State Industries ULTRA FORCE 101, ULTRA FORCE 100 User Manual
ULTRA FORCE SUF 60 120 THRU SUF 100 250
SERIES 100 AND 101
COMMERCIAL GAS WATER HEATER
GAS-FIRED POWER BURNER
FOR DOMESTIC HOT WATER
• INSTALLATION • OPERATION • SERVICE • MAINTENANCE • LIMITED WARRANTY
WARNING: If the information in these
instructions is not followed exactly, a re
or explosion may result causing property
damage, personal injury or death.
– Do not store or use gasoline or other
ammable 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 no t use an y 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 re department.
– Installat ion and service must be
performed by a qualified installer,
service agency or the gas supplier.
Thank you for buying this energy efcient water heater
from State Water Heaters. We appreciate your condence
in our products.
CAUTION
TEXT PRINTED OR UNDERLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY. PLEASE
READ THOROUGHLY BEFORE INSTALLING AND USING
THIS APPLIANCE.
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND
NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED 0407 197784-000
1
500 Tennessee Waltz Parkway
Ashland City, TN 37015
ULTRA FORCE SUF 120 - 250A ROUGH-IN-DIMENSIONS
GAS VALVE PIPING
SUF-120, 199 & 250 1/2" NPT
SUF-150 3/4" NPT
Table 1. RECOVERY CAPACITIES - NATURAL GAS / L.P.
Approx.
Input Gas Gallon TEMPERATURE RISE - DEGREES °F - GALLONS PER HOUR
Model BTU/Hr. Usage Capacity 30 40 50 60 70 80 90 100 110 120 130 140
SUF 120 120,000 nat/lp 60 461 345 276 230 197 173 154 138 126 115 106 99
SUF 150 150,000 nat/lp 100 576 432 345 288 247 216 192 173 157 144 133 123
SUF 199 199,900 nat/lp 100 767 575 460 384 329 288 256 230 209 192 177 164
SUF 250 250,000 nat/lp 100 960 720 576 480 411 360 320 288 262 240 221 206
Approx.
Gas Liter TEMPERATURE RISE - DEGREES C - Liters PER HOUR
Model kW-Hr Usage Capacity 17 22 28 33 39 44 50 56 61 67 72 78
SUF 120 35 nat/lp 227 1744 1308 1046 872 747 654 581 523 476 436 402 374
SUF 150 44 nat/lp 379 2179 1635 1308 1090 934 817 726 654 594 545 503 467
SUF 199 58 nat/lp 379 2904 2178 1743 1452 1245 1089 968 871 792 726 670 622
SUF 250 73 nat/lp 379 3632 2724 2179 1816 1557 1362 1211 1090 991 908 838 778
Recovery capacities are based on 95% thermal efciency.
FOREWORD
These designs comply with the current version 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.
Detailed installation diagrams are found in this manual. These diagrams will
serve to provide the installer with a reference for the materials and methods
of piping necessary. It is highly essential that all water, gas piping and wiring
be installed as shown on the diagrams.
Particular attention should be given to the installation of thermometers at the
locations indicated on the diagrams as these are necessary for checking the
proper functioning of the heater.
In addition to these instructions, the equipment shall be installed in
accordance with those installation regulations in force in the local area
where the installation is to be made. These shall be carefully followed
in all cases. Authorities having jurisdiction should be consulted before
installations are made.
In the absence of local codes, the installation must comply with the current
editions of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and the
National Electrical Code, NFPA 70 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.
2
PAGE
ROUGH-IN DIMENSIONS ................................................................. 2
FOREWORD ..................................................................................... 2
FEATURES ........................................................................................ 3,4
Water Temperature Control ........................................................... 3
High Limit Switch (E.C.O.) ............................................................ 4
Dishwashing Machine Requirement .............................................. 4
Circulating Pump ........................................................................... 5
INSTALLATION INSTRUCTIONS ..................................................... 4-12
Required Ability ............................................................................. 6
Insulation Blankets ........................................................................ 6
Locating The Heater ...................................................................... 5
Clearances .................................................................................... 5
Hard Water .................................................................................... 6
Air Requirements .......................................................................... 6
Mechanical Exhausting of Room Air ............................................. 6
Unconned Space ......................................................................... 6
Conned Space ............................................................................. 6
Chemical Vapor Corrosion ............................................................ 6
Venting .......................................................................................... 6
Vent Pipe Termination ................................................................... 6-10
Installation Requirements for the
Commonwealth of Massachusetts ............................................... 7
Direct Venting ................................................................................ 10
Direct Vent Terminal Installation (Sidewall) ................................... 10
Installation Sequence .................................................................... 10
Vertical Vent Terminal Installation .................................................
Installation Sequence ....................................................................
Installation of Vent System ............................................................ 12
Vent Pipe Preparation ................................................................... 12
CONTROL AND SWITCHES ............................................................. 13
Blower Prover Switch .................................................................... 13
Blocked Outlet Prover Switch ........................................................ 13
Blocked Inlet Prover Switch .......................................................... 13
Low Gas Pressure Switch ............................................................. 13
On/Off Switch ................................................................................ 13
Hot Surface Igniter ........................................................................ 13
GAS PIPING ...................................................................................... 13
Connection of Gas Pipe ................................................................ 14
Purging .......................................................................................... 15
Gas Meter Size - City Gases Only ................................................ 15
Gas Pressure Regulation .............................................................. 15
TABLE OF CONTENTS
11
11
PAGE
Gas Valves .................................................................................... 15
SYSTEM CONNECTIONS ................................................................ 15
Thermometers ............................................................................... 15
Relief Valve ................................................................................... 15
Water Line Connections ............................................................... 15
Heater Wiring ............................................................................... 16
USING THE ELECTRONIC CONTROLLER .................................... 17
Overview ...................................................................................... 17
Operating States .......................................................................... 17
Adjusting the Operating Set Point ................................................ 18
Changing the Display Units .......................................................... 19
Fault and Warning Conditions ...................................................... 19
Access to the Current Fault or Warning ....................................... 19
Viewing the Fault History ............................................................. 20
PRIOR TO START-UP ...................................................................... 20
Required Ability ............................................................................ 20
OPERATING INSTRUCTIONS ......................................................... 21
Adjustment Procedure (Initial Start-Up) 120 and 150 Models ......
Adjustment Procedure (Initial Start-Up) 199 and 250 Models ......
Cathodic Protection ......................................................................
Precautions ..................................................................................
GENERAL INFORMATION ............................................................... 22
Power Burner ...............................................................................
High Limit .....................................................................................
High Altitude Installations .............................................................
MAINTENANCE ............................................................................... 22
General ........................................................................................
Maintenance Schedule ................................................................
Flushing ........................................................................................ 26
Draining ........................................................................................ 26
Sediment Removal ....................................................................... 26
Lime Scale Removal .................................................................... 26
Anode Inspection and Replacement ............................................ 26,27
Drain Valve and Access Panels ................................................... 27
Relief Valve .................................................................................. 27
Circulating Pump .......................................................................... 27
Vent System ................................................................................. 27
INSTALLATION DIAGRAMS ............................................................ 28-32
Manifold Kits ................................................................................. 33
CHECKLIST AND SERVICE INFORMATION .................................. 34
TROUBLE-SHOOTING .................................................................... 34,35
LIMITED WARRANTY ...................................................................... 36
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22
22
22
22
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22
FEATURES
IMPORTANT
IT IS REQUIRED THAT A QUALIFIED SERVICE TECHNICIAN PERFORM
THE INITIAL FIRING OF THE HEATER. AT THIS TIME THE USER SHOULD
NOT HESITATE TO ASK THE TECHNICIAN ANY QUESTIONS WHICH HE
MAY HAVE IN REGARD TO THE OPERATION AND MAINTENANCE OF
THE UNIT.
A CHECKLIST AND SERVICE INFORMATION section are included at the rear
of this manual. By using this checklist the user may be able to make minor
operational adjustments and save himself unnecessary service calls. However,
the user should not attempt repairs which are not listed in this section.
WATER TEMPERATURE CONTROL
TH IS WATE R H EATE R I S E QU IPP ED WIT H AN AD JUS TAB LE
DANGER
THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT WATER
TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHER AND
LAUNDRY USE CAN CAUSE SCALD BURNS RESULTING IN SERIOUS
PERSONAL INJURY AND/OR DEATH. THE TEMPERATURE AT WHICH
INJURY OCCURS VARIES WITH THE PERSON’S AGE AND THE TIME
OF THE EXPOSURE. THE SLOWER RESPONSE TIME OF CHILDREN,
AGED OR DISABLED PERSONS INCREASES THE HAZARDS TO THEM.
NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER TAP, OR TO
DRAW THEIR OWN BATH WATER. NEVER LEAVE A CHILD OR DISABLED
PERSON UNATTENDED IN A BATHTUB OR SHOWER.
THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE THE
GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET TEMPERATURES.
The water temperature is controlled using the Temperature Control Button
on the Display at the front of the unit (See Figure 1). This control utilizes
two temperature probes to determine the tank temperature. The primary
temperature probe is located at the top of the tank and the other is near
the water inlet.
The temperature may be adjusted from 90°F/32°C to 180°F/82°C. The
thermostat was adjusted to 120°F/49°C before the heater was shipped from
the factory. It is recommended that lower water temperature be used to avoid
the risk of scalding. It is further recommended, in all cases, that the water
3
temperature be set for the lowest temperature which satises your hot water
needs. This will also provide the most energy efcient operation of the water
heater and minimize scale formation.
SETTING THE WATER HEATER TEMPERATURE AT 120°F/49°C WILL
REDUCE THE RISK OF SCALDS. Some states require settings at specic
lower temperatures.
Figure 1 shows the approximate time-to-burn relationship for normal adult
skin. Short repeated heating cycles caused by small hot water uses can
cause temperatures at the point of use to exceed the thermostat setting by
up to 20°F/11°C. If you experience this type of use, you should consider
using lower temperature settings to reduce scald hazards.
Temperature Time to Produce 2nd & 3rd
Setting 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
FIGURE 1.
Valves for reducing point-of-use temperature by mixing cold and hot water are
available (see Figure 2). Also available are inexpensive devices that attach
to faucets to limit hot water temperatures. Contact a licensed plumber or the
local plumbing authority.
DISHWASHING MACHINE REQUIREMENT
All dishwashing machines meeting the National Sanitation Foundation
requirements are designed to operate with water ow 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 ow regulating control valve should
be used in the 180°F (82°C) line to the dishwashing machine, and should
be adjusted to deliver water between these limits.
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 ow by means of the
plug cock in the circulating line. (See installation diagrams.)
CIRCULATING PUMP
A circulating pump is used when a system requires a circulating
loop or there is a storage tank used in conjunction with the heater.
Refer to the piping diagrams at rear of manual for electrical hookup
information and 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.
FIGURE 2.
HIGH LIMIT SWITCH (E.C.O.)
The top immersion well of the dual bulb controller also contains the high limit
(energy cutoff) sensor. The high limit switch interrupts the main burner gas
ow should the water temperature reach approximately 202°F/94°C.
Should the high limit switch activate, the control system will automatically reset
the unit once the water temperature in the tank falls below 140°F/60°C. If the
unit is manually shut down and restarted, as long as the temperature in the
tank is lower than 160°F/71°C, the unit will reset and initiate operation.
High limit switch operation is the likely cause when higher than normal water
temperatures occur with a recurring need to restart the water heater. This
could be due to a malfunctioning thermostat allowing the gas valve to remain
open and the burner to continue ring even after water temperature in the
tank has already reached the set point. Contact your dealer or servicer if
continued high limit switch operation occurs.
Although circulators are oiled and operated by the manufacturer
some circulators must be oiled again before operated. Please refer
to manufacturer's instructions.
INSTALLATION INSTRUCTIONS
REQUIRED ABILITY
INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES
ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE
FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, GAS SUPPLY
AND ELECTRICAL WORK ARE REQUIRED.
INSULATION BLANKETS
Ins ula tio n blankets available to the general public for external use
on gas water heaters are not approved for use on your water heater.
The purpose of an insulation blanket is to reduce the standby heat
loss encountered with storage tank water heaters. Your water heater
meets or exceeds the ASHRAE/IES 90.1 1999 standards with respect
to insul ation and standby loss require ments, making an ins ulation
blanket unnecessary.
WARNING
Should you choose to apply an insulation blanket to this heater, you should
follow these instructions. Failure to follow these instructions can result in
re, asphyxiation, serious personal injury or death.
• Do not apply insulation to the top, or the upper 15" (38 cm) of the water
heater, as this will interfere with safe operation.
• 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 labels from State for placement on the blanket directly
over the existing labels.
4
LOCATING THE HEATER
WARNING
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 HEATER’S IGNITER OR
MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION. SOME LOCAL
CODES PERMIT OPERATION OF GAS APPLIANCES IF INSTALLED 18
INCHES (46 cm) OR MORE ABOVE THE FLOOR. THIS MAY REDUCE
THE RISK IF LOCATION IN SUCH AN AREA CANNOT BE AVOIDED.
THE HEATER SHALL BE LOCATED OR PROTECTED SO IT IS NOT
SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE.
DO NOT LOCATE THE HEATER WHERE NOISE FROM THE EXHAUST
OR INTAKE WILL BE OBJECTIONABLE. THIS INCLUDES LOCATIONS
CLOSE TO OR ACROSS FROM WINDOWS AND DOORS. AVOID
ANCHORING THE VENT AND INTAKE PIPES DIRECTLY TO FRAMED
WALLS, FLOORS OF CEILINGS UNLESS RUBBER ISOLATION PIPE
HANGERS ARE USED. THIS PREVENTS ANY VIBRATIONS FROM
BEING TRANSMITTED INTO THE LIVING SPACES.
WARNING
THIS WATER HEATER IS A CONDENSING UNIT AND REQUIRES A DRAIN
TO BE LOCATED IN CLOSE PROXIMITY TO ALLOW THE CONDENSATE
TO DRAIN SAFELY. THE CONDENSATE DRAINS FROM THE UNIT AT
THE EXHAUST ELBOW LOCATED AT THE BOTTOM OF THE UNIT. NOTE:
IT IS IMPORTANT THAT THE CONDENSATE HOSE NOT BE ELEVATED
ABOVE THE EXHAUST ELBOW (SEE FIGURE 3). THE CONDENSATE
BUILD-UP WILL BLOCK THE EXHAUST OUTLET, WHICH WILL CAUSE
IMPROPER OPERATION.
FIGURE 3.
WARNING
FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY OTHER
POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON
OR ADJACENT TO THE HEATER. OPEN CONTAINERS OF FLAMMABLE
MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM
WITH THE HEATER.
When installing the heater, consideration must be given to proper location.
Location selected should be as close to the intake and exhaust termination
points as practicable, with adequate air supply and as centralized with the
piping system as possible.
THE HEATER MUST NOT BE LOCATED IN AN AREA WHERE IT WILL BE
SUBJECT TO FREEZING.
LOCATE IT NEAR A FLOOR DRAIN. THE HEATER SHOULD BE LOCATED
IN AN AREA WHERE LEAKAGE FROM THE HEATER OR CONNECTIONS
WILL NOT RESULT IN DAMAGE TO THE ADJACENT AREA OR TO LOWER
FLOORS OF THE STRUCTURE.
When such locations cannot be avoided, it is recommended that a suitable
drain pan, adequately drained, be installed under the appliance.
Water heater life depends upon water quality, water pressure and the
environment in which the water heater is installed. Water heaters are
sometimes installed in locations where leakage may result in property
damage, even with the use of a drain pan piped to a drain. However,
unanticipated damage can be reduced or prevented by a leak detector or
water shut-off device used in conjunction with a piped drain pan. These
devices are available from some plumbing supply wholesalers and retailers,
and detect and react to leakage in various ways:
WARNING
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER.
IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT
THE APPLIANCE AND TO REPLACE ANY PART OF THE CONTROL
SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER.
CLEARANCES
These heaters are approved for installation on combustible ooring in an
alcove when the minimum clearances from any combustion construction are
followed as indicated in Figure 4.
In all installations the minimum combustible clearances from any vent piping
shall be 0". Vent piping passing through a combustible wall or ceiling must
be a continuous run (no joints).
A service clearance of 24" (61 cm) should be maintained from serviceable
parts such as relief valves, ue bafes, ue damper devices, thermostats,
cleanout openings or drain valves.
Always disconnect electrical power before servicing the unit.
• Sensors mounted in the drain pan that trigger an alarm or turn off the
incoming water to the water heater when leakage is detected.
• Sensors mounted in the drain pan that turn off the water supply to the entire
home when water is detected in the drain pan.
• Water supply shut-off devices that activate based on the water pressure
differential between the cold water and hot water pipes connected to the
water heater.
• Devices that will turn off the gas supply to a gas water heater while at the
same time shutting off its water supply.
FIGURE 4.
*ILLUSTRATION OF MINIMUM COMBUSTIBLE CLEARANCES IN AN
ALCOVE.
5
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 section for details of tank cleanout procedure.
AIR REQUIREMENTS
KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE MATERIALS,
GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATING AIR.
WARNING
FOR SAFE OPERATION PROVIDE ADEQUATE AIR FOR COMBUSTION
AND VENTILATION. AN INSUFFICIENT SUPPLY OF AIR WILL CAUSE
RECIRCULATI ON OF CO MBUSTION PRODUCTS RESU LTING IN
CONTAMINATION THAT MAY BE HAZARDOUS TO LIFE. SUCH A CONDITION
OFTEN WILL RESULT IN A YELLOW, LUMINOUS BURNER FLAME, CAUSING
CARBONING OR SOOTING OF THE COMBUSTION CHAMBER, BURNERS
AND FLUE TUBES AND CREATES A RISK OF ASPHYXIATION.
MECHANICAL EXHAUSTING OF ROOM AIR
Where an exhaust fan is installed in the same room with a heater, sufcient
openings for air must be provided in the walls. UNDERSIZED OPENINGS WILL
CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE HEATER’S
VENTING SYSTEM, CAUSING POOR COMBUSTION. SOOTING MAY
RESULT IN SERIOUS DAMAGE TO THE HEATER AND RISK OF FIRE OR
EXPLOSION. IT CAN ALSO CREATE A RISK OF ASPHYXIATION.
If the conned space is within a building of tight construction, air for combustion
and ventilation must be obtained from outdoors. When directly communicating
with the outdoors through vertical ducts, two permanent openings, located
in the above manner, shall be provided. Each opening shall have a free
area of not less than one square inch (6.5 cm²) per 4000 Btuh of the total
input of all appliances in the enclosure. If horizontal ducts are used, each
opening shall have a free area of not less than one square inch (6.5 cm²) per
2000 Btuh of the total input of all appliances in the enclosure.
CHEMICAL VAPOR CORROSION
WARNING
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.
Spray can propellants, cleaning solvents, refrigerator and air conditioning
refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes, and
process chemicals are typical compounds which are potentially corrosive.
PRODUCTS OF THIS SORT SHOULD NOT BE STORED NEAR THE
HEATER. ALSO, AIR WHICH IS BROUGHT IN CONTACT WITH THE
HEATER SHOULD NOT CONTAIN ANY OF THESE CHEMICALS. IF
NECESSARY, UNCONTAMINATED AIR SHOULD BE OBTAINED FROM
REMOTE OR OUTSIDE SOURCES.
VENTING
WARNING
THE INSTRUC TIONS IN THIS SE CTION ON VENT ING MUST BE
FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULATION
OF FLUE GASES. SUCH CONDITIONS CAUSE SOOTING OR RISKS OF
FIRE AND ASPHYXIATION.
UNCONFINED SPACE
In buildings of conventional frame, brick or stone construction, unconned
spaces may provide adequate air for combustion and ventilation.
If t he u nconfined spa ce i s within a building of t ight constructi on
(building s using the following construction: weather stripping, heavy
insulation, caulking, vapor barrier, etc.), air for combustion and ventilation
must be obtained from outdoors. The installation instructions for conned
spaces in tightly constructed buildings must be followed to ensure adequate
air supply.
CONFINED SPACE
When drawing combustion air from inside a conventionally constructed
building to a conned space, such a space shall be provided with two
permanent openings, ONE IN OR WITHIN 12" (31 cm) OF THE ENCLOSURE
TOP AND ONE IN OR WITHIN 12" (31 cm) OF THE ENCLOSURE BOTTOM.
Each opening shall have a free area of at least one square inch (6.5 cm²)
per 1000 Btuh appliances in the enclosure, but not less than 100 square
inches (645 cm²).
Heater must be protected from freezing downdrafts during shutdown periods.
WARNING
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.
VENT PIPE TERMINATION
NOTE: Before installing venting, determine place of vent pipe termination.
See Figures 5a & b and 6a & b before proceeding.
CAUTION
DO NOT TERMINATE THE VENTING WHERE NOIS E FROM THE
EXHAUST OR INTAKE WILL BE OBJECTIONABLE. THIS INCLUDES
LOCATIONS CLOSE TO OR ACROSS FROM WINDOWS AND DOORS.
AVOID ANCHORING THE VENT AND INTAKE PIPES DIRECTLY TO
FRAMED WALLS, FLOORS OR CEILINGS UNLESS RUBBER ISOLATION
PIPE HANGERS ARE USED. THIS PREVENTS ANY VIBRATIONS FROM
BEING TRANSMITTED INTO THE LIVING SPACES.
6
INSTALLATION REQUIREMENTS FOR THE 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 nished grade in the
area of the venting, including but not limited to decks and porches, the following requirements shall be satised:
INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas
fueled equipment, the installing plumber or gastter shall observe that a hard wired carbon monoxide detector with an alarm
and battery back-up is installed on the oor level where the gas equipment is to be installed. In addition, the installing plumber
or gastter 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 qualied 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 oor 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 certied.
SIGNAGE A metal or plastic identication plate shall be permanently mounted to the exterior of the building at a minimum
height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating
appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”
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 ue gases,
but identies “special venting systems,” the following requirements shall be satised 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.
7
U.S. POWER VENT
FIGURE 5a.
CAUTION
TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE
IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN
THESE TWO TERMINALS IS RECOMMENDED.
CANADIAN POWER VENT
FIGURE 5b.
8
U.S. DIRECT VENT
FIGURE 6a.
CAUTION
TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE
IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN
THESE TWO TERMINALS IS RECOMMENDED.
CANADIAN DIRECT VENT
FIGURE 6b.
9
IMPORTANT
The vent system must terminate so that proper clearances are maintained
as cited in local codes or the current editions of the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 or the Natural Gas and Propane Installation Code,
CAN/CSA-B149.1.
Do not terminate the exhaust vent terminal over public area where condensate
or vapor can cause nuisance or hazard.
Plan the vent system layout so that proper clearances are maintained from
plumbing and wiring.
Vent pipes serving power vented appliances are classied by building codes
as "vent connectors". Required clearances from combustible materials must
be provided in accordance with information in this manual under LOCATION
OF HEATER and CLEARANCES, and with National Fuel Gas Code and
local Codes.
IMPORTANT
Plan the layout of the vent system backwards from the vent termination to
the appliance.
FOR ALL
MODELS
FIGURE 8.
IMPORTANT
WHEN LOCATING THE TERMINALS ON A SIDEWALL, THE FOLLOWING
SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE
FOLLOWED.
USE ONLY THE VEN T TERMINA LS SUPPL IED WITH THIS UNI T.
WARNING
TERMINATION OF A VENT SYSTEM WITH A DEVICE OTHER THAN
TH E SU PP LI ED VEN T TERMINATIONS WILL AFF ECT SY ST EM
PERFORMANCE AND RESULT IN A SAFETY HAZARD.
DIRECT VENTING
The air intake provided on the unit contains a mesh screen (see Figure 7)
to prevent large particles from entering the unit.
FIGURE 7.
WARNING
WHEN THE UNIT IS TO BE SETUP AS A DIRECT VENT, THE MESH
SCREEN MUST BE REMOVED. THE INLET VENT PIPE MAY THEN BE
GLUED TO THE AIR INTAKE (see Figure 8) PROVIDED ON THE UNIT.
DIRECT VENT TERMINAL INSTALLATION
IMPORTANT
THIS UNIT CONSISTS OF TWO VENT TERMINALS - AN INTAKE VENT
TERMINAL AND AN EXHAUST VENT TERMINAL. THE INTAKE VENT
TERMINAL IS A 3" 45° PVC ELBOW WITH A DOME MESH WIRE SCREEN
AND THE EXHAUST VENT TERMINAL IS A 3" 45°PVC ELBOW WITH A
MESH WIRE SCREEN.
NOTE: TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO
THE AIR INTAKE IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL
DISTANCE BETWEEN THESE TWO TERMINALS IS RECOMMENDED
1. The intake vent terminal and the exhaust vent terminal must terminate on
the same exterior wall and must be located at a minimum of 24" (61cm)
from the vertical centerline of the exhaust vent terminal (see Figure 9). In
colder climates increasing the 24" (61cm) minimum will reduce possibility
of frost over from side winds blowing exhaust vapors to the air intake of
the direct vent.
2. The horizontal centerline of the intake vent terminal may not be located
lower than the horizontal centerline of the exhaust vent terminal
(see Figure 9).
INSTALLATION SEQUENCE
For installations in the City of Los Angeles, California Category IV PVC Pipe
such as that manufactured by Brownline Pipe Company, must be used as
vent pipe material
CAUTION
Vent terminals supplied with the heater must be used.
NOTE: BEFORE BEGINNING INSTALLATION OF ANY VENT PIPE READ
THE VENT PIPE MANUFACTURER'S INSTALLATION INSTRUCTIONS.
1. After the points of termination have been determined, use the cover plates
as templates to mark the holes for the vent pipes to be inserted through
the wall. BEWARE OF CONCEALED WIRING AND PIPING INSIDE OF
WALL.
2. If the vent terminals are being installed on the outside of a nished wall, it
may be easier to mark both the inside and outside wall. Align the holes by
drilling a hole through the center of the template from the inside through
to the outside. The template can now be positioned on the outside wall
using the drilled holes as a centering point for the template.
3. A) MASONRY SIDE WALLS
Chisel an opening approximately 1/2" (1.3 cm) larger than the marked
circle.
B) WOODEN SIDE WALLS
Drill a pilot hole approximately one quarter inch outside of the marked
circle. This pilot hole is used as a starting point for a saws-all or sabre saw
blade. Cut around the marked circle staying approximately one quarter
inch outside of the line. (This will allow the vent pipe to easily slide through
the opening. The resulting gap will be covered by the vent terminal cover
plates.) Repeat this step on the inside wall if necessary.
4. Cut a length of 3" PVC pipe about 3.5" (8.9 cm) longer than the wall
thickness at the opening.
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5. Glue the intake vent terminal to the section of the pipe.
VERTICAL VENT TERMINAL INSTALLATION
6. Slide the wall plate over the pipe to stop against intake vent terminal.
7. Place a bead of caulking (not supplied) around the gap between the pipe
and the wall. Place some of the caulking on the back of the plate to hold
it against the wall after installation.
8. If the vent pipe is installed up to the wall, with a coupling on the
end against the wall opening, the pipe with the vent terminal can be
prepared for gluing before inserting through the wall. Slide the pipe
through the wall and insert into coupling on the other side of the wall,
making sure that the vent terminal ends up pointed in the correct position
(See Figure 9).
IMPORTANT
WH E N TER MIN ATIN G THRO UGH A ROOF, THE FOL LOW ING
SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE
FOLLOWED.
1. Proper support must be provided for all pipe protruding through the roof.
2. The vertical roof terminations should be sealed with a plumbing roof boot
or equivalent ashing.
3. The intake vent termination and the exhaust vent termination must
penetrate the same side of roof.
4. The center line of the intake vent termination and the center line of the
exhaust vent termination must be no closer than 24" (61cm).
5. The intake vent terminal and the exhaust vent terminal must be oriented
facing downward and the same direction.
The specications are displayed in Figure 10 & 11.
NOTE: Exhaust vent terminal is installed using the same procedure.
INSTALLATION SEQUENCE
NOTE: BEFORE BEGINNING INSTALLATION OF ANY VENT PIPE, READ
“VENT PIPE PREPARATION” SECTION ON PAGE 12.
FIGURE 9.
1. After the points of termination have been determined, use the cover plates
as templates to mark the holes for the vent pipes to be inserted through
the roof.
2. Drill a pilot hole approximately 1/4" (6 mm) outside of the marked
circle. This pilot hole is used as a starting point for a saws-all or sabre
saw blade. Cut around the marked circle staying approximately one
quarter inch outside the line. (This will allow the vent pipe to easily slide
through the opening). The resulting gap will be covered by the roof
boot/ashing.
3. Suspend the pipe through the center of the hole using proper support.
4. Slide roof boot or equivalent ashing over pipe and secure roof boot
equivalent ashing to roof.
5. Seal around ashing.
6. Terminate intake terminal and exhaust vent terminal facing down as
shown in Figure 11.
FIGURE 10.
FIGURE 11.
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INSTALLATION OF VENT SYSTEM
WARNING
TH E OPTI ON AL IN TAKE VENT ING ARR ANG EM ENT A ND THE
EXHAUST VENTING ARRANGEMEN T MUST BE INSTA LLED TO
RUN DIRECTLY TO THE OUTDOORS AND NOT IN ANY WAY BE
CONNE CTED TO ANOTHER VENT ING SYST EM (I .E. FURN ACE,
DRYERS OR SPACE HEATERS). IT IS CRUCIAL THAT THE VENTING
ARRANGEMENT BE KEP T SEPARATE FRO M OTHER VENTING
SYSTEMS. IF THIS WARNING IS IGNORED, AND THE SYSTEM IS
VENTED INCORRECTLY, IT MAY CAUSE IMPROPER OPERATION,
FIRE, EXPLOSION, OR ASPHYXIATION.
1. Plan the route of the vent system from the vent termination to the planned
location of the appliance. Layout the total vent system to use the minimum
of vent pipe and elbows possible.
NOTE: for Water Heaters in locations with high ambient temperatures
(above 100°F or 38°C) and/or insufcient dilution air, it is recommended that
CPVC or ABS pipe and ttings (MUST USE SUPPLIED VENT TERMINAL)
be used.
4. It is important that condensate not be allowed to buildup in the exhaust
vent pipe. To prevent this from happening the pipe should be installed with
a slight, 1/8" (3mm) per 5' (152 cm) of pipe maximum downward slope.
5. The vent system should be supported every 5' (152 cm) of vertical run
and every 3' (91cm) of horizontal run of vent pipe length.
NOTE: Stress levels in the pipe and ttings can be signicantly 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.
2. The installer may add up to a MAXIMUM OF FIFTY (50) EQUIVALENT
FEET (15.2 m) of pipe to the exhaust venting arrangement. This
addition of FIFTY (50) EQUIVALENT FEET (15.2 m) of pipe on both
the intake venting arrangement and exhaust venting arrangement must
include any 3" PVC elbows which equals (5) EQUIVALENT FEET (1.5
m) of pipe.
Table 2. VENT LENGTH TABLE
Number 3" 3" 4"
of 90° Minimum Maximum Maximum
Elbows Pipe (Ft./M.) Pipe (Ft./M.) Pipe (Ft./M.)
ONE (1) 7/2 45/13.7 115/35
TWO (2) 7/2 40/12.2 110/33.5
THREE (3) 7/2 35/10.7 105/32
FOUR (4) 7/2 30/9.1 100/30.5
FIVE (5) 7/2 --- 95/29
SIX (6) 7/2 --- 90/27.4
4" PVC may be used for a MAXIMUM intake of ONE HUNDRED TWENTY
(120) EQUIVALENT FEET (36.6m) and a MAXIMUM exhaust of ONE
HUNDRED TWENTY (120) EQUIVALENT FEET (36.6m). The maximum
number of 90° elbows with the 4" venting is six (6) on the intake and six
(6) on the exhaust. A 90° elbow is equal to ve (5) equivalent feet (1.5m)
of pipe. One (1) 90° elbow is equal to two (2) 45° elbows. Any venting
conguration using less than 50 equivalent feet should use 3" venting.
See Table 2.
The 3 " v ent i n g ter m inal s ( pro v ided ) m ust b e u sed w i t h the
3" vent pipe. Two, approved 4" vent terminals (not provided) must be used
with 4" vent pipe. See replacement parts list for terminals.
IMPORTANT
When multiple units are direct vented through a wall (3" or 4" venting), all
intake vent terminals should be no lower than the highest exhaust vent
terminal.
NOTE: This unit can be vented using only PVC (Class 160, ASTM D-2241
Schedule 40, ASTM D-1785 ; or Cellular Core Schedule 40 DWV, ASTM
F-891) , Schedule 40 CPVC (ASTM F-411), or ABS (ASTM D-2661) pipe.
The ttings, other than the TERMINATIONS should be equivalent to PVCDWV ttings meeting ASTM D-2665 (Use CPVC ttings, ASTM F-438 for
CPVC pipe and ABS ttings, ASTM D-2661/3311 for ABS pipe. If CPVC or
ABS pipe and ttings are used, then the proper cement must be used for
all joints, including joining the pipe to the Termination (PVC Material). PVC
Materials should use ASTM D-2564 Grade Cement; CPVC Materials should
use ASTM F-493 Grade Cement and ; ABS Materials should use ASTM
D-2235 Grade Cement.
VENT PIPE PREPARATION
1. INITIAL PREPARATION
A. Make sure the solvent cement you are planning to use is designed
for the specic application you are attempting.
B. Know the physical and chemical characteristics and limitations of
the PVC, PVC cellular core, ABS or CPVC piping materials that you
are about to use.
C. Know the reputation of your pipe and cement manufacturer and
their products.
D. Know your own qualifications or those of your contractor. The
solvent welding technique of joining PVC, PVC cellular core, ABS or
CPVC pipe is a specialized skill just as any other pipe fitting
technique.
E. Closely supervise the installation and inspect the nished job before
start-up.
F. Contact the manufacturer, supplier, or competent consulting agency
if you have any questions about the application or installation of
PVC, PVC cellular core, ABS or CPVC pipe.
G. Take the time and effort to do a professional job. Shortcuts will only
cause you problems and delays in start-up. The majority of failures
in these systems are the result of shortcuts and/or improper joining
techniques.
2. SELECTION OF MATERIALS
PRIMER
It is recommended that Tetrahydrofuran (THF) be used to prepare the surfaces
of pipe and ttings for solvent welding. Do not use water, rags, gasoline or
any other substitutes for cleaning PVC cellular core, ABS or CPVC surfaces.
A chemical cleaner such as MEK may be used.
CEMENT
The cement should be a bodied cement of approximately 500 to 1600
centipoise viscosity containing 10-20% (by weight) virgin PVC material
solvated with tetrahydrofuran (THF). Small quantities of dimethyl formamide
(DMF) may be included to act as a retarding agent to extend curing time.
Select the proper cement; Schedule 40 cement should be used for Schedule
40 pipe. Never use all-purpose cements, commercial glues and adhesives
or ABS cement to join PVC or CPVC pipe and ttings.
SAFETY PRECAUTION: PRIMERS AND CEMENTS ARE EXTREMELY
FLAMMABLE AND MUST NOT BE STORED OR USED NEAR HEAT OR
OPEN FLAME. ALSO, USE ONLY IN A WELL-VENTILATED AREA.
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