instructions

Turn off the hot water faucet and reinstall the

unit cover panel.

Page 17

Care and Cleaning

Drain Valve

Cold Water Supply

Shut-Off Valve

CARING FOR YOUR WATER HEATER

DANGER: Shock Hazard – Make

certain power to the water heater is OFF before removing protective cover for any reason. Electric shock will cause death or serious personal injury.

WARNING: Combustible materials,

such as clothing, cleaning materials, or flammable liquids, must not be placed against or next to the water heater. Fire or explosion can occur causing death, personal injury, and/or product damage.

All care and cleaning to and around the water heater should only be performed with the water heater turned off and the electrical power supply disconnected.

Vacuum around the water heater to remove any

dust, dirt, and/or lint buildup.

NOTICE: The air intake requires a

minimum of 12 in. (30 cm) of clearance between the air intake opening and any obstruction.

Clean the water filter monthly, as described below and on page 18.

Water Filter Cleaning

Turn off the water heater and disconnect the

electrical power supply.

Clean the water heater and the remote control

with a damp soft cloth and mild detergent. Gently wipe and completely dry all surfaces.

Outdoor models

Check the air intake and vent outlet for

blockage and/or debris.

Turn off the water supply to the water heater.

Drain the water heater. See page 20.

Care Instructions

Page 18

CARING FOR YOUR WATER HEATER

Care and Cleaning (cont.)

CAUTION: Do not tap or force

the filter during removal. This can deform and/or damage the filter.

Unscrew the water filter from the base of the

cold water inlet line and carefully slide it out of the line.

CAUTION: Do not overtighten the

water filter. Overtightening can deform and/or damage the filter.

Replace the filter in the cold water inlet line and

tighten until it is snug.

Clean the water filter under running water. To

remove severe sediment and dirt, use a soft brush.

Care Instructions

Turn on the water supply, reconnect the

electrical supply, and turn on the water heater.

Page 19

CARING FOR YOUR WATER HEATER

Relief Valve

Preventive Maintenance

WARNING: Failure to perform

routine preventive maintenance can prevent the water heater from operating properly. Improper operation can cause carbon monoxide dangers, excessive water temperatures, and other potentially hazardous conditions resulting in death, personal injury, and/or product damage.

Properly maintaining your water heater will ensure dependable, trouble-free service.

User Preventive Maintenance

Establish and follow a routine preventive maintenance program. The following suggested items should be included in your program.

• Monthly check and clean the water filter. See “Water Filter Cleaning” on page 17.

WARNING: Hot water is released

during manual operation of the relief valve. Make sure all people and animals are clear from the area before performing this check to prevent death, personal injury, and/or property damage from hot drain water.

NOTICE: If the pressure relief valve on

the hot water heater discharges periodically, this may indicate a problem in the water system. Contact the water supplier or a plumbing contractor to correct the problem. DO NOT plug the relief valve outlet.

• Inspect and keep the area around the water heater clear and free of flammable materials, such as gasoline and other flammable vapors and liquids.

• Visually inspect the water heater for damage and/or denting. If present, contact a service personnel to verify proper operation.

• Check for abnormal sound during normal operation (e.g., hissing or banging noises). Contact a qualified service technician or plumbing contractor.

• Check all gas and water pipes for leaks. See page 53.

NOTICES:

– DO NOT operate the water heater if you feel something is wrong with the unit. – DO NOT allow children to operate or handle the unit.

• After inspections, maintenance, and/or cleaning, ensure proper operation by turning on a hot water faucet.

Care Instructions

• Annually check the operation of the pressure-

relief valve. Lifting the lever handle on the pressure-relief valve opens the valve to flush hot water through the discharge line to the drain. After several gallons have drained, release the lever handle to close the valve and stop draining.

Professional Preventive Maintenance

It is recommended that a periodic inspection of the water heater burner, relief valve, air intake filter, water filter, and venting system be made by a qualified service technician.

Page 20

Cold Water Supply

Shut-Off Valve

CARING FOR YOUR WATER HEATER

Draining the Water Heater

WARNING: Failure to follow these

draining instructions can cause serious personal injury from scalding and/or product damage.

Close the water shut-off valve.

Turn off the water heater by pressing the

POWER ON/OFF button on the control panel.

Close the gas shut-off valve(s).

At least 10 seconds after Step 1, unplug the

Care Instructions

water heater or disconnect the power supply at the circuit breaker box.

Using a suitable container to catch the water,

remove the water filter from the base of the cold water inlet line.

Connect a garden hose to the drain valve in the

hot water outlet line and place the other end in a suitable drain. Open the drain valve until all the water has drained from the water heater. Leave water heater as is until placed back in service.

Open all hot water faucets. Run the water until it

is COLD; then shut off the faucet.

Page 21

CARING FOR YOUR WATER HEATER

CAUTION: Even when drained

properly, a small amount of water will remain in the water heater. In cold weather conditions, this water can freeze. If this happens, allow the defrost protection on the water heater at least 30 minutes to melt the frozen water. The water heater will not work properly until this water is thawed.

To put the water heater back in service:

Open all hot water faucets and let run until all

air has been purged from the lines.

Disconnect drain hose. Make sure the drain

valve is closed.

Reinstall the water filter in the base of the cold

water inlet line.

Open the water shut-off valve.

Plug in the power cord or reconnect the power

supply at the circuit breaker box.

Open the gas shut-off valve(s).

Care Instructions

Press the POWER ON/OFF button on the

control panel to restart the unit.

Page 22

Cold Water

Service Valve

Hot Water

Service Valve

Hot Water

Service Valve

Pressure

Relief Valve

Relief

Valve

Water Outlet

Water

Outlet

Water

Inlet

Water

Inlet

Drain

CARING FOR YOUR WATER HEATER

Draining the Water Heater (cont.)

Preferred Drain Method

Isolator valve kits may be purchased from the manufacturer, distributor, or place of purchase. The kits include two full port isolation valves to be used in the inlet and outlet water lines. It is highly recommended to install isolator valve kits because these kits provide a means for full diagnostic testing and ease of system flushing.

Freeze Protection

WARNING: Failure to drain the

water heater can cause serious personal injury from scalding and/or product damage.

Whenever the water heater may be exposed to freezing conditions, make sure to completely drain the water from the unit. See page 20.

Freezing conditions come from the ventilation system on direct-vent models and from exposure to cold air on outdoor models.

All of these water heaters are equipped with a freeze protection electric heater. This heater prevents freezing inside the water heater down to an ambient temperature of approximately -30°F (-34°C). These temperatures are all based on temperatures without wind.

The heater only protects the internal components of the water heater.

NOTICE: Unplugging or disconnecting

Care Instructions

the power supply to the water heater will also disconnect the power to the heater.

External piping and valves require additional freeze protection. One method is to wrap insulation around the piping and valves.

Another method is to turn on a hot water faucet and leave a small amount of water running at a faucet. This will protect the water heater, piping, and valves from freezing.

Running Water Freeze Protection

Turn off the water heater by pressing the

POWER ON/OFF button on the control panel.

Close the gas shut-off valve(s).

Open a hot water faucet slightly until the water

stream is approximately 1/8 in. (0.3 cm). Be sure to check the flow periodically.

Page 23

CARING FOR YOUR WATER HEATER

Vacation and Extended Shutdown

WARNING: Failure to drain the

water heater can cause serious personal injury from scalding and/or product damage.

If the water heater is to remain idle for an extended period of time, the power and water to the heater should be turned off.

The water heater and piping should be drained if they might be subjected to freezing temperatures. See “Freeze Protection” section on page 22.

After an extended shutdown, the water heater’s operation and controls should be checked by a qualified service technician.

Troubleshooting Chart

The information in the following troubleshooting chart may help you diagnose and/or fix a problem you may be experiencing. Please review this chart before calling for service assistance.

DANGER: Shock Hazard – Make

certain power to the water heater is OFF before removing protective cover for any reason. Electric shock will cause death or serious personal injury.

Problem Possible Cause Solution

Not enough or no hot water.

9 1143

1. Unit is not ON. 1. Turn on the unit by pressing the

2. Water shut-off valve is not completely

opened.

3. Hot water faucet is not completely

opened.

4. Water piping is frozen. 4. Allow piping to thaw.

5. Electrical power is disconnected or

water supply is shut off.

6. The temperature may be set too low. 6. Increase the temperature setting.

7. Mixing valve malfunctions (if

applicable).

8. Error code displayed on the remote

control.

9. Not enough water demand. 9. Increase the hot water ow at the

10. Water lter is clogged or dirty. 10. Clean the water lter. (See page 17.)

11. Fixture aerator is clogged or dirty. 11. Clean the aerator.

12. Scale buildup in the heat exchanger. 12. Check for error code. If required,

13. Hot and cold water lines reversed. 13. Reverse the water lines.

WARNING: For Your Safety, DO

NOT attempt repair of electrical wiring, gas piping remote control, burners, vent connectors, or other safety devices. Refer repairs to a qualified service technician.

POWER ON/OFF button.

2. Check shut-off valve and open

completely.

3. Open hot water faucet completely.

(The main burner goes off when incoming water volume is inadequate.)

5a. Plug in the power cord or reconnect

the power supply at the circuit breaker box.

5b. Completely open the water supply

valve. (Inadequate water volume will cause the main burner to turn off.)

7. Check and replace the mixing valve.

8. See “Service Error Code Chart” on

page 25. If required, contact a qualied service technician.

faucet.

contact a qualied service technician.

Care Instructions

Page 24

CARING FOR YOUR WATER HEATER

Troubleshooting Chart (cont.)

Problem Possible Cause Solution

Water not hot enough.

1. The temperature may be set too low. 1. Increase the temperature setting at

the remote control.

Water too hot.

2. The gas valve is not completely

opened.

2. Check and completely open the gas

valve.

3. Gas supply pressure is low. 3. Contact your gas utility company or

4. Bleed-over in one of the hot water

xtures.

gas contractor to verify the gas meter and gas piping size.

4. Contact a dealer or a qualied service

technician.

1. Temperature is set too high. 1. Decrease the temperature setting at

the remote control.

2. Water shut-off valve is not completely

opened.

3. Small amount of water has been

heated.

2. Check and completely open the water

shut-off valve.

3. Increase the hot water ow at the

faucet to allow more water to ow through the water heater.

Fan continues to rotate after the hot water

Care Instructions

faucet is closed.

The post-purge cycle clears ue gases. Normal operation.

Page 25

CARING FOR YOUR WATER HEATER

Service Error Code Chart

Your water heater has an electronic diagnostic system built into it. When the water heater finds a problem, it displays an error code in the LED display on the remote control. The following chart lists the error codes along with their possible problem and solution. Using this chart may help you diagnose and/or fix a problem you may be experiencing. Please refer to this chart before calling for service assistance.

DANGER: Shock Hazard – Make

certain power to the water heater is OFF before removing protective cover for any reason. Electric shock will cause death or serious personal injury.

WARNING: For Your Safety, DO

NOT attempt repair of electrical wiring, gas piping, remote control, burners, vent connectors, or other safety devices. Refer repairs to a qualified service technician.

When an error code is displayed:

Turn off all the hot water faucets.

Turn off the water heater by pressing the

POWER ON/OFF button on the remote control.

Wait about 5 minutes; then restart the water

heater by pressing the POWER ON/OFF button.

Turn on a hot water faucet and recheck the

remote control display.

If the error code remains in the display:

1. Turn off the hot water faucet.

2. Turn off the water heater.

3. Unplug the water heater from power, wait about

30 seconds and plug back in.

Follow the error code chart information.

5. Restart the water heater, turn on a hot water

faucet, and recheck the remote control display.

If the error code is still shown:

1. Turn off the hot water faucet.

2. Turn off the water heater.

3. Make note of the displayed error code and call

for service assistance. See “Call for Assistance” section on page 26.

NOTICE: If the displayed error code is not

listed in the chart, immediately turn off the water heater and call for service assistance.

Care Instructions

Page 26

CARING FOR YOUR WATER HEATER

Service Error Code Chart (cont.)

Error Code Possible Cause Solution

61 or 99

Water heater has buildup of lime deposits. Contact a dealer or qualied service

Air intake or vent exhaust opening may be blocked.

The vent pipes on the vent termination may not be connected properly.

The gas shut-off valve is not fully opened. Check shut-off valve and open completely.

Gas service has been interrupted. Contact your gas utility company.

LP gas is running low (LP models only). Rell or replace your LP gas container.

If this code is still displayed after taking the numbered steps above.

Water heater is overheating. Contact a dealer or qualied service

The heat exchanger is too hot. Check for blockage in the vent. Contact a

Faulty inlet thermistor. Contact a dealer or qualied service

Faulty outlet thermistor. Contact a dealer or qualied service

Faulty blower motor. Contact a dealer or qualied service

Faulty water ow solenoid. Contact a dealer or qualied service

Not enough water ow to operate the unit. Increase the water ow from the xtures.

technician.

Remove any blockage. (Air intake requires 12 in. [30 cm] of clearance.)

Contact a dealer or qualied service technician.

technician.

dealer or qualied service technician.

technician.

IF YOU NEED SERVICE

Call for Assistance

1. All questions, adjustments, repairs, and/or

Care Instructions

routine maintenance should be directed to your installer, plumbing contractor, or licensed service agent. If your contacts have moved or are not available, please refer to the telephone directory, commercial listings, or local utility company for qualified service assistance.

2. If your problem has not been solved to your

satisfaction, contact the Manufacturer National Service Department at the following address:

Manufacturer

National Service Department 1241 Carwood Court Montgomery, Alabama 36117 Phone: 1-800-432-8373

When contacting the manufacturer, the following information will be requested:

A. Model and serial number. (See page 8 or the

ratings plate on the side of the water heater.)

B. Address where the water heater is located. C. Name and address of installation contractors

(page 8) and all qualified service companies that have worked on the water heater.

D. Original installation date. (See page 8.) E. Dates any service or preventive maintenance

was performed.

F. Details of the persisting problem. G. List of businesses that have tried to fix this

problem, along with dates of service.

Page 27

INSTALLATION

Installation

INSTRUCTIONS

FOR THE CONTRACTOR

Page 28

INSTALLATION INSTRUCTIONS

Coaxial Vent Pipe

and Air Intake

0" min.

(0 mm)

0" min. (0 mm)

0" min.

(0 mm)

Standards Compliance

General

This water heater must be installed in accordance with these instructions, local codes, and utility company requirements.

In the United States where local codes are not available, use the latest edition of the American National Standard/National Fuel Gas Code. A copy of the Fuel Gas Code can be purchased from either the American Gas Association, 400

Choosing a Location

WARNING: Fire Hazard –

Combustible construction refers to adjacent walls and ceilings and should not be confused with combustible or flammable products and materials. Combustible materials, such as clothing, cleaning materials, or flammable liquids, must not be placed against or next to the water heater. Fire or explosion could occur causing death, personal injury, and/or product damage.

A gas-fired water heater should never be installed in a space or room where liquids with flammable vapors are used or stored. Such liquids include gasoline, LP gas (butane or propane), paint, adhesives and their thinners, solvents, or removers. Flammable vapors carry long distances from where they are used or stored. The open flame of the water heater’s main burner can ignite these vapors causing an explosion or fire.

NOTICE: Elevating a gas-fired water

heater will reduce but NOT eliminate the possibility of lighting the vapor of flammable liquids which may be improperly stored or accidentally spilled.

North Capitol Street Northwest, Washington, DC 20001, as ANSI standard Z223.1, or National Fire Protection Association, 1 Batterymarch Park, MA 02269 as NFPA 54.

In Canada, use the latest edition of the CAN/CSA B149.1 Natural Gas and Propane Installation Code and the Canadian Electrical Code, CAN/CSA C22.1, Part 1.

NOTICE: This water heater should not

be located in an area where leakage of the heat exchanger or connections will result in damage to the area adjacent to it or to lower floors of the structures. When such areas cannot be avoided, install a suitable catch pan with an adequate drain under the water heater. This drain pan must not restrict the combustion airflow.

The following requirements will ensure a safe installation:

• The water heater must be located in an area

where it won’t sustain damage from moving vehicles, flooding, etc. If the water heater is installed in a storage garage, the direct ignition system and main burner should be no less than 18 in. (45 cm) above the garage floor.

• If the water heater is installed in a repair garage or in a private garage, the direct ignition system and main burner should be no less than 4.5 ft. (1400 mm) above the garage floor.

• The water heater should be installed as close as possible to the vent termination. This minimizes the vent length and the number of elbows and joints required for venting.

• The water heater should be installed with the proper venting and exhaust materials suitable for

Category III venting.

Page 29

INSTALLATION INSTRUCTIONS

12" min.

(300 mm)

12" min.

(300 mm)

0" min. (0 mm)

12" min.

(300 mm)

1/2" min.

(13 mm)

(0 mm)

Fire Stop Plate

(as required)

0" min. (0 mm)

Choosing a Location (cont.)

• Every vent pipe penetration of a floor or ceiling that is not in a fire-rated shaft requires a fire stop plate.

• Failure to install and properly vent the water heater to the outdoors as outlined on pages 34 through 45 can result in unsafe operation.

• Minimum water heater clearances from combustible and noncombustible construction are as follows: – 1/2 in. (1.3 cm) for sides – 0 in. (0 cm) for rear with support bracket(s) – 12 in. (30 cm) from the bottom, top, and front

NOTICE: Preferred maintenance

clearance is 24 in. (61 cm) from top, bottom, and front of unit.

General

• Long hot water lines should be insulated to

conserve water and energy.

• The water heater and water lines should be protected from exposure to freezing temperatures.

• Do not install the water heater in areas prohibited by National Fuel Gas Code in U.S. installation or CAN/CSA B149.1 in Canada installation.

• Do not install the water heater where it is subject to vibrations.

• Do not install the water heater in a recreational vehicle, mobile home, boat, or other watercraft.

• Do not install the water heater near vents for heating and cooling. If necessary, maintain a minimum clearance of 4 ft. (1.2 m).

• Minimum clearance around the coaxial vent pipe should meet the specifications listed on the instruction/warning label on the water heater. If no label is found, use the vent manufacturer’s specifications or a minimum clearance of 0 in. (0 cm) around the vent pipe.

Page 30

INSTALLATION INSTRUCTIONS

Product Inspection

General

• Visually inspect the water heater for any possible

damage.

•

Check the rating plate on the water heater to make sure the water heater was designed to be used with the supplied type of gas (natural or LP).

• Verify that all included supplied parts are present as shown.

Water Heater Installation

Corrosive Atmosphere

NOTICE: The water heater should not be

installed near an air supply containing halogenated hydrocarbons.

Avoid installing a water heater in any of the following locations: beauty shops, dry-cleaning establishments, photo processing labs, and storage areas for liquid and powdered bleaches or swimming pool chemicals. These locations often contain such halogenated hydrocarbons.

The air supply containing halogenated hydrocarbons is safe to breathe, but when passed through a gas flame, corrosive elements are released that will shorten the life of any gas-burning appliance.

Propellants from common spray cans or gas leaks from A/C and refrigeration equipment are highly corrosive after passing through a flame.

The water heater warranty is void when the failure is due to operation in corrosive conditions.

Page 31

INSTALLATION INSTRUCTIONS

Relief Valve

Service

Valve

Service

Valve

To Hot Water

Faucet(s)

Drain Valve

Wall

Plate

Vent Termination

With Protective

Screen

Water

Filter

Cold Water Supply

Shut-Off Valve

Discharge Line

(To Suitable Drain)

Power

Supply

Cord

Manual Gas Supply Line

Shut-Off Valve

1/4" Per Foot Downward Slope

(recommended)

Manual Gas

Shut-Off Valve

Union

Cap

Sediment Trap

Outside

Wall

90˚

Elbow

(150 mm)

Air Gap

Condensate Trap

To Drain: Dispose of condensate in accordance with local codes.

Union

Condensate Collector

Water Heater Installation (cont.)

NOTICE: The National Fuel Gas Code (NFGC) and CAN/CSA B149.1 mandate a manual gas

shut-off valve. See NFGC/B149.1 for complete instructions. Local codes or plumbing authority requirements may vary from the instructions or diagrams provided and take precedence over these instructions.

Typical Installation of Direct-Vent Water Heater (Venting Required)

General

Page 32

INSTALLATION INSTRUCTIONS

Cold Water

Service Valve

Hot Water

Service Valve

Hot Water

Service Valve

Pressure

Relief Valve

Water Outlet

Water

Outlet

Water

Inlet

Water

Inlet

Drain

Relief Valve

Service

Valve

Service

Valve

To Hot Water

Faucet(s)

Drain Valve

Cold Water Supply

Shut-Off Valve

Discharge Line

(To Suitable Drain)

Manual Gas Supply Line

Shut-Off Valve

Flue

Terminal

Cap

Union

Sediment Trap

(150 mm)

Air Gap

Manual Gas

Shut-Off Valve

Water

Filter

Hard-Wire

Union

Water Heater Installation (cont.)

General

Typical Installation of Outdoor Water Heater (No Venting Required)

This water heater is for OUTDOOR installation only.

WARNING: DO NOT install this

water heater indoors or in a confined area. It is designed for outdoor installation only. Any other type of installation can result in death, personal injury, and/or damage to the product or property.

Alternate Water Piping Arrangement With Preferred Valve Kit

A valve kit is available and can be used with all models. See “Water Supply Connections” on page 46 for installation instructions.

Page 33

INSTALLATION INSTRUCTIONS

3/8"–1 1/2" min.

(9.5–38 mm)

Mounting the Water Heater

CAUTION: Reinforcement of the

wall is required in case the wall is not strong enough to hold the water heater. Failure to do so could result in personal injury and/or product damage.

The mounting location for the water heater should allow for easy access and operation.

Position the upper mounting bracket and

partially install the center mounting screw. The clearance between the screw head and the wall should be about 1/8 in. (0.3 cm). Hang the upper bracket on the screw.

NOTICE: The image above may differ

in appearance from your water heater.

General

The water heater is designed to be installed

either inside the wall cavity between the wall studs or outside the wall cavity. Either installation requires the water heater to be supported with a wooden support brace between the wall studs or a piece of wood that is equal in size to the water heater and securely attached to the wall studs before the water heater is attached to it. This piece of wood can be installed inside or outside the wall. Use wood screws to secure brackets to the wall. If mounting to a concrete wall, use lag bolts designed for concrete.

Make sure the proper electrical outlet or supply

(120 VAC/60 Hz) is available and located near the unit. Direct-vent models come with a 6-ft. (1.8-m) power cord, while the outdoor models require hard-wiring or the addition of a plug.

Using two mounting screws and washers,

secure the lower mounting bracket to the wall. Then, secure the upper mounting bracket to the wall with two mounting screws and washers.

Position the water heater and tighten the

adjustment screws to complete the installation. The rear of the water heater can be positioned anywhere between 3/8 in. (0.95 cm) and 1 1/2 in. (3.8 cm) from the wall (indoor model only).

Page 34

INSTALLATION INSTRUCTIONS

Venting for Direct-Vent Water Heater

Venting

The water heater must be installed with 3-in./5-in. (7.6-cm/12.7-cm) diameter UL-approved Category III Coaxial Stainless Steel appliance vent pipe or water heater manufacturer-approved concentric vent pipe.

DANGER: Failure to install and

properly vent the water heater to the outdoors as outlined in this Venting section will result in death or serious personal injury. To avoid the risk of fire, explosion, or asphyxiation from carbon monoxide, NEVER operate the water heater unless it is properly vented and has adequate air supply for proper operation as outlined in this Venting section.

WARNINGS:

• Use 3-in./5-in. (7.6-cm/12.7-cm) UL-approved Category III Stainless Steel vent materials or water heater manufacturer-approved vent material. No other vent material is permitted for use with this appliance.

• Refer to page 29 for required clearances to combustible materials. Improper clearances can cause explosion or fire resulting in death, personal injury, and/or product damage.

Venting Requirements

The installation of venting must comply with national codes, local codes, and the vent manufacturer’s instructions.

The water heater must be vented to the outdoors as described in these instructions. DO

NOT vent this water heater through a chimney. It must be vented separately from all other appliances.

All inner coaxial vent components (adapters, pipe, elbows, terminals, etc.) should be water heater manufacturer-approved Stainless Steel Venting Material (e.g., 444 SS, 316 L).

Outer casing can be galvanized aluminum or other material.

The specified vent termination must be used. (Refer to page 45 for an example of concentric vent.)

CAUTION: Do not attempt to fabricate or adapt other vent pipe or materials to this venting.

Use the provided screws to connect the coaxial vent pipe together.

Follow the vent manufacturer’s installation instructions.

This water heater can be vented horizontally or vertically. All coaxial vent piping runs must be adequately supported. The maximum recommended unsupported span should be no more than 4 ft. (1.2 m). Only use support isolation hanging bands. DO NOT use wire to support pipe runs.

Preexisting Venting Notes:

If the water heater is being installed as a replacement for an existing water heater, a thorough inspection of the existing venting and air intake system must be performed prior to any installation work. Verify that the correct materials, vent lengths, and terminal locations as described in this manual have been met. Carefully inspect the entire venting and air intake system for any signs of cracks or fractures, particularly at the joints between elbows or other fittings and the straight runs of vent pipe. Check the system for signs of sagging or other stresses in the 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 the installation and putting the water heater into service.

See page 35 for additional requirements for the Commonwealth of Massachusetts.

Page 35

INSTALLATION INSTRUCTIONS

In the Commonwealth of Massachusetts

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through-the-wall vented gas appliances as follows:

5.08: Modifications to NFPA–54, Chapter 10

(1) Revise NFPA–54 section 10.5.4.2 by adding a second

exception as follows:

Existing chimneys shall be permitted to have their use continued when a gas conversion burner is installed, and shall be equipped with a manual reset device that will automatically shut off the gas to the burner in the event of a sustained back-draft.

(2) Revise 10.8.3 by adding the following additional

requirements:

(a) For all side-wall, horizontally vented, gas-fueled equipment installed in every dwelling, building, or structure used in whole or part for residential purposes, including those owned or operated by the Commonwealth and where the side-wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied.

1. INSTALLATION OF CARBON MONOXIDE

DETECTORS. At the time of installation of the side-wall, horizontally vented, gas-fueled equipment, the installing plumber or gasfitter shall observe that a hard-wired carbon monoxide detector with an alarm and battery backup is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a batteryoperated or hard-wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building, or structure served by the sidewall, horizontally vented, gas-fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard-wired carbon monoxide detectors.

a. In the event that the side-wall, horizontally vented, gas-fueled equipment is installed in a crawl space or an attic, the hard-wired carbon monoxide detector with alarm and battery backup may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision cannot be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements, provided, however, that during said thirty (30) day period, a batteryoperated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS.

Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034-listed and IAS-certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented, gas-fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”

4. INSPECTION. The state or local gas inspector of the side-wall, horizontally vented, gas-fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08 (2)(a)(1 through 4).

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08 (2)(a)(1 through 4):

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board, and

2. Product-approved side-wall, horizontally vented, gas-fueled equipment installed in a room or structure separate from the dwelling, building, or structure used in whole or in part for residential purposes.

(c) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of product-approved side-wall, horizontally vented, gas-fueled equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of product-approved sidewall, horizontally vented, gas-fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems,” the following requirements shall be satisfied by the manufacturer:

1. The referenced “special venting systems” instructions shall be included with the appliance or equipment installation instructions, and

2. The “special venting systems” shall be productapproved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all product-approved side-wall, horizontally vented, gas-fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

Venting

Page 36

INSTALLATION INSTRUCTIONS

Vent Pipe Wall Plate

Inspection

Access Panel

(Optional)

Inspection

Access Panel

(Optional)

CeilingFire

Stop

90˚

Elbow

1/4" Per Foot Downward Slope

(recommended)

Vent Seam

Venting for Direct-Vent Water Heater (cont.)

Venting

Recommended Vent Lengths

Number of 90°

Elbows (bends)

1 39 ft. (12.0 m)

2 37 ft. 6 in. (11.5 m)

3 36 ft. (11.0 m)

4 34 ft. 6 in. (10.5 m)

5 33 ft. (10.0 m)

6 31 ft. 6 in. (9.5 m)

Maximum Vent Length:

The system will not operate if there is excessive restriction (pressure drop) in the venting system. Use the chart above to calculate the maximum pipe run length with the required number of elbows (e.g., a maximum 39 ft. [12 m] of vent pipe may be used provided there is only one 90° elbow in the system).

A 90° elbow is equivalent to 1 ft. 6 in. (0.5 m) of straight pipe, while a 45° elbow is equivalent to 9 in. (0.25 m) of straight pipe.

The vent termination does not count as part of the straight pipe equivalent when determining the total vent length. The vent pipe should be installed with a slight downward slope of 1/4 in. per foot of horizontal run toward the vent termination. This ensures that any condensate formed during operation is evacuated from the water heater. It also prevents rain from entering the appliance. An upward slope on the vent termination is not acceptable for horizontal venting without using the condensate collector.

Maximum Length

of Straight Pipe

Minimum Vent Length:

The venting may be as short as 12 in. (30 cm), provided one vent termination is installed to the outdoors through a sidewall with one 90° elbow and one wall plate included in the installation. Total equivalent vent length is 30 in. (76 cm).

NOTICE:

the inner vent pipe in a horizontal run is towards the top of the installation as shown above.

Make sure that the seam of

Venting Through Closed Spaces

If the coaxial vent piping passes through a closed space, a minimum clearance of 0 in. (0 cm) for vertical piping or 6 in. (15 cm) for horizontal piping should be maintained between the coaxial vent pipe and combustibles and noncombustibles. Be sure to follow local codes and vent manufacturer’s installation instructions.

For maintenance and inspection purposes, the following access panels may be required.

• Two (2) inspection access panels large enough to

allow access for venting inspection. One access panel may be close to where the coaxial vent pipe enters the ceiling. The other access panel may be near the vent termination.

Page 37

INSTALLATION INSTRUCTIONS

Downward Slope

(recommended)

Upward Slope

Condensate Trap

Condensate Collector

Appliance Vent Adapter

CAUTION: Ensure that the

appliance vent adapter is securely attached to the water heater collar. Improperly connected vent adapter can cause damage to the appliance and/ or poor performance.

Metal Fab Inc. standard concentric vent pipe can be installed into the water heater collar without an appliance vent adapter. However, other Rheemapproved vent manufacturer's pipe cannot be installed without a UL-approved Category III Stainless Steel appliance concentric vent adapter.

NOTICE: To install the appliance vent

adapter, please follow the appliance vent adapter manufacturer's instructions.

Draining Vent Condensate

WARNINGS:

• Failure to provide a vent condensate drain close to the water heater could allow acidic flue gas condensate to enter into water heater flueways, causing premature failure of the water heater.

• If the condensate collector is not used, the drain fitting must be capped to prevent exhaust gases and condensate from entering the building. The cap is supplied on the water heater.

CAUTIONS:

• Condensate is known to be acidic; refer to federal, state (provincial), and local codes for proper handling and discharge methods.

• Condensate must be drained away from the water heater and should not be allowed to drain back into any part of the vent system.

• The condensate collector must be used with vertical vent installation.

• Condensate collector must be used with horizontal vent installation if the vent has an UPWARD slope toward the termination.

Provision should be made to collect and dispose of condensate from the venting systems.

Venting

When a water heater is vented horizontally, the vent pipe should have a DOWNWARD or UPWARD slope towards the termination. If an UPWARD slope is used, always attach a drain hose to the condensate collector and plumb the hose to a sanitary sewer drain.

When a water heater is vented vertically, an UPWARD slope must always be used. Always attach a drain hose to the condensate collector and plumb the hose to a sanitary sewer drain.

Properly installed condensate traps prevent the condensate from draining back into the water heater.

A high-temperature silicone tubing suitable for use with acidic condensate and appropriate for the temperature range should be used.

The drain tube is fashioned into a “pigtail” trap and must be filled with water to prevent flue gases from emitting into the building prior to operating the water heater.

Page 38

INSTALLATION INSTRUCTIONS

Outside Walls

Fixed

Closed

Fixed

Closed

Operable

Inside Wall

Vent Terminal

Air Supply Inlet

Area Where Terminal is Not Permitted

A J

Venting for Direct-Vent Water Heater (cont.)

Horizontal Vent Terminal Location

Venting

Page 39

INSTALLATION INSTRUCTIONS

Horizontal Vent Terminal Location (cont.)

The following chart details the minimal dimensional information needed to determine the proper location of the vent terminal for direct vent and outdoor tankless water heaters. See corresponding letter reference in the illustration on page 38.

Location

A = Clearance above grade, veranda, porch,

deck, or balcony.

B = Clearance to window or door that may be

opened.

U.S. Installation Requirements

12 in. (30 cm) 12 in. (30 cm)

• 6 in. (15 cm) for water heaters less

than or equal to 10,000 Btuh (3 kW).

• 9 in. (23 cm) for water heaters greater

than 10,000 Btuh (3 kW) and less than or equal to 50,000 Btuh (15 kW).

• 12 in. (30 cm) for water heaters

greater than 50,000 Btuh (15 kW).

C = Clearance to permanently closed window.

D = Vertical clearance to ventilated soft located

above the terminal within a horizontal distance of 2 ft. (61 cm) from the centerline of the terminal.

E = Clearance to unventilated soft.

F = Clearance to outside corner.

G = Clearance to inside corner.

H = Clearance to each side of centerline

extended above meter/regulator assembly.

I = Clearance to service regulator vent outlet.

J = Clearance to nonmechanical air supply inlet

to the combustion air inlet to any building or other appliance.

• 6 in. (15 cm) for water heaters less

than or equal to 10,000 Btuh (3 kW).

• 9 in. (23 cm) for water heaters greater

than 10,000 Btuh (3 kW) and less than or equal to 50,000 Btuh (15 kW).

• 12 in. (30 cm) for water heaters

greater than 50,000 Btuh (15 kW).

K = Clearance to mechanical air supply inlet. 3 ft. (91 cm) above if within 10 ft. (3 m)

L = Clearance above paved sidewalk or paved

driveway located on public property.

M = Clearance under veranda, porch, deck, or

balcony.

1 In accordance with current ANSI Z223.1/NFPA 54 National Fuel Gas Code. 2 In accordance with current CAN/CSA B149.1 Installation Codes.

For clearances not specied in ANSI Z223.1/NFPA 54 or CAN/CSA B149.1, one of the following shall be indicated:

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

gas supplier.”

†

A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single-family dwellings and

serves both dwellings.

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

horizontally.

Canadian Installation Requirements

• 6 in. (15 cm) for water heaters less

than or equal to 10,000 Btuh (3 kW).

• 12 in. (30 cm) for water heaters

greater than 10,000 Btuh (3 kW) and less than or equal to 100,000 Btuh (30 kW).

• 36 in. (91 cm) for water heaters

greater than 100,000 Btuh (30 kW).

3 ft. (91 cm) within a height of 15 ft. (4.57 m) above the meter/regulator assembly.

3 ft. (91 cm)

• 6 in. (15 cm) for water heaters less

than or equal to 10,000 Btuh (3 kW).

• 12 in. (30 cm) for water heaters

greater than 10,000 Btuh (3 kW) and less than or equal to 100,000 Btuh (30 kW).

• 36 in. (91 cm) for water heaters

greater than 100,000 Btuh (30 kW).

6 ft. (1.83 m)

7 ft. (2.13 m)

12 in. (30 cm)

†

‡

Venting

Page 40

INSTALLATION INSTRUCTIONS

Rising moisture will collect under eaves.

Inside

Corner

Caulk

If soffit vent is too close, block off and install new vent at another location.

Sheet metal plate on brick or masonry surface recommended.

6' (1.8 m) Caulk zone or to edge of window etc., starting within 6' (1.8 m)

(1.2 m)

Rising moisture will collect under eaves.

Inside

Corner

Caulk

If soffit vent is too close, block off and install new vent at another location.

6' (1.8 m) Caulk zone or to edge of window etc., starting within 6' (1.8 m)

(1.2 m)

12"

(300 mm)

Venting for Direct-Vent Water Heater (cont.)

Horizontal Vent Considerations

Venting

WARNING: Moisture in the flue gas

will condense as it leaves the vent terminal. In cold weather this condensate can freeze on the exterior wall, under the eaves, and on surrounding objects. Some discoloration to the exterior of the building is to be expected. However, improper location or installation can result in severe damage to the structure or exterior finish of the building.

– Do not locate vent terminal on the side of a

building with prevailing winter winds. This will help prevent water lines from freezing and moisture from freezing on walls and under eaves.

– Do not locate vent terminal too close to

shrubbery, since flue gases may damage them.

– All painted surfaces should be primed to

lessen the chance of physical damage. Painted surfaces will require maintenance.

– Guard against accidental contact with people

and pets.

INDOOR TANKLESS WATER HEATERS

WARNING: For multiple-unit

installation, a minimum distance between vent terminations must be maintained to prevent recirculation of vent gases. Maintain a center-tocenter distance between vent terminations of 19 in. (48 cm) for two-unit installation, or 21 in. (53 cm) for installation of three or more units.

– Do not terminate vent directly on brick or

masonry surfaces. A rust-resistant, sheet-metal backing plate is recommended behind the vent.

– Caulk all cracks, seams, and joints within

6 ft. (1.8 m) of the vent terminal.

– Caulk around wall faceplate for weather-tight

seal.

– Do not extend exposed vent pipe of indoor

water heaters outside of the building.

– This water heater requires its own separate

venting system. Do not connect the exhaust vent to an existing vent pipe or chimney.

OUTDOOR TANKLESS WATER HEATERS

– Install outdoor water heater such that air inlet

and flue outlet are above anticipated snow level.

Page 41

INSTALLATION INSTRUCTIONS

Horizontal Vent Installation

WARNING: Follow the vent

manufacturer’s installation instructions since design might vary from manufacturer to manufacturer. Improper vent installation can result in death, personal injury, product damage, and/or poor performance.

Venting

CAUTION: Use UL-approved

Category III Stainless Steel vent material only. No other vent material is permitted for use with this appliance.

Outer casing can be galvanized aluminum or other material.

Fasteners will vary depending on the wall type.

For particle board or

composite sheathing, use

4 hollow wall anchors. The anchors should be at least 1/8 in. (0.3 cm) in diameter and the appropriate length for the sheathing thickness.

For plywood or solid

wood sheathing or members, use 4 #10 x

1 1/4-in. wood screws.

For masonry walls, use suitable masonry anchors long enough to pass through the wall.

Apply high-temperature silicone sealant or

silicone/latex caulk around the vent section. Completely seal where it passes through the wall plate and where it is attached to the structure. This will provide a weather seal for the system, so it must be a good seal.

Attach the female end of the next vent pipe section to the male end of the 3-in./5-in. (7.6-cm/12.7-cm) concentric vent pipe. Push firmly on the pipe until the outer jacket has made contact with the snap ring on the male end of the concentric vent pipe section. Secure the two pipe sections with the provided selftapping screws.

NOTICE: When fully assembled, the

outer female end will overlap the male end about 1 in. (2.5 cm).

Reinstall the decorative sheathing around the faceplate. The decorative sheathing may be painted to match the exterior decor.

Do not attempt to fabricate or adapt other vent

pipe or materials to this venting.

Page 42

Vent Pipe Wall Plate

Inspection

Access Panel

(Optional)

Inspection

Access Panel

(Optional)

CeilingFire

Stop

2' max.*

(610 mm)

1/4" Per Foot Downward Slope

90˚

Elbow

INSTALLATION INSTRUCTIONS

Venting for Direct-Vent Water Heater (cont.)

Horizontal Vent Installation (cont.)

Venting

Using a thick bead of high-temperature silicone, seal the overlapping area of the outer 5-in. (12.7-cm) pipe.

Attach required vent sections between the water heater collar and the horizontal vent termination.

Typical Horizontal Termination with

1/4 In. Per Foot of DOWNWARD Slope

CAUTION: The condensate collector

must be used in horizontal terminations if vertical rise in the vent system exceeds 2 feet (610 mm).*

NOTICES:

• Maintain the proper clearance between the vent pipe and combustible or noncombustible materials as described on page 29.

• A clearance of 0 in. (0 cm) is allowed between the air intake pipes and combustible material.

• Use proper support for the vent and air intake pipes as described on page 34.

• Support method used should isolate the vent pipe from floor joists or other structural members. This helps prevent transmission of noise and vibration.

• Do not support, pin, or secure the venting system in a way that restricts the normal thermal expansion and contraction of the chosen venting material.

Page 43

INSTALLATION INSTRUCTIONS

Hole

Through Roof

Hole

Through Ceiling

A, B, C , D

Vertical Vent Installation

WARNING: Follow the vent

NOTICES:

• Only Raypak-approved termination and parts should be used during installation.

• Install a fire stop plate at every penetration of a floor or ceiling, whenever the vent is not running through a fire-rated shaft.

• Maintain the recommended air space clearance to combustible materials and building insulation.

Support vertical and horizontal runs as

described on page 36. Vertical supports are required every 4 ft. (1.2 m) along a vertical pipe route, after every transition to vertical, and after every offset elbow.

NOTICE: Free-standing vent pipe that

penetrates a roof/ceiling requires another means of support from a second location.

Venting

Cut a hole through the roof and interior ceiling to accommodate the vent pipe.

Complete the vent pipe installation to the water heater vent collar. If required, use hightemperature silicone sealant where the vent connector joins the water heater.

Determine the vent terminal height and install

the vent pipe accordingly. Refer to “Vertical Vent Terminal Location” on page 44 for clearance requirements.

Install adequate flashing where the vent pipe

passes through the roof.

Page 44

INSTALLATION INSTRUCTIONS

A, B, C, D

Vent Pipe

Through Roof

Venting for Direct-Vent Water Heater (cont.)

Vertical Vent Terminal Location

Venting

The following chart with diagrams details the minimum dimensional information needed to determine the proper location of the vertical vent terminal for direct-vent indoor tankless water heaters:

U.S. Installation

Location

A = Minimum clearance above the roof level. 12 in. (30.5 cm) above roof level. 18 in. (45.7 cm) above roof level.

B = Minimum clearance above anticipated snow

level.

C = Maximum clearance above roof level (without

additional vent support).

D = Maximum clearance above anticipated snow

level (requires additional vent support).

E = Required vent clearance from any gable,

dormer, or other roof structure with building access (i.e., vent, window).

F = Required vent clearance from any forced air

inlet, including dryer and furnace air inlets.

1 In accordance with current ANSI Z223.1/NFPA 54 National Fuel Gas Code. 2 In accordance with current CAN/CSA B149.1 Installation Codes.

NOTE: Only manufacturer-approved termination and parts should be used during installation.

Requirements

12 in. (30.5 cm) above anticipated snow level.

24 in. (61 cm) above roof level. 24 in. (61 cm) above roof level.

24 in. (61 cm) above anticipated snow level.

4 ft. (1.2 m). 4 ft. (1.2 m).

10 ft. (3 m) 6 ft. (1.8 m)

Canadian Installation Requirements

12 in. (30.5 cm) above anticipated snow level.

24 in. (61 cm) above anticipated snow level.

Page 45

Standard Vertical Vent Termination

Adjustable Roof Flashing

Vertical Termination Adapter

Air Intake

Storm Collar

Support Clamp

Fire Stop

To Drain: Dispose of condensate in accordance with local codes.

Condensate Trap

Fire Stop

3" to 5" Concentric Pipe

Support Hanger

1/4" Per Foot Upward Slope

INSTALLATION INSTRUCTIONS

Venting

CAUTION:

The condensate collector must be used with vertical vent installation.

Page 46

INSTALLATION INSTRUCTIONS

Water Supply

Plumbing

CAUTION: This water heater

MUST ONLY be used with the following water supply conditions to prevent product damage and operation failure.

• Clean, potable water free of corrosive chemicals, sand, dirt, or other contaminates.

• Inlet water temperatures above 32°F (0°C), but not exceeding 120°F (49°C).

• DO NOT reverse the HOT and COLD water connections.

• DO NOT connect this heater to water lines previously used for space heating. All water piping and components shall be suitable for potable water.

Chart for Recommended Water Quality Levels

6.5–8.5 Up to 500 mg/L Up to 15 mg/L

Cited reference: National Secondary Drinking Water Regulations

TDS (Total

Dissolved Solids)

Free Carbon

Dioxide (CO

)

Total

Hardness

Up to

200 mg/L

Aluminum Chlorides Copper Iron Manganese Zinc

0.2 mg/L

Up to

Thermal Expansion

A thermal expansion tank will be required if the water heater is installed in a system with a recirculation or storage tank. This prevents damage to the heater, related piping, and the relief valve.

NOTICE: Replacing the relief valve will

not correct the problem! The expansion tank is designed with a built-in air

cushion that compresses as the system pressure increases. This relieves the over-pressure condition and eliminates the repeat operation of the relief valve.

For other approved methods of thermal expansion, contact an installing contractor, water supplier, or plumbing inspector.

Up to

200 mg/L

Up to

1.0 mg/L

Up to

0.3 mg/L

Up to

0.05 mg/L

Up to

1.0 mg/L

Water Supply Connections

CAUTION: IMPORTANT—Do

not apply heat to the HOT or COLD water connections. If sweat connections are used, sweat tubing to the adapter before fitting the adapter to the water connections on the water heater. Any heat applied to the water supply fittings will permanently damage the internal components of the water heater.

NOTICE: In cold environments, ice can

accumulate in the water heater’s connectors. Plug in the water heater power cord for approximately 10 minutes before making these connections. This will melt any ice buildup.

Plumbing should be carried out by a qualified plumbing contractor in accordance with local codes.

Only use approved plumbing materials. To allow the full flow capacity, it is recommended

to keep water inlet and outlet pipes 3/4-in. (1.9-cm) diameter or larger.

To conserve energy and to prevent freezing, insulate both COLD and HOT water supply lines. Do not insulate the pressure-relief valve.

Recirculation

Direct recirculation is allowed, provided the loop is thermostatically controlled, and a timer is used to turn the pump off during off peak periods. The pump must be sized for a minimum of 5 gpm at 25 ft of head plus building head. A 10°F difference between the loop thermostat setting and water heater temperature setting must be maintained.

Page 47

INSTALLATION INSTRUCTIONS

Water Supply Connections (cont.)

To ensure proper operation of the water heater, follow these water pressure guidelines.

• Operation of the water heater requires a

minimum water pressure of 14 psi (97 kPa) and a minimum activation water flow rate of 0.4 gpm (1.5 lpm).

• Continuous operation of the water heater requires a minimum water flow rate of 0.25 gpm (1.01 lpm).

• Water pressure of 40 psi (276 kPa) is required to achieve maximum flow rate.

• To maintain proper performance, there must be sufficient water supply pressure.

Required Water Pressure =

Min. Operating Water Pressure

(14 psi [97 kPa])

+ Pipe Pressure Loss

+ Faucet Pressure Loss

+ Safety Margin

(more than 5 psi [34 kPa]).

• To supply HOT water to upper floors, additional water pressure will be required (0.44 psi [3 kPa] per foot of height). Calculate the distance between the water inlet of the water heater (ground level) to the HOT water faucet farthest away from the water heater (upper floor level).

• Well water systems should be set to ensure a minimum system pressure of 40 psi (276 kPa). The pressure should remain constant and stable during the operation of the water heater.

• Gravity water pressure is not recommended.

When the water is supplied from a water supply tank, the height of the tank, the diameter of the supply pipes, and their relation to water pressure need to be taken into consideration.

Plumbing

Water Supply Installation

NOTICES:

• Use only Teflon tape on all COLD and HOT water connections.

• If the water flow resistance of a showerhead is too high, the burner in the water heater will fail to ignite. Keep all showerheads clean from debris that could cause additional pressure drop.

• If using mixing valves on the outlet, choose one that prevents COLD water pressure from overcoming HOT water pressure.

• If multiple water heaters are installed in a manifold system, the water piping MUST be in “parallel” and the water pressure at each water heater should be 40 psi (276 kPa).

NOTICE: It is not recommended to use

pipes with smaller diameters than the water supply connection of the water heater.

Before attaching the water line to the water

heater, open the shut-off valve. Run the water until it has purged all contaminants (sand, debris, air, caulking).

Install a COLD water shut-off valve near the

inlet line on the water heater. This valve will be used for servicing and draining purposes.

Install a service valve on the end of the COLD

water supply line and connect it to the water inlet on the water heater.

Page 48

INSTALLATION INSTRUCTIONS

Cold Water

Service Valve

Hot Water

Service Valve

Hot Water

Service Valve

Pressure

Relief Valve

Relief

Valve

Water Outlet

Water

Inlet

Water

Inlet

Drain

Water Supply (cont.)

Plumbing

Water Supply Installation (cont.)

Open the drain valve in the COLD water outlet line to check the water flow through the water heater.

Close the shut-off valve and remove, clean, and replace the water filter.

NOTICES:

• Be sure to connect the COLD water inlet and the HOT water outlet as shown on the water heater. If reversed, the water heater will not function.

• The flow rate of HOT water may vary when more than two faucets (appliances, fixtures, etc.) are being used simultaneously.

• The pipes MUST be completely drainable. If the HOT water faucets are located at a point higher than the water heater, place a drain valve at the lowest point.

It is recommended to use unions and flexible copper connections at the COLD and HOT water lines. They allow the water heater to be disconnected easily for servicing.

Use the following guidelines when connecting the HOT WATER OUTLET:

• Connections between the water heater and

point(s) of use should be as short as possible.

• Local codes shall govern the piping used for water connections.

• To conserve energy and to prevent freezing, insulate both COLD and HOT water supply lines.

Do not insulate drain line or pressure-relief valve.

Alternate Water Piping Arrangement With Preferred Valve Kit

Service valve kits are available for all tankless water heater systems. Most kits include two fullport isolation valves to be used in the COLD and HOT water lines. When installed, these valves allow one person full diagnostic testing and ease of flushing the system. Contact your distributor or place of purchase for availability and installation information.

Page 49

INSTALLATION INSTRUCTIONS

Cold Water Supply

Shut-Off Valve

Union

Service

Valve

Service

Valve

Relief

Valve

Cold Water

Supply Inlet

Hot Water

Supply Outlet

Relief Valve

Discharge Line

Relief Valve

A new pressure-relief valve, complying with the Standard for Relief Valves and Automatic Gas Shut-Off Devices for Hot Water Supply Systems, ANSI Z21.22/CSA 4.4, must be installed at the HOT water outlet connection of the water heater during installation. Local codes shall govern the installation of any relief valves.

NOTICES:

• The following drawing illustrates a pressure-only relief valve. If local codes require a combination temperature and pressure-relief valve, you may need to install an extension piece to ensure that the relief valve probe is not directly in the flow path of the water.

• Local codes govern the installation of relief valves. If local codes require that a temperature and pressure-relief valve be installed, the manufacturer recommends a type 40XL Watts temperature and pressure-relief valve or equivalent model be used.

• Manual operation of relief valves should be performed at least once a year.

• If the relief valve on the system discharges periodically, a problem exists. Turn off the water heater, unplug the unit, and call for service.

For safe operation of the water heater, be sure that:

• The pressure rating of the relief valve must not

exceed 150 psi (1,034 kPa) or the maximum working pressure of the water heater. (See the rating plate on the water heater.)

• The BTUH rating of the relief valve must equal or exceed the BTUH input of the water heater. (See the rating plate on the water heater.)

• No valve of any type should be installed between the relief valve and the water heater.

• Discharge from the relief valve should be piped to a suitable drain. Piping used should be of a type approved for the distribution of hot water.

• HOT and COLD water lines should be insulated up to the water heater. See page 50.

• The discharge line must be NO SMALLER than the outlet of the relief valve. The drain line must pitch downward to allow for complete drainage of the line and the valve.

• The end of the discharge line should not be threaded or concealed and should be protected from freezing. No valve of any type, restriction, or reducer coupling should be installed in the discharge line.

Plumbing

One end of the relief valve discharge line connects to the HOT water outlet pipe as shown above. The other end of the pipe should be routed to a suitable drain to eliminate potential water damage.

Page 50

INSTALLATION INSTRUCTIONS

Cold Water

Service Valve

Hot Water

Service Valve

Relief Valve

Water Outlet

Water

Inlet

Water

Inlet

Drain

Union

Manual Gas Supply Line

Shut-Off Valve

Cap

Sediment Trap

Manual Gas

Shut-Off Valve

Water Supply (cont.)

Hot and Cold Pipe Insulation Installation

For increased energy efficiency, use pipe insulation as shown in the diagram. Insulate the pipes all the way to the top. DO NOT cover any drain or pressure-relief valve(s).

• When pipe insulation is not rated for the appropriate weather conditions, install electric heat tracing or equivalent to prevent freezing of the pipes.

• Do not insulate or block drain valve on the hot outlet fitting.

• If pipes are allowed to freeze, the water heater and the pipes may malfunction or leak due to freezing water.

NOTICE: The hot and cold water supply

PlumbingGas Supply

pipes should be insulated to provide additional freeze protection.

WARNINGS:

Gas Supply

Gas Supply Connections

WARNING: Do not attempt to

convert this water heater for use with a different type of gas other than the type shown on the rating plate. Doing so could result in death, personal injury, explosion or fire, product damage, and/or poor operating conditions or performance.

NOTICES:

• Gas piping shall be in accordance with local utility company requirements and/or in the absence of local codes, use the latest edition of National Fuel Gas Code (NFGC), ANSI Z223.1. In Canada, use the latest edition of CAN/CSA B149.1, Natural Gas and Propane installation code.

• Apply a thin coat of pipe compound to all threaded male ends. Compound must be of the type resistant to the action of LP gas.

• To ensure proper water heater operation, the gas pipe and gas meter must be sized correctly.

• If flexible connectors are used, the minimum inside diameter must be 3/4" or greater and the rated capacity of the connector must be equal to or greater than the BTU capacity of the water heater. See manufacturer information for the gas connector. Lengths over 36 inches are not recommended.

• Do not use excessive force (over 31.5 ft. lbs. [42,7 Nm]) when tightening the pipe sections. Excessive force can damage the water heater, especially when Teflon pipe compound is used.

Page 51

Gas Supply (cont.)

INSTALLATION INSTRUCTIONS

Gas Piping

Pipe-Sizing Procedure – Example

The gas supply must be capable of handling the entire gas load at the location. Gas line sizing is based on gas type, the pressure drop in the system, the gas pressure supplied, and gas line type. For gas pipe sizing in the United States, refer to the National Fuel Gas Code, NFPA 54. For Canadian gas pipe sizing, refer to the Natural Gas and Propane Installation Code CAN/CSA B149.1. The information below is provided as an example. The appropriate table from the applicable code must be used.

1. Determine the cubic feet per hour of gas required by dividing the gas input (on the rating plate) by the heating value of the gas (available from the local gas company). The gas input needs to include all gas products at the location and the maximum BTU usage at full load when all gas products are in use.

Gas Input of Cubic Feet Water Heater (BTU/HR) Per Hour (CFH) = Heating Value of Gas (BTU/FT3)

2. Use the table for your gas type to find the pipe size required for your cubic feet per hour of gas and your pipe length.

Example: The heating value of propane gas for your location is 2500 BTU/FT of the tankless water heater is 199,900 BTU/ HR. Additional appliances at the location require 75,000 BTU/HR. Therefore, the cubic feet per hour = (199,900 + 75,000)/2500 = 109 FT3/HR. If the pipe length is 100 ft., then the 3/4-inch pipe size capable of supplying 197 FT3/HR of propane gas will be adequate.

. The gas input

Gas Supply

Pipe-Sizing Table – Natural Gas

Schedule 40 Metallic Pipe

Inlet Pressure: Less than 2 psi (55 inches W.C.)

Length

10 273 514 1060 1580

20 188 353 726 1090

30 151 284 583 873

40 129 243 499 747

50 114 215 442 662

60 104 195 400 600

70 95 179 368 552

80 89 167 343 514

90 83 157 322 482

100 79 148 304 455

125 70 131 269 403

150 63 119 244 366

175 58 109 224 336

200 54 102 209 313

Pressure Drop: 0.3 inches W.C.

Specic Gravity: 0.60

(Capacity in cubic feet per hour)

Pipe Size (inches)

3/4 1 1 1/4 1 1/2

Pipe-Sizing Table – Propane Gas

Schedule 40 Metallic Pipe

Inlet Pressure: 11.0 inches W.C.

Pressure Drop: 0.5 inches W.C.

Specic Gravity: 1.50

(Capacity in cubic feet per hour)

Length

10 291 608 1150 2350

20 200 418 787 1620

30 160 336 632 1300

40 137 287 541 1110

50 122 255 480 985

60 110 231 434 892

80 101 212 400 821

100 94 197 372 763

125 89 185 349 716

150 84 175 330 677

175 74 155 292 600

200 67 140 265 543

1/2 3/4 1 1 1/4

Pipe Size (inches)

Refer to current National Fuel Gas Code, NFPA 54.

Page 52

INSTALLATION INSTRUCTIONS

Gas Supply (cont.)

Gas Supply Installation

Install the manual gas appliance shut-off valve

to the gas connection at the water heater. The shut-off is supplied with the water heater.

Gas Supply

Install a ground joint union or ANSI design-

certified semi-rigid or flexible gas appliance connector to the open end of the manual gas appliance shut-off valve. The (NFGC) ANSI Z223.1 and CAN/CSA B149.1 codes mandate the use of manual gas shut-off valves.

Using the proper-size piping, fittings, and

components, build the gas supply line to the water heater.

NOTICE: The gas supply line should

be a minimum of 3/4-in. (1.9-cm) black steel pipe or other approved gas piping material.

Install a sediment trap at the lowest portion of

the gas line.

The inlet gas pressure to the water heater must NOT exceed 10.5 in. w.c. (2.6 kPa) for natural gas and 13 in. w.c. (3.2 kPa) for LP gas. For purposes of input adjustment, the minimum inlet gas pressure (with main burner on) is shown on the water heater rating plate. If high or low gas pressures are present, contact your gas supplier for correction.

Install a manual gas supply line shut-off valve

to the end of the gas supply line.

NOTICE: Lever-type gas shut-offs

should all be T-handle type.

Page 53

INSTALLATION INSTRUCTIONS

Leak Testing

WARNING: Never use an open

flame to test for gas leaks, because death, personal injury, and/or property damage can result.

The water heater and its gas connections MUST be leak-tested at normal operating pressures before the unit is placed in operation. These tests should also include all factory connections.

Turn on the gas shut-off valve(s) to the water heater.

Use a soapy water solution to test for leaks at all the connections and fittings. If bubbles are seen, it indicates a gas leak that must be corrected.

Contact a qualified service technician.

Gas Supply

Pressure Testing the Gas Supply System

CAUTION: Install a gas pressure

regulator in the gas supply line. This regulator should not exceed the maximum supply pressure. DO NOT use an industrial-type gas regulator.

The water heater and its manual gas shut-off valve must be disconnected from the gas supply piping system whenever the pressure testing will exceed 1/2 psi (14 in. w.c. [3.5 kPa]).

The water heater must be isolated from the gas piping system whenever the pressure testing will be less than and/or up to 1/2 psi (14 in. w.c. [3.5 kPa]). Closing the manual gas shut-off valve will isolate the water heater from the gas piping system.

Page 54

INSTALLATION INSTRUCTIONS

Gas Supply (cont.)

Gas SupplyElectrical

High-Altitude Installation

The water heater is certified for installations up to 3,280 ft. (1,000 m) above sea level. The input rating of this water heater is based on sea level operation. At higher elevations, the actual input rate may be lower than the value listed on the rating label.

Electrical Wiring

DANGER: Shock Hazard – Before

servicing the water heater, turn off the electrical power to the water heater at the main disconnect or circuit breaker. Failure to do so will result in death or serious personal injury.

WARNING: Field wiring connections

and electrical grounding must comply with local codes or, in the absence of local codes, with the latest edition of the National Electrical Code, ANSI/ NFPA 70, in the U.S., or Canadian Electrical Code, CAN/CSA C22.1, Part 1, in Canada.

CAUTION: Labeling all wires prior

to disconnection is recommended. Wiring errors can cause personal injury, product damage, and/ or dangerous operating conditions. Verify correct operation after servicing.

NOTICES:

• Do not connect power until venting installation is complete (see Venting Installation pages 34–45).

• Wait ninety (90) seconds after power is connected for the first time to initiate operation of the water heater.

• Power consumption is up to 100 Watts during normal operation, 3-5 Watts during standby, waiting to run, and up to 200 Watts during the freeze protection operation.

Power Cord

• The electric power supply requirement for this water heater is 120 VAC/60 Hz, 2 Amps.

• A dedicated circuit is recommended for the water heater. Do not connect to a GFCI or AFCI circuit. Multiple units may be connected to a single circuit up to the circuit rating.

NOTICE:

• For installations above 3,280 ft. (1,000 m) elevation, contact a qualified service technician to make the proper altitude adjustments. See pages 66 and 67 for additional information.

WARNING: Do not install this

water heater at elevations above 3,280 ft. (1,000 m) without the proper adjustments. Please contact your installer, local gas supplier, place of purchase, or the Customer Service phone number listed on page 26 in the “Call for Assistance” section.

• Do not use 3-prong to 2-prong adapters. Do not use power strips or multiple outlet adapters.

• All direct-vent gas models come with a threeprong power cord. Only use this power cord and a matching grounded electrical outlet.

• All outdoor gas models do not come with a power cord. Only hard-wire to an appropriate power outlet with a ground terminal.

• Keep any excess length of the power supply cord on the outside of the water heater.

• If local codes require hard-wiring, see instructions for “Hard-Wiring the Electrical Connections” below.

Hard-Wiring the Electrical Connections

• Wiring should be performed by a qualified electrician in accordance with local codes.

• The water heater requires a properly grounded 120 VAC/60 Hz power supply. Multiple water heaters may be connected to a single circuit up to that circuit’s rating.

•

DO NOT connect grounding wire to water pipes, gas pipes, telephone cables, lighting conductor circuits, or to any other grounding circuits that require a GFCI or AFCI (arc fault circuit interrupter).

• An ON/OFF switch must be provided and installed for the incoming 120 VAC power supply.

• Wire the water heater exactly as shown in the wiring diagram. This wiring diagram can also be found inside the water heater cover panel.

• The green screw is provided in the enclosure for a grounding connection.

• Connect the live wire to the black wire and neutral wire to the white neutral wire.

Page 55

Electrical Wiring (cont.)

Wiring Diagram

INSTALLATION INSTRUCTIONS

Electrical

Page 56

INSTALLATION INSTRUCTIONS

Electrical Wiring (cont.)

Remote Control Selection and Location

WARNING: Field wiring connections

CAN/CSA C22.1, Part 1, in Canada.

NOTICES:

•

The provided remote control will allow maximum temperature settings of 120°F (49°C). Temperatures up to 185°F (85°C) for commercial applications* can be achieved with the MAIN (UMC-117) remote control. Only qualified service personnel should perform this adjustment.

• An optional cable (EZ Link CableTM) can be purchased separately to manifold two water heaters together.

• Do not attempt to disassemble a remote control. All controls are sealed and calibrated for accurate water heater control and operation.

Review the following considerations before determining the location of the remote control(s):

• Do not install any remote control

outdoors or where it can come in contact with water.

Avoid installing the remote control in

•

the following areas and/or conditions: – area exposed to heat. – area exposed to steam. – area exposed to oil. – area exposed to direct sunlight. – areas near stored or used

flammable products.

• Place remote control out of children’s reach.

• The remote control should be installed in a

convenient location (e.g., kitchen, laundry room, utility room, or directly next to the water heater).

• The maximum distance between the water heater and the remote control installation location is limited to 195 ft. (59 m) of wire.

Electrical

One remote control is provided with the water heater. Additional remote controls may be purchased separately. The available remote controls are listed in the following chart. Up to three remote controls can be used with the water heater. No other manufacturer’s controls are

suitable for use with this water heater.

Remote Control

Model Number

UMC-117 MAIN

USC1-117

USC2-117 BATH 2

MIC-6 or MIC-185**

Manifold System

**When a manifold system is installed, the main remote control connected to the manifold controller (MIC-6 or MIC-185) has priority over the remote controls connected to the water heater.

Remote Control

Description

BATH 1

Manifold System Optional (Sold Separately)

Temperature

Set Point Range Availability

100°F–120°F (38°C–49°C) Factory Default

85°F (29°C)

125°F–185°F (52°C–85°C)

100°F–120°F (38°C–49°C) Optional (Sold Separately)

85°F (29°C) Qualied Technician Adjustment

100°F–120°F (38°C–49°C) Optional (Sold Separately)

85°F (29°C) Qualied Technician Adjustment

Adjustment for Commercial Products*

Qualied Technician

Page 57

INSTALLATION INSTRUCTIONS

Remote Control Installation

WARNING: Field wiring connections

CAN/CSA C22.1, Part 1, in Canada.

NOTICES:

• Extension cable can be any Type–T 18 AWG wire similar to a thermostat wire and need not be polarity-sensitive.

• It is not recommended to have wiring exposed.

• Do not apply sealant to remote control cable.

• Do not use network cable, telephone wire, or

any twisted-pair cable.

Connecting the MAIN (UMC-117) Remote Control to a Wall:

Drill a 1- to 1 1/2-in. (2.5/3.8-cm) hole at the proposed control location. Install the remote control cable between the location of the remote control and the water heater.

Install the base plate to the wall using suitable

screws and wall anchors.

NOTICE: The tabs on the base plate

should always point out.

Connect the remote control to the remote

control cable.

Electrical

Position the remote control on the base plate.

Remove the remote control from the base plate.

Feed the remote control cable through the large center hole in the base plate.

NOTICE: The tabs on the base plate

should line up with the slots on the back of the control panel.

Secure the control panel to the base plate with

one screw into the bottom tab.

NOTICE: Do not attempt to connect the

remote control or control wire to the water heater while the water heater has power applied to it. Damage to the water heater will occur. Do not cut or strip the wiring while it is connected to the water heater or while the water heater has power applied to it.

Page 58

Remote Control

Connection Cover

INSTALLATION INSTRUCTIONS

Electrical Wiring (cont.)

Remote Control Installation (cont.)

Connecting the Remote Control to the Water Heater:

Firmly tighten the terminal screws by hand.

Ensure that the power to the water heater has been disconnected.

Electrical

Loosen the one screw located on the remote control connection cover. The connection cover is made of white plastic.

NOTICE: DO NOT REMOVE FRONT

PANEL. Remote control wires are connected on

the bottom of the unit.

There are no accessible remote control terminals inside the water heater.

Connect the remote control extension cables from the remote control to the remote control connection terminals.

Secure the remote control extension cable on

the hook located on the side of the remote control connection base.

Reinstall the remote control connection cover

and secure with the one screw.

Switch on the power supply to the water heater.

Check for proper operation of the remote control and the water heater.

NOTICE: The remote control wire

connection terminals are not polarity-sensitive.

Page 59

Insulation Blankets

INSTALLATION INSTRUCTIONS

In general, insulation blankets for external use on gas water heaters are not necessary. The purpose of an insulation blanket is to reduce the standby heat loss from the water heater’s storage tank. Since these water heaters do not store water, they eliminate the need for the insulation blanket.

WARNING:

• NEVER cover the air inlet, flue outlet, or operating and warning labels attached to the water heater. Covering these components will cause dangerous operating conditions that can lead to death, personal injury, property damage, and/or product damage.

Installation Precautions

• Follow all installation instructions covered in this manual.

• Check the inlet gas pressure to make sure it is within the range specified on the rating plate.

• Make sure there is adequate air for combustion and ventilation as described on pages 38–39 or page 43 in this manual.

• Maintain proper clearances to combustibles and noncombustibles as specified on the rating plate.

• Make sure the venting system complies with local codes, National Fuel Gas Codes (ANSI Z223.1/NFPA 54) or CAN/CSA B149.1, and the guidelines found on pages 34 through 45 in this manual.

The manufacturer’s warranty does not cover any damage or defect caused by insulation, insulation attachment, or use of any type of energy-saving or other unapproved devices (unless authorized by the manufacturer). The use of unauthorized energy-saving devices can result in death, personal injury, and/or property damage. The manufacturer disclaims any responsibility for such loss or injury resulting from the use of such unauthorized devices.

• Contact the local gas company to make sure the gas meter and gas piping are adequately sized.

• Use Teflon tape on all male water line connections and fittings.

• Do not block or restrict any air intake openings.

• Do not remove the front cover unless absolutely

necessary. This should only be done by a qualified service technician.

• Do not install this product where standing water may occur.

• Do not use pipe dope on water line connections and fittings.

Electrical

Page 60

INSTALLATION INSTRUCTIONS

Installation Checklist

Checklist

A. Water Heater Location

Indoor water heaters must be installed indoors.

Outdoor water heaters must be installed outdoors.

Close to area of ventilation termination (indoor models).

Protected from freezing temperatures.

Proper clearance from combustible material observed.

Sufficient fresh air supply for proper operation of water heater.

Air supply free of corrosive elements and flammable vapors.

Provisions made to protect area from water damage.

Sufficient room to service heater.

Combustible materials, such as clothing, cleaning materials, and rags, clear of the heater and vent piping.

Water heater is properly attached to the wall.

B. Coaxial Vent (Indoor Models)

Vent pipe material is Category III and is manufacturer-approved.

Horizontal vent runs have 1/4 in. per foot of DOWNWARD slope towards the vent terminal.

Vertical venting is installed as described on pages 44 and 45.

Connector(s) securely fastened together with high-temperature silicone (500°F [260°C]) and airtight.

C. Water Supply/Relief Valve

Water supply has sufficient pressure.

Air has been purged from the water heater and the piping.

Water connections tight and free from leaks.

Water filter is clean and in place.

All piping has been assembled as described on pages 47 and 48.

Water pipes are insulated and protected from freezing, if necessary.

Pressure-relief valve properly installed with discharge line running to open drain.

Discharge line protected from freezing, if necessary.

D. Gas Supply

Gas type matches listing on rating plate.

Gas supply pressure is sufficient for the water heater.

Gas line equipped with shut-off valve, union, and sediment trap as described on page 52.

Approved pipe-joint compound has been used on all gas pipe connections.

All connections and fittings have been checked for leaks with a soapy water solution.

Gas company inspected installation (if required).

E. Electrical Wiring

Supply cord and/or wiring meets all local codes, National Electrical Code, ANSI/NFPA 70, in the U.S., or Canadian Electrical Code, CAN/CSA C22.1, Part 1, in Canada.

Voltage matches listing on rating plate.

All coaxial vent runs are properly installed.

Vent terminal is properly installed.

Maximum vent length is observed.

Water heater is properly grounded.

F. Condensate

Drain hose is attached to the condensate collector, and condensate is drained as described on page 37.

Page 61

Piping for Space Heaters

Cold Water

Supply

Potable Water

Expansion Tank

(2 gallons)

Tankless

Water Heater

Air Handler

Union

Cold Water Supply

Shut-Off Valve

Check

Valve

Gas Supply

Line

Drain Valve

Tempering

Valve

Tempered

Water

Shut-Off

Valve

Air

Separator

Relief Valve

INSTALLATION INSTRUCTIONS

Local codes or plumbing authority requirements may vary from the instructions or diagrams provided in this manual and take precedence over these instructions.

Combination Potable and Space Heating Application

DANGERS:

• When this system requires water for space heating at elevated temperatures (above 125°F [52°C]), a mixing or tempering valve must be installed in the hot water supply line to the house in order to reduce the scald hazard potential.

• Any piping or components used in the installation of this water heater in a combination potable and space heating application must be suitable for use with drinking water.

• If this water heater is installed in an application intended to supply domestic hot water needs and hot water for space heating purposes, do not connect the heater to an existing heating unit or components of a heating system that have previously been used with a nondrinking water system. Toxic chemicals such as those used for boiler treatment may be present and will contaminate the drinking water supply causing possible health risks. Never introduce toxic chemicals, such as those used for boiler treatment, into this system.

• This water heater is not approved as the dedicated space heating unit. This water heater must be used for combination applications with air handler only and not for indoor heating applications.

Typical Combination Illustration

(Pump included)

Space Heater

Page 62

INSTALLATION INSTRUCTIONS

Lighting the Water Heater

WARNING: Before operating

this water heater, be sure to read and follow the instructions on the following label, all labels on the water heater, and the “Important Safety Information” section in this manual. Failure to do so can result in unsafe operating conditions that can result in death, personal injury, property damage, and/or product damage.

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING

causing property damage, personal injury or loss of life.

: If you do not follow these instructions exactly, a fire or explosion may result

NOTICE: If you have any problems

reading or following the instructions in this manual, STOP and call a qualified service technician or contractor.

1.STOP! Read the safety information above on this label.

2.Turn off all electric power to the appliance.

3.Do not attempt to light the burner by hand.

4.Turn the Gas Shutoff Valve located on the outside of the unit clockwise to the "OFF" position.

5.Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow "B" in the safety information above on this label. If you don't smell gas, go to the next step.

6.Turn the Gas Shutoff Valve located on the outside of the unit counterclockwise to the "ON" position.

7.Turn on all electric power to the appliance.

Start/Adjust

8.If the appliance will not operate, follow the instructions "To Turn Off Gas To Appliance" and call your service technician or gas supplier.

1.Turn off all electric power to the appliance if service is to be performed.

2.Turn the Gas Shutoff Valve located on the outside of the unit clockwise to the "OFF" position.

OPERATING INSTRUCTIONS

GAS SHUTOFF

VALVE

OPEN CLOSE

TO TURN OFF GAS TO APPLIANCE

Page 63

Operating Instructions

Read, understand, and follow the safety information listed on the operating label on page 62 and in the “Important Safety Information” section on pages 2-8 in this manual.

Disconnect all electric power to the water heater.

INSTALLATION INSTRUCTIONS

Turn on all electric power to the water heater.

The water heater burner will automatically light when there is a demand for hot water.

WARNING: Do not attempt to light

the burner by hand. Lighting the burner by hand is an unsafe operating condition that can result in death, personal injury, property damage, and/or product damage.

If the water heater burner will not light, turn off

the water heater as described below and call your service technician or gas supplier.

Turn the gas shut-off valve clockwise to the OFF position. This valve is located on the outside of the water heater. Wait 5 minutes to clear any gas. If you don’t smell gas, proceed to Step 3.

NOTICE: If you smell gas, STOP and

follow the safety instructions listed under B on the operating label or on the front cover of this manual.

Turn the gas shut-off valve counterclockwise to the ON position.

Shutting Off the Water Heater

Disconnect all electric power to the water heater.

Turn the gas shut-off valve clockwise to the

OFF position.

Start/Adjust

Page 64

INSTALLATION INSTRUCTIONS

The contents on pages 64 through 67 should only be performed by qualified service personnel.

Setting the Water Temperature

WARNING: Improper adjustment,

alteration, service, or maintenance can result in death, personal injury, property damage, and/or product damage.

Maximum Temperature Adjustment by the Main Remote Control (UMC–117)

DANGER: Water temperatures above 125°F

(52°C) will result in death and/or severe burns from scalding.

WARNING: Refer to chart below and the

scald potential warnings on page 4 on this manual before making an adjustment. Changing this setting is done at your own risk.

Time/Temperature Relationship in Scalds

Water Time to Produce Temperature a Serious Burn

Indicator

In-Use

Indicator (Lit during operation)

Temperature

Adjustment

LED Display

(Displays

water

temperature

and error

codes)

To change the temperature settings up to 185°F (85°C):

Buttons

ON/OFF

Button and

Indicator

Turn off the gas and water to the water heater by closing the shut-off valves.

Priority

Table courtesy of Shriners Burn Institute

Commercial water heater temperatures can be adjusted up to 185°F (85°C). Do not perform the following adjustment if a setting of up to 185°F (85°C) is not required.

Start/Adjust

Temperature Conversion Chart °F/°C

85 100 102 104 106 108 110 112 114 116 118 120 125 130 140 150 160 170 185°F 29 38 39 40 41 42 43 44 46 47 48 49 52 54 60 66° 71 77 85 C

urn off the remote control.

NOTICE: LED display only shows °F.

Remove the front cover panel on the water heater.

Page 65

INSTALLATION INSTRUCTIONS

Setting the Water Temperature (cont.)

Dip Switches

Printed Circuit

Find DIP Switch 1 located in the top-right portion

of the PCB. The switch labeled “DIP 1” is the top switch.

Board (PCB)

Change the fourth switch on “DIP 1” back to the

OFF position (DOWN). The display of the remote control turns off.

As set from factory

MIN

The factory settings for this switch should all be in

the OFF position (DOWN).

MAX

ADJ

Change the fourth switch on “DIP 1” to the ON

position (UP). The display of the remote control starts to flash.

Replace the front cover.

Turn on the remote control.

Press the UP or DOWN adjustment button to set the

desired temperature.

Start/Adjust

Press “MAX” button located at the top right hand side on the PCB for more than 1 second. The display of the remote control is on continuously.

Turn on the gas and water to the water heater by

opening the shut-off valves.

Page 66

INSTALLATION INSTRUCTIONS

Setting the Water Temperature (cont.)

Minimum Temperature Adjustment by the Main Remote Control (UMC–117, USC1–117, and USC2–117)

Commercial water heater temperatures can be adjusted down to 85°F (29°C), when required.

To change the temperature settings down to 85°F (29°C):

Tur n on the remote control.

Turn off the gas and water to the water heater by closing the shut-off valves.

Press the DOWN adjustment button repeatedly until 100°F (38°C) shows in the LED display.

NOTICE: LED display only shows °F.

Press the DOWN adjustment button 3 times within 5 seconds. The display will show “85.”

Turn on the gas and water to the water heater by opening the shut-off valves.

NOTICE: The maximum flow rate at 85°F

(29°C) is 1.3 gpm (5.0 L/m).

High-Altitude DIP Switch Adjustments

When the water heater is installed above 3,280 ft. (1,000 m), the settings on the DIP switch located on the printed circuit board (PCB) need to be changed. If these settings are not changed, the water heater may not function properly.

NOTICE: If the water heater is installed

under 3,280 ft. (1,000 m) altitude, no adjustments

Start/Adjust

are necessary.

Verify the altitude that the water heater is installed.

Turn off the gas and water to the water heater

by closing the shut-off valves.

Page 67

Printed Circuit

Board (PCB)

Dip Switches

Dip switch adjustment

3,280 feet (1,000 m)

thru 6,560 feet

(2,000 m)

Dip switch adjustment

6,560 feet (2,000 m)

thru 9,840 feet

(3,000 m)

INSTALLATION INSTRUCTIONS

High-Altitude DIP Switch Adjustments (cont.)

If altitude is above 3,280 ft. (1,000 m) and

below 6,560 ft. (2,000 m), change the third

switch on “DIP 2” to the ON position (UP).

Remove the front cover panel on the water heater.

If altitude is above 6,560 ft. (2,000 m) and

below 9,840 ft. (3,000 m), change the fourth

switch to the ON position (UP).

Find DIP Switch 2 located in the top-right portion of the PCB. The switch labeled “DIP 2” is the bottom switch.

As set from factory

The factory settings for this switch should all be in the OFF position (DOWN).

NOTICE: Do not alter any other DIP

switch settings. The manifold pressure will be reduced accordingly.

Replace the front cover panel.

Turn on the gas and water to the water heater

by opening the shut-off valves.

Start/Adjust

Page 68

PARTS REPLACEMENT

Parts Ordering

WARNING: For your safety, do not

attempt to disassemble, repair, or replace any portion of this unit. Refer all repairs, service, and/ or adjustments to qualified service personnel.

Address all parts orders to the distributor or store where the water heater was purchased. All parts orders should include:

Direct-Vent Gas Components

1. The model and serial number of the water

heater from the rating plate.

2. Specify the gas type (natural or LP) as marked

on the rating plate.

3. Parts description (as shown below) and number

of parts desired.

Parts

Ref # Description

1 Control Board

2 Gas Valve Assembly

3 Burner Assembly

4 Igniter Coil

5 Blower Motor

6 Burner Manifold

7 Gas Inlet Connector 3/4"

8 Water Control Valve

Ref # Description

8a Water Bypass Valve

9 Water Inlet Connector 3/4"

10 Inlet Water Filter

11 Hot Outlet Connector 3/4"

13 Front Cover

14 Remote Control Terminal Block

15 Concentric Vent Connector Assembly

Page 69

PARTS REPLACEMENT

Outdoor Gas Components

Ref # Description

1 Control Board

2 Gas Valve Assembly

3 Burner Assembly

4 Igniter Coil

5 Blower Motor

6 Burner Manifold

7 Gas Inlet Connector 3/4"

8 Water Control Valve

8a Water Bypass Valve

9 Water Inlet Connector 3/4"

10 Inlet Water Filter

11 Hot Water Outlet Connector 3/4"

13 Front Cover

14 Remote Control Terminal Block

Parts

Page 70

LIMITED WARRANTY

For the Raypak Commercial Tankless Gas Water Heaters.

GENERAL

This Limited Warranty is only available to the original owner of the water heater at the original installation location. It is not transferable. Raypak warrants this tankless gas water heater, and its component parts, to be free from defects in materials and manufacture, under normal use and service, for the Applicable Warranty Periods. At its option, Raypak will repair or replace the defective water heater, or defective component part(s), in accordance with the terms of this Limited Warranty, if it fails in normal use and service during the Applicable Warranty Periods. The replacement water heater must be manufactured by Raypak. The replacement component part(s) must be Raypak authorized component part(s). The replacement unit will be warranted only for the unexpired portion of the original unit’s Applicable Warranty Periods. Raypak strongly recommends that this tankless water heater be installed by a contractor which is licensed, state qualified and trained on Raypak's tankless products since improper installation may invalidate warranty coverage.

EFFECTIVE DATE

The Effective Date of warranty coverage (or the beginning of the Applicable Warranty Periods) is the date of installation of the water heater, if properly documented. Otherwise, it is the date of manufacture of the water heater plus ninety (90) days.

APPLICABLE WARRANTY PERIODS:

Commercial: any commercial application where the unit is used for potable water

Commercial: with recirculation, controlled loop

Five (5) years from the Effective Date for the heat exchanger, five (5) years from the Effective Date for the component parts, and one (1) year for certain labor as described under the heading, LABOR, SHIPPING AND PROCESSING COST. Provided that the recirculation system is an on demand type system or the pump is controlled with a temperature sensor (aquastat) and timer.

Commercial: with recirculation, uncontrolled loop

All Applicable Warranties will be limited to three (3) years from the Effective Date if the water heater is installed in a system in which the water is re-circulated using a continuously operating pump.

Commercial: any commercial application where the unit is used to provide other than potable water

All Applicable Warranty Periods will be limited to one (1) year from the Effective Date if the water heater is installed anywhere that the unit will supply water for a non-potable use, such as an industrial process.

WARRANTY EXCLUSIONS

This Limited Warranty will not cover: a) Service trips to your business to teach you how to install, use, or maintain this water heater or to bring the water heater installation into

compliance with local building codes and regulations or manufacture installation requirements. b) This tankless water heater if it is installed for use in: spa or pool heating; a recreational vehicle; a boat or any other watercraft. c) Units installed in any circulating system in which the temperature of the incoming water to the water heater is in excess of 140° f. d) This tankless water heater if it is installed in any installation supplying radiant heat, such as in floor, baseboard, radiators, snow melt or closed

loop systems, or any system using glycol. e) Damages, malfunctions or failures resulting from failure to install the water heater in accordance with applicable building codes/ordinances or

good plumbing and electrical trade practices. f) Damages, malfunctions or failures resulting from improper installation or failure to operate and maintain the unit in accordance with the

manufacturer’s instructions provided including outside recommended water quality levels: g) Performance problems caused by improper sizing of the water heater or the gas supply line, the venting connection, combustion air openings,

electric service voltage, wiring, or fusing. h) Damages, malfunctions or failures caused by improper conversion from natural gas to lp gas or lp gas to natural gas fuel source. i) Damages, malfunctions or failures caused by operating the water heater with any parts removed or with modified, altered, or unapproved parts

installed. j) Damages, malfunctions or failures caused by abuse, accident, fire, flood, freeze, lightning, acts of god and the like. k) Heat exchanger failures (leaks) caused by operating the water heater in a corrosive or contaminated atmosphere or damages, malfunctions or

failures caused by lime, mineral build-up, or scale. l) Damages, malfunctions or failures caused by operating the unit at water temperatures exceeding the maximum setting of the operating, or

high limit, control. m) Heat exchanger failures caused by operating the water heater when it is not supplied with potable water, free to circulate at all times. n) Damages, malfunctions or failures caused by subjecting the heat exchanger to pressures, or firing rates, greater than those shown on the

rating label. o) Damages, malfunctions or failures resulting from the use of any attachment, including any energy saving device, not authorized by raypak. p) Units installed outside the fifty states (and the district of columbia) of the united states of america and the dominion of canada. q) Units removed from the original installation location and reinstalled elsewhere. r) Units that have had their rating labels altered, tampered with, or removed. A water heater should not be operated if the rating label is

removed.

LABOR, SHIPPING, AND PROCESSING COSTS

For one (1) year after the Effective Date, Raypak will cover reasonable labor costs necessary to repair or replace a tankless water heater or component part it determines to be defective in material and/or manufacture by a contractor which is licensed, state qualified, and trained for Raypak's tankless water heaters. This Limited Warranty does not cover any labor expenses for general service, inspection, reinstallation, permits, removal and disposal of the failed water heater or defective component part(s), or updating the installation to meet manufacture or local code requirements. All such expenses are your responsibility. Raypak will pay the transportation costs for an “in-warranty” replacement water heater, or “in-warranty” replacement component part(s), to a convenient delivery point (selected by Raypak) near the place the original water heater, or original component part(s), is located: such as a local water heater distributor. You must pay any local freight charges, including the cost of returning the failed water heater, or defective component part(s) to a convenient shipping location (selected by Raypak): such as a local Raypak distributor. Raypak does not authorize, recommend, or receive any benefit from any claims processing or similar fees charged by others to process warranty claims for any water heater or component part(s). Raypak will not reimburse any party for these, or any other, fees not specifically covered in this Limited Warranty document.

Page 71

HOW TO OBTAIN WARRANTY CLAIM ASSISTANCE

Any claim for warranty assistance must be made promptly. First, determine if your water heater is “in-warranty” (that is, within the Applicable Warranty Period). You can determine your unit’s warranty status by adding its Applicable Warranty Period to its date of installation. However, if you do not have documentary proof of your water heater’s date of installation, your unit’s warranty status will be based on its date of manufacture as determined from the serial number.

Add the Applicable Warranty Period plus ninety (90) days to the date of manufacture to determine whether the water heater is still covered by this Limited Warranty. You may also determine your unit’s warranty status by obtaining the complete model number, complete serial number, and date of installation of your water heater and then accessing the “Warranty Verification” information on Raypak’s internet website (www.raypak.com) or contacting Raypak’s Claims Department (telephone (800) 621-5622) during normal business hours (in the Central Time Zone) to determine if the Applicable Warranty Period has expired.

If your water heater is “in-warranty”, contact the plumber, or mechanical contractor, that installed it for assistance with the warranty repairs, or replacement, required. Raypak’s Technical Service personnel are available to assist you (by telephone at (800) 432-8373 or via e-mail at techserv@ rheem.com) in obtaining “in-warranty” service or to answer your questions about the operation or repair of your water heater during normal business hours (in the Central Time Zone). Be prepared to provide the plumber, mechanical contractor, or Raypak Technical Service person you call with the complete model number, the complete serial number, and the date of installation of your water heater in addition to an explanation of your water heater problem.

If an exact replacement is not available, Raypak will provide you with the current model of your water heater, or component part(s), or a replacement unit with comparable operating features. If government regulations or industry certification or similar standards require the replacement water heater, or replacement component part(s), to have features not found in the defective water heater, or the defective component part(s), you will be charged for the difference in price represented by those required features. If you pay the price difference for those required features and/or to upgrade the size and/ or other features available on a replacement new water heater, you will also receive a complete new Limited Warranty (with the full Applicable Warranty Periods) for the replacement new water heater.

Raypak reserves the right to inspect, or require the return of, the failed water heater or the defective component part(s). Each “in-warranty” failure water heater must be made available to Raypak (with the rating label and all the component parts intact) in exchange for the replacement water heater. Each defective “in-warranty” component part to be replaced must be returned to Raypak in exchange for the replacement component part.

Warranty compensation is subject to validation of “in-warranty” coverage by Raypak Claims Department personnel.

• To obtain warranty compensation for an “in-warranty” water heater failure, you must provide Raypak with the failed water heater (with the rating label and all the component parts intact) the complete model number and the complete serial number of the Raypak water heater that replaced the failed unit; and the date the original water heater failed. You may also be required to provide documentary proof of the failed water heaters date of installation to establish its “in-warranty” status.

• To receive warranty compensation for an “in-warranty” defective component part, you must provide Raypak with: the defective component part; the complete model number and the complete serial number of the Raypak water heater from which the defective component part was removed; and the date the defective component part failed. You may also be required to provide documentary proof of the date of installation of the Raypak water heater from which the defective part was removed – or the date of purchase of the part (If it was purchased separately) – to establish the “in-warranty” status of the defective component part.

• If Raypak determines that the water heater or component part returned to Raypak is free of defects in material and manufacture and/or that it was damaged by improper installation, the warranty claim for the product, component part and/or labor maybe denied. Warranty claim documentation should be mailed promptly to Raypak, Claims Department, 1241 Carwood Court, Montgomery, Alabama 36117, or in

Canada, 125 Edgeware Rd. Unit 1, Brampton, ON, Canada L6Y 0P5

DO NOT RETURN THIS WATER HEATER OR PART TO RAYPAK WITHOUT A RETURN AUTHORIZATION.

EXCLUSIVE WARRANTY – LIMITATION OF LIABILITY

This Limited Warranty is the only Warranty for this unit given by the Water Heater Division of Raypak Inc. No one is authorized to make any other warranties on behalf of Raypak. ANY IMPLIED WARRANTIES, INCLUDING MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE,

SHALL NOT EXTEND BEYOND THE APPLICABLE WARRANTY PERIODS, SPECIFIED PREVIOUSLY. RAYPAK’S SOLE LIABILITY, WITH RESPECT TO ANY DEFECT, SHALL BE AS SET FORTH IN THIS LIMITED WARRANTY, AND ANY CLAIMS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING DAMAGE FROM WATER LEAKAGE) ARE EXCLUDED. Some states do not allow limitations on how long an implied warranty

lasts, or for the exclusion of incidental or consequential damages, so the above limitations or exclusions may not apply to you. This Limited Warranty gives you specific legal rights, and you may also have other rights, which vary from state to state. We suggest you immediately complete the information below and retain this Certificate of Limited Warranty in the event warranty service is needed. Reasonable proof of the date of installation of your water heater may be required to establish its “in-warranty” status. Otherwise, the Effective Date of this Limited Warranty will be the date of manufacture of the water heater plus ninety (90) days.

DO NOT RETURN THIS DOCUMENT TO RAYPAK. KEEP IT WITH YOUR WATER HEATER OR BUSINESS RECORDS.

Name of Owner:_ _______________________________________________________________________ Owner’s Address:_______________________________________________________________________

_____________________________________________________________________________________ Name of Plumber/ Mechanical Contractor – Installer:________________________________________________________ Address of Plumber/ Mechanical Contractor – Installer :________________________________________________________ _____________________________________________________________________________________ Telephone Number of Plumber/ Mechanical Contractor – Installer:___________________________________________________________ Date of Water Heater Installation:___________________________________________________________ Model Number of Your Water Heater:___________________________________________________________ Serial Number of Your Water Heater:_ ___________________________

COMMERCIAL TANKLESS GAS WATER HEATER WITH A 5 YEAR HEAT EXCHANGER, 5 YEAR PARTS, 1 YEAR LABOR LIMITED WARRANTY____________________________

Page 72

NOTES