Loading...
Instruction Manual
commercial gas water heaters
500 Tennessee Waltz Parkway |
Ashland City, TN 37015 |
ANSI / NSF 5 |
WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
•Do not try to light any appliance.
•Do not touch any electrical switch; do not use any phone in your building.
•Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
•If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or the gas supplier.
Thank you for buying this energy efficient water heater. We appreciate your confidence in our products.
MODELS SUF-60-120 THROUGH SUF-100-250 SERIES 100 & 101
INSTALLATION - OPERATION - SERVICE - MAINTENANCE - LIMITED WARRANTY
Read and understand this instruction manual and the safety messages herein before installing, operating or servicing this water heater.
Failure to follow these instructions and safety messages could result in death or serious injury.
This manual must remain with the water heater.
place these instructions adjacent to heater and notify owner to keep for future reference.
PRINTED IN THE U.S.A. 0310 |
197784-001 |
Table Of Contents
Safe Installation, Use and Service 3 General Safety Information 4
Precautions 4 Introduction 6
Qualifications 6 iCOMM™ & BACnet Compatible 6 Preparing For The Installation 6
Features And Components 7
Basic Operation 7 Top Views 8
Side Views 10 Installation Considerations 11
Rough In Dimensions 11
Recovery Capacities 12 Locating The Water Heater 12
Clearance To Combustible Materials 13 Service Clearance 13
Insulation Blankets 13 Installation Requirements 14 Gas Pressure Requirements 14 Supply Gas Line 14 Supply Gas Regulator 14
Power Supply 14
Mixing Valves 15 Dishwashing Machines 15 Closed Water Systems 15 Thermal Expansion 15
Temperature-Pressure Relief Valve 16
Condensate Drain 17 Air Requirements 18 Commonwealth of Massachusetts 21 Venting Installation 22 General Venting Information 22
Category IV Appliance 22 Power Vent Configuration 22 Direct Vent Configuration 22
General Venting Instructions 22
Venting Requirements 24
Maximum Equivalent Lengths 24 Minimum Equivalent Lengths 24 Maximum Number Of Elbows 24
Venting Installation Sequence 25 Power Vent Installation 25
Direct Vent Installation 25 Vertical Termination Installation 27
Sidewall Termination Installation 29 Concentric Termination Installation 30
Multiple Concentric Termination Clearances 32 Multiple Concentric Termination Arrangements 33
Venting Arrangements 34
Termination Clearances Sidewall Power Vent 36 Termination Clearances Sidewall Direct Vent 37 Water Heater Installation 38
Condensate Drain Installation 38
Supply Gas Line Installation 39
Supply Gas Regulator Installation 40 Electrical Wiring 41
Power Supply Connections 41 Enable/Disable Circuit 41
Water Line Connections 42 T&P Valve Discharge Pipe 42 Temperature Regulation 43 High Temperature Limit Control (ECO) 43 Thermostat Control 43 Control System Operation 44 Control System Navigation 44
The Desktop Screen 44 Status Icons 45
User Settings & Control System Menus 47
Temperatures Menu 47 Heater Status Menu 48 Display Settings 49 Heater Information 49 Current Fault 50 Fault History 50 Fault Occurrence 50 Restore Factory Defaults 50 Service Contact Information 51
Start Up 52 Initial Start Up 52
Supply Gas Pressure Adjustment 54 Manifold Gas Pressure Adjustment 54
Checking The Firing Rate 55 High Altitude Installations 55 Lighting The Water Heater 56 Lighting & Operation Labels 56 Troubleshooting 58 Installation Checklist 58 Sequence Of Operation 58 Sequence Of Operation Flow Chart 59 Operational Problems 60
Rough Starting, Rough Operation 60 Momentary Ignition 60 Not Enough Or No Hot Water 60
Fault And Alert Conditions 61
Fault Conditions 61 Alert Conditions 61 Resetting Control System Lock Outs 61 Diagnostic Checks 61 Fault And Alert Messages 62
Maintenance 64 Maintenance Schedule 64 Diagrams 67
CCB - Central Control Board Layout 67 SUF 120 & 150 Wiring Diagram 68
SUF 199 & 250 Wiring Diagram 69
Circulation Pump Wiring Diagrams 70
Water Piping Diagrams 71
Limited Warranty 78
2
Safe Installation, Use and Service
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
DANGER indicates an imminently
DANGER hazardous situation which, if not avoided, will result in injury or death.
WARNING indicates a potentially hazardous
WARNING situation which, if not avoided, could result in injury or death.
CAUTION indicates a potentially hazardous
CAUTION situation which, if not avoided, could result in minor or moderate injury.
CAUTION used without the safety alert CAUTION symbol indicates a potentially hazardous
situation which, if not avoided, could result in property damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and how to avoid the risk of injury.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.
This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This appliance can cause low level exposure to some of the substances listed in the Act.
APPROVALS
ASME CRN ANSI / NSF 5
Note: ASME construction is optional on the water heaters covered in this manual.
3
General Safety Information
Precautions
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER. Immediately call a qualified service agency to inspect the appliance and to make a determination on what steps should be taken next.
If the unit is exposed to the following, do not operate heater until all corrective steps have been made by a qualified service agency.
1.External fire.
2.Damage.
3.Firing without water.
GROUNDING INSTRUCTIONS
This water heater must be grounded in accordance with the National Electrical Code and/or local codes. These must be followed in all cases. Failure to ground this water heater properly may also cause erratic control system operation.
This water heater must be connected to a grounded metal, permanent wiring system; or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the water heater.
Hydrogen Gas Flammable
Explosion Hazard
Flammable hydrogen gases may be present.
Keep all ignition sources away from faucet when turning on hot water.
Hydrogen gas can be produced in a hot water system served by this appliance that has not been used for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To reduce the risk of injury under these conditions, it is recommended that a hot water faucet served by this appliance be opened for several minutes before using any electrical appliance connected to the hot water system. If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow. There should be no smoking or open flame near the faucet at the time it is open.
Verify the power to the water heater is turned off before performing any service procedures.
Read and understand this instruction manual and the safety messages herein before installing, operating or servicing this water heater.
Failure to follow these instructions and safety messages could result in death or serious injury.
This manual must remain with the water heater.
Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death.
Children, the elderly and the physically or mentally disabled are at highest risk for scald injury.
Feel water before bathing or showering.
Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at fixtures.
Explosion Hazard
Overheated water can cause water tank explosion.
Properly sized temperature and pressure relief valve must be installed in the opening provided.
CAUTION
Improper installation, use and service may result in property damage.
•Do not operate water heater if flood damaged.
•Inspect and anode rods regularly, replace if damaged.
•Install in location with drainage.
•Fill tank with water before operation.
•Properly sized thermal expansion tanks are required on all closed water systems.
Refer to this manual for installation and service.
4
General Safety Information
Fire or Explosion Hazard
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas pressure.
Use only the gas shown on the water heater rating label.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended periods of non-use.
Read instruction manual before installing, using or servicing water heater.
Breathing Hazard - Carbon Monoxide Gas
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.
CAUTION
Property Damage Hazard
•All water heaters eventually leak.
•Do not install without adequate drainage.
Electrical Shock Hazard
•Turn off power to the water heater before performing any service.
•Label all wires prior to disconnecting when performing service. Wiring errors can cause improper and dangerous operation.
•Verify proper operation after servicing.
•Failure to follow these instructions can result in personal injury or death.
Fire Hazard
For continued protection against risk of fire:
Do not install water heater on carpeted floor.
Do not operate water heater if flood damaged.
Fire and Explosion Hazard
Use joint compound or Teflon tape compatible with propane gas.
Leak test before placing the water heater in operation.
Disconnect gas piping and main gas shutoff valve before leak testing.
Install sediment trap in accordance with NFPA 54.
Fire and Explosion Hazard
Do not use water heater with any gas other than the gas shown on the rating label.
Excessive gas pressure to gas valve can cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service agency for installation and service.
Jumping out control circuits or components can result in property damage, personal injury or death.
•Service should only be performed by a qualified service agent using proper test equipment.
•Altering the water heater controls and/or wiring in any way could result in permanent damage to the controls or water heater and is not covered under the limited warranty.
•Altering the water heater controls and/or wiring in any way could result in altering the ignition sequence allowing gas to flow to the main burner before the hot surface igniter is at ignition temperature causing delayed ignition which can cause a fire or explosion.
Any bypass or alteration of the water heater controls and/or wiring will result in voiding the appliance warranty.
5
Introduction
Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service.
Abbreviations Used
Abbreviations found in this Instruction Manual include :
•ANSI - American National Standards Institute
•ASME - American Society of Mechanical Engineers
•GAMA - Gas Appliance Manufacturer’s Association
•NEC - National Electrical Code
•NFPA - National Fire Protection Association
•UL - Underwriters Laboratory
•CSA - Canadian Standards Association
Qualifications
Qualified Installer or Service Agency
Installation and service of this water heater requires ability equivalent to that of a Qualified Agency (as defined by ANSI below) in the field involved. Installation skills such as plumbing, air supply, venting, gas supply and electrical supply are required in addition to electrical testing skills when performing service.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualified Agency” - “Any individual, firm, corporation or company that either in person or through a representative is engaged in and is responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair or servicing of appliances and equipment; that is experienced in such work; that is familiar with all precautions required; and that has complied with all the requirements of the authority having jurisdiction.”
If you are not qualified (as defined by ANSI above) and licensed or certified as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the procedures described in this manual. If you do not understand the instructions given in this manual do not attempt to perform any procedures outlined in this manual.
iCOMM™ & BACnet Compatible
This water heater is compatible with the iCOMM™ remote monitoring system. The iCOMM™ system hardware and monitoring service is purchased separately. It allows users to monitor critical operational, diagnostic and energy usage data from a secure web site.
The iCOMM™ system can automatically notify selected personnel via email and/or cellular phone text messages if operational problems or user defined Alert Conditions occur.
iCOMM™ system hardware is compatible with BACnet compliant supervisory controls and building management systems. For more information call 888 928-3702.
Preparing For The Installation
1.Read the entire manual before attempting to install or operate the water heater. Pay close attention to the General Safety Information on page 4 and 5. If you don’t follow the safety rules, the water heater may not operate safely. It could cause property damage, injury and/or death.
This manual contains instructions for the installation, operation, and maintenance of the water heater. It also contains warnings throughout the manual that you must read and be aware of. All warnings and all instructions are essential to the proper operation of the water heater and your safety.
Detailed installation diagrams are also found in this manual. These diagrams will serve to provide the installer with a reference. It is essential that all venting, water piping, gas piping and wiring be installed as shown.
Particular attention should be given to the installation of thermometers at the locations indicated in the piping diagrams as these are necessary for checking the operation of the water heater.
The principal components of the water heater are identified in Features And Components on page 7 in this manual. Use this reference to locate and identify various components on the water heater.
See the Installation Checklist and Troubleshooting on page 58. By using this checklist the user may be able to make minor operational adjustments and avoid unnecessary service calls. However, service and diagnostic procedures should only be performed by a Qualified Service Agency.
Note: Costs to correct installation errors are not covered under the limited warranty.
2.Be sure to turn off power when working on or near the electrical system of the water heater. Never touch electrical components with wet hands or when standing in water.
3.The installation must conform to all instructions contained in this manual and the local code authority having jurisdiction. These shall be carefully followed in all cases. Authorities having jurisdiction should be consulted before installation begins if there are any questions regarding compliance with local, state or national codes.
In the absence of local codes, the installation must comply with the current editions of the National Fuel Gas Code, ANSI Z223.1/NFPA54 and the National Electrical Code, NFPA70 or CAN/CSA-B149.1, the Natural Gas and Propane Installation Code and CSA C22.1, the Canadian Electrical Code. All documents are available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131. NFPA documents are also available from the National Fire Protection Association, 1 Batterymarch Park, Quincy,
MA 02269.
4.If after reading this manual you have any questions or do not understand any portion of the instructions, call the toll free number on the back cover of this manual for technical assistance. In order to expedite your request, please have the full Model, Serial and Series number of the water heater you are working with available for the technician. This information is located on the water heater’s rating label.
5.Carefully plan the placement of the water heater. Examine the location to ensure that it complies with the requirements in Locating The Water Heater on page 12 and the Rough In
Dimensions on page 11.
6.For installation in California this water heater must be braced or anchored to avoid falling or moving during an earthquake. See instructions for correct installation procedures. Instructions may be obtained from California Office of the State Architect, 1102 Q Street, Suite 5100, Sacramento, CA
95811.
7.Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248-CMR 2.00: State Plumbing Code and 248-CMR 5. See Commonwealth of Massachusetts on page 21.
6
Features And Components
Basic Operation
The water heaters covered in this manual have a helical coil shaped heat exchanger that is submerged in the storage tank. The water heater’s Main Burner is a radial design burner, it is mounted on the top and fires downward through the heat exchanger. This is a forced draft burner; hot burning gases are forced through the heat exchanger under pressure and exit through the exhaust/vent connection located at the bottom of the water heater. See Figure 1 and Figure 2.
BLOWER
BURNER
ASSEMBLY
INTAKE AIR (combustion air) CONNECTION 3 INCH PVC
MAIN |
BURNER |
(radial design) |
HEAT |
EXCHANGER |
HELICAL |
COIL |
VENT (exhaust) |
OUTLET |
Figure 1
Blower/Burner Assembly Detail
INTAKE AIR |
|
COMBUSTION |
(combustion air) |
|
BLOWER |
CONNECTION |
|
|
3 INCH PVC |
|
|
BLOWER |
|
|
FLANGE |
|
|
FLAME |
|
|
SENSOR |
|
|
MAIN |
|
|
BURNER |
|
|
(radial design) |
HOT SURFACE |
|
|
IGNITER |
|
120,000 & 150,000 Btu/hr MODELS |
||
COMBUSTION |
|
INTAKE AIR |
BLOWER ASSEMBLY |
(combustion air) |
|
|
|
CONNECTION |
|
|
3 INCH PVC |
|
|
BLOWER |
|
|
FLANGE |
|
|
HOT SURFACE |
|
|
IGNITER |
FLAME |
|
MAIN |
|
BURNER |
|
SENSOR |
|
|
|
(radial design) |
|
|
|
|
199,000 & 250,000 Btu/hr MODELS |
||
Figure 2
Hot Surface Igniter
The control system energizes the Hot Surface Igniter with 120 VAC during the igniter warm up period. When the igniter is energized it produces sufficient heat, >1800°F (>982°C), to ignite the Main Burner.
Note: Care must be taken when handling the igniter to prevent breakage.
Flame Sensor
The control system also monitors the flame sensor to confirm a flame is present at the Main Burner. If a flame is not verified during the ignition trial period (3-5 seconds) the control system will immediately de-energize the 24 Volt Gas Valve. See the Sequence Of Operation Flow Chart on page 59.
7
Top Views
120,000 & 150,000 |
|
6 7 8 |
9 |
Btu/hr MODELS |
|
|
|
|
|
10 |
|
TOP VIEW |
5 |
2 |
11 |
|
|
||
|
|
|
4
12
13
3 
2 |
14 |
|
|
|
15 |
1 |
16 |
|
17 |
Figure 3
SUF 120 & 150 Components
1.Water Heater’s 120 VAC on/off switch.
2.Powered anode rods. The water heater’s covered in this manual are equipped with powered (non sacrificial) anode rod(s).The SUF 120 has one powered anode, all other models will have two. Protective current is fed by the control system to the titanium electrodes at the end of each anode rod. This current flows through the water to the conductive surfaces inside the storage tank which diminishes the corrosive effect (rusting) of water when it comes in contact with steel.
3.Central Control Board (CCB) enclosure. This enclosure houses the control system’s main circuit board. The CCB regulates water temperature and controls all water heater functions, see Control System Operation on page 44.
4.Intake air connection - 3 inch PVC.
5.120 VAC junction box. Incoming power supply and ground connections are made here. See Power Supply on page 14.
6.Water heater's 24 Volt Gas Valve.
7.Supply gas line connection. See the requirements for the
Supply Gas Line on page 14.
8.Low Gas Pressure switch. Normally open contacts that close on a rise in pressure. This switch is used to insure supply gas pressure is above minimum requirements. The control system monitors this switch and will disable heating operation if its contacts are open during a heating cycle. See Table 4 and the Gas Pressure Requirements on page 14.
9.Blocked Intake Air switch. Normally closed contacts that open on fall in pressure. This switch is used to insure intake (combustion) air to the water heater is not restricted. The control system monitors this switch and will disable heating operation if its contacts are open during a heating cycle.
10.Vent connection (exhaust elbow) - 3 inch PVC.
11.Combustion Blower.
12.Blocked Exhaust (vent) switch. Normally closed contacts that open on a rise in pressure. This switch is used to insure the Exhaust (vent) piping connected to the water heater is not restricted. The control system monitors this switch and will disable heating operation if its contacts are open during a heating cycle.
13.Blower Prover switch. Normally open contacts that close on a rise in pressure. This switch is used to insure the Combustion Blower is operating properly. The control system monitors this switch and will disable heating operation if its contacts are closed before the Combustion Blower is energized or open any time during a heating cycle. See Sequence Of
Operation on page 58.
14.Temperature-Pressure Relief Valve. See TemperaturePressure Relief Valve on page 16.
15.Upper Temperature Probe, 1 of 2 temperature probes. The water heater’s control system monitors this probe to detect water temperature in the upper portion of the storage tank.
The Upper Temperature Probe also houses the ECO (energy cut out) switch. This is a non adjustable high temperature limit switch. The ECO switch contacts are normally closed and will open on a temperature rise. See High Temperature Limit Control (ECO) on page 43.
16.Water outlet connection 1 1/2” NPT.
17.UIM (user interface module). The UIM includes the display circuit board, the control system’s LCD display and operational buttons. Used to adjust various user settings and view operational information. See Control System Operation on page 44.
8
Top Views (cont)
199,000 & 250,000 |
|
7 |
|
|
|
Btu/hr MODELS |
|
8 |
9 |
10 |
|
TOP VIEW |
|
|
|||
2 |
|
|
|
|
|
5 |
6 |
|
|
|
|
|
|
|
|
11
4
12
13
3 
2 |
14 |
|
|
|
15 |
1 |
16 |
|
17 |
Figure 4
SUF 199 & 250 Components
1.Water Heater’s 120 VAC on/off switch.
2.Powered anode rods. The water heater’s covered in this manual are equipped powered (non sacrificial) anode rods. The SUF 120 has one powered anode, all other models will have two. Protective current is fed by the control system to the titanium electrodes at the end of each anode rod. This current flows through the water to the conductive surfaces inside the storage tank which diminishes the corrosive effect (rusting) of water when it comes in contact with steel.
3.Central Control Board (CCB) enclosure. This enclosure houses the control system’s main circuit board. The CCB regulates water temperature and controls all water heater functions, see Control System Operation on page 44.
4.EBM Combustion Blower Assembly includes VFD (variable frequency drive), Gas Valve and Venturi gas feed system.
5.120 VAC junction box. Incoming power supply and ground connections are made here. See Power Supply on page 14.
6.Water heater's 24 Volt Gas Valve.
7.Blocked Intake Air switch. Normally closed contacts that open on fall in pressure. This switch is used to insure intake (combustion) air to the water heater is not restricted. The control system monitors this switch and will disable heating operation if its contacts are open during a heating cycle.
8.Supply gas line connection. See the requirements for the
Supply Gas Line on page 14.
9.Low Gas Pressure switch. Normally open contacts that close on a rise in pressure. This switch is used to insure supply gas pressure is above minimum requirements. The control system monitors this switch and will disable heating operation if its contacts are open during a heating cycle. See Table 4 and the Gas Pressure Requirements on page 14.
10.Vent connection (exhaust elbow) - 3 inch PVC.
11.Intake air connection - 3 inch PVC.
12.Blocked Exhaust (vent) switch. Normally closed contacts that open on a rise in pressure. This switch is used to insure the Exhaust (vent) piping connected to the water heater is not restricted. The control system monitors this switch and will disable heating operation if its contacts are open during a heating cycle.
13.Blower Prover switch. Normally open contacts that close on a rise in pressure. This switch is used to insure the Combustion Blower is operating properly. The control system monitors this switch and will disable heating operation if its contacts are closed before the Combustion Blower is energized or open any time during a heating cycle. See Sequence Of
Operation on page 58.
14.Temperature-Pressure Relief Valve. See TemperaturePressure Relief Valve on page 16.
15.Upper Temperature Probe, 1 of 2 temperature probes. The water heater’s control system monitors this probe to detect water temperature in the upper portion of the storage tank.
The Upper Temperature Probe also houses the ECO (energy cut out) switch. This is a non adjustable high temperature limit switch. The ECO switch contacts are normally closed and will open on a temperature rise. See High Temperature Limit Control (ECO) on page 43.
16.Water outlet connection 1 1/2” NPT.
17.UIM (user interface module). The UIM includes the display circuit board, the control system’s LCD display and operational buttons. Used to adjust various user settings and view operational information. See Control System Operation on page 44.
9
4 |
5 |
6 |
5 |
4 |
13 |
14 |
3 |
|
|
|
|||
|
|
|
|
|
||
|
|
2 |
|
|
|
|
|
|
|
|
|
3 |
|
|
|
|
7 |
|
|
|
|
|
|
|
|
|
|
2 |
|
|
8 |
|
|
|
|
|
|
|
|
|
|
|
|
|
9 |
|
|
|
|
|
|
|
|
|
15 |
|
|
|
10 |
|
|
|
1 |
|
|
11 |
|
|
|
|
|
|
12 |
|
|
16 |
|
|
|
|
|
|
|
|
LEFT SIDE |
|
RIGHT SIDE |
|
|
|
120,000 & 150,000 Btu/hr MODELS |
199,000 & 250,000 Btu/hr MODELS |
|||||
Figure 5
Side Views
1.Cleanout access panel, covers water heater cleanout opening.
2.CCB enclosure - see beginning on page 8 for description.
3.Intake air connection - 3 inch PVC.
4.Water heater 24 Volt Gas Valve.
5.Combustion Blower.
6.Water outlet pipe - 1 1/2” NPT connection.
7.UIM (user interface module). The UIM includes the display circuit board, the control system’s LCD display and operational buttons. Used to adjust various user settings and view operational information. See Control System Operation on page 44.
8.Temperature-Pressure Relief Valve. See TemperaturePressure Relief Valve on page 16.
9.Temperature-Pressure Relief Valve discharge pipe - see T&P
Valve Discharge Pipe Requirements: on page 16.
10.Lower Temperature Probe, 1 of 2 temperature probes. The water heater’s control system monitors this probe to detect water temperature in the lower portion of the storage tank.
11.Water inlet pipe - 1 1/2” NPT connection.
12.Water heater drain valve.
13.Supply gas line connection. See Supply Gas Line on page 14.
14.Low Gas Pressure switch, see description under beginning on page 8. See Table 4 and the Gas Pressure Requirements on page 14.
15.Vent connection (exhaust elbow) - 3 inch PVC.
16.Condensate trap with 1/2 inch PVC drain connection. See Figure 9 on page 17 and Condensate Drain Installation on page 38.
10
Installation Considerations
Rough In Dimensions
|
FRONT |
E |
|
T & P VALVE |
|
|
|
|
|
B |
|
|
D |
|
CLEANOUT |
3/4” NPT DRAIN |
|
|
|
|
|
1 1/2” NPT |
|
|
WATER INLET |
|
A |
C |
|
|
|
SUPPLY GAS |
INTAKE AIR CONNECTION |
CONNECTION |
3 INCH PVC |
|
WATER OUTLET |
|
HEIGHT |
BACK |
I |
F |
H |
|
|
VENT CONNECTION |
|
3 INCH PVC |
|
(exhaust elbow) |
|
CONDENSATE |
|
DRAIN CONNECTION |
|
1/2 INCH PVC |
|
G |
|
These designs comply with the current edition of the American National Standard for Gas Water Heaters, Volume III, ANSI Z21.10.3 / CSA 4.3 as an automatic circulating tank water heater, and automatic storage water heaters.
120,000 & 150,000 Btu/hr
MODELS
68°
22°
GAS
35° |
TOP VIEWS |
35° |
|
199,000 & 250,000 |
|
|
|
||||
|
|
|
|||
|
|
64° |
|
|
Btu/hr |
|
|
VENT |
MODELS |
||
|
|
|
|||
|
|
|
|
||
VENT |
|
3 |
INCH |
|
|
3 |
INCH |
|
PVC |
|
|
PVC |
|
|
|
||
INTAKE AIR 3 INCH PVC
*1 1/2” NPT
WATER
OUTLET
|
|
|
|
|
|
T |
|
|
|
|
|
U |
|
|
|
|
|
O |
|
|
|
|
|
N |
|
|
|
|
|
A |
|
|
|
|
|
E |
|
|
|
|
|
L |
|
|
|
|
|
|
C |
|
|
|
|
|
|
45°
|
T |
|
D |
& |
|
|
R |
P |
|
A |
V |
|
I |
A |
|
N |
L |
|
|
V |
|
V |
E |
|
A |
|
|
L |
|
FRONT |
V |
|
E |
||
18°
45°
SUPPLY GAS
CONNECTION
VERTICAL
*1 1/2” NPT
WATER
OUTLET
|
|
|
|
|
|
T |
|
|
|
|
|
U |
|
|
|
|
|
O |
|
|
|
|
|
N |
|
|
|
|
|
A |
|
|
|
|
|
E |
|
|
|
|
|
L |
|
|
|
|
|
|
C |
|
|
|
|
|
|
45°
|
|
INTAKE AIR |
|
|
|
3 INCH PVC |
|
|
T |
||
|
|
& |
|
D |
P |
||
RA |
V |
||
AL |
|||
|
I |
||
|
N |
V |
|
|
|
E |
|
|
V |
|
|
|
A |
|
|
|
L |
|
|
FRONT |
V |
|
|
E |
|||
18°
45°
* Center line of water outlet on top of the water heaters is approximately 7 inches from the front edge of the water heater.
|
|
|
|
DIMENSIONS |
|
|
|
SHIP |
SHIP |
|||
MODEL |
A |
B |
C |
D |
E |
F |
G |
H |
I |
WEIGHT |
WEIGHT |
|
STD |
ASME |
|||||||||||
|
|
|
|
|
|
|
|
|
|
|||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
INCHES/CM |
INCHES/CM |
INCHES/CM |
INCHES/CM |
INCHES/CM |
INCHES/CM |
INCHES/CM |
INCHES/CM |
INCHES/CM |
LBS/KG |
LBS/KG |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
SUF 60 120 |
3/7.62 |
27.75/70.5 |
6.3/16 |
35/88.9 |
55.5/141 |
48/121.9 |
11/27.9 |
42/106.7 |
47.5/120.6 |
460/208 |
490/222 |
|
SUF 100 150 |
3/7.62 |
27.75/70.5 |
6.3/16 |
55.5/141 |
75.5/191.8 |
68.5/174 |
11/27.9 |
63/160 |
69/175.3 |
555/252 |
595/270 |
|
SUF 100 199 |
3/7.62 |
27.75/70.5 |
6.3/16 |
55.5/141 |
75.5/191.8 |
75.5/191.8 |
11/27.9 |
63/160 |
69/175.3 |
555/252 |
595/270 |
|
SUF 100 250 |
3/7.62 |
27.75/70.5 |
6.3/16 |
55.5/141 |
75.5/191.8 |
75.5/191.8 |
11/27.9 |
63/160 |
69/175.3 |
555/252 |
595/270 |
|
Figure 6
11
Gas Line Connection Size
Table 1
† MODEL |
SERIES |
NATURAL GAS |
PROPANE GAS |
SUF 60 120 |
100/101 |
3/4 "NPT |
3/4 "NPT |
SUF 100 150 |
100/101 |
3/4 "NPT |
3/4 "NPT |
|
|
|
|
SUF 100 199 |
100/101 |
3/4 "NPT |
3/4 "NPT |
SUF 100 250 |
100/101 |
3/4 "NPT |
3/4 "NPT |
†Depending on the installed equivalent length, and/or the number of appliances connected, the supply gas line size may have to be increased beyond the minimum required sizes - see Gas Line Sizing on page 39.
Recovery Capacities
Table 3
Storage Capacities
Table 2
MODEL |
U. S. GALLONS |
LITERS |
SUF 60 120 |
60 |
227 |
|
|
|
SUF 100 150 |
100 |
379 |
SUF 100 199 |
100 |
379 |
SUF 100 250 |
100 |
379 |
|
|
|
|
|
|
|
U. S. Gallons/hr & litters/hr at temperature rise indicated |
|
|
|||||||||
Model |
Type of |
Input |
|
°F |
30°F |
40°F |
|
50°F |
60°F |
70°F |
80°F |
90°F |
100°F |
110°F |
120°F |
|
130°F |
140°F |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
Gas |
Btu/hr |
kW |
°C |
17°C |
22°C |
|
28°C |
33°C |
39°C |
44°C |
50°C |
56°C |
61°C |
67°C |
|
72°C |
78°C |
|
|
|
|
||||||||||||||||
|
|
|
|
|||||||||||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
SUF 60 120 |
Natural |
120,000 |
35 |
GPH |
461 |
345 |
|
276 |
230 |
197 |
173 |
154 |
138 |
126 |
115 |
|
106 |
99 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
Propane |
LPH |
1744 |
1308 |
|
1046 |
872 |
747 |
654 |
581 |
523 |
476 |
436 |
|
402 |
374 |
|||
|
|
|
|
|
||||||||||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
SUF 100 150 |
Natural |
150,000 |
44 |
GPH |
576 |
432 |
|
345 |
288 |
247 |
216 |
192 |
173 |
157 |
144 |
|
133 |
123 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
Propane |
LPH |
2179 |
1635 |
|
1308 |
1090 |
934 |
817 |
726 |
654 |
594 |
545 |
|
503 |
467 |
|||
|
|
|
|
|
||||||||||||||
SUF 100 199 |
Natural |
199,900 |
58 |
GPH |
767 |
575 |
|
460 |
384 |
329 |
288 |
256 |
230 |
209 |
192 |
|
177 |
164 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
Propane |
LPH |
2904 |
2178 |
|
1743 |
1452 |
1245 |
1089 |
968 |
871 |
792 |
726 |
|
670 |
622 |
|||
|
|
|
|
|
||||||||||||||
SUF 100 250 |
Natural |
250,000 |
73 |
GPH |
960 |
720 |
|
576 |
480 |
411 |
360 |
320 |
288 |
262 |
240 |
|
221 |
206 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
Propane |
LPH |
3632 |
2724 |
|
2179 |
1816 |
1557 |
1362 |
1211 |
1090 |
991 |
908 |
|
838 |
778 |
|||
Recovery capacities are based on 95% thermal efficiency.
Locating The Water Heater
Carefully choose a location for the new water heater. The placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance.
CAUTION
Property Damage Hazard
•All water heaters eventually leak.
•Do not install without adequate drainage.
Whether replacing an existing water heater or installing the water heater in a new location observe the following critical points:
1.The water heater must be located indoors.
2.The water heater must not be located in an area where it will be subject to freezing temperatures.
3.Locate the water heater so it is protected and not subject to physical damage by a moving vehicle.
4.Locate the water heater on a level surface.
5.Locate the water heater near a floor drain. The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure. When such locations cannot be avoided, it is recommended that a metal drain pan, adequately drained, be installed under the appliance.
6.Locate the water heater close to the point of major hot water usage.
7.Locate the water heater close to a 120 VAC power supply. See Power Supply on page 14 for requirements.
8.Locate the water heater where an adequate supply of fresh air for combustion and ventilation can be obtained. See Air
Requirements on page 18.
9.Locate the water heater where the vent and intake air piping, when installed, will remain within the maximum equivalent lengths allowed. See Venting Requirements on page 24.
10. Do not locate the water heater where noise (such as the Combustion Blower) during normal operation will be objectionable in adjacent areas.
11.Do not locate the water heater where the subsequent installation of the vent (exhaust) or intake air terminations would be objectionable due to noise at the termination(s). This includes locations close to or across from windows and doors. See Venting Installation on page 22.
Fire or Explosion Hazard
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas pressure.
Use only the gas shown on the water heater rating label.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended periods of non-use.
Read instruction manual before installing, using or servicing water heater.
12
There is a risk in using fuel burning appliances such as gas water heaters in rooms, garages or other areas where gasoline, other flammable liquids or engine driven equipment or vehicles are stored, operated or repaired. Flammable vapors are heavy and travel along the floor and may be ignited by the water heater’s igniter or Main Burner flames causing fire or explosion.
Flammable items, pressurized containers or any other potential fire hazardous articles must never be placed on or adjacent to the water heater.
Clearance To Combustible Materials
The water heaters covered in this manual are approved for installation on combustible flooring. The clearance to combustible and non combustible construction materials is 0 inches on the back and sides of the water heater. These water heaters are also approved for installation in an alcove.
Note: Adequate clearance for servicing should be maintained on all installations. See Service Clearance below.
ALCOVE |
CLEARANCES TO COMBUSTIBLE |
|
AND NON COMBUSTIBLE |
|
CONSTRUCTION MATERIALS |
TOP COVER |
|
|
0 |
|
0 |
WATER |
0 |
HEATER |
|
FRONT |
|
|
FRONT |
FRONT VIEW |
TOP VIEW |
|
Figure 7
Service Clearance
A service clearance of 24 inches (61 cm) should be maintained from serviceable parts such as the T&P valve, control system components, gas valve, clean out opening, drain valve, the vent connection (exhaust elbow) and the condensate drain. Leave as much room as possible above the water heater and near the exhaust elbow for this reason. See Figure 9 on page 17.
Intake Air and Vent Pipe Clearances
The minimum clearance from combustible materials for the vent (exhaust) and intake air piping shall be 0 inches. Vent or intake air piping passing through a combustible wall or ceiling must be a continuous run (no joints).
Extended Vent Terminations
The water heaters covered by this manual can be installed using 3 inch pipe for the intake air and/or vent piping up to a maximum of 50 equivalent feet (15.2 m). The intake air and/or vent piping can be extended up to 120 equivalent feet (36.5 m) by installing 4 inch pipe. See the Venting Requirements on page 24.
The water heater ships from the factory with two (2) 3 inch terminations that are 45° PVC elbows with a debris screen installed. When 4 inch intake air or vent pipe is installed, factory supplied 4 inch terminations must be used.
Contact your local distributor or call the parts department phone number listed on the back cover of this manual to order 4 inch termination(s).
Optional Concentric Terminations
The water heaters covered in this manual can be installed in a Direct Vent configuration using an optional concentric termination. See Concentric Termination Installation on page 30.
Hard Water
Where hard water conditions exist, water softening or the threshold type of water treatment is recommended. This will protect the dishwashers, coffee urns, water heaters, water piping and other equipment. See Maintenance on page 64 for sediment and lime scale removal procedures.
Circulation Pumps
A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the water heater. See the Water Piping Diagrams beginning on page 71 for installation location of circulating pumps.
See Circulation Pump Wiring Diagrams on page 70 for electrical hookup information. Install in accordance with the current edition of the National Electrical Code, NFPA 70 or the Canadian Electrical Code, CSA C22.1.
All-bronze circulators are recommended for used with commercial water heaters.
Some circulating pumps are manufactured with sealed bearings and do not require further lubrication. Some circulating pumps must be periodically oiled. Refer to the pump manufacturer’s instructions for lubrication requirements.
Insulation Blankets
Breathing Hazard - Carbon Monoxide Gas
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.
Insulation blankets are available to the general public for external use on gas water heaters but are not necessary with these products. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. The water heaters covered by this manual meet or exceed the Energy Policy Act standards with respect to insulation and standby heat loss requirements, making an insulation blanket unnecessary.
Should you choose to apply an insulation blanket to this heater, you should follow these instructions. See the Features and Components section of this manual for identification of components mentioned below. Failure to follow these instructions can restrict the air flow required for proper combustion, potentially resulting in fire, asphyxiation, serious personal injury or death.
•Do not apply insulation to the top of the water heater, as this will interfere with safe operation of the blower assembly.
•Do not cover the control system LCD on top of the water heater.
•Do not cover the Temperature-Pressure Relief Valve.
•Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.
•Do obtain new warning and instruction labels from the manufacturer for placement on the blanket directly over the existing labels.
•Do inspect the insulation blanket frequently to make certain it does not sag, thereby obstructing combustion air flow.
13
Installation Requirements
Gas Pressure Requirements
Table 4
Model |
*Manifold Pressure |
†Minimum Supply Pressure |
‡Maximum Supply Pressure |
||||
NATURAL GAS |
PROPANE GAS |
NATURAL GAS |
PROPANE GAS |
NATURAL GAS |
PROPANE GAS |
||
|
|||||||
|
|
|
|
|
|
|
|
SUF 60 120 |
4” W. C. (1.0 kPa) |
10” W. C. (2.49 kPa) |
4.9” W. C. (1.22 kPa) |
11” W. C. (2.74 kPa) |
10.5” W. C. (2.62 kPa) |
14” W. C. (3.49 kPa) |
|
SUF 100 150 |
4” W. C. (1.0 kPa) |
10” W. C. (2.49 kPa) |
4.9” W. C. (1.22 kPa) |
11” W. C. (2.74 kPa) |
10.5” W. C. (2.62 kPa) |
14” W. C. (3.49 kPa) |
|
SUF 100 199 |
0” W. C. (0 kPa) |
0” W. C. (0 kPa) |
4.9” W. C. (1.22 kPa) |
11” W. C. (2.74 kPa) |
10.5” W. C. (2.62 kPa) |
14” W. C. (3.49 kPa) |
|
SUF 100 250 |
0” W. C. (0 kPa) |
0” W. C. (0 kPa) |
4.9” W. C. (1.22 kPa) |
11” W. C. (2.74 kPa) |
10.5” W. C. (2.62 kPa) |
14” W. C. (3.49 kPa) |
|
*Manifold gas pressure; reading can only be taken while gas is flowing. Reading taken should be ± 0.3” W. C. of the listed value. 120,000 and 150,000 Btu/hr models are certified for use without modification for altitudes up to 7,700 feet (2,347 m). 199,000 and 250,000 Btu/hr models are certified for use without modification for altitudes up to 10,100 feet (3,078 m). See High Altitude Installations on page 55 for higher elevations.
†Minimum supply gas pressure; readings are taken while gas is not flowing (static pressure) AND while gas is flowing (dynamic pressure). Supply pressure must never fall below the minimum values. Supply gas pressures should be measured with all gas fired appliances connected to a common main firing at full capacity. If supply pressure drops more than 1.5” W. C. as gas begins to flow the supply gas system (gas line/regulator) may be restricted or undersized. See Table 5 and the Supply Gas Regulator requirements below. See Supply Gas Line Installation on page 39 and Supply Gas Regulator Installation on page 40 for sizing and installation instructions also.
‡Maximum supply gas pressure; reading are taken while gas is not flowing (static pressure) AND while gas is flowing (dynamic pressure). Supply pressure must never exceed this maximum value.
Supply Gas Line
The high efficiency water heaters covered in this manual require an adequate volume of fuel gas for proper operation. A lack of fuel gas volume can lead to ignition failure, rough starting and rough operation. Increasing the supply gas pressure does not necessarily increase the volume of gas supplied to the water heater and must remain below the maximum supply gas pressures shown in Table 4.
The minimum supply gas line sizes shown in Table 5 must be observed on all installations to help insure an adequate volume of fuel gas is provided. Do not use flexible gas piping.
Supply gas lines serving more than one appliance may require larger sizes than what is shown in Table 5. See Gas Line Sizing on page 39.
MINIMUM SUPPLY GAS LINE SIZE Table 5
† MODEL |
NATURAL GAS |
PROPANE GAS |
SUF 60 120 |
3/4” NPT |
3/4” NPT |
SUF 100 150 |
3/4” NPT |
3/4” NPT |
SUF 100 199 |
3/4” NPT |
3/4” NPT |
SUF 100 250 |
3/4” NPT |
3/4” NPT |
†Depending on the installed equivalent length, and/or the number of appliances connected, the supply gas line size may have to be increased beyond the minimum required sizes shown in this table - see Gas Line Sizing on page 39.
Supply Gas Regulator
The high efficiency water heaters covered by this manual require a supply gas regulator to be installed in the supply gas line serving the water heater for proper operation. Supply gas regulators are required on high and low pressure gas supply systems. On multiple water heater installations each water heater shall have its own dedicated supply gas regulator installed in the supply gas line serving the water heater.
Supply gas regulators must be rated at or above the input Btu/ hr rating of the water heater they supply. Supply gas regulators shall have inlet and outlet connections not less than the minimum supply gas line size for the water heater they serve as shown in Table 5. The Maxitrol 325-7L or equivalent is recommended.
See Supply Gas Regulator Installation on page 40.
Power Supply
The water heaters covered in this manual require a 120 VAC, 1Ø (single phase), 60Hz, 15 amp power supply and must also be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/ NFPA 70 or the Canadian Electrical Code, CSA C22.1.
Power Fluctuations and Electrical Noise
The water heater’s control system requires a source of stable clean electricity for proper operation. Connecting the water heater to a branch circuit that is subject to fluctuations in voltage level or electrical line noise such as EMI (electro magnetic interference) or RFI (radio frequency interference) may cause erratic control system operation and malfunction.
A high quality power supply filter/suppressor such as the Kleen Line model SELF/T-10 Series SC-L or equivalent must be installed if the above conditions exist. Call the technical support phone number listed on the back cover of this manual for more information.
Note: Malfunctions caused by the power supply and the costs to install power supply filters are not covered under the limited warranty.
Dedicated Power Wiring and Breakers
Dedicated power supply wires, ground wiring and dedicated circuit breakers often prevent electrical line noise and should be considered when installing the water heater.
Polarity Sensitive
The control system on the water heaters covered in this manual is polarity sensitive; electronic flame sensing requires correct polarity. The control system is programmed to monitor the incoming power supply. If the Hot and Neutral wires in the 120 VAC power supply are reversed, the control system will declare a Fault condition and lock out, heating operation will be disabled until the power supply is correctly wired. The control system will display the “AC Reversed” Fault message on the LCD.
See Electrical Wiring on page 41 for installation instructions.
14
Mixing Valves
Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death.
Children, the elderly and the physically or mentally disabled are at highest risk for scald injury.
Feel water before bathing or showering.
Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at fixtures.
Water heated to a temperature which will satisfy clothes washing, dish washing, and other sanitizing needs can scald and cause permanent injury upon contact. Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the water heater’s temperature setting by up to 20°F (11°C).
Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm and the physically/mentally disabled. Table 6 shows the approximate time-to-burn relationship for normal adult skin. If anyone using hot water provided by the water heater being installed fits into one of these groups or if there is a local code or state law requiring a certain water temperature at the point of use, then special precautions must be taken.
In addition to using the lowest possible temperature setting that satisfies the demand of the application a Mixing Valve should be installed at the water heater (see Figure 8) or at the hot water taps to further reduce system water temperature.
Mixing valves are available at plumbing supply stores. Consult a Qualified Installer or Service Agency. Follow mixing valve manufacturer’s instructions for installation of the valves.
Table 6
Water Temperature |
Time to Produce 2nd & 3rd |
|
Degree Burns on Adult Skin |
||
|
180°F (82°C) |
Nearly instantaneous |
170°F (77°C) |
Nearly instantaneous |
160°F (71°C) |
About 1/2 second |
150°F (66°C) |
About 1-1/2 seconds |
140°F (60°C) |
Less than 5 seconds |
130°F (54°C) |
About 30 seconds |
120°F (49°C) |
More than 5 minutes |
Dishwashing Machines
All dishwashing machines meeting the National Sanitation Foundation requirements are designed to operate with water flow pressures between 15 and 25 pounds per square inch (103 kPa and 173 kPa). Flow pressures above 25 pounds per square inch (173 kPa), or below 15 pounds per square inch (103 kPa), will result in improperly sanitized dishes. Where pressures are high, a water pressure reducing or flow regulating control valve should be used in the 180°F (82°C) line to the dishwashing machine and should be adjusted to deliver water pressure between these limits.
HOT WATER
OUTLET
12” TO 15” (30-38 cm)
TEMPERED WATER
OUTLET
COLD |
|
CHECK |
WATER |
|
VALVE |
INLET |
|
MIXING |
|
CHECK |
|
|
VALVE |
|
|
VALVE |
|
|
|
|
|
TO TANK |
|
|
INLET |
|
Figure 8
The National Sanitation Foundation also recommends circulation of 180°F (82°C) water. Where this is done, the circulation should be very gentle so that it does not cause any unnecessary turbulence inside the water heater. The circulation should be just enough to provide 180°F (82°C) water at the point of take-off to the dishwashing machine.
Adjust flow by throttling a full port ball valve installed in the circulating line on the outlet side of the pump. Never throttle flow on the suction side of a pump. See the Water Piping Diagrams beginning on page 71.
Note: To comply with NSF Standard 5 installation requirements the bottom of the water heater must be sealed to the floor with a silicone based sealant or elevated 6 inches above the floor.
Closed Water Systems
Water supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure reducing valves, check valves, and back flow preventers. Devices such as these cause the water system to be a closed system.
Thermal Expansion
As water is heated, it expands (thermal expansion). In a closed system the volume of water will grow when it is heated. As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent Temperature-Pressure Relief Valve operation: water discharged from the valve due to excessive pressure build up. This condition is not covered under the limited warranty. The Temperature-Pressure Relief Valve is not intended for the constant relief of thermal expansion.
A properly sized thermal expansion tank must be installed on all closed systems to control the harmful effects of thermal expansion. Contact a local plumbing service agency to have a thermal expansion tank installed.
See Water Line Connections on page 42 and the Water Piping
Diagrams beginning on page 71.
15
Temperature-Pressure Relief Valve
Explosion Hazard
Temperature-Pressure Relief Valve must comply with ANSI Z21.22CSA 4.4 and ASME code.
Properly sized temperaturepressure relief valve must be installed in opening provided.
Can result in overheating and excessive tank pressure.
Can cause serious injury or death.
This water heater is provided with a properly rated/sized and certified combination Temperature-Pressure Relief Valve (T&P valve) by the manufacturer. The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA 4.4, and the code requirements of ASME.
If replaced, the new T&P valve must meet the requirements of local codes, but not less than a combination TemperaturePressure Relief Valve rated/sized and certified as indicated in the above paragraph. The new valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (150 psi = 1,035 kPa) and a discharge capacity not less than the water heater Btu/hr or kW input rate as shown on the water heater’s model rating label.
Note: In addition to the factory installed Temperature-Pressure Relief Valve on the water heater, each remote storage tank that may be installed and piped to a water heating appliance must also have its own properly sized, rated and approved TemperaturePressure Relief Valve installed. Call the toll free technical support phone number listed on the back cover of this manual for technical assistance in sizing a Temperature-Pressure Relief
Valve for remote storage tanks.
For safe operation of the water heater, the Temperature-Pressure Relief Valve must not be removed from its designated opening nor plugged. The Temperature-Pressure Relief Valve must be installed directly into the fitting of the water heater designed for the relief valve. Install discharge piping so that any discharge will exit the pipe within 6 inches (15.2 cm) above an adequate floor drain, or external to the building. In cold climates it is recommended that it be terminated at an adequate drain inside the building. Be certain that no contact is made with any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstances. Excessive length, over 30 feet (9.14 m), or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve.
No valve or other obstruction is to be placed between the Temperature-Pressure Relief Valve and the tank. Do not connect discharge piping directly to the drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in adequate quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water flow may cause property damage.
CAUTION
Water Damage Hazard
•Temperature-Pressure Relief Valve discharge pipe must terminate at adequate drain.
T&P Valve Discharge Pipe Requirements:
•Shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions.
•Shall not be plugged or blocked.
•Shall not be exposed to freezing temperatures.
•Shall be of material listed for hot water distribution.
•Shall be installed so as to allow complete drainage of both the Temperature-Pressure Relief Valve and the discharge pipe.
•Must terminate a maximum of six inches above a floor drain or external to the building. In cold climates, it is recommended that the discharge pipe be terminated at an adequate drain inside the building.
•Shall not have any valve or other obstruction between the relief valve and the drain.
Burn hazard.
Hot water discharge.
Keep clear of TemperaturePressure Relief Valve discharge outlet.
The Temperature-Pressure Relief Valve must be manually operated at least twice a year. Caution should be taken to ensure that (1) no one is in front of or around the outlet of the Temperature-Pressure Relief Valve discharge line, and (2) the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot. If after manually operating the valve, it fails to completely reset and continues to release water, immediately close the cold water inlet to the water heater, follow the draining instructions in this manual, and replace the Temperature-Pressure Relief Valve with a properly rated/sized new one.
Note: The purpose of a Temperature-Pressure Relief Valve is to prevent excessive temperatures and pressures in the storage tank. The T&P valve is not intended for the constant relief of thermal expansion.Aproperly sized thermal expansion tank must be installed on all closed systems to control thermal expansion, see Closed Water Systems and Thermal Expansion on page 15.
If you do not understand these instructions or have any questions regarding the Temperature-Pressure Relief Valve call the toll free number listed on the back cover of this manual for technical assistance.
16
Condensate Drain
The water heaters covered in this manual are condensing appliances and require a building drain to be located in close proximity to allow the condensate to drain safely.
Condensate drains from the water heater at the exhaust elbow located at the bottom. The field installed condensate drain line must not be elevated above the condensate drain connection on the condensate trap, see Figure 9. If the condensate does not drain properly it will build up in the exhaust (vent) elbow. This will restrict the flow of flue gases and cause the Blocked Exhaust pressure switch to open its contacts. The control system monitors all pressure switches, if the Blocked Exhaust Switch contacts are open the control system will lock out and disable heating operation. The “Blocked Exhaust” Fault message will be displayed on the control system’s LCD, see Fault And Alert Conditions beginning on page 61.
Note: If the “Blocked Exhaust “ Fault message is ever displayed on the control system LCD, check the condensate drain first and ensure it is not blocked.
CLEANOUT |
EXHAUST (VENT) |
|
ELBOW |
||
PLUG IS |
CONDENSATE DRAIN |
|
REMOVED |
||
LINE CONNECTION |
||
TO CLEAR |
||
|
||
DRAIN |
CONDENSATE DRAIN |
|
|
||
|
LINE - FIELD INSTALLED |
|
FACTORY INSTALLED |
BUILDING |
|
CONDENSATE TRAP |
DRAIN |
Figure 9
Condensate Drain Water Trap
Breathing Hazard - Carbon Monoxide Gas
Ensure a functioning water trap is
installed in the condensate drain.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.
Do not remove the factory installed condensate trap for any reason, see Figure 9. The water heater’s vent pipe is under a slight positive pressure. The water trap prevents flue gases from escaping into the installed space. See Condensate Drain
Installation on page 38.
Condensate PH Level
The condensate drains from the water heater’s covered in this manual have PH levels between 4.3 and 5.0. Install a commercially available neutralizing kit if required by local codes.
Note: Lower PH levels are acidic. Do not connect a metal drain line, such as copper, to the water heater for this reason. See Condensate Drain Installation on page 38.
Combustible Material Storage
Fire or Explosion Hazard
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas pressure.
Use only the gas shown on the water heater rating label.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended periods of non-use.
Read instruction manual before installing, using or servicing water heater.
Keep appliance area clear and free of combustible materials, gasoline and other flammable vapors and liquids.
Contaminated Air
Breathing Hazard - Carbon Monoxide Gas
Install water heater in accordance with the Instruction Manual and NFPA 54 or CAN/CSA-B149.1.
To avoid injury, combustion and ventilation air must be taken from outdoors.
Do not place chemical vapor emitting products near water heater.
Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.
Corrosion of the flue ways and vent system may occur if air for combustion contains certain chemical vapors. Such corrosion may result in failure and risk of asphyxiation.
Combustion air that is contaminated can greatly diminish the life span of the water heater and water heater components such as hot surface igniters and burners. Propellants of aerosol sprays, beauty shop supplies, water softener chemicals and chemicals used in dry cleaning processes that are present in the combustion, ventilation or ambient air can cause such damage.
Do not store products of this sort near the water heater. Air which is brought in contact with the water heater should not contain any of these chemicals. If necessary, uncontaminated air should be obtained from remote or outdoor sources. The limited warranty is voided when failure of water heater is due to a corrosive atmosphere. (See limited warranty for complete terms and conditions).
If the water heater will be used in beauty shops, barber shops, cleaning establishments, or self-service laundries with dry cleaning equipment, it is imperative that the water heater(s) be installedinaDirectVentconfigurationsothatallairforcombustion is derived directly from the outdoor atmosphere through a sealed intake air pipe. See Venting Installation on page 22.
17
Air Requirements
Breathing Hazard - Carbon Monoxide Gas
Install water heater in accordance with the Instruction Manual and NFPA 54 or CAN/CSA-B149.1.
To avoid injury, combustion and ventilation air must be taken from outdoors.
Do not place chemical vapor emitting products near water heater.
Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.
For safe operation an adequate supply of fresh uncontaminated air for combustion and ventilation must be provided.
An insufficient supply of air can cause recirculation of combustion products resulting in contamination that may be hazardous to life. Such a condition often will result in a yellow, luminous burner flame, causing sooting of the combustion chamber, burners and flue tubes and creates a risk of asphyxiation.
Do not install the water heater in a confined space unless an adequate supply of air for combustion and ventilation is brought in to that space using the methods described in the Confined Space section that follows.
Never obstruct the flow of ventilation air. If you have any doubts or questions at all, call your gas supplier. Failure to provide the proper amount of combustion air can result in a fire or explosion and cause property damage, serious bodily injury or death.
Unconfined Space
An Unconfined Space is one whose volume is not less than 50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input rating of all appliances installed in the space. Rooms communicating directly with the space, in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconfined space.
Makeup air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers and fireplaces shall also be considered in determining the adequacy of a space to provide combustion, ventilation and dilution air.
Unusually Tight Construction
In unconfined spaces in buildings, infiltration may be adequate to provide air for combustion, ventilation and dilution of flue gases. However, in buildings of unusually tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.) additional air must be provided using the methods described in the Confined Space section that follows.
Confined Space
A Confined Space is one whose volume is less than 50 cubic feet per 1,000 Btu/hr (4.8 cm per kW) of the total input rating of all appliances installed in the space.
Openings must be installed to provide fresh air for combustion, ventilation and dilution in confined spaces. The required size for the openings is dependent on the method used to provide fresh air to the confined space and the total Btu/hr input rating of all appliances installed in the space.
Direct Vent Appliances
Appliances installed in a Direct Vent configuration that derive all air for combustion from the outdoor atmosphere through sealed intake air piping are not factored in the total appliance input Btu/ hr calculations used to determine the size of openings providing fresh air into confined spaces.
Exhaust Fans
Where exhaust fans are installed, additional air shall be provided to replace the exhausted air. When an exhaust fan is installed in the same space with a water heater, sufficient openings to provide fresh air must be provided that accommodate the requirements for all appliances in the room and the exhaust fan. Undersized openings will cause air to be drawn into the room through the water heater’s vent system causing poor combustion. Sooting, serious damage to the water heater and the risk of fire or explosion may result. It can also create a risk of asphyxiation.
Louvers and Grilles
The free areas of the fresh air openings in the instructions that follow do not take in to account the presence of louvers, grilles or screens in the openings.
The required size of openings for combustion, ventilation and dilution air shall be based on the “net free area” of each opening. Where the free area through a design of louver or grille or screen is known, it shall be used in calculating the size of opening required to provide the free area specified. Where the louver and grille design and free area are not known, it shall be assumed that wood louvers will have 25% free area and metal louvers and grilles will have 75% free area. Non motorized louvers and grilles shall be fixed in the open position.
18
Fresh Air Openings For Confined Spaces
The following instructions shall be used to calculate the size, number and placement of openings providing fresh air for combustion, ventilation and dilution in confined spaces. The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only. Do not refer to these illustrations for the purpose of vent installation. See Venting Installation on page 22 for complete venting installation instructions.
Outdoor Air Through Two Openings
Figure 10
The confined space shall be provided with two permanent openings, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The openings shall communicate directly with the outdoors. See Figure 10.
Each opening shall have a minimum free area of 1 square inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure. Each opening shall not be less than 100 square inches (645 cm2).
Outdoor Air Through One Opening
Figure 11
Alternatively a single permanent opening, commencing within 12 inches (300 mm) of the top of the enclosure, shall be provided. See Figure 11. The water heater shall have clearances of at least 1 inch (25 mm) from the sides and back and 6 inches (l50 mm) from the front of the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of the following:
1.1 square inch per 3000 Btu/hr (700 mm2 per kW) of the total input rating of all appliances located in the enclosure, and
2.Not less than the sum of the areas of all vent connectors in the space.
Outdoor Air Through Two Horizontal Ducts
Figure 12
The confined space shall be provided with two permanent horizontal ducts, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The horizontal ducts shall communicate directly with the outdoors. See Figure 12.
Each duct opening shall have a minimum free area of 1 square inch per 2,000 Btu/hr (1100 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure.
When ducts are used, they shall be of the same cross sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall be not less than 3 inches.
19
Outdoor Air Through Two Vertical Ducts |
|
Air From Other Indoor Spaces |
The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only.
Do not refer to these illustrations for the purpose of vent installation. See Venting Installation on page 22 for complete venting installation instructions.
Figure 13
The confined space shall be provided with two permanent vertical ducts, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The vertical ducts shall communicate directly with the outdoors. See Figure 13.
Each duct opening shall have a minimum free area of 1 square inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure.
When ducts are used, they shall be of the same cross sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall be not less than 3 inches.
Figure 14
The confined space shall be provided with two permanent openings, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. See Figure 14.
Each opening shall communicate directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an Unconfined Space.
Each opening shall have a minimum free area of 1 square inch per 1,000 Btu/hr (1100 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure. Each opening shall not be less than 100 square inches (645 cm2).
20
Installation Requirements - Commonwealth of Massachusetts
Commonwealth of Massachusetts
For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:
INSTALLATION OF CARBON MONOXIDE DETECTORS
At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.
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 back-up may be installed on the next adjacent floor level.
In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
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 CSA certified.
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 onehalf (1/2) inch in size, “gas vent directly below. Keep clear of all obstructions.”
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.
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.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED
When the manufacturer of Product Approved side wall horizontally vented gas 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.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED
When the manufacturer of a Product Approved side wall 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 system” instructions shall be included with the appliance or equipment installation instructions; and
2.The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.
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.
21
Venting Installation
Breathing Hazard - Carbon Monoxide Gas
•Install vent system in accordance with codes.
•Do not operate water heater if flood damaged.
•Special consideration must be taken with installations above 10,000 feet (3,048 m) refer to high altitude section of this manual.
• Do not operate if soot buildup.
• Do not obstruct water heater air intake with insulating jacket or blanket.
• Do not place chemical vapor emitting products near water heater.
• Gas and carbon monoxide detectors are available.
•Never operate the heater unless it is vented to the outdoors and has adequate air supply to avoid risks of improper operation, fire, explosion or asphyxiation.
•Analyze the entire vent system to make sure that condensate will not become trapped in a section of vent pipe and therefore reduce the open cross sectional area of the vent.
Breathing carbon monoxide can cause brain damage or death. Always read and understand the instruction manual.
Never operate the water heater unless it is vented to the outdoors.
The instructions in this section of the manual must be followed to avoid choked combustion or recirculation of flue gases. Such conditions cause sooting of the combustion chamber, burners and flue tubes and creates a risk of asphyxiation.
General Venting Information
The water heaters covered in this manual are operationally equivalent to Category IV appliances and may be installed in either a Power Vent or Direct Vent configuration.
Category IV Appliance
Category IV appliances operate with a positive vent (exhaust) static pressure and with vent gas temperatures low enough to produce condensate in the vent piping.
Power Vent Configuration
Power Vent configurations derive all combustion air from the room where they are installed and discharge all flue gases to the outdoor atmosphere through a sealed vent (exhaust) pipe. Power vent configurations have one vent pipe connected to the water heater which can be terminated in a vertical or horizontal arrangement. See Figure 40 and Figure 41 on page 34.
Direct Vent Configuration
Direct Vent configurations derive all combustion air directly from the outdoor atmosphere through a sealed intake air pipe and discharge all flue gases to the outdoor atmosphere through a sealed vent (exhaust) pipe. Direct Vent configurations have two pipes connected to the water heater, one vent pipe and one intake air pipe. Direct Vent configurations can be terminated in one of six different arrangements. See Figure 42 on page 34 through Figure 47 on page 35.
General Venting Instructions
These instructions must be followed on all installations.
1.Do not install the water heater in a Power Vent configuration unless there is adequate supply of fresh air, seeAirRequirementsonpage18.Iftheinstallationspacedoes
not provide an adequate supply of fresh air the water heater must be installed in a Direct Vent configuration.
2.If the water heater is to be installed in a beauty shop, barber shop, cleaning establishment, a laundry with dry cleaning equipment or any space with contaminated air it is imperative that the water heater(s) be installed in a Direct Vent configuration so that all air for combustion is derived from the outdoor atmosphere.
3.The vent and intake air piping must terminate outdoors.
4.The minimum clearance from combustible materials for the vent (exhaust) and intake air piping shall be 0 inches. Vent piping passing through a combustible wall or ceiling must be a continuous run (no joints).
5.The water heater must be protected from freezing downdrafts during shutdown periods.
6.The vent (exhaust) pipe must not be combined or connected to any other appliance’s vent system or chimney.
7.The intake air pipe must not be combined or connected to any other appliance’s intake air piping.
8.Locate the water heater where the vent (exhaust) and intake air piping will remain within the maximum equivalent lengths allowed. See Venting Requirements on page 24.
9.Do not install the vent or intake air piping in a manner that will allow water to be trapped in the piping.
10.Vent pipes must be pitched a minimum of a 1/4 inch per foot back to the water heater (to allow drainage of condensate).
11.Do not anchor the vent or intake air pipe directly to framed walls, floors or ceilings unless rubber isolation pipe hangers are used to prevent vibration noise from being transmitted.
12.Use only approved vent/intake air pipe sizes and materials.
See Venting Requirements on page 24.
13.Use only factory supplied vent and intake air or concentric terminations. See the Venting Requirements on page 24.
14.Do not locate the vent (exhaust) or intake air terminations where they would be objectionable due to noise at the termination(s). This includes locations close to or across from windows and doors.
15.Direct venting into dead air spaces such as alleys, atriums, and inside corners can cause recirculation of flue gases. Recirculation of flue gases will cause sooting, premature failure of the heat exchanger and icing of the combustion air intake during severe cold weather. To prevent the recirculation of flue gases, maintain as much distance as possible between the intake air and vent terminations.
16.Do not locate the vent termination over a public area where condensate or vapor can cause a nuisance or ice hazard.
17.Ensure the screens in the factory supplied terminations are securely installed to prevent blockage in the vent system.
18.Stress levels in pipe/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 stressed, or high thermal stresses may be formed when the pipe heats up and expands. Install accordingly to minimize such stresses.
19.Ensure the intake air connection Tee fitting is oriented properlyonSUF199/250models,seepage23forinstructions.
20.Carefully read the Venting Requirements on page 24 and then proceed to the Venting Installation Sequence on page 25.
22
SUF 199 & SUF 250 Intake Air Connection
SUF 100 199 and SUF 100 250 models are factory equipped with a unique Combustion Blower and intake air connection Tee fitting. The Tee is a 3" x 3" x 1/2" fitting. The intake air connection Tee fitting has a hose barb installed in the 1/2 inch branch to connect the Blocked Intake Air switch sensing tube, see Figure
15.
FACTORY INSTALLED INTAKE AIR TEE FITTING
1/2 INCH BRANCH
HOSE BARB FITTING FOR BLOCKED INTAKE AIR SWITCH SENSING TUBE
COMBUSTION BLOWER
FERNCO
COUPLING
COMBUSTION BLOWER ASSEMBLY
199,000 & 250,000 Btu/hr MODELS
Figure 15
Ensure the hose barb installed in the Tee fitting is not facing down towards the ground (180° - 6 o'clock position) before venting installation begins. The barb fitting must be angled between 90° and no more than 130° as shown in Figure 16. If the barb fitting is facing down, residual condensate that occasionally forms in the intake air pipe can drain into the Blocked Intake Air switch through the attached sensing tube and damage the switch. This condition can also lead to Blocked Intake Air fault conditions and associated control system lock outs.
90° TO 130° |
END VIEW |
CORRECT ORIENTATION |
INTAKE AIR TEE FITTING |
Figure 16
The intake air Tee fitting is factory installed with the 1/2 inch branch and hose barb angled to the right at approximately 130° when viewed from the end, see Figure 16. The Tee fitting's 1/2 inch branch and hose barb must not be angled any lower (towards the ground) than this factory specification. Angling higher, up to a 90° position, will not adversely affect operation and is acceptable.
Inspect/Adjust Intake Air Tee Fitting
Inspect the angle of the Tee fitting's 1/2 inch branch and hose barb while viewing from the end of the Tee, see Figure 16. If the angle of the Tee fitting 1/2 inch branch and hose barb is lower than shown, adjustment will be necessary. To adjust the intake air Tee fitting angle follow the steps listed below.
Adjustment Procedure:
1.Ensure the water heater is turned off at the on/off switch on the front of the water heater.
2.Disconnect the Blocked Intake Air switch sensing tube, see Figure 4 on page 9 for location.
3.Loosen the large hose clamp on the Fernco coupling that connects the intake air connection pipe to the Combustion blower, see Figure 17.
4.Adjust the angle of the Tee fitting so that the 1/2 inch branch and hose barb are at the proper angle as shown in Figure 16.
5.Retighten the large hose clamp on the Combustion Blower intake air Fernco coupling,
6.Reconnect the Blocked IntakeAir switch sensing tube making sure the sensing tube is securely connected at both ends and is not kinked.
LARGE HOSE |
FERNCO |
CLAMP |
COUPLING |
INTAKE AIR |
3 INCH PVC |
TEE FITTING |
|
INTAKE AIR CONNECTION PIPE |
|
199,000 & 250,000 Btu/hr MODELS |
|
Figure 17
23
Venting Requirements
Approved Materials
Approved vent and intake air pipe materials that may be used in the United States:
•PVC Schedule 40 (ASTM D 2241 / CSA B181.2, ASTM D 1785 / CSA B137.3
•CPVC Schedule 40 (ASTM F-411 / CSA B137.6)
•ABS (ASTM D-2661)
Approved vent and intake air pipe materials that must be used in Canada:
• ULC S636 PVC / CPVC
Field Supplied Fittings
Field supplied fittings should be equivalent to the piping material being installed. Field installed/supplied fittings will add equivalent feet to the vent or intake air piping as indicated below. All field supplied/installed fittings and piping must be factored into the equivalent feet calculations.
•90° elbows (short or long radius) are equivalent to 5 linear feet (152 cm) of pipe.
•45° elbows (short or long radius) are equivalent to 2.5 linear feet (76 cm) of pipe.
Primer and Cement
Tetrahydrofuran (THF) primer should be used to prepare the surfaces of pipe and fittings for solvent welding. If CPVC or ABS pipe and fittings are used, then the proper cement must be used for all joints, including joining the pipe to the factory provided terminations (PVC material). PVC Materials should use ASTM D-2564 Grade Cement; CPVC Materials should useASTM F-493 Grade Cement and ABS Materials should use ASTM D-2235 Grade Cement.
Pipe Size Requirements
The water heaters covered in this manual are certified for the use of 3 and 4 inch pipe for the vent (exhaust) and intake air piping. If the installed equivalent length for the intake air or vent piping will be 50 feet (15.2 m) or less, 3 inch pipe must be used. If the installed equivalent length will be more than 50 feet (15.2 m), 4 inch pipe must be used.
Note: Install the pipe size required for the installed equivalent length of each pipe independently. IE: If the intake air pipe will be 50 equivalent feet or less and the vent pipe will more than 50 equivalent feet; the intake air pipe must be installed using 3 inch pipe and the vent must be installed using 4 inch pipe.
Maximum Equivalent Lengths Three Inch Pipe
The water heaters covered in this manual are certified to a maximum length of 3 inch pipe for the exhaust venting arrangement of 50 equivalent feet (15.2 m). The certified maximum length of 3 inch pipe for intake air piping is also 50 equivalent feet (15.2 m). IE: On Direct Vent installations both pipes can be up to 50 equivalent feet (15.2 m).
Four Inch Pipe
The water heaters covered in this manual are certified to a maximum length of 4 inch pipe for the exhaust venting arrangement of 120 equivalent feet (36.5 m). The certified maximum length of 4 inch pipe for intake air piping is also 120 equivalent feet (36.5 m). IE: On Direct Vent installations both pipes can be up to 120 equivalent feet (36.5 m).
Minimum Equivalent Lengths Three Inch Pipe
The water heaters covered in this manual are certified to a minimum length of 3 inch pipe for the vent (exhaust) of 7 equivalent feet (2.1 m). There is no minimum equivalent feet requirement for the intake air pipe.
Four Inch Pipe
The water heaters covered in this manual are certified to a minimum length of 4 inch pipe for the vent (exhaust) of 50 equivalent feet (15.2 m). There is no minimum equivalent feet requirement for the intake air pipe.
Maximum Number Of Elbows Three Inch Pipe
The vent pipe may have a maximum of four 90° elbows installed when 3 inch pipe is being used. The intake air pipe may also have a maximum of four 90° elbows installed. IE: in a Direct Vent configuration each pipe can have up to four 90° elbows installed.
Four Inch Pipe
The vent pipe may have a maximum of six 90° elbows installed when 4 inch pipe is being used. The intake air pipe may also have a maximum of six 90° elbows installed. IE: in a Direct Vent configuration each pipe can have up to six 90° elbows installed.
Factory Supplied Fittings
The water heater ships with two (2) factory supplied 3 inch terminations (PVC 45° elbows with debris screen). Factory supplied vent and intake air terminations or concentric terminations must be used. Factory supplied terminations and installed fittings (exhaust elbow and intake air connection) add zero equivalent feet to the vent and intake air piping.
Table 7
Number of |
3 Inch Pipe |
4 Inch Pipe |
|
90° Elbows |
|
|
|
Maximum Feet (Meters) |
Maximum Feet (Meters) |
||
Installed |
|||
|
|
||
One (1) |
45 feet (13.7 meters) |
115 feet (35.0 meters) |
|
|
|
|
|
Two (2) |
40 feet (12.2 meters) |
110 feet (33.5 meters) |
|
Three (3) |
35 feet (10.7 meters) |
105 feet (32.0 meters) |
|
Four (4) |
30 feet (9.1 meters) |
100 feet (30.5 meters) |
|
Five (5) |
N/A |
95 feet (29.0 meters) |
|
Six (6) |
N/A |
90 feet (27.4 meters) |
4 Inch Extended Vent Terminations
When 4 inch intake air or vent pipe is installed, factory supplied 4 inch terminations must be used. Contact your local distributor or call the parts department (phone number listed on the back cover of this manual) to order 4 inch termination(s).
Optional Concentric Terminations
The water heaters covered by this manual may be installed in a Direct Vent configuration using a 4 inch concentric termination.
Concentric terminations must be ordered separately. Contact your local distributor or call the parts department phone number listed on the back cover of this manual to order.
Concentric Vent Termination Part Numbers:
• 4” Concentric Termination # 9006328005
24
Loading...