PRINTED 0920 100337174 2000577212B
Instruction Manual
COMMERCIAL GAS WATER HEATERSCOMMERCIAL GAS WATER HEATERS
LOW LEAD
CONTENT
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 750A & 1000A
SERIES 100 & 101
INSTALLATION - OPERATION
- SERVICE - MAINTENANCE
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.
• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED.
IF YOU ARE UNSUCCESSFUL, CALL THE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
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CONTENTSCONTENTS
SAFE INSTALLATION, USE, AND SERVICE ........................... 3
APPROVALS ...............................................................................3
GENERAL SAFETY INFORMATION .........................................4
Precautions ..............................................................................4
Grounding Inructions .............................................................4
Hydrogen Gas Flammable .......................................................4
INTRODUCTION ........................................................................6
Abbreviations Used ..................................................................6
Qualications ............................................................................6
ICOMM ..................................................................................... 6
ICC ...........................................................................................6
FEATURES AND COMPONENTS ............................................. 7
Basic Operation ........................................................................7
Modulation ................................................................................7
Components ............................................................................. 8
INSTALLATION CONSIDERATIONS ......................................10
Rough-In Dimensions .............................................................10
Locating the Water Heater ..................................................... 11
Hard Water ............................................................................. 12
Circulation Pumps ..................................................................12
INSTALLATION REQUIREMENTS.......................................... 13
Supply Gas Line Requirements .............................................13
Supply Gas Regulator ............................................................13
Power Supply .........................................................................13
Mixing Valves .........................................................................14
Dish-washing Machines .........................................................14
Closed Water Syems ........................................................... 14
Thermal Expansion ................................................................14
Temperature-Pressure Relief Valve .......................................15
Condensate Drain ..................................................................16
Combuible Material Storage ................................................ 16
Contaminated Air ....................................................................16
Air Requirements ...................................................................17
Conned Space ......................................................................17
INSTALLATION REQUIREMENTS - COMMONWEALTH OF
MASSACHUSETTS ..................................................................20
Signage ..................................................................................20
Inspection ............................................................................... 20
VENTING INSTALLATION .......................................................21
General Venting Information ..................................................21
General Venting Inructions ..................................................21
Venting Requirements ............................................................22
Venting Inallation Sequence ................................................ 23
Power Vent Inallation ...........................................................23
Direct Vent Inallation............................................................23
Direct Vent Air Intake Moiure Protection ..............................24
Vertical Termination Inallation .............................................. 24
AL29-4C
®
Vent Inallations ...................................................27
Termination Clearances Sidewall Power Vent ........................ 29
Termination Clearances Sidewall Direct Vent ........................ 30
WATER HEATER INSTALLATION ...........................................31
Condensate Drain Inallation ................................................31
Supply Gas Line Inallation ...................................................31
Purging ................................................................................... 33
Electrical Wiring .....................................................................33
Enable/Disable Circuit (For Building Management Syems) 33
Water Line Connections ......................................................... 34
TEMPERATURE REGULATION .............................................. 36
High Temperature Limit Control (ECO) .................................. 36
Thermoat Control .................................................................36
Intelligent Demand Response ................................................36
Firing Rate Modulation ...........................................................37
CONTROL SYSTEM OPERATION ..........................................38
Overview ................................................................................38
Control Syem Navigation .....................................................38
WI-FI ......................................................................................38
Lockout Function .................................................................... 38
The Desktop Screen ..............................................................38
User Settings & Control Syem Menus ................................. 41
START UP .................................................................................50
Prior to Start up ......................................................................50
TROUBLESHOOTING..............................................................53
Inallation Checkli ...............................................................53
Sequence of Operation ..........................................................53
Sequence of Operation Flow Chart ........................................ 54
Operational Problems ............................................................55
Fault and Alert Conditions ...................................................... 56
MAINTENANCE ........................................................................59
General ..................................................................................59
Maintenance Schedule ...........................................................59
Draining and Flushing ............................................................59
Sediment Removal ................................................................. 60
Lime Scale Removal ..............................................................60
Burner Flame Inspection ........................................................60
Powered Anodes Maintenance ..............................................61
Drain Valve and Access Panels .............................................61
Temperature-Pressure Relief Valve Te ................................61
Vent Syem Maintenance......................................................62
DIAGRAMS ...............................................................................63
CCB - Central Control Board Layout ...................................... 63
Wiring Diagram ......................................................................64
Circulation Pump Wiring Diagrams ........................................65
Water Piping Diagrams ..........................................................66
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3
SAFE INSTALLATION, USE, AND SERVICESAFE 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.
DANGER
WARNING
CAUTION
CAUTION
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
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.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION used without the safety alert
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.
IMPORTANT DEFINITIONS
• 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, electrical supply are required in addition to electrical testing skills when
performing service.
• ANSI Z223.1:
“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.”
APPROVALSAPPROVALS
All models are listed by Underwriters Laboratories Inc.
LOW LEAD
CONTENT
Note: ASME construction is optional on the water heaters
covered in this manual.
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4
GENERAL SAFETY INFORMATIONGENERAL SAFETY INFORMATION
PRECAUTIONS
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN
EXPOSED TO FLOODING OR WATER DAMAGE. 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 codes 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.
Explosion Hazard
Flammable hydrogen gases
may be present.
Keep all ignition sources away
from faucet when turning on
hot water.
HYDROGEN GAS FLAMMABLE
Hydrogen gas can be produced in a hot water system served by
this water heater that has not been used for a long period of time
(generally two weeks or more). Hydrogen gas is extremely
flammable. To reduce the risk of injury under these conditions,
it is recommended that a hot water faucet served by this water
heater be opened for several minutes before using any electrical
appliance connected to the hot water system. If hydrogen is
present there will probably be an unusual sound such as air
escaping through the pipe as the water begins to 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. The
Enable /Disable switch on front panel disables the 24 volt gas valve. Electrical supply must be turned
off at circuit breaker serving water heater.
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
Flammable hydrogen gases
may be present.
Keep all ignition sources away
from faucet when turning on
hot water.
Improper installation, use and service may
result in property damage.
CAUTION
•
Do not operate water heater if any part has been
exposed to flooding or water damage.
•
Inspect anode rods regularly, replace when significantly depleted.
•
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.
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5
Fire or Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Avoid all ignition sources if you smell gas.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating label.
Keep ignition sources away from faucets after extended
periods of non-use.
Maintain required clearances to combustibles.
Do not expose water heater controls to excessive gas
pressure.
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Breathing Hazard - Carbon Monoxide Gas
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
CAUTION
Turn off power at the branch circuit
breaker serving the water heater
before performing any service.
Electrical Shock Hazard
•
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
Do not install water heater on
carpeted floor.
Do not operate water heater if
exposed to flooding or water
damage.
For continued protection against
risk of fire:
Fire and Explosion Hazard
Leak test gas connections before
placing water heater in operation.
Disconnect gas piping at main
gas shutoff valve before leak
testing heater.
Install sediment trap in
accordance with NFPA 54.
Use joint compound or Teflon tape
compatible with propane gas.
Fire and Explosion Hazard
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
Excessive gas pressure to gas valve can
cause serious injury or death.
Do not use water heater with any gas
other than the gas shown on the rating
label.
Jumping out control circuits or components can
result in property damage, personal injury or death.
Service should only be performed by a qualified service
technician 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.
•
Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the appliance warranty.
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6
INTRODUCTIONINTRODUCTION
Thank You for purchasing this water heater. Properly installed
and maintained, it should give you years of trouble free service.
ABBREVIATIONS USED
Abbreviations found in this Instruction Manual include :
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• AHRI - Air Conditioning, Heating and Refrigeration Institute
• NEC - National Electrical Code
• 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: “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
This water heater comes equipped with the iCOMM™ remote
monitoring system. It allows users to monitor critical operations
and diagnose issues remotely using the manufacturer’s water
heater app (available for IOS and Android).
The iCOMM™ system can automatically notify selected
personnel via email and or cellular phone text messages if
operational problems or user defined Alert conditions should
occur. The system is expandable to meet the needs of multiple
heaters and groups of heaters.
ICC
This water heater is connectable to BACnet or Modbus compliant
Supervisory controls via the ICC BMS Gateway. This allows
connection of the water heater to local Building Management
Systems using Serial RS-485 (MS/TP) or IP connections.
To order or to find out more about iCOMM™ or ICC devices,
logon to the manufacturer’s website or call 888-928-3702
(888-WATER02) for more information.
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 (page 4). 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 (page 7) this manual. Use this
reference to locate and identify various components on the
water heater.
See the Installation Checklist and Troubleshooting (page 53).
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/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.
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
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7
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 Rough-In Dimensions (page 10) and Locating the Water Heater
(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 Installation Requirements -
Commonwealth of Massachusetts (page 20) .
FEATURES AND COMPONENTSFEATURES AND COMPONENTS
BASIC OPERATION
The water heaters covered in this manual have a primary heat
exchanger that is submerged in the storage tank and a secondary
heat exchanger mounted below the tank. The water heater’s
Main Burner is a radial-design burner that is mounted on the top
and fires downward through the two heat exchangers. This is a
forced draft burner; hot burning gases are forced through the two
heat exchangers under pressure and exit through the exhaust/
vent connection located at the bottom of the water heater. See
Figure 2.
MODULATION
The water heaters covered by this manual are capable of
modulating their firing rate. The CCB monitors the water
temperature in the tank and regulates the firing rate to achieve
the target temperature setpoint. The firing rate is dictated by the
hot water draw, proximity to the tank temperature setpoint, and
various other temperature limitations.
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8
COMPONENTS
1
2
3
4
105
6
8
27
7
22
21
2019
(Behind UIM)
23
31
23
29
28
24
32
25
33
26
Figure 1. Front View
13
12
11
14
8
9
7
Figure 2. Blower Burner Assembly
18
17
6
17
30
16
15
17
4
Figure 3. Top View (without plastic cover)
Important: The Enable/Disable switch listed in this manual is
NOT an “on/off” switch and does not disconnect 120
volt power to the CCB and other heater components.
1. Water Heater’s Enable/Disable Switch. When in the
“Disabled” position the switch removes electrical power from
the gas valve so that water heating is disabled. The display,
CCB, and other electrical components will still be energized
and the display will read “Water Heating Disabled.”
2. UIM (user interface module). The UIM includes the display
circuit board and the control system’s LCD Touch Display.
Used to adjust various user settings and view operational
information.
3. Central Control Board (CCB) enclosure. This enclosure
houses the control system’s main circuit board, power supply
board, power transformer, and configuration key. The CCB
regulates water temperature and controls all water heater
functions. See Control System Operation (page 38).
4. 120 VAC junction box. Incoming power supply, ground
connections, and other field installed electrical connections
are made here. See Power Supply (page 13) and Power Supply
Connections (page 33).
5. 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.
6. Temperature-Pressure Relief Valve. See Temperature-Pressure
Relief Valve (page 15).
7. 1” Honeywell modulating 24 VAC gas valve.
8. 6” PVC air intake connection.
9. Honeywell Venturi Mixing Unit.
10. Combustion blower.
11. Combustion sight glass.
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9
12. 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 VAC Gas Valve. See Sequence of Operation Flow Chart
(page 54).
13. Spark Electrode: The control system energizes the spark
ignition control with 120 VAC during the ignition period. The
spark ignition control then sends a high-voltage electrical
current to the spark igniter which in turn ignites the main
burner air/gas mixture.
14. Premix burner.
15. Spark Ignition Control. When energized, sends the electrical
current to the spark igniter.
16. Temperature Probe: The water heater’s control system
monitors this probe to measure The heater’s water
temperature. The 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) (page 36).
17. Powered anode rods: The water heater’s covered in this
manual are equipped with 3 powered (non sacrificial) anode
rods at the top. 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
of water when it comes in contact with steel.
18. 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.
19. 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.
20. CPAM (Commercial powered anode module ).
21. Power supplier for CPAM.
22. 75VA transformer.
23. Side-mounted powered anodes.
24. Heater’s internal recirculation pump.
25. Flow switch, vertically mounted, used for confirmation of
water flowing through the secondary heat exchanger during
the heater’s running.
26. Flue temperature sensor.
27. 2” NPT Gas supply connection.
28. Water heater drain valve.
29. 2”NPT cold water inlet connection
30. 2” NPT hot water outlet connection.
31. 1” NPT building recirculation return connection.
32. ½” NPT condensate drain connection.
33. Cleanout access panel, covers water heater cleanout
opening and ASME plate.
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10
INSTALLATION CONSIDERATIONSINSTALLATION CONSIDERATIONS
ROUGH-IN DIMENSIONS
33 1/8"
44
1
2
"
72"
6" PVC
AIR INTAKE
61"
2"NPT
GAS
CONNECTION
73"
20"
3/4"
Drain
23 1/2”
2" NPT
Cold Water
Inlet
ASME
Plate
Cleanout
6" Vent
Connection
80 3/4"
3/8"H X 1/2" NPT
Condensate
Connection
33"
1" NPT
Recirculation
Return
2” NPT Hot Water Outlet
Exhaust
Front
37º
Drain
Intake
Gas
20º
90º
Figure 4. Rough-In Dimensions
These designs comply with the current edition of the American
National Standard for Gas Fired Water Heaters, Volume III, ANSI Z21.10.3-
CSA 4.3. The 750 and 1000 models are Automatic Circulating Tank
Water Heaters or Automatic Instantaneous Water Heaters.
Table 1. Fuel Type/Connection/Size by Model
Model Series NATURAL GAS PROPANE GAS
750 100/101 2” NPT 2” NPT
1000 100/101 2” NPT 2” NPT
Table 2. Minimum Supply Gas Line Size
Gallons *Natural Gas Propane Gas
750 2" NPT 1 1/2" NPT
1000 2" NPT 1 1/2" NPT
Table 3. Storage Capacities
Model
U.S. Gallons Liters
ASME ASME
All 120 454
Top view with plastic
cover removed.
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11
Table 4. Gas Pressure Requirements
Model
*Manifold Pressure Minimum Supply Pressure Maximum Supply Pressure
Natural Gas Propane GaS Natural Gas Propane Gas Natural Gas Propane Gas
750
0” W. C. (0 kPa) 0” W. C. (0 kPa) 3.5" W .C. (0.87 kPa) 8” W. C. (1.99 kPa) 14” W. C. (3.49 kPa) 14” W. C. (3.49 kPa)
1000
0” W. C. (0 kPa) 0” W. C. (0 kPa) 3.5" W .C. (0.87 kPa) 8” W. C. (1.99 kPa) 14” W. C. (3.49 kPa) 14” W. C. (3.49 kPa)
* The manifold pressure is the factory setting and is not adjustable. A negative pressure will be seen with just the blower running without the
Gas Control Valve open.
Table 5. Recovery Capacities
U. S. Gallons/hr & Liters/hr a Temperature Rise Indicated
Model
Type of
Gas
Input
Thermal
Eciency%
°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
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
750
Natural
750,000 220 97
GPH 2940 2205 1764 1469 1260 1103 979 882 802 734 678 630
Propane LPH 11129 8347 6677 5561 4770 4175 3706 3339 3036 2778 2567 2385
1000
Natural
1,000,000 293 97
GPH 3920 2940 2352 1960 1680 1470 1307 1176 1069 980 905 839
Propane LPH 14839 11129 8903 7419 6359 5565 4948 4452 4047 3710 3426 3176
LOCATING THE WATER HEATER
Carefully choose a location for the new water heater. The
placement is a very important consideration for the safety of the
occupants in the building and for the most economical use of the
water heater.
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
CAUTION
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
water heater.
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 (page 13) for requirements.
8. Locate the water heater where an adequate supply of fresh
air for combustion and ventilation can be obtained. See Air
Requirements (page 17).
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 (page 22).
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 (page 21).
Fire or Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Avoid all ignition sources if you smell gas.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating label.
Keep ignition sources away from faucets after extended
periods of non-use.
Maintain required clearances to combustibles.
Do not expose water heater controls to excessive gas
pressure.
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.
When the water heater is installed directly on carpeting, the water
heater shall be installed on a metal or wood panel extending
beyond the full width and depth of the water heater by at least 3
in (76.2 mm) in any direction or, if the water heater is installed in
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12
an alcove or closet, the entire floor shall be covered by the panel.
The panel must be strong enough to carry the weight of the heater
when full of water.
Note: Adequate clearance for servicing should be maintained
on all installations. See Service Clearance (page 12).
TOP VIEW
0
0
0
ALCOVE
FRONT VIEW
CLEARANCES TO COMBUSTIBLE
AND NON COMBUSTIBLE
CONSTRUCTION MATERIALS
WATER
HEATER
FRONT
TOP COVER
FRONT
Figure 5. Clearances
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/condensate elbow) and the condensate
drain. Leave as much room as possible above the water heater
and near the exhaust elbow for this reason.
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).
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 Sequence of Operation (page 53) 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. The tank is provided with a 1” NPT recirculation loop
return connection. See Water Piping Diagrams (page 66) for
installation location of circulating pumps.
See Circulation Pump Wiring Diagrams (page 65) 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. Stainless steel circulating pumps are
recommended for use with commercial water heaters.
See the circulating pump manufacturer’s instructions for its
operation, lubrication, and maintenance instructions.
INSULATION BLANKETS
Insulation blankets are available to the general public for external
use on gas water heaters but are not necessary with these
products. The purpose of an insulation blanket is to reduce the
standby heat loss encountered with storage tank heaters. 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.
Do not obstruct water heater air intake.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Breathing Hazard - Carbon Monoxide Gas
If you choose to apply an insulation blanket to this heater, you
should follow these instructions. See Features and Components
(page 7) 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.
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13
INSTALLATION REQUIREMENTSINSTALLATION REQUIREMENTS
SUPPLY GAS LINE REQUIREMENTS
Low-pressure building supply systems are defined as those
systems that cannot under any circumstances exceed 14” W.C.
(1/2 PSI Gauge). These systems do not require pressure
regulation. Measurements should be taken to insure that gas
pressures are stable and fall within the requirements stated on
the water heater rating plate. Readings should be taken with all
gas burning equipment off (static pressure) and with all gas
burning equipment running at maximum rate (dynamic pressure).
The gas supply pressure must be stable within 1.5” W.C. from
static to dynamic pressure to provide good performance.
Pressure drops that exceed 1.5” W.C. may cause rough starting,
noisy combustion or nuisance outages. Increases or spikes in
static pressure during off cycles may cause failure to ignite or in
severe cases damage to appliance gas valves. If your low
pressure system does NOT meet these requirements, the installer
is responsible for the corrections.
High-pressure building supply systems use pressures that exceed
14” W.C. (1/2 PSI Gauge). These systems must use field supplied
regulators to lower the gas pressure to less than 14” W.C. (1/2
PSI Gauge). Water heaters require gas regulators that are
properly sized for the water heater input and deliver the rating
plate specified pressures. Gas supply systems where pressure
exceeds 5 PSI often require multiple regulators to achieve desired
pressures. Systems in excess of 5 PSI building pressure should
be designed by gas delivery professionals for best performance.
Water heaters connected to gas supply systems that exceed 14”
W.C. (1/2 PSI Gauge) at any time must be equipped with a gas
supply regulator.
All models require a minimum gas supply pressure of 3.5” W.C.
for natural gas and 8.0” W.C. for propane gas. The minimum
supply pressure is measured while gas is flowing (dynamic
pressure). The supply pressure should never fall below 3.5” W.C.
for natural gas and 8.0” W.C. for propane gas. The supply
pressure should be measured with all gas fired appliances
connected to the common main firing at full capacity. If the supply
pressure drops more than 1.5” W.C. as gas begins to flow to the
water heater then the supply gas system including the gas line
and/or the gas regulator may be restricted or undersized. See
Supply Gas Regulator (page 13) and Supply Gas Line Sizing (page
32). The gas valve on all models has a maximum gas supply
pressure limit of 14” W.C. The maximum supply pressure is
measured while gas is not flowing (static pressure).
SUPPLY GAS REGULATOR
The maximum allowable gas supply pressure for this water heater
is 14.0” W. C. (3.49 kPa) for natural and propane gas. Install a
positive lock-up gas pressure regulator in the gas supply line if
inlet gas pressure can exceed these pressures at any time.
1. If a positive lock-up regulator is required follow these
instructions:
2. Positive lock-up gas pressure regulators must be rated at or
above the input Btu/hr rating of the water heater they supply.
3. Supply gas regulators shall have inlet and outlet connections
not less than the minimum supply gas line size for the water
heater they supply. See Table 11 and Table 12 (page 32).
4. Positive lock-up gas pressure regulator(s) should be installed
no closer than 3 feet (1 meter) and no farther than 8 feet
(2.4 meters) from the water heater’s inlet gas connection.
5. After installing the positive lock-up gas pressure regulator(s)
an initial nominal supply pressure setting of 7.0” W.C. while
the water heater is operating is recommended and will
generally provide good water heater operation. Some
addition adjustment maybe required later to maintain a
steady gas supply pressure.
When installing multiple water heaters in the same gas supply
system it is recommended that individual positive lock-up gas
pressure regulators be installed at each unit.
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.
DEDICATED POWER WIRING AND BREAKERS
Dedicated power supply wires, neutral wires, ground wiring and
dedicated circuit breakers often prevent electrical line noise and
are required when installing the water heater.
Note: This water heater should not be connected to an electrical
supply with a Ground Fault Circuit Interrupter (GFCI) or
Arc Fault Circuit Interrupter (AFCI) with Integral GFCI
protection as defined in NFPA 70, CSA C22.1 and UL 943.
POWER FLUCTUATIONS AND ELECTRICAL NOISE
The water heater’s control system requires a source of stable
clean electricity for proper operation. Connecting the water heater
to a branch circuit that is subject to fluctuations in voltage level
or electrical line noise such as EMI (electro magnetic interference)
or RFI (radio frequency interference) may cause erratic control
system operation and malfunction.
A high quality power supply filter/suppressor must be installed if
the above conditions exist. Call the technical support phone
number listed on the back cover of this manual for more
information.
Note: Malfunctions caused by the power supply and the costs
to install power supply filters are not covered under the
limited warranty.
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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 valvecan be
installed, for example, at the water heater or at the hot water taps
to further reduce system water temperature. See Figure 6.
Check State and/or local codes for mixing valve requirements
and installation practices.
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. Burn Time at Various Temperatures
Water Tempera-
ture
°F (°C)
Time for 1st Degree
Burn
(Less Severe
Burns)
Time for Permanent
Burns
2nd & 3rd Degree
(Most Severe Burns)
110 (43)
(normal shower
temp.)
116 (47) (pain threshold)
116 (47) 35 minutes 45 minutes
122 (50) 1 minute 5 minutes
131 (55) 5 seconds 25 seconds
140 (60) 2 seconds 5 seconds
149 (65) 1 second 2 seconds
154 (68) inantaneous 1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)
DISH-WASHING MACHINES
All dish-washing 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 dish-washing machine
and should be adjusted to deliver water pressure between these
limits.
HOT WATER
OUTLET
TO TANK
INLET
CHECK
VALVE
MIXING
VALVE
COLD
WATER
INLET
TEMPERED WATER
OUTLET
12” TO 15”
(30-38 cm)
CHECK
VALVE
Figure 6. Mixing Valve
The National Sanitation Foundation also recommends circulation of
180°F (82°C) water. The circulation should be just enough to
provide 180°F (82°C) water at the point of take-off to the dish-
washing 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 (page
66) .
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 and pressurized 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 (page 34) and the Water Piping Diagrams
(page 66).
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15
TEMPERATURE-PRESSURE RELIEF VALVE
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22-
CSA 4.4 and ASME code.
Properly sized temperature-
pressure 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 Temperature-
Pressure 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 Temperature-Pressure Relief Valve
installed. Call the toll free technical support phone number
listed on the back cover of this manual for technical
assistance in sizing a 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.
Water Damage Hazard
Temperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
•
CAUTION
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 Temperature-
Pressure Relief Valve
discharge outlet.
The Temperature-Pressure Relief Valve must be manually
operated at least twice a year. Caution should be taken to ensure
that (1) no one is in front of or around the outlet of the
Temperature-Pressure Relief Valve discharge line, and (2) the
water manually discharged will not cause any bodily injury or
property damage because the water may be extremely hot. If
after manually operating the valve, it fails to completely reset and
continues to release water, immediately close the cold water inlet
to the water heater, follow the draining instructions in this manual,
and replace the Temperature-Pressure Relief Valve with a
properly rated/sized new one.
Note: The purpose of a Temperature-Pressure Relief Valve is to
prevent excessive temperatures and pressures in the
storage tank. The T&P valve is not intended for the
constant relief of thermal expansion. A properly sized
thermal expansion tank must be installed on all closed
systems to control thermal expansion. See Closed Water
Systems (page 14) and Temperature-Pressure Relief Valve
(page 15).
If you do not understand these instructions or have any questions
regarding the Temperature-Pressure Relief Valve call the toll free
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16
number listed on the back cover of this manual for technical
assistance.
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 near the bottom below
the drain valve. The field-installed condensate drain line must
not be elevated above the condensate drain connection. See
Figure 7. If the condensate does not drain properly, it will build
up in the exhaust outlet. 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 (page 56).
The water heater has a built-in condensate trap. Do not install
an additional trap in the condensate drain piping. See Figure 7.
If the “Blocked Exhaust “ Fault message is ever displayed on the
control system LCD, check the condensate drain first and ensure
that it is not blocked.
BUILDING
DRAIN
1/2 “CONDENSATE DRAIN
LINE - FIELD INSTALLED
DRAIN LINE TO TERMINATE NO
MORE THAN 6 INCHES
(15.2cm)
ABOVE DRAIN
Figure 7. Condensate Trap
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 (page 31).
COMBUSTIBLE MATERIAL STORAGE
Fire or Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Avoid all ignition sources if you smell gas.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating label.
Keep ignition sources away from faucets after extended
periods of non-use.
Maintain required clearances to combustibles.
Do not expose water heater controls to excessive gas
pressure.
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 the 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
installed in a Direct Vent configuration so that all air for combustion
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17
is derived directly from the outdoor atmosphere through a sealed
intake air pipe. See Venting Installation (page 21).
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 the 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.
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 (page 21) for complete venting
installation instructions.
OUTDOOR AIR THROUGH TWO OPENINGS
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 8.
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Figure 8. Outdoor Air Through Two Openings
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
Alternatively a single permanent opening, commencing within
12 inches (300 mm) of the top of the enclosure, shall be provided.
See Figure 9.
Figure 9. Outdoor Air Through One Opening
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 water heater. 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. One 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
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 10.
Figure 10. Two Horizontal Ducts
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.
OUTDOOR AIR THROUGH TWO VERTICAL DUCTS
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 (page 21) for complete venting
installation instructions.
Figure 11. Two Vertical Ducts
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 11.
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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.
AIR FROM OTHER INDOOR SPACES
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 12.
Figure 12. Two Permanent Openings
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).
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INSTALLATION REQUIREMENTS - COMMONWEALTH OF MASSACHUSETTSINSTALLATION REQUIREMENTS - 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:
INSTALLING CARBON MONOXIDE DETECTORS
At the time of installation of the side-wall horizontal-vented gas-
fueled equipment, the installing plumber or gas-fitter 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 gas-fitter 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 side-wall 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 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-fueled equipment provides a venting
system design or venting system components with the equipment,
the instructions provided by the manufacturer for installation of
the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting-system
design or the venting-system components
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.
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.
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VENTING INSTALLATIONVENTING INSTALLATION
Never operate the water heater unless it is vented to 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 Category IV
appliances and may be installed in either a Power Vent or Direct
Vent configuration.
APPROVED MATERIALS
Approved vent and intake air pipe materials that may be used in
the United States:
PVC pipe materials:
• DWV ASTM-D2665 or CSA B181.2
• Schedule 40, 80, 120 ASTM-D1785 or CSA B137.3
• SDR Series ASTM-2241 or CSA B137.3
CPVC pipe materials:
• CPVC 41 ASTM-D2846 or CSA B137.6
• Schedule 40, 80 ASTM-F441 or CSA B137.6
• SDR Series ASTM-F442
Polypropylene. See Polypropylene Installations (page 27).
• M & G Duravent PolyPro vent system
• Centrotherm InnoFlue vent system
AL29-4C Stainless Steel. See AL29-4C® Vent Installations (page
27).
• HeatFab Saf-T Vent
• Duravent FasNSeal
Approved vent pipe materials that must be used in Canada:
• ULC S636 PVC / CPVC
• ULC S636 Polypropylene. See Polypropylene Installations (page
27)
• AL29-4C Stainless Steel. See AL29-4C® Vent Installations (page
27)
Approved intake air pipe materials that must be used in Canada:
PVC pipe materials:
• DWV ASTM-D2665 or CSA B181.2
• Schedule 40, 80, 120 ASTM-D1785 or CSA B137.3
• SDR Series ASTM-D2241 or CSA B137.3
CPVC pipe materials:
• CPVC 41 ASTM-D2846 or CSA B137.6
• Schedule 40, 80 ASTM-F441 or CSA B137.6
• SDR Series ASTM-F442
Polypropylene. See Polypropylene Installations (page 27).
• M & G Duravent PolyPro vent system
• Centrotherm InnoFlue vent system
AL29-4C Stainless Steel. See AL29-4C® Vent Installations (page
27)
• HeatFab Saf-T Vent
• Duravent FasNSeal
Where applicable, the installation of the venting system should
be done in accordance with the venting system manufacturer’s
instructions.
Note: The use of cellular core PVC (ASTM F891), cellular core
CPVC, or Radel® (polyphenolsulfone) in non-metallic
venting systems is prohibited. Covering non-metallic vent
pipe and fittings with thermal insulation is prohibited.
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 Venting Arrangements (page 28).
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
several different arrangements. See Venting Arrangements (page
28).
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. See Air
Requirements (page 17). If the installation space does 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).
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5. The water heater must be protected from freezing down-
drafts 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 (page 22).
9. Do not install the vent or intake air piping in a manner that
will allow water to be trapped in the piping.
10. The vent (exhaust) piping 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 (page 22).
13. Use only factory supplied vent and intake air terminations.
See Venting Requirements (page 22).
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 public walkways or
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. Carefully read the Venting Requirements (page 22) and then
proceed to the Venting Installation Sequence (page 23).
VENTING REQUIREMENTS
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.
Note: See Table 9 and Table 10 for equivalent linear pipe length
of AL29-4C® 45° and 90° elbows.
PRIMER AND CEMENT
Tetrahydrofuran (THF) primer should be used to prepare the
surfaces of pipe and fittings for solvent welding. If CPVC 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 use ASTM F-493
Grade Cement.
PIPE SIZE REQUIREMENTS
The water heaters covered in this manual are certified for the
use six-inch pipe for the vent (exhaust) and intake air piping.
Maximum Equivalent Lengths
The water heaters covered in this manual are certified to a
maximum length of 6-inch pipe for the exhaust venting
arrangement of 100 equivalent feet (30.4 m). The certified
maximum length of 6-inch pipe for intake air piping is also 100
equivalent feet (30.4 m). For example, on Direct Vent installations,
both pipes can be up to 100 equivalent feet (30.4 m).
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).
Minimum Equivalent Lengths
The water heaters covered in this manual are certified to a
minimum length of six-inch pipe for the vent (exhaust) of 15 feet
(4.6 m). There is no minimum equivalent feet requirement for the
intake air pipe.
Maximum Equivalent Lengths
The water heaters covered in this manual are certified to a
maximum length of six-inch pipe for the exhaust venting
arrangement of equivalent 100 feet (30.4 m). The certified
maximum length of six-inch pipe for intake air piping is also 100
equivalent feet (30.4 m). In other words, on direct vent
installations, both pipes can be up to 100 equivalent feet (30.4
m).
Maximum Number Of Elbows
The vent pipe may have a maximum of six 90° elbows installed.
The intake air pipe may have a maximum of six 90° elbows
installed. IE: in a Direct Vent configuration each pipe can have
up to six (6) 90° elbows installed. Two (2) 45° elbows equal one
(1) 90° elbow. Each 90° elbow is equivalent to 5 feet (1.5 m) of
linear pipe, 45° elbows are equivalent to 2.5 feet (0.75 m) of
linear pipe.
Note: See Table 9 and Table 10 for equivalent linear pipe length
of AL29-4C
®
45° and 90° elbows.
FACTORY SUPPLIED FITTINGS
The water heater ships with one vent kit box containing one six-
inch coupling with screen for flue gas terminal, one six-inch
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90-degree elbow with screen for air intake terminal, and two 45
degree venting elbows. Factory-supplied vent and intake air
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.
VENTING INSTALLATION SEQUENCE
1. Read the General Venting Instructions (page 21) and Venting
Requirements (page 22) before proceeding. These instructions
and requirements must be followed on all installations.
2. Determine whether the water heater will be installed in a
Power Vent or Direct Vent configuration and which vent
system arrangement will be used for the installation. See
the various venting arrangements illustrated in Venting
Arrangements (page 28).
3. Proceed to the applicable installation instructions that follow;
Power Vent Installation (page 23) or Direct Vent Installation (page
23).
POWER VENT INSTALLATION
1. Read the General Venting Instructions (page 21)and Venting
Requirements (page 22) before proceeding. These instructions
and requirements must be followed in addition to the
instructions below that are specific for Power Vent
configurations.
2. Determine which Power Vent arrangement will be used for
the installation; vertical or horizontal termination. See Venting
Arrangements (page 28).
3. Plan the layout of the vent piping backwards from the
termination point outdoors to the water heater. Layout the
vent piping to use a minimum of pipe and elbows.
4. Install the termination first.
If the vent piping will terminate vertically, through a roof. See
Vertical Termination Installation (page 24).
If the vent piping will terminate horizontally, through a
sidewall. See Sidewall Termination Installation (page 25).
Six-inch PVC pipe,
eld-supplied.
Two six-inch 45°
PVC elbows
supplied with vent
termination kit.
Torque clamps to
24-30 IN/LBS.
Figure 13. Vent (Exhaust) Connection
5. When installation of the termination is complete install
necessary piping and fittings to route the vent piping back
to the water heater.
6. The vent pipe must be supported properly to avoid bending
or failure. The water heater manufacturer recommends that
the vent pipe be supported every 5 feet (152 cm) of vertical
run and every 3 feet (91 cm) of horizontal run.
7. Do not install the vent piping in a manner that will allow water
to be trapped in the piping.
8. All vent (exhaust) pipes must be pitched a minimum of a 1/4
inch per foot back to the water heater (to allow drainage of
condensate).
DIRECT VENT INSTALLATION
1. Read the General Venting Instructions (page 21) and Venting
Requirements (page 22) before proceeding. These instructions
and requirements must be followed in addition to the
instructions below that are specific for Direct Vent
configurations.
2. Determine which Direct Vent arrangement will be used for
the installation.
3. Plan the layout of the vent and intake air piping backwards
from the termination point outdoors to the water heater.
Layout the vent and intake air piping to use a minimum of
pipe and elbows.
Note: Any piping added to the air-intake fitting on the heater
MUST be glued or attached with screws.
4. Install the terminations first.
5. When installation of the termination(s) is complete, install
necessary piping and fittings to route the intake air and vent.
6. The intake air and vent piping must be supported properly
to avoid bending or failure. The water heater manufacturer
recommends that the vent and intake air piping be supported
every 5 feet (152 cm) of vertical run and every 3 feet (91 cm)
of horizontal run.
7. Do not install the vent or intake air piping in a manner that
will allow water to be trapped in the piping.
8. A field supplied condensate Tee fitting and drain hose must
be installed in the intake air piping near the water heater in
colder climates with heavy snow accumulations and in areas
that regularly experience high humidity. The drain hose must
be routed to an adequate floor drain separate from any other
condensate drains. See Figure 14 (page 24).
Note: Snow being pulled into the intake air piping and then
melting can lead to excessive amounts of water
accumulation and damage water heater components.
Warm, humid outdoor air can lead to excessive
condensation inside the intake air piping and may
also damage water heater components.
9. All vent (exhaust) pipes must be pitched a minimum of a 1/4
inch per foot back to the water heater (to allow drainage of
condensate).
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24
10. Use a torque wrench to tighten the vent pipe clamps to 24-
34 IN/LBS.
Six-Inch Intake Air
Connection
Connect the field-supplied flexi-
ble drain hose to barb fitting
and form a loop water trap in
the drain hose.
Run the drain hose to a suitable
floor drain separately from other
condensate drains.
Figure 14. Intake Air Condensate Tee Installation
11. Ensure the Intake Air Screen on the Intake Air Connection
is removed before connecting the intake air pipe to the water
heater. See Figure 15.
Do not obstruct water heater air intake.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Breathing Hazard - Carbon Monoxide Gas
Note: Do not leave the screen inside the Intake Air connection
in Direct Vent installations. Once the intake air pipe is
installed the screen will be hidden from view and may
become clogged with debris over time. This will cause
improper combustion.
Six-Inch Coupling - Factory Installed
Intake Air Screen
(Remove for Direct Vent)
Figure 15. Intake-Air Connection Detail
DIRECT VENT AIR INTAKE MOISTURE PROTECTION
The air intake piping in a direct vent system will normally not
have any moisture accumulation in it. However, in certain cases,
moisture may build up and needs to be drained. Typical situations
include, but are not limited to:
• Cold outdoor temperature, particularly if the air inlet is short
• High outdoor humidity
• Heater being used mostly for space heating
• Air inlet pipe has vertical rise near the heater
Installations with any of these conditions are required to provide
a moisture drain with a trap that flows to a waste drain. See Figure
14 (page 24) and Venting Arrangements (page 28). A horizontal
section of the air inlet pipe, near the heater should include a hose
barb fitting to drain the water. The drain tubing in any installation
should have a loop trap and flow to an appropriate waste drain.
The air intake drain line must be entirely separate from the
exhaust vent outlet condensate line.
VERTICAL TERMINATION INSTALLATION
1. Determine the location for the termination(s).
2. If installing only the vent (exhaust) piping in a Power Vent
configuration vertically through the roof, ensure that all exterior
vertical clearance requirements, shown in Figure 16 and Figure
17 (page 25), are being maintained. These clearances and
those cited by local and national codes must be maintained.
Note: On flat roof installations the vent termination must
be a minimum of 24 inches (60 cm) above any
parapet, vertical wall, or structure within 10 feet (3
m) horizontally. See Figure 17 (page 25).
3. If installing both intake air and vent piping in a Direct Vent
configuration vertically through the roof; ensure that all
exterior vertical clearance requirements shown in Figure 17
and Figure 18 (page 25) are being maintained. These
clearances and those cited by local and national codes must
be maintained.
Note: On flat roof installations the intake air and the vent
terminations must be a minimum of 24 inches (60
cm) above any parapet, vertical wall or structure
within 10 feet (3 m) horizontally. See Figure 17 (page
25).
4. If installing only vent piping in a Power Vent configuration
vertically through the roof, the following instructions must be
followed:
• The vent termination must be oriented facing upward as
shown in Figure 17 (page 25).
• The bottom edge of the vent termination must be a minimum
of 12 inches (30 cm), 18 inches (45 cm) in Canada, above
the average or expected snow level as shown in Figure 16.
5. If installing both intake air and vent piping in a Direct Vent
configuration vertically through the roof the following
instructions must be followed:
• The intake air and vent pipes must penetrate the same side
of the roof as shown in Figure 18 (page 25).
• The intake air and vent terminations must be oriented as
shown in Figure 18.
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25
• The intake air and vent terminations must have a minimum
separation of 24” (61 cm) measured on center line as shown
in Figure 18. In colder climates this separation should be
increased to at least 48 inches (122 cm).
• The bottom edge of the intake air and vent terminations
must be a minimum of 12 inches (30 cm), 18 inches (45
cm) in Canada, above the average or expected snow level
as shown in Figure 16 and Figure 18.
2” (5 cm)
MAXIMUM
FACTORY SUPPLIED
STANDARD TERMINATION
POINTED DOWN TOWARDS
THE GROUND
VERTICAL TERMINATION(S) INSTALLATION
INTAKE AIR AND/OR VENT (EXHAUST)
FIELD
SUPPLIED
90° ELBOW
FIELD
SUPPLIED
STRAP/SUPPORT
FIELD SUPPLIED
PLUMBING
ROOF BOOT
OR FLASHING
MAINTAIN 12” (30 cm)
18” (45 cm) FOR CANADA
MINIMUM CLEARANCE
ABOVE HIGHEST ANTICIPATED
SNOW LEVEL.
Figure 16. Vertical Termination(s) - Intake Air and/or Vent (Exhaust)
6. When the intake air and/or vent piping from multiple water
heaters will terminate in the same location the vent
terminations can be grouped together in close proximity 0
inches/touching. Intake air terminations can also be grouped
together in close proximity 0 inches/touching.
The distance between the closest vent and intake air
terminations must be a minimum of 24 inches (61 cm) as
shown in Figure 18. In colder climates this separation should
be increased to at least 48 inches (122 cm).
7. Cut a seven-inch (18 cm) diameter hole for six-inch pipe where
the pipe(s) will pass through the roof.
Note: Beware of concealed wiring and piping when cutting
through the roof.
8. Suspend the pipe(s) through center of hole using field supplied
metal strapping or equivalent support materials as shown in
Figure 16.
9. Slide a roof boot or equivalent flashing over the pipe and
secure roof boot or equivalent flashing to roof (see Figure 16)
and seal around the flashing.
10. Install the factory supplied intake air and/or vent termination(s)
using field supplied pipe and one field supplied 90° elbow as
shown in Figure 16. The short section of pipe that connects
between the field supplied 90° elbow and the factory supplied
termination must not be excessive in length. The exposed
portion of this pipe shall be no more than 2 inches (5 cm). See
Figure 16.
VERTICAL TERMINATION(S) FLAT ROOF CLEARANCE
INTAKE AIR AND/OR VENT (EXHAUST)
IF LESS THAN
24 INCHES (60 cm)
MINIMUM HEIGHT ABOVE
INTAKE AIR AND/OR VENT
TERMINATION(S) MUST BE A
MINIMUM OF 24 INCHES (60 cm)
ABOVE ANY PARAPET, VERTICAL
WALL OR STRUCTURE WITHIN
10 FEET (3 m) HORIZONTALLY.
10 FEET (3 m)
Figure 17. Vertical Termination(s) Flat Roof Clearance - Intake Air
and/or Vent (Exhaust
11. Return to Power Vent Installation (page 23) or Direct Vent
Installation (page 23) to complete the installation of the intake
air and/or vent piping between the termination(s) and the water
heater.
Minimum Clearance Above Highest
Anticipated Snow Level:
● 12” (30 cm) in US
● 18” (45 cm) in Canada
Vent Termination minimum
clearance above Intake Air
Termination: 24” (30 cm)
Minimum Horizontal Separaton:
● 24 inches (61 cm)
● 48 inches (122 cm) in colder climates
VENT (EXHAUST)
TERMINATION
Intake Air
Termination
FIELD SUPPLIED
PLUMBING
ROOF BOOTS
OR FLASHINGS
Figure 18. Vertical Termination - Direct Vent, Standard Terminations
SIDEWALL TERMINATION INSTALLATION
1. Determine the location for the termination(s).
2. If installing only vent (exhaust) piping in a Power Vent
configuration through a sidewall; ensure that all exterior
sidewall clearance requirements for the termination, shown
in Figure 27 (page 29), are being maintained. These clearances
and those cited by local and national codes must be
maintained.
3. If installing both intake air and vent piping in a Direct Vent
configuration through a sidewall; ensure that all exterior
sidewall clearance requirements for the terminations, shown
in Figure 28 (page 30), for the vent and intake air termination
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26
are being maintained. These clearances and those cited by
local and national codes must be maintained.
4. If installing both an intake air and vent termination in a Direct
Vent configuration through a sidewall there must be a minimum
of 24 inches (61 cm) separation, measured on vertical center
line, between the intake air and vent terminations. See Figure
19.
Note: In colder climates this separation should be increased
to at least 48 inches (122 cm) between the intake air
and vent termination or any other appliance vent that
discharges moisture-laden air such as clothes dryers.
This will reduce possibility of frost over from side
winds blowing exhaust vapors to the intake air
termination and is recommended for Canadian
installations.
5. If installing both intake air and vent terminations in a Direct
Vent configuration through a sidewall the intake air and vent
terminations must be installed at the same elevation measured
on horizontal center line - see Figure 19.
C
L
C
L
C
L
Side Wall
Exhaust Vent
Terminal
Air Intake
Terminal
24” Minimum
Figure 19. Sidewall Termination - Direct Vent
6. When the intake air and/or vent piping from multiple water
heaters will terminate at the same location through a sidewall,
the vent terminations can be grouped together in close
proximity - 0 inches/touching. The intake air terminations can
also be grouped together in close proximity - 0 inches/
touching.
However, the distance between the closest vent and intake
air terminations must be a minimum of 24 inches (61 cm).
In colder climates this separation should be increased to at
least 48 inches (122 cm). See Figure 19.
7. Cut a seven-inch (18 cm) diameter hole for six-inch pipe where
the pipe(s) will pass through the wall.
Note: Beware of concealed wiring and piping when cutting
through the wall.
8. Cut a length(s) of pipe being installed 3.5 inches (8.9 cm) to
9.5 inches (24.1 cm) longer than the wall thickness at the
opening. See Figure 20.
Note: Vent Termination – exhaust gases of this water heater
are less than 140°F. In cold climates water vapor in
the exhaust gases will condense into a cloud of vapor
where the vent exits the building. This vapor can
gradually discolor exterior building surfaces. The vent
termination should be located where this vapor cloud
and potential discoloration are not a concern.
Extending the exposed vent piping up to a maximum
of 6 inches (15.2 cm) from the wall helps vapor from
being trapped along a building’s face. To avoid this
problem, the vent can also be terminated vertically
through the roof. See Vertical Termination Installation
(page 24).
9. Cement the intake air and/or vent termination to the section(s)
of pipe cut to length in the above Step.
10. Slide the included metal wall plate(s) over the pipe(s) to stop
against the intake air and/or vent termination. Place some
silicone caulking (field supplied) on the back of the wall plate(s)
to secure it to the wall.
11. Working from outside, slide the pipe and termination(s)
assembled in the above steps through the wall. Ensure the
termination(s) is pointed down towards the ground. See Figure
20.
Air Intake Terminal - All Models
Outside
Building
Wall
12” (30.5 cm)
Minimum
Air Intake Terminal
with Screen
Wall Plates
Mortar or
Silicone
Caulk
From
Water
Heater
PVC
Coupling
Figure 20. Sidewall Termination Installation
12. Place a bead of silicone caulking (field supplied) around the
gap between the installed pipe(s) and the wall. Apply enough
to fill the gap between the pipe(s) and wall.
13. Press the wall plate flush against the outside wall.
14. Working from the inside apply enough silicone caulking on
the back of the interior wall plate(s) to hold it in place and slide
the wall plate over the installed pipe(s).
15. Install a coupling to the end of the pipe(s) inside the building.
Before the silicone caulking has time to completely set go
outside the building and ensure the termination(s) is still
pointing down towards the ground. See Figure 20.
16. Return to Power Vent Installation (page 23) or Direct Vent
Installation (page 23) to complete the installation of the intake
air and/or vent piping between the termination(s) and the water
heater.
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27
POLYPROPYLENE INSTALLATIONS
The water heaters covered by this manual have been approved
to be installed with Polypropylene vent material as shown in Table
7 and Table 8. The approved application of single wall, non-flexible,
non-concentric Polypropylene vent material is offered by two
specific manufacturers (Centrotherm ECO Systems and
DuraVent Polypropylene). These listed products must be installed
by following the vent manufacturer’s instructions. See Table 7 to
determine the maximum pipe length and number of elbows that
can be used.
Insulation should not be used on Polypropylene venting materials.
The use of insulation will cause increased vent wall temperatures,
which could result in vent pipe failure.
Use only the adapters and vent system listed in Tables below.
DO NOT mix vent systems of different types or manufacturers.
Failure to comply could result in severe personal injury, death,
or substantial property damage.
Installations must comply with applicable national, state, and
local codes. For Canadian installation, Polypropylene vent must
be listed as a ULC-S636 approved system. If Polypropylene vent
is not required by your local code, you may use either PVC or
CPVC pipes for your water heater that allows non-metallic venting
material installations.
Polypropylene vent systems do not use cement to connect the
pipe and elbow sections but use a push together gasket seal
method. Do not attempt to connect Polypropylene with sealant
cement. All vent connections MUST be secured by the vent
manufacturer’s joint connector. The installer must use a specific
vent starter adapter at the flue connection. The adapter is
supplied by the vent manufacturer to adapt to its vent system.
In order to be in full compliance with UL 1738 or ULC-S636 and
to meet the requirements of the water heater manufacturer, you
must use the metal joint connector rings, available from the
Polypropylene vent manufacturer, to stiffen the joints of six-inch
diameter pipes.
Table 7. M & G Duravent PolyPro Vent Syem Components
Nominal Pipe Diameter Flue Outlet Adapter Adapter Connector Ring Connector 90 Degree Elbow Vent Material
6” 300153 PPS-PACL 6PPS-LBC 6PPS-E90 PPS
Table 8. Centrotherm InnoFlue SW Vent Syem Components
Nominal Pipe Diameter Flue Outlet Adapter Adapter Connector Ring Connector 90 Degree Elbow Vent Material
6” ISAAL0606-EXT IAFC06 IANS06 ISEL0687 Polypropylene
AL29-4C
®
VENT INSTALLATIONS
(AL29-4C
®
is a registered trademark of Allegheny Technologies,
Inc.)
The water heaters covered by this manual are approved to be
installed with AL29-4C
®
stainless steel vent material using parts
from the manufacturers listed in Table 9 and Table 10 below. These
listed systems must be installed using the vent manufacturer’s
instructions including their listed clearances to combustible and
noncombustible materials. Use Table 9 and Table 10 below to find
the appropriate equivalent linear vent lengths for the AL29-4C
®
elbows.
Note: The equivalent lengths of the AL29-4C
®
elbows are
different than those from smooth walled plastic vents.
Consult Table 9 and Table 10 for the correct equivalent linear
vent lengths.
Listed vent systems composed of AL29-4C
®
must not mix parts
from the different manufacturers. The joints of these products
are sealed by internal gaskets. Do not use any other type of
sealant. When assembling these vent systems, follow the vent
manufacturer’s instructions for cleaning and lubricating the joints,
if required. Each section must be locked together using the
method supplied by the vent manufacturer.
The water heaters covered by this manual are approved to be
installed using the approved vent terminations shown in this
manual. This means that, the installer must use the adapter listed
in Table 9 and Table 10 and a short piece of PVC pipe to complete
the end of the vent system with an approved termination. In
Canada, the PVC pipe length must be listed to ULC636.
Table 9. HeatFab Saf–T Vent AL29-4C® Vent Syem Parts
Diameter Flue Outlet Adapter
*Straight Pipe (3’
Section) 45° Elbow
Equivalent Linear
Length, 45° Elbow 90° Elbow
Equivalent Linear
length, 90° Elbow Adapter to PVC
6" 9601 PVC 9607 9611 5 feet 9614 10 feet 9656CPVC
Table 10. Duravent FasNSeal AL29-4C® Vent Syem Parts
Diameter Flue Outlet Adapter
*Straight Pipe (3’
Section) 45° Elbow
Equivalent Linear
Length, 45° Elbow 90° elbow
Equivalent Linear
Length, 90° Elbow Adapter to PVC
6" 810005225 FSVL3606 FSELB4506 5 feet FSELB9006 10 feet 81005572
Consult vent manufacturer’s catalog for other available lengths.
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28
VENTING ARRANGEMENTS
Figure 21. Power Vent Vertical
Figure 22. Power Vent Horizontal
*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 23. Direct Vent Vertical
*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 24. Direct Vent Horizontal
*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 25. Direct Vent Vertical Vent
Horizontal Intake
*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 26. Direct Vent Horizontal Vent
Vertical Intake
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29
TERMINATION CLEARANCES SIDEWALL POWER VENT
Fixed
Closed
Operable
Fixed
closed
Operable
B
V
V
V
V
V
V
V
V
C
B
B
X
A
M
K
Regulator vent outlet
In the event no
regulator is present,
H and I can be
disregarded
.
V
Legend:
= Vent terminal
X
= Air supply inlet
= Area where terminal is not permitted
B
B
J
F
X
B
L
E
D
Inside
corner detail
V
A
G
H
15 ft
I
Figure 27. Power Vent Using Outside Air
Termination Clearances for Sidewall Power Vent
Type of Clearance Canadian Installations
1
US Installations
2
A
Clearance above
grade, veranda,
porch, deck or
balcony
12 inches (30 cm) 12 inches (30 cm)
B
Clearance to
window or door that
may be opened
• 6 in (15 cm) for appli-
ances ≤ 10,000 Btuh
(3 kW)
• 12 in (30 cm) for appli-
ances > 10,000 Btuh
(3 kW) and ≤ 100,000
Btuh (30 kW),
• 36 in (91 cm) for appli-
ances > 100,000 Btuh
(30 kW)
• 6 in (15 cm) for appli-
ances ≤ 10,000 Btuh
(3 kW)
• 9 in (23 cm) for appli-
ances >10,000 Btuh (3
kW) and ≤ 50,000 Btuh
(15 kW)
• 12 in (30 cm) for appli-
ances > 50,000 Btuh
(15 kW)
C
Clearance to
permanently closed
window
12 inches (30 cm)* 12 inches (30 cm)*
D
Vertical clearance
to ventilated sot
located above the
terminal within a
horizontal distance
of 2 feet (61 cm)
from the center line
of the terminal
12 inches (30 cm)* 12 inches (30 cm)*
E
Clearance to unven-
tilated sot
12 inches (30 cm)* 12 inches (30 cm)*
F
Clearance to out-
side corner
2 feet (60 cm)* 2 feet (60 cm)*
G
Clearance to inside
corner
18 inches (45 cm)* 18 inches (45 cm)*
Termination Clearances for Sidewall Power Vent
Type of Clearance Canadian Installations
1
US Installations
2
H
Clearance to each
side of center line
extended above
meter/regulator
assembly
3 ft (91 cm) within a
height of 15 ft (4.6 m)
Clearance in accordance
with local installation
codes and the require-
ments of the gas supplier
I
Clearance to service
regulator vent outlet
3 ft (91 cm)
Clearance in accordance
with local installation
codes and the require-
ments of the gas supplier
J
Clearance to a non
mechanical air sup-
ply inlet into building
or combustion air
inlet to any other
appliance
• 6 in (15 cm) for appli-
ances ≤ 10,000 Btuh
(3 kW)
• 12 in (30 cm) for appli-
ances > 10,000 Btuh
(3 kW) and ≤ 100,000
Btuh (30 kW)
• 36 in (91 cm) for appli-
ances >100,000 Btuh
(30 kW)
• 6 in (15 cm) for appli-
ances ≤ 10,000 Btuh
(3 kW)
• 9 in (23 cm) for appli-
ances >10,000 Btuh (3
kW) and ≤ 50,000 Btuh
(15 kW)
• 12 in (30 cm) for appli-
ances > 50,000 Btuh
(15 kW)
K
Clearance to a me-
chanical air supply
inlet
6 feet (1.83 m)
3 feet (91 cm) above
if within 10 feet (3 m)
horizontally
L
Clearance above
paved sidewalk or
paved driveway
located on public
property
7 feet (2.13 m)†
7 ft (2.13 m) for me-
chanical draft systems
(Category I appliances);
vents for Category II and
IV appliances cannot
be located above public
walkways or other areas
where condensate or va-
por can cause a nuisance
or hazard
M
Clearance under
veranda, porch,
deck, or balcony
12 inches (30 cm) ‡ 12 inches (30 cm) ‡
1. In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code.
2. In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings
where it can cause hazardous frost o ice accumulations on adjacent property surfaces.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.
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30
TERMINATION CLEARANCES SIDEWALL DIRECT VENT
Fixed
Closed
Operable
Fixed
closed
Operable
B
V
V
V
V
V
V
V
V
C
B
B
X
A
M
K
Regulator vent outlet
In the event no
regulator is present,
H and I can be
disregarded
.
V
Legend:
= Vent terminal
X
= Air supply inlet
= Area where terminal is not permitted
B
B
J
F
X
B
L
E
D
Inside
corner detail
V
A
G
H
15 ft
I
Figure 28. Sidewall Direct Vent Using Outside Air
Termination Clearances for Sidewall Direct Vent
Type of Clearance
Canadian Installations
1
US Installations
2
A
Clearance above
grade, veranda,
porch, deck or
balcony
12 inches (30 cm) 12 inches (30 cm)
B
Clearance to window
or door that may be
opened
• 6 in (15 cm) for appli-
ances ≤ 10,000 Btuh
(3 kW)
• 12 in (30 cm) for appli-
ances > 10,000 Btuh
(3 kW) and ≤ 100,000
Btuh (30 kW),
• 36 in (91 cm) for appli-
ances > 100,000 Btuh
(30 kW)
• 4 feet (1.2 m) below or
to side of opening;
• 1 foot (30 cm) above
opening
C
Clearance to perma-
nently closed window
6 inches (15 cm)* 6 inches (15 cm)*
D
Vertical clearance to
ventilated sot locat-
ed above the terminal
within a horizontal
distance of 2 feet (61
cm) from the center
line of the terminal
12 inches (30 cm) 12 inches (30 cm)
E
Clearance to unventi-
lated sot
12 inches (30 cm) 12 inches (30 cm)
F
Clearance to outside
corner
2 feet (60 cm)* 2 feet (60 cm)*
G
Clearance to inside
corner
18 inches (45 cm)* 18 inches (45 cm)*
Termination Clearances for Sidewall Direct Vent
Type of Clearance
Canadian Installations
1
US Installations
2
H
Clearance to each
side of center line ex-
tended above meter/
regulator assembly
3 ft (91 cm) within a
height 15 ft (4.6 m)
Clearance in accordance
with local installation
codes and the require-
ments of the gas supplier
I
Clearance to service
regulator vent outlet
3 ft (1.83 m)
Clearance in accordance
with local installation
codes and the require-
ments of the gas supplier
J
Clearance to a non
mechanical air supply
inlet into building or
combustion air inlet to
any other appliance
• 6 in (15 cm) for appli-
ances ≤ 10,000 Btuh
(3 kW)
• 12 in (30 cm) for appli-
ances > 10,000 Btuh
(3 kW) and ≤ 100,000
Btuh (30 kW)
• 36 in (91 cm) for appli-
ances >100,000 Btuh
(30 kW)
• 4 feet (1.2 m) below or
to side of opening;
• 1 foot (30 cm) above
opening
K
Clearance to a
mechanical air supply
inlet
6 feet (1.83 m)
3 feet (91 cm) above
if within 10 feet (3 m)
horizontally
L
Clearance above
paved sidewalk or
paved driveway locat-
ed on public property
7 feet (2.13 m)† 7 feet (2.13 m)
M
Clearance under
veranda, porch, deck,
or balcony
12 inches (30 cm) ‡ 12 inches (30 cm) ‡
1 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
Where it can cause hazardous frost or ice accumulations on adjacent property surfaces.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.
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31
WATER HEATER INSTALLATIONWATER HEATER INSTALLATION
CONDENSATE DRAIN INSTALLATION
Installation must conform with these instructions and local
building codes.
Condensate neutralizer kits are available. Contact your distributor
or Service Agency.
Field supplied materials required for installation include:
• Approved PVC cement and PVC primer.
• 1/2 inch PVC pipe - minimum length to equal the distance
between the water heater and a suitable building drain.
• 1/2 inch PVC fittings (elbows, couplings and adapters)
necessary to install a condensate drain line between the
exhaust/condensate elbow assembly and a suitable building
drain.
• Floor mounted standoffs to brace the drain line.
INSTALLATION NOTES
1. The condensate drains from the water heater’s covered by
this instruction have pH levels between 4.3 and 5.0. Install
a commercially available neutralizing kit if required by local
codes. Lower pH levels are acidic. Do not connect a metal
condensate drain line, such as copper pipe, to the water
heater for this reason.
2. The field installed condensate drain line must not be less
than 1/2 inch PVC in size. The condensate line must slope
to an open drain.
3. Do not install an additional trap in the condensate drain
piping.
INSTALLATION INSTRUCTIONS
1. Ensure the water heater’s Enable/Disable switch is in the
“Disable” position.
2. Install a 1/2 inch PVC condensate drain line between the
condensate drain connection on the heater and a suitable
building drain.
3. Terminate the condensate drain piping with an elbow above
the drain. Ensure that any discharge will exit the condensate
drain line no more than 6 inches (15.2 cm) above a suitable
building drain, or external to the building.
Note: In cold climates it is recommended the condensate
drain be terminated at a suitable drain inside the
building.
4. Ensure the condensate drain line is not elevated above the
condensate drain connection on the exhaust/condensate
elbow.
5. Brace the condensate drain line with floor mounted standoffs
every three feet.
6. Ensure the condensate drains freely during start up. See Start
Up (page 50).
SUPPLY GAS LINE INSTALLATION
Contact your local gas utility company to ensure that adequate
gas service is available and to review applicable installation codes
for your area.
Be sure that the gas meter has sufficient capacity to supply the
rated gas input of the water heater as well as the requirements
of all other gas fired equipment supplied by the meter. If the gas
meter is undersized, the gas company will have to install a
properly sized gas meter.
Fire and Explosion Hazard
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
Excessive gas pressure to gas valve can
cause serious injury or death.
Do not use water heater with any gas
other than the gas shown on the rating
label.
Make sure gas supplied is same type listed on the water heater’s
rating label.
The water heaters covered in this manual are not intended for
operation at higher than 14.0” W. C. (2.49 kPa) for natural and
propane gas supply pressure. See Table 4 (page 11). The water
heaters covered in this manual require supply gas regulators to
maintain required supply gas pressure. Exposure to higher gas
supply pressure may cause damage to the gas controls which
could result in fire or explosion. If overpressure has occurred
such as through improper testing of gas lines or malfunction of
the supply system the water heater’s gas valve must be checked
for safe operation by a Qualified Service Agency.
Ensure supply regulator vent lines and the safety vent valves are
protected against blockage. These are components of the gas
supply system, not the water heater. Vent blockage may occur
during ice storms.
It is important to guard against gas valve fouling from
contaminants in the gas ways. Such fouling may cause improper
operation, fire or explosion. If copper supply lines are used they
must be internally tinned and certified for gas service.
REGULATED GAS
SUPPLY LINE
MAIN GAS
SHUTOFF VALVE
TEE FITTING
PIPE CAP
SEDIMENT TRAP
Figure 29. Supply Gas Line Installation
Ensure all gas pipe is clean on the inside before installation. To
trap any dirt or foreign material in the gas supply line a sediment
trap must be installed as shown in See Figure 29. The sediment
trap must be readily accessible and not subject to freezing
Printed on 5/19/2022 11:24 AM CT
32
conditions. Install in accordance with the recommendations of
the local gas utility company.
SUPPLY GAS LINE SIZING
Minimum required supply gas line sizes are shown in Table 2
(page 10). Depending on the developed equivalent length and/
or the number of appliances connected to a common main, the
size of supply gas lines may have to be increased.
Size the supply/main gas line(s) in accordance with Table 11 or
Table 12. The values given in Table 11 and Table 12 are for straight
lengths of iron pipe at 0.5” W. C. (125 Pa) pressure drop, which
is considered normal for low pressure systems. Note that fittings
such as elbows and tees will add to the pipe pressure drop.
Schedule 40 Steel or Wrought Iron Pipe is the preferred material
for the gas line of this water heater. It is imperative to follow the
sizing recommendations in the latest version of the National Fuel
Gas Code if Corrugated Stainless Steel Tubing (CSST) is used as
the gas line for this water heater.
SUPPLY GAS LINE SIZING U. S. UNITS
Table 11. Supply Gas Line Sizing U.S. Units
LENGTH IN
FEET
NORMAL IRON PIPE SIZES (INCHES)
INPUT IN THOUSANDS BTU/HR
1 1/4” 1 1/2” 2” 2 1/2” 3” 4”
10
1400 2100 3960 6300 11000 23000
20
950 1460 2750 4360 7700 15800
30
770 1180 2200 3520 6250 12800
40
660 990 1900 3000 5300 10900
50
580 900 1680 2650 4750 9700
60
530 810 1520 2400 4300 8800
70
490 750 1400 2250 3900 8100
80
460 690 1300 2050 3700 7500
90
430 650 1220 1950 3450 7200
100
400 620 1150 1850 3250 6700
125
360 550 1020 1650 2950 6000
150
325 500 950 1500 2650 5500
175
300 460 850 1370 2450 5000
200
N/A 430 800 1280 2280 4600
SUPPLY GAS LINE SIZING METRIC UNITS
Table 12. Supply Gas Line Sizing Metric Units
LENGTH IN
METERS
NORMAL IRON PIPE SIZES (INCHES)
INPUT IN kW
1 1/4” 1 1/2” 2” 2 1/2” 3” 4”
3.0
410 615 1160 1845 3221 6735
6.1
278 428 805 1277 2255 4626
9.1
225 346 644 1031 1830 3748
12.2
193 290 556 878 1552 3192
15.2
170 264 492 776 1391 2840
18.3
155 237 445 703 1259 2577
21.3
143 220 410 659 1142 2372
24.4
135 202 381 600 1083 2196
27.4
126 190 357 571 1010 2108
30.5
117 182 337 542 952 1962
Table 12. Supply Gas Line Sizing Metric Units
LENGTH IN
METERS
NORMAL IRON PIPE SIZES (INCHES)
INPUT IN kW
1 1/4” 1 1/2” 2” 2 1/2” 3” 4”
38.1
105 161 299 483 864 1757
45.7
95 146 278 439 776 1610
53.3
88 135 249 401 717 1464
61.0
N/A 126 234 375 688 1347
GAS LINE CONNECTION
1. The water heaters covered by this manual are shipped from
the factory with a two-inch supply gas connection. See Table
1 (page 10). Connect the supply gas line to the water heater’s
24 VAC Gas Valve in accordance with all applicable local and
national code requirements.
2. Apply thread sealing compounds (pipe dope/ Teflon tape)
sparingly and only to the male threads of the pipe joints. Do
not apply sealing compound to the first two threads. Use pipe
dope or Teflon tape marked as being resistant to the action
of liquid petroleum (LP/propane) gases.
3. Use only a smooth jaw adjustable wrench (such as a monkey
wrench) as a back up on the body of the 24 VAC Gas Valve
when tightening the first pipe nipple into the body of the valve.
DO NOT use a standard pipe wrench (Stillson wrench) with
metal tooth jaws as this may permanently damage the valve.
4. Use a standard pipe wrench (Stillson wrench) as a back up
on the first pipe nipple installed above when connecting other
fittings and pipe in the supply gas line to prevent 24 VAC Gas
Valve on water heater from twisting during installation.
5. To prevent damage, care must be taken not to apply too much
torque when connecting the supply gas line to the water
heater.
6. Install a sediment trap as shown in Figure 29 (page 31).
7. Install a Main Gas Shutoff valve in the supply gas line as
shown in Figure 29 (page 31).
Note: If overheating occurs or the gas supply fails to shut off,
turn off the Main Gas Shutoff valve to the water heater.
GAS LINE LEAK TESTING
Fire and Explosion Hazard
Leak test gas connections before
placing water heater in operation.
Disconnect gas piping at main
gas shutoff valve before leak
testing heater.
Install sediment trap in
accordance with NFPA 54.
Use joint compound or Teflon tape
compatible with propane gas.
Any time work is done on the gas supply system perform a leak
test to avoid the possibility of fire or explosion.
1. For test pressures exceeding 1/2 psi (3.45 kPa) disconnect
the water heater and its Main Gas Shutoff Valve from the gas
supply piping system during testing. See Figure 29 (page 31).
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The gas supply line must be capped when disconnected from
the water heater.
2. For test pressures of 1/2 psi (3.45 kpa) or less, the water
heater need not be disconnected, but must be isolated from
the supply gas line by closing the Main Gas Shutoff Valve
during testing.
3. Paint all supply gas line joints and connections upstream of
the water heater with a rich soap and water solution to test
for leaks. Bubbles indicate a gas leak. Do not use matches,
candles, flame or other sources of ignition for this purpose.
4. Repair any leaks before placing the water heater in operation.
PURGING
Gas line purging is required with new piping or systems in which
air has entered. Purging should be performed per the current
edition of NFPA 54 the National Fuel Gas Code.
ELECTRICAL WIRING
All electrical work must be installed in accordance with the National
Electrical Code, ANSI/NFPA 70 or the Canadian Electrical Code, CSA
C22.1 and local requirements.
When installed, the water heater must 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.
If any of the original wire as supplied with the water heater must
be replaced, it must be replaced with 105°C rated wiring or its
equivalent, except in the burner housing. In this case 200°C rated
wire must be used.
DEDICATED POWER WIRING AND BREAKERS
Dedicated power supply wires, ground wiring and dedicated
circuit breakers often prevent electrical line noise and are required
when installing the water heater.
Note: This water heater should not be connected to an electrical
supply with a Ground Fault Circuit Interrupter (GFCI) or
Arc Fault Circuit Interrupter (AFCI) with Integral GFCI
protection as defined in NFPA 70, CSA C22.1 and UL 943.
POWER SUPPLY CONNECTIONS
Read the requirements for the Power Supply (page 13) before
connecting power.
The 120 VAC hot wire from the power supply must connect to
the black jumper wire or the “L1” terminal block location in the
junction box and the 120 VAC neutral wire must connect to the
white jumper wire or the “Neutral” terminal block location in the
junction box for correct polarity. See Figure 30 (page 33).
Power supply connections must be made as follows:
1. Turn off power at the water heater’s enable/disable switch
and the breaker that supplies power to the water heater.
2. Remove the junction box cover. See Figure 1 (page 8) for
junction box location.
3. Connect the 120 VAC hot wire from the power supply to the
black jumper wire or the terminal block location marked “L1”
inside of the junction box located on top of the water heater.
If the black jumper wire is used, make the connection inside
of the junction box with a properly sized wire nut and wrap
electrical tape around the wire nut and wire end. See Figure
30 (page 33) and the wiring diagram Figure 41 (page 64).
4. Connect the 120 VAC neutral wire from the power supply to
the white jumper wire or the terminal block location marked
“Neutral” inside of the junction box located on top of the water
heater. If the white jumper wire is used, make the connection
inside of the tape around the wire nut and wire end. See Figure
30 (page 33) and the wiring diagram Figure 41 (page 64).
Note: If electrical connections are made directly to the
terminal block remove the jumper wires before
making connection.
Connect the ground wire from the power supply to the green
jumper wire or the ground terminal location inside of the
junction box located on top of the water heater. If the green
jumper wire is used, make the connection inside of the
junction box with a properly sized wire nut and wrap electrical
tape around the wire nut and wire end. See the junction box
Figure 30 and wiring diagram Figure 32 (page 38).
5. Replace the junction box cover when connections are
complete.
Note: Do not apply power to the water heater before
installation is complete and the water heater is filled
with water.
Heater Wiring
(Factory Installed)
MOV
Ground
Ground
Terminal
Jumper Wire
L1
Neutral
Figure 30. Junction Box
ENABLE/DISABLE CIRCUIT (FOR BUILDING MANAGE-
MENT SYSTEMS)
The water heaters covered in this manual are equipped with an
enable/disable circuit for use with field supplied external
supervisory controls such as time clocks or Building Management
Systems. The enable/disable circuit may be used to disable
heating operation during periods when the building is unoccupied
or there is no demand for hotwater.
To use the enable/disable circuit it must first be activated by
selecting the “Use External Enable” from the UIM. Field supplied
wiring is then installed between the water heater’s CCB and a
set of “dry contacts” (no voltage or load) on the field supplied
external control.
Note: The water heater’s enable/disable circuit is a switching
circuit only: Do not apply external voltage or connect any
load (IE: relay coil) to this circuit. This will damage the
CCB circuit board and is not covered under the limited
warranty.
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CONNECTING AN EXTERNAL SUPERVISORY CONTROL
The enable/disable circuit is accessed from the CCB’s J17 plug
inside the CCB enclosure. See Figure 1 (page 8) to locate the
CCB enclosure and Figure 40 (page 63) for the CCB layout.
Install field wiring to the enable/disable circuit:
1. Turn off power at the water heater’s enable/disable switch
and the breaker that supplies power to the water heater.
2. Locate the CCB enclosure.
3. Carefully remove the Temperature Probe connectors and CCB
enclosure cover.
4. Locate pins 1 and 2 on the CCB J17 plug. See Figure 40 (page
63).
5. Connect the two field supplied control wires to pins 1 and 2
on the CCB J17 plug.
6. Thread the control wires out of the CCB enclosure with the
other wiring and carefully replace the CCB enclosure cover.
Ensure all wiring is routed through the intended area provided
for strain relief. Ensure no wiring is being pinched.
7. Reinstall the CCB enclosure cover.
8. Route the control wires inside the junction box on the top of
the water heater. See Figure 1 (page 8) to locate the junction
box. Use an available knock-out to route the wires inside the
junction box.
9. Install field supplied control wiring and conduit as required by
national and local codes between the water heater’s junction
box and the external supervisory control. Connect the wiring
from the external control to the control wires inside the junction
box using wire nuts and electrical tape.
10. Connect the control wiring to a set of dry contacts on the
external control. Follow the control manufacturer’s instructions
for making connections.
11. Restore power to the water heater.
12. From the water heaters UIM “Heater Information Screen”
select “Use External Enable” and change to “Yes”. See Figure
1 (page 8) to locate the UIM.
Note: Whenever the external control opens the set of dry
contacts used, water heating operation will be disabled.
Whenever the external control closes the set of dry
contacts used, water heating operation will be enabled. A
diagonal line and circle appears over the thermometer
icon on the UIM when water heating operation is disabled.
See the Status Icons descriptions in Table 14 (page 39).
Note: Ensure the water heater is protected from freezing
temperatures when water heating operation is disabled.
Damage to the water heater caused by freezing
temperatures is not covered under the limited warranty.
WATER LINE CONNECTIONS
The water piping installation must conform to these instructions
and to all local and national code authority having jurisdiction.
Good practice requires that all heavy piping be supported.
Read and observe all requirements in the following sections
before installation of the water piping begins:
1. Mixing Valves (page 14).
2. See Dish-washing Machines (page 14).
3. Temperature-Pressure Relief Valve (page 15).
4. Closed Water Systems (page 14) and Temperature-Pressure Relief
Valve (page 15).
5. For multiple water heater installation. See Water Piping
Diagrams (page 66).
WATER PIPING DIAGRAMS
This manual provides detailed water piping diagrams for typical
methods of application for the water heaters. See Water Piping
Diagrams (page 66).
The water heater may be installed with or without a separate
storage tank. When used with a separate storage tank, the
circulation may be either by gravity or by means of a circulating
pump. When a circulating pump is used, it is important to note
that the flow rate should be slow so that there will be a minimum
of turbulence inside the water heater storage tank.
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 (page
66).
Note: In addition to the factory installed Temperature-Pressure
Relief Valve (T&P valve) on the water heater, each remote
storage tank that may be installed and piped to a water
heating appliance must also have its own properly sized,
rated and approved Temperature-Pressure Relief Valve
installed.
Call the toll free technical support phone number listed on the
back cover of this manual for further assistance in sizing a T&P
valve for remote storage tanks.
THERMOMETERS (NOT SUPPLIED)
Thermometers are installed in the water piping system as a
means of detecting the temperature of the hot water supply at
critical points in the system. Field supplied thermometers should
be obtained and installed. See Water Piping Diagrams (page 66).
WATER (POTABLE) HEATING AND SPACE HEATING
1. All water piping components connected to the water heater
that are for space heating applications shall be suitable for
use with potable water.
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2. Toxic chemicals, such as those used for boiler treatment,
must NEVER be introduced into this system.
3. The water heaters covered in this manual may never be
connected to any existing heating system or component(s)
previously used with non-potable water heating appliance.
4. When the system requires water for space heating that
exceed safe temperatures at domestic water fixtures a mixing
valve must be installed. See Mixing Valves (page 14).
5. These water heaters cannot be used in space heating
applications only.
T&P VALVE DISCHARGE PIPE
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22-
CSA 4.4 and ASME code.
Properly sized temperature-
pressure 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 (T&P) relief valve
by the manufacturer. See Temperature-Pressure Relief Valve (page
15) for information on replacement and other requirements.
Water Damage Hazard
Temperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
•
CAUTION
Install a discharge pipe between the T&P valve discharge opening
and a suitable floor drain. 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.
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.
WATER LEAK PROTECTION
The water heaters covered by this manual have a water leak
detection feature that senses the buildup of water in the vicinity
of the appliance, setting off an alarm to alert the end user.
To use this feature, contact your local distributer or call Technical
Support for assistance in ordering this kit. See the contact
information label on the water heater.
Kit number 100302557
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TEMPERATURE REGULATIONTEMPERATURE REGULATION
HIGH TEMPERATURE LIMIT CONTROL (ECO)
This water heater is equipped with an ECO (energy cut off) non
adjustable high temperature limit switch. The ECO is a normally
closed switch that opens (activates) on a rise in temperature.
The ECO is located inside the Upper Temperature Probe (two
red wires). See Figure 1 (page 8) for location. The ECO switch
contacts will open when the water temperature reaches
approximately 202°F (94°C) and close at approximately 140°F
(60°C).
If the ECO activates (contacts open) due to abnormally high
water temperatures in the storage tank the control system will
immediately de-energize the 24 VAC Gas Valve and end the
current heating cycle. The control system will “lock out” disabling
further heating operation. The control system will display the
“Energy Cut Out (ECO)” Fault message on the LCD screen. It is
important that a Qualified Service Agent be contacted to
determine the reason for the ECO activation before resetting the
ECO. Once the reason has been determined and corrected the
ECO can be reset as follows:
Should the ECO activate, the water temperature must drop below
140°F (60°C) before the control system can be reset. Once the
water temperature has cooled below this point the power supply
to the water heater must be turned off and on again to reset the
control system.
THERMOSTAT CONTROL
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.
Hot water temperatures required for automatic dishwasher and
laundry use can cause scald burns resulting in serious personal
injury and/or death. Table 13 shows the approximate time-to-burn
relationship for normal adult skin.
The temperature at which injury occurs varies with the person’s
age and duration of exposure. The slower response time of
children, the elderly or disabled persons increases the hazards
to them. 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 can be
installed at the water heater or at the hot water taps to further
reduce system water temperature. See Figure 6 (page 14).
Never allow small children to use a hot water tap or 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.
Setting the Operating Set Point at 120°F (49°C) will reduce risk
of scalds. Some States require settings at specific lower
temperatures.
Table 13. Burn Time at Various Temperatures
Water Tempera-
ture
°F (°C)
Time for 1st Degree
Burn
(Less Severe
Burns)
Time for Permanent
Burns
2nd & 3rd Degree
(Most Severe Burns)
110 (43)
(normal shower
temp.)
116 (47) (pain threshold)
116 (47) 35 minutes 45 minutes
122 (50) 1 minute 5 minutes
131 (55) 5 seconds 25 seconds
140 (60) 2 seconds 5 seconds
149 (65) 1 second 2 seconds
154 (68) inantaneous 1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)
The water heaters covered in this manual are equipped with an
electronic control system to regulate the water temperature inside
the storage tank. The control system senses temperature from
two factory installed temperature probes, one installed in the top
of the storage tank and one installed near the bottom. See Figure
1 and Figure 3 (page 8) for location.
The “Operating Set Point” is adjusted to regulate water
temperature inside the storage tank. This is an adjustable user
setting in the control system’s “Temperatures Menu.” This and
all control system menus are accessed through the UIM (user
interface module) located on the front of the water heater. See
Figure 31 (page 37).
The Operating Set Point is adjustable from 90°F (32°C) to 180°F
(82°C). The factory setting is 120°F (49°C). See Operating Set
Point and Differential Adjustment (page 41) for instructions on how
to adjust the Operating Set Point and other user settings.
Set the Operating Set Point at the lowest setting which produces
an acceptable hot water supply. This will always provide the most
energy efficient operation.
INTELLIGENT DEMAND RESPONSE
The water heaters covered by this manual utilize an Intelligent
Demand Response (IDR) when the unit senses a large draw of
hot water. It allows the water heater to reduce the pre-set
differential to a lower setting so the appliance will have a more
rapid response to the draw of hot water to support maintaining
a steady state temperature at the outlet until the call for heat is
satisfied.
This functionality is preset at the factory to enable this feature.
If the feature is not required, it can be disabled in the field through
the user interface module (UIM).
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FIRING RATE MODULATION
The water heaters covered by this manual are capable of
modulating their firing rate. The central control board (CCB)
monitors the water temperature in the tank and regulates the
firing rate to achieve the target temperature setpoint. The firing
rate is dictated by the hot water draw, proximity to the tank
temperature setpoint, and various other temperature limitations.
High Temperature Applications
Higher operating temperatures cause more wear on all water
heaters and will decrease the life span of the water heater.
Consider installing a small booster water heater for high
temperature applications, such as commercial dishwashers, to
raise the outlet temperature from the larger primary water heater
to the desired point of use temperature. Contact your local
distributor or call the technical support phone number listed on
the back cover of this manual for further technical assistance.
Tank Temperature 103°F
Operating Set Point 120°F
Status: Heating
MENU HELP
GAS
OFF
O
N
Figure 31. User Interface Module Tank Temperature/Operating
Setpoint Screen
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CONTROL SYSTEM OPERATIONCONTROL SYSTEM OPERATION
OVERVIEW
The water heaters covered in this manual are equipped with an
electronic control system that regulates water temperature inside
the storage tank. Heating cycles and ignition are managed by
the control system. The ECO (energy cut out), flame sensor,
recirculation flow switch, exhaust flue temperature sensor,
pressure switches and temperature probes are monitored by the
control system. The Combustion Blower, Spark Ignition
Transformer, 24 Volt Gas Valve , 120 volt recirculator, and anode
rods are all powered by the control system.
The main components of the control system are a UIM (user
interface module) and a CCB (central control board). The UIM
is located on the top front side of the water heater. The CCB is
mounted inside a protective enclosure. This unit is equipped with
an Enable/Disable switch. To operate unit, make sure the switch
is set to Enable. See Features and Components (page 7) for location
of these and all water heater components.
POWER
SUPPLY
BOARD
TRANSFORMER
CCB
BOARD
(Not connected)
Figure 32. Control System Components
CONTROL SYSTEM NAVIGATION
All operational information and user settings are displayed and
accessed from the UIM. The UIM houses the control system’s
LCD Touch Display (liquid crystal display).
WI-FI
The water heaters covered in this manual feature a wi-fi
functionality that is enabled at the factory. If wi-fi is not required
for installation, it can be disabled through the iCOMM screen
from the main menu of the UIM.
LOCKOUT FUNCTION
The water heaters covered in this manual feature a lockout
functionality that is disabled at the factory by default. If the lockout
functionality is required by the end user, the initial installer/
contractor can access this functionality and enable it through the
UIM.
THE DESKTOP SCREEN
During normal operation the control system will display the
“Desktop” screen on the LCD Touch Display which is the default
screen. The control system will return to the Desktop screen
when there are no active Fault or Alert conditions or when there
has been no user input for several minutes.
• Manufacturer and water heater model information is displayed
in Title Bar at the top of the Desktop screen. Menu titles are
displayed in the Title Bar when navigating the control system
menus.
• The first temperature shown on the Desktop screen, Tank
Temperature, is the temperature of the water inside the water
heater’s storage tank.
• The second temperature shown on the Desktop screen is the
Operating Set Point. The Operating Set Point is the
temperature at which the control system will maintain the
water inside the storage tank.
• Beneath the Operating Set Point is the “Status” line. The
Status line shows the current operational state of the control
system in real time. See Table 15 (page 39) for a description
of the various operational states.
• The Desktop screen also displays animated “Status Icons” to
convey operational information. See Table 14 (page 39) for
descriptions of the Status Icons.
Tank Temperature 103°F
Operating Set Point 120°F
Status: Heating
GAS
OFF
O
N
HELPMENU
LCD Touch Display
Information
Display
Status Icons
Title Bar
Enable/Disable Switch
Operational menus are multi functional.
Figure 33. User Interface Module (UIM) Desktop Screen
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STATUS ICONS
The Status Icons are displayed on the Desktop screen and
convey operational and diagnostic information. The icons are
described in the table below. See Figure 33 (page 38). Ensure
the water heater is properly grounded. Flame sensing requires
an adequate earth ground. If the water heater is not properly
grounded, it will cause Ignition Failure. See Electrical Connections
(page 53).
Table 14. Status Icons
Icon Description
Water temperature in the tank has fallen. Shaded area of the animated thermometer icon will rise and fall in
response to water temperature in the storage tank as sensed from the Upper and Lower Temperature Probes.
See Figure 1 (page 8) and Figure 3 (page 8) for location of Temperature Probes.
Water temperature in the tank has reached the Operating Set Point. The control system enters the Standby
mode.
The control is unable to initiate a heating cycle. This will happen whenever a Fault condition is detected by the
control system or when the Enable/Disable switch on front panel is in disable position or Building Management
system Enable/Disable circuit is an open circuit. Display will read "Status: Water Heating Disabled". For more
information see Enable/Disable Circuit (For Building Management Systems) (page 33).
The Combustion Blower is being energized.
The Spark Igniter is being energized. See Figure 1 (page 8) and Figure 3 (page 8) for location of the Spark Igniter.
GAS
OFF
O
N
The 24 Volt Gas Valve is being energized.
The control system has sensed flame at the Main Burner from the flame sensor. See Sequence of Operation Flow
Chart (page 54) and Figure 2 (page 8).
The control system has declared a Fault condition and must be inspected/serviced by a Qualified Service Agent.
Fault message details can be viewed in the Current Fault menu. Heating operation is disabled (lock out) until
the condition that caused the Fault is corrected. Power to the water heater must be cycled off and on at the
breaker to reset the control system.
Note: Cycling power will not reset the control system if the condition that caused the Fault has not been
corrected.
The control system has declared an Alert condition and must be inspected/serviced by a Qualified Service
Agent. The water heater will continue to operate during an Alert condition.
OPERATING STATES
The current operational state of the water heater is displayed on
the Desktop screen as the “Status.” The common operational
states are described in the table below. See Figure 33 (page 38)
and Electrical Connections (page 53).
Table 15. Operating States
Status Description
Standby The water heater is not in an active heating cycle. IE: the Tank Temperature is at or above the Operating Set
Point.
Input Verification The control system is conducting a diagnostic check at the beginning of a heating cycle.
Water Heating
Disabled
A Fault condition is detected by the control, the Enable/Disable switch on front panel is in disable position, or
the Building Management system Enable/Disable is an open circuit.
Pre-Purge The Combustion Blower is energized to flush residual flue gases from the combustion chamber prior to ignition.
Spark Igniter
Energized
The Spark Igniter is energized.
Ignition
Activation
The 24 Volt Gas Valve is energized and opens to allow fuel gas to flow to the Main Burner.
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Table 15. Operating States
Status Description
Ignition
Verification
The control system is monitoring the flame sensor for the required minimum flame sensing current.
Ensure the water heater is properly grounded. Flame sensing requires an adequate earth ground. If the water
heater is not properly grounded it will cause Ignition Failure.
Inter-Purge The Combustion Blower is energized to flush residual fuel gas from the combustion chamber after a failed
ignition attempt.
Heating Ignition was successful, flame sensing current has been established. The water in the storage tank is being
heated.
Post-Purge The Combustion Blower is energized to flush residual flue gases from the combustion chamber at the end of
a heating cycle.
Fault The control system has detected a Fault condition. Heating operation is disabled until the Fault condition is
corrected. Power to the water heater must be cycled off and on at the breaker to reset the control system.
Note: Cycling power will not reset the control system if the condition that caused the Fault has not been
corrected.
CONTROL SYSTEM MENUS
From the Desktop screen pressing “Menu” on the LCD Touch
Display will display the “Main Menu” this is where all control
system menus are located. The table below describes the control
system menus.
Table 16. Control Syem Menus
Menu Description
Temperatures Most commonly accessed menu. Contains the Operating Set Point and Differential user settings.
Heater Status This menu displays the current state of all pressure switches and the ECO (open/closed). The on/off status
of the Combustion Blower, gas valve, Spark Igniter, flame sensor and other monitored water heater
components are displayed in this menu.
Display Settings Temperature units (°F or °C), the LCD appearance (brightness/contrast) and backlight delay user adjustable
settings are located in this menu.
iCOMM Displays iCOMM connection information.
Network Interface Displays the Network Address information.
Heater Information Elapsed time of operation, total heating cycle time, heating cycle count, heating on time along with UIM
and CCB software revisions can be viewed in this menu.
Current Fault Displays any current Alert or Fault messages.
Fault History This control system menu retains a list of the last nine (9) Fault and Alert messages with a time stamp.
The newest event will replace the oldest. Faults will clear after 30 days.
Fault Occurrence This control system menu retains a running total of how many times each Fault condition has occurred
since the water heater was first installed. The data does not clear and cannot be reset.
Restore Factory
Defaults
This control system feature allows the user to restore control system user settings to their factory default
settings. Display Settings preferences ARE NOT changed when factory defaults are restored.
Help Screens Text based operational and user information explaining how to change user settings, navigate the control
system menus and icon descriptions.
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USER SETTINGS & CONTROL SYSTEM MENUS
TEMPERATURES MENU
Operating Set Point and Dierential Adjument
The Operating Set Point is adjustable from 90°F (42°C) to 180°F
(82°C). The factory setting is 120°F (49°C). The Differential is
adjustable from 2° to 20°. The factory setting is 8°. These user
settings are accessed from the Temperatures menu. The following
instructions will explain how to adjust these settings and navigate
the control system menus.
When the water temperature sensed by the control system from
the Temperature Probes reaches the Operating Set Point the
control system will end the heating cycle. A heating cycle will be
activated again when the sensed water temperature drops below
the Operating Set Point minus the Differential setting.
Note: Lower Differential settings may cause excessive heating
cycles (short-cycling) which can cause premature failure
of heater components. Set the Differential at the highest
setting which produces an acceptable hot water supply.
Set the Operating Set Point to the lowest setting which
produces an acceptable hot water supply for most efficient
use.
TEMPERATURES MENU
DESCRIPTION/ACTION DISPLAY
From the Desktop screen, press MENU. The "Main Menu"
screen will be displayed.
Tank Temperature 71°F
Operating Setpoint 120°F
Status: Standby
HELP
MANUFACTURER /MODEL INFORMATION
MENU
The Main Menu is where all control system menus are listed.
See Table 16 (page 40) for a complete list and description of
control system menus. Use the Up and Down slidebar to view
all control system menus from the Main Menu.
Press "Temperatures" to access the Temperature menu.
Main Menu
HELPBACK
Temperatures >
Heater Status >
Display Settings >
iCOMM >
Network Interface >
Press Operating Setpoint to access the temperature setpoint
menu.
Press "CHANGE" to activate the adjustment mode for this
menu item.
Note: Higher Temperature settings increase wear and
operating costs. Set the Operating Set Point to the
lowest setting which produces an acceptable hot water
supply. This will always provide the most energy efficient
operation and longer life.
Temperatures
HELPBACK
Operating Setpoint 120°F >
Differential 8°F >
Tank Temperature 120°F
Flue Temperature 90°F
Tank Probe Offset 0°F >
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TEMPERATURES MENU
DESCRIPTION/ACTION DISPLAY
Use the "+" and "-" Buttons to change the current setting.
Press "ACCEPT" to save the new setting. Press "BACK" to
discard changes and return to the previously saved setting.
Note: Use this procedure to change the Differential setting
and other adjustable user settings in the control system
menus.
ACCEPT BACK
Operating Setpoint
MIN
90
°
F
MAX
180
°
F
120
°
F
• Differential Mode - Operating mode with an Intelligent
Demand Response (IDR). This mode allows the water
heater to reduce preset differential to a lower setting so
the appliance will more rapidly respond to large draws
to maintain water outlet temperature. This mode is
enabled at the factory by default, but can be disabled in
the field if required.
• Differential - Adjustable user setting that changes the
tank temperature differential with a range of 2° to 20°F.
The factory setting is 8°F.
• Tank Temperature - Non adjustable. Control system
sensed temperature (averaged from upper & lower
temperature probes).
• Tank Probe Offset - adjustable user setting, range -5°
to +5° (factory setting 0°).
Note: These settings should only be used if hot water
supply temperature varies greatly from the
Operating Set Point setting.
• The Tank Probe Offset is used to calibrate control system
temperature sensing. This can improve the precision of
temperature control in the storage tank and at points of
use. This feature can also be used to compensate for
building recirculation loops (hot water returning to the
storage tank) that may cause the heating cycles to
terminate prematurely.
• Example: If the current temperature from a temperature
probe is 120°F (49°C) and the Offset setting is adjusted
to a value other than 0°, the control system would
calibrate or “offset” the sensed temperature from the
probe and the averaged tank temperature. Heating
cycles would be activated and deactivated based on the
calibrated (offset) temperature. A -5° setting results in
+5° hotter water.
• These settings are adjusted as described in Operating
Set Point and Differential Adjustment (page 41).
Temperatures
HELPBACK
Operating Setpoint 120°F >
Differential Mode Auto >
Differential 8°F >
Tank Temperature 120°F
Flue Temperature 90°F
Tank Probe Offset 0°F >
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43
iCOMM Screen
Description/Action Display
Wi-fi Status - displays status of wi-fi connection.
Ethernet - displays status of Ethernet connection.
iCOMM Server - displays status the iCOMM server.
Wi-fi MAC - displays the wi-fi MAC number.
Ethernet MAC - displays the Ethernet MAC number.
DSN - displays the Device Serial Number (DSN). Used for
registration of the heater.
Wi-fi Strength - displays wi-fi signal strength as a series of bars.
Wi-fi Strength - displays wi-fi signal strength dBm units.
Wi-fi - Wi-fi functionality is enabled at the factory. In the bottom
portion of the menu, the wi-fi can be disabled by selecting the
Enabled> marker and selecting the Disable option. This is the only
item on this screen that can be adjusted. The other items are for
view and information purposes only.
Top of Menu
iCOMM
HELPBACK
Wi-Fi Status Enabled
Ethernet Not Connected
iCOMM Server Not Connected
Wi-Fi MAC A408EA514209
Ethernet MAC 0C84110004CD
DSN AC000W000657938
Bottom of Menu
iCOMM
HELPBACK
Wi-Fi MAC A408EA514209
Ethernet MAC 0C84110004CD
DSN AC000W000657938
Wi-Fi Strength
Wi-Fi Strength dBm
Wi-Fi Enabled >
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44
HEATER STATUS MENU
DESCRIPTION/ACTION DISPLAY
Press Heater Status from the Main Menu to enter this menu.
This menu contains non adjustable operational information.
Use the slidebar to navigate the menu.
• Status - displays the current Operating State. See Table 15
(page 39).
• ECO Contact, Low Gas PS, Blocked Inlet PS, Blocked
Outlet PS - displays the current state of the switch contacts;
open or closed.
• Igniter On, Gas Valve On - displays whether or not the
control system is currently energizing these water heater
components; yes = energized, no = de-energized.
• Flame Detected - displays whether or not the control
system has detected Main Burner flame during ignition
from the flame sensor.
• Blower RPM CMD – displays the controls commanded
blower rpms.
• Blower RPM – displays the actual blower rpms.
• Anode Current, Anode Tank Voltage, Anode Drive
Voltage – displays the powered anodes current and voltage
levels.
Note: Menu displays shown are for informational
purposes only. The actual heater display will vary
dependent upon the operational state of the water
heater.
Top of Menu
Heater Status
HELPBACK
Status: Standby
ECO Contact Closed
Low Gas PS Closed
Blocked Inlet PS Closed
Blocked Outlet PS Closed
Igniter On No
Middle of Menu
Heater Status
HELPBACK
Gas Valve On No
Flame Detected No
Blower RPM CMD 0
Blower RPM 0
Flue ECO Open
Pump Off
Anode Tank Voltage 2.641V
Bottom of Menu
Heater Status
HELPBACK
Anode CCB
Anode Current 51.00mA
Anode Tank Voltage 2.64V
Anode Drive Voltage 3.59V
Anode Module 1:
Anode Current 25mA
Anode Tank Voltage 3.5V
Anode Drive Voltage 4.3V
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Display Settings
Description/Action Display
Press Display Settings from the Main Menu to enter this menu.
This menu contains adjustable display options for viewing
information on the UIM’s LCD screen. Use the Slidebar to
navigate the menu.
• Temperature Units - Adjustable user setting that changes
temperature units display to Celsius °C or Fahrenheit °F.
• Backlight Delay - Adjustable user setting that determines
how long the UIM’s LCD backlight remains illuminated after
a key has been pressed. Available settings are; Always Off,
10, 30 or 60 seconds and Always On.
• Contrast - Adjustable user setting to adjust the UIM’s LCD
screen contrast between text and background.
Note: These settings are adjusted in the same way described
for the Operating Set Point and Differential Adjustment (page
41).
Display Settings
HELPBACK
Temperature Units °F >
Brightness 5 >
Backlight Delay 30s >
Language English
>
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46
Heater Information
Description/Action Display
Press Heater Information from the Main Menu to enter this
menu. This menu contains non adjustable operational
information.
• Elapsed Time - Total accumulated time the control system
(water heater) has been energized.
• Burner On Time - Total accumulated time the control
system has been in the heating operating state; burner run
time.
• Total Cycle Count - Total accumulated count of heating
cycles.
• CCB Version - Software version for central control board.
• Config CRC - Verifies the configuration key matches the
CCB programming.
• UIM Version - Software version for user interface module.
• Use External Enable - Enables/Disables the external
enable circuit.
• External Enable Status - Displays whether or not the
external enable circuit has been activated.
• Ignition Trials - Displays the number of ignition trials
allowed.
Note: Historical data is stored in the configuration key.
If this "key" is replaced during servicing the
historical data will be lost. The data stored in the
new configuration key will no longer reflect the
entire history of the water heater. The configuration
key should never be replaced unless directed by
Technical Support.
The Elapsed Time, Burner On Time and Cycle Count
indicate age, usage and wear.
If the Cycle Count per day is high (divide cycle count by
days to determine cycles per day) or the cycle duration
is short (determine burner on time total minutes, divide
burner on time total minutes by cycle count) consider
raising the Differential setting to avoid short cycling and
excessive component wear. See Operating Set Point and
Differential Adjustment (page 41).
This historical data can also be used to assist facilities
managers in forecasting planned replacement of
equipment to help avoid lengthy and costly hot water
supply interruptions.
Heater Information
HELPBACK
Elapsed Time 0days 0hrs 43mins >
Burner On Time 0days 0hrs 1mins
Use External Enable No >
External Enable Status No
Ignition Trials 3 tries >
Modulation Enabled >
Heater Information
HELPBACK
Ignition Trials 3 tries >
Modulation Enabled >
Total Cycles Counter 2
Ignition Failure Count 1 >
Flame Loss Count 0 >
CCB Version 3.17 >
Heater Information
HELPBACK
Ignition Failure Count 1 >
Flame Loss Count 0
CCB Version 3.17
Config CRC 0xD7A7
UIM Version 2.58
Configuration Raw 0x510C
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47
Current Fault
Description/Action Display
Press Current Fault from the Main Menu to enter this menu.
This menu contains non adjustable operational information.
Use the Slidebar to navigate the menu.
This menu contains the current Fault or Alert error message.
The time the Fault or Alert message occurred appears directly
below. A brief description of what causes the particular Fault
or Alert condition appears below that. Pressing "ADVANCED"
will give more detailed service information and a list of possible
causes for the Fault or Alert condition. See Fault and Alert
Conditions (page 56) for more detailed information and
diagnostic procedures.
If there is no Fault or Alert condition active this menu will not
contain any information, "(none)" will be shown next to Current
Fault in the Main menu.
ADVANCEDBACK
0 days 0 hr 0 min ago
Error Code: A8-1201
Blocked Exhaust
Restriction in exhaust pipe.
Check exhaust pipe and
termination for blockage.
Press the Advanced button for
Fault History
DESCRIPTION/ACTION DISPLAY
Press "Fault History" from the Main Menu to enter this menu.
This menu contains non adjustable operational information.
Use the Slidebar to navigate the menu.
This menu contains a list of the last nine (9) Fault and Alert
messages with a time stamp. The newest event will replace
the oldest. Faults will clear after 30 days.
Press the Fault to view details for each Fault or Alert message
stored.
Fault History
HELPBACK
1: Upper Temp Probe (Open) (47) >
0 days 2 hrs 37 mins ago
2: Hardware Failure (1A) >
0 days 2 hrs 37 mins ago
3: Upper Temp Probe (Open) (47) >
0 days 2 hrs 40 mins ago
Fault Occurrence
DESCRIPTION/ACTION DISPLAY
Press Fault Occurrence from the Main Menu to enter this
menu. This menu contains non adjustable operational
information. Use the Slidebar to navigate the menu.
This menu contains a running total of how many times each
Fault condition has occurred since the water heater was first
installed.
Note: Historical data is stored in the configuration key. If this
"key" is replaced during servicing the historical data will
be lost. The data stored in the new configuration key
will no longer reflect the entire history of the water
heater.
Fault Occurrence
HELPBACK
Ignition Failure 0 >
ECO 0
Low Gas Pressure 1
Blocked Intake Air 1
Blocked Exhaust 1
External Input 0
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Restore Factory Defaults
DESCRIPTION/ACTION DISPLAY
Press Restore Factory Defaults from the Main Menu to enter
this menu.
To restore the adjustable user settings to their factory default
settings press “YES.” The display will show text confirming
the factory default settings have been restored.
Press NO to exit the Restore Factory Defaults menu.
NoYe s
Restore Defaults
Are you sure you want to restore
the system to the factory
defaults?
SERVICE CONTACT INFORMATION
The control system has a discrete menu that Installing contractors
and/or service agents can access to enter contact information
for their customers. This contact information will be displayed
with all Fault and Alert messages.
Service Contact Information
Description/Action Display
From the Desktop Screen (see Figure 33 (page 38)) press and
hold down the middle (unmarked) Operational Button for 30
seconds and then release it. It is located between the "MENU"
and "HELP" buttons.
This will launch a discrete menu where personalized contact
information can be entered.
Using the Slidebar select (highlighted in black) the "Show Contact"
menu item.
Press "ACCEPT" to activate the adjustment mode for this
parameter.
Contact Information
HELPBACK
Show Contact No >
Change Contact Name >
Change Contact Phone >
Current Contact Info:
(000) 000-0000
Press the "+" and "-" Buttons to change the setting from "No" to
"Yes" and press "ACCEPT" to save the new setting.
Note: The Access Code at the bottom of the Service Contact
Information screen is for manufacturing engineering
purposes only. There are no user settings or information
accessed through this menu item.
Contact Information
HELPBACK
Show Contact Yes >
Change Contact Name >
Change Contact Phone >
Current Contact Info:
(000) 000-0000
Press the "Change Contact Name" to enter this menu.
Contact Information
HELPBACK
Show Contact Yes >
Change Contact Name >
Change Contact Phone >
Current Contact Info:
(000) 000-0000
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49
Service Contact Information
Description/Action Display
Press the "+", "-", "<", and ">" icons to enter your name or the
name of your company.
When finished press "ACCEPT" to save the new Contact Name.
The control system will return to the discrete menu.
Follow these same instructions to change the Contact Phone
Number.
ACCEPT
<
>
>
BACK
Change Contact Name
Access Code - Displays access code utilized to enable/disable
screen lock.
Enable Screen Lock - Factory default set to No. When enabled,
prevents access to any screen but the home screen and the
Contact Information screen. This feature restricts access code to
secure the water heater.
Calibration Mode -Used by service agent to adjust the gas valve for
minimum and maximum fire rate.
Calibration Speed - Used by service agents to adjust blower speed
to minimum fire rate if required.
Note: Calibration mode will reset back to No when the contact
information screen is exited either by pressing the Back
button or when the display times out. To be practical, the
installer/field service agent should first go to the Display
Setting screen from the Main Menu and set the Backlight
Delay to 240 (On) before setting Calibration mode.
Bottom of Menu
Contact Information
HELPBACK
(000) 000-0000
Access Code >
Enable Screen Lock No >
Calibration Mode No >
Calibration Speed Min >
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50
START UPSTART UP
PRIOR TO START UP
Installation and start up of this water heater requires abilities and
skills equivalent to that of a licensed tradesman in the field
involved. See Qualifications (page 6).
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN
EXPOSED TO FLOODING OR WATER DAMAGE. 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.
Light the water heater in accordance with the Lighting and Operation
Instruction Label (page 51) and on the water heater.
The water heaters covered by this manual are equipped with an
electronic control system, which automatically sequences the
Combustion Blower, pre and post purging of the combustion
chamber, spark generator, 24 VAC Gas Valve, 120 VAC
recirculator, Main Burner ignition, and flame sensing. See Control
System Operation (page 38). The control system will lock out after
three unsuccessful ignition attempts.
Before attempting start up, thoroughly study and familiarize
yourself with the exact sequence of operation. See the written
Sequence of Operation (page 53) and the Sequence of Operation Flow
Chart (page 54).
Be certain that the water heater is full of water, that air is purged
from the gas and water lines and that there are no leaks in the
gas and water lines. Ensure all inlet water valves are open.
FILLING THE WATER HEATER
Follow these steps to fill the water heater prior to start up.
1. Close the heater drain valve.
2. Open a nearby hot water faucet to permit the air in the system
to escape.
3. Fully open the cold water inlet valve allowing the piping and
water heater to fill with water.
4. Close the hot water faucet opened in Step 2 as water starts
to flow.
INITIAL START UP
Required Te Equipment
• One U-tube manometer, recommended ranges; 0-14” W.C.
(0--3.5 kPa) and 0-35” W.C. (0-8.7 kPa) or pressure gauges.
• One digital manometer can be used in place of U-tube
manometers or pressure gauges. Recommended ranges;
-14.00 to + 14.00” W.C. (0-3.5 kPa) resolution 0.01” W.C. and
0-35” W.C. (0-8.7 kPa) resolution 0.10” W.C.
Note: All test equipment must be acclimated to ambient
temperature before calibration and use.
PREPARATION
1. Using the control system menus, change the Operating Set
Point to the lowest temperature setting. See Operating Set Point
and Differential Adjustment (page 41).
2. Turn the water heater’s Enable/Disable switch to the “Disable”
position.
3. Close the Main Gas Shut Off Valve. See Figure 29 (page 31).
4. Wait five (5) minutes for any residual gas to clear.
5. Connect manometer to the supply gas pressure port on the
gas valve see Figure 34.
On the water heaters covered by this manual there are test
ports for supply pressure readings on the gas valve. Remove
the middle port plug with an Allen wrench and install the
manometer sensing tubing.
6. Open the Main Gas Shutoff Valve.
7. Measure and record the supply gas pressure, this is a “static”
supply gas pressure reading; while the water heater is not
firing. Adjust supply gas pressure as necessary. See Supply
Gas Pressure Adjustment (page 51).
Note: The manometer tubing should be purged before taking
any readings.
2" GAS INLET
PORT #2: SUPPLY-GAS
PRESSURE TEST PORT
OFF-SET ADJUSTMENT
UNDER SCREW COVER
THROTTLE ADJUSTMENT
UINDER BLUE COVER
Figure 34. Location of Gas Supply Pressure Test Port
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51
LIGHTING AND OPERATION INSTRUCTION LABEL
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FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING:
If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal injury
or loss of life.
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to the Enable position.
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to the Disable position.
Set the Enable/Disable switch on the control panel
to the Enable position.
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ELBASID/ELBANE
HCTIWS
Tank Temperature 120°F
Operating Set Point 120°F
Status: Standby
MENU HELP
SUPPLY GAS PRESSURE ADJUSTMENT
Fire and Explosion Hazard
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
Excessive gas pressure to gas valve can
cause serious injury or death.
Do not use water heater with any gas
other than the gas shown on the rating
label.
Supply gas pressure shall be measured while the water heater
is not firing (static pressure) AND while the water heater is firing
at full capacity (dynamic pressure).
If the supply gas pressure to the water heater is not between the
required minimum and maximum values given in Table 4 (page
11) adjust the supply gas regulator as necessary. Adjust the
supply gas regulator(s) per the regulator manufacturer’s
instructions to achieve the required “static” and “dynamic” supply
gas pressure.
Multiple Appliance Inallations:
In multiple water heater installations or in installations where the
installed water heater(s) share a common gas supply main with
Printed on 5/19/2022 11:24 AM CT
52
other gas fired appliances; the supply gas pressures shall be
measured at each water heater with all gas fired appliances
connected to a common main firing at full capacity.
On multiple water heater installations the supply gas line
regulators shall be adjusted to provide gas pressure to each
water heater within the minimum and maximum supply pressure
requirements listed in Table 4 (page 11) with all gas fired
appliances connected to a common gas main firing at full capacity.
Note: A pressure drop of more than 1.5” W. C. (0.37 kPa) when
the Main Burner ignites is an indication of an inadequate
supply of gas and can lead to ignition failure, rough starts
and/or rough operation. If a drop of more than 1.5” W. C.
(0.37 kPa) in supply gas pressure occurs when the Main
Burner ignites, ensure the supply gas lines and regulator(s)
are properly sized and installed. See Supply Gas Regulator
(page 13) and Supply Gas Line Requirements (page 13). See
Supply Gas Line Installation (page 31) and Supply Gas
Regulator (page 13). Ensure all requirements and
installation instructions are maintained.
CHECKING THE FIRING RATE
Follow these instructions to determine the actual firing rate of
the water heater:
Note: The heaters covered by this manual are capable of
modulating their firing rate. The firing rate should be
checked with the heater operating at it’s full firing rate.
1. Ensure there are no other gas fired appliances connected to
the gas meter firing during this test.
2. Contact the gas supplier to determine the heating value, in
Btu per cubic foot, of the gas supply.
3. Start the water heater and ensure it is firing.
4. Locate the gas meter serving the water heater.
5. Time how long (in seconds) it takes for one cubic foot of gas
to be used while the water heater is firing with a stop watch.
6. Use the formula below to “clock” the gas meter and determine
the actual firing rate of the water heater based on the heating
value (Btu per cubic foot) of the gas supply:
x H = Btu/hr
3600
T
x 1050 = 756,000 Btu/hr (221.6 kW)
Example:
3600
5.0
• 3600 = seconds in one hour.
• T = time, in seconds, to burn one cubic foot of gas.
• H = heating value of gas in Btu per cubic foot.
• Btu/hr = actual firing rate of the water heater.
Note: 1050 Btu per cubic foot is a standard value for natural
gas. Standard propane gas Btu content is 2500 Btu
per cubic foot. Btu values may change in certain
areas and at high elevations. Check with the local
gas utility company.
TO TURN OFF GAS SUPPLY
1. Change the Operating Set Point to the lowest temperature
setting. See Operating Set Point and Differential Adjustment (page
41).
2. When the water heater has completed its shut down sequence
and enters the standby mode, turn the water heater’s Enable/
Disable switch to the “Disable” position. When in the “Disable”
position the switch only removes electrical power from the
gas valve so that water heating is disabled. The display, CCB,
and other electrical components will still be energized and the
display will read “Water Heating Disabled”.
3. Close the Main Gas Shutoff Valve. See Figure 29 (page 31).
HIGH ALTITUDE INSTALLATIONS
The water heaters covered by this manual are certified for use
without modification for altitudes up to 10,100 feet unnecessary
to install high altitude orifices.
Fire and Explosion Hazard
Gas and carbon monoxide detectors are
available.
Overfiring could result in fire or
explosion.
Under no circumstances should the
input exceed the rate shown on the
water heater’s rating label.
Breathing Hazard - Carbon Monoxide Gas
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Under no circumstances should
the input exceed the rate shown
on the water heater’s rating label.
Overfiring could result in damage to
the water heater and sooting.
Gas and carbon monoxide detectors
are available.
Note: The actual firing rate of the water heater must not exceed
the input rating on the water heater’s rating label under
any circumstances.
Note: Due to the input rating reduction at high altitudes, the
output rating of the water heater is also reduced and should
be compensated for in the sizing of the equipment.
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53
TROUBLESHOOTINGTROUBLESHOOTING
INSTALLATION CHECKLIST
The list below represents some of the most critical installation
requirements that, when overlooked, often result in operational
problems, down time and needless parts replacement. This is
not a complete list. Before performing any troubleshooting
procedures use the list below to check for installation errors.
Costs to correct installation errors are not covered under the
limited warranty. Ensure all installation requirements and
instructions in this manual have been maintained and followed.
WATER HEATER LOCATION
1. Ensure proper clearances to combustibles are maintained
and there is sufficient room to service the water heater. See
Clearance To Combustible Materials (page 11).
2. Ensure the area is free of corrosive elements and flammable
materials. See Locating the Water Heater (page 11).
VENTING
1. Ensure the intake air and/or vent (exhaust) piping is the correct
size for the installed length. See Venting Requirements (page
22).
2. Ensure the maximum equivalent feet of pipe has not been
exceeded for the intake air and/or vent pipe. See Maximum
Equivalent Lengths (page 22).
3. Ensure the maximum number of elbows has not been
exceeded in the intake air and/or vent pipe. See Venting
Requirements (page 22).
4. Ensure the intake air screen is removed from the intake air
connection on the water heater when installing the water
heater in a Direct Vent configuration. See Figure 15 (page 24).
5. Ensure all exterior clearances for the intake air, vent,
terminations are maintained. See the following as appropriate:
• Vertical Termination Installation (page 24).
• Sidewall Termination Installation (page 25).
These clearances and those cited by local and national codes
must be maintained.
GAS SUPPLY AND PIPING
1. Ensure a supply gas regulator has been installed for each
water heater. See the requirements for a Supply Gas Regulator
(page 13).
2. Ensure the supply gas line to each water heater meets the
minimum supply gas line size requirements. See Supply Gas
Line Requirements (page 13) and the Supply Gas Line Installation
(page 31).
CONDENSATE DRAIN
Ensure that the condensate drain is properly connected to the
the water heater to prevent vent gases from escaping into the
installed space and drains freely to a suitable floor drain. See
Figure 7 (page 16) and Condensate Drain Installation (page 31).
ELECTRICAL CONNECTIONS
1. Ensure that the power supply connections to the water heater
are polarity correct. See the requirements for the Power Supply
(page 13) and Electrical Wiring (page 33).
2. Ensure that the water heater is properly grounded. Flame
sensing requires an adequate earth ground. If the water heater
is not properly grounded it will cause Ignition Failure.
SEQUENCE OF OPERATION
Read the Sequence of Operation below before attempting to
correct any operational problems. See Features and Components
(page 7) for the location of various water heater components
described below. See the Sequence of Operation Flow Chart (page
54) also.
1. When the control system is first powered, during boot up, it
will display water heater model information during initialization.
After a few moments the control system LCD which is part of
the UIM (user interface module) will display the default screen
known as the “Desktop” screen.
2. If the control system determines that the actual water
temperature inside the tank is below the programmed
Operating Set Point minus the Differential setting, a heating
cycle is activated.
3. The control system then performs selected diagnostic system
checks. This includes confirming that the recirculation flow
switch is open and that the blocked exhaust, blocked intake
and ECO (energy cut out) switch contacts are closed.
4. If all diagnostic checks are successfully passed, the control
system energizes the Combustion Blower for pre-purge.
5. The control system energizes the spark ignition control.
6. The control system energizes the 24 VAC Gas Valve allowing
gas to flow to the Main Burner.
7. The control system 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 the control system will try for
ignition up to two more times. If flame can not be verified after
three trials for ignition, the control system will lock out and
display the “Ignition Failure” Fault message.
8. If a flame is verified, the control system will de-energize the
Spark Ignition Control, energize the recirculator, and enter the
heating mode where it will continue heating the water until it
reaches the Operating Set Point. At this point, the control
system will de-energize the 24 VAC Gas Valve, de-energize
the recirculator after a 5 second delay, and then enter the
post-purge cycle (approximately 30 seconds).
9. The water heaters covered by this manual are capable of
modulating their firing rate. The firing rate is dictated by the
hot water draw and various other temperature limitations.
10. The Combustion Blower will run for the duration of the post-
purge cycle to purge the water heater of all combustion gases.
When the post-purge cycle is complete, the blower is de-
energized and will coast to a stop.
11. The control system now enters the standby mode while
continuing to monitor the internal storage tank water
temperature and the state of other system devices. If the tank
temperature drops below the Operating Set Point minus the
Differential setting, the control will automatically return to Step
2 and repeat the operating cycle.
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54
SEQUENCE OF OPERATION FLOW CHART
YES NO
120 V Recirculator
is energized
24 Volt Gas Valve
de-energized
Inter-Purge cycle
24 Volt Gas Valve
de-energized
Retries up to
two more times
Post-Purge cycle
Control System
Locks Out
“Ignition Failure”
Fault Msg is
displayed
Water heater goes
into standby mode
If tank temperature drops below Operating Set Point minus
Differential setting a heating cycle is activated
Spark Ignition Transformer is energized
24 Volt Gas Valve is energized
gas flows to Main Burner
Is flame sensed at the Main Burner?
(control system monitors the flame sensor)
Control System Locks Out
Displays Fault Msg
NO
Combustion Blower is energized
Pre-Purge cycle
Sequence is shown with Enable/Disable Switch in the Enable position
Control System performs diagnostic checks.
Normal state of all pressure switches, the flow switch, and
the ECO are checked.
Pressure Switches and the ECO are verified closed.
Water is heated to
set point
120 V Recirculator is
de-energized after
5-second delay
Figure 35. Sequence of Operation
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55
OPERATIONAL PROBLEMS
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.
This section of the manual is intended to be an aid in correcting
common operational problems, it is not all inclusive. The installer
may be able to observe and correct certain problems which might
arise when the water heater is first put into operation or when it
is re-fired after a prolonged shutdown. However, only qualified
service agents, as defined in Qualifications (page 6), using
appropriate test equipment, should perform any service
procedures on the water heater.
Note: Call the technical support phone number listed on the back
cover of this manual for further technical assistance or to
locate a qualified service agent in your area.
INSTALLATION ERRORS
Operational problems on new installations are often the result of
installation requirements that have been overlooked rather than
failed components. IE: A “Low Gas Pressure” Fault condition is
most often caused by low supply gas pressure rather than a
defective Low Gas Pressure switch. Rough starting and rough
operation are often caused by undersized supply gas lines and/
or the absence of a supply gas regulator at the water heater.
Prior to performing any operational checks inspect the water
heater installation to ensure all installation requirements and
instructions have been maintained and followed. See the
Installation Checklist on (page 53).
Note: Costs to correct installation errors are not covered under
the limited warranty.
ROUGH STARTING, ROUGH OPERATION
Fire and Explosion Hazard
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
Excessive gas pressure to gas valve can
cause serious injury or death.
Do not use water heater with any gas
other than the gas shown on the rating
label.
• Undersized supply gas line (low volume of supply gas). See
Power Supply (page 13).
• Supply gas regulator is not installed per installation
requirements (erratic gas supply volume/pressures). See
Supply Gas Regulator (page 13).
• Excessive supply gas pressure. See Table 4 (page 11) and
Supply Gas Pressure Adjustment (page 51).
• Vent (exhaust) gas recirculation at the vent and intake air pipe
terminations on Direct Vent installations. See Direct Vent
Installation (page 23).
• Excessive equivalent lengths of intake air and/or vent
(exhaust) piping installed. See Venting Requirements (page 22).
• Debris clogging/blocking the intake air screen(s). See Figure
15 (page 24) and Figure 19 (page 26).
• Debris clogging/blocking the Main Burner. See Figure 2 (page
8).
MOMENTARY IGNITION
Burn Hazard
Do not reach into the burner housing or
combustion chamber if the water heater
is still hot.
•
Allow the water heater to cool and always use
gloves when handling the main burner.
•
•
The combustion chamber and burner sleeve
and housing become very hot during operation.
CAUTION
If the Main Burner ignites momentarily but does not sustain
ignition allow the water heater to try to ignite up to two more times
until control system locks out and the Ignition Failure Fault
message is displayed on the control system’s LCD. If the water
heater is experiencing rough starts, see Rough Starting, Rough
Operation on this page. For momentary ignition problems without
rough starting check the following:
• Undersized supply gas line (low volume of supply gas). See
Supply Gas Line Installation (page 31).
• Supply gas regulator is not installed per installation
requirements (erratic gas supply volume/pressures) . See
Supply Gas Regulator (page 13).
• See the list of possible causes and things to check and repair
for the Ignition Failure fault message in Fault and Alert Conditions
(page 56).
• Debris clogging/blocking the intake air screen(s. See Figure
15 (page 24) and Figure 19 (page 26).
• Debris clogging/blocking the Main Burner. See Figure 2 (page
8).
NOT ENOUGH OR NO HOT WATER
• No power to the water heater, check breaker or fuses.
• Enable/Disable switch in “Disabled” position. Set to “Enable”
to allow unit to operate.
• Hot water supply valve(s) to fixtures closed.
• Operating Set Point is set too low, Differential setting is set
too high. See Control System Operation (page 38).
• Tank Probe Offset is causing the heating cycles to terminate
prematurely. See Temperatures Menu (page 41).
• The heating capacity of the water heater has been exceeded,
the water heater is unable to meet demand.
• Colder incoming water temperature lengthening the time
required to heat water to desired temperature.
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56
• Hot water piping leaks, open faucets, water heater drain valve
leaking or open.
• Sediment or lime scale accumulation may be affecting water
heater operation. See Maintenance (page 59) for sediment and
lime scale removal procedures.
• Water heater not firing at full input rating. Check actual firing
rate of the water heater. See Checking the Firing Rate (page 52).
Note: The water heaters covered by this manual are
capable of modulating their firing rate. The firing rate
is dictated by the hot water draw and various other
temperature limitations.
WATER IS TOO HOT
• Operating Set Point is set too high. See Operating Set Point and
Differential Adjustment (page 41).
• If installed check Thermostatic Mixing Valve settings.
• Tank Probe Offset setting improperly set. See Temperatures
Menu (page 41).
• Lime build-up on temperature probes. Inspect and clean.
• Improper water piping. See Water Piping Diagrams (page 66).
NOISY OPERATION
• Sediment or lime scale accumulations can cause rumbling
and pounding noises during heating cycles. See Maintenance
(page 59) for sediment and lime scale removal procedures.
• Normal operating noise of electrical components; Combustion
Blower, transformer hum, relay contact closure.
WATER LEAKAGE IS SUSPECTED
• Ensure the water heater drain valve is tightly closed.
• Check cleanout opening for leaks. See Figure 1 (page 8).
• Check inlet/outlet water connections and system piping.
• Check the Temperature-Pressure Relief Valve.
• Excessive water temperature.
• Excessive water pressure.
• Defective Temperature-Pressure Relief Valve.
Note: Excessive water pressure is the most common cause of
Temperature-Pressure Relief Valve leakage. Excessive
water system pressure is most often caused by “thermal
expansion” in a “closed system.” See Closed Water Systems
(page 14) and Temperature-Pressure Relief Valve (page 15).
The Temperature-Pressure Relief Valve is not intended
for the constant relief of thermal expansion.
Temperature-Pressure Relief Valve leakage due to pressure build
up in a closed system that does not have a thermal expansion
tank installed is not covered under the limited warranty. Thermal
expansion tanks must be installed on all closed water systems.
REPLACEMENT PARTS
Replacement parts may be ordered from the manufacturer,
authorized service agencies or distributors. When ordering parts
be sure to have the complete water heater Model Number, Serial
Number and Series Number available. This information can be
found on the rating label affixed to the water heater.
See the parts list included with the water heater from the factory
for more information or call the parts department or technical
support phone number listed on the back cover of this manual
for further assistance.
FAULT AND ALERT CONDITIONS
FAULT CONDITIONS
When the control system declares a Fault condition it will display
a Fault message on the control system’s LCD with an exclamation
“!” mark. The control system will lock out and disable heating
operation until the condition is corrected. The water heater must
be serviced by a qualified service agent before operation can be
restored.
ALERT CONDITIONS
When the control system declares an Alert condition it will display
an Alert message on the control system’s LCD with a question
“?” mark. The water heater will continue to operate during an
Alert condition but the water heater must be serviced by a
qualified service agent as soon as possible.
RESETTING CONTROL SYSTEM LOCK OUTS
To reset the control system from a lock out condition; turn the
electrical power supply off for approximately 20 seconds and
then back on. Keep in mind; if the condition that caused the Fault
has not been corrected, the control system will continue to lock
out.
DIAGNOSTIC CHECKS
Turn off power at the branch circuit
breaker serving the water heater
before performing any service.
Electrical Shock Hazard
•
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.
•
The following section Fault And Alert Messages (page 57) lists some
of the messages the control system will display on the LCD when
there are operational problems. This is not a complete list. Along
with each of the Fault and Alert messages described there will
be a list of possible causes and things to check and repair.
Only qualified service agents, as defined in Qualifications (page
6), using appropriate test equipment, should perform any service
procedures on the water heater.
Note: If you are not qualified and licensed or certified as required
by the authority having jurisdiction to perform a given task
do not attempt to perform any of the diagnostic or service
procedures described in the following section.
If you do not understand the instructions in the following section
do not attempt to perform any procedures.
Call the technical support phone number listed on the back cover
of this manual for further technical assistance or to locate a
qualified service agent in your area.
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57
Jumping out control circuits or components can
result in property damage, personal injury or death.
Service should only be performed by a qualified service
technician 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.
•
Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the appliance warranty.
FAULT AND ALERT MESSAGES
Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualified service
agent in your area.
Possible Causes - Check/Repair Displayed Fault/Alert Message
• Using a manometer, ensure that gas supply pressure is
above minimum requirement listed on heater’s data plate
and does not drop more than 1.5” W.C. when unit
fires.
• Ensure wire connections to gas valve are clean and tight.
• Ensure wire connections to flame sensor are clean and
tight.
• Ensure wire connections to spark igniter are clean and
tight.
• Inspect flame sensor, clean/replace as needed.
• Inspect spark igniter, realign igniter gap as needed
• Ensure adequate electrical ground to heater.
ADVANCEDBACK
0 days 0 hr 0 min ago
Error Code: B2-70
Ignition Failure
Flame not detected. Clean flame
rod. Check gas supply.
Press the Advanced button for
more information
• Confirm that the CCB’s pump contact function properly by
detecting the 120V present or not at the recirculator after
the flame icon shows up on UIM).
• Confirm the flow switch mounted correctly ( the flow arrow
pointing vertically upward) and function properly.
• Confirm the recirculator is installed properly (flow pointing
downward) and operate properly.
• Check water flow blockage at the recirculator’s impeller
area and inside the secondary heat exchanger.
• Flow switch malfunction, failed to “close” at water flowing.
Replace flow switch.
ADVANCEDBACK
0 days 0 hr 0 min ago
Error Code: 175-0
Flow Not Detected
Flow was not detected when in
heating state.
Press the Advanced button for
more information
Check the following:
• The power supply connection to CPAM
• The cable between CCB and CPAM
ADVANCEDBACK
0 days 0 hr 0 min ago
Error Code: 1C-101
Module Disconnected
CCB is expecting a module attached to
AIN communications and is not present.
Press the Advanced button for more
information.
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58
Possible Causes - Check/Repair Displayed Fault/Alert Message
• If the Blocked Intake error occurs before blower runs, make
sure the pressure switch connections are clean and tight.
Check the pressure switch continuity/resistance. The
switch should be closed (continuity/0 ohms). Replace the
switch if it is open (no continuity).
• If the Blocked Intake error occurs when blower is running,
check for restrictions in intake pipe, including intake-air
connection, outside termination, and inlet condensate
drains (if installed).
• Other possible causes: high wind conditions and excessive
negative air pressure in building.
CHANGE BACK
ADVANCED
Blocked Air Intake
Fault occurred 2 mins ago
Restriction in air intake. Check
intake pipe and termination for
blockage.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
• Ensure that the wire connections to the upper temperature
probe are clean and tight.
• Using a thermometer, check the water temperature of the
water heater.
• Use a multi-meter and check for continuity between the
two red wires of the upper temperature probe.
• If the two red wires are open (no continuity) and water
temperature is below 160°F, replace upper temperature
probe.
• If the water temperature exceeds 195°F, turn off the electric
power and gas supply and call Tech Support for further
instructions.
ADVANCEDBACK
0 days 0 hrs 0 mins ago
Error Code: A5 - 401
High Temp Limit Exceeded
Energy Cut Off has shut off
water heater due to high tank
temperature.
Press the Advanced button for
• Flow switch should be remain “open” during standby.
• Confirm the switch is set at “Open” (factory default).
• Confirm the switch is installed correctly with flow arrow
pointing upward vertically.
• Remove & inspect the flow switch’s vane free from any
debris.
• Replace the switch if malfunction detected.
ADVANCEDBACKACCEPT
0 days 0 hrs 0 mins ago
Error Code: D6 -8
Flow Switch Stuck Closed
Flow switch should be open
when heater is in standby state.
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59
MAINTENANCEMAINTENANCE
GENERAL
Keep water heater area clear and free from combustible
materials, gasoline, and other flammable vapors and liquids. See
Locating the Water Heater (page 11).
Water heater maintenance includes periodic tank flushing and
cleaning, and removal of lime scale. The water heater should be
inspected and adjusted to maintain proper combustion. See Initial
Start Up (page 50). A periodic inspection of the venting system
should be made. Where used, water circulating pump(s) should
be oiled according to the pump manufacturers recommendations.
PRECAUTIONS
Do not operate the water heater if it has
been exposed to or exhibits the following:
Exposed to flooding or water damage
.
•
External damage.
•
Firing without water.
•
Sooting.
•
Do not operate the water heater until all corrective steps
have been made by a qualified service technician.
CAUTION
Never operate the water heater without first being certain it is
filled with water and a properly sized and rated Temperature-
Pressure Relief Valve is installed in the relief valve opening on
the water heater. See Temperature-Pressure Relief Valve (page 15).
Explosion Hazard
Overheated water can cause
water tank explosion.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
If overheating occur or the gas supply fail to shut off, turn off the
Main Gas Shutoff valve. See Figure 29 (page 31).
MAINTENANCE SCHEDULE
Table 17. Maintenance Schedule
Component Operation Interval Reference
Tank Drain and Flush Every 6 Months See Draining and Flushing.
Tank
Lime Scale Removal
(Water Less Than
25 Grains Hard)
Not Required N/A
Tank
Lime Scale Removal
(Water Greater Than
25 Grains Hard)
Annually
See Lime Scale Removal
(page 60).
Burner Flames Inspection Every 3 Months
See Burner Flame Inspection
(page 60).
Burner Inspection/Cleaning As Needed
Contact qualied agency or
professional.
Moving Parts Lubrication Not Required N/A
Powered
Anodes
Inspection/Cleaning Annually
See Powered Anodes Mainte-
nance (page 61).
T&P Valve Test Operation Semi Annually
See Temperature-Pressure
Relief Valve Test (page 61).
Table 17. Maintenance Schedule
Component Operation Interval Reference
Vent System Inspection Annually
See Vent System Maintenance
(page 62).
Condensate
Neutralization
Inspection Annually
See manual for the conden-
sate neutralization kit.
Condensate
Collection
Cleaning Annually
See Vent System Maintenance
(page 62).
DRAINING AND FLUSHING
It is recommended that the water heater storage tank be drained
and flushed every 6 months to reduce sediment buildup. The
water heater should be drained if being shut down during freezing
temperatures. See Features and Components (page 7) for the
location of the water heater components described below.
Burn hazard.
Hot water discharge.
Keep hands clear of drain
valve discharge.
To drain the water heater orage tank:
1. Turn the Enable/Disable switch located on the front of the
heater to the Disabled position.
2. Turn off the electrical supply to the water heater.
3. Turn off the gas supply at the Main Gas Shutoff Valve if the
water heater is going to be shut down for an extended period.
4. Ensure the cold water inlet valve is open.
5. Open a nearby hot water faucet and let the water run until the
water is no longer hot.
6. Connect a hose to the water heater drain valve and terminate
it to an adequate drain.
7. Close the cold water inlet valve.
8. Open the water heater drain valve and allow all the water to
drain from the storage tank.
9. Close the water heater drain valve when all water in the
storage tank has drained.
10. Close the hot water faucet opened in Step 4.
11. If the water heater is going to be shut down for an extended
period, the drain valve should be left open.
To Flush the tank perform the following eps:
1. Turn the Enable/Disable switch located on the front of the
heater to the Disabled position.
2. Turn off the electrical supply to the water heater.
3. Ensure the cold water inlet valve is open.
4. Open a nearby hot water faucet and let the water run until the
water is no longer hot. Then close the hot water faucet.
5. Connect a hose to the drain valve and terminate it to an
adequate drain.
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60
6. Ensure the drain hose is secured before and during the entire
flushing procedure. Flushing is performed with system water
pressure applied to the water heater.
7. Open the water heater drain valve to flush the storage tank.
8. Flush the water heater storage tank to remove sediment and
allow the water to flow until it runs clean.
9. Close the water heater drain valve when flushing is completed.
10. Remove the drain hose.
11. Fill the water heater. See Filling The Water Heater (page 50).
12. Turn on the electrical supply to place the water heater back
in operation.
13. Allow the water heater to complete several heating cycles to
ensure it is operating properly.
SEDIMENT REMOVAL
Waterborne impurities consist of the particles of soil and sand
which settle out and form a layer of sediment on the bottom of
the tank.
For convenience, sediment removal and lime scale removal
should be performed at the same time.
LIME SCALE REMOVAL
When water is heated dissolved minerals in the water such as
calcium and magnesium carbonate (lime scale) become less
soluble. As the water temperature rises these minerals will
precipitate or “fall out” of solution.
The amount of lime scale released from water is in direct
proportion to water temperature and usage. The higher the water
temperature or water usage, the more lime deposits are dropped
out of the water.
Water hardness also affects lime scale accumulation. With the
temperature and usage being the same, hard water will release
more lime scale than softer water.
Lime scale reduces heating efficiency as it accumulates inside
a water heater. Heating transfer surfaces become coated with
lime scale deposits which increases fuel costs to operate the
water heater. Lime scale deposits can also cause rumbling and
pounding noises as air molecules trapped in the lime scale
escape when heated. Lime scale accumulation also reduces the
life span of water heaters. For these reasons a regular schedule
for deliming should be set up.
The depth of lime accumulation in the bottom of the water heater
should be measured periodically. Inspect by removing the
cleanout cover once every 6 months at first. Deliming maintenance
should then be performed based on the time it takes for 1 inch
(2.5 cm) of lime to accumulate in the bottom of the water heater.
Sediment and lime scale removal may be accomplished manually
through the cleanout opening furnished on the water heater. See
Figure 38.
MANUAL LIME SCALE REMOVAL
Note: Contact your local distributor or call the parts department
phone number on the back cover of this manual to order
a new cleanout gasket. Have the new gasket available
before removing the cleanout cover.
The cleanout opening is shown in Figure 55. To remove lime
scale manually through the cleanout opening proceed as follows:
1. Turn off the electrical supply to the water heater.
2. The water heater must be drained. See Draining and Flushing
(page 59). Follow the instructions on how to drain the water
heater.
3. Remove outer cleanout access panel from lower side of the
water heater jacket.
4. Remove the cleanout cover from cleanout opening.
5. Remove lime, scale and/or sediment using care not to damage
the glass-lining.
6. Install a new cleanout gasket if required.
7. Reinstall the cleanout cover. Be sure to draw plate up tight
by tightening screws securely.
8. Close the water heater drain valve.
9. Fill the water heater. See Filling The Water Heater (page 50).
10. Turn on the electrical supply to place the water heater back
in operation. See Initial Start Up (page 50).
11. Allow the water heater to complete several heating cycles to
ensure it is operating properly.
12. Check for water leakage.
13. Reinstall the cleanout access panel.
CHEMICAL LIME SCALE REMOVAL
To dissolve and remove more stubborn lime scale deposits, UN-
LIME® Professional Delimer should be used.
UN-LIME® Professional Delimer is an easy to handle patented
food grade acid formulated specifically for lime scale removal
from all types of water using equipment. Hydrochloric base acids
must not be used to delime the water heaters covered in this
manual.
Follow the instructions on the UN-LIME® to delime the water
heater.
Note: Call the parts department phone number on the back cover
of this manual to order UN-LIME® Professional Delimer.
See Table 18 for part numbers.
Table 18. UN-LIME
®
Professional Delimer
Part Number Description
100110459 4 - 1 gallon (case)
100110460 1 - 5 gallon
BURNER FLAME INSPECTION
Check main burner every three months for proper flame
characteristics. You can see the burner flame through the sight
glass on top of the burner plate. To access the sight glass, you
must remove the plastic cover.
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61
Sight
Glass
Location
Inlet Air
Connection
Figure 36. Location of Sight Glass
The main burner should display the following characteristics:
• Provide complete combustion of gas.
• Cause rapid ignition and carry over of flame across entire
burner.
• Give reasonably quiet operation during initial ignition,
operation and extinction.
• Cause no excessive lifting of flame from burner ports. See
Figure 36.
Figure 37. Normal and Abnormal Burner Flames
If the preceding burner characteristics are not evident, check for
accumulation of lint or other foreign material that restricts or
blocks the air intake fitting or air intake terminal.
To ensure continued good performance, keep the area around
the water heater clean and free from lint and debris. Sweep the
floor around the water heater regularly. This will reduce the dust
and dirt which can enter the burner and heat exchanger, causing
improper combustion and sooting.
If the air intake fitting and air intake terminal are clear and the
burner continues to exhibit abnormal flames, contact a qualified
service agency or have a qualified service professional inspect
and clean the burner.
POWERED ANODES MAINTENANCE
To insure a long, trouble-free operating life, the water heaters
covered in this manual are factory equipped with a powered
anode system. The anode rods are of a permanent design and
do not need replacing unless damaged. Inspection and cleaning
should be performed once a year.
1. Follow the instructions in drain the water heater in Draining and
Flushing (page 59) first.
2. Remove the powered anodes from the water heater by
loosening the 3/4” NPT bushing that forms the top of the
anodes. Do not disassemble the retaining nut and wire
terminal from the top while installed in the water heater. The
anode’s electrode may fall inside the tank.
3. Remove the entire anode rod from the water heater prior to
inspection.
4. Clean the anode rods with a soft cloth and reinstall.
5. Follow the instructions for filling the water heater in Filling The
Water Heater (page 50).
DRAIN VALVE AND ACCESS PANELS
The water heaters covered in this manual are equipped with a
drain valve. See Features and Components (page 7) for location.
The water heaters covered in this manual are also equipped with
a cleanout opening for sediment and lime scale removal. See
Figure 38 (page 61).
TANK
CLEANOUT
OPENING
CLEANOUT
COVER
CLEANOUT
GASKET
CLEANOUT
ACCESS PANEL
Figure 38. Cleanout Access
TEMPERATURE-PRESSURE RELIEF VALVE TEST
Burn hazard.
Hot water discharge.
Keep clear of Temperature-
Pressure Relief Valve
discharge outlet.
It is recommended that the Temperature-Pressure Relief Valve
should be checked to ensure that it is in operating condition every
6 months.
When checking the Temperature-Pressure Relief Valve operation,
make sure that (1) no one is in front of or around the outlet of
the Temperature-Pressure Relief Valve discharge line, and (2)
that the water discharge will not cause any property damage, as
the water may be extremely hot. Use care when operating valve
as the valve may be hot.
To check the relief valve, lift the lever at the end of the valve
several times. See Figure 39. The valve should seat properly and
operate freely.
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62
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 and drain the water heater. See Draining
and Flushing (page 59). Replace the Temperature-Pressure Relief
Valve with a properly rated/sized new one See Temperature-
Pressure Relief Valve (page 15) for instructions on replacement.
DISCHARGE PIPE
TEMPERATURE-PRESSURE
RELIEF VALVE
Figure 39. Testing the T&P Relief Valve
If the Temperature-Pressure Relief Valve on the water heater
weeps or discharges periodically, this may be due to thermal
expansion.
Note: Excessive water pressure is the most common cause of
Temperature-Pressure Relief Valve leakage. Excessive
water system pressure is most often caused by “thermal
expansion” in a “closed system.” See Closed Water Systems
(page 14) and Temperature-Pressure Relief Valve (page 15).
The Temperature-Pressure Relief Valve is not intended
for the constant relief of thermal expansion.
Temperature-Pressure Relief Valve leakage due to pressure build
up in a closed system that does not have a thermal expansion
tank installed is not covered under the limited warranty. Thermal
expansion tanks must be installed on all closed water systems.
DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF
VALVE OPENING. THIS CAN CAUSE PROPERTY
DAMAGE, SERIOUS INJURY OR DEATH.
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22-
CSA 4.4 and ASME code.
Properly sized temperature-
pressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
VENT SYSTEM MAINTENANCE
Examine the vent system once a year. Points of inspection are
as follows:
1. Check for obstructions and/or deterioration of the intake air
and/or vent piping and the intake air and vent terminations.
Replace immediately where needed.
2. The debris screens in the intake air and vent terminations
should be should be cleaned of foreign material and soot. See
Figure 19 (page 26).
Note: Do not reach inside the vent termination when the
heater is in operation.
3. Check all vent system connections for leakage and repair or
reseal as necessary
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63
DIAGRAMSDIAGRAMS
CCB - CENTRAL CONTROL BOARD LAYOUT
11
12
1
J16
J5
J3
J13
J4
J17
J10
J9
J14
J15
J1
J6
J12
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
4
5
5
5
5
5
5
6
6
6
6
6
6
7
78
8
8
9
9
7
10
8
Figure 40. CCB (Central Control Board)
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64
WIRING DIAGRAM
Splice
Splice
Green
Green
Ferrite
Bead
Tr
ansformer
Secondary
White / Red
White / Blue
Transformer
Primary
Black
White
Transformer
Power
Supply J2
1 Blue
3 Orange
4 White/Green
Power
Supply J1
2 White
3 Black
75VA
Power
Supply
Central Control Board
(CCB)
Blower
1 Black
2 White
3 Green
120V OUT to blower
L1
Neutral
PE
1 White / Brown
2 White / Orange
4 White / Blue
Blower
Speed
5 White / Green
24Vureg
PWM Signal
Speed f-back
Dgnd
8 White
Field Box
HIGH Voltage
J1
7 Black
6 Red
5 Green
Green
Neutral
L1
Aux 2 Common
Aux 2 NO
Open
Open
Open
Open
PE
Junction Box
CCB
J16
Low Voltage In
1 White/Red
2 White/Blue
4 Blue
5 Orange
6 White/Green
24VAC
24VAC
12VDC
5VDC
Dgnd
9 White
CCB J1
HIGH Voltage In
8 Black
7 Red
6 Green
3 Black
4 White
5
2 Red
1
Neutral
L1
Pump Common
Pump NO
AUX NO
AUX Common
AUX NC
PE
CCB J5
Blo
wer Logic
1 White/Brown
2 White/Blue
4 White/Orange
5 White/Green
24Vureg
PWM Signal
Speed f-back
Dgnd
Green
Yellow
CCB J14
Limit String
1 Blue
2 Green
3 Yellow
4 Black
6 Black
7 Red
8 Black
9 Red
10 Black
11 Red
12 Black
Anode
Dgnd
Flame Rod
Condensate
Gas PS
Gas V Switch
Gas V 24V
24V Rtn
Condensate
Gas PS
Gas V Switch
1 Red
2 Black
CCB J6
120V Out
Neutral
120 to Spark
Red
Black
Red
Black
Upper Temperature
Probe / ECO
1 Red
2 Black
CCB J9
Upper Probe
ECO
Thermistor
4 Red
3 Black
ECO
Thermistor
Gas Valve
Ground Bar
N
L
Heater
Pump
Neutral
Protective
Earth
= multi-conductor power limited cable, 18AWG 80°C 300V UL category QPTZ
Connects
to burner
bolt
= Spark ignition wire, 220°C 25kVDC 7mm EMI suppression
Flame
Rod
CCB J17
Low Voltage Field
No factory
connections
Enable/Disable Switch
CCB J10
Thermistor
Thermistor
Splice
Blue
Blue
P1-1
W1-Red
P1-2
W2-Green
P1-3
W3-White/Brown
P1-4
W4-White/Blue
CCB J12
Configuration Key
SDA (data)
SCL (data)
Write protect
P1-5
P1-6
W5-White/Orange
+5V
Dgnd
Configuration
Key
Outlet Pressure
Switch
1 Black
2 Red
CCB J15
Pressure
Switches
Inlet return
Outlet return / Inlet power
4 Green
Outlet power
Inlet Pressure
Switch
= 18AWG AWM wire 105°C 600V UL style 1015. Flame rod wire = 200°C 300V UL 1180.
Spark
Module
120V
Neutral
Spark
Rod
1 Red
2 Black
3 Green
Ground
BURNER
BOLT
L1
+5V
Data +
Data -
D gnd
1 Blue
3 Yellow
4 Orange
5 Violet
1 Blue
3 Yellow
4 Orange
5 Violet
Display J1
CCB J3
+5V
Data +
Data -
D gnd
Top
Anode
Rod
Blue
CCB J13
CPAM
Anode
Side
Side
Rod
Anode
Rod
Blue
Blue
Top
Anode
Rod
Top
Anode
Rod
1 Black
2 Black
3 Red
4 Red
CCB J4
Flue Probe
Flow Switch
Figure 41. Wiring Diagram
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65
CIRCULATION PUMP WIRING DIAGRAMS
CIRCULATING PUMP WIRING DIAGRAM
STORAGE TANK OR BUILDING RECIRCULATION
FIELD SUPPLIED TEMPERATURE CONTROL
INSTALLED IN THE STORAGE TANK
OR CIRCULATING LOOP RETURN LINE
CIRC
PUMP
MOTOR
L1 HOT
L2 NEUTRAL
120 VAC
POWER
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH APPLIANCE AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
Figure 42. Circulating Pump Wiring Diagram Storage Tank or Building Recirculation
CIRCULATING PUMP WIRING DIAGRAM
DISHWASHER LOOP WITH TOGGLE SWITCH
FIELD SUPPLIED TEMPERATURE
CONTROL INSTALLED IN THE
CIRCULATING LOOP RETURN LINE
DISHWASHER
TOGGLE
SWITCH
CIRC
PUMP
MOTOR
L1 HOT
L2 NEUTRAL
120 VAC
POWER
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH APPLIANCE AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
Figure 43. Circulating Pump Wiring Diagram - Dish-Washer Loop with Toggle Switch
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66
WATER PIPING DIAGRAMS
Before installation of water piping review the following:
1. See Mixing Valves (page 14).
2. See Dish-washing Machines (page 14).
3. See Temperature-Pressure Relief Valve (page 15).
4. See Closed Water Systems (page 14) and Temperature-Pressure
Relief Valve (page 15).
5. See The water piping installation must conform to these instructions
and to all local and national code authority having jurisdiction. Good
practice requires that all heavy piping be supported. (page 59).
6. If a pump is being installed between a water heater and
storage tank or on a building recirculation loop wire according
to Figure 42 (page 65).
7. If a pump is being installed in a recirculation loop between
the water heater and a commercial dishwasher wire
according to Figure 43 (page 65).
ONE WATER HEATER, SINGLE TEMPERATURE
WITH BUILDING RECIRCULATION
ANY MATERIAL, COMPONENT, OR VENDOR
CHANGE MUST HAVE PRIOR APPROVAL BY
THE APPLICABLE PRODUCT ENGINEERING
DEPARTMENT
.
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
Temperature &
Pressure Relief Valve
Pressure Relief Valve
Circulating Pump
Temperature Control
Probe
Drain
Full Port Ball Valve
Check Valve
Temperature Gage
Water Flow Switch
Legend
FINISHED FLOOR
HOT WATER
RETURN
COLD WATER
SUPPLY
EXPANSION
TANK
HOT WATER TO
FIXTURES
Pipe T&P to
Open Drain
NOTES:
1. Preferred piping method.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
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67
WATER PIPING DIAGRAMS
Before installation of water piping review the following:
1. See Mixing Valves (page 14).
2. See Dish-washing Machines (page 14).
3. See Temperature-Pressure Relief Valve (page 15).
4. See Closed Water Systems (page 14) and Temperature-Pressure
Relief Valve (page 15).
5. See The water piping installation must conform to these instructions
and to all local and national code authority having jurisdiction. Good
practice requires that all heavy piping be supported. (page 59).
6. If a pump is being installed between a water heater and
storage tank or on a building recirculation loop wire according
to Figure 42 (page 65).
7. If a pump is being installed in a recirculation loop between
the water heater and a commercial dishwasher wire
according to Figure 43 (page 65).
ONE WATER HEATER, TWO TEMPERATURES, WITH
HIGH-TEMPERATURE LOOP RECIRCULATION
ANY MATERIAL, COMPONENT, OR VENDOR
CHANGE MUST HAVE PRIOR APPROVAL BY
THE APPLICABLE PRODUCT ENGINEERING
DEPARTMENT
.
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
Temperature &
Pressure Relief Valve
Pressure Relief Valve
Circulating Pump
Temperature Control
Probe
Drain
Full Port Ball Valve
Check Valve
Temperature Gage
Water Flow Switch
Legend
Pipe T&P to
Open Drain
Expansion
Tank
Outlet
Hot Water
Return
Cold
Treated Water
Outlet
Mixing Valve
12” to 15”
Treated Water
Return
Hot
Finished Floor
NOTES:
1. Preferred piping method.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
Printed on 5/19/2022 11:24 AM CT
68
WATER PIPING DIAGRAMS
Before installation of water piping review the following:
1. See Mixing Valves (page 14).
2. See Dish-washing Machines (page 14).
3. See Temperature-Pressure Relief Valve (page 15).
4. See Closed Water Systems (page 14) and Temperature-Pressure
Relief Valve (page 15).
5. See The water piping installation must conform to these instructions
and to all local and national code authority having jurisdiction. Good
practice requires that all heavy piping be supported. (page 59).
6. If a pump is being installed between a water heater and
storage tank or on a building recirculation loop wire according
to Figure 42 (page 65).
7. If a pump is being installed in a recirculation loop between
the water heater and a commercial dishwasher wire
according to Figure 43 (page 65).
ONE WATER HEATER, SINGLE TEMPERATURE, WITH VERTI-
CAL STORAGE TANK, FORCED RECIRCULATION, WITH
BUILDING RECIRCULATION
Temperature &
Pressure Relief Valve
Pressure Relief Valve
Circulating Pump
Temperature Control
Probe
Drain
Full Port Ball Valve
Check Valve
Temperature Gage
Water Flow Switch
Legend
ANY MATERIAL, COMPONENT, OR VENDOR
CHANGE MUST HAVE PRIOR APPROVAL BY
THE APPLICABLE PRODUCT ENGINEERING
DEPARTMENT
.
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
Expansion
Tank
Cold Water
Supply
Hot Water
Return
Finished Floor
Storage Tank
Alternate
Cold Water
Connection
Pipe T&P to
Open Drain
Hot Water To
Fixtures
NOTES:
1. Preferred piping method.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
Printed on 5/19/2022 11:24 AM CT
69
WATER PIPING DIAGRAMS
Before installation of water piping review the following:
1. See Mixing Valves (page 14).
2. See Dish-washing Machines (page 14).
3. See Temperature-Pressure Relief Valve (page 15).
4. See Closed Water Systems (page 14) and Temperature-Pressure
Relief Valve (page 15).
5. See The water piping installation must conform to these instructions
and to all local and national code authority having jurisdiction. Good
practice requires that all heavy piping be supported. (page 59).
6. If a pump is being installed between a water heater and
storage tank or on a building recirculation loop wire according
to Figure 42 (page 65).
7. If a pump is being installed in a recirculation loop between
the water heater and a commercial dishwasher wire
according to Figure 43 (page 65).
ONE WATER HEATER, SINGLE TEMPERATURE, WITH HORI-
ZONTAL STORAGE TANK, FORCED RECIRCULATION, WITH
BUILDING RECIRCULATION
Temperature &
Pressure Relief Valve
Pressure Relief Valve
Circulating Pump
Temperature Control
Probe
Drain
Full Port Ball Valve
Check Valve
Temperature Gage
Water Flow Switch
Legend
ANY MATERIAL, COMPONENT, OR VENDOR
CHANGE MUST HAVE PRIOR APPROVAL BY
THE APPLICABLE PRODUCT ENGINEERING
DEPARTMENT
.
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
Finished Floor
Hot Water to Fixtures
Alternate
Location
Cold Water
Supply
Pipe T&P to
Open Drain
Expansion
Tank
Circulating
Pump
Hot Water
Return
NOTES:
1. Preferred piping method.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
Printed on 5/19/2022 11:24 AM CT
70
WATER PIPING DIAGRAMS
Before installation of water piping review the following:
1. See Mixing Valves (page 14).
2. See Dish-washing Machines (page 14).
3. See Temperature-Pressure Relief Valve (page 15).
4. See Closed Water Systems (page 14) and Temperature-Pressure
Relief Valve (page 15).
5. See The water piping installation must conform to these instructions
and to all local and national code authority having jurisdiction. Good
practice requires that all heavy piping be supported. (page 59).
6. If a pump is being installed between a water heater and
storage tank or on a building recirculation loop wire according
to Figure 42 (page 65).
7. If a pump is being installed in a recirculation loop between
the water heater and a commercial dishwasher wire
according to Figure 43 (page 65).
TWO WATER HEATERS, SINGLE TEMPERATURE, WITH
BUILDING RECIRCULATION
Temperature &
Pressure Relief Valve
Pressure Relief Valve
Circulating Pump
Temperature Control
Probe
Drain
Full Port Ball Valve
Check Valve
Temperature Gage
Water Flow Switch
Legend
ANY MATERIAL, COMPONENT, OR VENDOR
CHANGE MUST HAVE PRIOR APPROVAL BY
THE APPLICABLE PRODUCT ENGINEERING
DEPARTMENT
.
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
Pipe T&P to
Open Drain
Pipe T&P to
Open Drain
Hot Water
Return
Cold Water
Supply
Expansion
Tank
NOTES:
1. Preferred piping method.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
Printed on 5/19/2022 11:24 AM CT
71
WATER PIPING DIAGRAMS
Before installation of water piping review the following:
1. See Mixing Valves (page 14).
2. See Dish-washing Machines (page 14).
3. See Temperature-Pressure Relief Valve (page 15).
4. See Closed Water Systems (page 14) and Temperature-Pressure
Relief Valve (page 15).
5. See The water piping installation must conform to these instructions
and to all local and national code authority having jurisdiction. Good
practice requires that all heavy piping be supported. (page 59).
6. If a pump is being installed between a water heater and
storage tank or on a building recirculation loop wire according
to Figure 42 (page 65).
7. If a pump is being installed in a recirculation loop between
the water heater and a commercial dishwasher wire
according to Figure 43 (page 65).
THREE WATER HEATERS, SINGLE TEMPERATURE WITH
BUILDING RECIRCULATION
Temperature &
Pressure Relief Valve
Pressure Relief Valve
Circulating Pump
Temperature Control
Probe
Drain
Full Port Ball Valve
Check Valve
Temperature Gage
Water Flow Switch
Legend
ANY MATERIAL, COMPONENT, OR VENDOR
CHANGE MUST HAVE PRIOR APPROVAL BY
THE APPLICABLE PRODUCT ENGINEERING
DEPARTMENT
.
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HOT WATER
RETURN
Pipe T&P to
Open Drain
Pipe T&P to
Open Drain
Pipe T&P to
Open Drain
Expansion
Tank
Cold Water
Supply
Hot Water
to Fixtures
NOTES:
1. Preferred piping method.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
Printed on 5/19/2022 11:24 AM CT
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Printed on 5/19/2022 11:24 AM CT
