Rudd GHE100-250 Installation Manual
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Commercial High Efficiency Water Heater
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USE & CARE MANUAL
WITH INSTALLATION INSTRUCTIONS FOR THE CONTRACTOR
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Recognize this symbol as an Indication of Important
Safety Information!
NOTICE: This water heater is designed for use in a commercial application and the installation and maintenance of it should be performed by a qualified, licensed service personnel. If the foregoing assumption is not appropriate, then we recommend that you obtain
and retain our Residential Use & Care Manual.
CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California to cause cancer, birth
defects or other reproductive harm.
WARNING: If the information in these instructions are not followed exactly, a fire or explosion may result
causing property damage, personal injury or death.
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FOR YOUR SAFETY!
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— Do not store or use gasoline or other flammable
vapors or liquids or other combustible materials in
the vicinity of this or any other appliance. To do so
may result in an explosion or fire.
— WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
•
Do not touch any electrical switch; do not use any
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phone in your building.
Do Not Destroy this Manual. Please read carefully and
keep in a safe place for Future Reference.
Immediately call your gas supplier from a neighbor's
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phone. Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the fire
•
department.
Do not return to your building until authorized by
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the gas supplier or fire department.
— Improper installation, adjustment, alteration, service
or maintenance can cause injury, property damage or death. Refer to this manual. Installation and
service must be performed by a qualified installer,
service agency or the gas supplier.
Printed in USA
AP14729-1(10/09)
TABLE OF CONTENTS
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Safety Information
Safety Precautions . . . . . . . . . . . . . . . . . . .3-4
Introduction
Local Installation Regulations . . . . . . . . . . 5
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.
Water Heater Location . . . . . . . . . . . . . . . . . 5
Installation Instructions
Inspect Shipment . . . . . . . . . . . . . . . . . . . . . 5
Water Supply Connections . . . . . . . . . . . . . 6
Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Installation . . . . . . . . . . . . . . . . . . . . 8
Vent Installation . . . . . . . . . . . . . . . . . . . .9-21
Installation Checklist . . . . . . . . . . . . . . . . . 22
Operating Instructions
Lighting Instructions . . . . . . . . . . . . . . . . . 23
Water Temperature . . . . . . . . . . . . . . . . . . . 24
Emergency Shut Down . . . . . . . . . . . . . . . 24
User Interface . . . . . . . . . . . . . . . . . . . . .25-26
All safety messages will follow the safety alert symbol and either the word “DANGER”, “WARNING”,
“CAUTION” or “NOTICE”.
These words mean:
DANGER
WARNING
CAUTION
Notice:
An imminently hazardous
situation that will result in
death or serious injury.
A potentially hazardous situation that could result in
death or serious injury and/
or damage to property.
A potentially hazardous situation that may result in minor
or moderate injury.
Attention is called to observe
a specified procedure or
maintain a specific condition.
Care and Cleaning
Pressure Switch Inspection . . . . . . . . . . . 27
Venting Inspection . . . . . . . . . . . . . . . . . . . 27
Routine Maintenance . . . . . . . . . . . . . . . . . . 27
Anode Inspection . . . . . . . . . . . . . . . . . . . . 27
Seasonal Operation . . . . . . . . . . . . . . . . . . 27
Troubleshooting
Before You Call For Service . . . . . . . . 28- 29
Customer Service
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . 31
How to Obtain Service Assistance . . . . . 32
2
General Safety Precautions
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DANGER
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To meet commercial water use needs, the temperature on this
water heater is adjustable up to 185°F (85° C). However, water temperatures over 125°F (52° C) can cause severe burns instantly or
death from scalds. This is the preferred starting point for setting the
control for supplying general purpose hot water.
Safety and energy conservation are factors to be considered when
setting the water temperature. The most energy efficient operation
will result when the temperature setting is the lowest that satisfies
the needs consistent with the application.
Maximum water temperatures occur just after burner has shut off.
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D A N G E R
HOT
The following chart details the relationship of water temperature
and time with regard to scald injury and may be used as a guide
in determining the safest water temperature for your applications.
TIME / TEMPERATURE RELATIONSHIPS IN SCALDS
Temperature Time to Produce Serious Burn
120° F (49°C) More than 5 minutes
125° F (52°C) 11/2 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 11/2 seconds
155° F (68°C) About 1 second
The temperature of the water in the heater can be regulated by
setting the temperature on the display (see pages 18 & 19). To
comply with safety regulations the temperature was set at 120°F
before water heater was shipped from the factory. The illustration information on pages 25 & 26 shows the Display and how to
adjust the water temperature.
Hotter water increases the Potential for Hot Water SCALDS.
Table cour tesy of Shriners Bu rn Institute
BURN
Water temperature over 125°F can
cause severe burns instantly or
death from scalds.
Children, disabled and elderly are
at highest risk of being scalded.
See instruction manual before
setting temperature at water
heater.
Feel water before bathing or
showering.
Temperature limiting valves are
available, see manual.
To find hot water temperature being delivered, turn on a hot water
faucet and place a thermometer in the hot water stream and read
the thermometer.
See Section "User Interface" (pages 25 & 26) for setting the temperature.
NOTICE: Mixing valves are available for reducing point of use
water temperature by mixing hot and cold water in branch water
lines. Contact a licensed plumber or the local plumbing authority
for further information.
3
General Safety Precautions
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Be sure to read and understand the entire Use & Care Manual before attempting to install or operate this water heater. Pay par ticular attention
to the following General Safety Precautions. Failure to follow these warnings could result in a fire or explosion, causing proper ty damage, bodily
injur y or death . Should you have any problems understanding the instructions in this manual, STOP, and get help from a qualified installer or
ser vice technician or the gas supplier.
DANGER
WARNING
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Gasoline, as well as other flammable materials and liquids
(adhesives, solvents, etc.) and the vapors they produce,
are extremely dangerous. DO NOT handle, use or store
gasoline or other flammable or combustible materials anywhere near or in the vicinity of a water heater. Be sure to
read and follow the warning label pictured below and other
labels on the water heater, as well as the warnings printed
in this manual. Failure to do so can result in property damage, bodily injury, or death.
DANGER
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Failure to properly vent the water heater to the outdoors
as outlined in the Venting Section of this manual can result
in unsafe operation of the water heater. To avoid the risk
of 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 system for proper installation at
initial start-up and at least annually thereafter. Refer to the
Maintenance section of this manual for more information
regarding vent system inspections.
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D A N G E R
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LIQUEFIED PETROLEUM MODELS — Propane (LP) gas,
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.
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Make sure to look and smell for LP leaks before
attempting to light appliance. 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 an LP leak, be sure to sniff
near the floor too.
• Gas detectors are recommended in LP applications
and their installation should be in accordance with the
manufacturer's recommendations and/or local laws,
rules, regulations or customs.
• It is recommended that more than one method be used
to detect leaks in LP applications.
IF LP GAS IS PRESENT OR SUSPECTED:
• DO NOT attempt to find the cause yourself;
• DO NOT try to light any appliance;
• DO NOT touch any electrical switch;
• DO NOT use any phone in your building.
• Leave the building immediately and make sure your
family and pets leave also.
• Leave the doors open for ventilation and contact the
gas supplier, a qualified service agency or the fire
department.
• Keep the area clear until the service call has been
made, the leak is corrected, and a qualified agency
has determined the area to be safe.
this entire Manual with special emphasis on the Venting Sections (Pages 7,10-14) and Operation Section
(Pages 16-18) prior to any installation work.
Read and Review
FLAMMABLES
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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 and pilot flames
Read and follow water heater warnings and instructions. If owners
manual is missing, contact the retailer or manufacturer.
Flammable Vapors
Water heater has a main
burner and pilot flame.
The pilot flame:
1. which can come on at
2. will ignite flammable
Vapors:
1. cannot be seen,
2. are heavier than air,
3. go a long way on the
4. can be carried from
flame by air currents.
are at least 18" above the
floor. This will reduce, but not
eliminate, the risk of vapors
being ignited by the main
burner or pilot flame.
any time and
vapors.
floor and
other rooms to the pilot
WARNING
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Both LP and natural gas have an odorant added to help
detection. Some people may not physically be able to
smell or recognize this odorant. If unsure or unfamiliar
about the smell associated with LP or natural gas, ask the
gas supplier. Other conditions, such as "Odorant Fade",
which causes the odorant to "fade", or diminish in intensity can also hide or camouflage a gas leak.
DANGER
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Water heaters utilizing Liquefied Petroleum gas (LP) are
different from natural gas models. A natural gas heater will
not function safely on LP gas and vice versa. No attempt
should ever be made to convert a heater from natural gas
to LP gas. To avoid possible equipment damage, personal
injury or fire: DO NOT connect this water heater to a fuel
type not in accordance with unit data plate. Propane for
propane units. Natural gas for natural gas units. These
units are not certified for any other type fuel.
WARNING
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LP appliances 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.
4
Introduction
LOCAL INSTALLATION REGULATIONS
This water heater must be installed in accordance with these instructions,
local codes, utility company requirements and/or, in the absence of local
codes, the latest edition of the National Fuel Gas Code, ANSI Z223.1 in
the United States, or CAN/CSA B149.1 Installation Codes in Canada.
LOCATION
A. If this water heater is of the Direct Vent design, all air for combustion
and all products of combustion are routed through the venting system,
directly from and to the outside of the building.
Otherwise: This unit can also be set up as a Power Vent Unit. Combus-
tion air for a power vent unit will be obtained from the surrounding area.
Make sure that there is an adequate air supply for the water heater,
see codes in "Local Installation Regulations".
The water heater should be installed in a clean, dry location as close as
practical to the vent terminals. 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.
B. A gas fired water heater should not be installed in a space where liquids
which give off flammable vapors are to be used or stored. Such liquids
include gasoline, LP gas (butane and propane), paint or adhesives and
their thinners, solvents or removers. Because of natural air movement
in a room or other enclosed space, flammable vapors can be carried
some distance from where their liquids are being used or stored. The
open flame of the water heater’s main burner can ignite these vapors
causing an explosion or fire which may result in severe burns or death
to those in range, as well as proper ty damage. For these reasons,
installation of a gas fired water heater in a garage is not desirable.
C. All models are cer tified for installation on combustible floors and in
alcoves. The minimum side and top clearance to walls and ceiling for
providing protection of combustible materials are shown on the water
heater’s rating label. A front clearance of 18 inches (46 cm) should be
provided for adequate inspection and servicing.
If the water heater must be installed on carpeting, place a metal or
wood panel beneath water heater extending beyond its full width and
depth at least 3 inches (7.6 cm) in all directions. If the water heater is
installed in an alcove, the entire floor must be covered by the panel.
NOTICE: Auxiliary catch pan installation MUST conform to the ap -
plicable local codes.
CAUTION
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The water heater should not be located in an area where leakage of the tank or connections will result in damage to the area
adjacent to it or to lower floors of the structure. When such areas
cannot be avoided, it is recommended that a suitable catch pan,
adequately drained, be installed under the water heater. The pan
MUST NOT interfere with the operation of the water heater and
access of the serviceable components.
D. RESTAURANT INSTALLATION: — If the water heater is to be installed
in a restaurant or other location where NSF International listing is required, this unit must be sealed to the floor and other components must
be added utilizing Rheem's UL Listed NSF Seal Kit. A factory designed
sealing kit is available from the distributor or store where the water
heater was purchased. When installed according to the instructions
supplied with the kit, these heaters will meet the NSF international
requirements.
E. CORROSIVE ATMOSPHERES — The heater should not be installed
near an air supply containing halogenated hydrocarbons. For example,
the air in beauty shops, dr y cleaning establishments, photo processing labs, and storage areas for liquid and powdered bleaches or swim
pool chemicals often contain such hydrocarbons. The air there may
be safe to breathe, but when it passes through a gas flame, corrosive
elements are released that will shor ten the life of any gas burning
appliance. Propellants from common spray cans or gas leaks from
refrigeration equipment are highly corrosive after passing through a
flame. The limited warranty is voided when failure of water heater is due
to a corrosive atmosphere. (Refer to the Certificate of Limited Warranty
for complete terms and conditions.)The manufacturer’s warranty does
not cover any damage or defect caused by installation, or attachment,
or use of any special attachment such as energy saving devices (other
than those authorized by the manufacturer) into, onto, or in conjunction with the water heater. The use of such unauthorized devices may
shorten the life of the water heater and may endanger life and property.
The manufacturer disclaims any responsibility for such loss or injury
resulting from the use of such unauthorized devices.
1. INSPECT SHIPMENT — for possible damage. The manufacturer’s responsibility ceases upon delivery of goods to the carrier in good condition. Any claims for damage, shortage in shipments, or non delivery
must be filed immediately against carrier by consignee.
2. THERMAL EXPANSION — Determine if a check valve exists in the
inlet water line. It may have been installed in the cold water line as a
separate back flow preventer, or it may be par t of a pressure reducing
valve, water meter or water softener. A check valve located in the cold
water inlet line can cause what is referred to as a ”closed water system”. A cold water inlet line with no check valve or back flow prevention
device is referred to as an ”open” water system.
As water is heated, it expands in volume and creates an increase
in the pressure within the water system. This action is referred to as
”ther mal expansion”. In an ”open” water system, expanding water
which exceeds the capacity of the water heater flows back into the
city main where the pressure is easily dissipated.
A ”closed water system”, however, prevents the expanding water
from flowing back into the main supply line, and the result of ”thermal
expansion” can create a rapid, and dangerous pressure increase in
the water heater and system piping. This rapid pressure increase can
quickly reach the safety setting of the relief valve, causing it to operate during each heating cycle. Ther mal expansion, and the resulting
rapid, and repeated expansion and contraction of components in the
water heater and piping system can cause premature failure of the
relief valve, and possibly the heater itself. Replacing the relief valve
will not correct the problem!
The suggested method of controlling thermal expansion is to install an
expansion tank in the cold water line between the water heater and the
check valve. The expansion tank is designed with an air cushion built in
that compresses as the system pressure increases, thereby relieving
the over pressure condition and eliminating the repeated operation of
the relief valve. Other methods of controlling thermal expansion are also
available. Contact your installing contractor, water supplier, or plumbing
inspector for additional information regarding this subject.
If a recirculation line is installed, the return connection should be made
to a tee close to the inlet connection on the water heater. A check valve
should always be installed in the recirculation line to prevent cold water
from entering.
5
Installation
WATER CONNECTIONS — This water heater may be connected indi-
vidually, in multiples with others, or with an external hot water storage
tank.
Inlet water connections are made to the lower coupling on the heater,
and outlet water connections are made to the upper coupling.
Each water heater is supplied with the necessary components (Dif-
fuser tubes) to make the water connections that will ensure proper
performance. The components are supplied in a bag attached to the
water heater. If special instructions are required for any specific water
heater, they will be included in the bag.
Cap or plug unused connections. Use only clean, new galvanized steel,
copper or approved plastic pipe for water connections. Local codes
or regulations shall govern the exact type of material to be used. The
installation of unions on the inlet and outlet water lines and a shut-off
valve in at least the cold water inlet line is recommended, so the water
heater may be easily disconnected for servicing. Dielectric unions are
not required for protection of water heater.
When this water heater is supplying general purpose hot water require-
ments for use by individuals, a thermostatically controlled mixing valve
is recommended to reduce the risk of scald injury. Contact a licensed
plumber or the local plumbing authority for fur ther information.
Thermometer(s) should be installed so that they indicate the tempera-
ture of the water at or near the outlet of the water heater and storage
tank(s) if provided. See Fig. 2.
3. RELIEF VALVE — A new factory installed combination pressure and
temperature relief valve, complying with the Standard for Relief Valves
and Automatic Gas Shutoff Devices for Hot Water Supply Systems,
ANSI Z21.22, or Standard CSA 4.4, Temperature, Pressure, Temperature and Pressure Relief Valves and Vacuum Relief Valves is provided
with the water heater. No valve is to be placed between the relief valve
and the water heater. For a circulating tank installation, the separate
storage tank(s) must have similar protection. The pressure rating of
the relief valve must not exceed 150 psi (1034 kPa) (160 psi for ASME
models), the maximum working pressure as marked on front of the
water heater.
WARNING
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Connect the outlet of the relief valve to a suitable open drain.
The discharge line must pitch downward from the valve to allow
complete draining (by gravity) of the relief valve and discharge
line, and be no smaller than the outlet of 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. Local codes
shall govern the installation of relief valves.
The Btu/h rating of the relief valve must equal or exceed the Btu/h input
of the water heater as marked on its rating plate.
4. GAS SUPPLY — The inlet gas pressure to the water heater must not
exceed 10.5” w.c. (2.6 kPa) for Natural gas and 13.0" w.c. (3.2 kPa) for L.P.
gas. The minimum inlet gas pressure (with main burner on) is shown on
the rating plate. Check to see if high or low gas pressure is present and
then contact the gas company for correction.
The gas line should be of adequate size to prevent undue pressure
drop. Sizing based upon information in Table 2. No additional allowance
is necessary for an ordinary number of fittings.
A ground joint union and manual shutoff valve should be installed in
the gas line near the water heater so that the burner assembly may
be easily removed. The shut-off valve must be readily accessible for
turning on or off. See Fig. 2.
Where a sediment trap is not incor porated as part of the appliance, a
sediment trap shall be installed downstream of the equipment shutoff
valve as close to the inlet of the appliance as practical at the time of
the appliance installation. The sediment trap shall be either a tee fitting
with a capped nipple in the bottom outlet or other device recognized
as an effective sediment trap. See Fig. 2.
LEAK TESTING — The water heater and its gas connections MUST
be leak tested at normal operating pressure before it is placed in operation. Turn ON the manual gas shut-off valve near the water heater.
Use a soapy water solution to test for gas leaks at all connections and
fittings. Bubbles indicate a gas leak that must be corrected. The water
heater factory connections to the gas valve should also be leak tested
after placing the water heater in operation.
NEVER use open flame to test for gas leaks, as bodily injury or prop-
erty damage could result.
PRESSURE TESTING THE GAS SUPPLY SYSTEM — The water
heater and its manual gas shut-off valve MUST be dis connect ed from the gas supply piping system during any h ig h pressure
testing o f t h a t sy s tem a t pr essures in exce s s of 1/ 2 psi
(14” w.c. / 3.5 kPa).
The water heater MUST be isolat ed from the gas piping system
by closing the manual gas shut-off valve during any pressure testing of the gas supply piping at pressures equal to or les s than
1/2 psi (14” w.c. / 3.5 kPa).
5.
CONDENSATE
Filling The Condensate Trap:
THE CONDENSATE TRAP MUST BE FILLED WITH WATER, BEFORE
OPERATING WATER HEATER.
To fill the trap (Refer to Figure 1), remove the plastic cap on the left
side of the trap. Pour about one (1) cup of water into the trap and then
re-install the plastic cap.
This is a condensing high efficiency appliance, therefore this unit has
a condensate removal system. Condensate is nothing more than water
vapor, derived from the combustion products. This condensate does
have a low pH and condensate removal must comply with all local
codes. See information below for optional Condensate Neutralizer, if
required. It is very important that the condensate line is sloped away
from and down to a suitable inside drain. If the condensate outlet on
this unit is lower than the drain, you must use a condensate removal
pump. It is also very important that the condensate line is not exposed
to freezing temperatures, or any other type of blockage. Plastic tubing
should be the only material used for the condensate line. Steel, brass,
copper, or other metals will be subject to corrosion and deterioration.
A second vent may be necessary to prevent condensate line vacuum
lock if a long horizontal run is used. Also an increase to 1" tubing may
be necessary.
6
Figure 1 - Condensate Trap
INSTALLATION OF A CONDENSATE NEUTRALIZER AND PUMP (Not Supplied)
Installation
Plastic Cap
CONDENSATE LINE
TO DRAIN
Condensate line must be pitched down at least 1/4" per foot to properly drain. If this cannot be done or a very long length of condensate
hose is used, you must increase the condensate hose to a minimum
6. WIRING — A polarized 120V 50/60 Hz power supply, with suitable
disconnect means, must be connected to the black and white leads
provided. The maximum current draw by these models is 6 Amps.
The water heater, when installed, must be electrically grounded in accordance with local codes, or, in the absence of local codes, with the
National Electrical Code, ANSI/NFPA 70 in the United States; or CSA
C22.1 Electrical Code, in Canada. Improper grounding may result
in abnormal operation of the unit. Refer on page 31 of this manual
for water heater internal wiring diagrams.
WARNING
!
The water heater must be vented to the outdoors as
described in these instructions.
WARNING
!
DO NOT connect this water heater to an existing Vent or Chimney; it must be vented separately from all other appliances.
CONDENSATE LINE WITH PUMP
TO DRAIN
of 1" ID and place a tee in the line after the condensate neutralizer, to
properly reduce vacuum lock in the drain line.
WARNING
!
Failure to properly vent the water heater to the outdoors as outlined above and in the following section can result in unsafe operation of the water heater causing bodily injury, explosion, fire or
death.
WARNING
!
NOTICE: DO NOT use in conjunction with a GFCI.
To avoid the risk of 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. The
vent pipe must overlap a minimum of ½" on each connection. It is
important that the vent pipe engages fully into any pipe fitting and
be kept in that position until the adhesive has fully cured. DO NOT
drill or punch holes in the plastic pipe or fittings.
7
Vacuum Relief Valve
(Not Supplied)
If required, install per local codes
and valve manufacturer’s
instructions.
Vacuum Relief Valve
Sediment
Trap
To Gas Supply
Manual Gas Shut Off
Gas Pipe to Gas
Valve
Installation
Figure 2. — Typical Installation Drawing.
Temperature & Pressure
Relief Valve
Gas Valve Pipe Size
*130,160 & 200 1/2" NPT
*250, 300 ,350 3/4" NPT
Hot Outlet
Condensate Trap
Discharge Line to
suitable open drain
Air Gap 6"
Ther mal Expansion Tank
(if required)
* Can be GHE or THE
Shut -Off Valve
(Not Supplied)
If required, install per local codes
and valve manufacturer’s
instructions.
Cold Water
Inlet
8
NOTES:
1.) The gas supply piping must be adequately supported and
aligned to minimize loads (forces) on the water heater’s gas
valve and burner system.
2.) Refer to local codes for installation guidelines for the Thermal Expansion Tank (if required).
Installation
7. VENTING —
NOTE: This unit can be vented either as a Direct
Vent or Power Vent configuration.
NOTICE: This unit can be ve nted using only the followin g
recommended pipe material. Use only 2, 3- or 4-inch diameter pipe.
Refer to local codes for restrictions on the use of PVC, CPVC or ABS
pipe and fittings. All exhaust venting materials for product installed in
Canada must meet ULC-S636.
PVC (Schedule 40, ASTM D-1785)
CPVC (Schedule 40, ASTM F-441)
ABS (Schedule 40, ASTM D-2661)(Not permitted in Canada)
PVC Cellular Core (Schedule 40, ASTM F-891)(Not Permitted in
Canada)
The fittings, other than the VENT TERMINAL, should be equivalent to the following:
PVC (Schedule 40 DWV, ASTM D-2665)
CPVC (Schedule 40 DWV, ASTM F-438)
ABS (Schedule 40 DWV, ASTM D-2661)(Not permitted in Canada)
The unit may be vented horizontally through a wall or vertically through
the roof. Pipe runs must be adequately supported along both vertical
and horizontal runs. Maximum unsupported span is recommended to
be no more than 4 feet. It is imperative that the first hanger be located
on the horizontal run immediately adjacent to the first 90-degree elbow
from the vertical rise or at the blower outlet in the case of a horizontal
blower position. Support method used should isolate the vent pipe from
floor joists or other structural members to help prevent the transmission of noise and vibration. Do not support, pin or otherwise secure the
venting system in a way that restricts the normal thermal expansion and
contraction of the chosen venting material.
If the water heater is being installed as a replacement for an existing power
vented water heater, a thorough inspection of the existing venting system
must be performed prior to any installation work. Verify that the correct
materials, as detailed above have been used, and that the minimum or
maximum vent length and terminal locations as detailed in this manual
have been met. Carefully inspect the entire venting 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.
VENT PIPE CONNECTION —
NOTE: This unit can be vented either as a Direct
Vent or Power Vent configuration.
Refer to Figure 3, for connecting the vent pipe to the water heater.
These models can be vented either as a Direct Vent or as a Power Vent
water heater.
NOTICE: If the unit is installed as a Power Vent
water heater, the vent terminal with screen must still
be installed on the inlet air side.
Before starting the vent installation, careful planning should be given
to the routing and termination of the vent pipes. The length of the vent
pipes (inlet and outlet) should be kept to a minimum. Also, see Figure
10 for vent ter minal placement. Refer to the venting charts on Table
1, for the pipe sizes that can be used and the total equivalent length
of pipe that can be used. Do not exceed equivalent length of pipe in
charts.
Depending on the size of pipe that is chosen for venting the water
heater, it might be necessary to use a fitting for stepping up or down
in pipe size, to connect to the water heater. All models are shipped
with three ( 3 ) inch vent terminals with screen. If another size of pipe
is used for venting the unit, the proper vent terminal must be installed.
When the unit is vented as a Direct Vent , though a side wall, the vent
terminals must be on the same exterior wall mounted horizontally and
at least twenty-four (24) inches apart (on center). See Figure 10 for
other vent terminal restrictions.
JO I NING PIPES AND FITT I N GS – All pipe , fi tting s, so lve n t
cement, primers and procedur es, for the U.S., must con form to
American National Standards Institute and American Society for
Testing and Materials (ANSI/ASTM) standards. For Canada, all pipe,
fittings, solvent cement, primers and procedures must conform to ULC-
S636 and vent manufacture specifications
.
CEMENTING JOINTS – All joints in the vent piping must be properly
sealed and we recommend using the following material:
PVC materials should use ASTM D-2564 grade cement.
CPVC materials should use ASTM F-493 grade cement.
ABS materials should use ASTM D-2235 grade cement.
(ABS is not allowed in Canada)
Cleaner-Primer and Medium Body Solvent Cement
1. Cut pipe end square, remove jagged edges and burrs. Chamfer end of
pipe, then clean fitting socket and pipe joint area of all dirt, grease or
moisture.
2. After checking pipe and socket for proper fit, wipe socket and pipe with
cleaner-primer. Apply a liberal coat of primer to inside surface of socket
and outside of pipe. Do not allow primer to dry before applying cement.
3. Apply a thin coat of cement evenly in the socket. Quickly apply a heavy
coat of cement to the pipe end and insert pipe into fitting with a slight
twisting motion until it bottoms out.
NOTICE: Cement must be fluid; if not, re-coat.
4. Hold the pipe fitting for 30 seconds to prevent the tapered socket from
pushing the pipe out of the fitting.
Figure 3. — Vent Pipe Connection Locations
5. Wipe all excess cement from the joint with a rag. Allow 15 minutes
before handling. Cure time will vary according to fit, temperature and
humidity.
9
Installation
NOTICE: Stir the solvent cement frequently while using. Use a natural
bristle brush or the dauber supplied with the can. The proper brush
size is one inch.
FOR PROPER INSTALLATION:
CAUTION
!
• DO NOT use solvent cement that has become
curdled, lumpy or thickened.
• DO NOT t hin solvent cement. O bserve s helf
precautions printed on the containers.
• For ap p lica t ions b e low 32° F use only l o w
temperature type solvent cement.
• Appropriate solvent and cleaner must be used for
the type of vent pipe used (PVC, CPVC or ABS).
WARNING
!
DANGER OF FIRE OR BODILY INJURY – Solvent
cements and primers are highly flammable. Provide adequate ventilation and do not assemble
near heat source or open flame. Do not smoke.
Avoid skin or eye contact. Observe all cautions
and warnings on material containers.
DIRECT VENT INSTALLATION - Check to make sure flue gases
do not recirculate into the air intake terminal when using direct venting.
If the water heater is having service issues, flue recirculation may be a
contributing factor. Even when the minimum vent terminal separation
distances are followed, recirculation may still occur depending upon the
location outside the building, the distance from other buildings, proximity to corners, weather conditions, wind patterns, and snow depth.
Periodically check to make sure that flue recirculation is not occurring.
Signs of flue gas recirculation include frosted or frozen intake terminals, condensate in the intake terminal and venting system, oxidation
or white chalk material on the flame sensor or igniter shield. Correction
to flue recirculation may involve angling the intake away from the exhaust terminal, increasing the distance between them, or using inside
air for combustion. Check to be sure the intake and exhaust ter minals
are not obstructed, especially during periods of below freezing weather.
All intake and exhaust venting components must have the same diam-
eter size. Do not use a different size on the intake and exhaust venting.
Be sure the condensate runs freely to a drain and does not accumulate
inside the water heater. In cold climates, precautions may need to be
taken to insure that the condensate drain does not freeze. Make sure
the condensate trap or drain loop is installed to prevent flue gases from
being discharged into the room. Refer to the Venting section of the
Installation and Operating Instructions Manual for complete instructions
on venting and condensate drainage.
Stress levels in the pipe and fittings can be significantly increased by
improper installation. If rigid pipe clamps are used to hold the pipe in
place, or if the pipe cannot move freely through a wall penetration, the
pipe may be directly stressed, or high thermal stresses may be formed
when the pipe heats up and expands. Install accordingly to minimize
such stresses. Follow the following procedure to vent through the wall:
1. Cut two 2 1/2" (6.4 cm) diameter holes (for a 2" (5.1 cm) diameter
pipe), 3 1/2 in. (8.9 cm) diameter holes (for 3” (7.6 cm) diameter
pipe) or 4 ½” (11.4 cm) diameter holes (for 4” (10.2 cm) diameter
pipe) in the wall. Vent terminals must be a minimum of 24 inches
(61 cm) and a maximum of 36 inches ( cm) horizontally apar t (See
Figure 4).
2. Use the proper PVC cement to secure the exhaust vent and air
intake terminals provided with the water heater to the plastic pipes.
The distance between the back edge of the exhaust vent terminal
and the exterior wall (see Figure 7) must be 6 inches (12.7 cm) more
for the exhaust vent terminal than the air intake terminal. Use the
proper cement or sealant and assembly procedures to secure the
vent connector joints between the terminal and the blower outlet.
Provide support brackets for every 3 feet (.91 m) of horizontal vent
beyond the intake terminal as seen in Figure 7.
10
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